Multi-Barrier Machine Chiller Loop
The team was asked with redeveloping the multi-barrier cooling system at Winpak Winnipeg to reduce shutdowns and downtime of the three multi-barrier machines used to produce plastic packaging. The current setup has each multi-barrier machine connected to its own chiller, meaning that when a chiller fails, the multi-barrier machine must cease operation. Three concepts were developed by the team, including a single-loop system, an interconnected system, and a backup chiller system. The concepts were compared using a series of weighted decision matrices, and the single-loop system was selected for recommendation. The new single-loop system increases system reliability by allowing all three multi-barrier machines to continue operation in the event of a single chiller failure. The new single-loop system has all three chillers supplying cold fluid to the communal cold pipe, which then splits into three smaller pipes, each one supplying a set of heat exchangers for a multi-barrier machine. The three sets of heat exchangers return the hot fluid to the communal hot pipe, which splits into three smaller pipes, each one returning fluid to a chiller. In the case of a single chiller failure, this system will continue working as two chillers have the required cooling capacity to cool three multi-barrier machines. The design meets or exceeds all specifications and constraints given by the client, such as the requirement for the design to meet code using black iron schedule 40 pipes, meet ISO standards, and other requirements set out in the needs and constraints section of the report. With a safety factor of 1.25, 103.9 ft of head is required at the chiller one pump, 68.9 ft of head at the chiller two pump, and 79.4 ft of head at the chiller three pump. By analytical calculations, it was determined that an additional 0.64 tonnes of refrigeration is required to offset the heat gained through the pipe. Each chiller should be capable of supplying 206.32 tonnes of refrigeration with the 80% chiller utilization assumption, and 257.9 tonnes of refrigeration with a safety factor of 1.25. The design will effectively eliminate the downtime of a multi-barrier machine due to a single chiller failure, which has historically been. At a conservative estimate of CAD per hour of lost revenue, this will save CAD during a future chiller failure. The design may prevent the additional side effects of a multi-barrier machine being shutdown abruptly such as lost energy, the generation of waste material, and possible damage to the multi-barrier machine due to overheating. This report contains the introduction to the problem, the concept selection justification, in-depth research of academic literature and industry solutions, detailed design specifications, a bill of materials, and renders of the 2D AutoCAD drawing of the facility with the new single-loop system implemented. Included with this report is a PowerPoint presentation of the project and a poster presentation.