Chipita Russia – Industrial HVAC & Refrigeration
Confectionary & Sweets St. Petersburg, Russia 2015 Project scope was: Design & construction of the HVAC systems of the Chipita factory in St. Petersburg, Russia. Highlight The design & implementation
Industrial HVAC & Refrigeration
BCT company core expertise is the design and installation of HVAC and Refrigeration systems for Industrial Purposes.
Having developed numerous of solutions for almost all production processes BCT holds special know-how and experience to provide:
Temperature control and heat dissipation manipulation
Humidity control
Ventilation to meet specific environmental requirements
Volatile agents control
Particles generation control
Low and extra low temperature conditions
Each HVAC system comprises of a number of subsystems which are tailored developed to meet manufacturing process requirements. Those are:
Air Handling Systems
Cooling medium Systems
Humidification Systems
Pump Stations
Air Distribution Circuits
Cooling/Heating Medium Piping
Power & Control
Operation Monitoring
Air Handling Systems
All Air Handling Systems are designed by our Engineering Team with 3 main objectives:
To simulate the psychometric processes developed for each application (BCT expertise)
To achieve the less possible energy consumption. Energy reclaim form exhaust air streams with air-to air heat exchanger or run around coil exchangers is always implemented
To be manufactured with the appropriate materials for each application (SS or GS) allowing space for cleaning, sanitation and maintenance
CAPEX and OPEX optimization with respect to process requirements are the central goal which need to be achieved.
BCT integrates CIP self cleaning, UV sterilization and sanitating capabilities in hygiene AHUs for delicate food and bio-contamination applications.
Happy to share
our expertise!
Cooling Medium Systems
BCT group is qualified in designing and installing centralized cooling systems from 100 kW to 10,000 kW cooling capacities.
Large facilities with multiple cooling consumptions and with different cooling load peaks present a challenging area and demand expertise approach. Energy consumption can vary significantly depending on the applied system (more than 60% of consumed energy can be saved in partial loads operation) as well as it is not assured that all areas requirements can be achieved as the system adjusts to the current demand.
Successful operation does not only follow to proper selection of cooling equipment, but the entire system must be properly designed.
Special consideration must be drawn to critical loads that shall be served under any circumstances therefore reserved capacity shall be assessed accordingly.
Cooling medium (water or glycol) flow adjustment of the circulated quantity according to demand is a key element which determines ability to effectively accommodate the current loads and consume the less possible energy.
Our company makes centralized cooling systems with low GWP refrigerants (R1234ze, NH4, CO2):
Parallelized air and/or water-cooled chillers appropriately sized to accommodate minimum and maximum loads
Automatic adjustment of the circulated cooling medium according to current loads
Energy reclaim from the air-cooled condensers for production of warm water for the needs of the facility
Heating Medium Systems
Steam or hot water heating station consisting of one or multiple parallelized boilers using energy from natural gas, LPG or oil is a strong specialty in V. Bougatsos SA applications portfolio.
Systems are designed appropriately to accommodate for peak and partial loads with the less possible energy consumption and best adjustment to load fluctuations.
Our company makes centralized heating systems with:
single or multiple parallelized boilers (electroboilers, oil, natural gas ,LPG)
primary/secondary heating medium circuits
automatic adjustment of the circulated heating medium according to current loads
economizers in steam generators
integration of solar energy when it is possible
Dehumidification - Our Masterpiece
Apart from the processes that require extra low humidity dehumidification is important in many HVAC applications especially in Cleanrooms and Contamination Control Spaces as humidity favors microbial growth.
Humidity is generated in a space when:
Vapor processes take place (liquids heating / boiling/steam processes),
Cleaning procedures occur frequently (cheese plants)
Human concentration is high (now often in industrial spaces)
Humidity is introduced also in a space by fresh air intake, common situation in cleanroom applications as fresh air is used for rooms pressurization and in 100% fresh air systems / 100% air exhaust systems.
There are numerous of practices to control humidity. All are highly energy consumers, and some require important CAPEX devotion, especially when desiccant dehumidification technology must be integrated.
Nevertheless, if good psychometric approach is developed from the beginning dehumidification costs can be maintained to a minimum. This can occur by treating fresh air dehumidification separately to the rest air of the system, by providing precooling to desiccant dehumidification processes, by incorporating face and by-pass technics.
Proper control of the system operation is very important in dehumidification systems. In BCT all control systems are designed and developed in-house by our automation experts.
System integrators using cooling and reheating to perform dehumidification are often mislead reacting to relative humidity variations without assessing water content level in the air. This leads to excessive energy consumption as system air is subjected to low temperature cooling below due point level and then reheating.
In BCT we have developed special algorithms to perform dehumidification only when water content calls for it and always in analog proportional way. We apply these algorithms even in the simpler application to provide the lowest energy consumption.
Return air by-pass is always our first choice to minimize reheating demands.
