We were approached by a large automotive client, who had a number of old beside the press water cooled chillers circa 1989. Reliability was a major issue due to the age of the chillers. This coupled with spare parts becoming increasingly difficult to obtain and costly.
Consideration was given to their replacement on a like for like basis.
Given site run JIT and being individual beside the press chillers, should a failure be experienced this exposed the site to major down time and costly loss of production, not only in the injection moulding area but more noticeably in the downstream assembly areas.
Other considerations and concerns:
The existing chillers were nestled amongst the mould tool storage area, with footprint being extremely tight. Typical mould tool being 4000 x 3000 x 2500 weighing approx. 100 tonnes. Therefore as part of site HSE, when the mould tools are being changed (this being on a regular basis) the storage area had to be evacuated.
Energy efficiency and remote monitoring were also on the clients wish list.
To satisfy the cooling requirement and have resilience we supplied and installed two Zeta Rev 18.4 Air Cooled Chillers.
Chillers had be selected on a duty/standby configuration. However to take advantage of part load efficiencies both chillers were in the duty mode.
The Advance controller allows site to monitor each chiller for the remote maintenance office.
Install time was limited to site seven days shut down plus two weekends.