YPS 280 – Industrial Refrigeration Controls
Who this course is for
This course is designed for industrial refrigeration technicians, operators, engineers, and commissioning personnel who work with compressor control panels, system automation, and safety devices. It is applicable to both field service and plant operations roles.
Why this course matters
Modern industrial refrigeration systems rely heavily on automated controls to maintain stable suction pressure, manage refrigerant flow, protect compressors, and ensure safe operation. Poor control logic or improper tuning can lead to frequent trips, accelerated wear, high energy consumption, or unsafe conditions. This course explains how controls actually behave in refrigeration systems and how to interpret their responses.
Course Sections
Control Theory
Foundations of error‑based control and response behavior.
Controlling Digital Devices
On/off control, deadbands, and mechanical protection.
Controlling Analog Devices
PI and PID control applied to refrigeration equipment.
Tuning PI Loops
Practical tuning strategies for large refrigeration systems.
Compressor Capacity Control
Matching compressor output to system load efficiently.
Refrigerant Flow Control
Liquid control methods for evaporators and vessels.
Head and Stage Pressure Control
Maintaining stable pressure differentials for efficiency and reliability.
Compressor Safeties
Critical protection systems and shutdown logic.
Types of Control Systems
Microprocessor, PLC, and DCS control architectures.
Hazardous Area Classifications
Electrical classifications and risk mitigation methods.
Controls Installation
Signal integrity, EMI prevention, and installation best practices.
- Teacher: Don Faust
YPS 210 – Reciprocating Compressors
Who this course is for
This course is intended for industrial refrigeration technicians, operators, and maintenance personnel who work with reciprocating compressors in ammonia or halocarbon systems. It is also valuable for engineers, service supervisors, and commissioning personnel who need a solid working knowledge of reciprocating compressor operation and limitations.
Why this course matters
Reciprocating compressors remain widely used in industrial refrigeration for smaller loads, trim service, and specific process applications. Understanding how they operate—and where their limits are—is essential to preventing high discharge temperatures, lubrication failures, and unstable operation at part load. This course focuses on practical operating behavior rather than theory alone, helping technicians make informed decisions in the field.
Course Sections
Types of Compressors
Overview of compressor categories used in industrial refrigeration, including reciprocating, screw, and centrifugal compressors. Focuses on operating principles, flow characteristics, and where reciprocating compressors are best applied.
Characteristics of Reciprocating Compressors
Detailed look at reciprocating compressor construction, drive arrangements, pressure ratio limits, and capacity calculations. Covers swept volume, volumetric efficiency, and how compression ratio affects performance.
Cooling and Lubrication Methods
Explains lubrication systems, oil cooling requirements, and oil management practices. Covers common cooling methods and how oil is separated, recovered, and returned to maintain reliability.
Capacity Control
Describes part‑load operation using cylinder unloading and hot gas bypass. Emphasizes maintaining stable suction conditions, avoiding overcooling, and understanding minimum capacity limits.
- Teacher: Don Faust
YPS 210 – Screw Compressors
Who this course is for
This course is designed for industrial refrigeration technicians, operators, maintenance personnel, and engineers who work with oil‑injected screw compressors in ammonia and halocarbon systems. It is well suited for those responsible for operation, troubleshooting, maintenance planning, or system optimization.
Why this course matters
Screw compressors are widely used in industrial refrigeration due to their reliability, broad capacity range, and ability to operate at high compression ratios. However, improper application, incorrect volume ratio selection, or poor capacity control can significantly reduce efficiency and equipment life. This course focuses on how screw compressors actually behave in operating systems and how design choices affect power, stability, and reliability.
Course Sections
Introduction to Screw Compressors
Overview of screw compressor operation, geometry, and oil‑injected design.
Application Limits
Defines practical operating limits for pressure, temperature, capacity, and materials.
Compression Process
Step‑by‑step comparison of screw and reciprocating compression cycles.
Discharge Ports
Explains axial and radial ports and how discharge timing affects efficiency.
Volumetric Efficiency
Shows why screw compressors maintain higher volumetric efficiency at high ratios.
