Cold Storage at
The University of Manchester
Dr. A. R. Nicholas, FIScT
Directorate of Estates & Facilities
Fac. Life Sci. & Fac. Med & Human Sci.
The University of Manchester,
Carys Bannister Building,
Oxford Road,
Manchester.
M13 9PL
UK
arthur.nicholas@manchester.ac.uk | Tel +44(0) 161 275 5084 | Mobile +44 (0) 7798617816 | Fax + 44 (0) 0161 275 1985|
http://www.sustainability.manchester.ac.uk/
Content
Our Approach to Characterising Cold Storage Systems
Our Approaches to Achieving Safe Sustainable Efficiencies
 Our Achievements to Date
 Our Works in Progress & Future Aspirations
Our Approach to Characterising Cold Storage Systems:
 A Holistic Approach to Maximisation of Safety, Operational Efficiency & Energy Saving in
Cold Storage Systems
 A Collaborative Approach: Technical & Academic Staff, Post Graduate Students Working
Together with Staff in the University’s Directorate of Estates & Facilities and Health & Safety
Services Plus our Equipment Suppliers.
 An Evidence Led Approach, Qualitative & Quantitative, to Defining the Challenges and
Demonstrating Successful Interventions
 An Outward Looking Approach: Sharing Best Practice and Collaborating with Individuals
and Organisations External to The University of Manchester
Defining Storage System Component Parts:
 Samples
 Equipment: Fridges/Freezers/Dewars
 Environment & Services in Areas Housing Equipment
 Management Control
 Maintenance & Stock Control
 Incentives/Penalties to Scrap Inefficient Systems & Practices
 The Users
All 7 components need to be systematically reviewed and optimised in order to achieve
change i.e. a cultural shift in driving forward operational & energy efficiency in respect
of Cold Storage Systems
Our Approaches to Achieving Safe Sustainable
Efficiencies:
 Maximise research & teaching efficiency by improvements to curation & sample retrieval
processes
 Minimise the risk of loss of storage conditions, loss of stock and injury to staff depositing &
retrieving samples
 Maximise security of stock
 Reduce primary energy consumption & costs associated with us of storage systems e.g.
reduce electricity/ Liquid Nitrogen usage
 Reduce secondary energy consumption & costs associated with housing storage systems,
i.e. minimise use of space & environmental control systems e.g. air conditioning
 Effect Behavioural Change and Promote Sustainable Practice
It is important to state that these aims highlight synergies in improving lab operational
efficiency and reducing energy consumption in Cold Storage Systems
Deploying our Approaches and our Achievements to Date:
Planned Preventative Maintenance
“Simple” Sample Tracking Systems & Laboratory Information Management System {L.I.M.S}
Energy Efficient Equipment
Cryogenic Systems
Planned Preventative Maintenance
The provision of a Faculty wide annual maintenance service for 123 -80 Freezers in Laboratories
located across 4 Buildings
Resources: Equipment; Staff; Time
Tasks: Suitability of location (environmental & geographical), Filter inspection, Physical condition,
PAT, Alarm Functionality - local & BMS, Promote best practice with users
Methodology and further detail for the 2013 maintenance programme can be found at
http://www.sustainability.manchester.ac.uk/campus/sustainablelabs/freezer
Decant, Defrost, Maintain, Repair, Rationalise
Frost accumulation inside the freezer or around the freezer door creates gaps in seals, which allow
cold air to leak out and warm air to enter the freezer. Frost can also damage the seals on the
freezer
Suitability of Location (Environmental & Geographical)
Air Extract
Air Supply
Freezer
Freezer
Create chimney,
plenum, or hot aisle
Reject heat management with panels and stratification
From Doyle, A . (2012) ULF Freezer Management Guide
Filter Inspection & Cleaning
Dust or grime build-up on the filter blocks the normal air flow through the condenser,
which reduces the ability of the ULT freezer to effectively dissipate heat
Some Benefits
Energy savings: Early indications of 20% reduction in energy consumption post maintenance
Savings in repair and maintenance costs and reduced breakdowns
“Health checks” identify most energy inefficient Freezers, replacing with new energy efficient
models, with a contribution to replacement cost from the Faculty Sustainability budget
Reduced procurement of Freezers arising from: freeing up of storage space; sharing storage
capacity, increased longevity of freezers
Improvement in practice and behaviour of users giving rise to improved efficiencies in
teaching and research
Minimise the risk of loss of storage conditions, loss of stock and injury to staff depositing &
retrieving samples
Reduce secondary energy consumption associated with housing storage systems, i.e.
