Refrigeration Issues and Developments Mike Odey Key words, skills and technology, competent person, peer review. This paper needs to be read in conjunction with one I presented last year titled “The Challenges of Refrigeration Piping Compliance in a Seismic Environment”. It is printed in the IRHACE Journal Sept / Oct edition last year.

Last presented to CSA in Ammonia Refrigeration – Queenstown Oct 2006 Ammonia Refrigeration – Risks and Compliance

August 2016 Refrigeration Safety Standard Changed

AS/NZS 1677 – Refrigerating Systems Part 1: Refrigerant Classification has been replaced by AS/NZS 817 Refrigerants – Designation and Safety Classification

AS/NZS 1677 – Refrigerating Systems Part 2: Safety Requirements for fixed application has been replaced by AS/NZS 5149 Parts 1 to 4 Refrigerating systems and heat pumps – Safety and environmental requirements

AS/NZS 5149 – Part 1 Definitions, classifications and selection criteria

AS/NZS 5149 – Part 2 Design, construction, testing, marking and documentation

AS/NZS 5149 – Part 3 Installation site

AS/NZS 5149 – Part 4 Operation, maintenance, repair and recovery

Is the ISO document with Appendices (Z Is the ISO document with Appendices (Z*) modifying, and with examples, to NZ and Australian conditions (e.g. calls up AS/NZS Standards)

The new standards change EVERYTHING related to refrigeration facilities design, operation, and maintenance

Ammonia refrigeration equipment spaces are either : Open Air Machinery Rooms, or Occupied Spaces

Ammonia Machinery Rooms require Gas Detectors and Ventilation

Ammonia refrigerant charges in excess of 4 Ammonia refrigerant charges in excess of 4.5 tonnes require alarm technical personell on site response within 60 minutes

Ammonia Machinery Room Ventilation should follow “Ventilation for Ammonia Systems” by Andy Pearson

Ammonia Emergency Wash - now required to be between 25 and 30oC Star Refrig Technical Bulletin No. 134

AS/NZS 1170 – Structural Design Actions Importance Levels

Seismic Design Process Determine the Seismic Design Factors To determine the accelerations to which the equipment may be subjected in an earthquake These are the coefficients which modify the Geographical Hazard Factor “Z” to determine the accelerations to which the item of equipment will be subjected. “The Seismic Coefficient in percentage of “g” (acceleration of gravity).

Equipment Height above Ground Level Flexibility Ductility Importance Level Soil Type Equipment Height above Ground Level Flexibility Ductility Design Working Life – for pressure equipment a minimum of 25 years. The longer the life, the higher the chance of a seismic event. There are additional factors to those mentioned above, including how components interact with each other, degree of redundancy within structure, “P-Delta” effects of vertical loads created by off centre loads with displacement, eccentric structures can twist vertically as they deflect horizontally, earthquake displacement can be in any direction, horizontally or vertically, or combination of those, generating complex loads on the structure, etc.

Importance Level Low Hazard 5 Catastrophic risk to a large area (e.g. 100km2) or a large number of people (e.g. 100,000) – for pressure equipment a minimum of 25 years. The longer the life, the higher the chance of a seismic event. There are additional factors to those mentioned above, including how components interact with each other, degree of redundancy within structure, “P-Delta” effects of vertical loads created by off centre loads with displacement, eccentric structures can twist vertically as they deflect horizontally, earthquake displacement can be in any direction, horizontally or vertically, or combination of those, generating complex loads on the structure, etc.

Industry Practice for IL 2 Coolstore Buildings 3 Ammonia Plant Rooms and Ammonia pipe / equipment supporting structures – for pressure equipment a minimum of 25 years. The longer the life, the higher the chance of a seismic event. There are additional factors to those mentioned above, including how components interact with each other, degree of redundancy within structure, “P-Delta” effects of vertical loads created by off centre loads with displacement, eccentric structures can twist vertically as they deflect horizontally, earthquake displacement can be in any direction, horizontally or vertically, or combination of those, generating complex loads on the structure, etc.

