Project information: New Era Cold Storage (NECS) Located in Phu An Thanh Industrial Park, Ben Luc, Long An, it is one of the largest cold chain logistics centers in Vietnam and Southeast Asia with record-breaking capacity. 102,642 pallet positions. In this project, Tan Long Refrigeration and Electrical Engineering Joint Stock Company Undertaking the role of EPC General Contractor for the central HVAC system: Design, fabrication of the pressure vessel substation, installation of MYCOM twin-screw compressor unit (Mayekawa, Japan) and programming of SCADA automation control.
Faced with a massive cold storage facility boasting a volume of hundreds of thousands of cubic meters of air and a clear height exceeding 30 meters, the technical requirements for Tan Long's engineering team went beyond simply "cooling," focusing instead on precise microclimate control, saving every kWh of electricity, and ensuring absolute safety for the ammonia (NH3) refrigerant system, which would be filled with tens of tons of gas.
Below is an authentic technical log recorded by the chief engineers of the Tan Long project throughout the implementation of the NECS large-scale warehouse project.
Overview of the NECS (New Era) Cold Storage facility – Capacity of 102,642 pallet positions in Ben Luc, Long An.
1. Challenge 1: Power and oil return problem for MYCOM screw compressor station
3D Perspective Drawings & Site Images of the NECS Cold Storage Project (102,642 Pallets)
NECS (New Era Cold Storage) in Phu An Thanh Industrial Park, Ben Luc, Long An, is a leading automated cold logistics center in Southeast Asia. Tan Long was the contractor for the entire industrial ammonia (NH3) refrigeration system with a total cooling capacity of approximately 3.08 MW across three phases:
With its enormous storage capacity, the thermal load fluctuates extremely complexly between daytime (when hundreds of container trucks are constantly loading and unloading) and nighttime (when the warehouse doors are closed). To solve this problem:
- Choose your compressor configuration: Tan Long has calculated the load distribution and integrated the twin-screw compressor unit. MYCOM (Mayekawa – Japan) Specifically designed for NH3 refrigerant. This compressor series is globally renowned for its reliability and high-pressure, micro-machined screw compressors.
- Multi-stage automatic oil return system: In NH3 refrigeration systems, lubricating oil is insoluble in the liquid refrigerant and has a higher density, making it prone to settling at the bottom of the tanks and evaporators, severely reducing heat transfer efficiency. Tan Long's engineering team designed a high-efficiency 3-stage oil separator combined with a thermosyphon oil cooler and an automatic oil recovery pump that returns oil from the low-pressure tank to the compressor crankcase, ensuring a stable lubricating oil level under all operating conditions.
The MYCOM screw compressor station is installed and positioned on a specialized anti-vibration foundation in the NECS central machine room.
2. Challenge 2: Fabrication of pressure equipment and testing standards for X-ray welding 100%
Safety is always the top priority in the construction of NH3 refrigeration systems. All pressure vessels, such as high-pressure receivers, liquid separators, intermediate vessels, and level control vessels, are inspected. Tan Long Refrigeration and Electrical Engineering directly manufactures its products at its 10,000m² factory in Duc Hoa 1 Industrial Park. according to ASME Section VIII standards and national regulations QCVN 02:2019/BLDTBXH.
| Quality control category | Standards applied at Tan Long | Results of the on-site acceptance testing at the NECS project. |
|---|---|---|
| Steel materials for manufacturing pipes and tanks. | ASTM A106 Gr.B / ASTM A516 Gr.70 seamless cast steel for sub-zero temperatures | Complete with CO/CQ certificates and Charpy V-Notch impact test results at -40°C. |
| Pipe welder's skill | 6G welders with international certifications apply TIG rooting and arc welding methods. | 100% welders passed a preliminary certification test before going to the construction site. |
| Non-destructive testing (NDT) | Radiographic (RT) and ultrasound (UT) imaging of pressure welds. | The product meets the 100% standard, with no defects such as slag bubbles or cracks detected. |
| Hydraulic durability testing & Leakage testing | Hydraulic test at 2.5 MPa, leak test with dry nitrogen gas at 1.8 MPa, holding pressure for 48 hours. | Pressure drop = 0 bar after adjusting for ambient temperature variations. |
The process piping system and NH3 pressure vessels are installed and undergo rigorous safety inspections at the NECS facility.
3. Challenge 3: Control the microclimate without thermal dead zones at a height of 35m using SCADA.
In a cold storage facility with ceilings up to 35 meters high, air stratification presents a significant physical challenge: Hot air tends to rise to the ceiling while cold air sinks to the floor. If the cooling system is not properly positioned, the temperature difference between the first and twelfth levels of the pallet racking system can reach 4°C–6°C, causing serious damage to sensitive goods.
Tan Long's technical solutions include:
- Fluid dynamics simulation (CFD): Accurately calculate the air velocity field and airflow trajectory of each ceiling-mounted cooling unit, ensuring that the circulating cold air evenly sweeps through all the gaps between the pallets.
- Central SCADA control system: The system is programmed using Mitsubishi/Siemens industrial PLC technology, connecting a network of over 80 high-precision PT100 temperature sensors strategically placed at various heights throughout the warehouse.
- Intelligent automatic defrosting cycle: Instead of defrosting at fixed times, which increases local temperature, the SCADA system automatically calculates the pressure difference across the coil to defrost with hot gas at the right time, saving defrosting energy and maintaining a stable warehouse temperature of -20°C ± 0.5°C.
The PLC control panel system is precisely wired at NECS.
The SCADA interface visually displays pressure and temperature in real time.
4. Lessons Learned & Affirming Tan Long's Position as EPC General Contractor for Mechanical and Electrical Engineering
The successful handover and stable operation of the NECS cold storage facility with 102,642 pallet positions is the clearest evidence of our superior EPC capabilities. Tan Long Refrigeration and Electrical Engineering:
- Proactively developing mechanical manufacturing capabilities: Owning a 10,000m² factory in Duc Hoa 1 allows Tan Long to independently manage the manufacturing schedule of pressure vessels, compressor frames, cold storage doors, and control cabinets without relying on subcontractors.
- A highly skilled team of field engineers: The entire construction process, including pressure welding, compressor alignment, and refrigerant charging, is directly supervised and carried out by Tan Long's experienced engineers.
- Lifetime support service: After handover, Tan Long continues to provide a regular maintenance package, 24/7 technical support, and remote control software optimization support for customers.
🤝 Are you looking for a practical EPC contractor for a large-scale cold storage project?
We invite you to visit the actual projects that Tan Long has completed and our pressure equipment manufacturing plant to verify our capabilities before deciding to sign a contract.
👉 See also: General Contractor Services for Construction & Installation of Industrial Cold Storage Facilities Chief Engineer Hotline: 0933 357 058
Is your business in need of a survey, upgrade, or new design for your industrial refrigeration system?
With over 18 years of practical experience leading more than 29 major national projects, Tan Long's team of HVAC engineers is committed to providing accurate thermal load calculations, optimizing the COP efficiency coefficient, switching between natural refrigerants NH3/CO2, and saving 20–30% in operating electricity costs.
Engineer Nguyen Toan Thinh (Technical Director)
With over 18 years of practical experience in directing, consulting, designing, and constructing heavy industrial refrigeration systems, ASRS automated warehouses, and IQF freezing systems across more than 29 major national projects.
