Course Details

This course is appropriate for a wide range of professionals but not limited to:

• Operation and maintenance technicians
• Mechanical and refrigeration engineers
• Process plant operators and supervisors
• Plant inspectors and reliability personnel
• Anyone involved in the operation, monitoring, or maintenance of ammonia compressor systems

• Expert-led sessions with dynamic visual aids
• Comprehensive course manual to support practical application and reinforcement
• Interactive discussions addressing participants’ real-world projects and challenges
• Insightful case studies and proven best practices to enhance learning

By the end of this course, participants should be able to:

• Understand the thermodynamic principles of ammonia refrigeration cycles and compressor operation.
• Identify and describe different types of ammonia compressors (reciprocating, screw, centrifugal).
• Interpret compressor components, layout, and auxiliary systems, including lubrication, cooling, sealing, and capacity control.
• Conduct safe start-up, normal operation, shutdown, and emergency procedures for ammonia compressors.
• Recognize operational indicators of abnormal performance and apply systematic fault diagnosis.
• Follow best practices in ammonia safety, emergency response, leak detection, and environmental compliance.
• Apply preventive and predictive maintenance strategies to maximize compressor efficiency and reliability.

DAY 1

Fundamentals of Ammonia & Refrigeration Compressors

• Welcome and introduction
• Pre-test
• Introduction to ammonia refrigeration
• Properties of ammonia (R-717) and comparison with other refrigerants
• Ammonia vapor-compression cycle
• Types of compressors used with ammonia:

• Reciprocating compressors
• Screw compressors
• Centrifugal compressors

• Compressor selection criteria
• Safety considerations when handling ammonia in compressor systems

DAY 2

Compressor Construction, Components & Auxiliary Systems

• Detailed compressor components and functions
• Piston/cylinder assemblies, rotors, bearings, seals
• Suction and discharge valves
• Lubrication systems: oil circulation, filtration, cooling
• Cooling systems and inter-coolers
• Capacity control mechanisms:

• Slide valve (screw compressors)
• Clearance pockets
• VFD control

• Oil separators and gas purification
• Instrumentation & monitoring devices

DAY 3

Operation Procedures & Control Systems

• Start-up sequence and safety checks
• Bringing compressors online and loading procedures
• Normal operating parameters (pressure, temperature, vibration, oil levels)
• Compressor control systems:

• PLC / DCS interfaces
• Pressure/temperature controllers
• Automatic shutdown and trip logic

• Shutdown procedures: normal vs. emergency
• Load balancing between multiple compressors
• Efficiency and energy optimization techniques

DAY 4

Troubleshooting & Fault Diagnosis

• Recognizing abnormal compressor behavior
• Common operating problems:

• High discharge temperature
• Liquid carryover
• Oil foaming or oil loss
• Excessive vibration or noise
• Low suction pressure
• Motor overload

• Root-cause analysis methods
• Troubleshooting reciprocating vs. screw compressors
• Case studies from industry incidents
• Proper documentation and reporting practices

DAY 5

Ammonia Safety, Maintenance & Best Practices

• Ammonia hazards and risk mitigation
• Leak detection technologies and emergency response
• Personal protective equipment (PPE) for ammonia environments
• Preventive and predictive maintenance planning
• Vibration analysis and performance monitoring
• Compressor overhauls and inspection procedures
• System cleanliness and dehydration
• Best operational practices for long equipment life
• Final group exercise: developing an operational & maintenance plan
•  Post-test
• Certificate ceremony