Monthly Archives: March 2019

Service Welding for Industrial Refrigeration

Industrial Refrigeration Service Welding

Industrial Refrigeration Service Welding of the Pipework

The ammonia had been removed to perform industrial refrigeration service welding. This was carried out using the zero-zero breaking in procedure. This visit was to replace rusted pipework. The welder got strait to it: grinding out the components ready for the welding. After the welding was completed, the vessel was leak tested and pressure tested. Another part of the system which contained liquid required works so:

Ammonia Refrigerant Transfer Pump

The ammonia refrigerant transfer pump failed during the recovery of 6 tonnes of anhydrous ammonia. There was a tight schedule as delays would mean less time for the upgrade during factory shutdown. Our engineer quickly took the side covers off the ammonia refrigerant transfer pump. He found that the coupling had come loose. Luckily, he found it to be not damaged more than scratches. Therefore, he bolted it together again and tested it: back in production

0161 370 7193

service@maximuschillers.com

Contact Form

Shell and Tube Service

After the above was carried out- the plant was inspected. The condenser had failed on the industrial refrigeration plant. Ammonia had been leaking into the water system causing the ammonia warning alarm being triggered with plant shut down

Burst Tubes

Our shell and tube technician identified the tubes. Then, industrial refrigeration service welding was carried out on the burst ones. Dehydration was easy as the ammonia refrigerant had been leaking out with not much water getting in. Also, the water system was drained prior to removing the refrigerant

Run Testing

The customer signed off the paperwork for the job. The readings were monitored for some time to look for any abnormalities. All readings were okay- another happy customer!

Are you a factory manager or facility manager? Have you got service issues with your industrial refrigeration plant? Bills too high? For service: Maximus Chillers can help Click Here

For the International Institute of Ammonia Refrigeration (IIAR) Click Here


Chiller Controller Replacement and Refurbishment

Chiller Controls Refurbishment and Testing

Chiller Controls Refurbishment

Chiller controls refurbishment is cost effective because the main cost of a large screw or centrifugal chiller is mostly in the fixed plant. That is to say: the two main heat exchangers and the compressor. Therefore, chiller refurbishment is the most environmentally friendly option as the carbon footprint of building new chilling plant is very high. This is not mentioned when you purchase a new chiller. With chiller  controls refurbishment, this kind of plant lasts for 30 years. One of our competitors has been carrying this out to a chilling plant that dates back to the 1970s and is still in service!

Refurbishment of the Chiller Evaporator

Chiller refurbishment of broken tubes can be performed by plugging the tubes on either end. Larger scale chiller refurbishment of the tubes can be carried out by cutting a door in the shell to access the tubes. This is a major overhaul at a fraction of the cost of replacing the water chiller

0161 370 7193

service@maximuschillers.com

Contact Form

The Compressor

We strip the chiller compressor down. It is made from heavy castings so will last a very long time. We provide a 12 month warranty on all our chiller compressor refurbishments. Read More about centrifugal compressor remanufacturing on our web page

Refurbishing the Chiller Controls

Refurbishing the chiller controls can be carried out by fitting state of the art controls. These will surpass the controls fitted by the builders of the chiller. The controls that come with the chiller are made 'in house' so they often are prone to spurious trip outs which can loose you production. A control panel, designed specifically for that chiller comes ready built. All you have to do, is wire in the various sensors and transducers. The run signal, compressor soft start, remote loading and monitoring can be easily integrated

Chiller repairs at Maximus Chillers | Centrifugal, air cooled and water cooled chillers | National and Global | Click Here

Read more about the chiller controls we fit to existing chillers


Air Cooled Glycol Chiller Maintenance

Chiller Maintenance Schedule Air Cooled Glycol

Air Cooled Chiller Maintenance Schedule Bodger Watch

A chiller maintenance schedule is usually very good, but this is bodger watch!

We maintain the air cooled chillers in an office building. The customer told me there had been this guy who used to come who spent most of his time in the canteen- reading manuals on his lap top! Not even the manuals for that site either! You couldn't make it up could you? What kind of a chiller maintenance schedule is that? They said he used to fix everyone's bathrooms in the evening to make up his pay! This is bodger watch!

