analysis
VOLUME FOUR NUMBER ONE
HVAC
I S S U E S A N D A N S W E R S
In this issue...
ASHRAE Standard 15-1994
and its implications for
mechanical room design
should be required reading
for every HVAC profession-
al, especially since it is now
being used to write local
municipal building codes.
In the last several years, the
standard has been revised
to address the rapid
changes regarding refriger-
ant phaseouts, alternative
refrigerants and the safe
installation and operation
of mechanical refrigeration
systems. This issue of
Analysis discusses the
standard and its recent
addenda. It is intended not
as a substitute for reading
the standard, but as a guide
to assist in understanding
and applying ASHRAE 15.
Educate Your Customers:
The highlights of the revised
ASHRAE 15-1994 are
summarized in Carrier’s
SYNOPSIS newsletter, which
is written specifically for
building owners and managers.
To download copies of SYNOPSIS, use of these refrigerants,
Vol. 4, No. 1. at no charge,
visit our web site www.carrier.com, prohibited for all refriger-
click on Commercial/Industrial
Heating and Cooling Systems
and see Newsletter under
Resource Center.
F O R T H E C O N S U L T I N G /
ASHRAE 15-1994: Implications
for Mechanical Room
Design — 2001 Update
Introduction
First issued as a safety
code (Standard B9) in 1930,
the same year that CFC
(chlorofluorocarbon) refrig-
erants were introduced in
the United States, ASHRAE
Standard 15 has undergone
unusually rapid change over
the last decade. During this
same period, the air condi-
tioning industry and its cus-
tomers have been faced with
The Clean Air Act
Amendments of 1990.
These amendments legislate
the phaseout of CFC pro-
duction by the end of
1995, and the end of new
production equipment
using HCFCs (hydrochloro-
fluorocarbons) by 2020.
Although the regulations
permit the responsible
intentional venting is strictly
ants, including HFCs
(hydrofluorocarbons).
At the time of this
legislation, neither ASHRAE
nor ARI safety standards had
been updated to address the
(SUPERSEDES VOLUME ONE NUMBER ONE)
S P E C I F Y I N G
new alternative refrigerants
that were already appearing
in the marketplace. Thus,
ASHRAE 15 was revised in
1992 and again in 1994, fol-
lowed by several addenda in
the last two years. The cur-
rent standard is now being
used to formulate municipal
codes for the safe installa-
tion and operation of
mechanical refrigeration
systems throughout the
United States and beyond.
Code Compliance
and Safety
ASHRAE Standard
15-1994 was intentionally
C O M M U N I T Y
written in code language
so it could be adopted
nearly verbatim, if desired,
by model code associations.
The primary goal of the
standard is to mitigate safety
risks to the environment,
to mechanical room opera-
tors and, ultimately, to the
general public.
With the introduction
of alternative refrigerants
such as HCFCs, HFCs and
mixtures of refrigerant com-
pounds known as blends,
new refrigerant safety classi-
fications were added under
ASHRAE Standard 34-1992,
“Number Designation
and Safety Classification
1
of Refrigerants.” Allowable cal room supplies chilled
exposure limits for the water for air conditioning.
various refrigerants range Equipment may be 10, 20, 30
from a low of 10 ppm or even 50 years old — each
(parts per million) to a cap unit installed to comply with
of 1,000 ppm. Some blends the codes of the day.
comprise one or more Given the new ASHRAE
flammable compounds, standard and the approach-
introducing yet another ing HCFC production
safety concern. Using phaseout, now is the right
ASHRAE 34-1992 as a start- time for owners, operators
ing point, ASHRAE 15-1994 and engineers to conduct a
and its subsequent addenda complete mechanical room
have been written to help safety check and review
professionals minimize potential liability problems.
risk and promote safety. The following checklist high-
Because ASHRAE lights the many important
15-1994 is written in code items to look for (Figure 1).
language, it can be difficult Are exhaust outlets
to read and understand. located near inlet vents?
