Ammonia Site Evacuation

To stay or not to
stay?
Adam Bowey - Grenco Refrigeration Ltd.
 To Stay or Not To Stay
AGENDA

Ammonia Emergency Evacuation

Procedures
Ammonia Emergency Evacuation
Training Validation
Ammonia Procedure
Case Studies:- To stay or not to stay?

Adam Bowey - Grenco Refrigeration

Ltd.
Ammonia Emergency Evacuation
Procedures
Why do we need an emergency
evacuation procedure?
Safety devices and strict design makes the
risk of a leak very small, however
additional measures must be in place in
the unlikely event of a major ammonia
leak.

Adam Bowey - Grenco Refrigeration

Ltd.
Ammonia Emergency Evacuation
Procedures
How will I know that there has been an
ammonia leak?

Leak sensors are sited all round the

refrigeration plant, in the event of a leak an
alarm will sound.
An announcement will be made to all staff.
The announcement will advise the course of
action to be followed. On no account are you
to leave the building until you are told to do
Adam Bowey - Grenco Refrigeration
Ltd.
so.
Ammonia Emergency Evacuation
Procedures
Will I be able to smell ammonia in the main
building?

Probably not, if a leak does occur it is most likely that it

will be in the refrigeration plant room or in the roof
void. These areas have automatic extract ventilation
that will discharge ammonia at roof level, ammonia
gas is lighter than air it will disperse in the
atmosphere.

What if I smell ammonia where I am working?

Evacuate to the nearest adjacent room with your

colleagues and report the incident. Note that
ammonia can be detected by smell at very low
Adam Bowey - Grenco Refrigeration
concentrations, much lower Ltd. than those that cause

harm This provides useful early warning system

Ammonia Emergency Evacuation
Procedures
Why do we not evacuate the building?

Ammonia is a liquid, which very quickly turns to gas

when it comes in contact with air, and as such will be
carried by any wind. Depending on the area the leak is
and in the direction of the wind, you may be able to
continue working, or you may be asked to assemble in
a particular area of the building, as it may be safer to
stay inside.

Where will we assemble?

There are designated site assembly points.

Adam Bowey - Grenco Refrigeration
Ltd.
Ammonia Emergency Evacuation
Procedures
How will we know where to assemble?
The assembly point you have to go to will depend on the wind
direction because ammonia is a gas. The announcement will
tell you exactly which assembly point you have to go to.
Remember the direction of the wind will not always be the
same.

If we evacuate what route do I use?

Unlike a fire evacuation you may not be able to use the most
direct or quickest route to an evacuation point, you will be
given clear directions at the time as to which route you should
use.
Do remember that as with a fire evacuation, you must not stop
to collect personal belongings, run, or re-enter an affected
area or the building until you have been given clear
instructions that it is safe to do so.
Adam Bowey - Grenco Refrigeration
Ltd.
Ammonia Emergency Evacuation
Procedures
What part do the emergency services have in this
procedure?

In the event of ammonia leak the Fire Brigade will be called to

site, on arrival the Senior Fire Officer will assume command of
the situation and will advise management on staff movements
around the site, and will issue instructions to the maintenance
contractors with a view to making the plant safe.

I am a driver what do I do?

In the event of a leak a member of the emergency team will

collect company drivers and direct them to an assembly point.
The emergency team will collect 3rd party drivers and direct
them to an assembly point.
Adam Bowey - Grenco Refrigeration
Ltd.
Ammonia Emergency Evacuation
Procedures
SUMMARY:
Ammonia leak incidents are rare.

Assembly Points and Evacuation Routes will be

announced

Listen carefully to all Assembly and Evacuation

instructions.

Do not evacuate the building unless instructed to

do so.

If assembly or evacuation is ordered ensure that

you are aware ofAdam
the appropriate
Bowey - Grenco Refrigeration Assembly
Ltd.
Point(s) and the Route(s) to take to evacuate the
 AMMONIA EMERGENCY EVACUATION
Staff Training Validation

How will you know if there has been an ammonia leak?

