Filling and Emptying of Ammonia Systems

As a part of the maintenance and repair of chillers there is often a need to safely empty the ammonia refrigerant. The selection of equipment and method is determined based on the amount of ammonia being handled, the type of installation, temperature/pressure of the ammonia, as well as the possibility of supplying heat to the section of installation that is going to be emptied etc. During emptying/filling for repairs/notching/reconstruction, the time available for the installation needs to be included in the time estimate for the system to be in operation again. Filling/Emptying of ammonia should always be carried out so as not to cause damage to the inner or outer environment. Risk assessment: Before starting work, an assessment of risks should be carried out. Is there an evacuation plan for the premises? Are all exits/doors unlocked so evacuation routes are not blocked? Are gas alarms installed? Is there a central shutdown for the cooling plant and other electricity in the premises? Is there emergency lighting? Is there emergency ventilation in the premises; how is this started? Is there a working emergency shower and eye rinsing facility? How is external assistance summoned? Always have a cellular phone ready with an up-to-date number pre programmed in. Is the access to the worksite restricted to the repair team only? An adequate safety zone around the work place should be closed off to anyone other than those working directly with filling/emptying. The size of the safety zone should be assessed on site. Warning sign(s) and barriers should be placed so that no one can enter the closed-off security zone by mistake. The customer/owner should be consulted so they can understand the work and the necessary safety precautions their employees will need to take. Normally, the facility owner/person responsible for operations is always the person responsible for safety. The customer needs to know about what risks the work entails. It is important not to scare anyone, but at the same time the customer needs to be fully aware of the safety plan if for any reason the work were to result in a discharge of ammonia. Rules for personnel: The filling/emptying of ammonia shall be carried out by technicians employed by Johnson Controls There should always be at least 2 people present during the filling/emptying of ammonia. Person No. Person 2 can be a person who is qualified for operating an ammonia installation and employed by the customer/facility owner. The responsible personnel from Johnson Controls should make sure that employees have understood their duties in connection with the filling/emptying operation. If necessary, person number 2 should be able to call for assistance. Person 2 should never be inside the same premises as the person carrying out the work itself. Work stoppages The work place must never be left with an open connection between a bottle/tank and the facility. Protective equipment:
Form # 12.08.08.03 Page 1 of 5 Effective Date 01 Jan 2010
This document contains trade secrets and proprietary information of Johnson Controls, Inc. Disclosure of this publication is absolutely prohibited without express written permission of Johnson Controls, Inc. 2009 Johnson Controls, Inc. All rights reserved. Uncontrolled copy of an online document.

Filling and Emptying of Ammonia Systems

A full-face gas mask with a filter for ammonia (colour designation green), check the date of the filter and that the mask is in good condition. A chemical suit. Long lined chemical gloves designed for ammonia. An appropriate rubber material is Nitrile. Protective boots.

Application Ammonia containers should be stored in such a way that they are not exposed to sunlight. Ammonia containers should be stored and handled so that they cannot overturn and cause injury to people or damage to equipment. Only hoses and fittings equipped with aluminium seals designed for ammonia may be used. A face mask and gloves should be used when connecting and disconnecting bottles. A personal gas mask should be readily accessible. Open the connection between a container and system slowly. Check for leakage. There will be a smell of ammonia in the room when connecting and disconnecting. Think about the gas alarm before it shows any reading. In the event of a discharge that is greater than what is considered to be normal, the customer/facility owner should be summoned. A warning procedure should be decided with the person with primary responsibility for communicating with the owner. Make sure that there is good ventilation during the operation and take the surroundings into consideration. Never leave a bottle unattended while emptying or filling as long as a valve on a bottle or tank in the facility is open. Filling During filling, ammonia bottles are placed one by one in a bottle stand. Ammonia containers must not be heated with anything more than 40C to increase pressure. Hot water with a limited temperature is appropriate. Document the filling after the operation has been completed.

Form # 12.08.08.03

Page 2 of 5

Effective Date 01 Jan 2010

This document contains trade secrets and proprietary information of Johnson Controls, Inc. Disclosure of this publication is absolutely prohibited without express written permission of Johnson Controls, Inc. 2009 Johnson Controls, Inc. All rights reserved. Uncontrolled copy of an online document.

