STANDARD OPERATION PROCEDURE DOCUMENT NO: SOP 01
REVISION NO: 00
DATE OF ISSUE: 2021.12.15
Ammonia Plant
1.0 Objective: To ensure safety, cleanliness and proper operation of emergency generator.
2.0 Scope: Efficient plant operation.
3.0 Responsibility: Overall responsibility goes to Head of the section, Electrical Engineer,
Electrical Supervisor and Electricians.
4.0 Safety Precautions:
a. Safety Shoes and Gloves Should be worn.
b. Relevant equipment should be used.
5.0 Compressor initial Startup
I. Operating conditions (suction and discharge pressure and temperature, lubrication oil
temperature, lubrication oil level, etc.) to ensure a safe start-up.
II. Corrective actions required if the conditions are outside of allowable limits.
III. Location of the compressor electrical connections.
IV. Position of the compressor isolation and service valves.
V. Status of the lubrication oil cooling system.
VI. Function of the compressor alarm systems.
VII. Steps to start the compressor.
6.0 Monitoring Normal Operation
I. Verify that the following compressor parameters are within expected operating limits
and troubleshoot as necessary:
a. Discharge pressure and temperature.
b. Suction pressure and temperature.
c. Oil pressure and temperature.
d. Oil filter pressure drop.
e. Oil level.
II. Verify that shaft seal leakage is within the allowable limits specified by the
manufacturer.
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STANDARD OPERATION PROCEDURE DOCUMENT NO: SOP 01
REVISION NO: 00
DATE OF ISSUE: 2021.12.15
Ammonia Plant
III. Verify that there are no ammonia or oil leaks from the compressor beyond allowable
limits of shaft seal leakage specified by the manufacturer. Verify that there are no
unusual noises or vibrations.
7.0 Condenser Initial Startup
I. Appropriate practices if the condenser will be started following general maintenance,
emergency shut down or after a system modification.
II. Appropriate conditions (pressure, temperature, water flow, etc.) to ensure a safe start
up.
III. Corrective action required if the conditions are outside of appropriate limits.
IV. Location of the condenser electrical disconnect.
V. Position of the condenser isolation and service valves.
VI. Function of the condenser alarm systems.
VII. Steps to start the condenser water flow and fans.
8.0 Condenser Monitoring Normal Operation
I. Verify that the following condenser parameters are within expected operating limits
and troubleshoot as necessary:
a. Discharge pressure.
b. Water treatment limits.
c. Water temperature.
II. Verify that there are no ammonia or water leaks from the condenser.
III. Verify that the water supply to the condenser(s) is on and if a sump is used the water is
at the proper level.
IV. Verify that the level control is properly working.
V. Verify that the water pump shaft seal is not leaking.
VI. Verify that there are no unusual noises or vibrations.
VII. Verify good water spray on coils.
VIII. Verify tension on fan belts.
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STANDARD OPERATION PROCEDURE DOCUMENT NO: SOP 01
REVISION NO: 00
DATE OF ISSUE: 2021.12.15
Ammonia Plant
9.0 Preventive Maintenance
I. Compressors should be inspected annually according to manufacturer's
recommendations.
II. Oil should be inspected and replaced periodically in accordance with compressor
manufacturer's recommendation.
III. Filters should be cleaned or replaced periodically.
IV. Safety controls should be inspected and operated manually to insure that they are
functioning properly. Replacements should be made immediately where necessary.
V. Shut-off valves should be checked by operating each valve. The valve stem should be
free of paint or rust and the packing must not leak.
VI. Electrical control valves should be checked by operating manually. Defective
components, such as coils, pilot lights, and gauges should be replaced. Strainers in the
line feeding the valve in question should be checked and cleaned, especially if the
system has a loss of capacity.
VII. Oil drains should be checked frequently and excess oil removed. All caps or plugs
should be refitted after completion of the oil draining operation.
VIII. Expansion valves should be checked for proper setting. If thermostatic expansion
valves are used, make certain that there is no damage to either the bulb or the capillary,
and that the bulb is clamped firmly in its correct position.
IX. Pressure gauges and thermometer should be checked and recalibrated or replaced where
necessary.
