Climate Technologies Corp

Advanced Climate & Environmental Solutions for Commerce and Industry

Climate Technologies Now Offers HVAC Equipment Rental

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Polygon Humidity and Temperature Control Equipment RentalClimate Technologies now offers cost-effective equipment rental for temperature and humidity control through our partner Polygon.

With experience from more than 20,000 projects, Polygon has the know-how and the equipment to help you work without delays while maintaining temperature and humidity requirements at the lowest possible cost.

Polygon offers a complete line of equipment along with the engineering expertise to size and integrate a system specific to your needs, allowing you to reduce energy usage while ensuring job-site dependability.

Polygon’s application knowledge can help with humidity and temperature control on jobs such as:

  • Manufacturing processes
  • Blasting and coating operations
  • Condensation control in food processing
  • Power plant lay-up and turn-around
  • Construction drying
  • Many other industrial applications

Temperature and Humidity Control Equipment Rental

Polygon Equipment Rental for Temperature and Humidity ControlPolygon supplies as much or as little as you need. They can provide ductwork, inlet/outlet transitions, oversize blowers, high static blower units, transformers, and gas or steam-regenerated dehumidifiers.

Equipment can be adapted to a range of voltages. Generally, equipment is provided on skids with forklift slots.

Minimum rental period: 1 month (1 week in emergencies).

Rental Equipment Available

Polygon has the following types of temperature and humidity control equipment available for rent:

  • Desiccant dehumidifiers
  • DX units
  • Chillers and cooling coils
  • Indirect-fired heaters
  • Electric heaters
  • Filter modules

Advantages of Equipment Rental through Polygon

  • Try Before You Buy
  • Dependable Operation
  • Off-site Equipment Monitoring

 

Read more about Polygon Equipment Rental

Discover the Science of Heat Balancing

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Published by permission of Cooling Technology, Inc.

The most fundamental principle in process cooling is heat balancing. The amount of heat removed by the chiller must equal the heat generated by the process, no more, no less.

Heat Removed = Heat Input

Frequently implemented methods for heat balancing are:

  • Compressor Cycling
  • Compressor Cylinder Unloading
  • Extra Capacity
  • Hot Gas Bypass

Not listed among these methods are additional solutions that may be more suitable for enhanced plant-wide efficiency.

heat balancing, compressor cycling

Compressor Cycling

Without a control mechanism, a refrigeration unit will continue to cool until it reaches its maximum chilling capacity. In other words, after the chiller satisfies its process load, it probably will generate additional cooling.

Compressor cycling is one method to control the level of cooling of a refrigeration unit. It involves the use of a thermostat and the predetermined refrigeration temperature “set point”. When cooling reaches the set point, the thermostat interrupts this potential run-away cooling and stops the compressor from circulating refrigerant through the system.

Without the compressor off, the coolant circulation pump continues to operate. At the same time, the process keeps on generating the heat, increasing the temperature. Once detected, the thermostat calls for cooling by energizing the compressor. This thermostatic control of turning the compressor on and off according to the temperature “set point” is called “compressor cycling”.

The main drawback of compressor cycling is over-use of the compressor for non-productive purposes, or “rapid cycling”.  This condition is particularly significant when the process heat load is much less than the chiller capacity.

Rapid cycling’s greatest impact occurs when the compressor restarts. As the compressor’s electric motor turns on, a momentary and large current spike occurs to overcome friction demands – often 600% more than normal. This spike causes the motor windings to overheat. If allowed to operate in this condition for prolonged periods, the overall wear of the electric motor will cause premature failure. The failure often results in electric motor burnout.

heat balancing, Compressor Cylinder Unloading

Compressor Cylinder Unloading

Another method of heat balancing is capacity control through compressor cylinder unloading. In this case, a thermostat energizes a solenoid (or solenoids if there are multiple cylinders in the compressor) that forces the discharge valve to stay open. Since the cylinder chamber opens to the discharge manifold, no compression of the refrigerant can take place. The result is a drop in refrigeration capacity that is in direct proportion to the number of cylinders being “unloaded”. The torque on the electric motor reduces, resulting in lower energy consumption.

Cylinder unloading is most desirable as a method of capacity control since it balances a chiller’s capacity to the processing load and saves energy.

