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COOLMATION Cools JCB’S State-Of-The-Art Engine Test Cells

Coolmation, the UK’s leading industrial cooling specialist, has supplied JCB, one of the world’s top three construction equipment manufacturers, with a new cooling system for its raft of new engine test cells in its JCB Power Systems plant in Derbyshire.

JCB prides itself in being at the forefront of cutting edge innovation and has some of the finest engineering facilities across the globe. Therefore when EU regulation, Tier 4/ Stage 4 non-road emissions limits, required reductions in engine emission levels, JCB decided to construct new test cells to ensure its engines met the new requirements.

The latest investment sees the opening of one of the world’s most sophisticated engine test facilities. JCB Power Systems has built a new Research & Development Centre that includes10 test cells. These test cells require very accurately controlled parameters to perform the development work required to meet future emissions legislation.

Since each test cell requires cooling in two areas at different temperatures, JCB’s brief for Coolmation was to design a cooling system which would be installed in two phases and combining within each phase, air blast cooling and water chilling. General engine cooling is required where the fluid temperature needs to be cooled from 47deg C to 30 deg C. Combustion air cooling is also required demanding fluid temperature to be cooled from 5 deg C to 2 deg C with approximately 36kW needed per test cell. With the cooling capacities varying depending on the size of the engine being tested. Coolmation had to make allowances for this to ensure precise test cell results.

Phase one of the cooling system was installed to meet the demands of the five initial test cells in 2009 and phase two for the following five test cells in 2010. Coolmation’s initial cooling system incorporated a combined 440kw and an 800kW adiabatic cooler for the general engine cooling and a 180kWRhoss TCAEY BT air cooled chiller for the combustion air cooling. The second phase of the project will require the same capacity of adiabatic and chilled water cooling as in phase one.

Coolmation’s decision to provide Adiabatic Air Blast Coolers for the engine cooling, rather than standard air blast coolers, was based on their requirement for cooling water temperatures closer to all year round wet bulb temperatures.

The Rhoss TCAEY BT 4230 air cooled chillers were selected because the full load will eventually be spread across eight scroll compressors, four in each chiller, which will enhance load matching and energy consumption. Their weight and footprint also suited the available space and reduced the cost of the load bearing steel structure.

Each of the TCAEY chillers is also fitted with Rhoss’s unique predictive control system, Adaptive Function Plus, a winner at the 2010 H&V Awards, which can reduce the energy consumption of the chillers by as much as 18%, and deliver the close control of water leaving temperature required of this particular application, +/- 1şC - 2°C.

Pumps and buffer tanks were carefully selected by Coolmation to maximise the performance and energy efficiency of the cooling and chilling plant and the pipework system, fully insulated on completion, is designed and installed to provide the required water flow rates at minimum pressure drop. The system control panels incorporate energy efficient staging of the cooling and chilled water capacity to ensure that energy is only being consumed in proportion to the amount of cooling and chilling required.

“As a project manager the challenge of this project was delivering a world class technical facility by employing multiple specialist suppliers chosen for their expertise and product performance, instead of a turnkey solution from one supplier. However, this process was a success as the project benefited from individual industry experts, such as Coolmation, that could offer a reliable precise solution to our brief.” explains Stuart Thompson, project manager at JCB Power Systems.

“Coolmation is delighted to been involved in such a World-class research facility which will allow JCB to stay at the forefront of diesel engine technology. With our considerable knowledge of the requirements for industrial cooling systems and our expertise in the design and installation of them, we were able to offer exactly the right solution for the very precise needs of JCB’s test cells” says Steve Warnock, managing director of Coolmation.

An intrinsic part of Coolmation’s industrial cooling system, Rhoss chillers are designed for high energy efficiency and reliability, manufactured to internationally recognised quality standards and tested to Eurovent standards within the Rhoss Eurovent certified laboratory. They are available in the UK exclusively through Coolmation. With offices in Lancashire, Leicestershire, Bedfordshire, Bristol and a Head Office in Ringwood, Hampshire, operates nationwide in chiller sales and installation, service, hire and technical support.

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