FOOD STORAGE & DISTRIBUTION FEDERATION

7 Diddenham Court, Lamb Wood Hill, Grazeley, Reading, Berkshire. RG7 1JQ

SERVICE ENGINEERS SECTION

OF THE INSTITUTE OF REFRIGERATION
Kelvin House, 76 Mill Lane, Carshalton, Surrey SM5 2JR

THE DANGEROUS SUBSTANCES AND EXPLOSIVE

ATMOSPHERES REGULATIONS (DSEAR/ATEX) 2002

Self-assessment checklist for ammonia systems

Guidance Notes:

Introduction

This self-assessment form has been prepared by the Technical and Safety Committee of the Food
Storage and Distribution Federation (FSDF) with assistance from the Technical Committee of the
Institute of Refrigeration (IoR). It is intended to give owners of ammonia charged1 refrigeration
systems a quick indication of whether their system is likely to be technically compliant with the
Dangerous Substances and Explosive Atmosphere Regulations (2002). It does not address issues
related to or the hazards arising from the toxicity of ammonia. These are not covered by DSEAR
(2002), but they do need to be considered to ensure compliance with the regulations listed below.

This self-assessment is not a substitute for the formal risk assessment required by
DSEAR (2002) nor is it a substitute for the annual inspection required under the
Pressure Systems Safety Regulations (2000).

If ALL the ammonia is in the machinery room and the room meets the requirements of
EN378:2008 or later then it is more likely to be a simple task to show that it complies with the
requirements of DSEAR (2002).

Likewise if there are NO flanges, valves or equipment in enclosed spaces such as a roof void or
the cold space it is also more likely to be compliant. However if there are non-permanent joints
outside the machinery room then additional steps may be required to meet the requirements of
DSEAR (2002).

Scoring - How to interpret the results of your Self-assessment

Section 1: multiply the refrigerant charge in tonnes by the number of compressors and the
number of evaporators
Section 2: if the answer to any of these questions is NO then a formal assessment of the
machinery room is required.
Section 3: if the answer to any of the last four questions is YES then a formal assessment
of the evaporator installation is required.
Section 4: if the answer to any of the last four questions is YES then a formal assessment
of the valve station installation is required.
Section 5: if the answer to any of the questions is Moderate or Severe then a formal
assessment of the valve station installation is required. If the answer to any of the

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Thecontentsofthisdocumentapplysolelytorefrigerationsystemsthatarechargedwithammonia.

DSEAR Self-assessment checklist for ammonia systems
Issued: February 2013

questions is Slight and the score in Section 1 is greater than 20 then a formal
assessment of the valve station installation is recommended.
Possible cost impact

Section 2: if the answer to any of these questions is NO then the cost of compliance may be
significant.
Section 3&4: If however, the answer to all of the first three questions in Section 3 and Section 4
is YES then compliance costs are likely to be low.

In addition to DSEAR (2002) this guidance for ammonia systems is set out against a background of
legislation in force in the UK at the time of its publication. These include for example:
* Environmental Protection Act (1990)
* Health and Safety at Work etc. Act (1974)
* Construction (Design and Management) Regulations (2007)
* Control of Substances Hazardous to Health Regulations (2002)
* Electricity at Work Regulations (1989)
* Management of Health and Safety at Work Regulations (1999)
* Regulatory Reform (Fire Safety) Order (2005)
* Pressure Systems (Safety) Regulations (2000)
It is therefore recommended that an Ammonia Hazard Study & Risk Assessment as required by
DSEAR (2002) and the Management of Health & Safety at Work Regulations (1999) and other
relevant legislation should be covered in one document.

When must the DSEAR/ATEX workplace requirements be met?

In areas where dangerous quantities and concentrations of flammable ammonia gas or vapour
may arise, protective measures must be applied in order to reduce the risk of explosions in order
to comply with DSEAR (2002).
The specific DSEAR (2002) requirements dealing with explosive atmospheres come into effect at
different times depending on when the equipment (or system) is first used. The exact dates are
as follows:
All equipment in use before July 2003 must be compliant with DSEAR (2002) by July 2006
Equipment installed before July 2003 that has been modified before July 2006 must be
compliant from the time the modification was carried out
All equipment installed after June 2003 must be compliant from the time it comes into use

Hazardous Area Classification

The International Standard IEC 60079 Part 10-1: Classification of areas Explosive gas
atmospheres sets out the essential criteria against which the ignition hazards can be assessed, and
gives guidance on the design and control parameters which can be used in order to reduce such a
hazard.

The FSDF guidance document HAZARDOUS AREA CLASSIFICATION OF REFRIGERATION

PLANTS USING AMMONIA (R717) AS THE REFRIGERANT2 complements IEC 60079-10-1
as it provides detailed requirements for hazardous area classification of permanent and
temporary refrigeration plants using ammonia as the refrigerant charge.

2013 FSDF & IoR - All Rights Reserved

February 2013

2
CopiesofallFSDFTechnicalBulletins,Guidesandallotherpublicationsareavailabletomembersfreeof
charge.TherecanalsobepurchasedbyothersdirectfromtheFSDFsubjecttopaymentoftheappropriate
fee.

Copyright 2012 All Rights Reserved Page |2


DSEAR Self-assessment checklist for ammonia systems
Issued: February 2013

System Name Location

Assessed by: Date: DD/MM/YY

1. System Information

Type of System Cold Store Chill Store Production Other

Original date of installation DD/MM/YY Date of last major modification DD/MM/YY

Total system charge Kgs Number of compressors

Number of pumps Number of evaporators

Defrost Type Number of condensers

2. Machinery Room

Ammonia detection system YES NO Date of last calibration DD/MM/YY

Emergency Ventilation YES NO Date of last functional check DD/MM/YY

Ventilators correctly sited YES NO Date of last functional check DD/MM/YY

Relief Lines vent outside room YES NO PRV Discharge in low risk area YES NO

Separate Electrical Room YES NO Electrical Room Pressurised YES NO

Automatic electrical breaker YES NO No sources of ignition in room YES NO

3. Evaporators

Ammonia detection system YES NO Date of last calibration DD/MM/YY

Emergency Ventilation YES NO Date of last functional check DD/MM/YY

Automatic electrical breaker YES NO Date of last functional check DD/MM/YY

Flanges in room YES NO Mechanical equipment in room YES NO

Valves in room (inc. solenoids) YES NO Strainers/Drains in room YES NO

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DSEAR Self-assessment checklist for ammonia systems
Issued: February 2013

4. Valve Stations

Indoor or outdoor OUT IN In store or roof void Store/Void

Ammonia detection system YES NO Date of last calibration DD/MM/YY

Emergency Ventilation YES NO Date of last functional check DD/MM/YY

Automatic electrical breaker YES NO Date of last functional check DD/MM/YY

Flanges in room NO YES Mechanical equipment in room NO YES

Valves in room (inc solenoids) NO YES Strainers/Drains in room NO YES

5. Physical Condition

Is there rust on exposed pipe None Slight Moderate Severe

Is there ice on insulated pipe None Slight Moderate Severe

Ammonia smell in machinery room None Slight Moderate Severe

Leaks around liquid pumps None Slight Moderate Severe

Ammonia smell in roof void None Slight Moderate Severe

Ammonia smell at evaporators None Slight Moderate Severe

Any banging/knocking during defrost None Slight Moderate Severe

Describe any instances of rust or ice

that have been assessed as moderate
or severe. Use additional pages if
necessary. Treat each instance
separately so that their repair can be
scheduled and confirmed.

Recommended date for next assessment DD/MM/YY Signed:

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