Dosing Glycol Chillers

Our junior engineer rang me from a job the other week. Struggling to carry out glycol chiller maintenance. Get your refractometer out I said before you ring. We are teaching how to think for himself instead of just ringing everybody up. He came back with the result- too much glycol. The customer uses propylene even though the site is heavy industrial. This is because the price is narrowing between propylene and ethylene and propylene is not toxic

0161 370 7193

service@maximuschillers.com

Contact Form

Customer Dosing of Glycol

The customer adding glycol is the usual course. It means their onsite chiller maintenance engineer can keep on top of things on site. This onsite engineer was a little too keen though: he had been putting too much in

Glycol Removal

The glycol chiller was performed by telling my engineer to get half of it out into the empty drums that were still on site. The glycol can be used again in the future maintenance of the chilling plant. He then topped up the water system with water

For the efficient running of your chilling plant- choose Maximus Chillers to service & maintain Click Here for more info

Clear Site

Last but not least all off our engineers give the machine a wipe down and the chiller location a sweep. Good house husbandry is a part of expert chiller maintenance

Visit Refcom for industry guidance and advice


Service of the chiller's Fan Speed Controllers

Chiller Service of Fan Decks

Chiller Service of Fan Decks Bodger Watch

The chiller service of fan decks is usually very good, but this is bodger watch!

A new customer of ours was telling me about this little guy that used to come to carry out chiller service of fan decks. He was reported to have been running around like the apprentice- ringing everybody up! Then when help came, it came in the form of this huge big man who proceeded to get stuck in the chiller! You couldn't make it up! This is bodger watch! The customer needed some professional chilling plant service from Maximus Chillers

Repeated Leaks on Chilling Plant

Our engineer found the head pressure control was bringing the fans thumping on and off forwards and backwards. During a water chiller service visit the fans were found to be rattling the frame and juddering the chiller into leaks

0161 370 7193

service@maximuschillers.com

Contact Form

Learning How to Think

Instead of just swapping like for like parts. Our engineers have the capability to think outside the box and make changes to chiller design. Our ex-services engineers attend the Maximus School of Chillers at Head Office in Droylsden, Manchester. Read More on the Chiller Company page

Fan Speed Controller

Maximus Chillers fitted off the shelf, Carel fan speed controllers from our stores, on a chilling plant service visit. We fitted one for each system. These fan speed controllers are stand alone- they do not need to be integrated into existing chiller service controls. When the pressure builds up- the fan speed controller speeds the fans up from the minimum (cut in) to the maximum (same volts as the incoming supply)

Chiller Service of Fan Decks Seamless Operation

Now the fan speed controllers are fitted- there are no more leaks. Any chiller can be made to settle down into seamless operation. This is done through chiller service and chiller upgrade

Are you a factory manager or facilities manager? Tired of expensive service for your chillers? Look no further than Maximus Chillers Click Here

Visit the Institute of Refrigeration to read a paper on the comparison between air cooled condensers and evaporative condensers


Float valve on an industrial refrigeration machine

Industrial Refrigeration Maintenance

Industrial Refrigeration Maintenance of Float Valve

On a recent visit to a site in the South East, the industrial refrigeration maintenance of float valve was carried out. It was an easy job as the electronic part can be easily removed and replaced without breaking into the system. It works by detecting a level in the float chamber and operating the expansion valve solenoid coil

High Head Pressure

The call out had been to investigate a high head pressure issue. Our engineer arrived on site about 9 o clock and started to investigate the industrial refrigeration fault- a cup of coffee in hand. The machine started to load up and at around 70% it backed off with high lift warnings on the display. There was a low temperature drop on the liquid line between the float valve and the expansion valve- float valve failure. The float valve is stand alone as it will let anhydrous ammonia liquid through when it builds up- that is if it works of course

0161 370 7193

service@maximuschillers.com

Contact Form

Industrial Refrigeration Maintenance of Electronic Parts

Industrial refrigeration maintenance was carried out to the electronic parts with a straight swap

Slide Valve Sensor

A common kind of slide valve sensor on an industrial refrigeration system works by converting the length of the slide arm into 4-20mA. 4 being closed and 20 being open. To get it to work you have to set the minimum position on the slide arm with a lock nut- then set that to 0 in the program

Failed Slide Arm Electronics

A common fault is when the slide arm electronics fail, giving a stuck reading on the display. The chiller controls notice the abnormality and shut down the plant

Calibration

If the slide arm is okay, calibration can sort out the problem. In the program, the minimum and maximum positions can be set to ensure the smooth running of the plant, therefore maintenance can be kept to a minimum

Are you concerned with high maintenance costs and a tight budget? Maximus Chillers can relieve the stress- Click Here

Visit the Institute of Refrigeration for industry publication resource


Translate