TIPS & TOOLS:  Maintaining Ammonia Safety

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Ammonia is the most widely used refrigerant in the food and beverage industry.  There are several ways that you can insure that your plant reduces the risk of leaks and injury. The following are 10 tips for maintaining ammonia safety in your plant.

1. Use only qualified and experienced refrigeration contractors to install, modify or service your ammonia system.  PSM requires that an outside contractor complete an annual inspection of your plant and SOP’s.
2. Most operators know how the plant runs. Be alert of noises that are out of the ordinary and maintain daily logs that can show slight changes in the system that can cause a problem. Keep an eye out for problems like excessive oil use, pipe vibration, high levels in vessels and flange leaks.
3. When installing a new system, locate the ammonia piping and valve stations outside of the building on the roof.  For older facilities, consider moving the mains, valve stations and branch pipe connections onto the roof. In the event of a flange leak, the leak will be outside of the building. 
4. On a new system, plan for future loads and install branch isolation valves. Always cap the valve and use a drain valve in the stub for pressure release in the event the branch valve leaks. Cap all abandoned and service valves when not in use. An example would be your oil drain valves.
5. Check for deficiencies in your pipe insulation. Deficiencies in the insulation can rupture the vapor barrier and allow in moisture, the moisture can corrode the pipe. All insulation deficiencies and corroded pipe should be replaced.
6. Provide ongoing training for the ammonia system operators. Training should include safety, maintenance, operation and emergency response. Ongoing training is part of your PSM program.
7. Operators should be aware and study the start up, shutdown and SOP procedures for all pieces of equipment and valves.
8. Complete routine maintenance, make repairs to equipment and valves, and report the deficiencies. Keeping the system in tip top shape is the best way to avoid leaks and problems.
9. Make sure that you have all of your emergency and maintenance PPE. Keep it in good working order and in an easily accessible area.
10. Be sure to work with the local authorities, fire department and inspectors, in the event that you have an ammonia release. This will make an incident go smoothly. Also keep all of the emergency phone number listed in multiple locations in the plant

The key to safety is a well-maintained and operating plant. We all want to avoid an ammonia leak and go home safely to our families each night.