Alternative cooling solution to replace HCFC equipment

Under the law, refrigeration or air-conditioning units found to use HCFCs, (particularly the ozone depleting R22 refrigerant), will become obsolete, and will no longer be able to be serviced.

ICS Cool Energy Ltd recommends that sites with existing cooling systems of poor condition, or those with systems not meeting current cooling loads, should upgrade to one that uses non-ozone depleting refrigerants, such as R410A and R134a.

Similarly, units in good working order will also need updating with a convert solution. Depending on the existing system, replacements could take form of a simple retro-fill operation, carried out during a standard service drop-in. Alternatively, a more comprehensive modification may be needed, which may require a new oil type, an additional compressor and/or a heat exchanger.

Currently, there is no recognised retro-fill solution for flooded or pump-circulation systems, so if an existing system incorporates a flooded HCFC, then a refrigeration contractor should be contacted. While conversion is a potential option, a converted flooded system may have less cooling capacity and, potentially, be less efficient than a new unit.

As a solution to the change of legislation and to replace equipment containing HCFCs, ICS Cool Energy recommends energy-saving Turbocor compressors; a system that they have already supplied and installed in a number business premises.

Explaining how the Turbocor units work, Adam Spolnik, HVAC Director at ICS Cool Energy said: “The Turbocor compressor uses a digital rotor speed control that allows high partial load efficiencies of 60% higher than European seasonal energy efficient ratio (ESEER) values, to be achieved.”

“Magnetic levitation works within the compressor, so there are no moving parts, and this significantly reduces noise emissions by up to 8dB(A). Even at low conditions, a building’s requirements can be matched through inlet guide vanes, which extend the compressor’s operational limit. For certain applications, units can use high condensing temperatures, enabling recovered heat to be used elsewhere onsite. So, rather than rejecting this heat through a cooling tower or air blast, outlet temperatures of up to 50°C can be channelled to drive water-cooled chillers.”

ICS Cool Energy Ltd has recently installed turbocor chillers at Pinners Hall in East London, owned by Internationales Immobilien-Institut (iii-investments), as part of the phase out and replacement of R22.

The installation included three water-cooled 562kW Turbocor chillers and an intelligent management system that regulates the units, ensuring optimum coordination of working times and cooling capacities; it also balances strategy among units, providing superior reliability and maximum energy efficiency as a result of specific logic of the pumping groups.

The units have a compact size and weight ratio, making it ideal for simplified site operations and space optimisation. Weighing less than 300lbs, the Turbocor is a fraction of the weight of a conventional compressor.

John Pinagli, Building Manager at Pinners Hall comments: “The management system allows me to accurately monitor the three unit’s cooling output and observe how much energy each one is using. At night, we are capable of running the units on part loads, due to low occupancy of the building, and this will save us massive costs in the long run.”

ICS Cool Energy Ltd provides a planned preventative maintenance contract to limit production downtime, while regular maintenance ensures energy costs are reduced and that the chillers run efficiently.

The old units at Pinners Hall were decommissioned by ICS Cool Energy, with complete installation of the units and pipe work provided as in a turnkey package. Pinagli continues, “ICS Cool Energy provided an efficient service; decommissioning the existing cooling system and replacing it with the new kit. The regular maintenance checks give us confidence in the units and ensure all personnel within the building are at a comfortable temperature.”