Training & Briefing

Ammonia Refrigeration System

For New Cold Rooms in Block I,J & K

Conducted By :
Mr. Terrence (012-7218 025)
Mr. Chong (014-9043 810)

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PREFACE
 Do not operate the system without a full understanding
of the contents of this manual.

 Replace missing or lost operation manuals immediately

from Mayekawa technical support.

 The specifications are subject to change without notice,

for product improvement. Please contact Mayekawa
technical support for clarification of any section of this
manual.
MAYEKAWA (M) SDN. BHD.
TEL: (60) 3-7805-1406 / 1395
FAX: (60) 3-7805-1409

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 DANGER
 Do not shut refrigerant liquid in a closed space (example: shutting
valves on both ends of piping). It will cause blowout when the
refrigerant is heated up by atmosphere and expands its volume.

 Keep flammable objects away from equipment. If equipment is

exposed to high temperature for a long period, the fusible (safety
relief) valve may cause blowout of refrigerant gas.

 Always disconnect the power before maintenance or inspection.

Do not touch terminals when working with breakers on the control
panel or switches. Do not allow water to contact the control panel
or the electrical equipment.

 Ensure guards are securely mounted for the rotating equipment.

Keep people away from the rotating equipment before starting.

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 WARNING
 Falling Hazard: Do not climb on the equipment or piping.
 Burn Risk: Some parts of compressor and piping are heated. Do not touch
without protection.
 Cold injury: Improper handling of refrigerant could cause cold injury or
blindness.
 Fire or Earthquake: In the case of fire or earthquake, immediately shut down
the power and evacuate personnel from the site. Refrigerant leakage from a
broken pipe or equipment will cause serious injury.
 Lightning: In the case of a lightning strike, immediately shut down the power
and keep away from the site to avoid electric shock.
 Changing Settings of the Safety Equipment:
Incorrect adjustment may lead fire, explosion, suffocation or
breakdown. Consult a service company when settings need to be changed.
 Repair, Disassembly, Modification and Adjustment:
Incorrect repair, disassembly, or modification could lead to fire, electric
shock, burn, suffocation or breakdown. Consult a service company when
these jobs are necessary.

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 CAUTION
 Keep the Equipment Area Clear of Obstructions
 Turn Off the Power before Inspection
 For Security Interlock
Please contact MAYEKAWA when safety devices or safety interlock is turned
on.
 Use the Specified Power
 Do Not Change the Default Setting of Equipment Control
Incorrect adjustment may lead fire, explosion, suffocation or breakdown.
Consult a service company when settings need to be changed.
 Do Not Use Unauthorized Parts - Only use genuine parts for replacement.
 Daily Inspection
Perform daily inspections. Please contact a service company for any
abnormal sound or operation

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 IN CASE OF EMERGENCY
 The person in charge of operating equipment must put the first
priority on safety in case of emergency.
 In case of emergency such as fire or abnormal sound/vibration, please
shut down the compressor and turn off the power.
 In case of a large amount of refrigerant leakage, please shut down the
compressor by pressing the emergency stop button on the compressor
control panel.
 In case of extreme emergency situation, disconnect the power and
immediately evacuate personnel to a safe area.
 A large amount of gas lowers the level of oxygen in the atmosphere,
thus leading to asphyxiation. Immediate medical attention is required.
Artificial breathing will be necessary in an emergency situation.
 In all the above cases, immediately contact the fire department,
police, hospital and facility/plant manager.

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Refrigerant - Ammonia
a. Characteristic of Ammonia (NH3):
 The refrigeration system holds Ammonia as refrigerant.
 Ammonia is known as its high efficiency in refrigeration
cycle and has no impact on both issues of Ozone Layer
depletion and global warming.
 However, it has a characteristic of toxic, corrosive to
copper and insoluble to normal mineral based oils.
 Ammonia is lighter than air.
 Therefore, operation of the system must be handled by
well-trained refrigeration staff.

