Monthly Archives: April 2019

Service to Industrial Refrigeration Controller

Industrial Refrigeration Service Visit

Tick Sheet

The industrial refrigeration plant is inside a walk in room so some of it can be serviced in the dry, Good job because it is a bit of a rainy day- don't want to get the tick sheet wet

Chiller Controller

The controller for the industrial refrigeration plant has been problematic from when the chiller was first lifted in. It faults out regularly: reoccuring known faults known to the customer. Part of the problem are low load conditions. This causes the chiller to go into various alerts then it eventually trips out

Over Complicated Industrial Refrigeration Service

Another part of the problem are over complicated controls. I often think about the same industrial refrigeration machine in a critical process environment. This machine is bespoke so there will be a bog standard version as well. The controls on this version have too many sensors, generating too many faults. There is always something which trips it out when no fault as such is present. The controls themselves are a fault if they are problematic. Factory Managers don't like an industrial refrigeration plant tripping out and needing service all the time- they want the plant to just run seamlessly. This customer, however, has to pay for more parts and more industrial refrigeration service is to keep it running

0161 370 7193

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Handling the Ammonia Refrigerant

The chiller has a low refrigerant charge so a service visit has been arranged to handle the Ammonia. We have state of the art ammonia refrigerant handling units Read More but these are used when handling tonnes of ammonia refrigerant. This is just a small 200kw industrial refrigeration plant so we will be using a smaller ammonia refrigerant handling system

Oil Return

Due to the low refrigerant charge, the oil is migrating to the low side of the system. The oil will need to be manually recovered from various vessels following the ammonia oil recovery procedure

Chiller Evaporator after Service

Service to Chiller Evaporator

Service to Water Chiller Shell of Evaporator

Not often does this kind of chiller service fault occur. Usually the water chiller evaporator has frozen up and burst the tubes inside the shell. This fault involved the shell of the chilled water system itself bursting. On close inspection- the shell was made out of thin steel- not the usual heavy rolled steel. It looked like the near end on the photo had sagged down, causing the evaporator shell to buckle

Replacement of Evaporator

This option would be expensive due to the cost of the evaporator. It would be a difficult chiller service visit because of access issues. The builders decided to site the water chillers round the back of the building. This makes glycol chiller service very difficult. A dedicated lift and shift company would be needed to get the old chiller evaporator out and the new on in. There is a difficult corner to get round where the evaporator would have to be tilted up to get it round. Also, a fence wound have to be taken down around the chillers. Of course security is an issue but so is chilled water system service to glycol chillers and air cooled chillers

0161 370 7193

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Water Chiller Service with Silver Solder

Because of the above it was decided by the customer to attempt chiller service using silver solder. The Risk Assessment Method Statement allowed for the chilled water system service to be carried out with a half hour fire watch. The oxy-acetylene lines were leak tested prior to the chiller service. Both leaks were soldered up but despite the evaporator being drained down, there was still water and steam trying to get out. Not the best water chiller service soldering resulted- but it held

Air Cooled Chiller Paintwork

Because air cooled chillers are usually outside- the service of the chiller paintwork is essential. Poor water system service of paintwork will reduce the chiller's life. After preparing the surface, direct to rust paint was applied so as to protect it for the future

Lagging Service for Glycol Chiller

The main purpose of Armour Flex lagging is to reduce heat gain from the environment to the chilled water system being serviced. This provides service protection from the elements for the glycol water chiller as well