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Ammonia
Safety Handling
Presented By:
S J Chew
Technical Director
NRS Process Systems Sdn Bhd
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Equipment
• Ice Maker Types
• Ice Applications
• Ice Maker Configurations
• Refrigeration Diagrams
Ammonia
• Why Ammonia
• Ammonia Vs HFCs
• Pressure -Temp Relationship
• Ammonia Concentration
Limits
Safety
• Service & Maintenance
• Planning, Tools & PPE
• Service & Maintenance
• Piping & Cold Insulation
• Pressure Vessels & Valves
• Pressure Testing & Leaks
• Training & Certification
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Ice Making Equipment

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Block Ice
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Flake Ice
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Plate Ice
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Tube Ice
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Turbine Inlet Air Cooling

3 x 300 Ton Plate Ice
24 x 10’ x 10H m Ice Tank
Chill Water 0°C
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Ice Thermal Storage

Baby Milk Production
2 x 120 Ton Plate Ice
Exiting Ice Tank
Chill Water 0°C
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Factory Packaged
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Field Erected
Ice Machine & Compressor
Systems Separated
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Refrigeration Flow Diagram

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Ice Maker Control Devices

Thermostats
Pressure Switches
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Ice Maker Control Devices

Thermostats
Pressure Switches
Liquid Level
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Ice Maker Control Devices

PLC Controls
▪ Microprocessor boards showing I/O
Modules, CPU and Analog Board
▪ Full View Touch-Screen or HMI
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Ice Maker Controls

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Typical Block Ice Plant

System Components
Suction Trap Oil Separator

Condenser
Surge Drum
Ice Cans

Receiver

Evaporator
Brine Tank
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Typical Flake Ice Plant

System Components

Surge Drum Suction Trap Oil Separator

Evaporator
Flake Ice Condenser

Receiver
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Typical Tube-Ice Machine

System Components
Surge Drum Suction Trap

Oil Separator

Condenser

Evaporator Receiver
Tube-Ice
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Typical Arrangement
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Ammonia
Refrigerant
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Why Ammonia?
Dominant Natural refrigerant - widely used since 1830’s
Ammonia does NOT Contribute to ODP or GWP
Ammonia stinks
Ammonia has Higher Efficiency over HFCs
Ammonia allows easy plant Tie-In’s & Expansion
Ammonia is easier to dispose
Ammonia is inexpensive compared to HFCs
Ammonia is not an accumulative poison
Ammonia is toxic in high concentrations, >1,000 ppm
Ammonia is flammable by spark ignition in concentrations of 16-25%
by volume in air.
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Comparison – At a glance
Ammonia HFC/HFOs
Natural Refrigerant Synthetic Refrigerants
Decomposes, 3-4 days Decomposes,1 to ‘000s years
Stinks – Self-Alarming No Smell – Asphyxiation Risk
Toxicity Lower Flammability Issue
Flammability Issue Less Energy Efficient
Energy Efficient Higher Cost, Refrigerant
Low Cost, Refrigerant Glide Issues
Low oil carry-over Oil Carry-Over Issues
Wide Operating Envelop Expansion Difficulties
Expansion Is Easy Environmental Issues
Disposal
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Hazards – At a Glance

Hazards of NH3
Hazards of HFC / HFO
Hazards of CO2
Refrigerants, A2L
While CO2 is not flammable, it’s While NH3 is not poisonous, it is While many HFC/HFO’s are not
high pressure, toxicity at high toxic at high concentrations and flammable, it’s pressure, toxicity
concentrations and potential of flammability issues must be must be taken into consideration
“dry ice” formation must be taken considered: when using it:
into consideration when using it:
Flammability Issue Asphyxiation Risk
Asphyxiation
Toxicity Charge Limitations (indoors)
High Pressure
High Pressure
Trapped Liquid
Flammability Issues
“Dry Ice”
Glide
Freezer Burn
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Refrigerants: Pressure Temperature Relationship

http://www.emersonclimate.com/en-
us/Resources/Mobile_Apps/Pages/em
erson_ptpro.aspx

http://www.bitzer.de/eng/apps
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−9°C

2.0
barG 112°C 38°C

13.7 13.7
barG barG

0°C 2.0
barG

Condenser

Evaporator Receiver
Tube-Ice
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Ammonia Compressor
Operating Temperature Conditions