Safety relief devices on
Mechanical Room chillers are typically vented
Safety Check to the outside, most often
through the roof. It is
For many building own- important to know how close
ers, mechanical rooms are this vent is to the air intakes
virtually unknown areas of on the roof, and to insure
their property. “Out of sight, that there is at least 20 feet
out of mind” rings true in far between them.
too many cases. Most owners Are roof drains vulnera-
understand only that the ble to collecting refrigerant?
equipment in the mechani- If you lose refrigerant from
FIGURE 1
Mechanical Room Safety Check
an exhaust outlet and it vents
a few feet above a flat,
curbed roof, the refrigerant
could very well spread across
the roof and find the first
exit. This would most likely
be down the roof drains,
most of which lead directly
to a sewer system.
Where does the purge
vent? A conventional purge
loses three to 20 pounds of
refrigerant for every pound
of non-condensible air it
removes from the system.
Most vent directly into the
mechanical room which may
invite unnecessary problems.
All purges should vent
outside. If high efficiency
purges are applied, it is
best to specify them in
accordance with the new
ARI Standard 580-2000.
Where are safety rup-
ture disk outlets located?
On a CFC-11 or HCFC-123
chiller, the safety device is a
thin carbon rupture disk that
is meant to shatter at 15 psig,
allowing the charge to safely
exit the system. These disks
are often vented through the
roof or side of the building.
Yet in climates with warm
days and cool nights, mois-
ture often condenses in the
pipes before it can evaporate
off. Then, along with the
rust and other accumulations
in the pipe, moisture ends
up “sitting” on the rupture
disk. Over time, this may
corrode the joint and result
in failure of the seal.
Are rupture lines the
right size and length? For
convenience, safety devices
sometimes run into a com-
mon header if they have
common refrigerants.
Chillers with different
headers should never share
common headers as they
operate at different pres-
sures. Also, an improperly
sized header can exacerbate
problems in an emergency,
when the discharge capacity
of safety lines is put to
the test.
Are chiller drain valves
secured? More often than
not, chiller drain valves are
an easy way for an inexperi-
enced technician to get into
trouble. Make sure the
valves are locked off.
Is access to the mechani-
cal room restricted? Most
mechanical rooms have
neither a door nor any other
barrier to restrict people
from entering unsupervised.
If there is a fire door, it is
typically left open. Not only
are mechanical rooms poten-
tially hazardous places, but
they contain systems critical
to a building’s operation.
Restricting access is only
common sense. The
mechanical room door
should have a tight seal to
isolate the room in case of
an emergency. The entry
restriction should apply to
all personnel not trained
in emergency procedures
relating to mechanical
room operation.
2
 Are there any pits (low
areas) in the mechanical
room? Check the condition
of any pits or other areas
below floor level. They may
house a host of unwanted
chemical residues such as
acids, spilled refrigerant,
cleaning solvents, etc.
Where do the floor
drains empty? Most floor
drains were constructed
to handle wash water and
empty into the sewer system.
But if your chiller and occu-
pied space share the same
floor, they may also share
drainage systems — and
drainage traps can dry out.
Check to see if drains in
the occupied space (i.e., in
restrooms) are connected
to those in the mechanical
room. Imagine losing a full
charge and “finding” it in
a restroom!
These are some of the
many factors to consider
when evaluating the safety
of your mechanical room.
And when assessing a
property, the condition of
the mechanical room and
its equipment should be
significant considerations
in your purchasing decision.
Applying ASHRAE
15-1994
What is your compliance
obligation to ASHRAE
15-1994? If you are a
professional engineer, a
manufacturer or an owner,
you are liable under the
standard simply by being
aware of it. Compliance
with ASHRAE 15-1994 is
also mandated in the
following situations.
Contracts
The specification that
equipment and service “must
be in compliance with the
latest ASHRAE 15” has
become standard contract
language for installation
submittals and service
agreements.
