Glycol systems
Seven warning signs your glycol system needs attention
How venues can identify developing glycol-system faults before taps start pouring warm product.
1. Product temperature drifts during busy periods
A system that pours correctly when quiet but warms during peak trade may be losing capacity. The cause can include inadequate refrigeration duty, poor heat rejection, weak circulation, low fluid level or an increasing load that exceeds the original design.
Record when the drift occurs and which taps are affected. A pattern limited to the far end of the python suggests a different investigation from a temperature rise across the whole system.
2. The chiller runs continuously
Long run time is normal under load, but continuous operation combined with poor temperature control indicates the plant is not achieving its target. Dirty condensers, restricted airflow, refrigerant faults and degraded insulation are common areas to investigate.
Do not simply lower the controller setpoint. That can increase run time without fixing the cause and may create freezing or viscosity problems elsewhere in the circuit.
3. Pump noise, vibration or intermittent flow
Changes in pump sound often precede complete circulation failure. Air in the circuit, low fluid, bearing wear, obstruction and cavitation can all reduce performance.
Inspect for visible leaks and confirm the reservoir level without opening or disturbing equipment beyond normal operator checks. A technician should test pressure, flow and pump condition.
4. Ice, condensation or wet insulation
Localised icing may indicate an abnormal temperature or flow condition. Persistent condensation on pipework usually points to damaged, incomplete or saturated insulation. Both conditions waste capacity and can damage surrounding finishes.
Wet ceiling tiles, corrosion or mould near a glycol route should not be treated as a building issue until the insulated pipework has been inspected.
5. Frequent resets or alarm codes
A reset may restore operation temporarily but the alarm history contains useful evidence. Photograph the display and record the time, trading load and ambient conditions before resetting equipment.
Repeated high-pressure, low-flow or temperature alarms are a developing failure, not a nuisance. Early diagnosis is usually cheaper than an emergency call during service.
6. Uneven tap performance
If nearby taps pour correctly while distant taps run warm, the problem may involve circuit balance, local insulation, python condition or restricted flow. Comparing supply and return conditions helps isolate the affected section.
Do not compensate indefinitely by changing gas pressure. Pressure adjustments can create new pouring problems without restoring cooling.
7. Increasing product waste
A rise in foam, warm first pours or staff dumping product is often the first financial indicator of a cooling problem. Track wastage by product and bar.
The system should be assessed when wastage changes without a corresponding change in product, cleaning practice or staff technique. Product loss can exceed the cost of timely maintenance.
Need the system assessed?
Beer Works services commercial beer, glycol and related refrigeration systems across South East Queensland. Call (07) 3204 0607 or email info@beerworks.au.