Our "What's New" page will be updated regularly. Please visit us frequently for news and information about Industrial Refrigeration Service and the ammonia industry. Large Brewery – Refrigeration Installation The Facility Industrial Refrigeration Service, Inc. recently completed a major refrigeration installation on an expansion project for a well-known beverage facility in the Shenandoah Valley of Virginia. The timely completion of this project was of the utmost importance, so manning this site with the right personnel was crucial. We welcomed this challenge and not only did we complete it on time, but more importantly, completed it to the full satisfaction of our customer! Refrigeration System The expansion added 100,000 square feet to the process facility which increased the plant’s capabilities. This state-of-the-art process facility will produce 6-7 million barrels (31 gallons per barrel) of beverage product annually. Ammonia refrigerant and 3,945 tons of screw compressor capacity utilizing 5,250 motor horsepower were used to handle the process loads. All the equipment in the Machine Room is controlled by a computer control system. The Ammonia Machine Room consists of four (4) electric driven screw compressor packages, six (6) evaporative condensers, one (1) thermosyphon receiver, one (1) high pressure receiver, one (1) controlled pressure receiver, one (1) pump recirculation package, one (1) oil still, and one (1) automatic purger. Adjacent to the Machine Room is a CO2 recovery system that uses a separate ammonia refrigeration system. The ammonia side of the CO2 recovery system consists of one (1) electric driven screw compressor package, one (1) shell and tube ammonia condenser, one (1) high pressure receiver, one (1) controlled pressure receiver, one (1) shell and tube CO2/ammonia condenser, and two (2) shell and tube evaporators. The process load consists of six (6) flooded plate and frame heat exchanger skid packages and forty-six (46) silo heat exchangers. The People The refrigeration portion of the project involved extensive planning and coordination and required almost fifteen (15) months to complete. Meeting the completion dates requested by the owner was critical. We manned the site with a full team of fitters, welders, engineers, project managers, and office personnel, who all worked six (6) days a week to assure that the project was completed on time. At peak performance, there were eighty-five (85) employees working on the jobsite for Industrial Refrigeration Service, Inc. The Industrial Refrigeration Service, Inc. staff provided the complete installation of the refrigeration system, the start-up of the refrigeration system and the turn over of an operating system to the customer on time. This project was a challenge, but there is no better satisfaction than knowing that our very dedicated and talented staff was more than capable of meeting this challenge. They are always ready and willing to take on the next one. Refrigeration Skid Package For Spiral Freezer Industrial Refrigeration Service, Inc. recently designed and fabricated a single stage R22 refrigeration package for a meat production facility in New York State. This assembly was custom designed for the owner’s new spiral freezer. The custom compressor room package was mounted on a structural steel skid, allowing it to be installed as one piece of equipment. Thus saving field installation time, and allowing for a single power connection point. The new R-22 system is capable of 77.7 tons of refrigeration with a -45°F Saturated Suction Temperature. The package itself required approximately 5,000 lbs. of refrigerant which was distributed between the vertical combination thermosyphon/high pressure receiver and the horizontal pumped recirculation package. The liquid feed to the remote spiral freezer is supplied by two hermetic R-22 pumps supplying 58 gpm at 28 psid. The heart of the system is a Mycom Model 200 VLD, 300 H.P. screw compressor utilizing a Direct Expansion liquid sub-cooler supplying liquid refrigerant to the feed to the pumped recirculation package. The compressor is driven by a 94.5% efficient RAM 445 TS frame ODP motor with a solid state starter. All components of the assembly were customized to provide the end user with trouble free operation including: motorized feed valve for make up to the pump package (with redundant back up solenoid valve), oil return system, refrigeration reclaim valves, and liquid line filter dryer with full bypass. Also included is a Hansen “NEAP” auto purger to remove all non-condensibles from the system, thus lowering the operating energy cost. Every valve on the compressor room skid had valves manufactured by one company. All isolation and control valves on the compressor, the vessels, sub-cooler and pumps were manufactured by Danfoss. On board the compressor room skid is a small motor control center to operate the remote condenser water pumps, the liquid refrigerant pumps, and a Variable Frequency Drive for the condenser fan. The VFD was wired back to, and directly controlled by the compressor Microprocessor. Energy conservation will be achieved by matching the condenser fan speed to maintain the lowest practical head pressure. All controls and control valves and level sensors were interlocked to allow smooth operation. As per code, an oxygen depletion sensor was also in the package to provide for operator safety. Upon a drop in the oxygen below acceptable levels within the compressor area, an alarm horn and strobe is activated. All package mounted relief valves were piped into a central relief vent manifold in accordance with ANSI-ASHRAE. Te entire skid package was then completely insulated, wired, painted and non-skid tread was installed allowing field access to all components. Fresh Foods - New Giant Facility Recently, Industrial Refrigeration Service, Inc. assisted Giant Foods in building a new Fresh Foods facility in Jessup, Maryland. Time was of the essence on this project, and Industrial Refrigeration Service played a vital role in finishing the project on time. Construction of the new 300,000 square foot Fresh Foods facility was designed to refrigerate meat, poultry, seafood, vegetables, and even flowers. The refrigeration system for this project is comprised of five (5) screw compressor packages, two (2) dual-ended evaporative condensers, twelve (12) penthouse style evaporators, twenty-five (25) ceiling hung evaporators, two (2) pump recirculation packages, one (1) thermosyphon receiver, a humidification system, an ammonia detection system, and a computer control system. All the major equipment was provided from Frick Company a division of York International. The system was designed with two suction temperature loads, +15ºF and +30ºF. Total load of the system tops out at 1,400 tons, with an operating charge of 25,000 lbs. of ammonia. Room temperatures range from +30ºF to +55ºF. The system and piping were designed for future expansion.
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Industrial Refrigeration Service, Inc. P.O. Box 70019 - Baltimore, Maryland 21237 Phone: 410-686-8900 - Fax: 410-686-0288 info@IndustrialRefrigServ.com