Northstar Glycol Chiller

by | Jan 15, 2025

Industrial Refrigeration
Moving the Glycol Chiller to the roof

Crane Rgging

Crane Lifting Glycol Drum To Roof

Glycol Tank Being Unloaded To Roof

Chilled Glycol in a drum

Glycol Tank Level 9-8

A Rohde Brothers Designed Chiller System

Chiller – Controls End

Rohde Brothers, Engineered Solution

  • Chiller Configuration: Design and installation of two dual circuit chiller skids, each providing 170 tons of refrigeration to produce 425 gpm of 30°F chilled glycol.
  • Compressors: Each skid includes two 85-ton sliding-vane screw compressors, powered by 140 HP motors.
  • Evaporators: Two shell and tube evaporators per skid.
  • Condensers: Two fan-cooled condensers per skid, with seven 30-inch fans per circuit, designed for 86°F ambient conditions.
  • Expansion Valves: Installation of two electric expansion valves per skid.
  • Economizers: Two economizers per skid.
  • Refrigerant: R134a refrigerant charge for each chiller skid.
  • Piping and Insulation: All copper piping with a combination of closed-cell PE and fiberglass insulation, aluminum jacketed.
  • Chilled Glycol System:
  • Glycol Surge Tank: A 2,000-gallon HDPE glycol surge tank, insulated with urethane closed-cell foam with headers to stratify the tank with cold supply glycol on the bottom and warm return glycol on the top.
  • Circulation Pumps: Two dehumidifier glycol circulation pumps, each with a capacity of 425 gpm and 70’ TDH.
  • Chiller Pumps: Two glycol chiller circulation pumps, each with a capacity of 275 gpm and 30’ TDH.
  • Controls:
  • Sensors and Wiring: Installation of pressure, flow, and temperature sensors, along with necessary control wiring.
  • Control Hardware: Allen-Bradley PLC and HMI hardware, including associated programming.
  • Motor Control Panel: UL-listed motor control panel with power wiring.
  • Fan Programming: Implementation of staged condenser fan programming for efficient operation.
  • VFD Controllers: Integration of Variable Frequency Drive (VFD) pump controllers for precise flow control.
  • Process Trending: Real-time process trending for monitoring and optimization.
  • Remote Monitoring: Enabling remote monitoring capabilities via an internet connection.
  • New corrosion resistant PVC piping and valves.

Northstar Processing Chilled Glycol Project

In Litchfield, MN, Revela Foods (previously Northstar Processing) utilizes a spray drying facility to provide product drying services to food manufacturers. Many of the products being dried are sticky and difficult to dry in the summer due to the humidity. To address these issues, Revela Foods contracted Caloris Engineering LLC to add an inlet air dehumidification unit to the Dryer.

 Caloris ran into project delivery complications because of extremely long lead times, more than 52 weeks, for glycol chilling equipment sourced from the common brand name suppliers. Without a new solution, Revela Foods would miss an entire summer drying season waiting on the chiller delivery. 

 Enter Rohde Brothers, Inc.! Rohde was able to manufacture and deliver a state-of-the-art chilled glycol system for Revela Food’s spray drying facility, in just weeks. The project involved the design, fabrication, and installation of multiple dual-circuit chiller skids, glycol circulation pumps, and advanced control systems to ensure optimal performance and reliability.

The roof-mounted chiller system featured two 170-ton chiller skids, using four sliding-vane screw compressors, economizers, and fan-cooled condensers, all controlled by Allen-Bradley PLC and HMI hardware. The design included a redundant chiller circuit and the ability to expand for the future addition of Spray Dryer #1. This high-efficiency system included high turndown capabilities and low ambient controls allowing for effective operation over a wide range of conditions.

The roof-mounted chilled glycol system featured a decoupled system. This system employs independent glycol pumps to circulate glycol to the chillers, as well as glycol pumps to circulate to the dehumidification equipment. Fused and insulated high density polyethylene (HDPE) piping connected the 1,500-gallon insulated polyethylene surge tank to both the chillers and the dehumidification equipment. The entire system was filled with 30% propylene glycol.