Equipment Design
Manufacturers’ labels
reference compliance with
the standard.
Safety Stewardship
Professionals who can
prove that they have gone
to the furthest extent possi-
ble to promote safety will
minimize their legal liability.
This is true for all profession-
als in the HVAC business,
including property develop-
ers, consulting engineers,
contractors and others.
Mechanical Room
Changes
The CFC and HCFC
refrigerant production
phaseout has raised the
critical issue of what to
do with existing chillers.
Each possible solution —
containment, conversion
or replacement — brings
with it new concerns. It is
particularly important to
understand that if the type
of refrigerant in a chiller is
changed or if the chiller
itself is replaced, ASHRAE
15-1994 applies. Section 5.3
of the standard reads: “A
change in the type of refrig-
erant in a system shall not be
made without the notifica-
tion of the authority having
jurisdiction, the user and
due observance of safety
requirements. The refriger-
ant being considered shall be
evaluated for suitability.” On
the other hand, the addition
of containment devices, i.e.,
high efficiency purges and
back-up relief valves, to your
existing equipment does
not trigger application of
the standard.
The cost of mechanical
room upgrades is typically
11 to 13% of the total chiller
conversion/replacement
project cost, depending on
the room’s age and location.
This expense should be
factored into the refrigerant
planning cost analysis.
Building Code Compliance
The major U.S. building
code jurisdictions are cur-
rently in various stages of
incorporating ASHRAE 15-
1994 into their model codes.
These updated codes will
ultimately be passed down
to state and municipal levels.
For this reason, it is always
a good idea to meet with
your building inspector
before mechanical room
changes are made. Find
out what’s happening to
codes in your area, then
decide how to proceed.
ASHRAE 15-1994
Overview
A walk through
ASHRAE 15-1994 begins
with a general look at the
property in question and
its mechanical refrigeration
systems. The type of occu-
pancy — institutional,
public assembly, residential,
commercial, large retail, ind-
ustrial or mixed occupancy
— determines which system
application rules apply.
The next step is to iden-
tify the type of refrigerant
system involved — direct or
indirect. In direct systems,
the chiller sends refrigerant
out into the cooling coils
near the occupied spaces.
In indirect systems, refriger-
ant runs through the chiller
only, and chilled water in a
separate circuit produces the
cooling in the airside system.
Indirect system types include
double indirect open spray
systems, indirect closed sys-
tems and indirect vented
systems (all described in
ASHRAE 15-1994).
The probability of refrig-
erant reaching the occupied
spaces depends in large part
on the type of system
involved. To characterize
the degree of risk, ASHRAE
15-1994 introduces the broad
categories of “low-probabili-
ty” and “high-probability”
systems. Low-probability
systems are those in which
the leakage of refrigerant
from a failed component
cannot enter the occupied
spaces. Examples include
indirect closed systems;
double indirect systems;
and indirect open spray
systems where the secondary
coolant pressure exceeds
refrigerant pressure.
Conversely, high-proba-
bility systems are described
in the standard as those in
which leakage of refrigerant
from a failed component will
enter the occupied spaces.
High-probability systems
include all direct systems, as
well as indirect open spray
systems where the refrigerant
pressure always exceeds the
secondary coolant pressure.
Refrigerant
Classifications
In its 1992 update,
ASHRAE 15 refined the
way refrigerants are classified
for toxicity (Figure 2).
Refrigerant compounds
were divided into two
groups, “low-toxicity” and
“high-toxicity,” designated
by the letters A and B.
Refrigerants with allowable
exposure limits (AELs) of
more than 400 ppm are
classified as type A (lower
toxicity) refrigerants, and
those with AELs of less
than 400 ppm are type B
(higher toxicity).
