is 660 (1963): safety code for mechanical refrigeration

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IS 660 (1963): Safety code for mechanical refrigeration[MED 3: Refrigeration and Air Conditioning]

Indian &mdard

lS:660-1963 ( Reafficd 19% )

SAFETY CODE FOR MECHANICAL REFRIGERATION

( Revised )

Eighth Reprint MARCH 1999

UDC 621.56: 614.8

@ CopVright 1963

BUREAU OF INDIAN STANDARDS MANAK BHAVAN, 9 BAHADUR SHAH ZAFAR MAHG

NEW DELHI 110002

Gr 4 August 1963

IS:660-1963

Indian Standard


( Revised )

Refrigeration and Air Conditioning Sectionai Committee, BDC 18

Chairman

SHRI J. C. KAPUR

Re@rascnting

Air-Conditioning Corporation Ltd, Calcutta; oad Air-Conditioning and Refrigeration Council of’ India

A4embcrs

Snnr MORAN T. ADVANI Blue Star Engineering Co ( Bombay ) Private Ltd, Bombay

SHRI RAM D. MALANI ( Altrmalc 1 Saw Y. D. &IIJJA The Economy Refrigeratiop and Enginceriirg

Co Ltd, Bombay SHRI N. BALASUBRAMANIAN Voltas Ltd, Bombay

SERI K. V. RAMAN ( Al&mole ) LT S. N. BHAH~AVA Naval Headquarters SHRI S. K. BHATTACRARYA Central Public Works Department Saa~ S. K. CHAUDHURY Ministry of Food & Agriculture SERI N. K. D. CHOUDEURY Central Building Research Institute ( CSIR ),

Roorkee SHRI B. C. RAY CHOUDHURY ( Al&mute )

SHRI P. N. DEOBEAKTA Development Wing ( Ministry of Economic & Dcfence Co-ordination )

SHRI A. N. .MUKHERJEE ( Allcmate ) SHRI K. C. JERATH Engineer-in-Chief’s Branch, Army Headquarters Snar G. K. KABRA The Hyderabad Allwyn Metal Works Ltd,

Hyderabad SHRI H. J. LENTIN SURQ-Coal M. S. MALIIOTXA

Godrej & Boyce Mfg Co ( Private ) Ltd, Bombay Ministry of Defence ( R & D )

SH~I NAUNIHAL S~NGH MATIKUR National Physical Laboratory ( CSIk ), New Delhi; and Indian Society of Rrfrigcrating Engineers, Calcutta

SHRI A. P. SHIVDASANI Indian Society of Rcfrigcrating Engineers, Calcutta ( Alfcrnate )

SHRI S. N. MUKERJI Government Test House, Calcutta San: 8. K. B~UKRERJEE ( Alkrnatc )

( Conlinud on page 2 )

BUREAU OF INDIAN STANDARDS MANAK BHAVAN, 9 BAHADUR SHAH ZAFAR MARC

NEW DELHI 110002

IS I 660 - 1963

Members Representing

SHRI AMAR SINon NAGIU Railway Board ( Ministry of Railways ) SHRI C. B. PATEL National Buildings Organisation ( Ministry of

Works, Housing & Rehabilitation ) SHRI V. D. TIWAIU ( Alfcrnofc )

SARI K. N. R. PILLAR Directorate Grneral of Posts & Telegraphs ( Ministry of Transport & Communications ), Jahalpur

SHBI K, R. D. IYt?NoAR ( AIlrrnale ) SARI R. BAI.ASZTBRAMANIAM ( Alternote )

SHRI B. J. RI% \KHIANI Ministry of Labour SHRI u. s. SAX Ascoon Directorate General of Supplies & Disposals

( Ministry of Economic & Defencc Co-ordination) SRRI D. T. GURSAHANI ( AIfernate )

DR H. C. VISVESVARAYA, Director, IS1 ( Ex-o&o Member) Deputy Director ( Bldg )

Secretmy

Snnr C. R. RAMA Rio

Assistant Director ( Bldg), IS1

Commercial Equipment Including Safety Standards

Subcommittee, BDC 18 : 2

Convener

SHRI S. K. BHATTAC~ARYA Central Public \Yorks Department

SHRI P. C. MALKANI ( Alternate to Shri S. K. Bhattacharya )

SHRI R. AIYADURAI Refrigerators & Home Appliances ( Private ) Ltd, Madras

SHRI R. RAMACHANDRAN ( Alfcrnate ) SERI S. K. CHAUDHURY Ministry of Food and Agriculture SHRI NAUNIHAL SIN(:I~ MATHUR Indian Society of Refrigerating Engineers,

Calcutta SHRI A. P. S~IV~ASANI ( Alternafe )

SHRI D. R. MEHTA Capital Refrigeration Co, New Delhi SHRI R. N. SETH Blue Star Engineering Co ( Bombay ) Private

Ltd, Bombay SHRI S. A. SHAlI American Rrfrigerator Co Ltd, Calcutta

2

h&an Standard


0. FOREWORD

0.1 This revised Indian Standard was adopted by the Indian Standards Institution on 5 August 1963, after the draft finalized by the Refrigeration and Air Conditioning Sectional Committee had been approved by the Building Division Council.

