Main refrigeration system of plants that has high load and uses NH3 as refrigerant.

1. Flash gas – refrigerant in Gas Form produced simultaneously
when condensed liquid is subjected to boiling
- Normally perceived as an unwanted condition caused by
dissociation between the volume of the system and the
pressures and temperatures that allow the refrigerant to be
liquid
Common causes of flash gas
- Excessive length of pipeline
- Small diameter of pipeline
- Throttling of valve
- Lack of subcooling
Subcooling – liquid existing at a temperature below its normal
boiling point
Liquid overfeed – evaporator is overfed given more liquid that
can evaporate. Overfeed rates vary from 2.5 to 4. An overfeed
ratio of 4 means it is given 4 times more than it can evaporate.
For instance an evaporator can vaporize 1lb/min of liquid, it is
fed 4 lbs/min. the 1 lb evaporates and the 3 lbs as liquid.
25-30% concentration of glycol. Less than 25% may decrease
inhibitor and may be at risk for bacterial contamination.
Load calculation: Q=mCpT; CpBeer=4.03
1BTU = 1.055 KJ
1TR= 12,000BTU/hr
35.2 KW= 1TOR
Refrigeration load 90.83% of the time is 122-345 BTU
Max load at a given time is 540.15TR
Ammonia: high latent heat of vaporization, low cost, easy
detectable
MRS power ratio = 3.120
Switch Frick 3 to Frick 2 at start of wort boiling
Switch Frick 2 to Frick 3 at the end of wort cooling
Switch Frick after 6 hrs from do-in
Wort boiling (after 2 hrs)
Wort cooling time : (1FST) = 15hrs 30min / (1 brew) = 1hr 30
min / interval = 30min-1hr
Wort cooling = 2hrs and 15 mins after boiling
Condenser
Evaporator
High pressure
Low pressure
Liquid
Gas
CT pump/fan
EVAPCO
Solenoid
GRP
BBT
NH3

2. Condensate – a liquid state of water at saturated
temperature that is formed when
steam gives off its enthalpy, usually after heating process
LSFo decreased SO2 by half (0.9%) 67% diesel
3 Pesos pricy than BFO
273 holes. 96 in length, 204.5 dia
Minimun header temperature: 170F
Fire tube boiler: Cheaper, limit pressure up to 25bars
(350psi)
8,200-8,500 L/day
Condensate recovery – 80%
Condensate blowdown – TDS
Blowdown – deposits and sludge, suspended solids
<40ppb DO at deaeration
1:100 rise to length 30-50m, fall not less than 1.27cm in
3meters
Every 15 meters condensate drip legs
3-5 meters pipe support
COC=Boilerwater TDS/Boiler feedwater TDS
Pilot flame – 25 seconds
Thermostatic – variation in temperature
Mechanical – difference in specific gravity/density
Thermodynamic – volumetric and pressure difference
Pchem 100x – prevents sludging of strainers and filters,
prevents formation of sticky resin, improves combustion
efficiency
Pchem500fs – increase tolerance of blending heavy fuels,
inhibits storage tank sludge, reduce Nox and Sox
emissions
Steam supply:
6 hrs before – packaging
2 hrs before – brewing
34.5 lbs steam/hr = 1Bo. HP = 9.81 KW
Level switches: microswitch and kasuga
13.009 kg steam/li fuel
2L pchem500fs/16,00 LSFO
Condensate recovery = (feedwater-make up)/feedwater
CA150 - phosphate indicator
CA900+ - sulfate indicator
450 – 500 liters to create steam

3. Ammonia: Boils at -28F
Freezes at -107F
CO2 compressor
- Every 6 month servicing of intercooler and aftercoooler
- Suction and discharge valves, valve plates
- Piston ring inspection
- Oil analysis and change oil
Iodine number of deodorizer not less than 1000
Liquid ammonia receiver: 0.75cu.m.
Glycol chiller: 12TOR
Ammonia compressor: 12TOR
Ammonia condenser: 12TOR
CO2=8pesos/kg
°P x 0.412 x hL Ferm
Scrubber – 11ft. 4 in. 2ft dia
Deodorizer – 6ft. 8 in. 2ft dia
Drier – 8ft. 4 in. 1ft dia
Vaporizer – 10ft. Length
Expansion tank – 11ft. 3 in.
scrubber – 2.5-4L/1kg CO2
210 psi – Mycom trip off
Co2 liquefies at -10F (-23.33C)
22 tons remaining after sold
2.0665 gms Glucose~1gm alcohol and 0.9565 CO2
Activated carbon: 4x12 coconut shell mesh. Replace if
iodine number <1000
Activated alumina – replace if 50% reduction in size or off
white color
Booster – Necessary to overcome pipe friction and pressure
drop across CO2 gas purifiers
Quarterly sterilization of supply lines
CO2 rec = ending – beginning + sold + consumed
25 tons – maximum storage tank level
90 tons – maximum nurse tank level
CO2 rousing – 10 hrs

