Mechanical Integrity Inspection for the Ammonia Refrigeration System

• Audit Title

• Client / Site

• Conducted on

  Date

• Prepared by

• Personnel

Sign In Sheets

• Inspector Name

  Sign

• Supervisor, Leads, Operators, Safety Coordinator Names In Attendance On Audit

  Sign

• Signature

Signature

• Supervisor, Leads, Operators, Safety Coordinator Names In Attendance On Audit

  Sign

Roof

Valve Stations

• Gauges in place and working properly

  Yes

  No

  N/A

• Paint is in good condition.

  Yes

  No

  N/A

• Defrost pressure between 65-70 PSI

  Yes

  No

  N/A

• Valve stems clean and lubricated

  Yes

  No

  N/A

• Valve stems exercised regularly

  Yes

  No

  N/A

• Pipe plugs in place

  Yes

  No

  N/A

• No evidence of leaks

  Yes

  No

  N/A

• Electrical boxes and conduit in good condition

  Yes

  No

  N/A

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Pipe and Insulation Condition

• Crossovers in place and in good condition

  Yes

  No

  N/A

• Piping in good condition

  Yes

  No

  N/A

• Proper pipe labels being used and in place

  Yes

  No

  N/A

• Insulation in good condition.

  Yes

  No

  N/A

• Pipe labels in good condition

  Yes

  No

  N/A

• Pipe saddles in place at pipe stands

  Yes

  No

  N/A

• Pipe stands in place and properly supporting pipes

  Yes

  No

  N/A

Safety Relief Vent Line

• Vent line exhaust 7.25 feet above working surface and 20 feet from any opening to the building.

  Yes

  No

  N/A

• Vent line sensor installed.

  Yes

  No

  N/A

• Rain cover in place on relief line to prevent contamination

  Yes

  No

  N/A

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Condenser

• Fans in good condition

  Yes

  No

  N/A

• Fan belts in good condition

  Yes

  No

  N/A

• Fan blades in good condition

  Yes

  No

  N/A

• Bearings in good condition

  Yes

  No

  N/A

• Piping in good condition

  Yes

  No

  N/A

• Paint on piping in good condition

  Yes

  No

  N/A

• Tubes in good condition - check for corrosion and scaling

  Yes

  No

  N/A

• Nozzles have good water pressure and coverage over tubes, none plugged.

  Yes

  No

  N/A

• Drift eliminators, sun blockers and fill media in place, clean, and in good condition

  Yes

  No

  N/A

• Water sump clean and free of debris

  Yes

  No

  N/A

• Water pumps running properly with no leaks

  Yes

  No

  N/A

• Structural steel in good condition

  Yes

  No

  N/A

• Electrical conduit and junction boxes in good condition

  Yes

  No

  N/A

• Water treatment is effective.

  Yes

  No

  N/A

• Valves in good working condition

  Yes

  No

  N/A

• Valves, Drift Eliminators and nozzles easily accessible

  Yes

  No

  N/A

DHU

• Does this facility have a Dehumidification Unit

  Yes

  No

• Filters in place and not clogged

  Yes

  No

  N/A

• Sensors in place and working properly

  Yes

  No

  N/A

• Valves in good working condition

  Yes

  No

  N/A

• Belts in good working order

  Yes

  No

  N/A

• Desiccant wheel in good working condition

  Yes

  No

  N/A

• Equipment operating properly

  Yes

  No

  N/A

Machine Room

Condenser Pumps and Water Treatment

• Condenser pumps working properly with no leaks

  Yes

  No

  N/A

• Condenser water is tested and results recorded daily.

  Yes

  No

  N/A

• Condenser Water Usage is Tracked

  Yes

  No

  N/A

• Condenser side stream filter is working properly.

  Yes

  No

  N/A

• Condenser water treatment chemical feed equipment is working properly.