Humidification
As low excessive humidity is detrimental for many manufacturing processes the same applies to low humidity content.
There are manufacturing processes where humidity must be maintained in a stable controlled level, such as Paper and Paper products industry, Printing Plants, Tabaco and wood industry.
Humidification is a delicate issue as it incorporates water or steam.
Water has a series of special parameters which need to be taken care of such as water treatment, salts that clog vaporization equipment and sanitation. On the other hand, steam requires also water treatment and is a high energy consumer. Both solution require effective maintenance and special care by the operators and service personnel.
In BCT we assess carefully every case to suggest the most appropriate solution taken into consideration the experience, capabilities and SOPs of the plant in terms of water treatment and steam equipment.
Pump Stations
Pump station in HVAC-R systems are related to cooling or heating medium circulation to the manufacturing plant to feed equipment (HVAC, Refrigeration or Process).
Pumping equipment, especially in large scale production facilities, requires also careful design as it is a high energy consumer as well, it determines system effectiveness and in some times determines system success.
There are not less cases where we have seen inability of pumping volume adjustment proportionally to cooling / heating loads and consequently return water from inert cooling equipment to be mixed with chilled water and finally the mixture to be incapable of performing laten cooling and water condensation.
Pumping station design is always related to the piping circuit design and the way cooling / heating medium feeds consumptions. When two way analogue valves are used pump station can have variable water flow achieving substantial energy conservation. Special care must be drawn to variation limits in primary chillers water to assure unloading of the evaporators.
Pump station redundancy is important. Critical loads must always be satisfied even in the event of one pump malefaction.
Air Distribution Circuits
Our air distribution circuits are made of:
Galvanized metal sheet ducts
Stainless steel metal ducts
Textile ducts especially for air diffusion
For metal duct circuits construction, we follow SMACNA standards. Air distribution circuits are sized with respect to static regain technic or equal total pressure loss in all circuit branches.
Air leakages must be eliminated especially in cleanroom applications where air volume rates are highly necessary to be maintained.
In many cases Duct Circuits commissioning takes place and Pressurization Test.
Duct insulation is important for minimizing energy loss and temperature modification from what is controlled by the AHU but also in order to eliminate air condensation in the outer surface of the duct.
Cooling / Heating Medium Piping
Our piping circuits are made of:
Polypropylene Random Plastic (PPR) for clean water and brine circuits
Stainless Steel for water, brines and refrigerant circuits
Copper cryogenic tubes for CO2 of halocarbon circuits
Use of black carbon steel piping is selected after assessement taking into consideration piping rusting overtime and potential heat exchangers clogging.
Piping circuits insulation is important aiming to minimize energy losses and condensation drainages. Pipping cladding especially in outdoor spaces is performed to protect insulation material by weather conditions deterioration.
Valves and special circuit devices, deaerators, vessels etc are part of the piping circuit and need to be carefully sized and incorporated in the system. In these we shall add axial pipe expansion joints to absorb pipe expansion and contraction as well as seismic expansion joints in positions where pipe is passing through building joints.
Piping supports, anchoring and pipes penetration to walls and roof are very important to assure proper static resistance, sustainability and building shell tightness in respect to water penetrations etc.
All piping circuits must undertake pressure test, deaeration and cleaning before operation.
Power & Control
Power and control systems are the heart of a system as it leads the whole operation.
The automation system is the brain of the application, and it determines proper operation and achievement of the desired requirements.
In BCT Group we have a qualified team of experienced automation engineers who design the application’s automation system providing the most effective interaction of all parts of equipment. We develop our own automation systems simulating the Psychrometric & Cooling cycle Processes into HVAC-R Control Language.
In this way system is 365d/24h adapted to external conditions (ambient, fluctuation of internal load) in order to assure full compliance with the Requirements
ACMS
ACMS stands for Automated Controlling Management Systems and is the HEART & BRAIN of our Systems
Users supervise all operation from a monitor
Access to ACMS systems is provided from everywhere though web
Valuable information considering consumptions are real time Cloud filed, user knows real time operation costs
ACMS is the best partner of preventive maintenance as data related to service are constantly monitored, notifications for actions are provided on time
Operation Monitoring
Coding Air and Refrigeration Processes
All Processes (psychometrics, cooling cycles etc) are simulated into source code. All conditions are measured by sensors and action is energized by servomotors, actuators, EC motors, VSD etc. Operation Scenarios are developed by V. Bougatsos SA, based on engineering design verified by commissioning experience.
Monitoring Systems
Every System is Depicted in active graphics providing real time full monitoring trough installed screen and web. Programming Scenarios can easily be upgraded through web without real presence on site
IoT & Machine Learning
Data are constantly gathered, and different scenarios initiated by different conditions are energized. Machine learning algorithms are newly integrated to upgrade system decision making to most efficient operation, achieving conditions and minimizing energy consumption
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