VAHTERUS NEWS 2/2014
A more compact version of the separate droplet separator
The new VES p. 13
FROM NH3 TO CO2 – THE DEVELOPMENT OF REFRIGERATION AT BERN POST FINANCE ARENA
P. 10
Dear partner, VAHTERUS NEWS 2/2014
Publisher Vahterus Oy
Editor in Chief Sari Kesälä
Lay-out Mainostoimisto Tekokuu
Interviews Raija Herrala
Press Euraprint
On the cover Toni Sigrist Walter Wettstein AG Kältetechnik
Vahterus Oy Pruukintie 7 FI-23600 Kalanti FINLAND Tel.: + 358 2 840 70 sales@vahterus.com
Vahterus Americas, LLC PO Box 77264 Charlotte NC 28271 USA Tel.: +1 704 846 5050 sales.americas@vahterus.com
Vahterus Deutschland GmbH Magnolienweg 26 63741 Aschaffenburg GERMANY Tel.: +49 6021 181 700 webmaster@vahterus.de
Vahterus Heat Exchangers Shanghai Co. Ltd Room 816, Enterprise Square Mei Yuan Road 228, Zha Bei District 200070 Shanghai CHINA Tel.: +86 21 638 00848*113 sales_china@vahterus.com
Vahterus (UK) Ltd 12-14 Derby Road Melbourne Derbyshire DE73 8FE UK Tel.: +44 1332 863175 vahterus.uk@vahterus.com More news and articles can be found at www.vahterus.com 2
VAHTERUS & SALES MEETING Over 50 Vahterus distributors from around the world arrived in Kalanti in September to exchange customer experiences and their own findings about selling Plate & Shell Heat Exchangers. Over the course of the meeting, participants learned about the new products and were introduced to the range of new developments made in the production processes. For Vahterus, being a pioneer means continually developing and improving our knowledge of heat exchange and product manufacture, so that we can guarantee our customers competitive heat exchange solutions. These solutions can be standard or tailor-made heat exchangers, designed to suit the customer’s needs. It was wonderful to see our distributors enthusiasm and desire to find new solutions to continue to improve and bring new and efficient heat exchange solutions to customers. I believe that at the next Sales meeting in two years’ time, there will be even more of us, and our growth will have been able to continue. In order to make this vision a reality, Vahterus is prepared to invest more and more in personnel and equipment. Diverse, highly international customers and end users are demanding heat exchangers for their own use that are competitive and efficient by all indicators. Quality is another area where compromises cannot be made. Continuous regeneration and development of our products is essential in this industry. History is proof of this. It is important that we remain a pioneer in the future. The future is still interesting.
VAHTERUS & THE CURRENT YEAR As I stated in our last magazine, 2013 provided a solid springboard for this year, thanks to a good stock of orders. Both in the factory and in our processes, a considerable amount of reorganisation has gone on to allow us to meet the heat exchanger needs of you, our valued customers, in terms of quality and technical solutions. Even more than before, we are searching for expertise in three selected business areas (chemical- and process, energy and refrigeration). In these areas we are attempting to seek out the key applications where we believe our expertise and PSHE heat exchangers are the most efficient and competitive solution for customers. We will present these in this magazine. Another element typical of this year has been the highly effective close development and cooperation work with long-term partners. Together we are building and developing genuine, client-specific heat exchanger solutions. The cooperation has been very lasting and rewarding, and I believe this has provided both sides with good business. One of our aims is to invest further in this direction. In this respect, bespoke service is key, and this is the basis of Vahterus’s operations.
VAHTERUS & CHILLVENTA Our internationalisation has been founded on product innovation, but also on strong investment in international trade fairs around the world. Sometimes we have our own stand, and sometimes we join forces with our wide distribution network. We have learned that customers want to see the product, and in particular the people behind the product. Even today, heat exchangers are rarely bought online, although development needs to be made in that direction. The Chillventa trade fair will be Vahterus’s most important fair this year. We will be presenting all new heat exchanger solutions designed for use in compressor units.
At the fair, I believe there will be even more talk about the growing use of natural refrigerants, such as ammonia, carbon dioxide and propane, in the refrigeration process. This is because the importance of environmental values is being highlighted ever more in everything we do, even in growing economies such as Brazil and China. It is also a pertinent issue in the USA. In these areas Vahterus already has a globally important role. We have a strong desire to be a trailblazer in terms of the development of these energy solutions in the future too. Come and talk to us, challenge us. We make PSHE heat exchangers for you, our customers, to bring mutual success. Together we succeed!
Mauri Kontu 3
MADE BY VACKAFINNAR
SINCE THE MIDDLE AGES SOUTHWEST FINLAND HAS BEEN AN IMPORTANT CENTER OF INTERNATIONALITY, TRADE AND INDUSTRY. IN THESE PAGES WE WILL TELL MORE ABOUT PRESENT PHENOMENA, COMPANIES AND INNOVATIONS OF THIS REGION.
