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For Official Use Only

Ammonia RefrigerationAmmonia Refrigeration

RAGAGEPsRAGAGEPs

For Official Use Only

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Objectives

Gain a basic understanding of: Gain a basic understanding of: – RAGAGEPs unique to Ammonia

RefrigerationRefrigeration– Equipment-specific RAGAGEP

requirementsrequirements

Again, this is an overview discussion. There is usually an exception to most rules

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RAGAGEP Organizations

ASME ASME

ANSI /ASHRAE

IIAR

NB NB

NIOSH

RMA

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ASME / NB

BPVCDesign, fabrication, inspection, testing and certification of vessels operating above 15 psig (internal and/or external)psig (internal and/or external)

B31.5Refrigeration Piping and Heat Transfer Components

NBIC NB-23In-service inspections, repairs, alteration, re-

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rates

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ANSI / ASHRAE

ANSI/ASHRAE 15 ANSI/ASHRAE 15Safety Standard for Refrigeration SystemsRefrigeration Systems

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IIAR

Process Safety Management Guidelines for Ammonia Refrigeration (update coming soon)

Ammonia Refrigeration Piping Handbook

Ammonia Data Book Ammonia Data Book(chemical and technology PSI resource)

Oil D i i G id li Oil Draining Guidelines

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IIAR

ANSI/IIAR Standard 2Equipment, Design, and Installation of Closed-Circuit Ammonia Mechanical Refrigeration SystemsRefrigeration Systems

Bulletin No. 107Suggested Safety and Operating Procedures When Making Ammonia Refrigeration Plant Tie InsRefrigeration Plant Tie-Ins

Bulletin No. 108

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Guidelines for Water Contamination in Ammonia Refrigeration Systems

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IIAR

Bulletin No. 109Guidelines for IIAR Minimum Safety Criteria for a Safe Ammonia Refrigeration System

Bulletin No. 110Guidelines for Start-Up, Inspection, and Maintenance of Ammonia Mechanical Refrigeration Systems

Bulletin No. 111Guidelines for Ammonia Machinery Room

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Ventilation

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IIAR

Bulletin No. 112Guidelines for Ammonia Machinery Room Design

Bulletin No. 114Guidelines for Identification of Ammonia Refrigeration Piping and System Components

Bulletin No. 116Bulletin No. 116Guidelines for Avoiding Component Failure in Industrial Refrigeration Systems Caused by

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Abnormal Pressure or Shock

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NIOSH

Publication No. 79-120Working Safely with Anhydrous Ammonia

Publication No. 79-119A Guide for Developing a Training Program for Anhydrous Ammonia Workers

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RMA

Publication IP-14Publication IP 14Specifications for Anhydrous Ammonia Hose

Publication IP-11-2 Hose Technical Bulletin - Manual for UseHose Technical Bulletin Manual for Use, Maintenance, Testing, and Inspection of Anhydrous Ammonia Hose

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ANSI/ASHRAE 15

Safety Code for Mechanical RefrigerationSafety Code for Mechanical Refrigeration

Establishes safeguards for personnel and propertyproperty

Applies to:– Design, construction, test, installation,

operation, and inspection– Modifications (non-RIK)– Substitutions of refrigerants

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Subst tut o s o e ge a ts

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ANSI / IIAR Standard 2

Standard for Equipment, Design & Installation of Ammonia Mechanical Refrigerating Systems

Applies to closed-circuit mechanical refrigeration systems

Provides minimum requirements for:Equipment– Equipment

– Machinery room design

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– Installation of systems

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IIAR Bulletin No. 109

Minimum Safety Criteria for a SafeMinimum Safety Criteria for a Safe Ammonia Refrigeration System

Identifies mandatory safety requirements Identifies mandatory safety requirements

Provides safety inspection checkliststo be performed annually

References other codes and standards as e e e ces ot e codes a d sta da ds asbasis for checklists

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IIAR Bulletin No. 110

Start-Up, Inspection, and Maintenance ofStart Up, Inspection, and Maintenance of Ammonia Mechanical Refrigerating Systems

Startup StartupPSSR, Evacuation, Dehydration, Leak Checking, Charging Testing Protective DevicesCharging, Testing Protective Devices

I&MSystem Log/inspection Compressors PVs andSystem Log/inspection, Compressors, PVs, and HEs, Pumps, Valves, Piping, Oil, Motors

Provides example ITPM planSlide 16

– Provides example ITPM plan

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IIAR Bulletin No. 110

System log/inspection – at least dailySystem log/inspection at least daily (example in Appendix I)

