Atlas Copco

The Client

Atlas Copco is a world leading provider of compressors, ancillaries and systems.

The Oil-free Air is a division within the business area Compressor Technique of the Atlas Copco Group with the main production centre located in Antwerp, Belgium.

Two ZR160, variable speed drive FF oil-free air compressors were requisitioned for installation at the Belfast facility of Diageo Global Supply, to include the ongoing operation, monitoring and maintenance of both compressors, receivers and a Stadco Cooling closed circuit water cooler.

At its Belfast facility in Northern Ireland, Diageo Global Supply bottles and cans approximately 10million cases, annually, of global premium brand goods such as Guinness, Budweiser and Smirnoff Ice.

The upgrade at the plant ensured a 100% oil-free 'clean' and dry supply for essential valve and instrumentation operations.

The Objective

• To cool two ZR160 VSD Air Compressors with drier, requiring a total water/glycol (30%) flow rate of 18.3 m3/hr with a temperature rise from 30 degrees Centigrade to 45 degrees Centigrade through the equipment
• The heat load was calculated as 320 kW and design ambient temperature determined as 26 degrees Centigrade dry bulb.

The Solution

Sealed and pressurised closed circuit water cooling system.

The cooling system was designed so that the coolant, in this case a water/glycol mixture is continuously recirculated to avoid water loss and eliminate water costs.

To be hermetically sealed, linking the pump module and air blast radiators directly to the process they were required to cool, eliminating limescale corrosion and direct contact between the water and air, which eliminates the risk of potential environmental problems (eg Legionella).

Fully weatherproofed and winterised for outdoor installation.

Copies of assembly and electrical drawings, together with an installation and maintenance manual were also provided upon completion of the order.

The system comprised:

• Air blast radiator (Dry air cooler)
• Sealed dual pump module (1 duty, 1 standby)
• Electrical control cabinet

The Result

• Reduction in operating costs
• Improved performance
• Improved reliability – sediment free water
• Water conservation
• Considerable energy savings
• Reduction in corrosion
• Elimination of limescale
• Reduction in maintenance costs
• Elimination of water treatment

The Endorsement

Joe Newman at Atlas Copco says "When we use Stadco Cooling sealed and pressurised closed circuit cooling systems we know that we can rely on the products and don't have to worry about their performance.

We can fit them and forget them, which demonstrates the suitability and reliability of sealed system cooling in a busy industrial environment."

"Stadco Cooling provide a complete range of cost effective and dependable solutions, which specifically meet all of our needs."