VAHTERUSRING as an example of using natural refrigerants in sports facilities. Uusikaupunki ski tunnel cools with carbon dioxide. Even if we get a rainy autumn, there will be at least one fully functioning ski track in Uusikaupunki; the one-kilometre Vahterusring ski tunnel, which had a record number of users in autumn 2013. Completed in spring 2005, the Uusikaupunki ski tunnel is a good example of a sports facility where refrigeration is handled using natural refrigerants. The pipes beneath the kilometre-long ski track and the curling sheet are filled with carbon dioxide. During its nine years of operation, Vahterusring has provided information on and experience in the leisure use of this chosen technology, and its energy consumption has been cut in half. “We have identified the correct temperatures and needs related to various scenarios so we can adjust the operation in real time. We have been able to significantly reduce the consumption of electricity,” affirm chairman of the board Reijo Aalto and property manager Jarno Ihala. One of the future goals is to use the 4
condensation heat in other nearby sports facilities. At the moment, the condensation heat is only used to heat up the adjacent tunnel for runners, cyclists and roller skaters but there is enough capacity to keep an entire football pitch clear of snow and ice. The Uusikaupunki ski tunnel is a company owned by approximately 350 shareholders, and Vahterus Oy has played a significant role in its operation since the beginning. The idea came up when Mauri Kontu, Managing Director of Vahterus, and other avid sportsmen were longing for better sports facilities in the middle of one snowless winter in Southwest Finland. Together with the exercise venue, they conducted an experimental refrigeration project with outside expertise from the Tampere University of Technology, among others. VTT Technical Research Centre of Finland has also made use of the ski tunnel as a test environment.
Aiming for low running costs Vahterusring is the only ski tunnel in Finland forming a closed loop and the only ski
tunnel in the world using carbon dioxide as refrigerant. According to Aalto, there are plans to build another similar tunnel elsewhere in Finland and one in Russia. Due to the challenging economic climate, however, it has not been possible to start construction in these locations. The initial hypothesis was that using carbon dioxide as refrigerant would result in slightly reduced energy consumption compared to traditional refrigerants but throughout the years the consumption of electricity has reduced much further. The decision made four years ago to stop cooling during the summer has had the greatest effect, but even during ski season the costs have been reduced by meticulous observation and adjustment. “Low running costs have been the number one goal when managing the tunnel,” says Aalto, who monitors the operation of the equipment several times a day over the internet. He has been involved in the project since its planning and construction stages through the company that was in charge of HVAC, electrical and plumbing plans.
VAHTERUS NEWS 2/2014
Later he has acted as the property manager and as a board member in charge of technical operation.
Improving slide by adjusting temperatures The site allowed for a circular shape and changes in altitude. In the planning stage, the goal was to make a light and affordable structure that could be erected quickly and with technology that could function in fluctuating humidity and temperature.
“Looking back we can say that we succeeded: the structure works and it’s durable,” Aalto says. In the initial planning stages, the snow temperature was -3°C. However, skis perform better when the temperature is closer to zero, and the snow is treated. An evaporator is used to cool the air inside the ski tunnel to zero degrees. The refrigeration system has units on both the south and the north side of the tunnel, which means that they can be inde-
pendently adjusted, for example when the spring sun increase the temperature more on the south side. A tube runs 500 metres from the refrigeration unit to a manifold, from which the copper pipes laid underneath the ski track bring the carbon dioxide back to be cooled. At first the cooling pipes ran under the snow on the floor surface, but now they have been covered with grit. In the autumn, the cooling begins with the freezing of the grit layer. Once it has frozen solid, even something as heavy as a tractor can run across it without damaging the pipes. Spreading the new snow and making the ski tracks ready for use can be accomplished in a matter of days. The cooling pipes underneath the curling sheet have also been covered by moulding a deck on top of them. According to Jarno Ihala, an even surface is paramount for on a curling sheet. The cooling system has different settings for autumn, winter and spring. On top of that, the external conditions must be taken into account. The entire system, both the refrigerants and the monitoring and adjustment equipment, ensures that the ski tunnel is used in a way that allows us to optimise its energy usage.