ASHRAE 15-1994 fur-
ther classifies refrigerants
according to their degree
of flammability: type
1 — no flame propagation;
type 2 — low flammability;
and type 3 — high flamma-
3

FIGURE 2
ASHRAE 34 Safety Group
High
Flammability
Low
Flammability
No Flame
Propagation
bility. Ammonia, for
example, is considered a
low-flammability refrigerant,
while refrigerants like
HCFC-22 and HFC-134a
have no flame propagating
properties.
It should be noted that
R-600a and R-1270a, found
in some blends, are flamma-
ble and would fall into
class 3 if they were used
as single compounds.
Although their flammability
is mitigated when they are
mixed into a blend, flamma-
bility may still be an issue
in leak situations. When
blends leak, the highest-
pressure compound exits
first, mixed with the next
highest-pressure compound.
The lowest-pressure com-
pound, then, is likely to be
left in the vessel, and in
this state the mixture may
be flammable. A recent
addendum to ASHRAE 34-
1992 reflects the fact that the
flammability classification of
a blend may change as it
leaks. The addendum states
that a blend will be classified
to reflect the highest poten-
tial flammability or toxicity
of its components, as shown
in Figure 3.
A3 B3
Propane
A2 B2
R-142b, 152a Ammonia
A1 B1
R-11,12,22, R-123, SO2
114,500,134a
Lower Toxicity Higher Toxicity
Complying With
ASHRAE 15-1994
Here are some of the
primary issues to consider
when examining a mechani-
cal equipment room for
compliance with ASHRAE
15-1994.
Maximum Refrigerant
Without a Mechanical
Room
Table 1 of the standard
lists allowances for all
refrigerants in pounds of
refrigerant per 1,000 cu. ft.
of occupied space. Often
misinterpreted, these figures
represent the maximum
refrigerant levels allowable
without a separate mechani-
cal equipment room. If
you have more than the
allowable amount of
refrigerant, your system
must be housed in a separate
mechanical room.
Table 1 is often misinter-
preted in an effort to exempt
or somehow restrict the
application of large chillers.
Simply put, Table 1 requires
almost all commercial
chillers to be in a “machin-
ery room” as a result of their
relatively high refrigerant
levels. The intention of
Table 1 and the restriction
of refrigerant quantities is
to allow small commercial
refrigeration units to be
used in “occupied spaces.”
When the rules in
ASHRAE 15 refer to Table 1
of the standard, you must
calculate the amount of
refrigerant per 1,000 cu. ft.
of occupied space for the
application. Determine
the amount of refrigerant
in the largest single unit of
the system or the largest
refrigeration circuit. Then,
determine the occupied
space and do the calculation.
Different calculations must
be used for unventilated and
ventilated spaces.
• Unventilated Occupied
Spaces: In a hotel room,
for example, the air con-
ditioning unit is typically
a PTAC unit. The room
houses the refrigeration
unit and there is no
special ventilation — it is
considered an “unventi-
lated occupied space.”
If the hotel had a large
chiller instead, the vol-
ume of the occupied
space would be the build-
ing the chiller serves.
In the case of the PTAC
unit, the allowable refrig-
FIGURE 3
ASHRAE 34 Safety Group
Examples Of Blend Refrigerant Classification
High
Flammability
Low
Flammability
No Flame
Propagation
Lower Toxicity
*R-406 = 55% R-22, 4% R-600a, 41% R-142B
erant quantity in Table 1
would be below the limit.
For a chiller, the volume
would exceed any of the
limits and would require
a “machinery room.”
• Ventilated Occupied
Spaces: Ventilated space
is where a refrigeration
unit may have the evapo-
rator or condenser coil
located directly within
the duct system that
supplies the occupied
space. In this case,
Table 1 would consider
the occupied space to be
the entire space served
by the duct system.
There are some restric-
tions, such as 1) Where
the air flow in the space
can be reduced below
25% of the design, that
space must not be consid-
ered in the calculated
total space volume; and
2) Plenum space cannot
be included unless it is
continuous and part of
the return air system.
