Execution Strategy:
Installation & Integration
- Installed 4 MCCs fitted with Allen Bradley ControlLogix processors and safety I/O.
- Commissioned 600 kW Danfoss VSDs to modulate compressor speed and ABB VSDs on evaporator fans and pumps.
- Implemented power‑monitoring relays and soft‑starters to AS/NZS 3000 standards.
Testing & Optimisation
- Performed full functional testing of interlocks, E‑stop circuits, and high‑level ammonia alarms.
- Tuned PID loops to maximise energy efficiency and reduce compressor short‑cycling.
- Verified remote monitoring and data‑logging via Inghams’ enterprise SCADA.
Project Challenges & Solutions
- Food‑grade environment: Stainless‑steel conduit and HACCP‑approved installation techniques maintained hygiene compliance.
- Stringent energy‑efficiency targets: High‑capacity VSDs and soft‑start sequencing delivered >25 % power savings versus fixed‑speed operation.
- Long‑term reliability: Oversized heat‑sink cooling and Class F insulation ensure the drives will operate trouble‑free for years to come.
Client Response
The facility achieved its target storage temperature within 24 hours of start‑up, with measured energy consumption being much lower than legacy benchmarks. Inghams praised the workmanship and expects the system to remain in reliable service for decades.
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