Functional and safe “If we were building the ski tunnel now, the cooling pipes would be covered with grit right from the start,” Aalto says. The lighting and window placement would also be reconsidered slightly but he would not
make any other major technical changes. Ihala estimates that minor adjustments would be made to the curves, start location and routes, in consideration of skiers and cyclists. In Aalto’s opinion, the natural refrigerants have been a good choice in terms of function and usability. In addition to the carbon dioxide circulating through the cooling pipes, ammonia is used in the compressor outside the public facilities. The safety of using carbon dioxide in public facilities is enhanced by the fact that increased levels are easily detected and can be quickly responded to. There are about ten sensors along the track and even the use of a ski track maker can trigger them and start ventilation if track maintenance has not been pre-programmed beforehand into the monitoring devices. The monitoring system will also quickly detect if the level of carbon dioxide in the system starts falling. The pressure within the cooling system is approximately 40 bar, so maintenance has to be precise, especially in the cooling pipes. The summer break offers an excellent opportunity for periodical maintenance. Thanks to pre-emptive maintenance, disruptions have been prevented. In winter 2014, 5,000 square metres of snow was blazed into a storage facility at the centre of Vahterusring where it can withstand the summer heat covered in peat. In September it will be spread to a layer at least 10 cm thick to make new tracks, and the ski season is ready to begin again!
The pipes beneath the kilometre-long ski track and the curling sheet are filled with carbon dioxide.
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Vahterus&World
FROM AROUND THE GLOBE Americas
Business in the Americas this year has been a case of Hot and Cold
Business in the Americas this year has been a case of Hot and Cold. The first half year of 2014 has been a matter of fighting through the cold of a very long and hard winter, and now are we are starting to feel the warmth again. Our business has followed the weather but we are now expecting great things for the remainder of the year. Our business make-up in the Americas spans all industries, and this year our order book reflects that. In the Oil & Gas sector we have scored some notable successes with existing clients such as BP, ATP and Williams Gulfstar for installations in the Gulf of Mexico; as well as continuing work on FEED studies for prospective future projects and investments in the region. Our client portfolio in the Chemical sector is an extension of our successful partnerships from Europe, with business developing very well in both North and South America. On the heating side of our business, the applicability of PSHE in steam systems, has seen a boost in recent times through our alliance with Preston Phipps, a market leader in this field, based in Montreal, Canada. From their 10 offices across
UK
tinue to collaborate very closely with our Vahterus partners in Europe and beyond. Thus keeping a chill on our business!! A balance of Hot and Cold is what we are aiming for in the Americas, and it is just what 2014 is proving to be! Dr. Jonathan Pascoe, Precident, Vahterus Americas, LLC.
Together with Vale Europe Ltd to increase production at its Clydach Refinery.
Clydach Refinery Located near Swansea in South Wales UK is one of Europe’s largest nickel refineries, producing high purity nickel pellet and powder products for specialist applications such as high nickel alloys, batteries, nickel plating and automotive products. As part of the refinery’s continuous improvement strategy and it’s aspiration of achieving and annual production of 45,000 tonnes (representing a capacity increase of
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Canada, we see new Preston Phipps installations using Vahterus PSHE, in both institutional and industrial settings, on a monthly basis. In Power Plants, Vahterus recently initiated business with Vogt Power, a Babcock Power Inc company. This is viewed as a major success and we hope to report on some key installations in future editions of this magazine. Therefore we can really see things are heating up! In our Refrigeration business, which still proves to be our consistent base for the US business, our client list increases continually. As one of the largest contractors in the USA, and based very close to our office in Charlotte, NC, Republic Refrigeration has recently started to use Vahterus PSHE in CO2 cascade applications. In addition, Colonial Webb, has secured two further projects for Pepsi, using Vahterus Combined. Both partners secured with the assistance of MidAtlantic Refrigeration, our Representative based in Hanover, PA. Add these to our long standing partners – JCI/Frick, M&M Refrigeration, Innovative Refrigeration – and the signs are very good. Other strategic work continues within this sector with our global OEM partners, where we con-
over 10%), it was necessary to increase the rate of cooling on its Copper Liquor line which is part of the nickel refining process. A Vahterus 5HH-156/1/1 Plate and Shell unit serial number 4810 has been installed on this line since 1998 and has been giving excellent maintenance free service ever since. Vale therefore contacted Vahterus UK with a view to increasing the cooling capacity. After visiting Gareth Jones at the refinery
and following number of discussions, a proposal was put forward that would eventually double the amount of available cooling capacity. This was done with the aim of making it future proof. In the short term this would be limited by the amount of capacity available on the cooling water chilling system which Vale intends to upgrade in the near future. The new unit was manufactured earlier this year and has now been delivered.
