Dresden / Dortmund. VON ARDENNE Anlagentechnik GmbH in Dresden is one of the leading manufacturers of inline production systems for coating architectural glass and photovoltaic modules, especially for the so-called thin-layer technology. Facing the increased demand in energy-saving and efficient building techniques as well as regenerative energy production systems, the successful company had to continuously expand its production capacities. In 2006, the production site was extended by an assembly shop as well as a logistics building and a building with social and technical areas. Planning the building complex, the corporate management placed high demands on reliability, economy and energy efficiency of production engineering and of building services. Concerning the required pump technology, the pump expert WILO SE could meet the high demands of the investor in the best way due to its broad product portfolio and its energy efficient technology.

 

Special system concept
A characteristic of VON ARDENNE´S building services is the cooling water supply, covered by an underground rainwater storage tank. The heat produced has to be led off to avoid damage of the technical equipment during installation of thin-layer photovoltaics. Depending on the system specific requirements this leads to a cooling demand between 500 and 1.000 kW. Two open circuits with different temperature levels enable a continuous recycling of the cooling water. In the event of fire the water stored in the rainwater storage tank can also be used as fire water.

 

The cooling water is provided by 22 borehole pumps of the "Wilo-EMU NR" series designed as pressure boosting systems. They provide a failure-free process cooling at an operating pressure of 6.5 bars. The maximal volume flow of the three pressure boosting systems with 18 pumps in the first cooling circuit is 324 m3/h in total. The maximal volume flow of the pressure boosting system with two borehole pumps in the second cooling circuit is 36 m3/h. Additionally, two further borehole pumps are available for emergency water supply as replacement pumps. The pressure boosting systems are electronically controlled by control devices of the type "Wilo-CR-System" to enable efficient operation.

 

High-performance coolant supply
The cooling circuits which supply the required temperature for the cooling water are operated by extremely reliable, electronically controlled inline pumps in glanded construction of the "Wilo-CronoLine-IL-E" and "Wilo-VeroTwin-DP-E" series. An evaporative cooler with approximately 800 kW power and closed water-glycol circuit as well as an air-cooled compact cold water set with 200 kW power and free cooling are used to achieve the required cooling temperatures of both cooling circuits.

 

The double pumps of the „Wilo-VeroTwin-DP-E” series are installed redundantly. One of the two pumps runs in main operation, whereas the second pump is available as standby pump. In regular intervals the pumps alternate to achieve an equal load of both pumps. The pumps used in the cooling and cold water circuits are optimally adapted to the operating conditions in air-conditioning and cooling.

 

Flow losses are minimised thanks to very smooth surfaces inside the pump housing and the impeller so that an optimum efficiency is achieved. A cataphoretic coating as standard as well as additional paintwork protect the pump against corrosion. Moreover, the motor housings are factory-equipped with drain labyrinths to discharge occurring condensate. The result is an effective motor protection. So the pump's service life is prolonged and, at the same time, maintenance costs are reduced.

 

Power saving potentials by high-efficiency pumps
In heat generation and distribution, savings can be achieved thanks to pump technology from Wilo and the innovative cool water concept. The demand of the installed water-water heat pump with 107 kW thermal powers is also covered from the rainwater storage tank by a borehole pump. The heat pump achieves optimal operating parameters due to the process cooling water, which is considerably warmer than the ground water. The building is heated by very energy-efficient ceiling mounted radiant panels and panel heatings with a large quantity of radiant heat. The heating reduces primary energy consumption and significantly relieves the energy costs. Additionally, nearly no dust particles are blown up by convected air. This means that with radiant heatings the room air remains as dust- and particle-free as possible. This is especially an advantage for the sensitive production systems and processes at VON ARDENNE.

 

Eleven high-efficiency pumps of the "Wilo-Stratos" series supply heat pump circuits as well as the floor heating and the ceiling mounted radiant systems installed for heat transfer. More than 80 percent electricity costs can be saved in comparison to uncontrolled standard pumps due to the automatic adaptation of the pump power to the changing operating conditions.

So an ecologically exemplary and optimally adapted overall concept could be realised with the support of the Dortmund pump expert Wilo. This concept sets standards in industrial plants.