Mechanical Integrity Inspection for the Ammonia Refrigeration System

• Site conducted

  Select

• Audit Title

• Client / Site

• Conducted on

  Date

• Prepared by

• Personnel

• 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 reading correct pressure

  Yes

  No

  N/A

• Paint is not pealing and missing

  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 have been exercised regularly

  Yes

  No

  N/A

• Pipe plugs in place

  Yes

  No

  N/A

• Ammonia drains for isolated filter/strainers.

  Yes

  No

  N/A

• No evidence of leaks

  Yes

  No

  N/A

• Electrical conduit and junction boxes are properly supported and undamaged

  Yes

  No

  N/A

Pipe and Insulation Condition

• Crossovers in place and in good condition

  Yes

  No

  N/A

• Piping does not have any rust or corrosion

  Yes

  No

  N/A

• Proper pipe labels being used and in place

  Yes

  No

  N/A

• Insulation does not have any cracking, gaps, holes, or damage.

  Yes

  No

  N/A

• Pipe labels easily legible and not damaged or pealing

  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

Condenser

• Fan belts are adjusted to specification with no damage

  Yes

  No

  N/A

• Fan blades are clean with no scale buildup

  Yes

  No

  N/A

• Bearings are greased, no noise while running

  Yes

  No

  N/A

• Piping is painted and does not have any rust or corrosion

  Yes

  No

  N/A

• Paint on piping is not pealing or damaged

  Yes

  No

  N/A

• Tubes are clean - check for corrosion and scaling. Must include at least 4 photos of the tubes with the water turned off.

  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 as needed with no leaks

  Yes

  No

  N/A

• Structural steel completely painted with no corrosion or damage

  Yes

  No

  N/A

• Electrical conduit and junction boxes are supported with no sags and undamaged

  Yes

  No

  N/A

• Water treatment is effective.

  Yes

  No

  N/A

• Valves and Handles painted and accessible

  Yes

  No

  N/A

• 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 correctly

  Yes

  No

  N/A

• Valves in working condition

  Yes

  No

  N/A

• Belts adjusted to specification and not damaged

  Yes

  No

  N/A

• Desiccant wheel in working condition

  Yes

  No

  N/A

• Equipment operating as designed

  Yes

  No

  N/A

Machine Room

Condenser Pumps and Water Treatment

• Condenser pumps working operating 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 running. Water is clean

  Yes

  No

  N/A

• Condenser water treatment chemical feed equipment is working properly.

  Yes

  No

  N/A

Underfloor Warming

• Is there an Underfloor Air Blower for floor freeze protection.

  Yes

  No

• Is the Blower Running

  Yes

  No

• Is the Blower Drive mechanism and duct work in good condition.

  Yes

  No

• Is the Blower drive belt adjusted properly and in good condition

  Yes

  No

• Is there air flow through every underfloor air outlet.

  Yes

  No

• Is there a Glycol underfloor warming for floor freeze protection

  Select Yes No

  • Yes
  • No

• Heat exchanger Warming glycol to temperature set point

  Yes

  No

  N/A

• Relief valves in place and in compliance

  Yes

  No

  N/A

• Glycol pump runs when called for, is painted and clean with no leaks

  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 and flow adjusted to a minimum of 5* gpm, clean and undamaged. *5 gpm at 42" centers on pipe

  Yes

  No

  N/A

• Glycol temperature probes working properly

  Yes

  No

  N/A

Cross Connection Regulator

• Cross connection regulator set to design specifications 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 and reading pressure correctly

  Yes

  No

  N/A

• Economizer open and working as designed

  Yes

  No

  N/A

• Set points set for operating conditions

  Yes

  No

  N/A

• Guards in place

  Yes

  No

  N/A

• Filter pressure within acceptable limits

  Yes

  No

  N/A

• Operating limits are properly set for conditions

  Select Yes No N/A

  • Yes
  • No
  • N/A

• Anchors and grouting tightened properly and undamaged

  Yes

  No

  N/A

• Safety switches in place and cutout points set and verified

  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 is not pealing or damaged

  Yes

  No

  N/A

• No oil leaks are evident

  Yes

  No

  N/A

• Valves will isolate as needed

  Yes

  No

  N/A

• Equipment is operating as designed for conditions

  Yes

  No

  N/A

• Starters are working as designed

  Yes

  No

  N/A

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 reading pressures correctly