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b. In case of Ammonia leakage:
 In case of leakage, first get a gas protection mask and
check the following place where leakage is most likely
happened.
- Compressor
- Bolts & Nuts
- Valves
- Pressure gauges
- Flanges
- Sockets

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c. Concentration of Ammonia
Level of concentration and symptoms:

5-10 ppm : could be noticed by smell

100 ppm : could cause irritation on nose and throat
150 - 200 ppm: could cause partial inflammation
500 - 700 ppm: could have strong irritation to eyes
1000 ppm : could lead difficulty in breathing
1500 ppm : could damage on nerves
2500 ppm : could cause death

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d. Procedure to check for ammonia
leakage
• Sulphur Sticks / Sulphur Powder
Burning sulphur sticks or suplhur powder shows a dense
white smoke when NH3 is present. Poisonous

• Soap bubble test

Pour soap water on suspected leakage point. Inspect if there
is any bubble formation

• Wet litmus paper

Turns red in contact with ammonia.

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e. First aid treatment when contact with
high concentration ammonia
 Eyes
- Rinse eye with 2% of boric acid solution or with water.
Note : Contact lenses should never be worn when working
with ammonia.
 Skin
- Rinse the contacted area with water or 2% of boric acid
solution.
 Nose and throat
- Gargle with water. Drinking water with lemon water is
recommended

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Ammonia Gas Leak Detector

50 ppm - Small leak detected

- Alarm ring, system continue
running

200 ppm - Serious Leak detected !!

- Alarm ring, system trip

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Scope of work
 The works to supply, testing, installation & commissioning
of MYCOM Ammonia Refrigeration System.

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System Outline
• Installed equipment as following:
• 2 units MYCOM Compound Screw Compressor MCN2016LLC-LBL
c/w 250kW motor and inverter:
• 1 unit Evaporative Condenser;
• 1 unit Low Receiver;
• 1 unit Thermosiphon Receiver;
• 1 unit High receiver;
• 1 unit Oil Drum;
• 2 units Teikoku Liquid Pump;
• 15 units of Air Coolers;
• 1 unit Starter and Control Panel.

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P&ID

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Cold Room Layout

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HMI Main Screen

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Evaporative Condenser
No. Item Colour Remark
Indication
Evap. Green Running
1 Condenser
Fan Grey Stop

Evap. Green Running

2 Condenser
Motor Grey Stop

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Low Receiver
No. Item Colour Remark
Indication
Orange Level Reached
1 Liquid High Level
White Level Not
Reached
Orange Level Reached
2 Liquid Control
Level White Level Not
Reached
Orange Level Reached
3 Liquid Low Level
White Level Not
Reached
4 NH3 Liquid Temp N/A

5 Liquid Supply Yellow Opened

Solenoid Valve
Grey Closed

Green Running
6 Liquid Pump 1
Grey Stop

Green Running
7 Liquid Pump 2
Grey Stop

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Cold Room Evaporator
No. Item Colour Remark
Indication
1 Suction Solenoid Blue Opened
Valve
Grey Closed
2 Liquid Supply Yellow Opened
Solenoid Valve
Grey Closed
Hot Gas Supply Red Opened
3 Solenoid Valve
Grey Closed
Green Fan Running

4 Cooler Fan Blue Defrosting (Fan

Stop)
Grey Stop
5 Fan Ring Heater Green ON
Grey OFF
6 Room Temp. N/A
7 Cooling Start N/A
Temp.
8 Cooling Stop N/A
Temp.
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Compressor

No. Item Colour Remark

Indication
Green Running
1 Compressor Motor Yellow Trip / Failure
Grey Stop
2 Oil Pump Green Running
Grey Stop
3 Compressor Data N/A
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Room Cooling Setting
No. Item Description

START Cooling Start

1 Temp. can be
Temp. Setting set
DIFF DIFF can be
2 set (Start
Temp – Diff =
Stop Temp)
ON Fan keep
running when
Fan cooling
3 Continuous process stop
On
OFF Fan Stop when
cooling
process stop
START Cooling
process in
Auto mode
(Start when
4 Cooling Room Temp >
Process Start Temp)
STOP Manually Stop
Cooling
Process