VAHTERUS NEWS 2/2014
China
Vahterus Combined Took Off in China
The summer 2014 in Eastern China area has been the coolest since 2000. This is also the region Vahterus China operations are located. Unlike the summer holiday season in western countries, summer months are normally very active manufacturing months in China. During July 2014, Vahterus China has received 45 units heat exchanger orders, which is a new monthly record for China operations. In addition to the energy, chemical segments, July has been a very good month for refrigeration segment business. We successfully manufactured the first Vahterus Combined CO2/ NH3 cascade (40 bar design pressure) for food cold storage application. During 2013 and 2014 we also supplied units for CO2 processing application for beverage industrials in China. After decades of strong growth in infrastructure and industrial new investments, China’s annual GDP growth has clearly slowed down from two digits to one digit level. The country has been transforming from an export driven economy to a more balanced model. Also during the last two decades, the demographic structure in China has undergone dramatic change - urbanization has reached 53% in this vast populated 1.3 billion mega
country. With the growing urban population and improving living standard in China, refrigeration systems for food storage and transportation have been growing strongly. During 9-11 April 2014, Vahterus China participated in the annual China Refrigeration Show in Beijing (CRH 2014). A wide variety of industrial players, including compressor system providers, cold storage design institutes and contractors visited Vahterus stand. The market has shown strong interests in Vahterus Plate and Shell heat exchanger solutions for demanding CO2 and Ammonia applications. The order of our first combined unit c am e sh o r tl y after the exhibition. Compared with developed mar ket s, CO2 systems are still in early adoption stage in China. Global compressor system providers and leading Chinese players are
all putting strong R&D and sales efforts in promoting CO2 systems in China. The market recognizes Vahterus as a leading player in this segment due to our strong track record and good market reputation in this application globally. With the first China assembled Combined unit delivered, a new page of Vahterus in Chinese industrial refrigeration market has been turned. Valtteri Haavisto, Operations Manager, Vahterus Heat Exchangers Zhangjiagang Co.
Gareth has reported that the unit has now been installed and it is up and running. He also says that it is performing far better than predicted.
Together we succeed! Phil Chesters Technical Manager Vahterus UK Ltd.
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Vahterus&Us
QUALITY THROUGH PEOPLE The job of the sales coordinator is to stay in touch with the clients and all departments within the company. She also monitors the progress of orders and organises transportation for the finished product so that deliveries find their way to their destination on time – even on the other side of the world. “The most important part of my job is to communicate with the clients and keep them updated about how their order is proceeding,” explains sales coordinator AnnaLiisa Aula. Altogether, Vahterus employs four sales coordinators. Anna-Liisa Aula’s area of expertise is the orders of refrigeration solutions clients. She coordinates the orders of the
the production phase or at least when the new heat exchanger has been completed. “We always have a weekly meeting with the production team where we go through the orders that go out that week and decide on the dispatch date. If the delivery date is different from what was agreed, the client will be informed. If everything is as agreed, the client will be contacted when the heat exchanger has been dispatched. The dispatch note is also sent to the client at this point,” says Aula. Usually, the sales coordinators use email and telephone for their communications but Aula will occasionally tag along with the sales team to meet the clients face-to-face in the
international business. “I did my practical training here and, after I graduated, I was given the opportunity to continue here. It was brilliant, I’ve really enjoyed my work here! Even though, in a way, I do the same things every day, each day is still different from the next,” she explains. Sometimes one phone call can change the course of the entire day. “This happens a lot, especially with transportation. And transportation is, of course, a big part of our business. We need to get our products delivered all around the world. The majority of the orders in the refrigeration group go to different parts of Europe. The deliveries travel by lorry and ship to
Sales Coordinator running the show Anna-Liisa Aula, sales coordinator
refrigeration group together with Anna Ahola. “I enter the order checked by a member of our sales team into our system, give each heat exchanger a unique serial number and forward the order to the production planning team. The production planner tells me the delivery date. After this, I send to the client an order confirmation where they can see the delivery date and address and all the other details related to their order,” explains Aula. There is often a need for communication even during
clients’ premises or at trade fairs. She also meets with clients visiting Vahterus, many of whom have become familiar faces over the last six years. Anna-Liisa Aula has worked at Vahterus for over six years. She graduated as a Bachelor of Business Administration specialising in international business from the Satakunta University of Applied Sciences. After graduation she got the perfect job for applying all the knowledge she had acquired in the field of
Anna-Liisa Aula 8
Travemünde in Germany, and then further on from there. Completed products are also sent to the Americas and other distant locations by air freight. The Vahterus mission is for their heat exchangers to meet the needs of their clients as well as possible. Coordinating transportation is Aula’s role in this. “My job is mainly focused on the production and ensuring that the client receives the delivery on time. If it is a rush delivery, choosing the right type of transportation is critical. The best part of my job is that I get to serve and be in touch with our clients, and that my work is very diverse,” says Anna-Liisa Aula. In last January, Aula began new studies at the Satakunta University of Applied Sciences unit in Rauma. She is aiming to finish the Master of Business Administration course, conducted entirely in English, in 2.5 years alongside her work. Currently, she is struggling to find much time for hobbies outside of her work and studies but she likes to spend any free time that she gets doing different types of physical activity. Aula lives in the neighbouring town, Laitila, where she also grew up.
