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refrigeration. Workers were evacuated when the concentrations. The Occupational Safety and Health
leak was detected. A short time later, an explosion Administration (OSHA) Permissible Exposure Level
occurred that caused extensive damage, including (PEL) is 50 parts per million (ppm), 8-hour time-
large holes in two sides of the building. The forklift weighted average. Effects of inhalation of ammonia
was believed to be the source of ignition. In this range from irritation to severe respiratory injuries,
incident, physical barriers would have provided with possible fatality at higher concentrations. The
mechanical protection to the refrigeration system National Institute of Occupational Safety and Health
and prevented a release. (NIOSH) has established an Immediately Dangerous
to Life and Health (IDLH) level of 300 ppm for the
Another incident highlights the need for an adequate purposes of respirator selection. Ammonia is
preventive maintenance program and scheduling. In corrosive and exposure will result in a chemical-type
a 1996 incident involving a cold storage warehouse burn. Since ammonia is extremely hygroscopic, it
facility, compressor oil pressure progressively readily migrates to moist areas of the body such as
dropped during a long weekend. The low oil eyes, nose, throat, and moist skin areas. Exposure to
pressure cutout switch failed to shutdown the liquid ammonia will also result in frostbite since its
compressor leading to a catastrophic failure as the temperature at atmospheric pressure is 28F.
compressor tore itself apart. A significant release of
ammonia ensued. Periodically testing all The American Industrial Hygiene Association
refrigeration-related safety cutout switches is (AIHA) has developed Emergency Response Planning
absolutely necessary to minimize the likelihood of Guidelines (ERPGs) for a number of substances to
such incidents. assist in planning for catastrophic releases to the
community. The ERPG-2 represents the
Two other incidents illustrate the potential for concentration below which it is believed nearly all
serious effects from accidental releases from individuals could be exposed for up to one hour
ammonia refrigeration systems, although the causes without irreversible or serious health effects. The
of these releases were not reported. In a 1986 ERPG-2 for ammonia is 200 ppm. EPA has adopted
incident in a packing plant slaughterhouse, a the ERPG-2 as the toxic endpoint for ammonia for the
refrigeration line ruptured, releasing ammonia. Eight offsite consequence analysis required by the Risk
workers were critically injured, suffering respiratory Management Program (RMP) Rule under section
burns from ammonia inhalation, and 17 others were 112(r) of the Clean Air Act.
less severely hurt. A 1989 ammonia release in a
frozen pizza plant led to the evacuation of nearly all In refrigeration systems, ammonia is liquefied under
of the 6,500 residents of the town where the plant pressure. Any liquid ammonia released to the
was located. The release started when an end cap of atmosphere will aerosolize producing a mixture of
a 16-inch suction line of the ammonia refrigeration liquid and vapor at a temperature of 28F. The
system was knocked off. Up to 45,000 pounds of released ammonia rapidly absorbs moisture in the air
ammonia was released, forming a cloud 24 city and forms a dense, visible white cloud of ammonium
blocks long. About 50 area residents were taken to hydroxide. The dense mixture tends to travel along
hospitals, where they were treated with oxygen and the ground rather than rapidly rising. This behavior
released, while dozens of others were treated with may increase the potential for exposure of workers
oxygen at evacuation centers. and the public.
An important property of ammonia is its pungent training are listed in the Training Resources
odor. The threshold concentration at which Section of this Alert.
ammonia is detectable varies from person to person;
however, ammonia can be usually detected at Consider using a spring-loaded ball valve
concentrations in the range of 5 ppm to 50 ppm. (dead-man valve) in conjunction with the oil
Concentrations above about 100 ppm are drain valve on all oil out pots (used to collect
uncomfortable to most people; concentrations in the oil that migrates into system components) as
range of 300 to 500 ppm will cause people to leave an emergency stop valve.
the area immediately.
