dairy plant

Propane Chillers Future Proof Dairy

The Client –

Dairy Processor, North Of England


The Challenge –

Future Proofed Cooling System


The Solution –

Propane Chiller System Install

Propane chiller technology has ensured a dairy plant in the North of England is not only highly energy efficient but also extremely environmentally friendly.

Our client provides goats’ milk to supermarkets across the UK as well as processing the raw milk into a range of products, including yoghurt, cheese, butter and cream.

When Aqua were commissioned to design a replacement cooling system for their dairy processing facility, future proofing the dairy for the years ahead was a key driver in the decision-making process. This, coupled with the current phase-out of hydrofluorocarbons (HFCs), led to R290 propane being their refrigerant of choice.

New F-Gas regulations came into effect initially in 2015, designed to control emissions from fluorinated greenhouse gasses (F-gases), including HFCs. The EU’s overall aim is to cut F-gas emissions by two-thirds by 2030, when compared with 2014 levels. By 2020 the use of virgin HFC refrigerants with a Global Warming Potential (GWP) of above 2500 will be banned. This includes previously mainstream refrigerants such as R-404A and R-434A.

Aqua can supply a range of chillers that run on the refrigerant grade propane, R290. Propane refrigerant is 100% natural, has excellent thermodynamic performance, is non-toxic, has a GWP of just 3 and a zero Ozone Depletion Potential (ODP).

The new dairy system looks after the cooling for the entire facility, from the raw milk being offloaded from tankers, through to the processing and bottling stages. Aqua also designed a bespoke galvanised steel gantry frame and staircase, allowing the new equipment to be sited at high level with the area below still accessible. As well as achieving an extremely efficient and high performing system, our client has dramatically reduced their overall carbon footprint as a business.

The full solution includes:

  • 2 x R290 propane chillers
  • Process tank with hot & cold section
  • Inverter driven process pumps
  • Full design, mechanical installation & commissioning
  • Preventive maintenance contract

“R290 refrigerant is becoming increasingly high profile, especially with clients within the food & beverage sector” explains Aqua Group’s Mike West. “With all the regulatory changes over the last few years, choosing the most suitable refrigerant can be a minefield for both clients and potential customers. It’s our job to make that more straightforward and transparent for customers, helping them to achieve the most efficient and energy effective solution for their specific needs.”

propane chiller

salmon

Bespoke System Helps Scottish Salmon Industry

The Client –

Scottish Salmon Producer


The Challenge –

Expansion Of Production Facility


The Solution –

Custom Designed Cooling System

When a seafood company looked to expand their salmon production across Scotland, Aqua were commissioned to design a fully bespoke cooling system to upgrade their existing facility.

The client, one of the worlds’ leading producers of farmed salmon, was looking to upgrade their salmon hatchery in a drive towards longer term sustainability and efficiency. The new hatchery would not only dramatically increase the number of employees on site but also improve their ability to grow out smolts which would then supply their network of Scottish sea farms.

A smolt is a young salmon and refers to the development stage before full adulthood. The salmon start their life in hatcheries or loch farms before moving on to sea farms where they grow to full adulthood.
Aqua supplied a 1,550 kW custom designed system which worked on the principle of water being taken from a local river, into a large buffer tank. This water is circulated through two chillers which are specially designed with cupro-nickel water cooled condensers so they can operate on river water. The chillers then supply four plate heat exchangers to separate the salt water from the chilled water and to protect the livestock. Each of these heat exchangers is associated with an independent tank which either houses the very small salmon fry or the larger smolts.

As well as keeping the tank temperature at the optimum for the well-being and development of the salmon, the system is designed for maximum energy efficiency. Each chiller has 6 highly efficient multiple scroll compressors which are installed in 3 fully independent circuits with 2 compressors – giving 6 separate capacity stages. They each also have triple circuit shell & tube evaporators as well as shell and tube condensers. Each chiller unit has a COP (Coefficient of Performance) value of just 5.11 under full load conditions.