 Because of Rohde’s planning and on-time execution, Revela Foods was up and running, just in time for their 2023 summer drying season!

 

 

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NEW Zoo Penguin Exhibit

by | Jan 9, 2025

NEW Zoo Penguin Exhibit - Life and Safety Systems

New Zoo Penguin Exhibit
Ozone system controls

Ozone System – front view

Pumps that recirculate water from a zoo penguin exhibit

Pool Recirculation Pumps

Waterco Sand Filters

Sand Filters

Ozone Generator for Water Filtration System

Ozone Generator Control Panel

Thanks to Rohde Brothers, Inc., the penguins at the Northeast Wisconsin (NEW) Zoo and Adventure Park now have an upgraded habitat to call home.

The system had become obsolete and was still using chlorine to disinfect the water in the pools. The new system included an extra sand filter, redundant backup systems and an ozone generator, effectively removing the need for chlorine, which has noticeably improved the lives of the African Penguins living in the exhibit.

 

To combat the concerns of the NEW Zoo’s facilitators, Rohde Brothers, Inc. installed a state-of-the-art life support system (LSS) for the 39,000 gallon African penguin habitat at the Northeast Wisconsin (NEW) Zoo and Adventure Park in Green Bay, WI. The new water filtration system was designed to enhance the living conditions of these endangered birds while meeting the rigorous standards established by the Association of Zoos and Aquariums (AZA) in their Spheniscidae Care Manual. This project was completed on schedule to coincide with the spring opening and came in under budget. It required many innovative approaches to overcome a wide range of challenges, including extremely tight spaces,  winter construction, and the addition of  an Ozone water sanitizing technology.

A rigorous value analysis and engineering process was central to the project’s success. Early in the design phase, Rohde conducted a comprehensive review of materials, design elements, and construction methods. Rohde identified opportunities for cost savings without compromising quality or performance. Using 3-D CAD we modeled the extremely small 10×14′ space to ensure all of the new equipment would fit. Planning equipment placement ahead of time also made onsite construction much more efficient.

 

 

The Rohde Customized Solution

  • Duplex Hayward LifeStar MV pumping system with integrated strainer
  • Triplex Waterco High Rate Sand Filters with multiport valves
  • Dryden Aqua AFM recycled glass anti-microbial filtration media
  • Airsep Topaz Ultra  Oxygen Concentrator
  • IO3S Ozone Water Sanitizing System
  • New Piping and Hardware

New Zoo

Village of Stockbridge – Wastewater Treatment

by | Feb 21, 2024

Waste Water Treatment Plant Upgrade - Village of Stockbridge

Clarifier at waste water treatment plant
Unit Heater for wastewater plant addtion

Unit heater for expansion with venting

Test Stations at waste water plant

Dual M3 Test Stations with controls

HVAC Vent at Wastewater Plant

HVAC VENTING

Chemical piping at a wastewater treatment plant

Chemical piping HDP

Process Piping at Waste Water Plant

Piping to Aeration Tanks

Blower Aeration Tanks at a waste water plant

Aeration Tanks

Waste Water Clarifier

Clarifier

Chemical Storage Tank in waste water plant

6000 Gallon Chemical Storage Tank

Control Panel at Waste Water Plant

Controls

Customized Solution:

  • Installed a 6000 gallon chemical storage tank.
  • Installed a new 2 unit test center for automated testing and data reporting.
  • A new fine screen and associated pump were also installed.
  • A solid waste screw type pump out was installed at the head of the plant.
  • All associated piping, pluming, and sensors were also installed.
  • A full automated controls center was installed with remote interface. 

The Village of Stockbridge hired Rohde Brothers, Inc. to general it’s wastewater treatment plant upgrade and expansion. Rohde brothers added a 5000 gallon reinforced chemical storage tank, testing center, and associated pumps, piping, controls, and electrical.