  Yes

  No

  N/A

• Set points set up to operate at system pressure

  Yes

  No

  N/A

• Guards in place

  Yes

  No

  N/A

• Filter pressure within acceptable limits

  Yes

  No

  N/A

• Operating limits are set for conditions

  Yes

  No

  N/A

• Anchors tightened and grouting undamaged

  Yes

  No

  N/A

• Safety switches in place and will cut when activated

  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 as designed

  Yes

  No

  N/A

• No oil leaks are evident

  Yes

  No

  N/A

• Valves will isolate when closed

  Yes

  No

  N/A

• Starters are operating as designed

  Yes

  No

  N/A

Vessels

• Name plate / ASME stamp legible

  Yes

  No

  N/A

• Level controls will control level to set point

  Yes

  No

  N/A

• Linear Liquid Level Indicators protected (Glass Level Columns)

  Yes

  No

  N/A

• Bulls eyes visible and undamaged

  Yes

  No

  N/A

• Oil pots insulated with no damage or painted with not pealing paint

  Yes

  No

  N/A

• Oil Pot is properly rated for vessel temperature

  Yes

  No

  N/A

• Insulation in place with no damage

  Yes

  No

  N/A

• Feed valves control liquid feed at proper rate

  Yes

  No

  N/A

• All Safety float cut outs will cut out all compressors connected to vessell

  Yes

  No

  N/A

• Relief valves in place and in compliance

  Yes

  No

  N/A

• Piping shows no corrosion where visible

  Yes

  No

  N/A

• Equipment is clean

  Yes

  No

  N/A

• Valves are accessible, painted and in working condition

  Yes

  No

  N/A

• Electrical conduit and junction boxes are properly supported and undamaged

  Yes

  No

  N/A

• Equipment is operating properly

  Yes

  No

  N/A

Ammonia Pumps

• Pumps operating at correct pressures.

  Yes

  No

  N/A

• Gauges in place and and reading proper pressure

  Yes

  No

  N/A

• Equipment operation as designed

  Yes

  No

  N/A

• Does the system have Cornell pumps?

  Yes

  No

• Oil cutout switch will stop pump on low oil

  Yes

  No

  N/A

• Rotary guard protecting pump from cavitation

  Yes

  No

  N/A

• Shaft seal in good condition - no seal leakes

  Yes

  No

  N/A

• Guards in place

  Yes

  No

  N/A

Oil Recovery System

• Oil recovery piping painted, no visible corrosion and supported properly

  Yes

  No

  N/A

• Vessel paint is not pealing and no visible corrosion

  Yes

  No

  N/A

Floors, Walls and Room Cleanliness, and Door Signage.

• Eyewash and Showers are located properly and Unobstructed

  Yes

  No

• Doors are Self closing doors with panic hardware

  Yes

  No

• The Room have two means of egress

  Yes

  No

• 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

• Ammonia cannot enter floor drains

  Yes

  No

• Floors have no large cracks

  Yes

  No

  N/A

• Walls are clean and undamaged

  Yes

  No

  N/A

• Pipe penetrations in the walls are sealed

  Yes

  No

• The machine room including tools and benches are clean?

  Yes

  No

  N/A

Electrical / Panels

• Electrical panels are clean, and doors closed

  Yes

  No

  N/A

• No unused penetrations are in panel, especially the top

  Yes

  No

  N/A

• Panel air filter is clean and fits opening correctly

  Yes

  No

  N/A

Pipes and Insulation

• Pipe hangers are adequate and adjusted to support pipe.

  Yes

  No

  N/A

• Manually operated valves that are inaccessible from floor must be operable from portable platforms, fixed platforms, ladders, or chain operated<br>

  Yes

  No

  N/A

• Pipes show no corrosion and are painted with no pealing paint

  Yes

  No

  N/A

• Insulation has no gaps or damage and pipe saddles are in place

  Yes

  No

  N/A

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

  Yes

  No

  N/A

High Pressure Reciever

• Ammonia level within acceptable range

  Yes

  No

  N/A

• High pressure receiver is painted, paint is undamaged and the vessel clean with no visible corrosion