Let’s look at an
example. Figure 4 shows
a mixed-occupancy facility
that uses a 20-ton packaged
rooftop unit (classified as
a high probability system)
containing 20 lbs. of R-22
A3 B3
A2 B2
R-406*
A1 B1
Higher Toxicity
4
refrigerant (classified A1, low
toxicity, no flammability).
All areas of the facility are
supplied with conditioned
air, except the conference
rooms and the hallway,
which can be shut off with
a variable volume vent.
The ceilings are 10 feet high.
The quantity of refriger-
ant in the packaged unit for
every 1,000 cu. ft. is as fol-
lows: 20 lbs./(27,500/1,000)
=.727 lbs. per 1,000 cu. ft.
Table 1 allows up to 9.4 lbs.
per 1,000 cu. ft. for R-22 in
this type of system. This
facility does not exceed that
amount; therefore a separate
mechanical room is not
required for compliance
with ASHRAE 15-1994.
The limits in Table 1
can also be used to calculate
the minimum volume of
occupied space a refrigera-
tion system requires. For
example, the allowable 9.4
lbs. per 1,000 cu. ft. inverted
(1000/9.4) determines that
106.38 cu. ft. of occupied
space is required for each
pound of R-22.
Purge System and
Relief Devices
The standard specifies
that all purge systems —
including high-efficiency
systems — and other relief
devices must vent outside.
While it may be economical
to tap into existing rupture
disk lines, do consider
putting a drain valve in the
line or wrapping the line
in heater tape. Even the
highest-efficiency purges
lose some refrigerant. When
warm gas hits a cold pipe it
will condense down into the
pipe, depositing refrigerant
against the safety rupture
disk. These disks are usually
only a 0.03" thick layer of
carbon and are not tolerant
of corrosive conditions.
FIGURE 4
Mixed Occupancy Facility
Hallway
Office
15'x15'
Office
15'x15'
Office
15'x15'
Conference Room
Sizing of Relief and
Rupture Devices
ASHRAE 15-1994 speci-
fies the appropriate sizing of
pressure relief devices based
on a minimum required dis-
charge capacity in pounds of
air per minute. The equa-
tion is shown in Figure 5.
When converting a
chiller to a new refrigerant,
it is critical to check the size
FIGURE 5
Discharge Capacity of
Pressure Relief Devices
C=fDL
Where:
C = minimum required
discharge capacity of
relief device in pounds
of air per minute (kg/s)
D = outside diameter of
vessel in feet (m)
L = length of vessel
in feet (m)
f = factor dependent
upon type of refrigerant*
* identified in the standard
for most refrigerants
(if not, consult your
equipment or refrigerant
manufacturer).
Manufacturing Area
20'x40'
Reception Area
15'x15'
of existing safety devices to
be sure they are suitable.
The new standard 15-1994
also includes rating formulas
for discharge capacity of rup-
ture members and maximum
length of discharge piping
(Figures 6 and 7).
Additional detailed informa-
tion on maximum lengths
for discharge piping is
addressed in ASHRAE 15
addenda a, b and c.
A word of caution:
chillers with different refrig-
FIGURE 6
Discharge Capacity of
Rupture Member
2
C = 0.64 p1d
d = 1.25 (c/p1)
0.5
Where:
C = rated discharge
capacity in pounds
of air per minute(kg/s)
d= smallest of the internal
diameter of the inlet pipe,
retaining flanges, fusible
plug, and rupture member
in inches (mm)
p = (rated pressure
psig [kPa gage] x 1.10)
+ 14.7 (101.33)
Offices (3) 2,250 cu. ft. each.... 6,750 cu. ft.
Reception area.......................... 6,000 cu. ft.
Warehouse................................. 6,750 cu. ft
Manufacturing area..................8,000 cu. ft.
Total............................................27,500 cu. ft.
