The material and energy balance should document the overall change in energy in the compressors, cooling evaporators, and condensers. Ideally it will provide indication that the compressor capacities exceed the projected system loads, and that the condenser capacities exceed the compressor capacities.

The following items should be included in the relief system design calculation documentation:

• Identification and description of each relief device.
• A listing of all equipment which will be relieved through the device.
• Design pressure.
• Set pressure.
• Listing of all sources of overpressure considered.
• Identification of the worst case overpressure scenario or relief design.
• State of material being relieved (i.e., liquid, vapor, liquid-vapor, liquid-vapor-solid, along with an identification of the material which was the basis for the relief device selection).
• Physical properties of the relieved materials, vapor rate, molecular weight, maximum relieving pressure, heat of vaporization, specific gravity and viscosity.
• Design calculations.

The valve tag index contains a full list of all the valves in the refrigeration system with their line names and normal operating positions. 

Facilities must have piping and instrument diagrams (P&IDs) for the equipment in the refrigeration system. P&IDs are detailed drawings which may contain the following items:

• A lead sheet containing a legend of the symbols and abbreviations used on the P&IDs.
• Refrigeration equipment (vessels, compressors, pumps, condensers, etc.) and a descriptive name or identification number. P&IDs should be set up to indicate relative elevations of equipment and to depict gravity and pumped flows where possible. Pre-fabricated equipment packages will typically not be shown in detail unless it is necessary for a clear portrayal of the refrigeration piping, instrumentation or utility connections.
• Equipment description blocks which often list the manufacturer, model number, capacity, design limits, and materials of construction.
• Valves, strainers, and relief valves shown schematically using the symbols on the lead sheet.
• Instruments (pressure gauges and transmitters, level gauges and transmitters, temperature gauges and transmitters, etc.) identified and numbered in accordance with the lead sheet and ISA standards. Control strategy, including associated alarms and interlocks, should be clearly indicated with instrument functions and mounting locations shown.
• Refrigeration piping contained in the system. Sections of piping typically contain a unique identification number which indicates the line size, service (contents of the line), line number (a unique number for referring to that line), pipe class (material of construction), insulation (if applicable), and heat tracing (if applicable).
• Refrigeration line continuations from drawing to drawing which extend to the edge of the drawing.
• Title blocks for each drawing indicating the company name, facility location, type of drawing, simplified drawing name, drawing number, person who prepared the drawing, revision number, revision date, and provisions for drawing approval.

The materials of construction of each equipment item must be clearly documented. Items which may be used to document the materials of construction for the refrigeration systems include:

• Equipment description blocks contained on the piping and instrument diagrams.
• Piping identification systems associated with the piping and instrument diagrams.
• Equipment data forms filled out by facility personnel.
• Fabrication or installation drawings provided by the manufacturer or vendor.
• Material certificates provided by the manufacturer such as U-1, U-1A, U-2, and R-1 manufacturers data reports for pressure vessels.
• Vendor manuals

Areas of a facility which contain flammable or combustible materials are normally classified according to the flammability of these materials and the probability that they may be released from their normal containment system. This classification is conducted to determine the degree of protection required to prevent ignition of flammable materials by installed equipment or temporary equipment.
References which may be used to define hazardous area classifications are:

• NFPA 70, National Electrical Code, National Fire Protection Association (NFPA).
• NFPA 497A, Classification of Class I Hazardous (Classified) Locations for Electrical Installations in Chemical Process Areas, National Fire Protection Association (NFPA).
• ANSI-ASHRAE 15, Safety Code for Mechanical Refrigeration, American National Standards Institute-American Society of Heating, Refrigerating and Air-Conditioning Engineers, Inc. (ANSI-ASHRAE).
• ANSI-IIAR Standard 2–2014 Addendum A, Guidelines for: Ammonia Machinery Room Ventilation, International Institute of Ammonia Refrigeration (IIAR).

Ammonia machinery rooms may be classified as non-hazardous, unclassified locations under the National Electrical Code (NEC) if they meet the criteria for ventilation systems set out in documents such as ANSI-ASHRAE 15 and ANSI-IIAR Standard 2–2014 Addendum A. Non-hazardous classification will eliminate the requirements imposed by a Class 1, Division 2 classification.

ANSI/IIAR-2 2014 Addendum A Section 6.8.1 which states:

Machinery rooms shall be designated as Unclassified Locations, as described in the Electrical Code, where the machinery room is provided with emergency ventilation in accordance with Section 6.14.7 and ammonia detection in accordance with Section 6.13.

Ammonia refrigeration equipment operating procedures include:

• Objectives and Purpose.
• Safety and Health Considerations.
• Equipment Information.
• Function.
• Identification and Capacity/Size
• Operating Limits.
• Safe upper and lower limits.
• Consequences of deviation.
• Steps required to correct or avoid deviation.
• Steps for each operating phase:
  • Initial startup.
  • Normal operations.
  • Temporary operations.
  • Emergency shutdown.
  • Emergency operations.
  • Normal shutdown
  • Start up after an emergency shutdown

We can also offer training for you on your newly developed operating procedures at your location or we can offer you training through a webinar if desired. Additional cost will be applied.

Certification by a national board of boiler and pressure vessel Inspectors that the pressure vessel has been constructed in accordance with ASME Boiler and Pressure Vessel Code. Manufacturer data reports such as ASME U1, U1A, or U3 forms should be kept on file for all system pressure vessels.

The process or block flow diagram includes the basic flow of refrigerant through each piece of equipment within the refrigeration system. 

The ventilation system design calculation determines the applicable codes and standards requirements for ventilation capacity. It should then display the installed ventilation system capacities and ensure they meet the code requirements.

Lockout/Tagout procedures are designed for each piece of equipment to safely isolate or shut the equipment down for maintenance.

The maximum intended inventory calculation includes the maximum intended and design inventory of refrigerant within the system. 

Calculation that estimates the amount of refrigerant lost during a leak using basic engineering principles and industry standards.

The design codes and standards document is created for the initial construction of any faciliity and any subsequient expansions/additions. The documentation describes the codes and standards that were in effect during the design/build process.

The EPA RMP submission requires all facilities that hold above a threshold quantity of a hazardous chemical to develp a isk Management Plan which identifies the potential effects of a chemical accident, identifies steps the facility is taking to prevent accidents, and lays out emergency response procedures in the event an incident does occur.