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Defrost Setting

Setting Time: Time interval to be set

Pass Time: Current accumulated time

No. Item Description

1 Defrost Cycle Evaporator start defrosting when cooling time reach defrost cycle
setting time
2 Pump Down Time Time interval of pump down

3 Hot Gas Time Time interval of Hot Gas supply

4 Drain Time Time interval of Water Draining

5 Manual Defrost Press On Button to manually start defrosting

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Control Setting

Item Description

Fan Stop Delay Time
After Defrost Advance Liq.Supply Time
Cooler fan continue running according to the
set point when defrosting start.
When defrosting process done, liquid supply
and suction solenoid valve open.Cooler fan will
only start running after this interval.
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Alarm History

No. Item Description

1 Date Date and Time when alarm

occurred
2 Message Alarm details

3 Recovery Time when alarm is reset

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MYPRO TOUCH MAIN SCREEN

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No. Item Description
1 Current Condition Control Target Show current pressure inside Low Receiver

SV Percentage Compressor Low Stage Slide Valve percentage

Cut In Compressor start running when Suction Pressure is higher than this set
point
Cut Out Compressor Autostop when Suction Pressure lower or equal to this set
point
Comp State Compressor current status

Operation Mode Compressor Operation Mode:

Remote: start/stop control by PLC
Local: manually start/stop on MYPRO TOUCH
Auto: start/stop based on CUT IN/CUT OUT set point
Timer Show any sort of delay time for compressor to operating

Run Time Hrs Running hours of compressor

2 Main PV SP Suction Pressure

DP Discharge Pressure

OP Oil Pressure

IP Intermediate Pressure

AFP After Filter Pressure

dOP OP-DP

dFP DP-AFP

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 dP AFP-IP

ST Suction Temp.

DT Discharge Temp.

OT Oil Temp.

IT Intermediate Temp.

SSH Suction Super Heat

DSH Discharge Super Heat

ISH Intermediate Super Heat

HSV High Stage Slide Valve Percentage

LSV Low Stage Slide Valve Percentage

MA Motor Ampere

3 Alarm/Failure Compressor Alarm/Failure List

4 Capacity Control / VFD Control Show current PID Control Output for Slide Valve Control or VFD
Control
5 Start Button Start Compressor manually when in LOCAL/AUTO MODE

6 Stop Button Stop Compressor manually when in LOCAL/AUTO MODE

7 Clear Alarm Button Clear Existing Alarm

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System Operation:

1. System START Operation

1. Turn on the main breaker.
*Do not turn off except for maintenance or long time shut down.
2. Turn on the breakers for other equipment and control devices.
*Do not turn off except for maintenance or long time shut down.
3. Ensure “Auto” mode is selected for all equipment from the Control Panel.
Note : there are standby units (ex : liquid pump and etc..)
4. Ensure all alarm from PLC and Compressor MYPRO TOUCH have been
cleared and reset.
6. Press the “ON” Button on Control Panel.

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 2 System STOP Operation

1. Press the stop button on Control Panel

2. Compressor starts to slowly unload.
3. Compressor stops.

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Inspection & Maintainance
 Record the running data on daily basis;
 Check overall operation;
 Check if there is any abnormal noise or
vibration;
 Check any leakage of refrigerant or water;
 Check compressor oil level; (half of
compressor oil separator)
 Check Ammonia level at High Receiver;
 Check any sign of liquid flood back or mist
sucking during operation.
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Ammonia level can be measured and checked from High
Receiver Liquid Level Gauge

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Compressor Oil Level can be checked from oil sight glass
installed at the oil separator

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Compressor Oil Management:

 Periodically conduct oil analysis is recommended;

 Periodically drain oil from receivers When the oil volume in the compressor is
decreased, it is most likely accumulated inside these places.
 Periodically conduct refrigeration oil replacement at least once a year.

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Emergency Stop Button

In case of any serious leakage, accidents or emergencies,

“PUSH” the emergency button immediately.

Turn the button ‘clockwise’ to release.

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THANK
YOU!

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