  Yes

  No

  N/A

• Safety Relief valves in place and in compliance

  Yes

  No

  N/A

Ammonia Dispersion Tank

• Dispersion tank is in painted and clean with no visible corrosion and no leaks

  Yes

  No

  N/A

• Tank has proper water level

  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 to design specifications

  Yes

  No

  N/A

• Relief valves in place and in compliance

  Yes

  No

  N/A

• Pump in working condition

  Yes

  No

  N/A

• Temperature set to design specifications

  Select Yes No N/A

  • Yes
  • No
  • N/A

• Glycol flow is acceptable

  Yes

  No

  N/A

• Valves are accessible and working to isolate when needed

  Yes

  No

  N/A

• Temperature probes reading proper temperature

  Yes

  No

  N/A

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 is removing Non-Condensables. No leaks.

  Yes

  No

  N/A

• Purger cycle counts recorded

  Yes

  No

  N/A

Exhaust System

• Ammonia detection Alarms at 25 ppm and shutdown is at 250 ppm

  Yes

  No

  N/A

• Exhaust system operates when ammonia is detected

  Yes

  No

  N/A

• Exhaust system meets IIAR2-2008 standards

  Yes

  No

  N/A

• Fan belts are adjusted to specification and show no damage

  Yes

  No

  N/A

• Fan blades in are clean and undamaged

  Yes

  No

  N/A

• Intake dampers are in proper location and working when called for

  Select Yes No N/A

  • Yes
  • No
  • N/A

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

  Yes

  No

  N/A

Evaporators

Freezer Evaporators / Penthouses

• Unit defrosting cleanly with no ice bridges

  Yes

  No

  N/A

• Temperature set points set to quality control standards. See separate document provided by facility for standards.

  Yes

  No

  N/A

• Penthouse doors closing and sealing tightly

  Yes

  No

  N/A

• Electrical conduit and junction boxes in good condition

  Yes

  No

  N/A

• Fans are 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 are free of ice with no damage

  Yes

  No

  N/A

• Support hangers in place and properly adjusted

  Yes

  No

  N/A

• Guards in place

  Yes

  No

  N/A

• Equipment operating as designed

  Yes

  No

  N/A

• Sensors in place and working properly

  Yes

  No

  N/A

• Piping properly painted with no visible corrosion

  Yes

  No

  N/A

• Insulation in place with no cracks, holes, separation, or damage

  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 clean 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 with no cracks. holes or damage

  Yes

  No

  N/A

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 clear and draining properly

  Yes

  No

  N/A

• Condensate drip pans are free of ice and show no damage

  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 properly painted with no visible evidence of corrosion

  Yes

  No

  N/A

• Insulation in place and in good condition

  Yes

  No

  N/A

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 are properly supported and undamaged

  Yes

  No

  N/A

• Fans clean and working

  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 clear

  Yes

  No

  N/A

• Condensate drip pans free of ice and no damage

  Yes

  No

  N/A

• Support hangers in place and adjusted to support unit

  Yes

  No

  N/A

• Guards in place

  Yes

  No

  N/A

• Equipment operating as designed

  Yes

  No

  N/A

• Sensors in place and reading proper temperature and pressure

  Yes

  No

  N/A

• Piping properly painted with no evidence of corrosion

  Yes

  No

  N/A

• Insulation in place, no cracks holes or damage.

  Yes

  No

  N/A

Cleanliness of Control Cabinets

• HOA Switches set correctly for current operation

  Yes

  No

  N/A

• Cabinets undamaged and clean inside and out

  Yes

  No

  N/A

Electrical Panels

• Panels undamaged and clean inside and out

  Yes

  No

  N/A

• No unused penetrations that are not plugged

  Yes

  No

  N/A

Temperature and Pressure Sensors

• Sensors set up and reading proper temperature and pressure

  Yes

  No

  N/A

Ammonia Detectors and Operation

• Ammonia detectors in designated locations and working

  Yes

  No

  N/A

Labeling

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

  Yes

  No

  N/A

Alarm Settings

• Alarm settings are set properly and active

  Yes

  No

  N/A

Paperwork / Safety Equipment

• Proper P&ID displayed

  Yes

  No

• Does emergency shutdown documentation exists

  Yes

  No

• Emergency shutdown valves tagged

  Yes

  No

Alarms Audible and Visual

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

  Yes

  No

  N/A