This document is a standard for the installation of closedcircuit ammonia mechanical refrigeration systems and. Ammonia in refrigeration systems this manual describes the hazards of ammonia and how to prevent and control exposure. Firstly the general requirements of safe refrigeration system design will be considered, based on the accident statistics given in section 2 and secondly the specific additional requirements particular to ammonia. In this video were going to be looking at industrial refrigeration system basics with a focus on ammonia refrigeration systems, well start at the basics and work our way up covering some typical systems for single stage, two stage as well as cascade systems to help you learn the basics of industrial refrigeration. Basic closed cycle refrigeration system has changed very little since then. Provides is a tutorial and reference book that represents the collective efforts of the most knowledgeable. The design of safe ammonia systems will be considered from two aspects. Industrial refrigeration system basics ammonia refrigerant. Second, the operation is sensitive to the initial charge and later. Ammonia refrigeration and handling requires well guided experiential training specific to the substance. It lets you know your responsibilities as an employer and shows you how to prepare for emergencies and investigate ammonia releases to help prevent future accidents. This booklet is part of the first stage of the project. The liver converts ammonia ion rapidly to harmless urea, which is used in the body process or is excreted in the urine. Smartpac packaged ammonia heat pumps capture the heat from your ammonia refrigeration system that is normally rejected to the atmosphere.
Understanding industrial refrigeration from the inside out edition 3 and. Safe management of ammonia refrigeration systems january 2016 page 12 of 49. A typical example is household refrigeration systems. In an effort to bring consistency to the industry and aid in training and safety efforts, bulletin 114 was revised to also include a suggested color scheme for ammonia refrigeration piping. Safe management of ammonia refrigeration systems january 2016 page 5 of 49 introduction 1. This guide aims to provide answers to the various questions relating to industrial refrigeration.
Finding ammonia system leaks the second part of a series on ammonia refrigeration systems explores the various tools and sensors that are available to help service techs find system leaks art one on ammonia svslerns in last months issue of rses journal explo. Absorption refrigeration systems are the most successful practical applications of cchp and studies have been concentrated in lithium bromidewater 5 6 7 and water ammonia 8 9 absorption refrigeration systems. Ice machine company, which manufactured systems under patents purchased from the hungarian julius sedlacek 1 the rise and fall of carbon dioxide systems about the author. Safe design of closedcircuit ammonia refrigeration systems fertilizer storage ragagep. Industrial refrigeration ammonia and co2 applications danfoss. The advantages and disadvantages of ammonia refrigerant are discussed. Hazards of ammonia releases at ammonia refrigeration facilities accident prevention and response manual for anhydrous ammonia refrigeration system operators anhydrous ammonia theft additional ammonia safety resources. Ammonia refrigeration systems with 10,000 pounds or more of ammonia are a covered process subject to the requirements of the process safety management standard 29 cfr 1910. Decommissioning of ammonia refrigeration systems shall comply with. Drawings of appleton arena with refrigeration system layout are in appendix a.
Smartpac then transforms this valuable resource into hot water that can then be utilized throughout your industrial facility. Because ammonias properties are best suited to large refrigeration systems, there is likely to be a large amount of ammonia in any system that uses it. Introduction chapter 1 introduction courtesy of frick background this guide identifies and discusses best practices for making industrial refrigeration systems both energyefficient and productive. Optimal operation of an ammonia refrigeration cycle.
Assists employers and employees in identifying and controlling the hazards associated with the operation and maintenance of ammonia refrigeration systems. Ammonia refrigeration systems have traditionally employed evaporators supplied with liquid by either gravity flooding with surge drums, or pumped overfeed either with mechanical pumps or discharge gas rdriven vessels. Credit earned on completion of this program will be reported to ces records for aia members. Ammonia1 has been used as a refrigerant in industrial applications for more than 150 years. The absorbent with a high concentration of ammonia refrigerant in solution is heated to drive the refrigerant out of solution and produce high pressure ammonia vapor. Almost all refrigeration systems have the purpose of reducing the temperature of an object like the air in a room or the objects stored in that room. T he refrigerant of the system is an open flow and is not a closed recirculation circuit. As the leading authority on ammonia refrigeration, the international institute of ammonia refrigeration developed the ammonia refrigeration management arm program to help small facilities improve safety, enhance system reliability and assist iiar ammonia refrigeration piping handbook regulatory compliance. Industrial refrigeration basics the engineering mindset.