The full solution included:

  • 2 x 770kW water cooled chillers
  • 8,000 litre polypropylene buffer vessel
  • IE3 motor, run and standby pump system
  • Energy efficient design – including R410a refrigerant
    and COP value of 5.11 for compressor under full load conditions
  • Reduced noise specification – including
    acoustic jackets on chiller compressors
  • Centralised control system
  • Full design service plus electrical and mechanical installation

The versatile design of the cooling system means that during the warmer months when the ambient temperature is higher both chiller units can be fully operational. But, during the cooler Spring & Autumn months the system can simply reduce to medium/low load. In this scenario just one chiller needs to operate – massively increasing operating costs and efficiency, by turning the pump motors off – yet the control system will rotate between both units at start up so that they are both used equally.

Ian Clynes, Aqua’s Northern Project Manager, explains; “Scottish salmon has a great reputation around the world and the aquaculture process is vital to the country’s economy, so this was a great project to be involved with. The unique system design is a fantastic example of Aqua’s ability to engineer energy efficient solutions that can really make a difference to clients’ businesses.”

marine

washing machine

Adiabatic Cooling Puts A Spin On Things For Home Appliance Manufacturer

The Client –

Home Appliance Manufacturer, UK


The Challenge –

Hydraulic Cooling Upgrade


The Solution –

Adiabatic Cooling System

Built in redundancy and energy efficiency are often key factors for clients when they’re considering upgrading their cooling equipment. This was exactly the case for a client who wanted to replace an aging air-cooled chiller system which provided hydraulic oil cooling to their manufacturing process.

Our customer is a market leading manufacturer of home appliances, including a range of washing machines and tumble dryers. In addition to being old, their existing chillers ran on R407C refrigerant, which limited their energy efficiency potential.

During the manufacturing process, our client uses a cold press to produce component parts. In very basic terms, a sheet of metal is inserted between two metal plates. A hydraulic system then creates a sheer force which presses the required shape into the metal sheet.

Our in-house design team removed 3 chiller units from the existing cooling system, replacing them with a single adiabatic cooler. One larger chiller unit was retained as a back up option. Moving to an adiabatic system meant the required cooling capacity could be achieved without the need for a refrigeration system. As well as decreasing electrical power consumption, this has the added benefit of removing moving mechanical parts, so reducing running cost and future maintenance costs.

A shell and tube heat exchanger was also included, taking the hydraulic oil one side and cooling fluid on the other.

The adiabatic cooler supplied had 5 fans, so if 1 should ever fail, the cooling function would continue unaffected. The fans can also be replaced whilst the unit is operational, so you gain built in redundancy.

The full solution included:

  • 250kW adiabatic cooler with EC fans
  • Shell & tube heat exchanger
  • Process pumps, inverters and pressurisation unit
  • Mechanical installation, pipework and commissioning

“This project is a great example of how a relatively simple system upgrade can achieve a multitude of benefits for clients. For this customer their total cost of ownership really reduced, and they gained peace of mind that their process now incorporated redundancy on the cooling side” explains Aqua Sales Manager, Shaun Lancaster.

adiabatic

adiabatic

Adiabatic Re-Design Overcomes Site Challenges

The Client –

UK Automotive Component Manufacturer


The Challenge –

Failing Adiabatic Cooler + Access Challenges


The Solution –

Replacement Adiabatic With Reduced Footprint

Our design team are used to overcoming access restrictions on sites but an extremely narrow passageway and overhead cabling on a recent project posed a real challenge.

The client, a leading manufacturer and distributor of automotive components, tasked us with replacing an old, failing adiabatic cooler. Removing a legacy unit and replacing it with new equipment is relatively straight forwarded most of the time – but on this occasion things were going to be trickier! A narrow walkway restricted access and overhead electrical and telecommunication cables ran above the site’s fencing, meaning using a traditional HiAB lift wasn’t going to be an option.

Whilst our client wanted a like for like replacement, our engineers used the initial design phase as a chance to reduce the dimensions of the new adiabatic cooler, giving more room for manoeuvre – quite literally! Whilst the new unit could achieve the same duty as the existing, our design team managed to make it significantly smaller in size.

Aqua supplied a 500+kW adiabatic, working on a water supply temperature of 30+°C, with a return temperature of 43.4°C, with a wet bulb of 19°C. Fluid was 25% ethylene glycol/water. By changing the configuration of the unit’s fans, the footprint was considerably reduced.

Whilst replacing the old adiabatic with the new unit wasn’t easy, positioning and installation was made much easier by the unit’s reduced dimensions. It also made navigating the restricted access ways a more straightforward task.

