Case Study

Restoring Reliable Ammonia Refrigeration Capacity for a Large Manufacturing Site

Case Study

Restoring Reliable Ammonia Refrigeration Capacity for a Large Manufacturing Site

The upgrade restored reliable refrigeration capacity, improved compliance, and established a repeatable technical standard for future compressor replacements across the client’s wider asset base.

TEG Projects helped a large industrial manufacturing site restore safe, reliable ammonia refrigeration capacity after an unplanned compressor failure threatened production continuity. Working closely with site operations, maintenance, contractors, and consultants, the team delivered a staged solution that included a temporary chiller rig, a new screw compressor, and compliance upgrades to keep the plant running. The result was improved reliability, reduced maintenance burden, and a stronger long-term refrigeration system with better compliance and lower overhaul frequency.

Client Information

The client operates a large industrial manufacturing site where refrigeration capacity is critical to maintaining production continuity. In 2024, the site experienced a failure of an existing ammonia compressor, creating an urgent need to restore safe and reliable refrigeration capacity while also addressing compliance gaps identified through a refrigeration audit. Delivery required close collaboration with client operations, automation and maintenance personnel, alongside refrigeration contractors, specialist subcontractors, and third-party consultants
as required, while maintaining live production constraints.

Goal

The objective was to restore safe, reliable ammonia refrigeration capacity following an unplanned compressor failure, while using the opportunity to improve long-term reliability and compliance.

This included:

Implementing a temporary refrigeration solution to maintain operations during replacement works
Replacing the failed reciprocating compressor with a modern screw compressor to improve reliability and reduce maintenance burden
Delivering targeted upgrades to bring the refrigeration services building into full compliance, including ventilation upgrades, shunt trip reconfigurations, and emergency response improvements

A key long-term goal was reducing overhaul frequency from annual to five-yearly intervals, lowering maintenance effort and cost.

Why TEG Projects

TEG Projects was engaged early to guide project delivery and align technical decisions with operational constraints and long-term asset performance goals.

TEG Projects brought:

Proven experience delivering ammonia and refrigeration projects in industrial manufacturing environments
A methodical approach to risk management and compliance
Strong relationships across the refrigeration supply chain
The ability to balance technical outcomes with operational realities in a live production environment

TEG Projects also helped structured the refrigeration audit findings into discrete, manageable compliance projects, supporting faster delivery and clearer prioritisation.

Solution

The project was delivered in stages to minimise refrigeration downtime and maintain production continuity.

TEG Projects scope included:

Facilitating optioneering and concept design for compressor replacement
Managing detailed design by others, procurement, and installation of the new ammonia compressor
Structuring audit findings into discrete compliance work packages
Project managing delivery of ventilation upgrades, shunt trip reconfigurations, and emergency response improvements

To minimise production impact during installation, a temporary chiller rig was deployed to supplement refrigeration load while the new compressor was installed and commissioned.

Challenges

Key challenges included:

Maintaining production continuity while major refrigeration equipment was replaced
Returning the plant to a safe, fully functional condition under tight time constraints
Addressing compliance gaps identified during the refrigeration audit

These challenges were managed through careful planning, close coordination with site teams, and a staged delivery approach—including the use of a temporary chiller rig to reduce refrigeration downtime during installation and commissioning.

Results

Results

The upgrade restored reliable refrigeration capacity, improved compliance, and established a repeatable technical standard for future compressor replacements across the client’s wider asset base.

Outcomes included:

A fully functional ammonia refrigeration plant with improved compliance
Replacement of legacy reciprocating technology with modern screw compressor technology
Reduction in overhaul frequency from annual to five-yearly intervals
Lower long-term maintenance effort and cost
A repeatable compressor upgrade solution suitable for deployment at other sites

By integrating short-term operational needs with long-term reliability improvements, TEG Projects helped the client turn an unplanned failure into a strategic asset. Do you need help from TEG Projects Industrial Plant Services team for an urgent or overdue project?

Capabilities

Service Areas

Project
Management

Construction
Project
Management

Restoring Reliable Ammonia Refrigeration Capacity for a Large Manufacturing Site