This expanded three-day intensive training program provides mechanical and electrical engineers, senior foremen, foremen, and AC technicians with comprehensive, industry-focused expertise in AC and Chiller Plant Maintenance, Overhauling, and Troubleshooting. Designed to meet the rigorous demands of marine and industrial applications, the course offers an in-depth progression from fundamental principles to advanced diagnostic and repair procedures. Participants will master the complete technical workflow—from initial plant inspection and component evaluation to advanced compressor overhaul, precise refrigerant management, systematic troubleshooting, and final commissioning.
The additional day allows for deeper exploration of complex fault scenarios, hands-on practical workshops, and advanced system optimization techniques, ensuring attendees can confidently address both routine maintenance and unexpected system failures. Through a blend of theoretical instruction, detailed case studies drawn from real-world SOW requirements, and practical demonstrations, this program enhances participants’ understanding of engineering design, manufacturing standards, and calculation methodologies, ultimately empowering them to ensure peak plant reliability, operational safety, and maintenance excellence.
COURSE OBJECTIVES
Upon completion of this course, participants will be able to:
- Conduct comprehensive pre-maintenance plant inspections and accurately document all operational parameters.
- Systematically inspect, test, and evaluate the condition of all critical system components, including sensors, valves (mechanized, NRV, solenoid, expansion), evaporators, and hot/cooled lines.
- Perform effective leak detection and testing on system lines and evaporators using appropriate methods like cooling tests.
- Utilize system schematics and engineering drawings to identify components, understand system configuration, and locate correct spare part numbers.
- Execute detailed compressor disassembly, inspection, overhauling, and reassembly procedures following manufacturer specifications.
- Demonstrate proficiency in using a micron gauge to achieve and verify proper system evacuation levels before recharging.
- Accurately calculate required refrigerant charge and perform correct oil level management to ensure system lubrication and efficiency.
- Apply structured troubleshooting methodologies to diagnose a wide range of common and complex system failures, identifying root causes.
COURSE METHODOLOGY
At Intelliness, our training methodology is built around delivering meaningful learning experiences that translate into real workplace capabilities. Each program is carefully engineered to blend theory with practice, ensuring participants not only understand the concepts but can confidently apply them on the job.
Engaging Learning Environment
Sessions are conducted using real case studies, scenario-based discussions, and collaborative activities that encourage critical thinking and practical problem-solving.
Practical Skill Application
Participants take part in structured hands-on exercises and simulations designed to mirror real operational challenges, enabling them to develop confidence through doing—not just listening.
Smart Learning Tools
Our programs leverage modern digital platforms, including LMS-based modules, interactive content, and online resources that support flexible learning and continuous progress monitoring.
Ongoing Evaluation & Guidance
Regular checkpoints, quizzes, and facilitator feedback help track understanding, close knowledge gaps, and ensure each learner progresses at the right pace.
After-Training Reinforcement
To promote long-term retention, we provide post-training materials, optional follow-up sessions, and access to expert guidance, ensuring learners can continue applying their skills effectively beyond the classroom.
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Module 1: Introduction to Marine & Industrial AC & Chiller Plants- Overview of system thermodynamics and operational principles.
- Detailed review of typical system components and their functions.
- Key engineering, design, and manufacturing considerations for reliability.
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Module 2: Pre-Maintenance Assessment & Plant Inspection
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- Protocol for initial plant inspection and safety checks.
- Techniques for accurate recording of operational parameters (pressures, temperatures, currents).
- Inspection of electrical connections, control panels, and instrumentation.
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Module 3: Detailed Component Inspection & Testing
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- Hands-on inspection of various valve types: operation, leakage, and failure signs.
- Evaporator and condenser inspection procedures.
- Practical session on leak testing for lines and components using nitrogen and bubble tests.
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Module 4: Compressor Overhauling – Theory & Practice
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- Study of compressor drawings, internal components, and assembly sequences.
- Step-by-step guided practice on compressor disassembly and reassembly.
- Criteria for part inspection, wear assessment, and replacement decisions.
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Module 5: System Evacuation, Dehydration & Charging
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- Principles of deep vacuum and use of micron gauges.
- Workshop on proper system evacuation techniques and vacuum decay testing.
- Methods for calculating and charging refrigerant, including subcooling/superheat measurement.
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Module 6: Lubrication & Refrigerant Management
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- Oil types, viscosity, and system compatibility.
- Procedures for checking, draining, and replacing compressor oil.
- Environmental regulations and safe handling of refrigerants.
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Module 7: Advanced Systematic Troubleshooting
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- Developing a diagnostic approach based on symptom analysis.
- Troubleshooting common issues: poor cooling, high head pressure, compressor short cycling, electrical faults.
- Analysis of sensor and actuator failures within the control loop.
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Module 8: Practical Case Studies & Problem-Solving Workshop
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- Interactive session on real-world scenarios from marine applications.
- Group exercises to diagnose complex faults using system drawings and simulated data.
- Developing and presenting repair action plans.
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Module 9: Commissioning, Performance Testing & Handover
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- Final pre-start checks and safe plant startup procedure.
- Monitoring and recording all parameters during initial run-up.
- Commissioning checklist completion, performance validation, and documentation for handover.
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