  Yes

  No

  N/A

Glycol Loop

• Heat exchanger working properly

  Yes

  No

  N/A

• Relief valves in place and in compliance

  Yes

  No

  N/A

• Glycol pump working and in good condition

  Yes

  No

  N/A

• Glycol temperature between 40-50 degrees

  Yes

  No

  N/A

• Glycol flow is appropriate

  Yes

  No

  N/A

• Glycol liquid level is appropriate

  Yes

  No

  N/A

• Glycol valves in good condition

  Yes

  No

  N/A

• Glycol temperature probes working properly

  Yes

  No

  N/A

Cross Connection Regulator

• Cross connection regulator set properly and working

  Yes

  No

  N/A

Compressors - Screw

• Name plate legible

  Yes

  No

  N/A

• Relief valves in place and in compliance

  Yes

  No

  N/A

• Gauges in place and in good working condition

  Yes

  No

  N/A

• Economizer working properly

  Yes

  No

  N/A

• Set points set up properly

  Yes

  No

  N/A

• Guards in place

  Yes

  No

  N/A

• Filter pressure within acceptable limits

  Yes

  No

  N/A

• Operating limits are good

  Yes

  No

  N/A

• Anchors and grouting in good condition

  Yes

  No

  N/A

• Safety switches in place and working properly

  Yes

  No

  N/A

• Oil quality and changing is based on oil sampling analysis

  Yes

  No

  N/A

• Sensors reading accurately

  Yes

  No

  N/A

• Equipment is clean

  Yes

  No

  N/A

• Paint is in good condition

  Yes

  No

  N/A

• No oil leaks are evident

  Yes

  No

  N/A

• Valves are in good shape and working properly

  Yes

  No

  N/A

• Equipment is operating properly

  Yes

  No

  N/A

• Starters are in good condition and working properly

  Yes

  No

  N/A

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Compressor - Reciprocating

• Does system have Reciprocating Compressors?

  Yes

  No

• Name plate legible

  Yes

  No

  N/A

• Relief valves in place and in compliance

  Yes

  No

  N/A

• Gauges in place and in good working condition

  Yes

  No

  N/A

• Set points set up properly

  Yes

  No

  N/A

• Guards in place

  Yes

  No

  N/A

• Filter pressure within acceptable limits

  Yes

  No

  N/A

• Operating limits are good

  Yes

  No

  N/A

• Anchors and grouting in good condition

  Yes

  No

  N/A

• Safety switches in place and working properly

  Yes

  No

  N/A

• Oil quality and changing is based on oil sampling analysis

  Yes

  No

  N/A

• Sensors reading accurately

  Yes

  No

  N/A

• Equipment is clean

  Yes

  No

  N/A

• Equipment is operating properly

  Yes

  No

  N/A

• No oil leaks are evident

  Yes

  No

  N/A

• Valves are in good shape and working properly

  Yes

  No

  N/A

• Starters are in good condition and working properly

  Yes

  No

  N/A

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Vessels

• Name plate / ASME stamp legible

  Yes

  No

  N/A

• Level controls working properly

  Yes

  No

  N/A

• Bulls eyes in good condition

  Yes

  No

  N/A

• Oil pots in good condition

  Yes

  No

  N/A

• Insulation in place and in good condition

  Yes

  No

  N/A

• Feed valves working properly

  Yes

  No

  N/A

• All Safety float cut outs working properly

  Yes

  No

  N/A

• Relief valves in place and in compliance

  Yes

  No

  N/A

• Vessel is in good condition

  Yes

  No

  N/A

• Piping in good condition

  Yes

  No

  N/A

• Equipment is clean

  Yes

  No

  N/A

• Valves in good working condition

  Yes

  No

  N/A

• Electrical conduit and junction boxes are in good condition

  Yes

  No

  N/A

• Equipment is operating properly

  Yes

  No

  N/A

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Ammonia Pumps

• Pumps operating properly.

  Yes

  No

  N/A

• Gauges in place and working properly

  Yes

  No

  N/A

• Equipment operation good

  Yes

  No

  N/A

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• Does the system have Cornell pumps?

  Yes

  No

• Oil cutout switch working properly

  Yes

  No

  N/A

• Rotary guard working properly

  Yes

  No

  N/A

• Shaft seal in good condition - no seal leaked

  Yes

  No

  N/A

• Guards in place

  Yes

  No

  N/A

Oil Recovery System

• Oil recovery system in good condition and working properly

  Yes

  No

  N/A

Floors, Walls and Room Cleanliness, and Door Signage.

• Is the machine room restricted to authorized personal only?

  Yes

  No

  N/A

• Is There Proper Warning Signs on the Door?

  Yes

  No

  N/A

• No unauthorized storage in a machine room. Only refrigeration equipment and parts allowed

  Yes

  No

  N/A

• Floors in good condition

  Yes

  No

  N/A

• Walls are in good condition

  Yes

  No

  N/A

• Is the machine room including tools and benches clean?

