Garden City Ammonia Program
Randy Williams Training Program
Day One: Ammonia Refrigeration Basics
Covers all aspects of using ammonia as a refrigerant. Describes both single-stage and two-stage ammonia systems. Explains the importance of accumulators and intercoolers in ammonia refrigeration. Concludes with coverage of liquid recirculation system operation.
Ammonia Characteristic Topics:
Ammonia sources, uses, and chemical characteristics; Environmental, hazardous material concerns; Temperature-pressure relationships; Materials compatibility; MSDS criteria; Safety
Single-Stage Ammonia System Topics:
Positive-displacement systems; Refrigeration loads; Primary, secondary refrigeration system components; Components in parallel; Superheat; Single-stage pressure-enthalpy diagram
Two-Stage Ammonia System Topics:
Compression ratio; Compressor capacity; Two-stage system division, Booster desuperheater, intercooler; Two-stage system components, performance; Complex two-stage systems
Suction Accumulators and Intercooler Topics:
Need for suction accumulators; Accumulator design features; Liquid/vapor separation; Intercoolers; Shell-and-coil vs flash intercoolers; Alternate intercoolers
Liquid Overfeed (Recirculation) System Topics:
Liquid overfeed, recirculation systems; Recirculation system advantages and disadvantages; Recirculation vessel design; Pumper drum system; Controlled pressure receiver system
Day Two: Positive-Displacement Compressors
Begins with coverage of reciprocating compressors-their design, lubrication, efficiency, and application. Covers rotary vane compressor operation and limitations. Details screw compressors and the operation of related drive, lubrication, capacity control, and safety systems. Discusses oils and the importance of system lubrication.
Reciprocating Compressor Topics:
Features of industrial ammonia reciprocating compressors; Capacity control; Lubrication; Efficiency; Application data; Compound compressors
Sliding-Vane Rotary Booster Compressor Topics:
Rotary vane compressor design and operation; Fixed volume ratio; Applicability; Limitations; Capacity control
Oil-Flooded Screw Compressor Topics:
Oil-flooded screw compressor operation; Fixed volume ratio; Capacity control in fixed - variable compressors; Efficiency; Compound compressors; Application criteria
Screw Compressor Unit Topics:
Screw compressor systems; Drive systems; Lubrication, refrigerant/oil separation - oil cooling, economizer/side load, capacity control, microprocessor control, and safety systems
Ammonia Systems Lubrication/Oil Management Topics:
Need for lubrication; Miscibility; Viscosity; Lubricants and oils; Lubricant selection - handling and management; Separators; Low-side oil recovery
Day Three: Evaporators, Condensers, and Controls
Covers gravity feed, overfeed, dump trap, CPR, and DX supply systems. Describes evaporator and evaporative condenser design, selection, and operation. Discusses various defrost systems-hot gas, electric, water, and glycol spray. Examines stop, shutoff, relief, check, solenoid, expansion, pressure-regulating, and float valves.
Liquid Ammonia Evaporator Supply Method Topics:
Gravity feed, liquid overfeed, pumped overfeed, dump trap, controlled pressure receiver - direct expansion, and flooded liquid chiller systems
Evaporator operation and heat transfer principles; Tube design; Chillers; Air coils; Freezers; Ice makers; Specialty evaporators
Air Unit Defrost System Topics:
Reasons for defrost; Hot gas, soft hot gas, electric, water, continuous glycol spray - and room air defrost; Defrost cycle initiation and termination
Evaporative Condenser Topics:
Evaporative condenser basics and design features; Condenser selection; Condenser location; Refrigerant piping; Winter operation and capacity control; Water treatment
Control Valves and Switches Topics:
Safety relief, stop and shutoff, check, solenoid, hand expansion, pressure regulating, and float valves; Float valve switches and controllers
Day Four: Purging, Piping, and Safety
"GCAP's TEST AT END OF THIS DAY"
Explains the effects of noncondensables on an ammonia system and the importance of their removal. Covers a wide range of piping considerations-sizing, flow rate, pressure drop, and others. Concludes with a thorough coverage of safety codes and programs, including ANSI/ASHRAE, IIAR, OSHA, and EPA information.
Purging Air and Noncondensables Topics:
Materials to be purged; Effects of noncondensables; Power penalty; Purge point locations; Automatic purging; Economics of purging
Ammonia System Piping Topics:
Pressure drop in pipes; Laminar and turbulent flow; Line sizing, flow rate, suction line pressure drop, discharge line pressure charts; Special piping situations
Ammonia System Safety Codes and Guidelines Topics:
Codes for ammonia refrigeration systems; ANSI/ASHRAE 15-1994; ASMEB 31.5; IIAR2; IIAR bulletin 111; IIAR bulletin 112
OSHA Process Safety Management Topics:
OSHA regulations; PSM requirements; Estimation of ammonia inventory; PSM plan development; Process safety information, hazard analysis; Standard operating procedures; Contractor procedures
EPA Regulations and Ammonia Safety Topics:
40 CFR 68; Worst case/alternate ammonia release scenario; Elements in common with OSHA PSM; Penalties for nonconformance
All the material above including lectures, which the students receives with the course, and hands on demonstrations in our hands on lab, should help quick start the student's career in the ammonia industry. No other school offers this amount of information for the first course. We feel that you cannot build an operator in a week, it takes years and we want to get the material in their hands early so a complete training package so on the job training will be affective.
This will prepare them to grow into an Industrial Refrigeration Technician. With the standard we follow, students will be successful.
Operator I Syllabus