Operations and Maintenance of Propane Refrigeration Systems

Introduction:

This unit in the series of Propane Refrigeration System, Operations, and Maintenance training focuses on refrigeration system operation, covering its fundamental principles. It provides an overarching account of all mechanical components of the refrigeration cycle, including the surge drum, expansion valve, chiller, refrigeration compressor, and condenser.

In this course, learners will engage with the design, operational control, maintenance, efficiency enhancement, and troubleshooting of refrigeration systems for natural gas processing plants. Upon completing this unit, trainees will gain knowledge and hands-on experience with natural gas propane refrigeration systems and propane refrigeration plants.

Propane refrigeration is a complex process that can be best understood through a combination of text and visual aids. This training program includes advanced training courses featuring illustrations and charts on the refrigeration cycle, outlining its flow and components to enable trainees to fully comprehend propane refrigeration units and packages.

Objectives:

At the end of this Operations and Maintenance of Propane Refrigeration Systems course, the following broad goals will have been achieved:

• Recognize characteristics of propane refrigerant.
• Evaluate factors responsible for heat transfer.
• Develop a conceptual design of a propane refrigeration system.
• Use and operate a propane refrigeration system.
• Manage the control of a propane refrigeration system.
• Troubleshoot and repair problems in a propane refrigeration system.
• Evaluate the functioning of a propane refrigeration design.
• Maintain a propane refrigeration system.

Training Methodology:

• Lectures and presentations
• Interactive demonstrations
• Hands-on practical sessions
• Group discussions and case studies
• System design simulations
• Troubleshooting exercises
• Visual aids and diagrams
• Assessment quizzes and feedback

Course Outline:

Unit 1: Fundamentals

• Introduction to Refrigeration
• Propane Properties
• Heat Transfer
• Refrigeration Systems
• Basic Refrigeration Cycle
• Refrigeration Components
• Secondary Cooling Systems

Unit 2: Design, Operation, and Control of Propane Refrigeration System Components Cycle

• Overview of typical single-stage propane refrigeration systems
• Propane surge drum and pump loading
• Float-type expansion valves in refrigeration systems
• Functions and construction of propane chillers within the refrigeration cycle
• Economizers and the propane refrigeration process improvement
• Emphasis on propane condensers and other refrigeration system components

Unit 3: Propane Refrigeration Centrifugal Compressor

• Introduction to Centrifugal Compressor Principles
• Understanding the working of Conventional Centrifugal Compressors in Propane Refrigeration
• Integration of Ideal Centrifugal Compressors in System
• Discussion on Multi-Stage and Axial Compressors
• Components: Casings, Rotors, Guide Vanes
• Disintegration of Diffuser and Volute, Diaphragms, and Shaft Seals
• Compressor parts: Shaft Bearings, Lubricating Systems, Seal Oil Systems
• Cooling System principles, Drivers, Couplings, and Controls
• Compressor Performance, Surging, safety devices, and their classification

Unit 4: Propane Refrigeration Reciprocating Compressor

• Operating Principles of a Reciprocating Compressor
• Gas Compression and its role in propane refrigeration systems
• Profiles of Compressors suitable for propane refrigeration
• Piston mechanism and operating mechanisms of Reciprocators
• Components of the compression unit and processes involved
• Description of compressor valves, air cooling methods, and water cooling methods
• Lubrication of the Cylinder and Compression Unit
• Wiper or Scraper Rings, Clearances, Pockets, and Unloaders
• Power pack assembly: drive unit, crank assembly, cross head, and connecting rod
• Power Units: Balanced-Opposed, Integral, and Multi-Stage Units

Unit 5: Propane Refrigeration Troubleshooting and Efficiency Improvement

• Performance indicators and verifications necessary for efficient functioning
• Importance of active operational checks for system usability and reliability
• Identifying operating problems, their causes, and solutions
• Refrigeration System Controls – Options and Applications
• Understanding operation characteristics and overcoming challenges
• Fouling control in propane refrigeration units
• Types of maintenance and developing a maintenance plan