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Refcool delivered two custom cooling projects: a multi-circuit skid for a plasma power system with raw/deionized water and gas distribution, and dual pump skids for an international furnace operation, each designed for reliability and easy maintenance.
Refcool’s engineering versatility was on full display in two recent projects serving very different industrial needs – one for a plasma power research application in the UK and another for an industrial furnace system in Greece. In the first case, a plasma technology specialist required a complex cooling skid to manage multiple fluids (including raw and deionized water) and gases for high-energy plasma torches. In the second, an international manufacturing company needed reliable dual pump cooling sets to support large furnaces. Both clients turned to Refcool for custom cooling solutions to ensure their operations run safely and efficiently.
Plasma Cooling System: The plasma power specialist’s project involved cooling several plasma torches and associated power electronics. The system was unusually complex – it required three separate cooling circuits, each at different pressure levels, to handle distinct parts of the process. Some circuits used raw water, others used deionized water, and the cooling skid also had to incorporate feeds for inert gases (Nitrogen and Argon) delivered to various outlets. Maintaining water purity (for the deionized loop) and preventing any cross-contamination was critical. Additionally, a fail-safe pressure control was needed for the electronics cooling circuit to protect sensitive equipment. The entire package had to be installed underground via a lift shaft, meaning the cooling system had to be modular and sized for tight access during installation. This constrained build space and disassembly requirement added a significant logistical challenge on top of the technical complexity.
Furnace Cooling Pump Sets: The company in Greece required cooling for industrial furnaces, specifically via two water-to-water dual pump skids. The main challenge here was to provide continuous cooling with redundancy – each skid needed twin pumps in duty/standby configuration so that if one pump failed or needed servicing, the other could seamlessly take over. The pumps also had to handle high flow rates and pressures to circulate cooling water through furnace heat exchangers. Another important feature was the inclusion of a combined fill and vent tank in each skid. This tank allows operators to easily add glycol (for freeze protection) and purge air from the system by diverting flow through the tank during priming. Designing the skids to accommodate these functionalities while keeping the footprint manageable was a key consideration. Long-term maintainability was also crucial; the pump skids needed to be robust and simple to operate for plant technicians, given that they would be shipped overseas and integrated at the client’s site without Refcool’s continuous presence.
Plasma Cooling Skid: Refcool developed a bespoke plasma cooling skid constructed on a base frame that was split into four interlocking sections. This modular design allowed the system to be built and factory-tested as larger subassemblies, then separated for transport and reassembly underground. The skid contained three dedicated cooling circuits: one for the plasma torches using raw water, one for the plasma torches or related gear using deionized water, and one for the power electronics. Each circuit included its own pumps, heat exchangers, and controls to maintain the required pressures and flow rates independently. A distribution manifold was integrated to channel the cooled fluids (both raw and DI water) to multiple torch outlets, and it also handled the delivery of Nitrogen and Argon gases alongside the cooling lines, effectively bundling all utilities to the plasma torches in a neat configuration. The electronics cooling loop was outfitted with a fail-safe pressure regulation system – ensuring that if any anomaly occurred, the sensitive equipment would not be subjected to over- or under-pressure conditions.
Careful attention was given to materials: all components in contact with deionized water were selected to be compatible and prevent ion leaching or contamination. Stainless steel and inert plastics were used to keep water purity high. The entire skid was designed for easy connection on site; once lowered through the lift shaft, the four parts bolt together with unions for piping and quick connectors for electrical and control lines. This clever mechanical design made on-site installation quick and ensured that the system could be up and running with minimal assembly error. Refcool’s solution provided the client with a comprehensive, plug-and-play cooling system for their plasma application, tailored exactly to their multi-fluid, multi-pressure requirements.
Furnace Dual Pump Skids: For the furnace cooling needs, Refcool manufactured two water-to-water dual pump skids built to the client’s specifications. Each skid features two heavy-duty centrifugal pumps: one acts as the primary pump while the second remains on standby, wired to automatically activate if the primary pump’s performance falls or if it’s switched off for maintenance. This configuration offers true duty/standby redundancy, greatly improving the reliability of the furnace cooling system. Both skids were built with a steel frame and a mounted tank (the fill and vent tank) that serves multiple purposes: it provides a reservoir for adding inhibitor chemicals like glycol, and its venting section helps remove trapped air by cycling a portion of the flow through the tank during system start-up or maintenance. This design makes it easy for the end user to maintain proper coolant mixture and system pressure without introducing air locks.
All necessary valves, gauges, and safety controls (like pressure relief valves) were included on the skids, making them self-contained units. The piping on the skid was arranged with bypass lines so that either pump can be isolated and serviced while the other continues to circulate water through the furnaces. The compact yet robust design means the client can install these skids alongside their furnaces with minimal modifications. Refcool delivered the skids with complete documentation and assisted the client’s local team in Greece with installation guidelines to ensure proper integration.
Both projects underscore Refcool’s ability to deliver custom-engineered cooling solutions for complex industrial applications:
Plasma Cooling System: The installed plasma cooling skid met the specialist client’s rigorous needs. It provides stable cooling across all three circuits, enabling the plasma torches to operate at full power without overheating and the electronics to remain within safe temperatures. The inclusion of gas distribution in the skid simplified what would otherwise have been a tangle of separate lines, thus the client lauded the solution for its clever integration. The underground installation went smoothly; the modular sections fit into the service lift and were reassembled on-site as designed. The client now has a reliable and easy-to-manage cooling setup that supports their plasma processes, which is a competitive advantage in their high-tech field.
Furnace Pump Skids: The dual pump skids have significantly improved the robustness of the furnace cooling circuits for the international client. With the duty/standby pump arrangement, unplanned downtime due to pump failure has been virtually eliminated – if one pump needs servicing, the other seamlessly takes over, so the furnaces remain properly cooled at all times. The fill and vent tanks on each skid have made maintenance simpler; plant engineers can top up glycol and bleed air in one convenient location, reducing maintenance time and ensuring the system’s longevity. Since commissioning, the furnace operations have experienced more stable temperatures and fewer maintenance interruptions, validating the design’s effectiveness. The client in Greece was particularly impressed with Refcool’s build quality and attention to detail, noting that the skid units were truly “plug and play” and integrated into their process with minimal adjustments.
These case studies collectively demonstrate Refcool’s strength in tackling specialized cooling challenges. Whether it’s managing the intricacies of plasma technology cooling with multiple media or delivering rock-solid pump systems for furnace cooling, Refcool provides persuasive evidence to B2B customers of our problem-solving expertise and commitment to reliable, efficient solutions.