Supermarket on Co2 Down Under

[750valve]

Here's a few pics form a couple of sites that we have installed full liquid recirc Co2 systems in supermarkets. One plant is R134a/Co2 cascade with water cooled hi stage and screw compressors, the other R404a/Co2 and air cooled. All field pipework is copper pipe with steel pipe on the rack on the larger diameter pipes.


Site #1 R404a/Co2

http://i163.photobucket.com/albums/t311/750valve/Co2%20refrig/P1010012.jpg
Plantroom

http://i163.photobucket.com/albums/t311/750valve/Co2%20refrig/P1010019.jpg
Co2 vessel and low stage Co2 rack

http://i163.photobucket.com/albums/t311/750valve/Co2%20refrig/P1010021.jpg
Switchboard internal

http://i163.photobucket.com/albums/t311/750valve/Co2%20refrig/P1010022.jpg
Switchboard external

http://i163.photobucket.com/albums/t311/750valve/Co2%20refrig/P1010050.jpg
Co2 pipework back of house

http://i163.photobucket.com/albums/t311/750valve/Co2%20refrig/P1010051.jpg
Co2 pipework

http://i163.photobucket.com/albums/t311/750valve/Co2%20refrig/P1010052.jpg
Co2 Coolroom evaporator with hand expansion valve

[750valve]

Site #2 R134a/Co2

http://i163.photobucket.com/albums/t311/750valve/Co2%20refrig/Rosuehillco2.jpg
Co2 Rack

http://i163.photobucket.com/albums/t311/750valve/Co2%20refrig/RouseHilldanfoss.jpg
Switchboard controls

http://i163.photobucket.com/albums/t311/750valve/Co2%20refrig/RouseHillswbd.jpg
Switchboard internals

http://i163.photobucket.com/albums/t311/750valve/Co2%20refrig/rousehillco212.jpg
Plantroom pipework

http://i163.photobucket.com/albums/t311/750valve/Co2%20refrig/rousehillco213.jpg
Co2 piping entering/exiting plantroom

http://i163.photobucket.com/albums/t311/750valve/Co2%20refrig/rousehillco25.jpg
Bitzer screw rack R134a

http://i163.photobucket.com/albums/t311/750valve/Co2%20refrig/rousehillco26.jpg
Bitzer screw rack R134a

[750valve]

Actually here is a third site with a decent piperun under the store (carpark)

http://i163.photobucket.com/albums/t311/750valve/Co2%20refrig/IMAGE_00082.jpg
Quadruple stacked main run to shopfloor

http://i163.photobucket.com/albums/t311/750valve/Co2%20refrig/IMAGE_00079.jpg
Plantroom internal pipwork - water lines, Co2 and R404a lines

http://i163.photobucket.com/albums/t311/750valve/Co2%20refrig/IMAGE_00076.jpg
Co2 pipework turning onto rack

[jemawalton]

Wow! How long did some of those jobs take? I love the attention to detail. That pipe work looks great.

[fcs]

Looks nice.

[yellowirenut]

great googaly moogaly! it all looks planned out nicely and orderly detailed draowings? Mega store it looks like? Some times our layouts are just scribbles on a piece of paper..that when the fights start for space between the contractors

[icemeister]

Congratulations on such a beautiful installation! It's extremely well done.

I simply can't imagine a supermarket chain here in the States spending the money to get such workmanship and detail.

Thanks so much for posting those pics. :)

[krh1air]

Sweet!!!

Is there a full time tech there to moniter those babies?

[-frozen-ocean-]

Very nice. its nice to see someone who takes pride in his work.:D

[knewguy]

Very impressive. Neat, organized and well done. :)

[pherman]

Who is the rack manufacturer? Fantastic by the way.

[crackertech]

Sweet I would love to get my hands on a market like that.

[Dowadudda]

AKA 265 Danfoss controls.

God Jamnit them screws use a lot of oil. Look at the size of the oil separator.

Looks good. "yes sir, mr store manager, I need to come back tomorrow and repaint all the discharge lines again, the red paint is peeling".

Wally world is about to go full on with co2 I am told. Won't look all perty like that on though.

[Dowadudda]

most racks piped out in our neck of the woods look similar with the piping on hangers like that. That seems normal to me. Nothing weird.

[jpsmith1cm]

most racks piped out in our neck of the woods look similar with the piping on hangers like that. That seems normal to me. Nothing weird.

Ditto. The only thing unusual about the piping was the labeling.

The racks look NICE!

[750valve]

Thanks for the kind words guys, the company I work for completed these jobs over the last 3 years - I cannot take credit for the jobs entirely (especially a lot of the impressive pipework) although I had major input throughout the construction of each store and commissioned all sites. As mentioned by Dowadudda the standard of pipework is nothing out of the ordinary - it is high but that is expected by the major chains over here, it is more the fact it is very well thought out with any major pipe crossovers in the plantroom or out on the shopfloor being eliminated. One site has 44 sets of lines, this is about the norm for an average sized store on Co2 utilising copper lines. The jobs take about 3 months from start to hand over.

As for manufacturers of racks, the recip racks are by the company I work for, the screw racks are made by Bitzer Australia and the Co2 ones as well based on a design by our company - although we now make our own Co2 and screw racks.

[750valve]

Oh and NO there are no in store techs at any stores in Australia, these are fully automated and only see monthly maintenance and breakdown calls. All in all they have been pretty reliable, the only issue is keeping the Co2 on a power failure as its sub-critical and needs to be refigerated to keep its pressure below 40bar. There is a transcritical store in Adelaide which is a bit of a test plant, its in an independant supermarket.

[Tech Rob]

These pictures rank among some of the most impressive things I've ever seen. I had no idea supermarkets got that high tech... It seems like they don't here in the US.

So the CO2 is a secondary loop, and the actual refrigerant charge is contained in the plant room and rooftop condenser? Neato.

[yellowirenut]

All in all they have been pretty reliable, the only issue is keeping the Co2 on a power failure as its sub-critical and needs to be refigerated to keep its pressure below 40bar.
Dont know about other places but our Fire Dept. loves to kill all power. I know of several deep freeze storage facilities around town using ammonia..strict orders to fire dept not to cut power...but they still do. Sister is dating a firefighter i asked him about it...he could care less what is inside they just need to cut power regardless...i tried to tell him the dangers and his eyes glassed over. Fire...cut power, tear, rip, water...no fire basically what he knows.

[750valve]

Dont know about other places but our Fire Dept. loves to kill all power. I know of several deep freeze storage facilities around town using ammonia..strict orders to fire dept not to cut power...but they still do. Sister is dating a firefighter i asked him about it...he could care less what is inside they just need to cut power regardless...i tried to tell him the dangers and his eyes glassed over. Fire...cut power, tear, rip, water...no fire basically what he knows.


Very true, we actually have an Ammonia/Co2 cascade system in a supermarket here which is susceptible to frequent power outages. The Co2 just blows off, you either refill with bottles or a mini-tanker and away you go - Co2 is REALLY cheap to buy so the only major issues is getting it up and running to prevent a stockloss (if power is out for a while the food is gone anyway though).

We do have a small backup system chilling a DX coil wrapped around the insulated vessel, this is powered by the stores emergency generator. We have had up to 8 hours off time before any major loss of charge but on some sites we have seen as little as 1 hour before its venting the majority of its charge, depends on vessel size vs total charge.

[frankie89]

just beautiful