Copy of Case Stories: JRG Refrigeration

THE CHALLENGE

Jack Gage of JRG Refrigeration manages a new ice cream production factory and cold storage warehouse for Casper’s Ice Cream in Richmond, Utah. In order to maintain its quality, ice cream requires storage at a temperature of -200F. This application also requires a consistent liquid feed into vessels that meter the flow from high to low pressure and keep the pressure steady. If the valve opens too quickly, it's difficult to regulate the flow of liquid and maintain steady pressure.
To ensure consistency, Jack needed a solution that enables the level in a given vessel to be customized and maintained with precision. Jack contacted Hansen regarding the newly designed Hansen Motorized Control Valve (MCV) and selected a pair of Hansen’s MCVs for the ice cream factory and warehouse. 

THE SOLUTION

The Hansen MCV Motorized Control Valves are perfect for this type of application because of their ability to modulate flow. Combined with the right controls, motorized valves can match their feed rate to the consumption rate of the system providing a constant and even feed rate to the vessels. Having a steady feed rate helps the overall suction pressure stability which has a positive effect on the stability of the delivered product and system efficiency. 

RESULTS

The MCV valves provide the level control Jack needed. To verify his findings, he pulled data from the control system and compared performance before and after the new MCV installations. The old system had an average swing in the vessel levels of 3-3.5%. On the new valves Jack saw an average swing of 2-2.5% in the vessel levels. 

ON WORKING WITH HANSEN

“All of Hansen's folks are great to work with. Hansen has been a preferred manufacturer for us for many years. They have reliable products that we can count on for the long term.” 

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ENGINEER
Jack Gage – Owner, JRG Refrigeration

TECHNICAL SPECS
Two Hansen Motorized Control valves having reduced capacity V-ports (Type MCR). Liquid make-up arrangement from the high pressure receiver-to-intercooler vessel and intercooler vessel-to-pump recirculator vessel. Both valves have special reduced capacity V-ports. 

DETAILS

  • Application #1: Liquid make-up to intercooler
  • Refrigeration Load: 350 tons (1230 kW) Liquid Supply: +850F (290C)
  • Suction Temp: +200F (-70C)
  • Application #2: Liquid make-up to pump recirculator
  • Refrigeration Load: 100 tons (350 kW)
  • Liquid Supply: +200F (-70C)
  • Suction Temp: -300F (-340C) 

FACILITY
Casper’s Ice Cream Factory and Cold Storage Warehouse 

CHALLENGE
A consistent liquid feed is required into vessels to keep pressure steady. If the valve opens too quickly, it’s difficult to regulate the flow of the liquid. 

SOLUTION
The Hansen MCV Motorized Control Valves with reduced V-port allows gradual and controlled liquid feed metering resulting in more steady liquid feeds with lower swing levels.

• Additional benefit: Integrated display that’s easy to use and see. 

Case Stories: Banana Ripening Rooms

THE CHALLENGE

Joe Cole oversees banana ripening rooms for a major US retailer. Banana ripening is a detailed and precise process. The room must be kept at a consistent humidity level and temperature over five to seven days to ensure proper ripening. Utilizing 20 motor control valves, Joe was experiencing issues with power head function due to moisture build up in some of his units. Motors were overheating and intermittently shorting out. When Joe contacted Hansen, they suggested that his facility participate in a field test for the newly designed Hansen Motorized Control Valve (MCV). Joe was provided with MCV conversion kits to upgrade
his existing control valves. 

THE SOLUTION

Converting the existing valves to the new MCV which virtually eliminates the potential for moisture build-up and results in much more reliable and precise operation overall. 

RESULTS

Improvements were noted in these key areas: Motor actuator housing, function, forward-facing digital readout, and an improved power cable with stronger connections. The molding appeared more secure, as well, and the housing seal now eliminates moisture inside which, in the past, contributed to shorting. Together these factors provide more reliable functionality all around. An additional benefit Joe noted in the new construction is that the indicator light is helpful in letting you know when you’re in the program settings. 

ON WORKING WITH HANSEN

“Hansen’s technical support is excellent. Hansen responds quickly and
comes to our facility immediately when needed. Hansen techs have a wealth of knowledge and extensive operational backgrounds. It’s obvious that Hansen representatives have worked in the field. We found them to be very detailed in their evaluation of our needs and in troubleshooting unique solutions. We will continue working with them.” 