Safe management of ammonia refrigeration systems refcom. Additionally, if the ammonia leaks in or near food products the food is contaminated and need to be disposed of to prevent poisoning. In this case, the threshold for an ammonia release, the reportable quantity rq is 100 pounds in a 24 hour period and must be reported within one hour of the release. The packaged system shall be designed for reduced system ammonia charge and may vary between 2. Smartpac enables you to make more efficient use of your ammonia refrigeration system. Performance of an activated carbonammonia adsorption. Sep 03, 2008 or from a pipeline, the refrigeration system is to liquefy the gas and send the liquid to other facility or to a storage tank.
Thus, the basics of refrigeration technique have not been presented. The danfoss product range for the refrigeration and air. Industrial ammonia refrigeration books ammonia psm rmp. Safety aspects in the design, construction and installation of refrigerating appliances and systems last published in 1995, as well as the relevant version of the institute of refrigeration guidance. Low ammonia charge refrigeration systems for cold storage october 2014 version 1 5. Explains how water can contaminate an ammonia refrigeration system, how this can be prevented, and how water can be removed. Schematic of a basic vapor compression refrigeration system it can be seen that the condenser has to be capable of rejecting the combined heat inputs of the evaporator and the compressor.
Smlc acs designed and supplied a packaged ammonia chiller with screw compressors for process cooling with a capacity of 1200 kw to smlc, pepsico. Ammonia being a natural refrigerant is small part of the solution ammonias cycle. Operating procedures, operation and maintenance checklists, daily logs, facility. Ammonia systems are now available in compactsmaller systems. Managers, ammonia system technicians, ammonia system operators, and roundsman. Industrial refrigeration best practices guide 1 chapter 1. Aug 09, 2019 mechanically pumped liquid overfeed system arrangement. Safe management of ammonia refrigeration systems january 2016 page 2 of 49 foreword this guidance has been developed by industry, following the withdrawal of hses publication pm81, to give clear current crosssector guidance on the safe management of ammonia refrigeration systems. Application handbook automatic controls for industrial refrigeration systems.
Additionally, epa has published a wide range of ammonia safetyrelated publications, including. Absorption refrigeration systems another form of refrigeration that becomes economically attractive when there is a source of inexpensive heat energy at a temperature of 100 to 200oc is absorption refrigeration, where the refrigerant is absorbed by a transport medium and compressed in liquid form. Manual for refrigeration servicing introduction technicians. In 1834, the first vapor compression refrigeration machine, that actually worked, was built. Certificates of completion for nonaia members are available on request. Feb 19, 2009 as a consequence, the refrigeration industry has been divided into those dealing primarily with halogenated hydrocarbons using copper tubing and hermetic or semihermetic compressors, and those using ammonia in largecapacity systems with steel tubing and open compressors.
Oct 09, 2018 iiar ammonia refrigeration piping handbook. Understanding ammonia refrigeration systems understanding the differences among the three types of ammonia refrigeration systems and how each works is a necessity for every technician that works on them by rick dumas and chris harmon s far back as can remember man has used ammonia for one reason or another it is in. This testing provides valuable information into how low charge ammonia systems operate differently than a traditional system. Using ammonia for refrigeration is effective, saves resources and is generally. The rise and fall of carbon dioxide systems ashrae. It has remained the main refrigerant used in industrial refrigeration systems because of its superior thermodynamic properties and low cost. For ammonia systems, iiar bulletin also addresses the subject of safety valves. Ammonia in refrigeration systems manufacturing safety. Ammonia refrigeration units can be used in refrigerated storage or in certain sport. Industrial refrigeration systems have used anhydrous ammonia for more than a sesquicentennial.