The full Aqua solution included:

  • 505kW adiabatic cooler
  • Bespoke design service
  • Mechanical disconnection & disposal of the legacy cooler
  • Full delivery and installation
  • Hoses and related ancillaries

“This installation is a great example of how important the initial design phase can be” explains Aqua Sales Engineer, Bhaskar Choudhury. “Once we visited site the access and delivery restrictions became clear and the work our design team then did at that early stage made life so much simpler when it came to the final install, saving our client both time and cost.”

adiabatic

gauges

Bespoke Design Solution Overcomes Space Challenge

The Client –

UK Industrial Gas Manufacturer


The Challenge –

System Upgrade, Within Restricted Footprint


The Solution –

Built To Order Air Blast Solution

Our client specialises in the manufacture of industrial gases which are used across several sectors including food & beverage, medical and petrochemical, to name just a few. As well as more widely known gases such as oxygen, nitrogen and helium, some speciality gases are manufactured for specific processes.

Aqua were tasked with upgrading the cooling to the compression system used in the gas manufacturing process. As production has increased over recent years, our customer was keen to replace their existing dated equipment with new whilst increasing the system’s cooling capacity at the same time.

Limited by the footprint available, our design team worked on a specially manufactured air blast cooler design to ensure the new system would fit within the existing space. Along with the cooler, sits pumps, pressurisation set, expansion and header tanks. Using 3D imagery, our designers ensured all the equipment would fit into the restricted footprint.

The system is sat on a skid, with a control system bespoke to the client’s specifications. The skid design enabled the entire system to be delivered to site and connected, keeping installation work and disruption to production at a minimum.

The bespoke 490kW capacity air blast cooler, incorporates EC fans and the pumps have inverter drives, maximising overall energy efficiency. It’s anticipated that energy saving will be over 50% compared to the legacy cooler that was in situ.

The full solution included:

  • Custom skid design
  • Bespoke equipment manufacture
  • Air blast cooler, pumps, pressurisation set and tanks,
  • Bespoke control system

In addition, because the air blast cooler is in a coastal environment, final specification included marine paint and coated fins to eliminate any risk of corrosion.

air blast

simons array

Aqua Supports Research Into Origins Of The Universe

The Client –

University Of California


The Challenge –

Cooling In Chile’s Atacama Desert


The Solution –

Air Blast Radiator Technology

The search for the origins of the Universe is being advanced with the help of Air Blast Coolers supplied by award-winning Fareham engineering firm Aqua Cooling.

For the past five years the specialist chilling equipment has been used in a multi-million dollar astronomical observatory in Chile’s Atacama Desert; now additional units have been fitted by Aqua Cooling as more telescopes are brought in to search the skies for a particular type of cosmic wave that experts believe was created immediately after the Big Bang.

Scientists at James Ax Observatory are undertaking an experiment into the polarisation of background radiation in a project named Polarbear and have already published significant findings. The facility is positioned 5,200m above sea level — it is one of the highest observatories in the world — and is manned by a team of researchers from several US universities including the University of California, San Diego, alongside several international partners.

The scientists’ aim is to prove the theory of inflation – that the Universe grew rapidly after the Big Bang, inflating like a balloon. Key to proving the theory is detecting a certain type of background radiation, which the Ax Observatory has already done. The team’s success has led to funding for an array of three telescopes to move the research forward.

Aqua Cooling was asked to supply more of its Air Blast radiators to support the new Simons Array of telescopes. Cooling is essential because the receivers on each of the telescopes must operate at cryogenic temperatures. This is achieved using commercial helium gas-cycle refrigerators and these refrigerators have compressors that are cooled by Aqua Cooling’s radiators.

“The original Polarbear experiment has been running off an Aqua radiator for more than five years,” explained Nathan Stebor of the University of California, San Diego. “We needed more radiators to accommodate the new receivers coming online for the Simons Array and Aqua’s solution was perfect in terms of simplicity and compatibility.”

Matt Goodman, Key Accounts Manager at Aqua Cooling, said: “Playing a part in the fascinating work going on at the James Ax Observatory demonstrates the versatility of our chilling equipment and our ability to deliver projects in some of the most remote areas of the world.”