Warehouse
15'x45'
Conference
Room
15'x15'
20'x30'
erants should never have
common relief piping.
Every refrigerant has a
unique pressure rating.
Using common relief valve
or rupture disk piping could
implode or interfere with
proper operation.
Refrigerant Sensors
According to ASHRAE
15-1994, all mechanical
rooms must have a sensor
capable of detecting refriger-
ant loss. Sensors should be
FIGURE 7
Maximum Length of
Discharge Piping
L = 9 p2d5/16Cr2
Where:
Cr = rated discharge
capacity as stamped
on the device by
manufacturer in
pounds of air per
minute (kg/s)
d = internal diameter of
pipe, in inches (mm)
p = length of discharge
pipe in feet (m)
5
FIGURE 8
Examples of Sensor Locations
(Examples Not in Standard)
positioned where vapor from
a refrigerant leak would most
likely concentrate, providing
early warning so that person-
nel can prevent catastrophic
refrigerant loss (Figure 8).
Sensors should be calibrated
so that the allowable expo-
sure limit for the refrigerant
will not be exceeded.
Exposure limits are
expressed as threshold limit
value, time-weighted average
(TLV-TWA). This is the
time-weighted average
concentration for a normal
eight-hour work day and a
40-hour work week to which
nearly all workers may be
repeatedly exposed without
adverse effects.
The sensors should actu-
ate an alarm and mechanical
ventilation, as well as activate
visual and audible alarms
inside and outside the
mechanical room. The reset
for these alarms should be
manual, and located inside
the mechanical room.
Rather than a refriger-
ant detector, the old version
ASHRAE 15-1992 required
an oxygen deprivation sensor
for class A1 refrigerants.
The old standard stated that
the sensor should be capable
of detecting a 0.5% decrease
in room oxygen levels (air is
typically 20% oxygen, so the
sensor would detect a drop
to 19.5%). In this old
scenario, 67,000 ppm refrig-
erant concentrations could
accumulate before the sen-
sor issued a warning! Safety
stewardship and refrigerant
containment are better
served by using a quality
refrigerant sensor with all
refrigerants. A good choice
is a multi-port refrigerant
detector using infrared spec-
trometry sensing units rather
than metal oxide sensing
units. Infrared sensors typi-
cally hold calibration and are
of higher overall quality.
Facilities may find it use-
ful to have multiple levels of
alarms or to provide a refrig-
erant detector that indicates
the actual refrigerant level
(with a digital readout show-
ing refrigerant ppm). This
will provide technicians with
a better understanding of
the refrigerant leak and the
proper protection and
response. The main alarm
must still be a manual reset
housed in the mechanical
room. It is unwise to rely
on automatic detectors to
announce that an event is
over. They do not allow
technicians to distinguish
between an alarm reset when
the concentration dropped
(e.g., because ventilation
fans controlled the incident)
and one that may reset
because the detector was
damaged. In the latter case,
anyone entering the refriger-
ating machinery room might
be entering a hazardous
area. Alarms or indicators
intended to communicate
normal, current conditions
inside the mechanical room
may, of course, be automati-
cally re-setting.
Mechanical Ventilation
to the Outdoors
Mechanical rooms
must be vented to the
outdoors using mechanical
ventilation. The formula
ASHRAE provides for
calculating ventilation
capacity requirements is
shown in Figure 9.
Access Restrictions
The revised standard
specifies that access to
mechanical rooms should
be restricted to authorized
personnel. In addition, the
room must have tight-fitting
doors that open and close
freely (i.e., no fire doors)
and any other opening that
would permit the passage of
refrigerant must be sealed.
Each entrance to a refrigerat-
ing machinery room must
have a legible permanent
sign that reads “Refrigerating
Machinery Room —
Authorized Personnel Only,”
and should communicate
that when an alarm has
been activated, entry is
forbidden except by trained
personnel who can address
emergencies.