Jacob perkins, an american living in england, was the builder and he charged the machine with ether. If the refrigeration mechanic is there for an emergency call,such as the system being down,the refrigeration logs can help troubleshoot the problem and,in most cases,save valuable time and effort in getting the system running again. Refrigeration systems using ammonia refrigerant and the buildings in which such systems are installed shall comply with iiar2 for system design and installation and iiar7 for operating procedures. Jul 17, 2017 ammonia refrigeration systems operate in a similar manner to fluorocarbon systems, but have several key differences. Ammonia1 has been used as a refrigerant in industrial applications for more than. While you will not usually find an ammonia based system inside a home ammonia is a very toxic substance, and the refrigerators are very expensive, they are used in factories that need large refrigeration devices that can cool substances very quickly. The typical open cycle refrigeration system is that the system for ammonia storage or lpg storage.
This guidance may go further than the minimum needed. If your refrigeration facility has an inventory of 10,000 pounds or more of anhydrous ammonia, your facility is subject to the osha process safety management and the epa risk management program regulations. But not only is the installation of an ammoniabased refrigeration system about 10 to 20 percent cheaper than similar systems, operating costs are also significantly. Low ammonia charge refrigeration systems for cold storage. Ammonia ions are a naturally occurring body chemical and are produced in the kidneys and by the metabolism of proteins. Improving winery refrigeration efficiency wine business. Lack of components for ammonia small capacity systems. End users of ammonia refrigeration systems are increasingly interested in reducing the charge of ammonia in evaporators and in the overall system in the interest of minimizing the risk to workers and products associated with ammonia leaks. However, despite the above mentioned advantages and some new smallcapacity products. Iiar ammonia refrigeration piping handbook pdf iiar ammonia refrigeration piping handbook. Commercial refrigeration systems tend to be smaller, modular, and may use a different refrigerant for each evaporator temperature. Ammonia chargeammonia charge in the cascade system is restricted to the chiller and is classified as an indirect systemit makes 10 15% of the charge in the direct ammonia system plant room ventilation higher the ammonia charge, greater the minimum ventilation rate. The manufacturer shall maintain a set of international standards of quality management to ensure product quality.
I1 refrigeration system on a tuna seiner vessel layout brine transfer system refrigeration system components expansion valves shutof f valves coils suction headers and manifolds back pressure regulator suction accumulator safety relief valves ammonia compressors oil separator check valve oil trap condenser receiver pressure gauges. In the event that pressure control systems do not function or cannot control pressures, an ammonia storage tank flare has been installed to combust the ammonia vapors prior to atmospheric release. Introduction to ammonia refrigeration systems ashrae. Anhydrous ammonia as a refrigerant where is ammonia used as a refrigerant. It continues to be the refrigerant of choice in many food processing. Iiar minimum safety criteria for a safe ammonia refrigeration system. The umc change recognizes that ansiiiar 2 now includes content necessary to serve as both a code and a standard. Either of the refrigeration systems can control pressure on either or both storage tanks. Ashrae standard 15 for ammonia systems, and the 2018 uniform mechanical code umc is proposing to entirely drop requirements for ammonia refrigeration in favor of a mandatory reference to ansiiiar 2. When 1 pound of ice melts, it absorbs 144 btu, as latent energy. These gases are made of many different substancesmost household refrigerants are actually a synthetic mixture designed for efficiency, but ammoniabased version simply use ammonia.
Low charge adx ammonia global cold chain expo 2018. Inspection, and maintenance of ammonia mechanical refrigeration systems. Guidelines for ammonia refrigeration plant equipment. Industrial refrigeration systems explore solutions danfoss. Summary of tools and resources in this document this document contains industryspecific information for the implementation of the chemical accident risk reduction carr national enforcement initiative nei. Automatic controls for industrial refrigeration systems. Many of the requirements of the process safety management standard, 29 cfr 1910. All piping mains, headers and branches should be identified as to the physical state of the refrigerant, i.