Discharge Temp
Suction Temp <150°C
5-10K Superheat

Oil Temp <65°C

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Ammonia Exposure Limits

NH3 Vapor Effects of Unprotected Exposure
Concentration
(ppm) Workers Period

20 Noticeable odor to some people

25 Recommended 8 hr exposure level (AGGIH)

35 Recommended max exposure, 15 mins (AGGIH)

Permissible for 8hr working exposure (NIOSH,

50 Detectable Odor
OSHA)
Moderately strong odor,
100 Moderately irritating to the nose
Ordinarily no serious results following infrequent
400 Causes major irritation of throat
short exposure (<1 hr is hazardous)
No exposure permissible (may be fatal after short
1,720 Causes convulsive coughing
exposure less than 30 mins
Causes respiratory spasm,
5,000 strangulation, asphyxia
No exposure permissible (rapidly fatal)

Causes burns and blisters to

15,000 unprotected skin
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Service & Maintenance

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Service Manuals
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What Is Needed?
Plan Ahead When Performing Service
Identify Tasks Ahead
Notify Parties / Obtain Permits etc
Safety Lock-Out/Tag-Out Requirements
Have Sufficient Spares Available
Have Correct Tools & PPE Available
Have Sufficient Manpower Available
Address Issues about Safety & Chemical Handling
Dispose of waste responsibly
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Isolate Area of Work

Ensure Lock-Out/Tag Out procedures to power down
equipment being worked on;
Use Personnel Protective Equipment (PPE);
Have access to water ready (bucket, hose, etc);
Ensure pressure is released to zero (0) on the equipment
being worked on;
Ensure ammonia is cleared from equipment being worked on
by cracking open the valve or ammonia lines;
Keep drain or vent valves open on equipment or ammonia
lines being worked on;
Keep emergency kits available;
Have trained personnel to work on ammonia systems;
Dispose of waste responsibly.
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Safety Signage
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Basic Tools
Ratchet wrench Amp Probe
Torque wrench Infra-red thermometer
Inspection mirror Pocket thermometer
Multi-meter w/leads Flashlight
Assortment of Tapes PPE
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Typical Safety Equipment

SCBA
Hard Hats Eyeglass

Gloves Face Goggle with Face Shields

NH3 Canisters

Ear Phones
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Gas Masks
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Safety Shower
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Additional Safety Equipment

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Oil Pot
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• Low temp systems operating in vacuum

or near vacuum
• Air can enter during service intervals, oil
changing oil or oil filters, leaky valve
stems, seals, etc
• Air in system causes high condensing
temperatures, reduces capacity and
increase power cost
• Only air is removed. Very little ammonia
is lost.
• Water bubbler (usually supplied) offers
discharge of air with minimum odor.
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Manual Detectors
Your nose
Sulfur Sticks
Soap
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When Not In Use, Refrigerant Cylinders Should

ALWAYS be stored in an upright position
Be stored away from heat and sources of ignition
Have protective cap installed
Secured by chain or other suitable material
When empty, be marked with MT or EMPTY

When In Use, Refrigerant Cylinders

Be secured, if possible
After attaching charging lines, leak check with gas
only in the lines
Wear appropriate safety equipment (PPE)
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Piping & Cold Insulation

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Piping in Refrigeration Systems

Connects System Components Together
Allows transfer of refrigerant in liquid or vapor phases
Allows transfer of fluids like refrigerants or lubricants
Designed for the pressure and temperature of the system
Must be compatible to refrigerant and oil being used
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Piping Materials
Ammonia Systems
Follow ASME B-31.5 or IIAR 2-2014 Guidelines
Use ASTM A53/106 Grade B Electric Resistance Welded Pipe
(ERW) or Seamless (S) Carbon Steel Pipe
Use ASTM A312 Stainless Steel 304 Piping
<DN-40 (1-1/2”) Sch.80 < DN-40 (1-1/2”) Sch.40
<DN-50-250 (2 to 10”) Sch 40 DN-50 to 200 (2” to 8”) Sch 10
>DN-300 (12”) Std Weight (0.322” or 0.375” thick min)
Use A-234 Steel Fittings

Halocarbon Systems
Follow ASME B-31.5 Piping Codes
Steel Pipes for Ammonia May be Used, or
ASTM B-88, Type K or L, Copper Tubing or Pipes
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Piping Materials
Ammonia Systems

Halocarbon Systems
Follow ASME B-31.5 Piping Codes
Steel Pipes for Ammonia May be Used, or
ASTM B-88, Type K or L, Copper Tubing or Pipes
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Pipe Welding & Brazing

Welding for Steel Piping

Follow Appropriate Welding Procedures, Codes & Standards
Typical Stick or GMAW (TIG or MIG) Welding Procedures
Pipe Needs to be Clean, and Butt-Ends Prepared for Welding
Check for Any Special Requirements (eg Radiography, etc)

Brazing for Copper Piping

Follow proper Brazing Procedures, Codes &
Standards
Use Quality Brazing Alloy with Fluxes
Copper-To-Copper - Usually Harris 0 or 5% Ag
Copper-To-Steel - Usually 45% Ag based Alloys
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Cold Insulation Systems