“We have been working closely with the University of California team to add the capacity they need and build upon our existing relationship. We shall be following the next stage of their research with great interest.”

simons array

university

Aqua Help Norwegian University Students Keep Cool

The Client –

University Of Stavanger – Norway


The Challenge –

Data Centre Cooling


The Solution –

Rear Door Technology with LPS

Aqua Cooling and their brand partners in Bedfordshire have linked up again to supply ground-breaking Data Centre Cooling technology to one of Norway’s top universities.

Aqua Cooling has delivered its multi-award winning state-of-the art Leak Prevention System (LPS) in conjunction with Bedford-based USystems’ Rear Door coolers to the prestigious University of Stavanger in a deal that consolidates the British firms’ links with the European higher education sector.

The LPS technology, which has won several industry prizes including a 2015 Queen’s Award for Enterprise (Innovation) and recognition by the Institute of Physics (IOP), was designed, developed and patented by Aqua. The Hampshire firm’s ground-breaking design complements USystems’ ColdLogik Rear Coolers, which themselves won a 2013 Queen’s Award for Enterprise (Innovation); the top-flight Norwegian university’s new Data Centre Cooling system combines the benefits of both designs.

This unique composite all-British product offers customers a leak-free guarantee that is transforming data centre cooling applications worldwide. Offering the most energy-efficient low-to-high-density Data Centre Cooling solution currently available, the ColdLogik cooling system has itself attracted many industry and environmental accolades.

By employing the basic scientific principle that water under negative pressure cannot escape through a hole or breach in pipework, the LPS offers Data Centres the option of using water-based cooling systems without running the risk of coolant leakage damage to sensitive electronic data storage equipment.

Mike West, product manager at Aqua DCS (Data Centre Services), said: “The University of Stavanger was looking for an effective cooling system for its Data Centre, and our system’s leak-free guarantee was definitely a key selling point.”

“The Data Centre industry represents an enormous market opportunity for Aqua and USystems — supplying and installing our technology in Data Centres overseas is always exciting, and being involved in the higher education sector is very rewarding.”

The University of Stavanger is ranked as one of Norway’s top ten academic institutions. “Working with such a prestigious establishment has opened the door to an exciting new market in Norway that we hope to develop further in the future,” said Mike.

Aqua’s and USystems’ previous education sector Data Centre deals include cooling system installations at the University of Swansea in Wales and the University of Bath in Somerset.

lps

hospital

Aqua Keeps South Western Ambulance Service Ticking Over

The Client –

South Western Ambulance Service


The Challenge –

Data Centre Cooling


The Solution –

In-Row And Rear Door Technology With LPS

Aqua Cooling was called in to regulate the temperature at a Bristol Data Centre that is the beating heart of the south west of England’s medical emergency provision.

The South Western Ambulance Service NHS Foundation Trust (SWASFT) provides ambulance services to the people of Cornwall and the Isles of Scilly, Devon, Dorset, Somerset, Wiltshire, Gloucestershire, and the former Avon area encompassing the cities of Bath and Bristol.

This summer the group turned to Aqua engineers to provide and install a complete Data Centre Cooling system incorporating its patented Leak Prevention System (LPS) in order to ensure the safe and secure storage of its sensitive computerised patient records held at SWASFT’s Bristol headquarters.

Chris Aitken, Data Centre sales engineer at Aqua DCS (Data Centre Services), said: “The SWASFT team was aware of a Data Centre chiller system we had already installed at the University of Bath and realised that a similar, tailor-made solution would be a perfect fit for its own data storage facility in Bristol.”

Aqua’s cooling solution is crucial to the efficient running of the region’s emergency ambulance service — having encountered problems with its previous system, SWASFT was looking for an effective, fail-safe system that would also bring cost and energy savings.

“We’re extremely happy to be working with the South Western Ambulance Service, an organisation that does such excellent and vital work. This opportunity to help ensure that the trust’s operations run smoothly was very exciting — the Aqua team is proud to be a part of such an important service,” said Chris.

Aqua supplied SWASFT with two LPS units, rear door cooler technology and high-performance in-row coolers forming a hot aisle containment system, complete with all the mechanical pipework required for the installation.

