Author Archives: Maximus Chillers

Chilled Water System EEV Service

Chilled Water System Service of EEV

The Expansion Valve Required Chilled Water System Service

Chilled water system service was being carried out because the mechanical parts of the expansion valve had failed. This particular valve is prone to this fault. It is an OEM part so our technician found the voltage for the motor and found a similar part with the same amount of steps

Electronic EEV Driver

The EEV driver was found to be functioning satisfactorily. Sometimes, depending on how the mechanical part has failed, this can be overloaded and burned out

Electronic Component Refurbishment

Where electronic parts, such as the EEV driver, are found to be burned out- Maximus Chillers has a refurbishment laboratory at head office. We have the capability to strip down the component and fault find where it has blown. Usually it is quite simple: the jammed mechanical part of the electronic expansion valve has burned out the power control on the driver for example. More complex fault finding and component replacement on the circuit board can be carried out also. Another option is to replace the driver with a like for like swap or retrofit to a different driver. In any case- we have the ability for: any part- any problem- any refrigerant anywhere

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Pump Down of the Chilled Water System

The chilled water system was easily valved off and pumped down. This saves on the time and recovery vessel to pump the refrigerant out

Remove and Replace

Once pumped down, our engineer removed and replaced the valve, sealing it on it's knife edge seal. The wire was passed up the conduit and into the panel. The wiring colour scheme was different on the new valve so some time was taken to ensure it was wired up correctly

Open it up and Switch it on

After leak testing, the refrigerant system valves were opened back up and the plant switched back on. The correct superheat and subcooling valued were achieved concluding a successful chilled water system service visit

To read the Institute of Refrigeration guide to expansion valves Click Here


Industrial Refrigeration Oil Service

Industrial Refrigeration Oil Service

Industrial Refrigeration Oil Service

An industrial refrigeration oil service visit was arranged because of an oil return issue. Several fans had been down on the air cooled chilled water system. This causes the chilled water system to unload so as to prevent a fault occurring. The lower mass flow rate of the refrigerant caused oil to migrate to the low side of the system. Several vessels are available with various forms oil return control. These vessels were valved off. A two man team with the correct ammonia PPE and breathing apparatus carried out the job

Not Enough Oil Recovered During Service to the Industrial Refrigeration Plant

Only some of the oil was recovered using during the industrial refrigeration service of the plant. Therefore, the engineers decided to add new oil to get the chilled water system running. The only problem with doing this is that once running the machine, the oil has to be got back out. Therefore, the industrial refrigeration oil service had to be carried out a second time to resolve the oil return issue

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Industrial Refrigeration Service by Fitting Fan Decks

For this industrial refrigeration service visit, scaffolding had been erected in accordance with the Risk Assessment. The old fan decks were lifted out by the two man team. A really good team was sent out: one of the men was more technical and the other more mechanical- complementing each other with their different skill sets. The new fans were an updated version and the wiring was different. The fault link had to be adapted but the 0-10v input from the controller was the same. The controller reads the pressure from a transducer, then sends out a voltage which the fan turns into the corresponding speed

Service Testing of the Industrial Refrigeration System

The fault link had been correctly modified, so service testing of the industrial refrigeration system was carried out. The machine loaded up to 62% and monitoring continued during the rest of the visit

Read More about International Institute of Ammonia Refrigeration Technology and Standards

 


Service to Industrial Refrigeration Controller

Industrial Refrigeration Service Visit

Tick Sheet for the Industrial Refrigeration Service Visit

The industrial refrigeration service visit is carried out inside a walk in room so some of the machine 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 plant has been problematic from when the chiller was first lifted in. It faults out regularly: reoccurring 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 Program for the PLC

Another part of the problem are over complicated controls. I often think about the same 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 too many industrial refrigeration service visits because of spurious trip outs- they just 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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Trim the Ammonia Refrigerant

The chiller has a low refrigerant charge so an industrial refrigeration service visit has been arranged to trim the ammonia refrigerant. We have state of the art ammonia refrigerant recovery 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 recovery method

Oil Return During the Industrial Refrigeration Service Visit

Low refrigerant charge diagnosed during the industrial refrigeration service visit causing the oil to migrate to the low side of the system. The oil will need to be manually recovered from various vessels following the ammonia oil recovery procedure

Read more about events from the iiar Click Here


Chiller Evaporator after Service

Water Chiller Service of Evaporator

Service to Water Chiller Shell of Evaporator

Not often does water chiller service to chiller evaporator fault occur. Usually the 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  visit because of access issues. The builders decided to site the water chillers round the back of the building. This makes glycol chillers very difficult to service. 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 water 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 job. 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 chiller paintwork is essential. Poor water chiller service of paintwork will reduce the it'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 water chiller being serviced. This provides protection from the elements for the glycol water chiller as well

See the Institute of Refrigeration Evaporator efficiency Click Here

 


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

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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 Refurbishment Company

Chiller Refurbishment Company

Choosing a chiller refurbishment company 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, this 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 replacement, 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 replacement 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

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Refurbishment of the Chiller Compressor

We strip the chiller compressor down for refurbishment in our workshop. It is made from heavy castings so will last a very long time. We provide a 12 month warranty on all our chiller compressors. 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 refurbishment Company: 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

Air Cooled Chiller Maintenance

Air Cooled Chiller Maintenance Bodger Watch

A chiller maintenance 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!

Air Cooled Chiller Maintenance of Glycol

Our junior engineer rang me from a job the other week. Struggling to carry out air cooled chiller maintenance- the glycol dosing. 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

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Customer Adding 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 job 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 chiller. He then topped up the water system with water

For the efficient running of your chilling plant- choose Maximus Chillers to 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

Category : chiller service

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 chiller 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 chiller service visit the fans were found to be rattling the frame and juddering the chiller into leaks

0161 370 7193

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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 chiller 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

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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


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