For Official Use Only

Ammonia Refrigeration
RAGAGEPs

For Official Use Only

Objectives

 Gain a basic understanding of:

– RAGAGEPs unique to Ammonia
Refrigeration
– Equipment-specific RAGAGEP
requirements

 Again, this is an overview discussion.

There is usually an exception to most rules

Slide 2
RAGAGEP Organizations

 ASME
 ANSI /ASHRAE
 IIAR
 NB
 NIOSH
 RMA

Slide 3
ASME / NB

 BPVC
Design, fabrication, inspection, testing and
certification of vessels operating above 15
psig (internal and/or external)
 B31.5
Refrigeration Piping and Heat Transfer
Components
 NBIC NB-23
In-service inspections, repairs, alteration, re-
rates
Slide 4
ANSI / ASHRAE

 ANSI/ASHRAE 15
Safety Standard for
Refrigeration Systems

Slide 5
IIAR

 Process Safety Management Guidelines for

Ammonia Refrigeration (update coming soon)
 Ammonia Refrigeration Piping Handbook
 Ammonia Data Book
(chemical and technology PSI resource)
 Oil D
Draining
i i G Guidelines
id li

Slide 6
IIAR

 ANSI/IIAR Standard 2
Equipment, Design, and Installation of
Closed-Circuit Ammonia Mechanical
Refrigeration Systems
 Bulletin No. 107
Suggested Safety and Operating
Procedures When Making Ammonia
Refrigeration Plant Tie
Tie-Ins
Ins
 Bulletin No. 108
Guidelines for Water Contamination in
Ammonia Refrigeration Systems Slide 7
IIAR

 Bulletin No. 109

Guidelines for IIAR Minimum Safety Criteria
for a Safe Ammonia Refrigeration System
 Bulletin No. 110
Guidelines for Start-Up, Inspection, and
Maintenance of Ammonia Mechanical
Refrigeration Systems
 Bulletin No. 111
Guidelines for Ammonia Machinery Room
Ventilation
Slide 8
IIAR

 Bulletin No. 112

Guidelines for Ammonia Machinery Room
Design
 Bulletin No. 114
Guidelines for Identification of Ammonia
Refrigeration Piping and System Components
 Bulletin No. 116
Guidelines for Avoiding Component Failure in
Industrial Refrigeration Systems Caused by
Abnormal Pressure or Shock
Slide 9
NIOSH

 Publication No. 79-120

Working Safely with Anhydrous Ammonia

 Publication No. 79-119

A Guide for Developing a Training
Program for Anhydrous Ammonia Workers

Slide 10
RMA

 Publication IP
IP-14
14
Specifications for Anhydrous Ammonia
Hose
 Publication IP-11-2
Hose Technical Bulletin - Manual for Use
Use,
Maintenance, Testing, and Inspection of
Anhydrous Ammonia Hose

Slide 11
Slide 12
ANSI/ASHRAE 15

Safety Code for Mechanical Refrigeration

 Establishes safeguards for personnel and
property
 Applies to:
– Design, construction, test, installation,
operation, and inspection
– Modifications (non-RIK)
– Subst
Substitutions
tut o s of
o refrigerants
e ge a ts
Slide 13
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
– Machinery room design
– Installation of systems
Slide 14
IIAR Bulletin No. 109

Minimum Safety Criteria for a Safe

Ammonia Refrigeration System
 Identifies mandatory safety requirements
 Provides safety inspection checklists
to be performed annually
 References
e e e ces ot
other
e codes a
and
d sta
standards
da ds as
basis for checklists

Slide 15
IIAR Bulletin No. 110

Start Up, Inspection, and Maintenance of

Start-Up,
Ammonia Mechanical Refrigerating Systems
 Startup
PSSR, Evacuation, Dehydration, Leak Checking,
Charging Testing Protective Devices
Charging,
 I&M
System Log/inspection,
Log/inspection Compressors
Compressors, PVs
PVs, and
HEs, Pumps, Valves, Piping, Oil, Motors
– Provides example ITPM plan
Slide 16
IIAR Bulletin No. 110

 System log/inspection – at least daily

(example in Appendix I)

Slide 17
IIAR Bulletin No. 110

Appendix G
Typical Inspection and Maintenance Plan

Slide 18
IIAR Bulletin No. 111

Ammonia Machinery Room Ventilation

 Ventilation Design
EAC, Emergency Vent Rate
EAC Rate, Fan
Selection & Layout, Detectors, Controls
 Operation & Maintenance
Fans/Intakes, Room Pressure, Detectors,
Controls

Slide 19
IIAR Bulletin No. 111

Slide 20
IIAR Bulletin No. 114

Identification of Ammonia Refrigeration

Piping and System Components
 Comprehensive labeling scheme
– Label size
– Colors
– Locations
– Label material requirements

Slide 21
Equipment-specific Requirements

Slide 22
Alarms & Detectors

 Each 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 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
ventilation system fails (IIAR-111, 3.5.3)
Slide 23
Alarms & Detectors

