Design of Ammonia Refrigeration Systems for Peak Performance and Efficiency

Day 1

Welcome and Introduction

Design Considerations for Energy Efficiency

• Review of systems: single-stage, DX, flooded, overfed, and multi-stage systems
• Energy efficiency considerations for industrial refrigeration systems

Load Calculations and Psychrometrics

• Temperature requirements
• Load types: envelope, product, internal, equipment, infiltration
• Psychrometrics review
• Sensible and latent loads
• Infiltration loads: theory vs. real-world
• Rules-of-thumb

Load Calculation Workshop Load Calculation Workshop (continues) Evaporators

• Types
• Performance characteristics
• Manufacturer's rating methods
• Selection process
• Energy efficiency considerations
• Variable speed drive fans

Assign Homework – Class Design Project

• Preliminary refrigeration system layouts
• Load calculations
• Evaporator selection/layout

Adjourn to Work on Class Project

Day 2

Homework Review Valves and Valve Selection

• Valve types and uses
• Actuating methods (direct-acting, pilot-operated)
• Installation considerations
• Typical valve groups
• Safety considerations
• Energy efficiency considerations

Condensers

• Performance characteristics
• Sizing considerations
• Selection
• Fan alternatives and methods of control
• Energy efficiency considerations

Condenser Selection Workshop

• Types: high-pressure receiver, thermosiphon, low-pressure accumulator, flash intercooler
• Configurations: horizontal or vertical
• Ratings
• Proper practices for system integration
• Knock-out velocity
• Down-comer sizing
• Refrigerant level control (floats, capacitance probes)

Vessel Sizing/Selection Workshop

Assign Homework

• Evaporator valve selection and valve train layout

Adjourn to Work on Class Project

Day 3

Homework Review Liquid Refrigerant Pumps

• Pump types and performance curves
• Net positive suction head: required and available
• Pump selection
• Energy efficiency considerations

Compressors

• Compressor ratings
• Full-load and part-load operation
• Oil cooler heat rejection methods (screw compressors)
• Volume ratio (fixed and variable)
• High stage and booster selection
• Energy efficiency considerations

Compressors (continued)

Class Design Project Assign Homework

• Select compressors
• Select condensers

Adjourn to Work on Class Design Project

Day 4

Homework Review Refrigerant Piping

• Sizing vapor lines (suction, discharge, hot gas)
• Liquid line sizing
• Wet return line sizing
• Piping practices to minimize potential for hydraulic hammer
• Riser pipe sizing practices
• Energy efficiency considerations

Refrigerant Piping Workshop Heat Recovery Opportunities

• Assessing the potential for heat recovery in ammonia systems
• Heat recovery options Design Project

Assign Homework

• Class design project

Adjourn to Work on Class Design Project

Day 5

Homework Review

Finalize Design Project

Design Project Presentations

Question/Answer Session

This course is part of the Process Safety Management Professional Certificate. Increase your knowledge and effectiveness at managing PSM/RMP programs for your ammonia refrigerated facility, while earning a recognized credential. Course can be taken individually as well.

Attendees participating in this course will be able to earn a digital badge as evidence of the knowledge they obtained during the course. Digital badges are micro-credentials that can be earned by successfully passing a final quiz administered online after completing the course. Find more information on digital badges.

Registration Date/Time:
9/8/2025 7:30am Central Time

Event Dates/Times:

• 9/8/2025  8:00am - 8:00pm Central Time
• 9/9/2025  8:00am - 8:00pm Central Time
• 9/10/2025  8:00am - 8:00pm Central Time
• 9/11/2025  8:00am - 8:00pm Central Time
• 9/12/2025  8:00am - 2:00pm Central Time

• Program Director

  Douglas Reindl

• Marc Claas

  Researcher

  Marc Claas is an Associate Researcher with the Industrial Refrigeration Consortium, specializing in industrial refrigeration since 2009. He focuses on system maintenance, safe operation, troubleshooting, and regulatory compliance, with a growing interest in emerging cooling technologies. Marc has led online operator training programs and brings extensive field experience in Process Safety Management (PSM), including audits and Process Hazard Analyses (PHAs). He also investigates energy efficiency and operational improvements in refrigeration systems. Marc holds a B.S. in Mechanical Engineering from UW-Platteville and an M.S. in Mechanical Engineering with a focus on Thermal Sciences from UW-Madison. He is an active member of the International Institute of Ammonia Refrigeration.

