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The Cofely Refrigeration GmbH customer newsletter

CREATING THE WORLD OF REFRIGERATION.DISTRICT COOLING NETWORKS | REFRIGERATION CONTAINERS FOR PHAR-MACEUTICAL PRODUCTION | CROSSING THE OCEANS WITH MARENUM

REFlect | Issue 02/20152

CREATING THE WORLD OF REFRIGERATION.Cofely Refrigeration has the right cooling solution for every situation and all require-

ments – and we would like to introduce you to a few particularly exciting ones in this

issue of REFlect.

The new QUANTUM P (Powerline) is an impressive addition to our product portfolio.

With a cooling output of up to 4.5 megawatts (MW), the QUANTUM P is the perfect

chiller for the technology of the future. Why? Because it has sufficient power to

sustain a district cooling network. This form of centralised cooling is becoming

increasingly important for larger building complexes – because district cooling is

efficient, economical, flexible and reliable. Which explains our intensive involvement

with this dimension of refrigeration.

In a completely different area, namely on the high seas, the MARENUM chiller is making

its mark. In a fascinating interview, Daniel Keller explains the strengths and the particular

capabilities of the MARENUM.

As this year progresses there are further discoveries to be made, with the

air-cooled QUANTUM G taking us a further step along the road to green refrigeration.

Like its water-cooled “cousin” that has been on the market since autumn 2014, the

air-cooled QUANTUM G uses environmentally friendly refrigerant R1234ze. So at the

end of 2015, we will be going even further with the dimension of sustainability at

Cofely Refrigeration.

And you’d also like to know how the building of our new company headquarters and

production plant in Lindau is coming along? We’ll be telling you about this right at the

end of our REFlect newsletter – enjoy your browsing and reading!

Best regards,

Jochen Hornung

EDITORIAL

REFlect | Issue 02/2015 3Jochen Hornung, Managing Director

Cofely Refrigeration GmbH

“We are convinced that district cooling is going to be increasingly important in the future. The demand for cooling will continue to grow as, for example, more and more people want air conditioning in their homes and their workplaces. QUANTUM P can be used to generate refrigeration in district cooling networks efficiently and convey it to consumers according to their needs. Due to their high thermal storage capacity, district cooling networks can be very efficiently integrated into a smart grid and operated there,” says Jochen Hornung, CEO of Cofely Refrigeration.

REFlect | Issue 02/2015 5

THE RIGHT POWER FOR LONG DISTANCES.

With cooling output of 2.5 to 4.5 MW, the QUANTUM P has enough power to be used in a district cooling network. And it has all the benefits of the tried and tested QUANTUM series: It operates without oil, so no oil separator is required – this saves space and maintenance costs. An integrated open flash economiser maxi-mises energy efficiency. And like all of the chillers in the QUANTUM series, the QUANTUM P is impressively quiet-running and reliable.

A chiller for the future of efficient coolingThe centralised supply of cooling has a number of advantages over multiple local cooling systems. Firstly, a single powerful chiller requires less space than a number of smaller ones – an aspect that cannot be disre-garded in times of high property prices. A central cooling system that is as “invisible” as possible is nearly always a positive thing – for example, it dispenses with the need for noisy, unaesthetic re-cooling systems on roofs. However, the main factor is efficiency: cooling can be generated more effectively in the megawatt range, and this means lower energy costs. A district cooling network also provides the consumers connected to it with a lot of flexibility – it only supplies the cooling that is actually required, at all times. Continuous moni-toring, without which a district cooling network would be unfeasible, ensures the total reliability of the supply. In summary: district cooling is efficient, economical, flexible and reliable. Which is why Cofely Refrigeration sees it as a thing of the future.

District cooling networks are an elegant solution for cooling large building complexes with high demands in a particularly efficient and future-proof way. Of course, this only applies if such a network is powered by a chiller that is capable of meeting these high demands. A few months ago, Cofely Refrigeration added a particularly powerful chiller to its portfolio: the QUANTUM P.


DISTRICT COOLING ON CAMPUS.The Karlsruhe Institute of Technology (KIT) has been a satisfied customer of Cofely Refrigeration for years. Now KIT Campus has chosen QUANTUM P (Powerline) and a state-of-the-art district cooling network to supply cooling to the individual institutes.