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IIAR Bulletin No. 110

Appendix GAppendix G

Typical Inspection and Maintenance Plan

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IIAR Bulletin No. 111

Ammonia Machinery Room VentilationAmmonia Machinery Room Ventilation

Ventilation DesignEAC Emergency Vent Rate FanEAC, Emergency Vent Rate, Fan Selection & Layout, Detectors, Controls

Operation & MaintenanceFans/Intakes, Room Pressure, Detectors, ControlsControls

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IIAR Bulletin No. 111

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IIAR Bulletin No. 114

Identification of Ammonia RefrigerationIdentification of Ammonia Refrigeration Piping and System Components

Comprehensive labeling scheme Comprehensive labeling scheme– Label size– Colors– Locations– Label material requirements

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Equipment-specific Requirements

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Alarms & Detectors

Each machinery room is equipped withEach machinery room is equipped with ammonia detection that alarms and starts ventilation at a concentration of no higher than 1,000 ppm (ASHRAE-15, 8.11.2.1)

Detector alarms annunciate with visualDetector alarms annunciate with visual and audible means both inside and outside each entrance to machinery room (ASHRA-15, 8.11.2.1)

Alarm is triggered when the continuous

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Alarm is triggered when the continuous ventilation system fails (IIAR-111, 3.5.3)

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Alarms & Detectors

A high-range detector will automaticallyA high range detector will automatically shut down all unclassified equipment in the machinery room at no more than 15,000 ppm (IIAR-111, 3.5.2)

Must be manual reset type with the resetMust be manual reset type with the reset located inside the refrigerating machinery room (ASHRAE-15, 8.11.2.1)

The meaning of each alarm shall be clearly marked by signage near the

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clearly marked by signage near the annunciators (ASHRAE-15, 8.11.2.1)

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Compressors

Fitted with high pressure cutoutsFitted with high pressure cutoutsthat unload the machine at 90% of the pressure relief valve set pressure (ASHRAE-15, 9.9)

Moving parts are guardedMoving parts are guarded(ASHRAE-15, 8.2)

Located such that there is Located such that there is unobstructed access for both normal and emergency tasks

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normal and emergency tasks (ASHRAE-15, 8.3)

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Compressors

Must have both suction and dischargeMust have both suction and discharge shut-off valves (ASHRAE-15, 9.12.4)

Fitted with nameplates that include: Fitted with nameplates that include: manufacturer, identification number, design pressures and refrigerant useddesign pressures, and refrigerant used (IIAR-2, 6.1.4)

Each must be identified with signage with Each must be identified with signage with lettering greater than 0.5" in height (ASHRAE-15 11 2 2)

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(ASHRAE 15, 11.2.2)

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Compressors

Each compressor has a high dischargeEach compressor has a high discharge temperature and pressure cutout(IIAR-2, 6.1.2.2)

Each compressor has a low suction pressure cutout (IIAR-2 6 1 2 2)pressure cutout (IIAR 2, 6.1.2.2)

Each compressor package with an oil pump has an oil flow failure indicatorpump has an oil flow failure indicator(more than just checking oil pressure and DP) (IIAR-2 6 1 2 2)

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DP) (IIAR 2, 6.1.2.2)

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Design Pressures

High-side components on systemsHigh side components on systems– 250 psig - evaporative condensing

300 psig air cooled condensing– 300 psig – air-cooled condensing(IIAR-2, 6.1 and 9.1)

Low-side components are rated for MAWPs of 150 psig or greater (IIAR-2, 9 1)9.1)

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Machinery / Engine Room

Head room of at least 7.25 ft below equipment it t d (ASHRAE 15situated over passageways (ASHRAE-15,

8.11.1)

Self-closing, tight-fitting doors that open outward (ASHRAE-15, 8.11.2)

No other wall penetrations that would allow ammonia tothat would allow ammonia to other parts of building (ASHRAE-15, 8.11.2)

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( , )

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Machinery Room

Emergency ventilation amount is greaterEmergency ventilation amount is greater than 100 times the square-root of the charge of refrigerant in pounds(ASHRAE-15, 8.11.5)

Continuous ventilation amount is at leastContinuous ventilation amount is at least 0.5 cfm/ft2 or 20 cfm/person(ASHRAE-15, 8.11.5 and IIAR-111, 3.2.3)

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Machinery Room

Does not permanently contain equipmentDoes not permanently contain equipment with continuous operating surface temperatures in excess of 800°F[ASHRAE-15, 8.12(a)]

Walls are noncombustible and at leastWalls are noncombustible and at least one-hour fire resistive construction [ASHRAE-15, 8.12(c)]

At least one door opens directly outside but not under a fire escape/open stairway

