Education for Industrial refrigeration

Training seminars for Industrial refrigeration technicians, manufactures, contractors and end users are the knowhow and experience gained by working more than 35 years in the Industrial refrigeration business area, condensed into training seminars.

The seminars are high level education for everyone working in the field of Industrial refrigeration.

Cool Partners training seminars are about all the know how you cannot achieve at any engineering high schools or other theoretical studies.

In the Cool Partner seminars and trainings, we will go through how Industrial refrigeration systems can and should be build, operated, and serviced, so they are highly efficient and have low service and maintenance cost.

Cool Partners training seminars | Subjects and contents

Cool Partners 10 seminars are divided into four groups of subjects.

In each group there will be seminars of 2 to 3 hours covering the subjects within the group.
During a full day of seminars, it is recommended to go thru 2 seminars.
3 seminars in one day might be possible but will be very demanding for the participants and leaves very little time for questions and discussions
If the seminars are given as webinars, only 1 seminar as webinar should be done in one day.

Contamination of industrial refrigeration systems and heat pumps.

Seminar 1: Air in industrial refrigeration systems
Seminar 2: Water in Industrial refrigeration systems
Seminar 3: Oil in industrial NH3 refrigeration systems
Seminar 4: Trouble shooting on contaminated industrial refrigeration systems based on case stories

Optimization and efficiency of Industrial R717 systems

Heat recovery and heat pumps

Industrial CO2 refrigeration systems

Prices

Seminars:

“live seminars” incl. 2 or 3 seminars per day 20.000 Dkk / 2667 Euro / 3080 USD a day

The price is excl. travel and accommodation cost
Traveling time is regarded as normal working time at 1000 Dkk / 134 Euro / 150 USD an hour

Max. 40 participants in a “live seminar” and there will be plenty of time to questions and technical discussions.

“Hard copies” of the presentation material may be printed with 2 to three slides on each A4 pages for the attendees. “Soft (electronic) copies” of the presentation material will be available only with “watermarks” on and only on request. No video or filming of the presentation will be allowed.

Webinars

Webinars with min 10 participants and max 25 participants 1300 Dkk / 175 Euro / 120 USD each participant.

Only one webinar a day, as it is very difficult to keep focus in more than 3-4 hours. There will be plenty of time to questions and technical discussions during the webinar. "Soft (electronic) copies" of the presentation material will be available only with “watermarks” on and only on request. No video or filming of the presentation will be allowed.

Group 1: Contamination of industrial refrigeration systems and heat pumps

In these four seminars the consequences of contamination in industrial ammonia refrigeration systems with primarily water, air, and oil, but also other substances like wrong oil types or chemical substances will be examined and discussed.

It will be discussed how the pollutions are discovered and how it can be removed manually and / or automatically.

The economic consequences for the operating economy as well as how this are calculated will be discussed. A free program for calculating the impact of water and air in ammonia systems will be introduced and reviewed. The program calculates reduced refrigeration capacity and the increased energy consumption as well as payback times when investing in automatic cleaning systems.

A couple of “trouble shooting cases” from real life is reviewed with an introduction to how you work systematically by using facts, knowledge, and experience in finding the “root courses” for big problems like compressor accidents, lack of refrigeration capacity, sludge in the systems etc.

Seminar 1: Air in industrial refrigeration systems.
How does it get there?
What are the consequences of air in the systems to discharge pressure, power consumption and chemical reactions?
How do we get the air out manually and / or automatically?

Air is the course of many problems in industrial refrigeration systems. It gives both increased power consumption and reduced refrigeration capacity as well as chemical reactivity with corrosion and oil decomposition. This leads to unnecessary large energy and service cost on the systems. In this seminar the consequences of air in the systems are reviewed. We look at how it is detected, how the economic consequences are calculated, and how the air is removed manually and / or automatically.

Seminar 2: Water in Industrial refrigeration systems.
How does it get there?
What are the consequences of water in the systems to suction pressure, power consumption, and chemical reactions?
How do we get the water out?
How do we calculate the cost of running the system with water?
The free CPAWcalc program for calculating the consequences of air and water in the systems are introduced and reviewed.

Water is the reason for many problems in industrial ammonia refrigeration systems. It gives both increased power consumption and reduced refrigeration capacity. Further it creates a very chemically reactive environment with corrosion and oil decomposition. This leads to unnecessary high energy and service cost. In this seminar the consequences of water in the systems are reviewed, how it is detected, measured, and removed. How to calculate the economic consequences is reviewed and a free calculation program made by Cool Partners will be introduced and reviewed. The CPAWcalc program will calculate reduced refrigeration capacity and the increased energy consumption as well as payback times when investing in automatic cleaning systems.