With more than 9,000 employees, the Karlsruhe Institu-te of Technology (KIT) is one of the biggest research and education facilities in the world. It was founded in 2009 when the Karlsruhe Research Centre and the University of Karlsruhe were merged. KIT Campus – the opera-ting company – is already making use of the expertise and technology provided by Cofely Refrigeration: two QUANTUM chillers are cooling the data centre. How-ever, in the last few years the overall energy needs of the campus have increased significantly, and a sustain-able solution had to be found. The result: a QUANTUM P chiller with a cooling output of four megawatts (MW) and seven TT500 compressors is replacing the old am-monia chiller at the cooling centre of the district cooling network.

The advantages for KIT Campus:

• Excellent energy efficiency • Maximum cooling output in

the smallest space• Operation without oil means

low maintenance• Operating reliability and

redundant layout of the seven compressors

• Very quiet-running and low vibrations


Mr Keller, the generation of cooling on board must func-tion under extreme conditions on the high seas. How did Cofely Refrigeration master the task of developing a par-ticularly sturdy but also safe, reliable and energy-efficient chiller?All MARENUM models are based on the tried and tested QUANTUM chiller series, the advantages of which include oil-free operation and a particularly low noise level. And therefore all of the MARENUM models are distinguished by their com-pact design, low noise and vibration emissions, and low main-tenance costs.

How many MARENUM models are there?Two different MARENUM versions are available: the MARENUM C model is suitable for civilian shipping, which in-cludes ferries, cargo ships and yachts. For warships such as frigates and patrol ships, we offer the MARENUM N model.

And have empirical values been compiled yet? How does MARENUM perform on the high seas?It has performed very well! Since 2011 it has been at sea with frigates of NATO standard. It has fulfilled the highest shock, noise and vibration requirements along with the correspon-ding EMC demands. This has been verified by the Bureau Veritas ship classification company.

For our technology enthusiasts: Mr Keller, please give us a brief insight into the design of a MARENUM.I’d be glad to. The system technology is reduced to the main components required for the generation of cooling – compressor, condenser, decompressor and evaporator, including the related

COOLING THAT STAYS ON COURSE.Even when things aren’t wild and stormy, a maritime environment is still especially demanding for a chiller. Even during normal operation it has to be exceptionally reliable, compact, have low noise and vibration levels, and be resistant to seawater. An interview with Daniel Keller about the special features of MARENUM chillers.

MARENUM CHILLERS FOR THE SHIPPING WORLD

measuring and control technology. As a result, the MARENUM is much less susceptible to faults than the conventional system technology that uses oil management. The frequency conver-ter integrated into the compressor can be used to adjust the compressor speed to the varying cooling load requirements at different seawater temperatures. The redundant design with up to six compressors per chiller increases the reliability and provi-des a maximum cooling output of 2.5 MW per chiller.

Is a scaled-down chiller like this still efficient? Or do trade-offs have to be made in the energy efficiency department to ensure this robustness?What is required above all for efficiency is intelligent controlling – and MARENUM has this to the fullest extent. It has a control con-cept developed by us that can be used to activate and deactivate individual compressors. If there are multiple chiller on board, this concept can be applied to all of the chillers by implementing the Cofely cooling manager. There is also the option to limit the maximum power consumption of the chillers if, for example, the power supply is restricted. The high-performance finned tubes used, which enable adequate heat transfer in the condenser while maintaining the resistance to seawater, mean that the ope-ration of the chiller is particularly energy efficient. The soft starter integrated into the compressors also contributes to the efficiency as it prevents current peaks when the chillers are started, and this results in starting currents of less than 5 amps. Due to the imple-mentation of the latest electrical filter technology – made possible by the innovative and compact measuring, controlling and regula-ting concept – the MARENUM can compensate reactive currents and keep harmonic waves to a minimum. So, as you can see, no energy efficiency trade-offs have to be made with the MARENUM.


A chiller contains liquid refrigerant. What happens to this in rough seas? Surely you can’t have it sloshing around ...No, certainly not. To keep the refrigerant in the condenser at a constant level even during heavy swelling, known as rolling and pitching, the controller of the expansion valve draws on the mean measurements from two sensors. The chiller can be made even more reliable with an optionally available dual-circuit version of the two heat exchangers. The MARENUM has a specially designed flooded evaporator with an integrated gravity separator. This design prevents the compressor from taking in refrigerant – even in rough seas. The con-trolling of the MARENUM regulates the refrigerant pressure in the condenser by means of a seawater-resistant 3-way valve. This ensures problem-free operation of the chil-ler at water temperatures in the range of –2°C to +36°C. A ship has a very typical way of accelerating – accordingly, the base frame of MARENUM chillers is set up on vibration or shock dampers, making it vibration-resistant. Therefore, vibrations and shocks are minimised in rough seas. Thanks to the magnet-bearing and low-vibration compressor tech-nology, the vibrations of the chiller itself do not have to be compensated – here we benefit from the tried and tested QUANTUM technology already mentioned. If the customer wishes, Cofely will also incorporate cold-water and seawater supply pumps into the system concept of the MARENUM. The pumps can either be completely integrated into the base frame of the chiller or merely controlled via the chiller.

