In 2016, Innovative Refrigeration Systems began work on a state-of-the-art ammonia/CO₂ cascade system.
The client needed an installation that would support their operations for the next 30-50 years, using natural refrigerants. The system was to be used to test engines and powertrains in extreme conditions, to temperatures as low as -55℉.
We manufactured 7 ammonia skid packages, 12 reciprocating compressors, a cascade condenser platform with 4 cascade condensers, and 8 remote chiller packages for the project, all to ASME B31.5 and IIAR2 2014 specifications.
We also installed a fully integrated Allen-Bradley PLC system with HMI graphics and 3D interface. Variable speed drives were included to allow superb turn-down control at low and partial loads.
The client also opted for our ePSM software to help facilitate daily operations, training, and regulatory compliance.
The chilled water system that we installed can produce 1,300 tons of chilled water, on an ammonia charge as low as 0.99 lbs per horsepower. The ammonia/CO₂ cascade system has an even lower charge: 0.89 lbs per horsepower.
One of the challenges that we faced during construction was moving packages into an existing facility which had been fitted with small doors. Because of this, all of our packages were design to be knocked down to fit through existing doorways, and were then reassembled in their final location.
We’re happy to have contributed one of our eco-friendly cascade systems to this extreme testing center.