BUT !!!!! AS/NZS 1170.0 Table 3.2 IL4 for Buildings and facilities containing hazardous materials capable of causing hazardous conditions that extend beyond the property boundaries. – for pressure equipment a minimum of 25 years. The longer the life, the higher the chance of a seismic event. There are additional factors to those mentioned above, including how components interact with each other, degree of redundancy within structure, “P-Delta” effects of vertical loads created by off centre loads with displacement, eccentric structures can twist vertically as they deflect horizontally, earthquake displacement can be in any direction, horizontally or vertically, or combination of those, generating complex loads on the structure, etc.

Major Hazard Facilities (HSE Regs 2016) Are workplaces that have significant inherent hazards due to the storage and use of large quantities of specified hazardous substances. – for pressure equipment a minimum of 25 years. The longer the life, the higher the chance of a seismic event. There are additional factors to those mentioned above, including how components interact with each other, degree of redundancy within structure, “P-Delta” effects of vertical loads created by off centre loads with displacement, eccentric structures can twist vertically as they deflect horizontally, earthquake displacement can be in any direction, horizontally or vertically, or combination of those, generating complex loads on the structure, etc.

Lower Tier (LT) Upper Tier (UT) Depends on the aggregated quantities of the specified hazardous materials – for pressure equipment a minimum of 25 years. The longer the life, the higher the chance of a seismic event. There are additional factors to those mentioned above, including how components interact with each other, degree of redundancy within structure, “P-Delta” effects of vertical loads created by off centre loads with displacement, eccentric structures can twist vertically as they deflect horizontally, earthquake displacement can be in any direction, horizontally or vertically, or combination of those, generating complex loads on the structure, etc.

For Anhydrous Ammonia Lower Tier (LT) 50 tonnes Upper Tier (UT) 200 tonnes – for pressure equipment a minimum of 25 years. The longer the life, the higher the chance of a seismic event. There are additional factors to those mentioned above, including how components interact with each other, degree of redundancy within structure, “P-Delta” effects of vertical loads created by off centre loads with displacement, eccentric structures can twist vertically as they deflect horizontally, earthquake displacement can be in any direction, horizontally or vertically, or combination of those, generating complex loads on the structure, etc.

A LT MHF is not required to prepare a safety case but have additional process safety related duties that are proportionate to potential major incident hazards at the facility – for pressure equipment a minimum of 25 years. The longer the life, the higher the chance of a seismic event. There are additional factors to those mentioned above, including how components interact with each other, degree of redundancy within structure, “P-Delta” effects of vertical loads created by off centre loads with displacement, eccentric structures can twist vertically as they deflect horizontally, earthquake displacement can be in any direction, horizontally or vertically, or combination of those, generating complex loads on the structure, etc.

Pressure Equipment Regulations All pressure equipment with an internal pressure of more than 50 kPa and volume of 0.5 litres is required to : Be designed Have the design peer reviewed Have the equipment fabrication inspected Health and Safety in Employment (Pressure Equipment, Cranes, and Passenger Ropeways) Regulations 1999, require :

Code of Practice for Pressure Equipment Requires OSH approved – Independent Design Verification for high hazard equipment Independent Fabrication Inspection of high hazard equipment OSH has issued the “Approved Code of Practice for Pressure Equipment (Excluding Boilers)” which provides a means of complying with the Pressure Regulations,

Health & Safety at Work Act Safety issues arising during construction and maintenance are much easier to resolve at the concept and design stage than after commissioning. OSH has issued the “Approved Code of Practice for Pressure Equipment (Excluding Boilers)” which provides a means of complying with the Pressure Regulations,

Flammable Refrigerants All Synthetic Refrigerants will have some degree of flammability in future OSH has issued the “Approved Code of Practice for Pressure Equipment (Excluding Boilers)” which provides a means of complying with the Pressure Regulations,