Champion helps Carlton reach new heights

Champion Compressors, Kinetic Performance Technology (KPT) and Parker domnick hunter have teamed up to provide Carlton Football Club (CFC) with a state-of-the-art altitude training facility.

Charged with the task of developing an elite training and administration centre, project directors Stratcorp Consulting enlisted the expertise of KPT to provide CFC with the 36 m³ altitude training room, which is designed to accommodate 12 athletes.

At altitude (anything above sea level), there is less oxygen in a given amount of air when compared with ambient air, which is made up of approximately 21% oxygen and 79% nitrogen. With exposure to natural altitude, the body makes various adaptations to cope more efficiently with the reduced oxygen availability. These physiological adaptations can increase capacity for exercise at altitude and increase performance at sea level. Altitude simulation reduces the oxygen content in the training environment to approximately 14 to 17%.

The KPT altitude simulation system developed for CFC replicates altitudes up to 3300 m above sea level and comprises three main process packages - a compressed air system, a ‘pressure-swing adsorption’ (PSA)-based air separation/nitrogen generation package, and a control system.

Essentially a ‘flow-through’ process, the KPT altitude simulation system involves the continuous delivery of nitrogen-rich air into the training room to establish and maintain an oxygen-depleted environment, while at the same time removing ‘stale’ carbon dioxide-rich air. At the heart of this process is a Champion Compressors compressed air system.

A single Champion 37 kW CSE37 air compressor, in conjunction with pre-filters, a desiccant dryer and an oil/vapour separator, delivers breathable compressed air to the nitrogen generation package. Here, the air is subjected to a PSA process where oxygen is removed using a pressurised carbon-based molecular sieve adsorbent, delivering nitrogen at 97% purity. This nitrogen is stored in a nitrogen header vessel.

The nitrogen is mixed with ambient air, diluting the oxygen content, and then distributed to the training room via process pipework and a network of ducting. Motor-driven blowers continuously circulate ‘fresh’ nitrogen-rich air through the training room to ensure the required oxygen level is maintained and carbon dioxide removed.

KPT worked with Champion Compressors to select a compressed air system coupled with a Parker domnick hunter PSA-based air separation/nitrogen generation package.

Champion Compressors was also responsible for the mechanical installation and commissioning of the compressed air system and associated pipework, while Parker domnick hunter commissioned the air separation/nitrogen generation package. “We ensured that the packages were modular and easily to install, so the altitude training facility could be brought online on time,” says Champion Compressors industrial and engineered projects specialist Quentin St Baker. “It will also allow for the straightforward relocation of the system if required in the future.”

All key components of the CFC’s KPT altitude system are linked to a central controller via a Modbus communications protocol network. This central controller can be accessed using the touch-screen control panel, or via a web connection established through the local area network.

Like all KPT altitude simulation systems, the CFC installation features a redundant fail-safe design to ensure the wellbeing of the athletes. Two paramagnetic oxygen sensors and a carbon dioxide sensor located in the training room ensure the oxygen/nitrogen mix and carbon dioxide levels are maintained at the required level.