Seminar 3: Oil in industrial NH3 refrigeration systems.
How does it get out in the system?
What are the consequences of oil in the system to efficiency?
Can we do something to stop it?
Can we return it to the compressors from the LP side?
Can the oil out blow be stopped on the HP side in the system?
Industrial refrigeration oils what are they and why?
oil analysis, how can we use them as trouble shooting tool

Oil give reason to many problems in industrial ammonia refrigeration systems. How can we prevent the oil from reaching the evaporators and what happens if the oil gets into the evaporators anyway?

How can the oil in a safe way be returned from the system to the compressors and how to avoid contaminating the oil in the compressors? What is the importance of the oil types and what happens if the wrong oil types are used? What can we see in oil analysis and how can oil analyses results be used as a powerful trouble shooting tool?

Seminar 4: Trouble shooting on contaminated industrial refrigeration systems based on case stories.
Severely decomposed oil suddenly appearing in compressors.
Reciprocating compressors failing and destroyed with no explanations?
Crystals and powder created in systems?
Sediments created in systems blocking oil passage.
Why is some oil “hanging” in the evaporators?
R22 in R717 systems, what happens?

Based on reel experienced “case stories” we review how systematic trouble shooting progress based on facts, know-how and experience. It is shown how the root course of the problems seen on the system is discovered and solved, so that not only the “symptoms” are being addressed and solved. It will be shown how important it is to find the reel root course of the problems behind expensive compressor failure and damage, to prevent it from happening again after a very short time.

Group 2: Optimization of Industrial R717 systems

In these three seminars we will go through correct / optimal design, construction, and assembly of industrial R717 refrigeration systems. How to make the systems so they will perform with optimum energy efficiency, low service cost and maximum refrigeration capacity. It will be emphasized how the system design is done best possible according to the customers’ needs and at the same time so energy saving as possible. It will be shown how to design so the very dangerous “liquid hammer” in pipes and valves in connection with hot gas defrost is avoided. “Liquid hammer” is the far most dangerous thing in industrial refrigeration systems and has been the “root course” of many of the worst and dangerous accidents with industrial R717 systems, where large amounts of ammonia was released, and people got severely hurt. There are no laws and / or regulations to prohibit design of refrigeration systems where “liquid hammer” can or will happen. It is completely up to the designers to ensure the systems are built in a safe way. Unfortunately, there are only very limited know how among refrigeration engineers in the area of what creates “liquid hammer” and how to avoid it from happening.

Seminar 5: Evaporators, correct circulation rates?
Evaporators, what are the correct circulation rates and why?
Suction lines, risers how do they work and why?
DX systems?
How do liquid separators work and what should be calculated /considered?
How to protect refrigerant pumps?
Dry suction lines, are they always dry?

In this seminar we are looking at the low-pressure side of the refrigeration system. How is an evaporator made correctly according to circulation rates and refrigeration capacity? What do we need to consider when dimensioning “wet” and “dry” suction lines and why? What are the consequences due to energy consumption and capacity on the system? What do you need to consider when liquid separators are dimensioned and why? How do a liquid separator work and what makes it work? Why do refrigerant pumps fail and how is it avoided? Real life “case stories” will show the importance in doing dimensioning and piping the right way.

Seminar 6: How to make the high-pressure side correctly?
Correct piping around the condensers.
HP float valve controlled systems and LP controlled systems, what’s the difference?
How to save energy when doing efficient hot gas defrost instead of using energy?
Liquid hammer, what is it and how to avoid it?
How to build the system efficient in praxis?
What should be considered and what must be secured?

In this seminar we look at the systems high pressure side. What does it mean for the energy consumption that piping is made correctly around the condenser? How can you design the system so hot gas defrost becomes extremely efficient and save energy while defrosting, instead of using energy? How to design, construct and control the system so the very dangerous phenomenon “liquid hammer” is avoided when initiating hot gas defrost? “Liquid hammer is the most dangerous thing we know in industrial refrigeration systems as it can lead to broken pipes and valves and course releases of ammonia, where people are severely injured.

Seminar 7: Screw or reciprocating compressors?
How do they work?
Advantages and disadvantages of them?
Capacity regulation how does it work and why are screw compressor capacity regulation with the capacity slide inefficient?
What is Vi regulation and why is it important?
Screws and VLT drives, what to be careful with?
Economizers, which types and systems are there and how do they work?
What is an economizer port and how can it be used efficiently?

