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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
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RAGAGEP Organizations
ASME ANSI /ASHRAE IIAR NB NIOSH RMA
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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, rerates
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ANSI / ASHRAE
ANSI/ASHRAE 15
Safety Standard for Refrigeration Systems

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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

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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
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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
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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
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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

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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

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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
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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 Machinery room design Installation of systems
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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

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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
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IIAR Bulletin No. 110


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

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IIAR Bulletin No. 110


Appendix G Typical Inspection and Maintenance Plan

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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

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IIAR Bulletin No. 111

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IIAR Bulletin No. 114


Identification of Ammonia Refrigeration Piping and System Components

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 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)
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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)
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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)
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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)
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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)
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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)

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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) )
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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)

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Machinery Room
Does not permanently contain equipment
with continuous operating surface temperatures in excess of 800F [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)]
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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)]

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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 pe personnel so e o only, y,


signage indicating MACHINERY ROOMAUTHORIZED PERSONNEL ONLY at each door (ASHRAE-15, 8.11.8 and 11.2.4)
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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)

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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" 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)

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Piping

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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)

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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

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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)
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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)
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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)
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Pressure Vessels
Pressure Press re vessels, essels incl including ding shell and t tube 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 4 4.6) 6)

Inspected
During daily rounds Annually Every 5 years
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Review
We covered
Ammonia Refrigeration RAGAGEPs Some equipmentspecific requirements i t

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Q Questions ti

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Chad Patschke

Manager, Mechanical Integrity Services ABS Consulting cpatschke@absconsulting.com 281 685 0988 281-685-0988

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