Design and Installation of Ammonia Compressor Panel
- Category: Sustainability
This project involved the redesign and complete replacement of the ammonia compressor control panel, a critical component responsible for operating the main freezer and cold room at the client’s facility. The original panel was over 30 years old, and despite minor repairs over the years, it had reached the end of its service life. It lacked up-to-date drawings, making troubleshooting and system control increasingly difficult.
Adding to the complexity, the project had to be executed during one of the coldest weekends in February, as this was the only window when the plant could afford to shut down the chillers. The tight space within the upgraded compressor room, coupled with the risk of ammonia odor buildup due to disabled fans during the power outage, presented unique technical and safety challenges.
Our scope of work was divided into three key phases:
Phase 1: Planning & Pre-Installation
Several months before the installation, we conducted a detailed site survey to document all existing equipment and control systems. Each unit was clearly tagged and mapped, allowing us to pre-design a custom base panel that would fit within the confined space and be light enough to carry by hand into the compressor room.
Phase 2: Panel Replacement & Installation
Once the system was powered down:
- All incoming and outgoing connections to the old panel were carefully marked and traced back to their corresponding equipment.
- The hole pattern from the original panel was transferred directly to the new one to allow seamless connection of existing conduits.
- The new panel was positioned, aligned precisely with existing pipe entries, and securely installed.
- Wiring was routed and organized to ensure safe, efficient operation.
Phase 3: Control System Integration
In this phase:
- We traced all existing control logic from the old system.
- Smart relays were programmed, and auxiliary contacts were rewired to integrate into the new control panel.
- The system was reconfigured for improved control and reliability.
This phase was essential in laying the groundwork for future manufacturing, upgrades, and maintenance.
Phase 3: Control System Integration
In this phase:
- We traced all existing control logic from the old system.
- Smart relays were programmed, and auxiliary contacts were rewired to integrate into the new control panel.
- The system was reconfigured for improved control and reliability.
This phase was essential in laying the groundwork for future manufacturing, upgrades, and maintenance.
Commissioning & Handover
After 36 continuous hours of work, the new panel was fully installed and ready for commissioning. Each function—from motor direction to defrost cycles—was individually tested, verified, and optimized for peak performance.
The system was brought back online within the scheduled downtime, and the plant was able to resume operations immediately, now supported by a modern, reliable control system built for longevity and efficiency.