X. Sight glasses should be clean and unobstructed; clean when necessary. Protective
shields should be properly placed.
XI. Float controls and level alarms should be inspected visually and checked operationally
to insure that they are functioning properly.
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STANDARD OPERATION PROCEDURE DOCUMENT NO: SOP 01
REVISION NO: 00
DATE OF ISSUE: 2021.12.15
Ammonia Plant
XII. Refrigerant pumps should be checked for performance. The packing should be checked
for leakage and the belts or couplings checked for tension, alignment, and possible
wear. All pumps should be lubricated periodically in accordance with the
manufacturer's recommendations.
XIII. Safety equipment such as gas masks, air packs, water sprays, eye wash stations, and
emergency lighting must be inspected regularly.
10.0 Observation of System to Prevent Incident
I. Refrigerant pipelines, hangers and valves should be checked for vibration, movement
or breakage. A check should also be made for damaged insulation, broken or loose
conduit, damaged wall or roof sleeves, water line leaks or roof leaks above or around
ammonia piping and equipment. Unrelated Items: Check to see that items not related
to the ammonia system have not been attached to pipes or hangers, and that all
obstructions have been removed from around safety equipment, valve stations, and
control groups.
II. Leaks: Check the system for leakage. Traces of oil at flanged or screwed connections
or on valve packing nuts are indicators of such a leak. Such joints should be tightened
and rechecked for possible leakage.
III. Water systems should be checked for traces of ammonia in the water, using litmus
paper (litmus will turn blue in the presence of ammonium hydroxide).
IV. Safety valves: Check to make sure that all safety relief valves are in place and that the
discharge piping from the valve outlet is correctly installed and that it is free of
obstructions.
V. Control valves and safety switches should be inspected and checked to see that their
covers are in place.
VI. Pipeline identification: Make sure all piping is correctly identified.
VII. Weather-exposed piping should be checked for rust, deterioration, blisters, loss of paint
protection, and deterioration of insulation and vapor barrier.
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STANDARD OPERATION PROCEDURE DOCUMENT NO: SOP 01
REVISION NO: 00
DATE OF ISSUE: 2021.12.15
Ammonia Plant
VIII. Steel support members should be checked for deterioration.
11.0 Ammonia Contact with Eyes
I. Even if only a small amount of ammonia enters the eyes, irrigate the eyes with an
abundance of water for a minimum of 15 minutes.
II. Continually and thoroughly flush the entire eye surface and the inner lining of the
eyelids. Eyes affected by ammonia close involuntarily, so the eyelids must be held open
so that water can flush the entire eye surface, as well as the inner lining of the eyelid.
12.0 Ammonia Contact with SKIN
I. It is essential that any ammonia spilled on the worker be removed immediately and
that the worker be moved to an uncontaminated area quickly.
II. Clothes that have been saturated by liquid ammonia may freeze to the skin. In any case,
the victim, still clothed, should get immediately under a shower, if available, or jump
into a stock tank, pond, or into any other source of water. Time is important! Remove
clothes only after they are thawed and they can be freely removed from frozen areas.
If the clothing is removed incorrectly, whole sections of skin can be torn off.
III. No salves, creams, ointments, or jellies should be applied to the skin during a 24-hour
period following the injury since this will prevent natural elimination of the ammonia
from the skin. After the 24 hour period, the medical treatment is the same for thermal
burns.
13.0 Inhalation
I. In all inhalation exposures, severe or minimal:
a. Take the exposed workers at once to a clean, uncontaminated area.
b. Watch workers exposed to low concentrations for a short period of time.
They will usually require no treatment and can be released.
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STANDARD OPERATION PROCEDURE DOCUMENT NO: SOP 01
REVISION NO: 00
DATE OF ISSUE: 2021.12.15
Ammonia Plant
II. For severe exposure to higher concentrations:
a. Call a physician.
b. Administer oxygen by an individual who is trained and authorized to do so
by a physician. This will help relieve pain and symptoms of lack of oxygen.
c. Begin artificial respiration immediately if the patient is not breathing.
d. Keep victim warm (but not hot) and rested until transported to the hospital.
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