 A high
high-range
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 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
annunciators (ASHRAE-15, 8.11.2.1)
Slide 24
Compressors

 Fitted with high pressure cutouts

that unload the machine at 90% of
the pressure relief valve set
pressure (ASHRAE-15, 9.9)
 Moving parts are guarded
(ASHRAE-15, 8.2)
 Located such that there is
unobstructed access for both
normal and emergency tasks
(ASHRAE-15, 8.3)
Slide 25
Compressors

 Must have both suction and discharge

shut-off valves (ASHRAE-15, 9.12.4)
 Fitted with nameplates that include:
manufacturer, identification number,
design pressures
pressures, and refrigerant used
(IIAR-2, 6.1.4)
 Each must be identified with signage with
lettering greater than 0.5" in height
(ASHRAE-15
(ASHRAE 15, 11
11.2.2)
2 2)
Slide 26
Compressors

 Each 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
(IIAR 2, 6
6.1.2.2)
1 2 2)
 Each compressor package with an oil
pump has an oil flow failure indicator
(more than just checking oil pressure and
DP) (IIAR
(IIAR-2
2, 6
6.1.2.2)
1 2 2)
Slide 27
Design Pressures

 High
High-side
side components on systems
– 250 psig - evaporative condensing
– 300 psig – air-cooled
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)

Slide 28
Machinery / Engine Room
 Head room of at least 7.25 ft below equipment
situated
it t d over passageways (ASHRAE
(ASHRAE-15,
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 to
other parts of building
((ASHRAE-15,, 8.11.2))
Slide 29
Machinery Room

 Emergency 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 least
0.5 cfm/ft2 or 20 cfm/person
(ASHRAE-15, 8.11.5 and IIAR-111, 3.2.3)

Slide 30
Machinery Room

 Does not permanently contain equipment

with continuous operating surface
temperatures in excess of 800°F
[ASHRAE-15, 8.12(a)]
 Walls 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
[ASHRAE-15, 8.12(d),(e)]
Slide 31
Machinery Room

 Emergency 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 a
control switch immediately outside of the
machinery room door [ASHRAE-15,
8.12(i)]

Slide 32
Machinery Room

 Signage indicating
– Name and address of installer
– Refrigerant number and amount
– Lubrication identity and amount
– Field test pressure (ASHRAE-15, 11.2.1)
 Access
ccess is
s limited
ted to aut
authorized
o ed pepersonnel
so e o only,
y,
signage indicating MACHINERY ROOM-
AUTHORIZED PERSONNEL ONLY at each
door (ASHRAE-15, 8.11.8 and 11.2.4)
Slide 33
Machinery Room Personnel Safety

 ANSI Z358.1
Z358 1 eyewash/safety
e e ash/safet
shower located in close proximity
outside of the machinery room
(IIAR-2, 13.3.1.4)
 ANSI Z358.1
Z358 1 eyewash/shower
h/ h
station should be located inside the
machinery room within 50 ft of any
point in the room (IIAR-2, 13.3.1.4)

Slide 34
Piping

 All refrigerant piping less than 6" NPS is at

least schedule 40 (B31.5)
 All refrigerant piping less than 2"
2 NPS is at
least schedule 80 (B31.5)
 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
state, relative pressure level
level, and
the direction of flow (IIAR-2, 10.5, IIAR-114) Slide 35
Piping

Slide 36
Piping

 Main shut-off valve(s) (i.e., king

valves) should be readily
accessible and identified with a
prominent sign
(IIAR-109, 4.10.3)

Slide 37
Pumps

 Pumps 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
(IIAR-2
2, 6
6.2.1.4)
2 1 4)
 Liquid refrigerant pumps are equipped with
low liquid level pump cut
cut-out
out

Slide 38
Relief Devices

 Pressure 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
device, it is full-port
full port and locked
open (ASHRAE-15, 9.4.7)
 Pressure relief device set pressure is equal to or
less than the maximum allowable working
pressure of the protected component(s)
(ASHRAE-15 and ASME Sect. VIII)
Slide 39
Relief Devices

 The 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 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)

Slide 40
Relief Devices

 Discharge 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 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
(IIAR-109
109, 4
4.9.7)
9 7)
Slide 41
Pressure Vessels

 Pressure
Press re vessels,
essels incl
including
ding shell and ttube
be
exchangers must have a nameplate
(IIAR-2
(IIAR 2, 7 and 9)
 Liquid level indicators should be protected
f
from physical
h i ld damage (IIAR
(IIAR-109,
109 44.6)
6)
 Inspected
– During daily rounds
– Annually
– Every 5 years Slide 42
Review

 We covered
– Ammonia
Refrigeration
RAGAGEPs
– Some equipment-
specific
requirements
i t

Slide 43
Q
Questions
ti

Slide 44
Chad Patschke

Manager, Mechanical Integrity Services

ABS Consulting
cpatschke@absconsulting.com
281 685 0988
281-685-0988

Slide 45