Maximize subcritical hours with adiabatic technology
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Yosemite Foods expanded their pork processing facility in Stockton, CA, installing a 100% CO2 refrigeration system to service the 116,000 square foot refrigerated space. The 5-rack system was designed for efficiency and redundancy using parallel compression. Key components included Danfoss controls, CRS compressor racks, BAC Trillium gas coolers, and a hot water heating loop. While some challenges occurred during installation and commissioning, the system is now operational and nearing production runs in July.
Maximize subcritical hours with adiabatic technology
- 2. Yosemite Foods, Stockton Ca. Industrial CO2 Refrigeration System
- 3. Presenters: • Michael Lau, Ph.D., Yosemite Foods, End User Perspective • Bryan Beitler, VP Engineering, CoolSys, Design and Installation Perspective • Project Partners, Q & A Danfoss CRS BAC RSI
- 4. Company Profile: • Yosemite Foods Inc., – Started as Yosemite Meat Co. in 1981 • Family Owned and Operated • Second Largest Pork Processor in CA • Supply 75% Ethnic Markets Throughout Northern CA
- 5. Project Scope: • Expansion 200,000 SF • Will Process 550,000 lbs. daily • 116,000 SF Refrigerated Space – 100% Transcritical CO2 System • Automation, Heat recovery, Robotics • Energy Efficiency
- 6. Decision Process: • Compared Multiple Systems – Ammonia, Cascade, Transcritical • Heavily Researched Transcritical: Limited Knowledge • Evaluated: • Regulations, Safety, Costs, Efficiency • Part of Story, Future Path in CA
- 7. System Design Objectives: • Alignment of Design Objectives with Customer needs • Build in Efficiencies Effecting Cost of Operation • Use Components that are Familiar to Service Tech’s • Redundancy, Keep Racks Similar • Future Capacity Considerations • Loop Piping Design, Simple to Install and Operate • Operator Friendly, Distributed Controls • Safety
- 8. Rack Design: • 5 Total Racks, 3 Suction Groups, Transcritical Design, Parallel Compression • LT capacity: 109 tons, each rack, -15 SST/+20 Tc, 80 HP • MT capacity: 163 tons, each rack, +20 SST/+82 Tc, 280 HP • HT capacity: 104 tons, +38 SST/+82 Tc, 130 HP • Each Rack Identical, 490 HP, 13 comps • 2200# CO2 Charge, Each Rack
- 9. CRS Compressor Rack Systems
- 10. CRS Rack System Features: • Parallel Bitzer Semi-hermetic Compressors • Parallel Compression: Offers Ability to Shift Between TC and SC Operation Seamlessly • High Quality Stainless Steel Piping System • Coalescing Oil Systems • Parallel Vessel Design • Booster De-superheating with Trillium System • Variable Speed Compressor Control for Max. Efficiency
- 11. Redundancy Roadmap Facility Picture, color coded
- 12. Chill Room Evaporators Picture of quick chill coils, etc.
- 13. Rooftop Piping system Picture of Rooftop piping
- 14. Transcritical Design with BAC Trillium Technology: • Allows Most Efficient Warm Weather TC Design • 200 F to 80 F gas temp. reduction in TC mode • TC operation will be minimal with Trillium technology (<1%) • High Efficiency Fans, Staging with VS Control • Wetted Pad Design with Anti UV, Stick and Algae Coating • 16 % Spare Capacity Built in • Water Saving Controls, Sustainability Features, Zero Chemicals • 10 FPI coils, Epoxy Coated Al. fins, K65 high Strength Cu Tubing • Trillium Desuperheater for LT Discharge, 76 F temp. Reduction
- 15. BAC Trillium Gas Coolers: Pictures of BAC Trilliums
- 16. Trillium Operation Details Stockton Design: 103.5 F DB 71 F WB
- 17. Features and Benefits: Hot Water Heating • Each rack is fitted with high side HX’s for process water heat • Approx. 7.5 MBTU contribution • Critical component in the Decision making process • Uses include wash down, product wash, underfloor heat • Significant natural gas savings
- 18. Features and benefits: Integrated Controls Architecture • Danfoss AK-SM800 series System Manager • Supervisory, Localized Smart Processors, EEV’s, as well as key CO2 System Control Valves all from one Manufacturer • Evaporator VFD’s for T24 Compliance and Energy Savings • Compressor VFD’s allow for Best Staging • Tried and Tested CO2 Programming and Strategies
- 19. Danfoss Control System Architecture Rack Control Panel AK-SM800AL System Manager 781 Pack Comm. 750 Case 750 Case Comm. Stepper valve control Pulse valve control Remote Evaporator Control Panel 208C Stepper
- 20. Rack and Defrost Controls
- 21. Features and Benefits: Hot Gas Defrost • 4 Pipe System, Waste heat off MT discharge • Hot gas pressure Regulator maintains 2-3 Bar flow differential • Slow opening valve allows deliberate flow control • Remote valve stations • Hot gas used for drain pan defrost
- 22. Defrost Operation Sequence: • EEV closes, pump down mode • Fans ramp to 0 Hz • Hot gas regulator enabled, 40 bar outlet press • Suction solenoids closed, hot gas solenoid open • Termination, 50 F coil outlet temp, time as failsafe • Hot gas solenoid closed, disable hot gas regulator • Drip Down cycle • Open suction bypass solenoid • Open Suction stop and enable EEV • Fans ramp to 80 % Refrigeration Gas Defrost
- 23. Hurdles: • Availability of Key Components • Evaporator Factory Leaks • On site Spare Charge Required • Some Evaporator Motors not VS Compatible • Existing Building, Rooftop Piping • City Inspections were Extremely Detailed • Larger Capacity Pulse Valves not Available
- 24. Current Status: • All Systems in Operation • Freezers have not been Pulled Down to Temperature • Hot Water Heating Loop not Functional yet • No Leaks, no Failures, Minimal Trips • Programming, Leak Detection Alarming, and System Controls Fully Functional • Target for First Product Runs, July 8
- 25. Q & A