Explain the ammonia refrigeration cycle and the maintenance role of compressors, condensers and evaporators.
Engineering & Maintenance
Maintenance of Industrial Refrigeration and Ammonia Plant Systems
Trains refrigeration and safety engineers to maintain ammonia compressors, evaporators and condensers, and to manage leak detection and mechanical integrity programmes.
🗓️Duration5 training days
📚Content4 modules · 8 sessions
🎓On completionAccredited attendance certificate
About the programme
Course Overview
An ammonia refrigeration system rewards careful maintenance and punishes neglect more severely than almost any other plant utility, because a leak is a safety event and a lost cold chain is a product loss, sometimes on the same afternoon. This course works through the ammonia vapour-compression cycle and the compressors, evaporators, condensers and receivers that make it up, then applies IIAR-aligned safety and mechanical integrity principles to machinery room maintenance. Participants learn compressor overhaul and oil management practices for screw and reciprocating machines, evaporator and evaporative condenser servicing, and the defrost and oil-draining routines that keep heat transfer efficient. Sessions cover ammonia leak detection system configuration, routine leak surveys, valve and relief system maintenance, and the piping integrity checks that catch fatigue and corrosion before they become releases. The course finishes with mechanical integrity programme design and energy optimisation strategies such as floating head pressure control, leaving participants able to keep an ammonia plant safe, compliant and efficient.
Expected Learning Outcomes
Apply IIAR-aligned safety and mechanical integrity practices to ammonia machinery room maintenance.
Perform preventive maintenance on screw and reciprocating compressors including oil management.
Maintain evaporators, evaporative condensers and defrost systems for reliable heat transfer.
Configure ammonia leak detection systems and investigate leak incidents to prevent recurrence.
Maintain valves, relief systems and piping integrity specific to ammonia refrigeration service.
Build a mechanical integrity and energy optimisation programme for an ammonia refrigeration plant.
Who Should Attend
Refrigeration engineers and technicians maintaining industrial ammonia plants.
Process safety engineers overseeing ammonia mechanical integrity programmes.
Facilities engineers in cold storage, food processing and dairy operations.
Maintenance planners scheduling compressor overhaul and vessel inspection work.
HSE professionals managing ammonia leak detection and emergency response plans.
Energy managers evaluating refrigeration system efficiency improvements.
Course Modules
Select any module to see its sessions and points.
01Ammonia Refrigeration System Fundamentals
2 sessions · 8 points
Session 1Refrigeration Cycle and Equipment Overview
- Explain the ammonia vapour-compression cycle and the role of compressors, condensers, evaporators and receivers.
- Distinguish screw, reciprocating and rotary vane compressor designs used in industrial ammonia systems.
- Identify high-pressure and low-pressure receiver configurations and their role in liquid and vapour management.
- Interpret pressure-enthalpy diagrams to diagnose system performance against design operating envelopes.
Session 2Safety Systems and Regulatory Framework
- Apply IIAR and process safety management principles relevant to ammonia refrigeration system maintenance.
- Identify mechanical integrity requirements for pressure vessels, piping and relief systems in ammonia service.
- Explain the role of emergency shutdown systems, ammonia detection and dilution systems in incident prevention.
- Assess permit-to-work and confined space requirements specific to ammonia machinery room maintenance.
02Compressor and Heat Exchanger Maintenance
2 sessions · 8 points
Session 1Compressor Maintenance and Oil Management
- Perform preventive maintenance on screw compressor bearings, rotors, slide valves and oil separators.
- Manage oil charge, oil return and oil cooling systems to maintain compressor lubrication reliability.
- Diagnose compressor capacity control and unloading system faults affecting part-load efficiency.
- Inspect suction and discharge valves on reciprocating compressors for wear and leakage.
Session 2Evaporator and Condenser Maintenance
- Inspect and clean evaporator coils and defrost systems to maintain heat transfer efficiency.
- Maintain evaporative condensers including spray nozzles, fill media and fan systems for heat rejection performance.
- Manage oil accumulation in evaporators and low-pressure receivers through scheduled oil draining.
- Diagnose reduced heat transfer performance from ice buildup, scaling or non-condensable gas accumulation.
03Leak Detection, Valves and Piping Integrity
2 sessions · 8 points
Session 1Ammonia Leak Detection and Response
- Configure fixed and portable ammonia detection systems to alarm at safe threshold concentrations.
- Conduct routine leak surveys using ultrasonic and chemical detection methods at valve packing and flanges.
- Plan emergency response procedures for ammonia release scenarios during maintenance activities.
- Investigate leak incidents to identify recurring failure points in valves, gaskets or piping joints.
Session 2Valve, Piping and Relief System Maintenance
- Maintain king valves, solenoid valves and hand expansion valves for correct refrigerant flow control.
- Inspect relief valves and rupture discs against required testing intervals and replacement schedules.
- Assess piping supports, insulation and vibration isolation for fatigue and corrosion risk in ammonia lines.
- Verify non-condensable gas purger operation to remove air ingress from the refrigeration system.
04Reliability Programme and Energy Optimisation
2 sessions · 8 points
Session 1Mechanical Integrity and Reliability Programme
- Build a mechanical integrity programme covering compressor overhaul intervals, vessel inspection and valve testing.
- Develop a spare parts strategy for compressor components, valves and control instrumentation.
- Integrate vibration monitoring and oil analysis into a predictive maintenance plan for ammonia compressors.
- Document maintenance records to support process safety management compliance audits.
Session 2Energy Optimisation and System Upgrades
- Evaluate floating head pressure control and other energy optimisation strategies for ammonia systems.
- Assess variable frequency drive retrofits on compressors and condenser fans for energy reduction.
- Plan system upgrades such as low-charge ammonia design when reducing refrigerant inventory is a priority.
- Present maintenance and energy performance data to plant management to support investment decisions.
What the participant receives
4 course modules
A structured syllabus
8 training sessions
across 5 days
32 detailed points
Applied, detailed content
Accredited attendance certificate
On completing the programme
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