Refrigerant Storage
Section 11.5 of ASHRAE
15-1994 reads: “The total
amount of refrigerant stored
in a machinery room in all
containers not provided with
FIGURE 9
Mechanical
Ventilation
Q = 100 x G0.5
Where:
3
Q = air flow in ft. per minute
(liters per second)
G = mass of refrigerant
in lbs. (kgs) in the largest
system, any part of which
is located in the
mechanical room
6
relief valves and piped in
accordance with the stan-
dard should not exceed
330 lbs.” This is designed
to allow building owners to
store adequate quantities
of refrigerant for chiller
servicing in separate,
approved storage tanks.
This is allowable under U.S.
Environmental Protection
Agency (EPA) guidelines,
and many owners are opting
to contain their CFC and
HCFC chillers and safely
store service refrigerant
onsite. Although the
ASHRAE recommendation
is for a maximum of 330 lbs.
per system, local building
and fire codes should
be checked for possible
exceptions.
Relief Discharge Location
The discharge location
of relief devices must be at
least 20 feet away from any
ventilation openings, and
not less than 15 feet above
ground level (to avoid
spraying someone with
refrigerant).
Combustion Device
Limitation
ASHRAE 15-1994
prohibits the location in
a mechanical room of any
open-flame device using
combustion air from inside
the room. On the other
hand, an open-flame device
such as a boiler may be locat-
ed in a mechanical room
if combustion air is drawn
from outside. Two accept-
able alternatives are to duct
outside, sealed ventilated air
in; or to install a sensor that
shuts the flame off in the
presence of refrigerant gas.
Most refrigerant sensors
are multi-port, so they can
run to several spots in the
mechanical room and be
programmed to shut the
boiler down if a chiller
leak is detected. Yet another
option (though not specified
in ASHRAE 15) is to
isolate the boiler or open-
flame device with a wall or
separate enclosure.
Room Dimensions
The new standard
defines an appropriately
sized mechanical room as
one that allows access to
all equipment, including
adequate space for service
and maintenance, as well
as operation.
Periodic Testing
Ventilation systems
and sensors must be periodi-
cally tested in accordance
with the manufacturer’s
recommendation and/or
local jurisdiction. This is
particularly important for
refrigerant sensors that are
detecting compounds with
low allowable exposure
limits. Many of these sensors
require frequent calibration.
Emergencies in
Refrigerating Machinery
Rooms
With the removal of
self contained breathing
apparatus (SCBA) under
Addendum d of ASHRAE
15-1994, machinery rooms
must have an emergency
response plan. The require-
ment for SCBA in the
previous standard was an
attempt to address toxicity
and concern over the risks
associated with refrigerant
loss. However, in most
commercial buildings
personnel properly trained
in the use of SCBA may
not be available during an
emergency, or it may be
difficult to locate the SCBA
in an area accessible to
these people.
When a refrigerant
detection level above
the threshold limit value
(TLV-TWA) trips the alarms,
personnel who are not
provided with and trained
to use respiratory protection
equipment appropriate for
the refrigerant (such as
canister respirators or SCBA)
must leave the room immedi-
ately. Keep in mind that
alarm activation is depen-
dent on the concentration
and the toxicity of the
refrigerant (programmed
in the alarm settings).
In a proper application of
ASHRAE-15, the machinery
room ventilation should
actuate, reducing the refrig-
erant concentration, and
respiratory protection may
not be needed.
Presence of refrigerant
above the TLV-TWA limit
does not by itself signal an
emergency; many routine
service operations can create
such levels, especially with
low pressure refrigerants
(e.g., R-123). Local or
national regulations often
prescribe that steps be taken
to protect the health and
safety of personnel working
in the machinery room when
refrigerant concentrations
rise above the threshold limit
value. In a more sophisticat-
ed facility, with appropriate
training and other measures
specified by local regulations,
refrigeration technicians
might use this alarm as a
signal to don respiratory
protection. Evacuation of
the machinery room may
not be necessary, although
warning bystanders not
to enter still is.