In the event of an ammonia leak what will you do?

Where are the ammonia leak assembly points inside the building?

Where are the ammonia assembly points outside the building?

How will you know which point to go to?

What dictates which assembly point you have to go to?

You must not do what, until given a clear instruction?

Trainees Signature: ______________________________________

Adam Bowey - Grenco Refrigeration

Ltd.
 Ammonia Procedure
1.0 Introduction

In the unlikely event of a serious leak of ammonia it is

vital that immediate action is taken to minimise risk to
life or property.

To this end the site that has ammonia refrigeration

shall produce Ammonia Alarm - Emergency
Response Instructions

In general the procedure for this site regardless of

staffing or configuration shares the essential steps of
internal notification, external notification and
evacuation.
Adam Bowey - Grenco Refrigeration
Ltd.
 Ammonia Procedure
2.0 Probability of Ammonia Leaks

The food manufacturers ammonia refrigeration system is

designed, built, maintained and inspected to strict regulatory
and industry standards. Catastrophic failure or serious leaks
in plants to these standards are very rare. Ammonia plants
are constructed entirely from steel pipework that is much less
prone to leakage than the copper pipework normally used with
other refrigerants.

Minor leaks, mainly in the refrigeration plant room (less often

in the condenser location) occasionally occur. These leaks
are usually from shaft seals, pipe flanges or valve stems.
Plant rooms containing ammonia equipment are fitted with
ammonia sensing alarms that automatically start ventilation
systems that vent ammonia gas to atmosphere.
Adam Bowey - Grenco Refrigeration
Ltd.
 Ammonia Procedure
3.0 Ammonia Hazards

Ammonia gas is toxic and in a fairly narrow band of concentration

with air (160,000 to 270,000ppm by volume) is flammable and
explosive.

Ammonias pungency is however a significant advantage as it can

be detected by smell at concentrations of 5ppm upwards and
therefore warns personnel against remaining in a harmful
concentration.

Short term exposure to concentrations of about 200ppm will cause

irritation and discomfort to the mucous membrane and the eyes but
with no lasting consequences. Exposure to concentrations above
1500ppm will damage or destroy body tissue whilst exposure to
2500ppm and above increases the risk of fatality

Adam Bowey - Grenco Refrigeration

Ltd.
 Ammonia Procedure
4.0 Ammonia Leak Detection

Automatic Leak Detection is installed in refrigeration plant

rooms and where applicable in roof voids via two stage
alarms: -

Level 1: - This level is set at a maximum 500ppm

Level 2: - This level is set at a maximum 30,000ppm (3% by

volume) and denotes a major leak.

Human Leak Detection at 5ppm upwards is more sensitive

than the automatic equipment and provides a valuable early
warning system
Adam Bowey - Grenco Refrigeration
Ltd.
 Ammonia Procedure
5.0 Plant and Equipment
The design and operation of ammonia refrigeration plants is
subject to number of regulatory and standards requirements
including, but not limited to: -

HSE Guidance Note PM81 (Published 1995)

Construction (Design and Management) Regulations 2007
Pressure Systems Safety Regulations (2000) Written Scheme
of Examination required
EC Pressure Equipment Regulations 1999 (PED)
BS EN 378:2008 Parts 1/2/3/4 Refrigerating Systems and Heat
Pumps Safety and Environmental requirements. (Part 1 not
issued)
Institute of Refrigeration Safety Code for Compression
Refrigerating Systems Utilising Ammonia (under revision)

Adam Bowey - Grenco Refrigeration

Ltd.
 Ammonia Procedure
6.0 Emergency Response Procedures

On actuation of alarm, emergency team

informed.
Call out to specialist refrigeration contractor.
Emergency team call fire brigade.
Establish wind direction and tailor evacuation
plans accordingly. (wind sock)
Emergency team will announce on the action
to be taken.
Adam Bowey - Grenco Refrigeration
Ltd.
 Ammonia Procedures
6.0 Emergency Response (continued)

