Refrigeration company Danfoss launched a new modular generation of pilot and motor-control- led regulating valves for industrial and commercial refrigeration in September.
The industrial control valve (ICV) is aimed at the industrial- and commercial-refrigeration markets. The new platform meets the increasing demand for high-pressure, reliable and competitive valves in the industrial-refrigeration market. The modular ICV concept is available in mechanical pilot-operated (ICS) and digital actuator-operated (ICM) configurations. The design consists of three parts: a valve body, a function module and a top cover. Each part is available in several varieties that can be combined according to customer needs. The ICV platform is based on a common valve-body design. The entire operating function, which is built as a module, is changeable with a simple removal of the top cover. The modular concept simplifies and improves valve serviceability. The system of interchangeable function modules and top covers gives flexibility in creating numerous configuration possibilities.
The ICS valves are pilot-operated, whereas the ICM valves are driven directly by a magnetically coupled digital actuator. The hermetically sealed magnetic coupling further eliminates a common leak potential, but also allows for easy actuator changeout or even manual operation with a simple tool. The actuators, which are controllable with standard signals, are speed adjustable, which improves system control, and are easily programmed with a menu-driven keypad. The automatic calibration system in the actuators provides the ICM valves with high reliability. “The ICV valve concept offers superior operating performance, improved reliability and serviceability, compared to standard control valves”, says Danfoss Industrial Refrigeration president Palle Kruse.
“We have been pleased with customers' and end-users' keen interest in the valves and their participation in our field-testing programme.
“The experience has provided valuable input into the development and quality assurance.
“At the same time, we also have the clear feeling that the ICV is the product capable of delivering the solutions which our customer are looking for.” In combination with the existing Danfoss pilots and controls, the ICV range handles 5 000 of the most common combinations of control applications, capacities and connections.
A key advantage of the ICV valve is its approved 52-bar working pressure - vital when dealing with modern refrigerants, such as CO2.
The ICV concept satisfies the demands of Europe, North America, Asia and South America. It is manufactured in low-temperature steel and can operate in temperatures of as low as 60 °C. While control valves in industrial refrigeration are usually mounted with flanges, the modular ICV construction enables direct welding or soldering of the body into the system. The hermetic connections reduce the risk of leaks, and the modular construction allows simple installation of the function module.
The interchangeable function modules and top covers are easily removed or replaced.
Three years were spent developing the ICV valve. During the last year, the ICV has been tested in meat-packing plants, food-processing facilities, ice cream-production plants and pharmaceutical factories in Denmark, Germany, the US, the UK, Poland, Holland, Australia and China.
The ICV was tested in a CO2 defrosting system at Star Refrigeration in Scotland as well as in other systems.
According to technical director Angus Gillies, the ICV was installed in April this year and was adjusted to open at 44 bar.
It has responded well at this high working pressure, providing good accuracy and repeatability.
“I find it encouraging that valve manufacturers are now developing high-pressure products for use with CO2 as a refrigerant.” Denmark-based Danish Crown technical manager Søren Søndergaard says: “The ICM valve has been installed in a wet suction line from six coolers in the cutting rooms.
“The valve has been placed on the roof and exposed to all kinds of weather. “Both the valve and the actuator have performed well and according to plan.” At HJEM-IS, in Esbjerg, Denmark, the ICV has been installed in an ammonia system to control the liquid level in a pump separator. Refrigeration engineer Knud Korsgaard says that the ICV has been installed outside and has controlled the expansion of subcooled ammonia between -10 °C and -45 °C.
“With the ICV valve, we have had a distinct improvement in the liquid level, which is now more stable than the previously-installed control system.” The ICV valve is thought to be a replacement for Danfoss's PM valve, which celebrated its 25th anniversary recently. Half a million pieces have been produced over the years. Production of the PM valve will continue, but the future belongs to the ICV valve.
“With the new valve, we can offer a flexible solution, which combines a high degree of reliability and fewer installation and service costs, compared to a standard valve,” concludes Kruse.