  Yes

  No

  N/A

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Electrical / Panels

• Electrical panels are in good condition and doors closed

  Yes

  No

  N/A

• No open holes are in panel, especially the top

  Yes

  No

  N/A

• If filters are in panel filter is clean and fits opening properly

  Yes

  No

  N/A

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Pipes and Insulation

• Pipe hangers are adequate and adjusted properly.

  Yes

  No

  N/A

• Pipes are in good condition and painted

  Yes

  No

  N/A

• Insulation is in good condition and pipe saddles in place

  Yes

  No

  N/A

• Pipe and equipment labels are in place and meet IIAR standards

  Yes

  No

  N/A

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High Pressure Reciever

• Ammonia level within acceptable range

  Yes

  No

  N/A

• High pressure receiver is in good condition

  Yes

  No

  N/A

• Safety Relief valves in place and in compliance

  Yes

  No

  N/A

Ammonia Dispersion Tank

• Dispersion tank is in good condition with no leaks

  Yes

  No

  N/A

Transfer Hose

• Transfer hose is suitable for ammonia and certification date has not expired

  Yes

  No

  N/A

HVAC

• Does the main refrigeration system provide cooling to the HVAC system?

  Yes

  No

• Heat exchanger working properly

  Yes

  No

  N/A

• Relief valves in place and in compliance

  Yes

  No

  N/A

• Pump in good working order

  Yes

  No

  N/A

• Temperature set properly

  Yes

  No

  N/A

• Glycol flow is acceptable

  Yes

  No

  N/A

• Valves in good working order

  Yes

  No

  N/A

• Temperature probes working properly

  Yes

  No

  N/A

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Purger

• Equipment clean and bubbler easy to see through

  Yes

  No

  N/A

• Insulation in place and in good condition

  Yes

  No

  N/A

• Purger operation working properly. No leaks.

  Yes

  No

  N/A

• Purger cycle counts recorded

  Yes

  No

  N/A

Exhaust System

• Exhaust system operates when ammonia is detected

  Yes

  No

  N/A

• Exhaust system meets IIAR2-2008 standards

  Yes

  No

  N/A

• Fan belts in good condition

  Yes

  No

  N/A

• Fan blades in good condition

  Yes

  No

  N/A

• Intake dampers working properly

  Yes

  No

  N/A

• Exhaust fans can be started manually from outside the engine room

  Yes

  No

  N/A

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Evaporators

Freezer Evaporators / Penthouses

• Unit defrosting properly

  Yes

  No

  N/A

• Temperature set points set properly

  Yes

  No

  N/A

• Penthouse doors closing and sealing properly

  Yes

  No

  N/A

• Electrical conduit and junction boxes in good condition

  Yes

  No

  N/A

• Fans in good condition and working properly

  Yes

  No

  N/A

• No excessive ice buildup

  Yes

  No

  N/A

• Coils clean

  Yes

  No

  N/A

• Unit clean

  Yes

  No

  N/A

• Heat trace in place and working

  Yes

  No

  N/A

• Drains in good condition and clear

  Yes

  No

  N/A

• Condensate drip pans in good condition

  Yes

  No

  N/A

• Support hangers in place and properly adjusted

  Yes

  No

  N/A

• Guards in place

  Yes

  No

  N/A

• Equipment operation good

  Yes

  No

  N/A

• Sensors in place and working properly

  Yes

  No

  N/A

• Piping in good condition

  Yes

  No

  N/A

• Insulation in place and in good condition

  Yes

  No

  N/A

• Does the facility have an ice cream freezer system separate from the main refrigeration system

  Yes

  No

Ice Cream Freezer

• Temperature set points set properly

  Yes

  No

  N/A

• Is discharge pressure in normal range

  Yes

  No

  N/A

• I suction pressure in normal range?

  Yes

  No

  N/A

• Is compressor motor amperage in normal range

  Yes

  No

  N/A

• Is evaporator super heat adjusted properly?

  Yes

  No

  N/A

• Does the system have a glycol cooled condenser?

  Yes

  No

• Is the glycol in and out temperatures adjusted properly?