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ENGINEER
Joe Cole - Refrigeration System Engineer, major US retailer

TECHNICAL SPECS
1" (20mm) Port Size, MCV20 Motorized Control Valve

DETAILS

  • Suction Control Valve
  • Refrigeration Load: 7.5 Tons (26.4kW)
  • Suction Temp: 45F (7.2C)
  • Room Temperature: 56F (13C)
  • Liquid Supply: 140 psig (9.6 bar), sub- cooled to 40F (4.4C)

FACILITY
52-foot trailer banana ripening rooms

CHALLENGE
Moisture in power head housing causing intermittent shorting of valves

SOLUTION
Hansen's new MCV replaced Joe's problematic valves. Improvements noted in these key areas:

• Overall valve construction is improved
• Power cable has noticeably improved connections & functions better
• Motor Actuator housing; more secure molding and stronger housing seal • Moisture build up in housing is eliminated
• Additional benefit: improved indicator light function

Product Announcement: MCXV

Hansen is pleased to announce the latest addition to the Motorized Control Valve (MCV) family with the release of the MCXV standalone and MCXV installed in the MVP13 product lines.

This will be the first of its size in an integrated platform in the industry. These products continue to expand our trend aligned MCV & MCV in MVP families which allows us to compete and win more new plants and expansion projects in industrial refrigeration. 

With this release, we will no longer be selling SMV standalone valves in the following models: HMXV, ¾”-2” (HMMV, HMMR, HMSV), and the power-close versions of the same. 

 
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Standalone Product Lines

MCXV (Pictured above) 

MCV/MCR20 thru
MCV/MCR50 (3/4” – 2”) 

 

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MVP Product Lines

MVP13 with MCXV in Position 4 (pictured above) 

MVP13 with MCXV in Position 3

MVP20 thru MVP50 with MCV/R in Position 3

 

 

Case Stories: Lake Ontario Fruit Co.

THE CHALLENGE

John Gay, Lake Ontario Fruit Co.’s plant engineer, needed a way to make sure the company’s inventory was protected during ripening intervals and through the critical harvest period. His main goal was to eliminate any mechanical problems and improve temperature control.

$500K IN INVENTORY

Apples require absolute reliability. Any variation or refrigeration failure can wipe out the work of an entire season. The net worth of just one 60 x 60 foot (18 x 18 meters) storage room at Lake Ontario Fruit Co. is typically $300 to $500 thousand. The company installed the Hansen MCV on the advice of its contractor in three of its ripening rooms.

“Our contractor said he liked the control and reliability of Hansen’s new valve, so we decided to go with the new MCV. We’re using it for our most sensitive apple varieties right now, but we’re looking at upgrading all of our older rooms with this new design as soon as we can.”

0.1F CONTROL RANGE

Temperature and atmosphere control make up the foundation of an apple storage and processing facility. Refrigeration is the essential first part of that equation, working to regulate ripening and minimize it as much as possible. At Lake Ontario Fruit Co. – where the ripening needs of most apple varieties demand that temperature vary only a tenth of a degree Fahrenheit (0.05C) – specificity and reliability are the most important factors.

“There's an absolute difference in quality in having fine control for apples. That’s why we chose these controls. The valves can make very fine adjustments in response to the control.”

24/7/365 PERFORMANCE

Rugged performance is important in any harvest operation. A mid-season valve failure is an unacceptable infrastructure problem, so the factors that could cause such a failure must be non-issues. The company chose the Hansen MCV on its reputation for rugged reliability and its ability to perform to extreme temperatures.

“We need continuity in this business. During the critical first four or five weeks of a harvest we cannot have a failure and maintenance, so these valves need to be rugged. When it’s time to perform, they just work.”

NEW LEVELS OF AUTOMATION

New advances in automation now allow fine temperature and pressure control. With Hansen’s MCV, Lake Ontario Fruit Co. could make smaller, automated adjustments resulting in a 50% improvement in temperature control range. The new valve design also moved Ontario Fruit to the next level in advanced control and communication between the valve and automated control system.

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ENGINEER
John Gay – Lake Ontario Fruit Co.
 

TECHNICAL SPECS
1-1/2" (40mm) Port Size, MCV40 Motorized Control Valve
 

DETAILS

  • Suction Control Valve Refrigeration
  • Load: 22.6 tons (80 kW)
  • Suction Temp: 22F (-5.5C)
  • Room Temperature: 32F to 38F (0 to 3.3C) depending on apple variety Liquid Supply: 70 psi (4.8 bar), sub- cooled to 22F (-5.5C)
  • Operating suction pressure: 30 psi (2.1 bar)
     

FACILITY
Three 60-foot by 60-foot (18 x 18 meters) apple ripening rooms (out of 18 total)
 

CHALLENGE
Introduce precision refrigeration, improve control and ensure reliability, eliminate any possible mechanical problems
 

SOLUTION
John installed Hansen's new MCV in three of his most temperature-sensitive ripening rooms. Improvements noted in these key areas:

  • Rugged Reliability: the MCV performed to a variety of extreme conditions, earning it a place in the company’s plan to upgrade the remaining 15 specialty ripening rooms
     
  • Precision: tighter control and responsiveness, efficiency increase
     
  • Automation: finite, auto-controlled temperature adjustment