Pipework installation began in August, and the system was completed in the autumn — it is now operational and running well. A second phase will see the introduction of a free cooler into the system to increase capacity and redundancy, thereby ensuring optimum energy-efficiency and reducing operating costs.

data centre

seals

Aqua Seals The Deal With Retro-Fit Free Cooling

The Client –

London Based Seal Manufacturer


The Challenge –

Increase Energy Efficiency Of Existing System


The Solution –

Free Cooling Upgrade

For a client running air cooled chiller units to feed their injection moulding hall, the simple addition of a bolt-on Free Cooler to their existing cooling system is forecast to save them over £34,000 in energy costs every year.

Our London based client specialises in producing seals and sealing solutions which are used in the fluid power industry worldwide. Their production facility runs 24/7, so it’s essential that any system downtime is kept to an absolute minimum.

The benefit of adding Free Cooling into a system is that overall power, or energy use, is greatly reduced. Because the lower ambient air temperature is used to cool the process return water wherever possible, the need for mechanical cooling is much less. In addition, by reducing the running time of the equipment you automatically extend its lifetime and lower lifetime maintenance costs. You also gain built in redundancy – if your chiller fails the Free Cooling side can still operate.

The technology within the Free Cooling unit senses both the return fluid temperature and the ambient air temperature. When the ambient is lower than the return water temperature, the fluid is passed through a coil that exchanges the heat in the fluid to the ambient air, using just the mechanical effect required to drive the fans to pull the air through. This means the load is either partially or totally (in the winter months in the UK) reduced – giving partial or full Free Cooling.

Our client already had two chillers on site, to which we added a 280kW Free Cooler. Whilst their system operated on plain, we added a heat exchanger between the system and the Free Cooler, so the latter could run on glycol to prevent freezing during extreme temperatures.

Full system included:

  • 280kW free cooler
  • 280kW heat exchanger
  • Single pump & tank

As the site operated 24/7 the client allocated our installation engineers just a 3-hour window one Monday morning to break into the existing system. Using isolation values, our engineers could then continue with the Free Cooler install whilst production restarted.

Installed in the Autumn, whilst being monitored for the first 3 weeks of running the system operated solely on Free Cooling. Due to the energy savings our client is on target to receive complete system payback in just over one year.

Aqua Sales Manager, Shaun Lancaster, explains; “This is a fantastic example of how retro fitting free cooling can really make an impact when it comes to putting money back on the bottom line. By lowering the plant’s running costs we’ve helped our client increase gross profit without even involving their sales team!”

free cooling

brush

Free Cooling Helps Family Engineering Business Expansion Strategy

The Client –

North Of England Plastics Extruder


The Challenge –

New Plant Machinery Requiring Additional Cooling Capacity


The Solution –

Energy Saving Free Cooling

When a family run engineering company needed to add extra cooling capacity to their plastic extrusion process, it seemed the ideal time to incorporate the energy saving benefits of Free Cooling into their new system.

Our client, based in the North of England, specialises in extruding plastic to produce brush filaments. Due to an increase in product demand they embarked on a project to increase the capacity and speed of their production facility. Key to this strategy was the introduction of an additional extruding line which subsequently changed their cooling requirements.

Historically our client had achieved all the cooling they needed for their production by natural cooling. Put simply, water from a pond outside of their factory was sprayed up into the air. This fountain effect removed the heat from the water which provide sufficient cooling for their existing set up.

However, their upgraded process needed much more accurate temperature control. Whilst giving increased speed and accuracy, the new extrusion machine required a guaranteed 15°C water supply. The existing natural cooling wouldn’t achieve this level of cooling, meaning mechanical cooling needed to come into play.

The Aqua solution included:

  • 136kW air cooled water chiller
  • 136kW free cooler
  • Supply only basis with full technical support
  • Commissioning

As an engineering specialist, our client had all the skills needed to install the equipment in-house, so Aqua offered a supply only basis.

Sales Manager, Shaun Lancaster, explains; “We supplied the equipment and a technical drawing, and the client did the rest themselves. Our engineers visited site for final commissioning and my client knew we were on hand during the install process to help if needed. For me this is a great example of how versatile Aqua Cooling are as a supply partner. We offer full installations with mechanical and electric works but are equally happy to work on a supply only basis.”

chiller

accreditation