There’s nothing better than hot toasted crumpets to warm the heart on a cold winter’s day but do we ever stop to think about all of the work which goes into creating these iconic symbols of a British winter? In fact crumpets have moved away from being purely a winter treat and are now consumed year round, making it more important than ever for production lines to be smooth and continuous.
So when BRS was invited to upgrade the plant cooling system which formed part of a crumpet production line we knew we had to do a good job. In a nutshell the task involved providing a continuous flow of cooling fluid which would feed the air handling units which provided cooling for crumpets.
The design consisted of two main elements; the chillers and the ring main, both operated via a control panel. The optimum design called for three chillers to be used to cool glycol in a 2000L bunded tank. With two out of the three chillers online at any one time the chiller configuration was set at duty, duty assist and standby with the control system alternating the chillers in order to ensure running hours were evenly spread over the three units. With each chiller having a separate glycol flow and return, chillers were designed to be stopped and started independently.
The design called for glycol to be circulated via a ring main from the cold side of the tank, through to the cooling coils and process (or the bypass) and back to the hot side of the tank. Two pumps controlled the circulation on the ring main operating either in duty or standby mode. The ring main pumps were enabled to work in auto and manual modes. When auto mode was selected the glycol ring main pump operated continually with running hours determining the rotation between the two pumps. Manual mode allowed pumps to be switched on and off as required.
The control panel operates via its own TPN supply from the factory distribution network, housing the controls for both the chillers and the glycol ring main pumps. An HMI provided the schematic range of chillers, pumps and valves; with operation and temperature indicators highlighting the current status for chillers and ring main.