  Yes

  No

  N/A

• Unit defrosting properly

  Yes

  No

  N/A

• Electrical conduit and junction boxes in good condition

  Yes

  No

  N/A

• Fans in good condition and working properly

  Yes

  No

  N/A

• No excessive ice buildup

  Yes

  No

  N/A

• Unit clean

  Yes

  No

  N/A

• Heat trace in place and working

  Yes

  No

  N/A

• Drains in good condition and clear

  Yes

  No

  N/A

• Condensate drip pans in good condition

  Yes

  No

  N/A

• Support hangers in place and properly adjusted

  Yes

  No

  N/A

• Guards in place

  Yes

  No

  N/A

• Equipment operation good

  Yes

  No

  N/A

• Sensors in place and working properly

  Yes

  No

  N/A

• Piping in good condition

  Yes

  No

  N/A

• Insulation in place and in good condition

  Yes

  No

  N/A

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Cooler Evaporators / Penthouses

• Unit defrosting properly

  Yes

  No

  N/A

• Temperature set points set properly

  Yes

  No

  N/A

• Doors closing and sealing properly

  Yes

  No

  N/A

• Electrical conduit and junction boxes in good condition

  Yes

  No

  N/A

• Fans in good condition and working properly

  Yes

  No

  N/A

• No excessive ice buildup

  Yes

  No

  N/A

• Coils clean

  Yes

  No

  N/A

• Unit clean

  Yes

  No

  N/A

• Heat trace in place and working

  Yes

  No

  N/A

• Drains in good condition and clear

  Yes

  No

  N/A

• Condensate drip pans in good condition

  Yes

  No

  N/A

• Support hangers in place and properly adjusted

  Yes

  No

  N/A

• Guards in place

  Yes

  No

  N/A

• Equipment operation good

  Yes

  No

  N/A

• Sensors in place and working properly

  Yes

  No

  N/A

• Piping in good condition

  Yes

  No

  N/A

• Insulation in place and in good condition

  Yes

  No

  N/A

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Dock Evaporators / Penthouses

• Unit defrosting properly

  Yes

  No

  N/A

• Temperature set points set properly

  Yes

  No

  N/A

• Doors closing and sealing properly

  Yes

  No

  N/A

• Electrical conduit and junction boxes in good condition

  Yes

  No

  N/A

• Fans in good condition and working properly

  Yes

  No

  N/A

• No excessive ice buildup

  Yes

  No

  N/A

• Coils clean

  Yes

  No

  N/A

• Unit clean

  Yes

  No

  N/A

• Heat trace in place and working

  Yes

  No

  N/A

• Drains in good condition and clear

  Yes

  No

  N/A

• Condensate drip pans in good condition

  Yes

  No

  N/A

• Support hangers in place and properly adjusted

  Yes

  No

  N/A

• Guards in place

  Yes

  No

  N/A

• Equipment operation good

  Yes

  No

  N/A

• Sensors in place and working properly

  Yes

  No

  N/A

• Piping in good condition

  Yes

  No

  N/A

• Insulation in place and in good condition

  Yes

  No

  N/A

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Controls / Electrical

Cleanliness of Control Cabinets

• HOA Switches set properly

  Yes

  No

  N/A

• Cabinets in good condition and clean inside and out

  Yes

  No

  N/A

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Electrical Panels

• Panel in good condition and sealing properly

  Yes

  No

  N/A

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Temperature and Pressure Sensors

• Sensors set up and working properly

  Yes

  No

  N/A

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Ammonia Detectors and Operation

• Ammonia detectors in proper locations and working

  Yes

  No

  N/A

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Defrost Schedule and Times

• Defrost schedules and timing set up and working properly

  Yes

  No

  N/A

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Labeling

• Labeling of piping, equipment and door signs meets IIAR standards

  Yes

  No

  N/A

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E-Stops

• E-Stops work properly and are tested per Maximo work orders

  Yes

  No

  N/A

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Alarm Settings

• Alarm settings are set properly and active

  Yes

  No

  N/A

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Paperwork / Safety Equipment

Oil Log

• Oil logs are used for both adding oil and removing oil from system

  Yes

  No

  N/A

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Daily Logs

• Building walk throughs are completed twice per day six days per week.

  Yes

  No

  N/A

• Hand written logs are available and used between shifts

  Yes

  No

  N/A

Alarms Audible and Visual

• Alarms are both audible and visual at each Machine Room entrance door.

  Yes

  No

  N/A

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