1. Building 180 NORMATEF TEST FACILITY Demineralized cooling water station upgrade
R. Bozzi / EN-CV

2. Overview
the water cooling station needs to be upgraded according to the new possible configurations of the tested magnets. The most frequent testing conditions now foresee loads between 5 and 20 kW, with a temperature difference of 30°C (spread 20÷50°C) and a maximum pressure drop of tested magnets up to 15 bar. Some exceptional conditions may also occur, i.e.: minimum load of 1.5 kW (corresponding to 0.72 l/min of flow rate), maximum load of 80 kW (corresponding to 38.2 l/min of flow rate).
the upgrade of the cooling station – described in the following – will allow to cover the entire range from 1.5 kW to 80 kW with the following limitations and conditions:
the retention of a permanent recirculation of 0.2 m3/h in all testing conditions (just excepting the maximum load condition of 80 kW): this recirculation will be provided by a by-pass pipe with a manual balancing valve (replacing the existing spring loaded by-pass valve VR-0168);

3. Overview
the need to stop manually the permanent recirculation (by closing manually the valve) and to reduce manually the recirculation through the demineralizing cartridge up to 0.3 m3/h (by acting manually on the balancing valve VR-0099 and checking the flow rate on the flow indicator FI-0100) when performing the test of magnets with a load of 80 kW;
when testing 80 kW magnets the maximum pressure drop which can be reached on users is ca. 13 bar (15 bar is not reachable).
the p set-point of demi water circuit shall not be less than 9÷10 bar: when testing magnets with a pressure drop less than 10 bar, the additional p to reach the 10 bar shall be provided by using the manual balancing valves installed on the return connections of users (valves VR-0148 / VR-0151 / VR-0610 / VR-0166)

4. Modifications on chilled water side
primary circuit (chilled water side), outside the skid:
removal of chiller
removal of buffer tank (RB-0004) and butterfly valves V-0003 / V-0009 / V-0010;
removal of manual balancing valve VR-0011;
removal of temperature transmitter TT-0002;
removal of pipes from the chiller to the skid (excepting the part of pipes installed inside the workshop);
supply and installation of new stainless steel pipework to connect the skid to the chilled water loop inside building 180 (the chilled water temperature will be now 5÷11°C instead of 12÷18°C);
re-displacement of Y-strainer FY-0073: to be removed from the actual position inside the skid and installed on the inlet pipe together with its differential pressure switch PDSH- 0074, adding n. 3 butterfly valves (interception and by-pass);
re-displacement of temperature transmitter TT-0002 and manometer PI-0051 on the new supply pipe feeding the skid;
re-displacement of the pressure connection of the instrument PDT-0068 (the one placed outside the skid);

5. Modifications on chilled water side
primary circuit (chilled water side), inside the skid:
removal of pump UPEB-0037 and related accessories:
butterfly valves V-0046 / V-0029;
check valve QSA-0045;
rubber joints CA-0039 / CA-0036;
instrumentation: PI-0043 / PI-0034 / PT-0041 / PSL-0032 / FSL-0044;
removal of pump UPEB-0055 and check valve QSA-0048;
removal of manometer PI-0051;
supply and installation of pipes and fittings to re-connect inlet/outlet of the removed pump UPEB-0055 (in red, see Figure 1);
removal of expansion vessels SEV-0235 / SEV-0238;
re-displacement of components inside the skid: manual balancing valve VR-0011 shall be removed from the actual position and installed on the outlet pipe instead of Y-strainer FY-0073;

6. Modifications on chilled water side
Figure 1 — removal of pump UPEB-0055

7. Modifications on chilled water side

8. Modifications on demi water side
secondary circuit (demi water side):
removal of existing pumps UPEB-0112 / UPEB-0130, substitution with n. 2 new ones, suitable for the new operating range, driven by variable speed drives directly mounted on-board (Grundfos CRNE 1-25)
removal of existing flow transmitter FT-0175, substitution with a new one suitable for the new operating range (ABB Orimaster);
removal of the spring loaded by-pass valve VR-0068, substitution with n. 1 new manual balancing valves (TA Hydronics);
modification of n. 1 final user connection: removal of existing manual balancing valve DN32 item VR-0160 and of the flow indicator DN40 item FI-0157, supply and installation of a new flow indicator Kobold mod. BGN DN25 scale 40÷400 l/h, a new balancing valve Gemü DN25;

9. Modifications on demi water side

10. The existing CW network

11. The existing CW network

12. The existing CW pump

13. The check of available Dp on CW side

14. The heat exchanger behaviour on CW side

15. The heat exchanger behaviour on CW side

16. The 3-way valve check on CW side
the CV of the 3-way valve is 48
the rangeability is 1/30
the CVmin is 1,6

17. The DW side
the users’ demi water possible configurations

18. The DW side
the operating range now compared to the existing pumps’ curve (constant speed)

19. The DW side
the new pump (variable speed)

20. The DW side

21. THANKS