• Todd Jekel

  Assistant Director

  Todd Jekel, PhD, PE is the Assistant Director of the Industrial Refrigeration Consortium (IRC) at the University of Wisconsin–Madison, where he leads applied research and technical outreach in industrial refrigeration. His work focuses on system and component modeling, refrigeration load and energy calculations, accumulator design, and safety relief vent systems. Dr. Jekel has contributed to the development and instruction of several web-based and in-person courses for refrigeration professionals, covering topics such as ammonia refrigeration, process safety, and energy efficiency. He holds degrees from Calvin College and the University of Wisconsin–Madison. In addition to his academic and research roles, he is an active member of ASHRAE and the International Institute of Ammonia Refrigeration (IIAR), serving on multiple technical committees. Dr. Jekel is recognized for his expertise in vessel design, oil separation, and dehumidification strategies for cold storage facilities.

• Douglas Reindl

  Professor

  Douglas Reindl, PhD, PE is a professor in the Department of Mechanical Engineering and a Program Director at the Office of Interdisciplinary Professional Programs at the University of Wisconsin–Madison. He brings extensive expertise in mechanical systems, with a particular focus on industrial ammonia refrigeration. As the founding director of the Industrial Refrigeration Consortium, Dr. Reindl is dedicated to advancing the safety, efficiency, and reliability of refrigeration infrastructure. He holds a BS in Mechanical Engineering Technology from the Milwaukee School of Engineering, and both MS and PhD degrees in Mechanical Engineering from UW–Madison. A registered professional engineer in Wisconsin, Dr. Reindl is widely recognized for his leadership in refrigeration education and applied research.

• Bent Wiencke

  Mechanical Engineer

  Bent Wiencke has 35 years of experience in the industrial refrigeration industry specializing in the design, optimization, operation, and installation of refrigeration systems. Throughout his international career he has worked for contractors, original equipment manufacturers (OEMs) and end-users. His broad work experience includes the food and beverage industry, marine industry, petrochemical and chemical industry using a wide range of refrigerants, such as: Ammonia, CO2, Hydro-Carbons, CFCs, HCFCs and HFCs. Bent is a longtime International Institute of Ammonia Refrigeration (IIAR) member and has been an active participant in the work of the IIAR Research Committee. In addition, he was a two-term member of the IIAR Board of Directors from 2010 to 2016. Throughout the years he contributed to the industry with numerous papers as well as championed numerous research and safety topics. In 2008 he won the "Andy Ammonia Award" for best paper. He has a MS and BS in Mechanical Engineering.

There will be optional workshop time from 5:00 PM - 8:00 PM Day 1-4.

This in-person course will have an online course site from which you will access the course materials, course evaluation, and participation certificate. Details on how to access the online course site will be sent with registration confirmation.

If you are planning to attend an Interdisciplinary Professional Programs course, payment is required at the time of registration. Below are the payment options:

Pay by Credit Card

Enroll online and pay by credit card.

• Search for the course on the website and then click on the Enroll Now button from the course webpage.
• Enter all necessary course attendee information and payment information on the course enrollment page.
• You will receive an email to confirm successful enrollment and payment.

Enroll over the phone and pay by credit card.

• Call CERC Registrations at 608-262-2451.
• Provide the registrations representative with:
  • the course name, dates, and/or course number.
  • the necessary course attendee information and payment information.
• You will receive either a mailed document or an email to confirm successful enrollment payment.

Pay by Check

Mail in a completed registration form and check payable to UW Madison.

• Fill out a registration form (found either in the back of the course brochure you received in the mail or here).
• Prepare a check, made payable to UW Madison.
• Mail the registration form and check to: CERC Registrations 21 N Park St, Ste 7101 Madison, WI 53715
• You will receive either a mailed document or an email to confirm successful enrollment and payment.

Pay by Purchase Order

• Request Purchase Order information from interpro@union.wisc.edu
  • If a fee quote is needed, contact custserv@interpro.wisc.edu first
• You will receive an invoice from UW–Madison Business Services for payment, usually within 3–5 business days

Military

If using SF-182 form, please call our registration number at 608-262-2451 or email interpro@union.wisc.edu for details and instructions.

Event Cancellation

We reserve the right to cancel a course due to insufficient enrollment or unforeseen events. If we cancel a course, participants will be notified via email or phone and will be given the option for a full refund or to transfer their registration and any fees paid to another course. We are not responsible for non-refundable plane tickets, hotel reservations, and other travel related expenses. For enrollee Course Cancellation, refer to notes on course page.

If you cannot attend, please notify us no later than one week before your course begins, and we will refund your fee. Cancellations received after this date and no-shows are subject to a $150 administrative fee. You may enroll a substitute at any time before the course starts.