Volume Ratio
Covers internal vs system volume ratio, efficiency losses, and variable Vi benefits.
Capacity Control Methods
Compares slide valve and variable speed control strategies and their limitations.
Mechanical Parts of a Screw
Identifies major internal and external compressor components.
Compressor Bearings
Explains bearing load management, lubrication needs, and design choices.
Benefits of Anti‑Friction Bearings
Details efficiency, reliability, and maintenance advantages.
Vibration Analysis of Screws
Introduces predictive maintenance techniques for bearing health.
Shaft Seals
Compares seal designs and explains leakage prevention strategies.
Economizers and Side Loads
Explains secondary suction concepts and efficiency improvements.
Oil Separation
Describes oil separation methods and velocity‑related risks.
Oil Cooling
Compares oil cooling techniques and selection criteria.
Compressor Assemblies
Reviews common screw compressor package designs and configurations.
- Teacher: Don Faust
YPS 230 – Auxiliary Components and Piping
Who this course is for
This course is designed for industrial refrigeration technicians, maintenance personnel, engineers, and system designers responsible for equipment beyond the compressor. It is suitable for those involved in system design, installation, operation, troubleshooting, or modernization of ammonia and industrial refrigerant systems.
Why this course matters
Auxiliary components and piping determine how well a refrigeration system protects its compressors, manages refrigerant and oil, and operates safely and efficiently under changing conditions. Poor vessel selection, improper piping design, or inadequate oil and refrigerant management can result in capacity loss, equipment damage, or safety risks. This course focuses on practical application rather than theory, helping personnel understand why systems behave as they do.
Course Sections
Pressure Vessels
Construction, function, and application of refrigeration pressure vessels.
Specifying Vessels
Design pressure, minimum temperature, corrosion allowance, and PWHT considerations.
High Pressure Receivers
Liquid refrigerant storage and pressure balancing on the high side.
Suction Accumulators
Protection of compressors from liquid carryover during system upsets.
Refrigerant Transfer and Recovery
Methods for moving refrigerant safely during maintenance.
Purgers
Removal of non‑condensable gases to improve efficiency and reliability.
Oil Management
Behavior of oil in refrigeration systems and oil separation methods.
Piping Codes and Standards
Applicable U.S. codes governing refrigeration piping design and inspection.
Refrigerant Piping Guidelines
Velocity limits, pressure drop, equivalent length, and layout practices.
- Teacher: Don Faust
YPS 250 – Heat Exchangers
Who this course is for
This course is designed for industrial refrigeration technicians, operators, engineers, and system designers who work with condensers, evaporators, and secondary refrigerant systems. It is applicable to food and beverage, cold storage, process cooling, and industrial refrigeration facilities.
Why this course matters
Heat exchangers determine how efficiently a refrigeration system moves heat, and small design or operating compromises can result in large energy penalties or reliability issues. Understanding how heat exchangers actually perform—rather than how they are rated—is essential for troubleshooting capacity shortfalls, high condensing pressures, unstable evaporators, and excessive pumping costs. This course emphasizes practical behavior under real operating conditions.
Course Sections
Heat Transfer
Foundations of heat transfer and the governing equation.
U – The Heat Transfer Coefficient
Material selection, fouling, and resistance to heat flow.
Area and Temperature Difference
Surface area, TD, LMTD, and exchanger ratings.
Heat Transfer Fluids
Water and secondary refrigerants used in industrial systems.
Selecting Brines
Freeze protection, viscosity, pumping cost, and efficiency tradeoffs.
Condensers
Heat rejection methods and condenser classifications.
Evaporative Condensers
Wet bulb performance, draft types, and maintenance considerations.
Non‑Evaporative Condensers
Air‑cooled, adiabatic, and water‑cooled alternatives.
Flooded Evaporators
High‑capacity boiling systems and submergence effects.
DX Evaporators
Low‑charge evaporators with superheat control.
Thermosiphon Evaporators
Natural circulation evaporators and process applications.
Overfeed Units
Pump‑driven evaporators with high surface utilization.
- Teacher: Don Faust