In this webinar we look at reciprocating and screw compressors. How do they work? What are the advantages and disadvantages of them? When should we use either type and for what purpose? What is Vi regulation and why is it so important? Why is a screw compressor so inefficient at part load? What is the relation between slide position and real capacity on screw compressors? How does economizer work and how can the economizer port be used more efficiently with sideload and what to be careful with? How do you use reciprocation and screw compressors most efficient?

Group 3: Heat recovery and heat pumps

In these two seminars we will investigate heat recovery on Industrial refrigeration systems and industrial heat pumps. It is often seen heat recovery equipment is mounted on Industrial refrigeration systems which is not working as it was supposed to and / or even make the refrigeration system work less efficient and use more energy. It demands a great deal of refrigeration know how to install heat recovery equipment correctly on industrial refrigeration systems so both the heat recovery and the refrigeration system will work as it is supposed to. What to be careful with and suggestions to do it correctly will be reviewed and explained. Different types of industrial heat pumps will be reviewed as well as what you should investigate and clarify before investing in an industrial heat pump. We will also investigate which known challenges and or / pitfalls there are when you need to design, mount, control, run and service large industrial ammonia heat pumps. Based on “case stories” from real life uncovers unexpected and mostly unknown problems when running large industrial ammonia heat pumps and we investigate what can be done to avoid these types of problems.

Seminar 8: How to make efficient heat recovery on ammonia refrigeration systems.
Desuperheaters and water-cooled condensers for heat recovery, how to make it work efficient?
Where to be careful?
Ammonia heat pumps how do they work?
Why is it not easy with ammonia heat pumps?
Hybride heat pumps how do they work and what is the experience with them?

We will go through the most common heat recovery initiatives used on industrial ammonia refrigeration systems and the most common refrigeration errors and mistakes made when installing them. The consequences of the refrigeration mistakes and errors and the impact on the refrigeration systems energy consumption and capacity will be explained. What kind of industrial heat pumps are available and what are the advantages and disadvantages of these different types.

Seminar 9: Pitfalls in design, mounting and use of industrial ammonia heat pumps.
What kind of problems have we seen and why?
Case stories with heat pump problems including both screws and recips.
Complicated findings in trouble shooting which no one had expected.
Suggestions on how to avoid these kinds of problems.
Some important lessons learnt and some general guidelines in where to be very careful.

What kind of unexpected pitfalls have shown when running large industrial ammonia heat pumps? By going through uncovered areas of problems and case stories we achieve insights in the often very complex and unexpected problems which have shown to be present when designing, installing, running, and servicing the industrial ammonia heat pumps. Guidelines on what should be considered, investigated, and secured before a large industrial ammonia heat pump is put into operation. We will go through some important “lessons learnt” from very costly experiences with ammonia heat pumps which it will be advisable to take into consideration when these systems are designed and build or you are a customer wanting to buy an industrial heat pump.

Group 4: Industrial CO2 systems

In this seminar we will review industrial CO2/NH3 cascade and CO2 trancritical systems. What are the differences on the two types of systems, what are the advantages and the disadvantages of them? How can they be made and pitfalls when designing and building them? What problems must be considered and solved when using Industrial CO2 transcritical flooded systems, and why will industrial CO2 transcritical system properly take over in the marine area, and on many land-based installations in the future.

Seminar 10: Industrial CO2 refrigeration systems.
CO2/NH3 cascade systems, how to make and control them.
Hot gas defrost, how can it be made?
Oil return systems, valve stations.
Stand still cooling, “power failure (black ship) what happens?
Cascade cooler, capacity regulation.
Defrost compressor, if such one is used.
Moisture in the CO2 system and what to do?
Transcritical industrial CO2 systems what are the problems with these and how to solve them? CO2 transcritical systems with pumped liquid what are the problems?
How can we solve the problems?
What is the future for industrial transcritical CO2 systems?

How can you build a CO2/NH3 cascade system with pump separator and hot gas defrost? Which kind of problems will you have to consider and solve in this type of systems? When and where will this type of systems be an advantage. What kind of problems are we facing on these types of installations? Industrial CO2 transcritical systems what are the advantages and the disadvantages?
Why are these systems nearly always build as DX systems? What must be done, and which problems must be solved before building good CO2 transcritical flooded systems with pump separator and hot gas defrost. Are we going to see more of these systems in the future and why?