Cold Link Africa July/August 2019 - Page 17

PROJECT INCORPORATING COLD CHAIN A basic breakdown of the various room and equipment specs, is as follows: PHASE 1 Cold room 1 (30m x 30m x 14.5m high) Two complete refrigeration systems with 100% standby capacity to operate between 2°C and 8°C. 185kW cooling at -5°C suction. Receiving cold room 1 (9m x 5.5m x 7.2m high) One complete refrigeration system to operate between 2°C and 8°C. 12kW cooling at -5°C suction. Air lock 1 (13m x 3.4m x 7.5m high) One complete refrigeration system to operate between 2°C and 8°C. 12 kW cooling at -5°C suction. Freezer 1 (9m x 5.5m x 5.5m high) Four complete refrigeration systems to operate between -25°C and -18°C. 44kW cooling at -25°C suction PHASE 2 Cold room 2 (40m x 30m x 14.5m high) Three complete refrigeration systems for 100% standby capacity to operate between 2°C and 8°C. 270kW cooling at -5°C suction. Receiving cold room 1 (15m x 5.5m x 7.2m high) One complete refrigeration system to operate between 2°C and 8°C. 12kW cooling at -5°C suction. Air lock 1 (15m x 3.4m x 7.5m high) One complete refrigeration system to operate between 2°C and 8°C. 12kW cooling at -5°C suction. SYSTEM DESCRIPTION All holding rooms meet the required cooling capacity and there is an entire extra condensing unit and evaporator set to ensure redundancy in case of a breakdown of any of the units. The gas used here is R507 across all systems (freezer and cold room). The total capacity of cooling installed on site is roughly 550kW. The refrigeration plant is located in a plant room 6m in the air above the airlocks and freezer rooms. The condensing units blow their warm air via steel ducting directly out the side of the plant room through louvres to create a neat façade where no one would even realise what goes on behind those walls. This was critical to create a neat appearance in line with Imperial Logistics’s clean pharmaceutical image. 1 ZERO DOWNTIME All holding rooms were designed with 100% standby capacity due to the value of product stored in these rooms and the critical importance of keeping them within the desired temperature bands. To illustrate just how crucial the product is, Imperial Logistics monitors all rooms with a Carel Plant Visor Pro system which monitors in excess of 10 temperature points in each room. If the temperature gets within 1°C of its limits (below 3°C or above 7°C), alarms go off and technicians must be on site within the hour to resolve the problem. However, this becomes a real challenge when doors are open or rooms defrost. To handle this, numerous evaporator coils were installed around the rooms and the distribution of evaporator coils is staggered around the room so that if one system goes down, you still have a well-balanced cooling distribution around the room. The plant is also set to run on a very tight band between 3.5°C and 4.5°C to stay far from its limits at all times. The level of care taken to ensure that the plant operates within the temperature (by not skimping on redundancy and refrigeration capacity), makes this one of the most robust pharmaceutical cold stores around. This could never have been achieved without absolute critical planning upfront. Each system is monitored by a pre-emptive alarm system that looks at every inch of the plant in fine detail so that the second a fan trips or a plants gas level starts to drop alarms go off and the plant is restored to correct operation immediately. We have repeater alarm boards around the facility to ensure that alarms are noted immediately. In the eight years leading into this project previous rooms were also run to this temperature specification, proudly never leaving the design temperature band once! 2 3 4 CHALLENGES The biggest challenge on this project was the extremely tight deadline. As well as running the Phase 1 cold rooms to these tight 1. Copeland six-cylinder semi-hermetic compressor. 2. The new storage facility is much bigger, more than double the height of the one that was knocked down. 3. Colcoil evaporators were used for the Phase 2 cold room. 4. Colcoil evaporators were also used in the freezer. COLD LINK AFRICA • July/August 2019 www.coldlinkafrica.co.za 17