We all know that saltwater can be very aggressive. How does a complex machine such as MARENUM withstand it?An alloy of copper, nickel and iron used for the tube pla-tes and high-performance finned tubes of the MARENUM ensures that the condenser is highly resistant to seawater. All other parts of the chiller that have direct contact with seawater are made of either seawater-resistant rubber coa-ting or high-quality austenites, depending on the customer’s wishes.

It might only be a fantasy of the real “landlubber”, but the image of a technician covered in oil tinkering with the innards of a ship is a very vivid one ... Does this still exist?This image is certainly dated. Even though ship engines can-not do without oil, our chillers certainly can. All MARENUM models used magnet-bearing, oil-free turbo radial compres-sors. As a result, there is no need for the expensive, high-maintenance oil management of conventional screw, reci-procating and turbo compressors. Cofely has already sold more than 2,400 QUANTUM chillers in which this oil-free compressor technology was successfully implemented. So there are definitely no more oil-stained technicians here!

One last question: What happens if a chiller does actually break down?The MARENUM system concept is rounded off by Cofely’s comprehensive service: an extensive international service network guarantees fast, expert support. The ship’s person-nel can be given training during the commissioning of the MARENUM chiller, or within the framework of test runs.

Mr Keller, many thanks for this informative interview!

Our interviewee, M.Sc. Dipl.-Ing. (FH) Daniel Keller, was the Marine Technical Coordinator within Cofely Refrigeration in Lindau up to the start of 2015. Daniel Keller worked for a number of years in the Tes-ting and Application Technology department of Cofely Refrigeration, where he specialised in cooling applications for the maritime sector. Since 2015, Daniel Keller has been Manager of Sales Support at Cofely Refrigeration.

AMMONIA CHILLEROPEN FLASH ECONOMIZERFLOODED EVAPORATIONTWO SPEED-CONTROLLED SCREW COMPRESSORSCOOLING OUTPUT OF 110 KILOWATTS (KW) AT OPERATING POINT (–26°C) BRINE MODULE INCLUDING BUFFER STORAGES7 CONTROL WITH TOUCH PANELVISUALISATION OF SUPPLY ON CONSUMER SIDEENERGY MEASUREMENT AND DOCUMENTATION


A COOL BOX GETS THE TEMPERATURE JUST RIGHT.The correct temperature often determines whether we feel well - and also whether certain processes run smoothly. During the production of medicines and specific pharmaceutical products, cooling must not be random: it is mandatory to have an absolutely reliable constant temperature. This is one of the reasons why Nordmark Arzneimittel GmbH & Co. KG in Uetersen chose a chiller from Cofely Refrigeration.

The cooling system at Nordmark was a little old and also ran on refrigerant R22, the use of which is restricted by the EU directive on fluorinated greenhouse gases (F-Gas Regulation). Renovating the system was uneconomical, and so a new cooling solution was needed, one that would be safe, efficient and quick to install. Additionally, the plan was to use the space taken up by the old system as an additional production area. The solution was an ammonia chiller in a container made by Cofely Refrigeration, to be set up outside on the grounds of the plant.

A bespoke cooling solutionA turnkey container solution does not mean that individual customer requests cannot be fulfilled – on the contrary: Because there was not enough space for a standard container, Cofely Refrigeration produced a container to specific dimensions for Nordmark. It also functions as the base frame for two dry coolers of energy efficiency class A. The roof of the container holds the transfer points for the production as well as supports for setting up an inspection platform. The brine module – i.e. the interface between the cooling generation and the customer process – was adapted to the higher demands of the pharmaceutical industry. A test run (factory acceptance test) carried out at the operating point at –26°C before the handover to the customer was immediately successful.

