Schwämmle Manufactures

Special Cooling Systems

WWH Special Cooling System

WWH Special Cooling System

The cooling systems of series WWH have been developed for processes that are very function-critical and cannot be shut down, if possible. This is the reason why the components are redundant, some components even several times. The design is extremely space-saving and thus energy-optimized. We can manufacture and run in the systems of this series in a turnkey manner in our factory which results in an extremely short installation and commissioning time. The individual main components are dismantled for transportation.

The cooling systems of series WWH have been developed for processes that are very function-critical and cannot be shut down, if possible. This is the reason why the components are redundant, some components even several times. The design is extremely space-saving and thus energy-optimized.

We can manufacture and run in the systems of this series in a turnkey manner in our factory which results in an extremely short installation and commissioning time. The individual main components are dismantled for transportation.

Structure and Function

Hydraulic System

The hydraulic unit is mounted in a complete frame and comprises the double-pump station for the consumer and for the cooling circuit via the dry cooler, the heat exchanger between the dry cooler circuit and the consumer circuit, the heat recovery as well as the entire hydraulic piping.

Cooling Module

The capacity of the cooling modules can be between 10 and 23 kW/unit with the complete internal piping by means of collector and distributor pipes included.

The highlight is: The cooling modules can be maintained or exchanged without an interruption of the overall system. Likewise, the cooling capacity can be increased by adding modules. It is possible to upgrade the cooling capacity up to approx. 160 kW.

Dry Cooler

The dry cooler can be delivered as a desktop version (flat) or as a V-shaped version to save space. It is installed outdoors. The size depends on its capacity and the maximum permitted noise level. It consists primarily of one or several large-dimensioned heat exchangers and a number of fans. The fans are speed-controlled depending on the cooling load and the ambient temperature. If dimensioned accordingly, the entire cooling can be achieved without any cooling unit by means of heat recovery on condition that temperatures are low!

Control System

The entire system is controlled via PLC. This includes: Visualization of all processes, flow charts, parameters, faults and warnings as well as recording of up to 16 different parameters like pressures, temperatures, flows. Data transfer to external users is possible.

Description of Operational Sequence

Function Flow

The entire control system is installed in a completely closed electrical cabinet. Generally, speed control of the respective drives has a considerable energy-saving effect. The supply pumps are speed-controlled via frequency inverters and maintain a constant pressure independent of the consumption.

The control system activates the individual modules according to the cooling capacity that is required. This successive switching on of modules also saves energy since only those modules that are really needed are in operation and the system can very well react to the various loading conditions.

The fans of the dry cooler are controlled the same way. As the capacities of the fans have been rated for high temperatures, the speed is reduced accordingly when the temperatures are low thus saving a lot of energy. Additionally, the control system monitors various flows, filling levels, feeding etc.

If one of the cooling modules goes into operation, one of the pumps for the dry cooler circuit will be switched on. The temperature in the dry cooler circuit is controlled via the speed control of the fans.

Sensor Technology

A temperature sensor is installed outside. Depending on the ambient temperature, the control system decides whether the cooling modules are required or whether free cooling is sufficient. In Stuttgart, Germany, for example, the temperature throughout the year is statistically under +10 °C during 5,300 h and under +12 °C during 6,040 h. With ambient temperatures of under approx. +12 °C, the complete cooling can be effected via free cooling. Therefore, only the fans must be driven and not the cooling units. As soon as the temperature falls below 12 °C, the speed of the fans will be reduced. Since the power consumption of the fans rises or drops approx. ex cube with the speed, this effect can be used for great energy savings. As you can see, a large dimensioning of the dry cooler and heat exchanger is definitely worth it!

WWH ECO Variant

With the WWH system in the variant WWH ECO, the compressors of the cooling units can be switched off when the ambient temperature is low so that cooling can be effected directly via the dry cooler. This requires a sophisticated system for measurement and control reducing the temperature of the glycol circuit and cooling the water via a heat exchanger. Thus, the entire cooling can be accomplished without a cooling unit!

Highlights

  • High modularity – adapts to fulfil your requirements
  • High reliability – some components with multiple redundancy
  • Save energy costs and reduce CO2 emission thanks to an intelligent ECO control system
  • Very short installation and commissioning times
  • All water-swept surfaces on side A: Stainless steel
  • Space-saving and efficient

Download data sheet (PDF)

Technical details, performance calculation etc. at a glance