Develop and require refrigeration
Hazard Reduction maintenance personnel to follow written,
standard procedures for maintaining the
system including such routine procedures as
The Chemical Accident Prevention Group of EPAs oil draining. Consider developing in-house
Region III (Pennsylvania, Maryland, Virginia, West checklists to guide maintenance personnel
Virginia, Delaware, and the District of Columbia) while they execute these procedures.
has been evaluating facilities in Region III with
ammonia refrigeration systems to gather information Remove refrigeration oil from the
on safety practices and technologies and to share its refrigeration system on a regular basis. Never
knowledge with these facilities. Region III has remove oil directly from the refrigeration
conducted more than 135 chemical safety audits system without pumping down and properly
from 1995 to the present of both large and small isolating that component.
facilities using ammonia for refrigeration. In
addition, over the past 2 years, Region III has Provide barriers to protect refrigeration
conducted 32 Risk Management Program (RMP) equipment, i.e., lines, valves, and
audits of ammonia refrigeration systems to ensure refrigeration coils, from impact in areas
compliance with the RMP rule and 17 General Duty where forklifts are used. Consider integrating
Clause inspections of systems that are not covered ammonia refrigeration awareness and
by the RMP regulation but had a near miss incident. discussion of the risks of forklift accidents
(A brief explanation of the General Duty Clause and that can lead to ammonia releases as part of a
the RMP Rule is found in the Statutes and formal forklift driver training program.
Regulations Section of this Alert). To share their
findings from the audits, including both the Develop and maintain a written preventive
deficiencies observed and the actions that facilities maintenance program and schedule based on
are taking to increase safety, Region III has made the manufacturers recommendations for all of
presentations to the Refrigerating Engineers and the refrigeration equipment. The preventive
Technicians Association (RETA). This Alert is maintenance program should include, but not
intended to communicate these findings to a wider be limited to:
audience. a) compressors
b) pumps
Ammonia refrigeration facilities should be aware of c) evaporators
the potential hazards of ammonia releases and of the d) condensers
steps that can be taken to prevent such releases. e) control valves
They should be prepared to respond appropriately if f) all electrical safety(s), including
releases do occur. Here are steps that ammonia 1) high pressure cutouts
refrigeration facilities could take to prevent releases 2) high temperature cutouts
and reduce the severity of releases that do occur: 3) low pressure cutouts
4) low temperature cutouts
Establish training programs to ensure that 5) low oil pressure cutouts
the ammonia refrigeration system is 6) automatic purge systems
operated and maintained by knowledgeable g) ammonia detectors
personnel. Some organizations that provide h) emergency response equipment,
ammonia refrigeration education and including,
1) air monitoring equipment
4 HAZARDS OF AMMONIA RELEASES AT AMMONIA REFRIGERATION FACILITIES (UPDATE) AUGUST 2001
2) self-contained breathing
apparatus (SCBA)
For large systems with many PRVs, consider
3) level A suit
using the arrangement shown in Exhibit 1 for
4) air- purifying respirators.
detecting leakage. This arrangement includes
installation of a rupture disc upstream of each
Perform regular vibration testing on PRV with a gauge port or transducer in
compressors. Document and analyze results between the disc and PRV and installation of
for trends. an ammonia sensor in the PRV common
manifold. In case of leakage from a PRV, the
Maintain a leak-free ammonia refrigeration sensor would set off an alarm. A check of
system. Investigate all reports of an either the pressure gauge or transducer signal
ammonia odor and repair all leaks would permit easy identification of which
immediately. Leak test all piping, valves, PRV has popped.
seals, flanges, etc., at least four times a year. Ensure that the ammonia refrigeration system
Some methods which can be used for leak is routinely monitored. Consider using a
testing are sulfur sticks, litmus paper, or a daily engine room log, recording process
portable monitor equipped with a flexible parameters (e.g., temperature and pressure
probe. levels) and reviewing the log on a regular
basis. Consider having the chief engineer and
Consider installing ammonia detectors in the refrigeration technician sign the daily
areas where a substantial leak could occur engine room log. In designing new systems
or if the facility is not manned 24 hours/day.
The ammonia detectors should be monitored
by a local alarm company or tied into a call-
down system. Ensure that the ammonia
detectors are calibrated regularly against a
known standard. Check the operation of
ammonia sensors and alarms regularly.