Pragmatic Solutions

The traditional method of reducing refrigeration capacity to match the heat load – compressor cycling, hot gas bypass, cylinder unloading, water regulation, and fan cycling – is useful in dealing with only a part of the extra capacity. In addition, most methods (excluding cylinder unloading) have a negative impact on the service life of the compressor, the most expensive component in a refrigeration system.

The heat balancing problem may be more effectively managed from a different perspective – that of pragmatic solutions. A portion of excess refrigeration capacity can be put to useful work, such as air conditioning.

In principle, redirection would come from a tap in the refrigerated water supply to air cooling. The new line can route a small amount of water through a fan coil unit. The fan coil unit consists of a finned tube air-to-water heat exchanger (like an automobile radiator) and a fan (or blower). A small amount of chilled water circulates through the fan coil.  When air passes over this coil, the result is cool refrigerated air.

This “free” air conditioning can be used for process cooling or cooling of the operator workspace near the equipment. On a larger scale, a central chilled water system can produce plant-wide air conditioning at relatively little expense by strategically locating fan coil units where machines and operators are stationed.

heat balancing, Extra Capacity

Extra Capacity

It is common practice in the plastics industry to size a chiller for mold cooling where the actual output of the chilled water system is greater than the process heat load. This practice started when plastics manufacturers opted to configure their production lines in multiples of five tons. The associated process cooling requirement simply parallels these multiples.

More cooling capacity may also exist as a safety margin. Plastics manufacturers frequently select the “next higher” 5-ton refrigeration to ensure that heat removal from the molds is complete. This further adds to the chiller capacity previously caused by the 5-ton multiples of the production lines.

Control of the additional chiller capacity is imperative. Left unchecked, the process cooling system can experience damage from “overcooling” or “freeze-up”. Heat-balancing methods ensure that the chiller’s capacity matches the process heat removal requirements.

heat balancing, Hot Gas Bypass

Hot Gass Bypass

A hot gas bypass valve meters hot refrigerant gas into the evaporator downstream of the expansion valve. The result is a reduction in the capacity of the refrigeration circuit. Its use is to supply the compressor with a continuous full load while the chiller is handling the partial load conditions. The valve is particularly important when operating a semi-hermetic compressor since the compressor must receive a full amount of refrigerant for motor winding cooling.

Normally, the compressor adds energy to the refrigerant by increasing its pressure and temperature. The resulting hot gas goes to the condenser. The condenser removes heat from the gas and allows it to pass to the thermal expansion valve (TXV) as a liquid. This flow path changes with a hot gas bypass.  As the compressor satisfies the processing load, water begins to over-cool.  A thermostat senses this drop in temperature.  At a preset temperature, the thermostat opens an electric solenoid hot gas bypass valve allowing refrigerant to take the path of “least resistance”.  Least resistance is the hot gas bypass.

A portion of the refrigerant bypasses the condenser and the TXV valve.  The un-condensed gas mixes with the refrigerant that has passed through the TXV.  Since the mixture of liquid and gaseous refrigerant loses some capacity to remove heat, a “freewheeling” occurs: without heat removal from the refrigerant, the water in the chiller begins to rise in temperature.  The thermostat detects this temperature increase in the chiller and closes the bypass valve when water reaches the set temperature.  In this way, the hot gas bypass prevents the compressor from short cycling when the chiller operates under partial load conditions.

About Cooling Technology

Cooling Technology
Cooling Technology’s full line of custom designed products includes:

  • Portable Air and Water Cooled Chillers (1 ton – 25 tons)
  • Central Air and Water Cooled Chillers (100 tons – 300+ tons)
  • Evaporator Condensed Chillers (100 tons – 300+ tons)
  • Integrated & Stand-Alone Tanks
  • Open & Closed Loop Tower Systems Including Cooling Towers, Tower Tanks, Heat Exchanger Skids, & Tower Support Structures
  • Dry Fluid Coolers
  • Hydronically Sealed Systems
  • Inline & Sand and Gravel Filters
  • Temperature Control Units
  • Specialty Controllers

Contact Climate Technologies to Find Out More

To learn more about these solutions, please contact Climate Technologies.

