Ammonia Refrigeration System Maintenance: Key Tips for Prolonging Equipment Life

Introduction:

Various industries utilize ammonia refrigeration systems to cool down and preserve goods and food that are easily spoilt. However, these systems are complex machinery that need stringent maintenance to perform at their best and keep the food fresh. If not maintained on time, issues can arise, leading to highly priced breakdowns, hazards for employees, and a significant loss of time & money. That is why this blog post will shed light on tips to keep these systems maintained and extend their life. We will cover routine inspections, handling procedures, and other actionable insights to help you run these systems smoothly for a long period of time.

Understanding the Basics of Ammonia Refrigeration Systems

Employees and everyone who is involved in maintaining ammonia refrigeration systems need to understand the components of the ammonia refrigeration systems thoroughly. The following is a brief overview of the different component's component:

The working principle of the ammonia refrigeration system is that they use a refrigerant ammonia (NH3) that absorbs the heat from a specific area and releases it at another place, cooling the application efficiently.

Working Principle:

The ammonia refrigeration system works on the vapor-compression refrigeration cycle and has 4 components:

• Compressor: Compresses low-pressure ammonia gas into high-pressure gas, raising its temperature due to the increase in pressure.

• Condenser: It releases the heat from the high-pressure gas and condenses it into the liquid state.

• Expansion Valve: It cools down the liquid ammonia instantly by reducing the pressure.

• Evaporator: Within the evaporator, heat is absorbed by the cold ammonia from the environment, which converts the liquid ammonia into a gas thereby completing the cycle.

To understand the safe operating procedures for the ammonia refrigeration system operations, read our comprehensive blog post here.

The amazing thermodynamic property of ammonia lets it absorb huge amounts of heat during evaporation. That is why the ammonia refrigeration system is more efficient as compared to those using synthetic refrigerants.

Notable Wear and Tear Signs of Ammonia Refrigeration System

Those dealing with ammonia refrigeration systems should check out for these signs and symptoms of malfunctioning:

Leaking Ammonia:

A strong odor around the ammonia refrigeration system is a sign of broken seals and damaged components of the system.

Varying Temperature Control:

Constant temperature fluctuations indicate compressor or evaporator damage.

Higher Utility Bills:

Wrong settings in the system and worn-out parts can lead to higher utility bills.

Weird Noises:

Mechanical failures and refrigerant leaks manifest through squealing, grinding, and hissing noises.

Development of Frost:

Frost development on the evaporator is due to airflow problems and low levels of refrigerant.

Repeated Cycling:

A broken thermostat or the pressure switch can lead to the development of constant on/off cycling.

Rusting and Corrosion:

Pipes and other components corroding is a sign of structural failures.

By keeping an eye on these signs, workers can catch problems early and fix them to maintain efficiency.

Routine Maintenance Practices to Increase the Shelf Life of the System

Simple routine maintenance checks and tips can save your day and boost the system's longevity. Follow these maintenance practices:

1. Cleaning and Inspecting the Main Components Frequently

• Routinely check for corrosion, wear, and dirt buildup in the condensers, compressors, and evaporators.
• Keep the evaporator and condensers clean to ensure that the heat transfer is proficient.
• Immediately repair or replace worn-out components to keep the system running smoothly.

2. Checking Ammonia Levels and Picking out the Leaks Early

• Measure the ammonia levels every now and then to make sure they are within the operational standards.
• Check and fix the leaks immediately by utilizing leak detection systems and sensors.
• Visually inspect the valves, pipes, and joints to determine possible leaks.

3. Proper Lubrication and Calibrating of the Equipment

• The systems need to be lubricated at regular intervals to cut down wear and tears. Lubricate the compressor and other moving components as per the manufacturing guidelines to keep the system efficient.
• The sensors, controls, and gauges should be calibrated routinely to ensure the system's accuracy.
• As per requirement, replace the lubricants to save the system from contamination and maximize performance.

4. A Detailed Documentation for the Ammonia Refrigeration Systems

1. Keep an Official Logbook: A permanent logbook will help document all the activities by the certified staff to ensure accountability and accuracy of the activities.

Note down the daily readings of pressure and temperature to help pick out issues with performance and deviations.

2. Keep Notes of All Services and Maintenance: Document critical activities such as emergency maintenance, inspections, and changes of oil and refrigerant.

   Track the schedules and detect performance issues by using this data.

3. Perform Hazard Assessments: Identify all the risks associated with the ammonia refrigeration systems, the required PPE, emergency routes, and respirator use duration, and develop a safety checklist to address them.

4. Follow the PPE Inventory: The required PPE should be stored and maintained to ensure its availability during emergencie

   All these maintenance practices can increase the lifespan and functionality of the ammonia refrigeration systems, cutting down the risks of hefty repairs and making the operations more efficient.

Utilizing Advanced Strategies for Maintenance

To further ensure the safe operations of the ammonia refrigeration systems, use the following advanced maintenance strategies.

1. Real-Time Monitoring:

Advanced sensors and data analytics can be used to continuously monitor the performance of the system and help in the early detection of possible issues.

2. Tentative Maintenance:

To perform maintenance, use predictive maintenance tools depending on the actual conditions of the system instead of maintenance at fixed intervals. This strategy aids in reducing downtime and optimizes resource allocation.

Use performance data to check the trends and anticipate failures to allow proactive maintenance and diminish the chances of unexpected breakdowns.

3. Staff Training to Operate the Ammonia Refrigeration Systems

The respective staff should be properly trained to handle emergencies regarding malfunctions in ammonia systems, such as detecting leaks and following procedures in an emergency state. Apart from safety training, the staff should be prepared to properly operate the refrigeration systems, perform maintenance tasks confidently to boost operational efficiency.

Conclusion

Industrial cooling is highly dependent on ammonia refrigeration systems, and that is when the need for their longevity comes in. The risks regarding the functionality of the ammonia refrigeration systems can be reduced by properly maintaining the system, performing regular inspections, and documenting data accurately. training the team members with the right knowledge and sticking to best practices keeps your systems running without a hitch for years.

References:

Broudat Kar Atlas, Guidelines Inspections of Ammonia Refrigeration Systems, https://broudat-kar.com/lang/en/guidelines-inspections-ammonia-refrigeration/

Berg Industrial Services, Maximizing Safety in Ammonia Refrigeration: Best Practices and Procedures, https://bergservice.com/blog/maximizing-safety-in-ammonia-refrigeration-best-practices-and-procedures/