Selection of the proper
respiratory protection for
the particular situation may
require additional informa-
tion, for example, whether
or not the refrigerant
concentration is above the
“immediately dangerous to
life or health” (IDLH) level.
This is defined as the maxi-
mum concentration from
which unprotected persons
are able to escape within
30 minutes without escape-
impairing symptoms or
irreversible health effects.
It should be noted that
donning respiratory protec-
tion is a last resort option
under most industrial
hygiene regimens — it is
preferable to provide engi-
neering controls to reduce
refrigerant concentrations
to tolerable levels. The
refrigerant detector should
activate the machinery
room ventilation system,
automatically reducing con-
centrations. In many cases,
this may be entirely adequate
to reduce the concentration,
and respiratory protection
may not be needed. An
alarm silence switch is useful
for situations when person-
nel are to remain working
in the room.
Figure 10 shows TLV-
TWA and IDLH levels for
two popular refrigerants.
Example Emergency
Procedure
As an example, let’s look
at a facility that uses its own
technicians to handle minor
problems in a mechanical
room. It is important to
remember, however, that
there are many other possi-
bilities; and that other types
of buildings, such as office,
shopping centers, theaters,
schools and other public
assembly areas may not
have their own technicians.
When a refrigerant
alarm sounds, personnel
should leave (or not enter)
the mechanical room and
facilities management should
be contacted immediately.
A readout of the current
refrigerant leak inside the
machinery room via a digital
reading outside the machin-
ery room should distinguish
the current reading from the
alarm trip level. This refrig-
7
 FIGURE 10
TLV-TWA and IDLH Levels
For Two Popular Refrigerants

Quantity of Refrigerant
Example Refrigerant Exposure Limits 45' x 45' x 12', Unventilated
Mechanical Room @ 72° F

Refrigerant TLV-TWA IDLH* TLV-TWA IDLH

HCFC-123 10 – 50 ppm** 4,000 ppm 6.8 oz. 32 lb.

HFC-134a 1000 ppm 50,000 ppm 34 lb. 1,701 lb.

* Based on ARI bulletin in conjunction with refrigerant manufacturers — no formal

IDLH levels have been set
** Different refrigerant manufacturers rate HCFC-123 differently: Allied at
10 ppm and Dupont at 50 ppm

erant level provides qualified coordination procedure

refrigerant technicians or
response teams with an
understanding of the
emergency, and appropriate
respiratory protection
suitable for use in an atmos-
phere containing refrigerant.
If the proper ventilation
is operating, the leak or
exposure may be below
the allowable expose limit.
After donning appropri-
ate respiratory protection,
technicians may re-enter the
machinery room to close
valves, fix leaks, shut off
alarms, etc. — if, and only if,
the current refrigerant level
is below the IDLH. In other
words, technicians may
re-enter the room if the
refrigerant release is inciden-
tal and they have been
trained in the use of protec-
tive respiratory equipment.
If, for some reason, the
IDHL level is exceeded or
the problem seems uncon-
trolled and getting worse,
technicians should leave
and call for emergency
responders. An emergency
with the local emergency
response agency should
be in place.
As we have learned
from past incidents,
the requirements in the
ASHRAE standard provide
minimum protection
to help prevent injury
from accidents.
READ ASHRAE
15-1994
Clearly, there are many
issues for professionals to
consider in order to achieve
compliance with ASHRAE
15-1994 and its addenda.
Your best strategy is to obtain
a copy of the standard and
read it thoroughly, using this
issue of Analysis as a point of
reference. ASHRAE 15-1994
offers many good, safe
solutions. Not only is it a
good idea to follow the new
standard, it may very well
be the law in your jurisdic-
tion — and as a professional
applying ASHRAE 15, the
risk is yours.