VAHTERUS NEWS 2/2014
Specialising in certain applications helps to improve the service provided to refrigeration clients. According to Principal Designer Mikko Lehtola, their individual needs and client-specific demands can be taken into account more efficiently. Another goal is to improve the efficiency of the order-to-delivery process. Mikko Lehtola is the head of the design team, which comprises six designers in total
application,” Lehtola explains. He is certain that having a dedicated team is more convenient and helpful for the client as well. The sales department has been the primary point of contact between Vahterus and clients, but in future there will be a more direct communication link with the design team. One of the special demands in the refrigeration sector is that products are often more
eral knowledge of the products, thanks to his full decade in house. Juha Taiminen, who has mainly worked with refrigeration applications, and especially the combined evaporator with integrated droplet separator, believes that closer connection to the team’s own clientèle will prove useful. When the team knows what specifically the unit will be used for, the client’s needs can be addressed more efficiently.
Dedicated design team for refrigeration device heat exchangers and focuses on refrigeration applications. Until now, applications for all client segments were administered jointly by all Vahterus designers. Tasks were assigned based on the level of complexity as well as relevant official and client demands. This reorganisation makes it possible to better concentrate on client groups’ demands. The teams met in their respective work spaces in the summer and new methods will be formulated during the autumn. Refrigeration is the largest user sector for Vahterus heat exchangers when considering number of units manufactured. The applications are sold mainly to Europe and to some extent to North America. ”In the future, we will form teams to serve clients who use a particular
complex in structure and have more components. However, material demands and the extent of inspections are not always as strict as they are, for example, in the chemicals industry. Particular client requirements may relate to the appearance, structural solutions, assembly placements or optional internal components in each application. Fitting the exchanger in the client’s existing assembly is particularly challenging.
Introducing the team Mikko Lehtola, head of the new team started at Vahterus as designer in 2005 and has also worked as project engineer. Lehtola says he has a strong gen-
It has been ten years since Taiminen came to Vahterus and for the past six years he has worked as designer. Ossi Kallila boasts the most experience as he has worked at Vahterus since 1996. He has witnessed the introduction of natural refrigerants, as well as the shift from countryspecific regulations to European standards. Before joining the design team, Kallila worked with plate pack production. In design, his work has included complex assemblies for refrigeration clients. ”Modern software has made the design of standard exchangers a lot easier. However, the assemblies are special applications and their specifications cannot be entered into programs,” Kallila explains. Other members of the team are Harri Häggström with 6 and a half years of experience in design, Kristian Meriläinen with 18 months of experience in design and Jari Vihersaari with 12 months of experience. In his previous job, Vihersaari was involved in making an EN 1090-compliant process to earn a product CE marking. This process included welding, adding this string to his bow.
Harri Häggström, Mikko Lehtola, Juha Taiminen, Kristian Meriläinen, Jari Vihersaari and Ossi Kallila. 9
FROM NH3 TO CO2 – the development of refrigeration at Bern Post Finance arena As one of the first industrial facilities in Switzerland, the Bern Post Finance arena was restructured from direct ammonia cooling to indirect cooling with ammonia and CO2 as a secondary medium. The restructuring of the cooling system was designed by Walter Wettstein AG, and the system includes altogether 20 Vahterus heat exchangers. With ice rinks being places of highenergy consumption, ice rink constructors have been called upon to find solutions, which make it possible for ice rink operators to run them safely, yet with the lowest possible consumption of energy. This was the challenge faced also by Post Finance arena in Bern in the 1990s.
Bern, located west of the center of Switzerland, is known as an ice hockey city. The most popular games are held in one of the biggest ice hockey stadiums in Europe, and the largest in Switzerland, Post Finance arena. The arena has a capacity of over 17000 people in addition to having ice rinks and the most modern curling rinks in Europe. The arena, originally known as Eisstadion Allmend and Bern Arena was built in 1967. Until 1999, the central cooling of the arena ran with direct ammonia. The cooling system demanded 11 tons of ammonia, which imposed a serious health-risk for the stadium as well the important buildings in its proximity close to the city center of Bern. After 33 years in operation, the central cooling of the arena had to be renewed. The restructuring of the arena’s cooling system was assigned to Walter Wettstein AG (WWAG) specialized in building cooling equipment for ice rinks and other winter sport facilities, and for whom Vahterus serves as a component manufacturer. In addition to the stadium, the exhibition center and a curling rink were served in the project.
From 11,000 to 1,800 The demands for the new cooling system were an energy efficient facility that covers all cooling and warming requirements for all seasons. The starting point for the new cooling system was to change the direct ammonia pump system to an indirect ammonia/CO 2 cooling system.