Safe and suitable for everyday useSpecific safety regulations apply to working with the refrigerant ammonia. Only specially trained staff are allowed in the vicinity of a system of this nature. The refrigeration container from Cofely Refrigeration provides a practical solution, having two separate rooms for the machine and the controls. The gas warning system and a cabinet for the staff’s protective clothing are integrated into the control room, with a separate door leading to the machine room.


GREEN AND AIRY. Green cooling is on the rise – for a good reason. The use of environmentally friendly chillers has ecological, economic and even legal benefits. Specific restrictions resulting from the new F-Gas Regulation may no longer apply when sustainable, environmentally friendly refrigeration solutions are used. For example, with the new air-cooled QUANTUM G from Cofely Refrigeration, no leak test is required.

In autumn 2014, Cofely Refrigeration had already reacted to the great demand for green refrigeration

solutions by launching the water-cooled QUANTUM G. QUANTUM G uses the environmentally friendly

refrigerant R1234ze, which has a GWP value (Global Warming Potential) of less than 1. Like the classic

QUANTUM, QUANTUM G is based on oil-free compressor technology – the entire refrigeration circuit runs

without oil, and this significantly reduces the maintenance overhead. The water-cooled QUANTUM G was

previously available with a cooling output of up to 1.1 MW. The maximum output of the chiller has now

been increased to 2 MW.

Coming in 2015: the air-cooled QUANTUM G

This year, an air-cooled QUANTUM G with a cooling output of up to 1.25 MW is being added to the QUANTUM

G series. The machines in this series, which also operate with refrigerant R1234ze, are not subject to the

leak test as per the F-Gas Regulation (517/2014). However, the reduced effect of an environmentally friend-

ly chiller on the environment and the atmosphere should not end with the refrigerant is uses – it should also

be particularly efficient and conserve resources. For this reason, the refrigeration process in the air-cooled

QUANTUM G is optimised by means of an open flash economizer, which further significantly reduces the EER

value (Energy Efficiency Ratio). Operators also benefit from the compact outdoor installation. Free-cooling

modules can also be added to the air-cooled QUANTUM G. This makes the system particularly efficient when

the ambient temperature is cool enough to make free cooling possible.

Small channels, big benefits

The goal of the technicians at Cofely Refrigeration is to never stop making improvements. Which is why the

air-cooled machines in the QUANTUM series are now using micro-channel heat exchangers to transfer the

condensation heat. These special heat exchangers effect a decrease in the pressure loss on the air side and

increase the energy efficiency. Less refrigerant is used, and the sturdy fins are easy to clean. A micro-channel

heat exchanger can also be recycled without any problems – in keeping with green refrigeration.

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Cofely Refrigeration wants to continue to grow, and so it has to expand – the path is already clear: in record time a new company headquarters was planned, with production, storage and administration. On 13 July 2015, the foundation stone was officially laid.

“This new plant will enable us to optimise processes and logistics,” said CEO Jochen Hornung, voicing his

approval of the site at Lake Constance during the celebration for the laying of the foundation stone. “Lindau

continues to provide a solid basis for our plans to expand. And we are also providing our employees here with

a perspective for the future.”

In the future it will be possible to produce a much greater number of chillers at the new plant, and machines

with a cooling output of up to 5 megawatts (MW) can be tested here. A new training workshop will provide

young people with a working and learning environment with state-of-the-art technology. Additionally, the

new administration building will contain a showroom for the products of Cofely Refrigeration.

THE FOUNDATION STONE

Viewpoint: looking at the future adminstration (left) and production building (right).

Viewpoint: the production plant under construction as seen from the future administration building.

Laying of the foundation stone: The time capsule, filled with various Cofely advertising media, the most important Cofely brochures, and of

course a daily newspaper.

FOR NEW GROWTH IS LAID.

Laying of the foundation stone: (Front left) Jochen Hornung (CEO of Cofely Refrigeration), Patrick Meier (CEO of i&R Dietrich Wohnbau), (front right) Alexander Stuchly (CEO of i&R Wohnbau) and Gerhard Ecker, Mayor of Lindau, bury the time capsule together.

Viewpoint: the administration building under construction.

COMPANY INFORMATION

Cofely Refrigeration GmbHKemptener Straße 11–1588131 LindauGermany

Fon +49 8382 706-0Fax +49 8382 [email protected]

Managing Director: Jochen Hornung

Marketing/Communication: Tatiana Köhler

Text/Editor: Tatiana Köhler

Conception/Layout:Katja Krimme

Photo credits: iStockphoto LPCofely Refrigeration GmbHCofely Deutschland GmbH

September 2015

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