Properly post ammonia placards (i.e. NFPA Establish written emergency procedures and
704 NH3 diamond) and warning signs in instructions on what to do in the event of an
areas where ammonia is being used as a ammonia release.
refrigerant or being stored (for example,
compressor room doors). Properly identify Regularly conduct emergency response drills.
the chemicals within the piping system(s); Emergency response personnel should "suit
label all process piping, i.e. piping up" as part of the drill process. As needed,
containing ammonia, as AMMONIA. members of the hazmat team should regularly
Label must use black letters with yellow suit-up to sharpen their emergency response
background. (This requirement is not the skills.
same as the in-house color coding system.)
Stage a realistic emergency response spill
Periodically inspect all ammonia exercise with the local fire company.
refrigeration piping for failed insulation/
vapor barrier, rust, and corrosion. Inspect Mount a compressor room ventilation fan
any ammonia refrigeration piping manual switch outside of the compressor
underneath any failed insulation systems for room and identify it with a placard for use in
rust and corrosion. Replace all deteriorated an emergency. Good practice would be to
refrigeration piping as needed. Protect all have ventilation switches located outside and
un-insulated refrigeration piping from rust inside of each door to the compressor room.
and/or corrosion by cleaning, priming, and
painting with an appropriate coating. Mount windsocks in appropriate places and
incorporate their use into the facility
Carry out regular inspections of emergency emergency response plan. In addition to the
equipment and keep respirators, including emergency response plan, consider
air-purifying and self-contained breathing developing additional materials (posters,
apparatus (SCBA), and other equipment in signs, etc.) to provide useful information to
good shape; ensure that personnel are employees and emergency responders in case
trained in proper use of this equipment. For of an emergency. In developing emergency
SCBA, it is important to ensure that air is information, consider whether materials
bone dry. For air-purifying respirators, should be developed in languages other than
replace cartridges as needed and check English.
expiration dates.
Keep piping and instrumentation diagrams
Consider using the compressor room (P&IDs), process flow diagrams, ladder
ammonia detector to control the ventilation diagrams, or single lines up-to-date and
fans. incorporate them into training programs for
operators. A good suggestion is to laminate
Identify the king valve and other emergency the P&ID and ladder diagrams and post
isolation valves with a large placard so that nearby to the equipment.
they can easily be identified by emergency
responders, in case of an emergency. These Frost accumulates on evaporator coils. The
valves should be clearly indicated on the evaporator can be "soft gassed" during the
piping and instrumentation diagrams defrost cycle by placing a smaller hot gas
(P&IDs) and/or process flow diagrams. solenoid valve in parallel with the main hot
6 HAZARDS OF AMMONIA RELEASES AT AMMONIA REFRIGERATION FACILITIES (UPDATE) AUGUST 2001
gas solenoid valve. The smaller valve is educational videos, short course, and an annual
sequenced to open first; thereby, allowing conference.
the evaporator pressure to rise slowly. An 110 North Glebe Road, Suite 250
alternative approach is to use a motorized Arlington, VA 22201
full port ball valve in the hot gas supply line Tel: (703) 312-4200
and open it slowly initially to accomplish www.iiar.org
the soft gassing. Once the pressure in the
evaporator is brought up, then fully open the Refrigeration Engineers Technicians Association:
valve. For additional information, consult offers self-study materials and a tiered
IIARs Ammonia Refrigeration Piping certification/evaluation program for refrigeration
Handbook. technicians/mechanics.
700 W. Lake Avenue
References Glenview, IL 60025-1485
Factory Mutual. 1993. Loss Prevention Data Tel: (847) 375-4738
Bulletin 12-61 (April 1993). www.reta.com
IIAR. 2000. Ammonia Refrigeration Piping CEPPO has prepared a general advisory on ammonia
Handbook (OSWER 91-008.2 Series 8 No. 2), available at:
www.epa.gov/ceppo/acc-his.html.
http://www.epa.gov/ceppo/
NOTICE
The statements in this document are intended solely as guidance. This document does not substitute for
EPA's or other agency regulations, nor is it a regulation itself. Site-specific application of the guidance may
vary depending on process activities, and may not apply to a given situation. EPA may revoke, modify, or
suspend this guidance in the future, as appropriate.