03-Review Of Refrigeration Equipment
REVIEW OF REFRIGERATION EQUIPMENT
The refrigeration package at the Janesville Ice Skating Center consists of a
Carrier compressor, a Delco electric motor, and a direct expansion Freon
refrigeration system. It is the original refrigeration system that was installed 32
years ago when the facility was constructed. Over the years there has been
maintenance, upgrades, and replacement of components for the system. The
system consists of the following:
1. 2 Carrier reciprocating compressors, capable of producing approximately
125 tons of refrigeration.
2. 2 Delco 125 HP electric motors with 1,750 RPM’s.
3. Baltimore Air Cooled (BAC) Cooling Tower.
4. Miscellaneous pumps, valves, and solenoids to operate the system.
5. An Estimate of 21,000 pounds of R-22 Freon.
At 32 years old, the refrigeration package is at the end of its designed life of 35
years. If the City of Janesville was committed to investing money in preventative
maintenance and upgrading system controls, the refrigeration package could last
another 5 to 20 years.
The existing ice rink floor is a 6” thick concrete poured slab with approximately
9.8 miles of 5/8” O.D. copper tubing. The tubing is spaced on 4” centers and
connected to a 2” copper liquid header, which carries the R-22 Freon to the ice
rink. A 5” copper suction pipe then returns the Freon to the refrigeration unit. The
refrigerated rink floor is currently performing acceptably with no issues that we
can detect. Rink Management Services recommends that the glycol used for the
PVC heating pipes (the sub floor heating system) be tested annually to verify the
integrity of the solution.
The lifespan of a typical ice rink floor can be 30-50 years with proper preventative
maintenance. Rink Management Services recommends a complete pressure test
of the refrigeration piping for verification of any leaks.
If in the future it is determined that the ice rink floor needs to be replaced, Rink
Management Services would recommend a concrete floor with indirect style
polyethylene piping. Polyethylene piping provides good heat transfer at a
reasonable cost. Polyethylene is highly resistant to corrosion and this is a proven
technology. The estimated cost for the replacement of the ice rink floor would be
approximately $425,000 to $475,000.
The challenge that the facility and the City face is that the Montreal Protocol of
1987 has mandated that in 2030 all HCFC’s will no longer be produced, and
refrigerants like R-22 will not be legally allowed to be imported to the refrigeration
system.
For more information and a complete phase out schedule, you can visit the EPA
website at: http://www.epa.gov/ozone/strathome.html
Due to the fact that the Janesville Ice Skating Center’s refrigeration system runs
completely on R-22, it would be prudent to plan for a replacement of the
refrigeration system if a new ice skating facility is not built within the next 5 to 10
years. In order to retro fit a 32 year old compressor system to a new,
environmentally friendly HCFC refrigerant, it would cost almost as much as
installing a new system in the ice skating center.
In addition, the current refrigeration system is not energy efficient compared to a
new system with computer controlled settings. As pieces of equipment fail, it will
become more and more difficult to find the parts to repair the system. With a
new environmentally friendly refrigerant like 134-A and much smaller pumps and
motors, the Janesville Ice Skating Center will see immediate savings in electricity
and gas, which will help off set the cost of purchasing a new refrigeration
package.
Rink Management Services Corporation recommends that the City of Janesville
plan to include a compressor package in their capital expense projects for the ice
skating center within the next 3 to 8 years if a new facility is not constructed.