Emergency team will check ventilation systems, doors and

windows.
Ammonia alarm sounder must be different from fire alarm
Call an ambulance if aware of injuries and ensure access
available for emergency vehicles.
Emergency team and specialist contractor must stand by to
assist fire brigade
Specialist contractor may effect repairs if safe
Employees and visitors must ONLY return to evacuated areas
after being instructed to do by emergency support team or fire
brigade.
Additional procedures will be required for out of hours

Adam Bowey - Grenco Refrigeration

Ltd.
 Ammonia Procedure
7.0 Ammonia Emergency Action Plan

Isolation of the leak and the rescue of any persons in the leak
area with the assistance of the emergency services

Location of plant rooms and associated pipework

Site general arrangement plan of ammonia plant and pipework.
Plant emergency shut down procedure
Risk Assessment of each area showing what action should be
taken if ammonia leak occurred in area; include details of fans
and means of escape.

COSHH assessment sheets and manufacturer safety data

sheet for ammonia

First aid treatment to be administered in the event of exposure

Adam Bowey - Grenco Refrigeration
Ltd.
 CASE STUDY No 1
Site Layout (Chilled Cold Store)
- Large Industrial Estate, With Ammonia Plant
Room At Rear Of Store.
- Access Road To Factory Runs Parallel To
Ammonia Plant Room
What Happened:-
Plant room contained ammonia / glycol heat
exchangers. A heat exchanger split leaking
ammonia content (1,000kg) onto the plant
room floor.

Adam Bowey - Grenco Refrigeration

Ltd.
 CASE STUDY No 1
(Continued)
Refrigeration contractor was on site working on the
refrigeration plant.
Action / Response
The plant room was evacuated and the relevant duty
manager notified of the incident. The internal
employers work force were limited to work in certain
zones of the store only.
The plant room had an exclusion zone and the access
road was closed. It was assessed to be unsafe to
enter the plant room due to the high concentration of
ammonia local to the heat exchangers. A decision was
made by the employer and the refrigeration contractor
not to call the emergency services (Fire Brigade)

Adam Bowey - Grenco Refrigeration

Ltd.
 CASE STUDY No 1
(Continued)
Conclusion
The ammonia content in the heat
exchanger and vessel above was left to
leak to atmosphere before the refrigeration
contractor was permitted to continue with
the service repair.
QUESTIONS / ANSWERS

Adam Bowey - Grenco Refrigeration

Ltd.
 CASE STUDY No 2
Site Layout (Frozen Food Distribution)
- Small distribution outlet, With Ammonia Plant
Room at rear of Building and close to
residential area (Refrigerant charge 700kg)
- Direction of leak away from residential area
towards well established trees and residential
road
What Happened:-
Operator error reassembling a flanged filter.
The engineer opened the supply line to the
filter and liquid ammonia filled the room.
Adam Bowey - Grenco Refrigeration
Ltd.
 CASE STUDY No 2
(Continued)
Action / Response
The plant room was evacuated and the
relevant duty manager notified of the incident.
The local emergency services were called
(Fire Brigade), who assessed residential area
as safe
The service engineer entered the plant room
but was unable to gain access to the filter
housing due to the dense ammonia cloud.
The Fire Brigade attended site and controlled
the area until all leakage had stopped
Adam Bowey - Grenco Refrigeration
Ltd.
 CASE STUDY No 2
(Continued)
Conclusion
After initial attempt by the engineer, the
ammonia content was left to leak to
atmosphere (with fire brigade in
attendance) before the refrigeration
contractor was permitted to continue with
the service repair.
Damage to near by Trees
QUESTIONS / ANSWERS
Adam Bowey - Grenco Refrigeration
Ltd.
 To Stay or Not To Stay
SUMMARY

Ammonia Emergency Evacuation

Procedures are not optional and must
be site specific
Ammonia Emergency Evacuation
Staff Training for non specialist must
be validated
Ammonia Procedure Intended for
specialist and emergency response
staff
Adam Bowey - Grenco Refrigeration
Case Studies:- To stay or not to stay?
Ltd.