Polyisocyanurate Insulation (PIR or PU)
Thermal conductivity 0.19-0.21 Btu/hr/ft2(oF/in)
Water Permeability ASTM E96 4.5 perm-in
Flame Spread Index, <25
Smoke Developed Index, <50
Applied Temp Range C1126 -182oC to 149oC
PIR has higher upper temperature limit, lower flame-index/smoke
generation test values, lower water absorption, better chemical
stability, greater rigidity, and better dimensional stability over PU
insulation.
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Pressure Vessels & Valves

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Provide Storage of Refrigerant

Contains refrigerant as heat exchanger
Contains refrigerant during service
Stores refrigerant during load fluctuations

Provide Separation of Liquid and

Vapor
Design to pressure vessel codes
and standards
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RECEIVER TANK
Outlet Storage of Refrigerant
Do Not Fill Over 90%
Charging

Inlet
EQ DSRV
Level
Column
Purge

Do Not Overfill (leave vapor gap)

Operating Level
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Vessel Maintenance
Keep Vessels Free Of Rust & Corrosion
Inspect vessels yearly (or as required by regulations)
Keep low temperature vessels properly insulated
Ensure Safety Relief Valves Burst Pressure is Equal or
Less Than nameplated MAWP
Replace Safety Relief Valves Every 5 yrs or as
Recommended by Mfr or Regulations
Maintain level controls and valve stations
Repairs to Vessel Need Re-Certification
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Condenser

Evaporator Receiver
Tube-Ice
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Pressure Vessels
Safety Relief Valve
Protects Vessels Against Overpressure
With 3-way Dual or Single
Lift Detection, LED Indication
Size Properly
Use Proper Pressure Relief Rating
Vent relief lines to atmosphere
Replace every 5 years
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Compressor
Safety Relief Valve
Protects Compressor Against
Over-Pressure
Size Properly
Use Proper Pressure Relief Rating
Vent relief lines to atmosphere
Replace every 5 years
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Pressure Testing & Leaks

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Pressure Testing
Nitrogen Cylinders
Nitrogen is an inert gas
DO NOT USE Air, O2 or CO2
Nitrogen is under high
pressure, >138 bar (2,000#)
Treat cylinders carefully
Use proper hoses & fittings
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Pressure Testing
Use Dry Nitrogen
No Oxygen Allowed
Always use Nitrogen regulator
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Pressure Testing
Pressure Can KILL
Industrial Gases in cylinders
Cylinders are high-pressure,
often over 138 bar (2,000#)
Use of pressure regulators is
mandatory
Never use Oxygen or CO2 for
pressure testing. Use only dry
Nitrogen,
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Emergency Response
Develop a procedure to work with local teams
to deal with an accidental release of NH3
Develop written procedures for containment
of the release
Trained & certified personnel
Develop an evacuation plan
Learn the required reporting procedures
required by local, state and federal authorities
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Training & Certification

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Field Erected Or Fty Packaged

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Industry Activities

Industry Activities
Training Schools
Technology Day Events
Technology Visits
Collaboration with Industry
Institutions (IIAR, ASHRAE,
Eurammon, ILP, etc)

Speaking Assignments
 CENTRE OF SKILLS EXCELLENCE HVAC
INDUSTRIAL TRAINING INSTITUTE KEPALA BATAS
HUMAN RESOURCE DEPARTMENT

CERTIFIED
REFRIGERATION PROGRAMME
 OUR RECOGNITION

Department of Gesellschaft für Internationale

Zusammenarbeit (GIZ) NRS Process System
Environment
GERMANY Sdn Bhd
DOE appointed us as Centre of
GIZ recognized us as training centre NRS- ILP Collaboration in Ammonia
Excellence for HPMP program
for Carbon Dioxide (Co2), Ammonia Training Centre Development
and Hidrocarbon Program
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AMMONIA REFRIGERANT
L P
TRAINING & CERTIFIED
D

PERSONNEL
D

Dedicated for Refrigeration using Ammonia.

 ILP – NRS
COLLABORATION
AMMONIA Refrigeration Training & Certified
Master Trainer Programme
This program is certified by
Manpower Department with
collaboration of NRS Process
Systems. It contains 5 days
training, examination and OJT.

Personnel
Ammonia Certified Master Certified for
Refrigerant Trainer for Ammonia Refrigeration
Research Center Ammonia Handling
Refrigeration
ARRC Personnel Training
Ammonia Refrigerant Research Center This program is certified by
is currently in setup progress. Expected Manpower Department with
Completion is around end of 2022. collaboration of NRS
It will contain a small 10x15 cold storage Process Systems It contains
using Ammonia as the cooling refrigerant 3 days training and
& an automatic monitoring control examination.
system
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Thank You
Your Questions Please