Filling and Emptying of Ammonia Systems

Emptying Rules for emptying equipment: Drain valves in facility and on a bottle or tank should be easily accessible. Scales with an adequate weighing plate for an ammonia bottle and measuring precision of +/0.2 kg. If a tank is being used, this should be equipped with a level meter so that it is always possible to check the level of the liquid in the tank. If an emptying unit is being used (with a compressor), this should be equipped with an automatic shutdown of high pressure (high pressure monitor). Install a check valve between system and hose. There are special discharge bottles (57 kg) with a red ring around the valve and tanks (520 kg) with level meters that can be rented from specialist suppliers. Emptying a bottle: Pipes or containers at the tapping point should be drained of oil before the work with emptying ammonia starts. Ammonia containers, once cooled down, are vertically placed on scales intended for this purpose with the valve facing upwards. The bottle should be secured against falling. The dead weight of the bottle will be checked against stamped pm value and the weight will be logged in a check list. A hose or steel pipe is connected to the installations liquid side; on the pressure side if the installation can be run and to the bottle. Use an undamaged aluminium gasket. Open the valve on the bottle carefully. The nut on the packing box can be loosened to facilitate the opening of bottle valve. The installations discharge valve is carefully opened; check for leakage in the entire connection. If the installation can be run, water with a max. temperature of 40C can be used to heat the installation section with liquid to maintain the pressure difference between installation and bottle. The bottle can be cooled with cold water to lower the pressure in the bottle. The weight of the bottle is checked continuously. Filling can be stopped when 95% of the bottles normal content is obtained, i.e. it should not be filled to more than 54 kg in a container stamped for 57 kg. The installations valve is closed. Wait until the hose/pipe is empty. The containers normal filling, often indicated on the bottle, implies 85% of the total volume. Close the bottles valve and disconnect the hose/pipe. There will be ammonia residue in the connection; for this reason, great care should be taken. A blind nut and a valve cover are mounted on a bottle. Think about the gas alarm when disconnecting a connection.

Form # 12.08.08.03

Page 3 of 5

Effective Date 01 Jan 2010

This document contains trade secrets and proprietary information of Johnson Controls, Inc. Disclosure of this publication is absolutely prohibited without express written permission of Johnson Controls, Inc. 2009 Johnson Controls, Inc. All rights reserved. Uncontrolled copy of an online document.

Filling and Emptying of Ammonia Systems

Discharging to a tank Among other things, when discharging to a tank one must decide upon the following during planning: Should an external compressor unit be used, should the external compressor unit be connected so that it sucks ammonia gas from the installation or to lower the pressure in the tank. Normally, the discharging compressor should be connected with the suction side to the tank and the pressure side to the part of the system to be drained of liquid. How should the last little drop be removed? Pipes or containers to be drained of ammonia should be drained of oil (see instruction for emptying oil) before emptying of ammonia can be started. If the tank is empty of ammonia, it should be vacuum extracted before emptying can be commenced. When draining the installation, often an external compressor is needed. A hose or steel pipe is connected to the installations liquid side; on the pressure side if the installation can be run and to the bottle. Use an undamaged aluminium gasket. Open the discharge valve on the tank carefully. The installations discharge valve is carefully opened; check for leakage. After completed discharge, the installations discharge valve is closed first. Emptying and disconnection of a hose/pipe should be carried out with great care. Try to empty the hose/pipe of liquid before the tanks valve is closed. Then the hose/pipe is disconnected. There will be ammonia residue in the transfer pipe; for this reason, great care should be taken. A blind nut/flange will be installed on the tanks connections

Discharging to a water bath As much as possible, discharging to a water bath should be avoided as water containing > 10% ammonia is regarded as hazardous waste. Such water should be delivered to an approved receiver of hazardous waste. Even water with small amounts of ammonia can be difficult to get rid of in any other way. Water containing ammonia must never be emptied in a watercourse, unknown street drains or directly on the ground. Blow-off to air In many contexts, blow-off to air may be the best method for preparing an installation section for intrusion. The method is often used in connection with service and the discharge of small volumes. The method can also be used to advantage for discharging larger gas volumes provided that there is an adjustment to the amount to be discharged. Blow-off to air should always be carried out so that air containing ammonia gas cannot be spread to rooms, buildings or areas in which people, products or other values can be damaged. Pay special attention to air intakes for ventilation.

Form # 12.08.08.03

Page 4 of 5

Effective Date 01 Jan 2010

This document contains trade secrets and proprietary information of Johnson Controls, Inc. Disclosure of this publication is absolutely prohibited without express written permission of Johnson Controls, Inc. 2009 Johnson Controls, Inc. All rights reserved. Uncontrolled copy of an online document.

Filling and Emptying of Ammonia Systems

People unfamiliar with ammonia become scared even for very small concentrations in air. Evaluate where the ammonia is to be blown off in proportion to the amount to be blown off. If possible, ammonia gas should be blown off above roof level, but: o Always check that ammonia gas cannot be sucked into ventilation intakes. o Always assess the direction of the wind in relation to the surrounding buildings and traffic (both pedestrian and vehicle traffic). If the condenser is placed on the roof, it may be advantageous to locate a blow-out pipe/hose so that the ammonia gas is transported upwards by the condenser fans.

Under no circumstances may liquid ammonia or water mixed with ammonia be led out into surface water culverts or creeks, brooks or lakes. In some municipalities, surface water drainage can be used after permission has been granted by the local purifying plant. Clarify exactly which well may be used. Locally, many surface water sewers can drain directly to watercourses. The destruction of ammonia should be carried out an approved receiving station

Form # 12.08.08.03

Page 5 of 5

Effective Date 01 Jan 2010

This document contains trade secrets and proprietary information of Johnson Controls, Inc. Disclosure of this publication is absolutely prohibited without express written permission of Johnson Controls, Inc. 2009 Johnson Controls, Inc. All rights reserved. Uncontrolled copy of an online document.