A flooded NH3 system was chosen as the cooling circle, and it included a Vahterus PSHE evaporator, PSHE condenser and a PSHE oil cooler. The skating rink cooling was served with a CO2 pump circle. In addition, a Vahterus PSHE cascade heat exchanger is working at the intersection between the ammonia and CO2 circles. “With Vahterus we found a competent partner for the NH3/CO2 cascade heat exchanger. The NH3/CO2 system proved to be a very efficient technology for the cooling of ice rinks”, explains Toni Sigrist from Walter Wettstein AG. At this stage of the restructuring, all in all 7 pieces of Vahterus NH3/CO2 heat exchangers were installed for the cooling of the ice rinks with CO2. A heat pump, which is connected to the NH3 circuit provides 40% of the heat consumption for warm water, heating and a district heating system. WWAG also developed a software-based controlling system, which optimizes the energy consumption of the whole plant considering use and weather conditions. In 2008, additional restructuring efforts were made. Because of the expansion of the arena, more Vahterus heat exchangers were added to the system. After the expansion, the following cooling needs had to be served: • four ice rinks with an ice surface of 7800 m² • two ice reservoirs for the offices’ and exhibition halls’ air conditioning • one glycol network for the direct cooling of the exhibition halls All ice rinks at Bern Post Finance arena now work indirectly with CO2. The liquid CO2 gets via pump systems to the different
VAHTERUS NEWS 2/2014
Pioneering in indirect cooling systems
cooling destinations. There the CO2 evaporates partly, and the partly evaporated and liquid CO2 mixture gets back to the NH3 cascade system. All in all, 20 Vahterus heat exchangers have been installed at Post Finance arena. Because of very limited space in the machine rooms and the use of Vahterus heat exchangers, providing significant space savings without losing high effi ciency, the designed cooling capacity has been achieved. Moreover, with the compact size of Vahterus heat exchangers, the machine rooms could be used without making expansions. With the new system, the amount of ammonia could be reduced from 11000 to 1800 kg, and the health risk in the surroundings of the ice rink reduced to almost zero.
Most ice rinks in Switzerland have had direct cooling systems using ammonia gas in the pipes under the ice rink. This design, used previously also at Post Finance arena, has proven to be economical in energy consumption and the most efficient system for cooling an ice rink. The disadvantage with the system, however, lies, in the fact that high amounts of ammonia gas needed for operation represent a serious safety hazard. Due to the safety hazard and the implementation of the Accident Ordinance in 1991, indirect cooling systems were introduced to refrigeration markets. Glycol and calcium chloride were already known medias in cooling systems, whereas ammonia and CO2 used in indirect cooling systems was new. WWAG pioneered in the energy-optimization of indirect cooling systems already years ago, being the first company in Switzerland to start using CO2 as an evaporating (secondary) ref r ig er ant . T h e benefits of an indirect cooling system
lie primarily in the possibility to reduce the use of ammonia, reducing the safety risk. Before the introduction of indirect cooling systems, the cooling was done by circulating a glycol / water or CaCI2 water mixture in the piping under the ice rink. An uneconomical side of these types of systems was higher energy costs. Considering both advantages and disadvantages of indirect and direct cooling systems, ice rinks using both technologies benefit the most. When ammonia is circulated in the machine room and CO2 is circulating under the ice rink, the following benefits can be taken advantage of: safety, excellent ice quality thanks to the short reaction time of CO2 as well as low energy costs, e.g. as a result of lower pumping costs of CO2.
“With Vahterus we found a competent partner for the NH3/CO2 cascade heat exchanger. The NH3/CO2 system proved to be a very efficient technology for the cooling of ice rinks�, explains Toni Sigrist from Walter Wettstein AG.
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VAHTERUS NEWS 2/2014
USA
Ole Christensen, Vice President of Engineering at M&M Refrigeration
ORDER #1: M&M REFRIGERATION Exactly 10 years ago, Vahterus received their first ‘official order’ from the USA. Well, in fact it was 30th July 2004, and at that time, Vahterus did not even have the ASME U-Stamp! From these very humble beginnings, the contractor and end user involved, have become cornerstones of Vahterus Refrigeration business in the USA, utilizing many Vahterus Plate & Shell Heat Exchangers (PSHE), notably in CO2 /NH3 cascade systems. The contractor was M&M Refrigeration and the end-user US Cold Storage (USCS). The key individuals involved on all sides are still involved today and this is what has made the working relationship and collaboration between all parties, very strong and long lasting. Ole Christensen, Vice President of Engineering at M&M Refrigeration, had previously encountered Vahterus in Europe, during his time with Sabroe in Denmark. When M&M Refrigeration was part of the York Group, he transferred to work with M&M Refrigeration in Federalsburg, Maryland, to whom he brought considerable knowledge of Refrigeration Compressors, Heat Exchangers, and very importantly, CO2 cascade systems. Ole Christensen said, “Because of my previous work as Global Product Manager for CO2 refrigeration systems at Sabroe/York Refrigeration, where we started to sell CO2/ 12