Rohde was also the plumbing and utilities contractor for this project. Rohde installed a pumpout stand as well as additional piping for a second set of pumps and updated controls for the entire system.

Stockbridge Wisconsin

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Rohde Brothers, Inc. Expansion

by | Feb 15, 2024

Rohde Brothers, Inc Expands Fabrication Space

40 tons of lifting in 2 cranes 4 hooks
Air-Handler with geothermal heat exchanger

Air-Handler

State-of-the-art boilers for the geothermal shop heat system

boilers

Rohde Brothers Headquarters in Plymouth, WI

building

geo-field-basin

geo-field-basin

Geothermal System- poly lines

geo-field-layout

HVAC-Duct in Fabrication Shop

HVAC-Duct

snow-melt-manifold

snow-melt-manifold

Snow melt tubes above ground

snow-melt-pex-and-rebar

Overhead view of snowmelt tubing

snow-melt-tubing

When Rohde Brothers, Inc. needed to expand it’s fabrication facility the leadership team decided to add some state-of-the-art features in order to innovate and save energy and cost at the same time. 

The new 11,000 sq foot space includes dual 20 ton cranes, dedicated stainless steel manufacturing space, an equipment test cell, and a host of energy efficiency features:

This project was designed in our facility using BIM/CAD. The project included a horizontal field type geothermal system, a boiler system to assist the geothermal, an ice bank system and dual chiller compressors to “cool” the space in the warmer months. The energy efficiency components of the system will likely save Rohde Brothers 36% on it’s heating and cooling costs annually.

In addition, a snow melt system was placed at the north end of the structure under the apron to prevent snow and ice accumulation. This system actually is safer for employees, uses heat that is already in the system, and removes the need to plow snow in that area, reducing CO2 emmisions.

Customized Solution:

  • 3D modeling used to facilitate an aggressive construction schedule, and to coordinate the complex mechanical and electrical system installation.
  • Waste heat from the chillers, hydraulic power unit and air compressors is utilized to provide heating and cooling.
  • A horizontal ground based geothermal system provides constant tempreture to heat/cool based on season.
  • Major equipment:
  • Dual KBX400 Boilers providing any needed heat for the snow melt or building heat.
  • 400 Gallon Hot Glycol storage tank insulated to maintain 108 degrees.
  • Dual 400 MBH Condensing units built at Rohde Brothers, Inc.
  • Gas Fired 300,000BTU unit heater.
  • Dual Rupp economizer exhaust units.
  • 15 Ton Ice Bank system
  • 5690CFM Fan Coil Unit

Rohde Brothers, inc.

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City of Portage Waste Water Treatment

by | Feb 12, 2024

Waste Water Treatment Plant Upgrade - City of Portage

Waste Water Treatment Contractors
Effluent piping to next phase - Old piping

Effluent piping to next phase – Old piping

Pump - old auger style washer

Pump – old auger style washer

Screener Evac Piping

Portage4

Band Screen Fine Screener

Band Screen fine screener

The city of Portage, WI rests on the banks of the Wisconsin River and is one of Wisconsin’s oldest cities.

The city decided to upgrade and update parts of its waste water treatment headworks in an attempt to improve the overall condition of it’s facility and it’s processes.

The job consists of a center flow band fine screen system with an integrated compactor. The equpment was very specific and built in Austrailia. To our knowledge this company is the only firm to make this exact equipment. The equipment is self cleaning and can be operated using a number of configurations.

The job also consisted of piping and pumps which happen in a second phase. Driver motors, gear reducers, and piping all needed to be installed to fully upgrade the system. 

Customized Solution:

  • RETROFIT a new center flow fine screen vertical screener with an integral compactor into the facility. With all new controls and piping to the next phase of the treatment process.
  • Controls for the equipment were installed per NEC specifications to operate and consist of 480 volt primary panel with PLC and an operator interface which can operate the screen, spray wash, and compactor.
  • New piping for solids coming from the screener
  • New piping and pumps for effluent to move liquid into other areas of the treatment plant

Appleton Wisconsin WWTP

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