4. Positive displacement – compression accomplished through
reduction of volume at the space
Dynamic – compression accomplished through acceleration
of the air by changing its momentum
FAD/CFM – volume of air delivered to some specific point and
converted back to ambient conditions at that location
Refrigerated dryer – cannot go below 3°C/37.5°F, ISO air
quality class 4 only
Desiccant Drier: Pressure release
Desorption
Cooling
Pressurizing
Stand by
Adsorption
Using of lube air for spent grain conveying:
- for lubrication
- cost implication
- more dense than dry air, better for conveying

5. Chlorinated Demi Brewing Softened
R.Cl 0.7-0.8 0.3-0.5 0.4-0.6
Total Hardness 1 20-40
Silica 30 60 60
Calcium Hardness 7.0-10
Alkalinity 0.7-1.0
pH 7-10 6.5-7.5 6.5-7.5
Softened water – no way to correct chlorine
Inject air around 15% to precipitate iron to remove
iron from water, pH=6.8
At least 50% free board for backwashing cation
and anion
FMA(yellow) – alkalinity(peal orange) – methyl
orange indicator
Total hardness(blue) – 2ml pH buffer 10 – EBT
Calcium hardness(violet) – 2ml 1 normal NaOH –
murexide
BOD – degree of pollutant, amount of oxygen
needed to treat organic pollutants of wastewater.
Indicator of pollution
Influent Lagoon2 Lagoon3 Lagoon4 Lagoon5 Lagoon6 Effluent
pH x x x x x x x
COD x Wed Wed x
BOD x Wed Wed x
TSS x Wed Wed Wed x
MLSS Wed Wed
MLVSS Wed Wed
COD 100 ppm
BOD 50 ppm
TSS 100 ppm
Color 150 TCU
pH 6.0-9.5
OAG 4 ppm
Phosphate 1 ppm
Nitrate 14 ppm
Ammonia 4 ppm
Total coliform 10000 MPN/ml
Fecal coliform 400 MPN/ml
MLVSS = sludge in aeration
MLSS = microorganisms in aeration tank
MLVSS = MLSS - ash
Deepwell = slotted type filter screens
Gaf filter – 150 microns
Deepwell disinfection – semi annual. Recirculation fo
Internal spray to bottle of hard water is detrimental a
rinse jets and spotted bottles

6. Dissolve oxygen – a good indicator of water quality and
capacity to support life form
Biochemical oxygen demand – measure of oxygen required
by microorganisms to decompose and stabilize the organic
(and biodegradable) mater in the water
Average influent volume 1500 m3.day with BOD of 500-
2,250 ppm
Bar screen – 40pcs. 60 mm thick by 25 wide. Inclined at 60
deg. (reduce BOD by 10%)
Presettling tank = 124.7 m3 retention of 1.6hrs. BOD
reduction of 20%, desludged annually
12 inches disk type membrane
Lagoon 4 desludging yearly
Rest of the lagoons – every 2 years
Wastewater contains vast quantities of bacteria and other
organisms that originate in discharged wastes. The feeding
activities of these organisms assist in decomposing
wastewater.
Total retention time = 10.94 days
Sources of sludge: Water, dead bacteria, live bacteria,
organic blown, dead fishes, inorganics, complex organics
Discharge: 2,500 m3/day

7. Activity Frequency
1 Oil burner nozzle cleaning Weekly
2 Heat scanning of boiler Weekly
3 Flue gas analysis 2 weeks
4 Fuel strainer cleaning 3 months
5 Steam trap servicing 3 months
6 BFO pump servicing 4 months
7 Desooting of boiler 6 months
8 Boiler servicing yearly
9 BFO regulator servicing yearly
10 PRV calibration yearly
Activity Frequency
1 System leak testing Weekly
2 Pre scrubber cleaning Monthly
3 Sterilization of CO² recovery line Monthly
4 CO² booster check-up and alignment Monthly
5 CO² compressor check-up and servicing 3 months
6 Dust filter cleaning 3 months
7 Sterilization of supply lines 3 months
8 CO² comp intercooler inspection and cleaning 6 months
9 Analysis of iodine number of deodorizer Yearly
10 Cleaning of CO² tanks Yearly
Activity Frequency
1 Equipment leak testing weekly
2 Physical testing of cooling tower water weekly
3 EVAPCO servicing 28 days, one EVAPCO per week
4 Cleaning of separator body Monthly
5 Oil pot draining 4 months
6 PRV calibration yearly
7 Compressor calibration yearly
Activity Frequency
1 Test run of diesel fire pump Weekly
2 Checking of bearing of water pumps Monthly
3 Manhole inspection Monthly
4 Checking of bed depth of ion exchangers 4 months
5 Deepwell disinfection 6 months
6 Cleaning of blended water tank and brewing water tank 6 months
7 Cleaning of unchlorinated, chlorinated and demi water tank Yearly
8 BIRM inspection Yearly
9 Deepwell inspection 2 years