The Technical Services & Refrigeration Group can help your plant minimize downtime and lost production associated with system failures. Simple wear components can be the largest contributors to extensive compressor damage.
Our training programs for soft drink production facility employees will provide a solid understanding of the design behind Refrigeration Systems, Carbo-Coolers, Flo-Mixes and Deaeration Equipment and how these processes affect each other.
Click on any of the programs below to learn more about our services or call 217-627-3998. Email David Smith, Technical Services & Refrigeration Group Manager, to get information tailored to your production lines.
Compressor General Service
Compressor Top End Service
Condenser Service Option
Valve Service Option
Back Pressure Regulating Valve Programs
Training Programs for Beverage Process & Refrigeration
Compressor General Service
Each compressor will receive the following activity every six months due to the OEM recommendation for general service and the typical operating hrs of a bottling production facility:
- Inspect starter operation and record delay, loading conditions, oil pressure, and function of all mechanical unloading and safety switches.
- Note all operating pressures and temperatures prior to removing from service
- Pump down and drain oil noting proper operation of discharge check valve
- Open crankcase and wipe crankcase clean, inspecting oil strainer screen
- Replace oil filter with new
- Inspect and adjust belt tightness and condition
- Recharge with new oil ( not included )
- Restart and record oil pressure, temperatures, suction pressure, discharge pressure
- Verify proper operation of all gauges
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Compressor Top End Service
Each compressor will receive the following activity one time every two years, a rotation will be established to provide 2 or 3 top ends every six months.
- All of the items listed in the general service
- Remove all cylinder heads and covers
- Clean water jackets ( when applicable )
- Remove all suction valve assemblies
- Remove all discharge valve assemblies
- Remove one piston and rod bearing assembly
- Remove piston rings, measure and record ring wear
- Measure and record liner wear on each liner by turning piston to bottom of liner
- Measure and record bearing condition
- Replace un-loader seals
- Measure and record crankshaft wear and condition
- Install piston and bearing back into liner
- Install new suction valves ( included )
- Install new discharge valves ( included )
- Reassemble heads and cylinder covers
If any of the following items fail wear specifications, the customer will be notified and the items will be replaced at an additional cost for parts and labor.
- Liners
- Safety Heads
- Pistons
If any of the following items fail wear specifications, the customer will be notified and the items will be replaced at an additional cost for parts and labor. If one of any of these parts requires replacement, all of the same parts in adjoining cylinders will also be replaced.
- Piston Rings
- Bearings
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Condenser Service Option
One time per year each condenser will be inspected for service with the following activity, and the refrigeration system will be scheduled down to perform this service:
- Insert citric acid and circulate through condenser to loosen scale deposits
- Remove scale sludge from condenser sump
- Remove and clean spray nozzles and verify clear for operation
- Check belts for tightness and condition
- Grease and inspect shaft bearings
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Valve Service Option
One time per year each of the following valves will receive a general service and replacement kit. The service will include gasket and seats. Valves requiring replacement piston kits will be charged additional.
- Back pressure regulating valve on each evaporator
- Liquid line solenoid valve on each evaporator
- Clean each strainer
- Verify proper electric operation
Note: Wolfe-Linde Valves will not be included do to availability of replacement parts. (Recommend Replacement Valve Program )
Call the Technical Services & Refrigeration Group at 217-627-3998 for further information on Compressor, Condenser and Valve Service.
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Call the Technical Services & Refrigeration Group at 217-627-3998 for further information on Beverage Preparation Programs.
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Back Pressure Regulating Valve Replacement Program
The soft drink industry is still saturated with Wolf-Linde Back Pressure Regulating Valves located on Carbo-Coolers. Many of you are aware that Wolfe-Linde valves have not been available for a couple of years and finding replacement parts is becoming almost impossible. A familiar problem exists with sluggish operation of these valves and poor temperature and pressure controls. We would like to take this opportunity to introduce a program to replace these control valves, and upgrade the Carbo-Cooler performance with new controls.
Complete Control Upgrade
Provide components, labor, materials and expenses to replace existing ammonia control valves and operating controls which include:
- New properly sized, Hansen Back Pressure Regulating Valve with mounted pressure control pilot and solenoid shutoff. Includes manual back pressure valve bypass.
- New three way safety relief valve assembly with dual 250# safety relief valves.
- New Liquid Line solenoid valve and strainer assembly
- New Hansen Veri-Level capacitance controller with column, isolation valves, flanges and Veri-Level capacitance probe.
- Installation materials which include carbon steel pipe, reducers and flanges and new isolation valves to the liquid line and the suction header.
- Installation labor which includes welder, fitter, travel and living expenses.
Back Pressure Control Upgrade Only
Provide components, labor, materials and expenses to replace existing ammonia back pressure regulating valve.
- New properly sized, Hansen Back Pressure Regulating Valve with mounted pressure control pilot and solenoid shutoff. Includes manual back pressure valve bypass.
- Installation materials which include carbon steel pipe, reducers and flanges and new isolation valve to the suction header.
- Installation labor which includes welder, fitter, travel and living expenses.
Call the Technical Services & Refrigeration Group at 217-627-3998 for further information on Back Pressure Regulating Valve Replacement Programs
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Beverage Process & Refrigeration Training
The most difficult refrigeration load, is the load experienced by the soft drink industry. The quality of carbonation and sometimes even Brix, require a good understanding of the refrigeration process. A stable environment between deaeration, blending, cooling and carbonation are all critical to the quality process of soft drink production.
Program Goal
To provide employees of production facilities in the soft drink industry with a solid understanding of the design behind Refrigeration Systems, Carbo-Coolers, Flo-Mixes and Deaeration Equipment and how these processes affect each other. This program features a combination of class room and field training, and is customized for different technical groups. Areas covered in training are:
Process Refrigeration:
- Basic Refrigeration Systems Understanding
- Components
- Pressure and Temperature
- Heat Distribution
- Controls
- Heat Exchangers
- Falling Film Carbo-Cooler Plates
- Shell and Tube Heat Exchangers
- Plate and Frame Heat Exchangers
Deaeration Systems:
- Vacuum Deaerators
- De-Ox Columns and other CO2 Scrubbers
- Reflux Deaeration ( Combination cooling and deaeration on Carbo-coolers.)
Blending:
- Head over Oriface Blenders
- Pressurized Blenders
- Two Stream Blending
Carbonating:
- Carbo-Cooler Vessels
- In Line Carbonation
Call the Technical Services & Refrigeration Group at 217-627-3998 for further information on Beverage Process and Refrigeration Training Programs.
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