Intermediate Refrigeration
Systems for Operators
A web-based course conducted by the
Industrial Refrigeration Consortium
Industrial Refrigeration Consortium
www.irc.wisc.edu
Intermediate Refrigeration Systems for Operators
This class is designed to build upon and extend the
skills developed in the introductory class. This class
furthers an operator's understanding of ammonia
refrigeration and reinforces many of the duties
required of an operator. It is not intended to replace
plant-specific operation training. Rather, this course
strengthens the operator’s understanding of ammonia
refrigeration theory making them better equipped to
receive plant-specific training. The course material is
suitable for anyone who has successfully completed
the introductory course.
A typical course outline is provided below, but can be modified to meet your
plant's/company's specific training needs. The course is taught in ten
sessions that are 2 hours in length. If desired, an examination can be
administered to participants upon completion to validate their comprehension
of the material.
Advantages of E-Learning
In its quest to provide companies with affordable and unified training for
operators, the IRC has refined its development of web-based training. Some
of the advantages include:
• Training is delivered live by qualified instructors.
• A uniform training program can be delivered to all operators across
multiple plants.
• Eliminates travel costs for both students and instructors.
• Can be tailored to your company’s training needs.
• Session can be recorded and played back at a later date.
• Students have multiple ways to interact with instructor both during and
after class.
• Homework and exams are to verify their level of comprehension.
All web-based courses offered by the IRC feature 1 or 2 instructors providing
live audio feed over phone lines while participants view slides, documents,
images and animations over their internet connection. Participants can
interact with the instructors both on-line and by telephone during the course or
can contact the instructors after the session has ended. Most courses are
taught in 2 to 4 hour segments over several days. This allows participants
stay productive within their plants since there is no off-site travel.
These courses are intended to build operator’s understanding of refrigeration
theory and fundamentals. Our experience has shown that operators with this
sounds knowledge make better decisions in their plants-particularly during
upset conditions. This foundation of knowledge also makes operators better
equipped to receive plant-specific procedure training as required by PSM.
Course Outline Refrigeration Components: Valves/Metering
Devices
Refrigeration Systems Review • Solenoid valves
• Check valves
• Single stage systems: direct expansion,
• Stop valves
flooded, liquid overfeed
• Expansion valves: hand-expansion,
• Multi-stage Systems: direct, indirect
thermostatic
Loads • Modulating valves
• Regulators
• Temperature requirements • Actuating methods (direct-acting, pilot-
• Envelope loads operated)
• Product loads • Installation considerations
• Internal loads • Service considerations: packings, stem
• Evaporator fan heat gains lubrication, valve exercising
• Psychrometrics overview
• Sensible & latent loads Refrigeration Components: Compressors
• Infiltration loads - theory vs. real-world
• Reciprocating
• Rules-of-thumb
• Screw (single/twin)
Assessing System Performance • Rotary
• Duty: high-stage, booster
• Basic vapor compression cycle • Compressor ratings: capacity, power,
• Performance measures efficiency
• Benchmarking • Capacity control/unloading
• Pressure-enthalpy diagrams • Variable volume control
• Influence of head pressure, suction • Methods of oil cooling
pressure, subcooling & superheat o Thermosiphon
• System balance o Liquid injection
Refrigeration Components: Condensers o Water-cooled
• Types: water-cooled, evaporative Refrigeration Components: Vessels &
• Performance characteristics Accumulators
• Wet/dry operation • Types: high-pressure receiver,
• Piping considerations (traps, vent line sizing, thermosiphon, low-pressure accumulator,
drainers) flash intercooler
• Fan alternatives - single speed, two speed, • Configurations: horizontal or vertical
and variable speed • Proper practices for system integration
Refrigeration Components: Evaporators • Refrigerant level control (floats, capacitance
probes)
• Evaporator types - Plate-fin, • Influence of oil on level controls & floats
o Plate-fin
o Sprayed glycol Refrigerant Management Issues
o Shell-and-tube
• Transfer systems - what are they and why
o Plate-and-frame
are they needed?
o Ice builders
• Gas pumping
• Refrigerant feed • Mechanical pumping
o Top-fed
• Advantages/Disadvantages
o Bottom-fed
o DX, Flooded, Overfeed Purgers and Purge Systems
• Defrosting
• Non-condensables
o Methods
• Determining presence of non-condensables
o Influence on head pressure
• Consequences of non-condensables
o Influence on compressor loading
• Purge locations and techniques
o Do I need high head pressure for
• Importance of muli-point purging
defrosting?
• Purger operation
• Installation considerations
Insulation Systems Operational Issues
• Insulation system types and alternatives • Methods for adjusting valves
• Thickness requirements o What, where, why?
• Vapor and vapor barrier considerations o Hand expansion valves
• Sheathing and jacketing o Thermostatic expansion valves
• PM & Inspection guidelines o Back-pressure regulators
• Estimating quantity of refrigerant released
Pumps during an incident
• Refrigerant Pumps • Estimating residual refrigerant inventory after
o Pump types and performance curves pump-out
o Net positive suction head required • Techniques for safely charging systems
o Net positive suction head available
Incidents
o Refrigerant pump cavitation (causes,
diagnostics, and cures) • Why do they occur?
• Secondary Fluid Pumps • How can they be minimized?
o Types & performance • Overview of incident investigation
o Influence of fluid selection o When is it required?
o Influence of operating temperature o What is required?
o Relationship to PHAs
Maintenance Overview
Troubleshooting
• Oil draining
o Where, when, why? • What are the causes of high head pressure?
o Techniques for safe draining What are the cures?
o Attire (personal protection) • Why can't I get my evaporators defrosted?
• Cleaning strainers How often should I defrost?
o Where, when, why? • What causes high-level alarms and shut-
o Techniques for safe pump-out downs?
o Attire • Hydraulic shock - what is it? How and why
• Testing ammonia for water do you want to prevent it?
o Where, when, why?
o Sample collection
Process Safety Management
• Process safety information
• Mechanical integrity
o Visible inspection techniques
o Inspection intervals
• Management of change
Safety Systems & Equipment
• Ammonia detectors
o Types
o Proper locations
o Testing & calibration requirements
• PRVs & relief piping
o Types
o Code requirements
o Inspection intervals
Web-based courses currently offered by the IRC
• Advanced Refrigeration Systems for Operators
• Ammonia Awareness Training for Employees
• Intermediate Refrigeration Systems for Operators
• Introduction to Refrigeration Systems for Operators
• Overview of Ammonia Refrigeration Systems
For more information, contact the IRC at [email protected].
Industrial Refrigeration Consortium
1415 Engineering Drive
Suite 2342
Madison, WI 53706
Toll-free: (866) 635-4721
Local: (608) 262-8220
Fax: (608) 262-6209
