Training Materials

• Students will receive a Hard Copy Workbook

Training will include:

• Plant On-The-Job Training and Demonstration
• Training for the way to properly do - Daily/Weekly Rounds.
• Develop a SAMPLE DAILY ROUNDS SHEET
• Compressor discharge, suction, oil temp, oil levels, dry side levels, thermosiphon, filter differential pressure.
• Vessel Levels (not just the HMI or PLC Control Panel), Recirculator Pumps types, Oil Pots (iced up or not iced up).
• Air Cooled Evaporators, ice buildup, vibration, fan operation, drip pans for leaks or plugged.
• Condensers, fans, belts, vibration, sump water level and PH levels and pump operation. HMI readout for PH Levels, foam on in water sump, leaks on condenser, water leaks, mist eliminators.
• Roof - Valve Stations on the roof, Penthouses, Silos, vibration, leaks, pipe supports, ice where there Is normally or not normally ice. (Ice Abnormality).
• Mezzanine - Crawl space how often are you looking at them?
• Sites Specific Equipment such as Oil Stills, Surge Drums, Transfer Drums, Purger, TXV valves - bulb location, etc.
• Basic Refrigeration System Video -Industrial Refrigeration system Basics - Ammonia refrigeration working principle.
• Refrigeration Cycle Diagram
• High side/ Low Side (High Discharge and Suction), High Side – HPR, Condensers, Compressors, Low Side – Evaporators, Compressor, Recirculators, Accumulators, etc.
• Review of the plants Piping and Instrumentation Diagrams and Block Flow Diagram (Facility Specific)
• Site specific SOPS – 1 for Each Type Compressor, Condenser and Evaporators, Recirculators, Surge Drums
• Normal Operating Ranges for Compressors, Condensers, etc. and WHY
• Vessel Operating Levels
• Consequences of Deviations and Corrective Actions from Normal Operating Ranges (REPORT ONLY), (What can cause High Head Pressure? What can cause a Compressor to Shut down?
• Review the SOP for Charging the System with Ammonia – Sites Procedure (based on regular Maintenance activities, or during a MOC).
• Video – charging the system with ammonia.
• Emergency Action Plan and Response
• Emergency Shutdown of System if needed. (based on Corporate Policy).
• Hit the E-Stop in the Compressor room
• HPR or TSR leak
• SOPS – Emergency Shutdown of the system
• Release at an EVAP (Emergency Shutdown, High Pressure Receiver, how do you isolate it, can you isolate a valve upstream, or only at the unit, when to hit the E-Stop Button?
• Minor Ammonia Leak (Facility SOP Review) (Video of Engine Room Leak and Explosion)
• Ammonia Handheld Detector Meter Use (how to use them and make sure they are calibrated. (Demonstration)
• Respirators and Papr hoods (Sites Specific Respirators)
• Awareness of the Maintenance Logs and purpose in Machine Room, Nuisance Odor Logs, Oil Draining Logs, Purge Logs, Ammonia log for inventory.
• Oil Draining Procedure/Locations of Oil Draining (Facility SOP Review)
• The difference between Operating Procedures and Maintenance Procedures and the requirements for both.
• Samples of Maintenance Procedures (IIAR-6 Requirements)
• Discuss Ammonia Safety Systems and Devices and Their Functions
• SRVs replacement procedure, Testing the Compressor Cutouts, High Level Floats on Vessels, Testing E-Stops, Ventilation Switches.
• The Functions of each – Plant specific - What should happen if the Emergency Ventilation goes off? If the Ammonia detector activates, does it turn on Emergency Ventilation etc. E-Stop shuts down all the compressors and turns on ventilation.
• Detectors/Sensors
• Ammonia Detectors (locations) (PPM) Alarms Levels and Testing Requirements
• Handheld Detectors (locations) (PPM)