minimise equipment footprint & environmental control systems: HVAC
Sample Management & Stock Control
“Simple” Sample Tracking Systems
Central Liquid Nitrogen storage facilities :
The commercial market for Stock Control Software Systems was surveyed for a system to be
introduced into managed Liq N2 Vapour Storage Units {7 x 13,000 vials/unit}. It will
compliment and enhance the existing benefits of the facility.
http://www.itemtracker.com/index.shtml
http://www.bradylab.com/
http://www.biostorage.com/
http://www.isber.org/biorep-services.html
http://ziath.com/index.php/products.html
A Ziath scanner designed for sample tracking with software called “Samples” has been
procured. Sample tubes, with 2D bar codes lasered onto the base, are housed in
Polycarbonate boxes containing holes through which the scanner can read.
Sample Management & Stock Control
“Sophisticated” Laboratory Information Management System {L.I.M.S}
Biobankingsolutions – 80 Freezer storage facilities : Storing > 500,000 aliquoted samples
(Blood, DNA, Saliva etc) from research facilities across the UK
Nautilus 8, Web enabled
http://www.thermoscientific.com
What is a LIMS ?
“Computer software that is used in the laboratory for
the management of samples, laboratory users,
instruments, standards and other laboratory functions
such as invoicing, plate management, and work flow
automation.”
MORE THAN a sample inventory system.
But…
NOT a repository for phenotype or genotype data. Nor does it make the tea!
Customisation Example: Folders
Define an SQL query in a FILTER
Associate each folder with a suitable FILTER
XL20 Tube Picking Robot Performing a Sample Withdrawal
Some Benefits of L.I.M.S
ACCURACY
THROUGHPUT
SECURITY
CONTINUITY
STANDARDISATION
CENTRALISATION
Benefits of Both “Simple” Stock Control & “Sophisticated L.I.M.S
Housekeeping Efficiency of Managed system
Terms of storage can be defined e.g.” shelf life” - stock clearance
Enables consolidation of dewar/freezer space - fewer dewars/freezers
Reduces need for paper records
Reduces duplication of records
Precise location information – reduced retrieval = reduced time with open dewar/ freezer
Saves valuable Research staff time
Energy Efficient Equipment
-80 Freezers, Model Dependent Storage Costs
Freezer Model
Revco
lshin
New Brunswick u570
RSbiotech ecl 700v
Sanyo
New Brunswick U570 hef
Running Cost
{£/year/Litre}
1.86
1.54
1.10
1.02
0.87
0.45
The rate of primary energy consumption (kW) for sample models of -80 Freezers was
measured, over a 48h period, at room temperatures set at 15oC; 18oC; 21oC; 24oC and
27oC. Data is based on the average consumption figures across all temperatures
Average Energy Consumption Energy cost @ 0.07£/kWh
Energy Efficient Equipment
-80 Freezers, Model Dependent Storage Costs
The Freezer model:
Model dependent variation in primary energy cost to cool one litre of space has the
potential to provide 76% savings in primary energy running costs.