NH3 cascade systems back in 1999, it was pretty exciting for me to start the introduction of these systems in USA, when I moved to here in 2004. There was a lot of interest in these “new” systems, mainly because of large reduction of ammonia charge and because of potential power savings in low temperature applications. Within the first year, we secured the first 2 orders and it has escalated to 36 systems/system expansions until now. The cascade heat exchanger is a very essential part of these systems and here at M&M Refrigeration we have used Vahterus heat exchangers in every project. I would be very hesitant to use anything else.” At a similar time to Mr. Christensen’s relocation to the USA, Chuck Toogood was Vice President of Engineering at USCS. Due to the resistance of large charge ammonia refrigeration systems in many jurisdictions throughout the USA, Toogood was looking for a sustainable and efficient refrigeration system, having a smaller refrigerant charge than the common systems in use. This search took Toogood to Europe where he was able to observe numerous Cascade CO2 /NH3 refrigeration systems, operating successfully in various industrial applications. Since the Cascade CO2 /NH3 refrigeration system generally has a refrigerant charge 1/10 of an equivalent two-stage ammonia system, the Cascade
CO2 /NH3 refrigeration system became a viable option to consider. The search then led Toogood to M&M Refrigeration, Inc. where he encountered Ole Christensen, who was of course very knowledgeable in the area of Cascade CO2 /NH3 refrigeration systems, both in Europe and USA. After careful considerations, and based on M&M Refrigeration recommendations, Vahterus Cascade Exchangers were selected for a number of reasons. Two of which were reliability and a lower refrigerant charge required than other types of heat exchangers. On this basis, the Vahterus Cascade exchangers were purchased by M&M Refrigeration for their 1st USCS system, to be installed at the Bethlehem, Pennsylvania facility. Following the success of this initial installation, many new systems and expansions have been installed by M&M Refrigeration at USCS facilities throughout the USA. In the early years, Vahterus Business Development in North America was led solely by Jonathan Pascoe, who was working remotely from a UK base to support M&M Refrigeration and other clients, not only within the Refrigeration sector. Under his leadership and with support of many colleagues throughout the last 10 years - notably Tanja Välimäki, Heikki Oksanen and Mikko Vilola - the Refrigeration sector and very importantly, M&M
VAHTERUS NEWS 2/2014
Refrigeration, have grown to become key components of Vahterus business in the Americas. Since the establishment of Vahterus Americas office in Charlotte, North Carolina at the end of 2011, day to day working between the companies has subsequently strengthened. Colleen Webster, who has worked at M&M Refrigeration for 15 years, has been a key collaborator, as has Aaron Purse in Purchasing.
In addition to their work in North America, M&M Refrigeration have expanded their international operations and installed base in places such as Mexico, Malaysia, Costa Rica, Colombia, the Philippines and Puerto Rico, again using Vahterus PSHE as a key component in their systems. Greg Robison, M&M Refrigeration Vice President of Sales, has been instrumental in securing many of these projects as they look not
“Vahterus is a wonderful company to work with, they always respond in a timely manner to any of our requests regarding quotations, delivery and technical advice. Vahterus is definitely a “Team” player. Shipments are on time as per their quoted delivery schedule. Everyone I have met or worked with from Vahterus are professional, have timely answers and assist with any of our requests. We could not ask for a better group to work with!” states Colleen Webster
only to develop their geographical coverage, but also take their knowledge into other related markets. Together, M&M Refrigeration and Vahterus, have built a very strong working relationship during the last 10 years, one which all believe provides a sound and exciting base for the future. Here’s to the next 10 years! Dr. Jonathan Pascoe, Precident, Vahterus Americas, LLC.
Dr. Jonathan Pascoe and Mrs. Elizabeth Corcoran from Vahterus Americas, LLC.
THE NEW VES
– A MORE COMPACT VERSION OF THE SEPARATE DROPLET SEPARATOR At the Chillventa fair this autumn Vahterus will present a new, more compact version of PSHE&VES. The existing one is already compact enough, but the unit’s measurements have been slimmed down even further. The PSHE&VES unit is equipped with Vahterus’s flooded evaporator (PSHE) and on top is a droplet separator (VES), whose technology of elimination of droplets carry over to the suction pipe is equivalent to Vahterus’ Combined heat exchanger. The first VES version has been on the market for two years, and has been well received. “We have plenty of experience in this. At the moment we have hundreds of Combined units in use around the world, and they run smoothly”, Michael Nganga R&D engineer in Vahterus emphasises. Along the existing PSHE&VES, there will be the new version, which has been modified and developed further to meet customers’ needs. In the development process, both the unit total height and the diameter of the droplet separator’s shell have been reduced. With these smaller dimensions, the refrigeration charge has also been cut down, which is a significant benefit, for example, when looking at the ammonia usage. The unit is lower due to the positioning of connections. They have been relocated with flexible installation in mind. There are also benefits of transportation, and the unit can be moved to its intended location through lower doorways than before, says Nganga. In addition, insulation is easy, thanks to the simpler shape. The oil separation system has also been developed further. The new VES version will provide new options for customers looking for optimal solutions, especially for capacities of over-1500 kW. The whole system will also be more competitive in terms of cost. Vahterus is the only Plate&Shell heat exchanger manufacturer that offers both an evaporator and droplet separator attached to each other. The development of the new VES has involved Vahterus’s product development, sales and design departments, as well as a partner with years of experience in refrigeration technology.