Epsilon Packaged Mechanical Plant for Holy Cross Hospital

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The Challenge

Hospitals are heavily regulated in terms of their size, total number of beds, the services they can provide, and fees they can charge. Given these regulations, it is a challenge to maximize the value of the facility.

Hospital facilities are built to last a long time and are among the most energy intensive buildings. Consequently, the mechanical systems must have a long service life, be of the highest quality, and be as efficient as practical.

Holy Cross Germantown Hospital in Germantown, Maryland, needed a solution that maximized the allowable area of the building, provided very high-quality mechanical components and offered maximum efficiency

The Solution

Epsilon Packaged Mechanical Plant

The solution involved the incorporation of an Epsilon Industries packaged mechanical plant. This is a free‐standing, completely factory designed, engineered, and fabricated mechanical plant. It consists of boilers, chillers, pumps, cooling towers, and electrical system.

Case Study: Epsilon Packaged Mechanical Plant for Holy Cross Hospital

This 2,000+ ton plant is enormous at over 5,000 ft2, yet it would have been twice that size had it been field built.

Working closely with the engineering firm, Epsilon used advanced 3D CAD to optimally arrange the system’s components. This, plus their closely controlled factory fabrication processes, resulted in minimum space required while ensuring adequate access.

The entire plant is classified as a piece of mechanical equipment (even though it shipped in 17 sections) because it is factory fabricated and bears the ETL label.

Case Study: Epsilon Packaged Mechanical Plant for Holy Cross Hospital

As a result of the optimal system design, Holy Cross was able to devote what would have been 5,000 ft2 or even 10,000 ft2 of mechanical room space inside the building to health services related space.

In addition to the system design, Epsilon provided job site labor and expertise during plant assembly and start‐up.

Refrigeration consists of three‐550-ton Daikin model WME magnetic bearing centrifugal chillers and two 190-ton Daikin TGZ Templifier water‐to‐water heat pumps.

Depending on fuel costs, the plant can produce hot water via gas, oil, or electric heat pump. The Templifier heat pumps “amplify” 44° CHW to 140° HW. The boilers are of the dual‐fuel 97% efficient condensing type. Sufficient structural integrity is provided to allow mounting of the heavy cooling towers on the plant’s roof.

The electrical distribution system consists of high voltage input switchgear and transformer inside a 1-hour fire‐rated enclosure. It serves chillers, towers, boilers, Templifier heat pumps, pumps, domestic hot water equipment, and fire pump.

An Allen‐Bradley PLC controls the entire facility through a local touch-screen interface. In addition, the PLC is connected to the main building BMS.

A packaged plant has many benefits. Not only is it a higher quality installation than a field‐built system, it is also less expensive, reduces engineering time, requires far less construction time, and allows the owner and engineer to get exactly the equipment and level of quality they want.

On this project, Epsilon worked closely with Holy Cross, the engineering firm, and the general and mechanical contractor on costs, design alternatives, equipment selection, and system layout. As a result, Holy Cross Germantown Hospital got exactly what they needed, at the right cost.

The plant qualified for a significant rebate from Pepco under the Empower Maryland Act.

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GM T1 Project – Chilled Water Plants

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When General Motors and their contractor Barton Malow needed three 7,500 Ton Chilled Water Plants for expansions at the GM plants in Fort Wayne, IN, Arlington, TX, and Flint, MI, they turned to Climate Technologies and Epsilon to design and fabricate modular central utility chilled water plants.

The chilled water plant shown (GM Fort Wayne) was installed in only two and one-half weeks.

Epsilon’s factory-built concept allowed General Motors and Barton Malow to save millions of dollars through the parallel path manufacturing process.

Using this manufacturing concept, these three plants were designed and delivered in significantly less time and expense as compared to stick building the same facilities on-site.

As a result of the factory-built concept, these projects did not encounter any weather delays, material handling problems, or other slowdowns that typically hamper on-site builds.

Each Epsilon chilled water plant delivered to GM is designed to accommodate future on-site expansion.

AVL America, GM Powertrain Prove Out Center

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Climate Technologies has delivered a 650 horsepower -40F M&M Refrigeration chiller and low temperature secondary fluid pumping package to AVL America.

The chiller will provide the low temperature fluid for prove out testing of the components for General Motors new state of the art powertrain testing facility to be built in Pontiac, MI.