By replacing the Faculty of Life Sciences entire stock {121 -80 Freezers housed across 4
buildings} with more energy efficient models we predict (based on a mean running cost of
£700 yr-1) a potential annual saving in primary energy cost of £54K yr-1
The Ambient Room Temperature:
The mean primary energy consumption, across all models tested, demonstrated only a
17% increase over the range 15oC to 27oC over the 48h test period
Maintaining all room temperatures, housing Freezers, at 15oC would result in primary
energy cost savings of:
£5.5K yr-1 in comparison to maintaining rooms at 21oC
£12.6 K yr-1 in comparison to maintaining rooms at 27oC
Potential Benefits and Issues Associated with -80 Freezer Clusters
Potential Benefits
Facilities more readily managed
Regulation of environmental conditions (ambient room temperature) is more efficiently achieved
Safety aspects e.g. CO2 backup system alarms more efficiently achieved
Security of stock i.e. access control more efficiently achieved
Reduced instillation cost of BMS linked alarm systems; increased detection of local alarm
activations (by virtue of security checks or increased foot fall to freezer cluster)
Potential Issues
Contingency arrangements
Best electrical supply (i.e. distribution of equip between circuits + circuit protection)
Archive location vs. “active stock” location (frequency of retrieval & proximity issues)
Best Location on/off site? Inside/outside of Building?
Energy Efficient Equipment
Liquid Nitrogen Dewars
35 portable sample storage dewars were filled with Liq
N2 twice a week from 3 portable pressurised dewars
by core facilities Technicians. The pressurised dewars
were filled by a BOC, Tanker delivery, outside the
building – dewars were shuttled via a goods lift
between the first floor and ground floor, outside the
building, twice a week
7 Vapour Storage dewars (~13K samples/dewar)
are automatically & simultaneously, kept toped
up with Liq N2 piped from a 950L static tank
outside the building, filled by a BOC tanker
approx. twice a week
Potential Benefits and Issues Associated with
Communal Liquid N2 Storage Facilities
Potential Benefits
Facilities more readily managed with competent/knowledgeable Technical support
Safety aspects e.g. reduced volumes of Liq N2 stored in facility; compliant alarms & emergency
extract; reduced manual handling & filling of dewars; controlled access; compulsory training
Reduced use of staff resource
Potential Issues
Contingency arrangements
Best electrical supply (i.e. distribution of equip between circuits + circuit protection)
Archive location vs. “active stock” location (frequency of retrieval & proximity issues)
Best Location on/off site? Inside/outside of Building?
Works Currently in Progress
Use lessons learned to deliver, summer 2013, a Freezer Cluster - Freezer Farm project
(housing 35 x -80 Freezers) as an exemplar for Safety and Sustainability
Review of liquid Helium security of supply {short, medium and long term} as well as the
carbon footprint – whether we recycle or buy new
Consideration of Energy Issues relating to Cold Rooms and Fridges
Our Future Aspirations
Ambient Temperature Storage
Led by Researchers Martin Yuille & Bill Ollier at The University of Manchester plus interaction
with US Store Smart Initiative and Biostabilizers Sandbox Discussion Group,
Rationalisation of Sample Storage Choices
Establish Criteria for sample storage conditions: Define clearly criteria for storage at: -196, -80, 40, -20, + 4 & ambient
Ambient Temperature Storage
Technologies have been developed (e.g. by Biomatrica & Gentegra) which mimic anhydrobiosis for
DNA, RNA, Tissues
Ambient Temperature Storage
Potential Benefits
Savings on cost of capital equipment, recurrent energy, space
Potential Issues
Contingency arrangements e.g. Power failure – dehumidifiers
Heat generated from storage units / dehumidifiers
Hydration /dehydration cycles leading to sample degradation (acid / enzyme based hydrolysis)
Air tight, inert gas filled storage units (access management)
Maintenance / cleaning; Silica gel (replacement)
Disposal of existing -80 freezer units
Our Future Aspirations
Environmental Control in Freezer Clusters (Ambient Temp) Costs
The findings presented herein relating to -80 Freezers, Model Dependent Storage Costs
represent only part of the energy consumption/cost picture
Working with our colleagues in the Directorate of Estates & Facilities we will obtain data relating
to secondary energy consumption i.e. energy & associated cost to maintain a known room
volume, with a defined heat load, at temperature ranges covered in this pilot study
??
-80 Freezer Heat Load
F
F
F
F
Air Extract
Air Supply
F
F
F
F
AC Cooling
Acknowledgments
I’d especially like to thank colleagues at the University of Manchester :
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Geoff Blunt {FLS}
Stephen Fawkes {FLS}
Stephen Manifold {FLS}
Jonathon Miller {FLS}
Rita Newbould {FLS}
Stephen Whittaker {FLS}