PlantPulse provides real-time ammonia refrigeration monitoring for the equipment that actually causes an NH3 release: the compressors, condensers, evaporators, pumps, and vessels at the heart of your system. Instead of waiting for a gas detector to react after ammonia is already in the air, we monitor machine health continuously so failures are caught weeks before they become a leak, a shutdown, or a recordable event.
For cold storage, food processing, and beverage plants, ammonia condition monitoring is also a compliance tool. Continuous vibration, temperature, and pressure trending creates the documented mechanical-integrity evidence that OSHA Process Safety Management (29 CFR 1910.119) and IIAR-6 inspection, testing, and maintenance programs expect — without manual rounds or a SCADA project.
Because PlantPulse installs over cellular in a single day and works on any brand of ammonia compressor, you get predictive maintenance coverage across your whole refrigeration system without IT involvement, network changes, or downtime.
What we monitor on your ammonia system
Sensors on the rotating and heat-transfer equipment that drives reliability and safety.
Screw & reciprocating compressors
Vibration, bearing, and discharge-temperature signatures that flag wear, imbalance, and liquid slugging before catastrophic failure.
Condensers
Fan and motor vibration plus temperature trends that reveal fouling and falling heat-rejection efficiency.
Evaporators
Coil and fan condition tracking so frost, airflow, and defrost problems surface before product is at risk.
Pumps & vessels
Vibration and pressure monitoring on recirculation pumps and key vessels across the NH3 loop.
Precursor failures we catch early
The developing conditions that precede an ammonia release or unplanned shutdown.
Liquid slugging
Abnormal vibration patterns that indicate liquid carryover into a compressor — a leading cause of catastrophic damage.
Bearing & rotor wear
High-frequency vibration signatures weeks ahead of a seized compressor or a seal failure that vents ammonia.
Fouled condensers
Rising temperatures and falling efficiency that drive head pressure — and energy cost — up.
Rising discharge temperature
Trend-based alerts on overheating before lubrication breaks down and damage spreads.
Why plants choose PlantPulse for ammonia
Built for the realities of a regulated, safety-critical refrigeration system.
Same-day cellular install
Sensors mount directly on your ammonia compressors and condensers and stream over cellular the same day — no SCADA tie-in, no plant network, no IT tickets, no capital project.
AI insights in plain language
Our AI models watch vibration, temperature, and pressure trends and tell your team what is failing and roughly when — not just another alarm to triage.
Brand-agnostic & retrofit
Works across mixed and aging fleets regardless of who built the ammonia compressors and condensers. No rip-and-replace, no OEM lock-in.
Audit-ready records
Continuous condition trending is retained for the life of the equipment, giving you documented evidence for inspections, insurers, and internal reliability reviews.
Built for PSM, RMP & IIAR-6
We frame monitoring around the standards your reliability and PSM coordinators actually answer to — and the continuous records they need to prove mechanical integrity.
- OSHA PSM — 29 CFR 1910.119(j) — Continuous trending supports the Mechanical Integrity requirements for covered ammonia refrigeration processes.
- EPA RMP — 40 CFR Part 68 — Documented equipment condition strengthens Risk Management Program prevention and audit posture.
- IIAR-2, IIAR-6 & IIAR-7 — Recognized RAGAEP for ammonia refrigeration design, inspection/testing/maintenance, and operating procedures.
- ANSI/ASHRAE 15 & ISO 20816 — Refrigeration safety and machine-vibration standards that underpin our alert thresholds.
Built for your facility
- Cold storage & warehousing
- Meat & poultry
- Dairy
- Beverage
- Ice rinks
- Pharmaceutical
Questions operations teams ask
Straight answers on installation, coverage, and compliance.
Does condition monitoring help with OSHA PSM and IIAR-6 compliance?
Yes. Continuous vibration, temperature, and pressure trending produces documented mechanical-integrity records that support 29 CFR 1910.119(j) and IIAR-6 inspection, testing, and maintenance requirements.
How is this different from an ammonia gas detector?
Gas detectors react after a release. PlantPulse monitors the compressor, condenser, and evaporator health that causes releases, catching developing failures weeks earlier.
Do I need SCADA integration or IT involvement to install it?
No. Cellular sensors mount directly on the equipment and stream data the same day with no plant-network dependency and no IT tickets.
What ammonia equipment can you monitor?
Screw and reciprocating compressors, condensers, evaporators, recirculation pumps, and key vessels — across mixed and older fleets, regardless of brand.
What is the ROI on ammonia refrigeration monitoring?
Recovering even 5% compressor efficiency on a $500K/yr energy bill is roughly $25K/yr — before counting avoided downtime, product loss, and OSHA/EPA penalty exposure.
Get a same-day ammonia monitoring assessment
Tell us what NH3 equipment you run and we will scope the fastest path to live, audit-ready monitoring.