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VAHTERUS’S GLOBAL SALES NETWORK COMES TOGETHER Members of Vahterus Oy’s sales network from all over the world came together in September in Finland. As a part of the meeting, there was a chance to explore the production premises, located in Kalanti, which were expanded two years ago, and to hear about topics such as Vahterus’s goals for the coming years, organisational reform and news about developments to heat exchanger products. In all, around fifty distributors took part in the meeting, with participants coming from Japan, China, Korea, Malaysia, Indonesia, Australia, South Africa, Canada, Saudi Arabia and a dozen European countries. Also with us were sales staff from Vahterus’s subsidiaries in the USA, China, Germany and the UK, as well as sales, design, R&D, procurement and production staff from Kalanti. At the beginning of the first day, Mauri Kontu discussed the events of the two years since the previous meeting. In autumn last
year, entries in the order book doubled suddenly and the pace remained high throughout the beginning of the year. New production staff have been added to the team, and long days have been worked to meet the demands this challenge has presented.
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Reorganisation has taken place in order to speed up the ordering process. In addition to sales, design has now been divided up by industry sector. The energy industry, refrigeration industry, and processing and chemical industries now each form their own sectors.The growth aims for the coming years in Vahterus’s updated company strategy remain challenging. The strategy has also been written to ensure that Vahterus remains a family business, says Mauri Kontu. During the meeting, the members of the sales network were shown the laser cutting that came into use last autumn, steel material experiments, the forthcoming steam laboratory for a power plant in Naantali, and both steam and refrigerant technology testing, amongst other things. In connection with the engine laboratory at Turku University of Applied Sciences, research has been underway into heat recovery from exhaust gases from engines.
The sales network members were very interested in the new developments presented at the meeting, right from the introduction to the production premises and the new laser cutting system.
Clement Ng from Malaysia came to the meeting with his wife Janice. The couple run their own business, which has been representing Vahterus products in Malaysia since 2008. Both were keen to hear about the developments presented during the meeting – from plate manufacture to organisational changes. Clement Ng hopes that Vahterus will continue to invest in product development and that the selection of applications will be extended further still. Currently, development work has been done in areas such as improving pressure resistance and it has been successful, he feels.
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“For me, the most important thing at the meeting was the human side of things, shaking hands with old and new friends”, says Adrian Foster, who works for Vahterus in the UK. “We have been selling Vahterus heat exchangers to all industrial sectors in the UK for 20 years, yet it feels like we have only scratched the surface – there is still lots to do and plenty of opportunities.” Deirdre McMahon from Ireland has represented Vahterus products for just two years, and was waiting to hear about lots of new products and technologies. Ireland’s economy is improving and people are investing again. The dairy industry is a good example of this recovery, says McMahon.
PS.
Vahterus will participate following exhibitions:
“Every sales meeting always brings interesting new developments and improvements, and this was no exception”, said Angelo Richelli. Richelli, who works in Milan, Italy, has been a Vahterus partner for over 20 years. It all started when an unusual item at a refrigeration technology trade fair attracted his attention. It was a plate stack manufactured by Vahterus. “What’s that? It looks interesting”, Richelli asked the demonstrator. The question lead to a long-lasting partnership. Datcor represents Vahterus’s products in Italy. In addition to refrigeration technology, sales of heat exchangers to industries such as the gas and chemicals industries have grown. At the moment, the market is quiet and investments are not showing significant movement. When the
Energia 2014 28.-30.10. Tampere, Finland Stand A 210 Off shore Korea 2014 12.-14.11.2014 Busan, South Korea Stand T507 EIC, Oil & Gas 2014 25.11. – 26.11.2014, Manchester, United Kingdom Stand A13 CoolEnergy 2014 27.11. – 28.11.2014 Odense, Denmark Stand 3201
economic situation gradually starts to improve, Richelli is confident that Vahterus’s heat exchangers will convince buyers once again. Datcor’s junior representative Marco Venezia was pleased that the guests were given the chance to see plate production in the factory. “Now it will be easier for me to explain to the customer how the exchanger is manufactured,” says Venezia.
NEWS & EVENTS
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Vahterus Oy designs and manufactures fully welded Plate&Shell Heat Exchangers in Kalanti, Southwest Finland. Over 90% of the production is exported all over the world, mainly to energy technology, process and chemical industry and refrigeration industry. Vahterus’ turnover is 35 million euros and the number of personnel is 220. Subsidiaries Vahterus Americas, LLC Vahterus Deutschland GmbH Vahterus Heat Exchangers Shanghai Co., Ltd Vahterus UK Ltd www.vahterus.com