Challenge

The Town of Manning, located in Alberta, Canada, faced significant issues with their aging ammonia-based ice plant at the Manning Sports Centre Arena. The problems, including frequent breakdowns, rising utility bills, and outdated safety standards led to costly repairs and escalating operational expenses. High utility bills strained the Town’s resources, and the existing system did not meet modern safety standards, posing a risk to the community. An arena of this size can require up to 100 tons of refrigeration, underlining the importance of an efficient, reliable, and affordable solution that the Town sought to implement.  

Solution 

To address these challenges, Town leadership collaborated with Trane to develop a strategy that aimed to help alleviate these financial and operational pressures. Trane experts approached the project by:

• Implementing a Tailored Approach 
  Determined to find the best solution for their community, representatives from the Town of Manning visited other arenas in Alberta that were currently operating Trane ice plants. Inspired by the efficiency and modern features of these systems, Manning chose to collaborate with Trane on their product. Trane’s customized plan included an air-cooled packaged chiller, an advanced ice plant automation system, and a “free-cooling” fluid cooler to leverage Manning’s cold winters. 
  
  
• Strategically Helping to Reduce Costs 
  The installation of the CGAM Air-Cooled Scroll Chiller and “free-cooling” fluid cooler outside the facility freed up significant mechanical room space, helping to eliminate the need for building upgrades and advanced safety systems. This reduction in capital cost, by over $460,000, allowed for more effective budget allocation.
  
  
• Updating Systems Comprehensively  
  In addition to the ice plant upgrades, the facility’s heating and domestic hot water systems were updated. New condensing boilers, an on-demand hot water system, and a variable frequency drive (VFD) for the heating distribution pump were installed. These updates helped resolve temperature issues and helped increase capacity and efficiency. Holistically, this configuration was designed to help be cost-effective, energy-efficient, and easy to maintain.

Results

By embracing advanced technology and sustainable practices, Manning has not only resolved its immediate facility issues but has also positioned the sports center to welcome visitors for years to come. The comprehensive upgrades have resulted in a range of improvements that highlight the transformative impact of strategic infrastructure investments, including: 

• Securing Community Recognition and Funding  
  The innovative project led to Manning receiving the Community Facility Enhancement Program grant, covering nearly half of the project cost.

• Achieving Significant Energy Savings 
  The new ice plant system, operational by September 2023, delivered immediate benefits, including a 50% reduction in overall electrical costs during the 2023/2024 season. The energy-efficient design and “free-cooling” feature significantly lowered utility bills.

• Increasing Facility Efficiency 
  The new system design helps improve Energy Efficiency Ratio (EER) by up to 72% at cooler outdoor temperatures. The “free-cooling” fluid cooler significantly helps reduce compressor operation, with some winter weeks not requiring any at all. The enhanced temperature control system and variable flow pumping help to reduce  energy consumption, and help deliver efficiency throughout the hockey season.

• Enhancing Ice Quality 
  The Trane chiller can efficiently produce fluid temperature as low as 10 degrees Fahrenheit / -12 degrees Celsius. Variable flow control based directly on ice temperature offers precise temperature control and the highest quality ice at all system loads. This precise temperature control provides excellent ice consistency, helping to greatly improve the skating experience.  

• Simplifying Operations and Maintenance  
  The new system requires minimal maintenance compared to the old ammonia plant, helping to eliminate the need for oil changes, compressor overhauls, and costly maintenance procedures. Using a Trane Tracer® SC+ building automation system (BAS), the Town can remotely monitor and control all arena systems via PC, tablet or smartphone. This user-friendly interface simplifies tasks like scheduling, adjusting settings, and managing alarms, while offering customizable alarm notifications across devices.