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but not under a fire escape/open stairway [ASHRAE-15, 8.12(d),(e)]

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Machinery Room

Emergency shutdown control of is locatedEmergency shutdown control of is located immediately outside of the machinery room door [ASHRAE-15, 8.12(i)]

Emergency ventilation fans are on a separate electrical circuit and have aseparate electrical circuit and have a control switch immediately outside of the machinery room door [ASHRAE-15, 8.12(i)]

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Machinery Room

Signage indicatingSignage indicating– Name and address of installer

Refrigerant number and amount– Refrigerant number and amount– Lubrication identity and amount– Field test pressure (ASHRAE-15, 11.2.1)

Access is limited to authorized personnel only, ccess s ted to aut o ed pe so e o y,signage indicating MACHINERY ROOM-AUTHORIZED PERSONNEL ONLY at each

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door (ASHRAE-15, 8.11.8 and 11.2.4)

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Machinery Room Personnel Safety

ANSI Z358 1 e e ash/safet ANSI Z358.1 eyewash/safety shower located in close proximity outside of the machinery roomoutside of the machinery room (IIAR-2, 13.3.1.4)

ANSI Z358 1 h/ h ANSI Z358.1 eyewash/shower station should be located inside the machinery room within 50 ft of anymachinery room within 50 ft of any point in the room (IIAR-2, 13.3.1.4)

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Piping

All refrigerant piping less than 6" NPS is at least schedule 40 (B31.5)

All refrigerant piping less than 2" NPS is atAll refrigerant piping less than 2 NPS is at least schedule 80 (B31.5)

Refrigerant piping must be fabricated by Refrigerant piping must be fabricated by certified welders-WPS/PQR/WQR (B31.5)

All piping mains, headers, and branches are identified including the refrigerant's physical state relative pressure level and

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physical state, relative pressure level, and the direction of flow (IIAR-2, 10.5, IIAR-114)

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Piping

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Piping

Main shut-off valve(s) (i.e., king valves) should be readilyvalves) should be readily accessible and identified with a prominent signprominent sign(IIAR-109, 4.10.3)

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Pumps

Pumps are protected from hydrostaticPumps are protected from hydrostatic overpressure with an relief device(IIAR-2, 6.2.1.2)

All exposed rotating parts of the pump are guarded (IIAR-2 6 2 1 4)guarded (IIAR 2, 6.2.1.4)

Liquid refrigerant pumps are equipped with low liquid level pump cut outlow liquid level pump cut-out

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Relief Devices

Pressure relief devices protecting ASME ratedPressure relief devices protecting ASME rated components are stamped with a UV or VR symbol (ASHRAE -15, 9.4.2)

If a stop valve exists on the discharge of a pressure relief device it is full-port and lockedpressure relief device, it is full port and locked open (ASHRAE-15, 9.4.7)

Pressure relief device set pressure is equal to or Pressure relief device set pressure is equal to or less than the maximum allowable working pressure of the protected component(s)

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pressure of the protected component(s) (ASHRAE-15 and ASME Sect. VIII)

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Relief Devices

The capacities of the relief devicesThe capacities of the relief devices protecting liquid containing vessels are equal to or exceed ASHRAE 15 requirements

The inlet and outlet piping of the relief deviceThe inlet and outlet piping of the relief device and the protected component is at least the same size as the relief device inlet and outlet connections (ASHRAE-15, 9.7.6 and 9.7.8.4)

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Relief Devices

Discharge from relief device(s) are greaterDischarge from relief device(s) are greater than 15 ft above the adjoining ground level (verify vent does not put people in "harms way") (ASHRAE-15, 9.7.8)

Discharge from relief device(s) are greaterDischarge from relief device(s) are greater than 20 ft from windows, ventilation intakes or building exits (ASHRAE-15, 9.7.8)

Replaced or cleaned/inspected tested every 5 years (IIAR-109 4 9 7)

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5 years (IIAR 109, 4.9.7)

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Pressure Vessels

Press re essels incl ding shell and t be Pressure vessels, including shell and tube exchangers must have a nameplate(IIAR-2 7 and 9)(IIAR 2, 7 and 9)

Liquid level indicators should be protected f h i l d (IIAR 109 4 6)from physical damage (IIAR-109, 4.6)

Inspected– During daily rounds– Annually

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Annually– Every 5 years

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Review

We covered– Ammonia

Refrigeration RAGAGEPs

– Some equipment-specific

i trequirements

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Q tiQuestions

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Chad Patschke

Manager, Mechanical Integrity Services

ABS Consulting

[email protected]

281 685 0988281-685-0988

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