A release of anhydrous ammonia could happen in a number of ways. Many of these requirements are identified in this etool as possible controls and are useful as recommended practices whether or not the ammonia refrigeration system is a covered process. Ammonia refrigeration fundamentals graphic products. The guide includes information on the unique hazards presented by ammonia gas and its use in refrigeration, and relevant duties that apply under the work health and safety whs legislation. The low charge ammonia refrigeration system has a capacity up to 75 tons while still maintaining a less than epa regulated 100 lbs of ammonia. The danfoss product range for the refrigeration and air conditioning industry. Globally, there is a growing interest in ammonia as a refrigerant, both by itself, and in cascade refrigeration systems with carbon dioxide and other secondary system designs. Twostage ammonia refrigeration system designed, installed and commissioned for one of the most advanced and prestigious chicken slaughterhouses in the region with a total capacity of 12000 bph. Refrigeration system is needed for ammonia storage for the following reasons. Ammonia refrigeration in cold storage facilities a brief history.
Welcome to the manual for refrigeration servicing technicians. Operation of ammonia refrigeration systems international institute of ammonia refrigeration introduction the purpose of this chapter is to provide a reference document containing suggested practices for the operation of an ammonia refrigeration system. Ammonia absorption refrigeration system a refrigeration system where ammonia refrigerant vapor is absorbed into another liquid or absorbent. It is an ebook for people who are involved in training and. A refrigeration system is based on a type of refrigerant gas, which is constantly run through the system to gather and disperse heat. Covers the safe design, operation, and inspection of ammonia refrigeration systems. Attendees who have not completed the previous course should have experience in the operation of an ammonia refrigeration system, or knowledge of ammonia refrigeration. Ammonia and co2 combined package systems for commercial and. Applications for ammoniabased refrigeration systems include thermal storage systems, hvac chillers, process cooling, air conditioning, winter sports, district cooling systems, heat pump systems, supermarkets, convenience stores, and increasing output efficiencies for power generation facilities. An introduction to ammonia refrigeration systems ashrae is a registered provider with the american institute of architects continuing education systems. Ansiashrae addendum a to ansiashrae standard 152016. No matter the amount of anhydrous ammonia in your refrigeration system, it is important to adhere to ragagep.
The majority of plants with industrial ammonia refrigeration systems utilize an oil pot which is a vessel equipped with an oil drain valve in series with either a selfclosing or manual quickclosing emergency stop valve connected to the oil drain point, a vent line, a vent line isolation valve, and an approved. This paper examines the causes of typical accidents experienced in industrial refrigeration and compares requirements for ammonia and fluorocarbon system. Ammonia refrigeration etool occupational safety and. There is a specific category in osha regulations concerning ammonia refrigeration systems and worker safety around ammonia refrigeration systems. Danfoss industrial refrigeration solutions offer highly efficient and reliable refrigeration systems optimized for ammonia and other natural refrigerants. In the past, this was done by collecting ice in the winter and using its specific heat to cool as the ice melted. Introduction to ammonia refrigeration systems madison ashrae. Installation of closedcircuit ammonia refrigeration systems american national standard for ansiiiar 42015. Hvac and refrigeration system bureau of energy efficiency 73 figure 4.
Industrial refrigeration mostly use floodedtype evaporator coils, while commercial refrigeration. Iiar ammonia refrigeration piping handbook epub pdfin website. The twin hazards of toxicity and flammability normally associated with ammonia also do not appear in the list of circumstances although approximately 90% of the companys business is in the supply and ongoing maintenance of ammonia systems. Emergency planning for ammoniabased refrigeration systems guide. As is customary in developing any product, evapco performs extensive testing on full scale products. Regulatory oversight on cfc, hcfc, and other synthetic refrigerants, have refocused attention on ammonia to.