Operator III Syllabus
I. Safety & Lead Tech Information "For Equipment Room Compliance"
1. Work with ammonia out side of the refrigeration system for testing and expansion rates. Live exercise with water being injected into ammonia liquid.
2. Guidelines for ammonia sensors and calibrations.
3.Guide to good practices for the operator of an ammonia refrigeration system (basic on Bulletin R1 iiar)
4.Guidelines for: IIAR Bulletin 107, Suggested Safety and Operating Procedures when making Refrigerating Plant Tie-In's.
5. Guidelines for: IIAR Bulletin 108, Water Contamination in Ammonia Refrigeration System
6. Guidelines for: IIAR Bulletin 109, Minimum Safety Criteria for a Safe Ammonia Refrigeration System
7. Guidelines for: IIAR Bulletin 110, Start-Up, Inspection and Maintenance of Ammonia Mechanical Refrigeration System.
8. Guideline for: IIAR Bulletin 111, Ammonia Machinery Room Ventilation
9. Guidelines for: Bulletin 112, Ammonia Machinery Room Design
10. Guidelines for: Bulletin 114, Identification of Ammonia Refrigeration Piping and System Components.
11. Guidelines for: Bulleting 116, Avoiding Component Failure in Industrial Refrigeration System by Abnormal Pressure or Shock.
II. Advance Troubleshooting
1. Corrective action to discrepancies in your systems.
2. Demonstrate proper techniques is piping to suction headers.
3. Oil Analysis and sampling.
4. Adjusting Liquid Injection Cooling High Stage (soc or Lic cooling) Hands-on Demonstration
5. Adjusting Liquid Injection Cooling Low Stage Hands-on Demonstration
6. Troubleshooting Heat Exchangers for leaks and efficiencies. Short cuts and signs
III. Flooded Control Stations and Defrost for Blast Freezers
1.Air Defrost for Surge Drums
2. Water Defrost for Surge Drums
3. Hot Gas for Surge Drums
4. Sprayed Defrost for Surge Drums
IV. Air Evaporator Defrost and Piping
V. Compressors using Economizer Ports and P&ID"S on systems
1. Back Pressure Regulators on CPR's
1. Deferent types of Controls and Feeds with drawings
2. Critical Safety Controls with P&ID"s on CPR's
VI. Over Feed Ratios and Set Points
1. Hand Expansion Valves Capacity Tables
2. Set Points for Hansen, Phillips, and Henry Hand Expansion Values
3. Setting Procedures for set points of flows of refrigerate across expansion valves
VII. Value Stem Setting for Manual Operations
VIII. Back Pressure Regulator
1 Drawings and troubleshooting for A4AB,A4WB,A4AD,A4WD,A4AD,A4AOE,A4AS
A4WS, A4AT All valves will be looked at for RS/Hubbell/Hansen on back pressure regulator
IX. Internal Operations of Solenoid Valves
1. All Pilot Valves
2. Direct Acting Valves
3. Example S4A, S4W, S5A, S6N, S7A, S8F, S9A S9W
X. Transfer Ammonia
1. Dump Trap to CPR
2. Dump Trap to HPR with Interrupter Valve
3. Dump Trap to HPR with Gravity Flow
4. Dump Trap to HRP with Pump
5. Pump to HRP
6. Transfer Hose and P.D.
7. Three way valves and operation functions
XI. Water Testing in NH3
1. Build a water testing kit
2. Water study in ammonia
3. Ice study in ammonia
XII. Vibration test
XIII. Relief Valves
1. Atmospheric Piping
2. Hydrostatic Piping
3. Sizing Relief Valves
4. Oil Pots Relief Valves
5. Liquid or Gas Relief
XIV. Competency Skills
1. Follow oral instructions: Listen for and identify key words . Listen for words that identify a procedure. Listen for steps or actions to be performed. Listen for clues regarding the order or sequence in which a task is performed.
2. Participate in group communication activities.
3. Estimate, apply and solve problems involving fractions, decimals, percentages, and real numbers.
4. Convert common units of measurement within and/or across measurement systems (metric/English, etc.).
5. Construct and interpret tables, charts, maps, and/or graphs.
6. Compile and maintain records, logs, lab notebooks, and other documents.
7. Build group consensus: Clarify statements. Reconcile disputes and disagreements, Propose alternative plans for action. Respond positively to ideas and suggestions. Express agreement or neutrality. Demonstrate conflict resolution skills. Express disagreement diplomatically.
8. Set priorities or the order in which several tasks will be accomplished.