Ammonia System Inventory & P&ID’s Tracing

Created: June 13, 2008

Industry Resources & Management Safety proposes to provide the following

Scope of services:

Ammonia Inventory Calculations

Prior to commencement of the project, Industry Resources & Management Safety would like to
obtain any available P&IDs of the existing systems of your facility this will help speedup process, in
addition to the same P&IDs in AutoCAD format, if no P&IDs yet exist, Industry Resources will sketch the
P&IDs from scratch. Upon completion of total system inventory we will leverage changes into your

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MOC program to ensure any changes made to your process in the future will be dually addressed

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during the initiation of MOC documentation. We will also provide calculation work sheets &
formulas which accurately describe our methods, and implement then into your Process Safety

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Information.

Industry Resources proposes to conduct the work in the following manner;

Ammonia Inventory Calculation Procedures

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1) Assumptions:
a) Charge is calculated while system is in operating mode (as opposed to off-cycle or pumpdown modes).

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b) Suction (return) lines contain the same weight of refrigerant as the corresponding liquid (supply) lines.
c) Refrigerant density varies with temperature, so the weight is calculated at operating temperatures.

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2) Measurements:

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a) Vessel operating levels were measured and converted to “Percent Volume”. These percentages are listed as
“Normal liquid level” on equipment worksheets.
b) Liquid lines (which include CD, HPL, TSS, TSR HTRL, LTRL, LTRS, and HTRS) were traced with a
measuring wheel if accessible. Inaccessible piping was scaled off of drawings after-field-verifying its
location.

3) Statement of accuracy:
a) The Refrigeration Industry has used the method described and applied herein since 1986. Calculated
charges are usually within 5 – 10% percent of the actual ticketed amount. <End of Procedures>

 Industry Resources will provide one field engineer on-site at your facility for the duration of the project to
properly document P&IDs (redline existing P&IDs, hand draw new ones, etc). This engineer will
work continuously for a {to be determined} consecutive weeks until all P&IDs are documented.
 Industry Resources AutoCAD resources in North Carolina will electronically update/create the P&IDs in
AutoCAD.
 Completed "record copy" P&IDs — in hard copy and electronic (AutoCAD) form — will be sent to your
facility as they are finished by Industry Resources & Management Safety

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Ammonia System Inventory & P&ID’s Tracing
Created: June 13, 2008

Our P&ID’s follow these specific guidelines:

The P&ID is a set of drawings that describe a “process;” for ammonia refrigeration, the
refrigeration system and its ancillary equipment are considered the process. (This contrasts with the
common usage in food plants, where the food is “processed” and the refrigeration system is “just a
utility.”)

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A good P&ID:

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 Provides a visual reference to equipment configuration, valving, sensors, etc.

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 Provides useful information to assist in analyzing process hazards (through a PHA study).
 Supports development of operating procedures (and to a lesser extent, maintenance schedules and
procedures).

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 Communicates the configuration of equipment clearly and concisely to improve operator understanding of
the process and reduce human errors.

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 Records the current (as-built) state of the process so that changes can be planned safely and effectively.

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What will be included (as an absolute minimum?)

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 All process chemical-containing equipment, including pressure vessels, compressors, condensers,
evaporators, other heat transfer equipment (desuperheaters, heat recovery water heaters, etc.), pumps,
air purgers, vaporizers, transfer/unloading stations, etc.

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 Essential valves, such as isolation valves and control stations, as well as all safety relief valves.
 Controls (regulators, float switches, etc.) and solenoid valves.
 Permanent instruments and sensors (pressure transducers, meters, etc.).
 Legend to symbols and abbreviations.
 Purge/gauge valves: providing these details will decrease the time to write and verify equipment
service procedures.
 Equipment/valve numbering: equipment and especially valves should be labeled on the P&ID (for an
additional cost Industry Resources will label all equipment & apply stainless steel numbered tags at all
main isolation valves, control stations, and pressure indicators)
 Line designations/purposes: some processes, such as refrigeration, have recognized systems for line
designation. For others, use a system that explains the line’s function and optionally includes other
information such as temperature and pressure levels, etc.
 Safety relief valve specifications: information on the relief valve “design and design basis” is required
before starting the PHA study. For simple processes, codes and standards such as NFPA 58 (LPG) and
ASHRAE 15 (refrigeration) specify the design ASME & National Board (i.e. Make, Model, Size
inlet/outlet, Install date, Capacity, Set pressure to relief)
 Control loops: these can become confusing on some P&IDs, but information on which float switch
controls which solenoid valve (for example) must still be developed.
 Flow direction: at a minimum, we will always show the permitted-flow direction on a check valve.
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Ammonia System Inventory & P&ID’s Tracing
Created: June 13, 2008

 Line sizes/reducers; expansion tie-ins and block valves, etc.(where applicable)

 Design working pressure and other pressure-vessel/equipment label information.

 Support equipment and non-“chemical” lines such as condenser water pumps, secondary heat transfer
fluid (glycol/brine) loops. (Where applicable)
 Items included in other equipment: often, P&IDs show screw compressor packages and other
complex equipment as a single symbol, even though the package includes motor, compressor section,
oil separator vessel, oil cooler, and various controls/sensors. Include, at a minimum, all vessels or other
“major” sub-equipment, as well as all valves connecting to the atmosphere and those separating

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portions of the package from one another.

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Industry Resources & Management Safety warrants that we will perform our services in accordance
with the guidelines of care and diligence consistent with industry and professional engineering

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practice at the time the project is completed.

Industry Resources & Management Safety will make every effort to provide services in a way that

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minimizes any inconvenience to your work force. Note that it is imperative that your facility
personnel be available to Industry Resources & Management Safety to ensure smooth, timely

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progress towards completion of accurately calculating total system charge.

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We look forward to the opportunity to be of assistance to your facility for this very important
process. We very much want to work with you and to provide the finest quality, most reliable

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and cost effective services.

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