0.2 The need for laying down safety requirements for mechanical refrigeration equipment has been well recognized with a view to safeguarding life and health of persons working in the plant rooms and also to protect the property. This standard consequently issued in 1955, covered the safety features of the design, construction, installation, operation and inspection of mechanical refrigeration systems including working conditions in the plant rooms which are considered reasonably necessary to safeguard life, health and property. After reviewing the standard in the light of the experience gained during its usage, this revision has been prepared incorporating the following important changes.

0.2.1 Recommendations have been added to give guidance on charging of the refrigerants. Modifications have been made to indicate the positions where the stop valves have to be provided on compressor, receiver and evaporator. References have been added to relevant Indian Standards which have been recently issued. The pressures at which pressure-relief devices should be set to blow off have been modified so as to relate them to the minimum field refrigerant leak test pressures. Incidentally, opportunity has been taken to specify ail the values in metric system.

0.3 The Sectional Committee responsible for the preparation of this standard has taken into consideration the views of producers, consumers and technologists and has related the standard to the manufacturing and trade practices followed in the country in this field. Due weightage has

3

ISr660-1963

also been given to the need for international co-ordination among standards prevailing in different countries of the world.

0.4 Wherever a reference to any Indian Standard appears in this code, it shall be,taken as a reference to its latest version.

0.5 Metric system has been adopted in India and all quantities and dimensions in this standard have been given in this system.

0.6 For the purpose of deciding whether a particular requirement of this standard is complied with, the final value, observed or calculated, express- ing the result of a test, shall be rounded off in accordance with IS : 2-1960 Rules for Round,ing Off Numerical Values ( Revised ). The number of significant places retained in the rounded off value should be the same as that of the specified value in this standard.

0.7 This standard is intended chiefly to cover the technical provisions relating to the safety features of the installations, operation and maintenance of mechanical refrigeration systems, and it does not cover all the necessary provisions of a contract.

1. SCOPE

1.1 This code covers safety features in the design, construction, installation, operation and inspection of mechanical refrigeration systems of vapour compression type, including working conditions in the plant room, which are considered reasonably necessary to safeguard life, health and property.

2. TERMINOLOGY

2.0 For the purpose of this code, the following definitions shall apply.

2.1 Compressor - The equipment in which refrigerant in a refrigerating machine is compressed to increase its pressure before liquefaction.

2.2 Condenser - A part of the refrigerating system where high pressure refrigerant gas is condensed to high pressure liquid.

2.3 Condensing Unit - A combination of equipment consisting mainly of compressors, condensers and liquid receivers ( when required ) for converting low pressure gas to high pressure liquid.

4

IS:660-1963

2.4 Evaporator - A part of the refrigerating system where liquid rcfri- gerant is evaporated to produce cooling.

2.5 Expansion Value - A valve which makes the liquid refrigerant to’ expand from a high pressure to a low pressure and controls the flow of the refiigerant.

2.6 Fusible Plug - A plug made of special fusible alloy which fuses at a predeiermined temperature and relieves pressure in the refrigerating system.

2.7 High Pressure Switch - An automatic protective device against excessive pressure on the high side. It automatically stops a compressor or a condensing unit when the pressure on the high side exceeds a predetermined limit.

2.8 Low Pressure Switch - An automatic protective device against excessively low pressure on the low side. It automatically stops a compressor or a condensing unit when the pressure on the low side falls below a predetermined limit.

2.9 Plant Room - Room in which a refrtgerating plant, other than domestic refrigerating appliances such as refrlgeratars, portable air condi- tioners, etc ( which are installed inside the living room ) is installed and operated.

2.10 Pressure Relief Device -A pressure actuated valve or device which automatically relieves the pressure in excess of its setting.

2.11 Pressure Vessel-It is a receiver containing refrigerants under pressure.

2.12 Receiver -A vessel forming a part of refrigerating system acting as a receptacle for liquid refrigerant.

2.13 Refrigerant - A chemical agent used to produce cooling by expansion from high pressure liquid to low pressure gas in a refrigerating system.

2.14 Refrigerant Container - A vessel for storage of liquid refrigerant.

2.15 Refrigerating System - An equipment consisting of condensing unit and evaporator in which refrigerant is circulated to extract and transfer heat.

5

18:660-1963 G

3. INSTALLATION REQUIREMENTS

3.1 Plant Room

3.1.1 Doors, Partitions and Openings -The plant room of each refrigerating system shall be provided with a door( s ) and shall have,no partitions or openings so as to avoid escape of refrigerants to other parts of the building.

3.1.2 No plant room door shall have locking devices from inside. However, facilities for bolting from inside may be provided.

3.1.3 Adequate ventilation shall be provided for each plant room. The ventilation required shall generally be in accordance with Table I. To achieve the required vemilation, windows or doors opening to outside air or power driven exhaust fans may be provided. The sizes of the windows and doors and air displacing capacity of the exhaust fans shall be in accordance with the requirements given in Table I. When exhaust fans are used, provision should be made for inlet of the air to replace the air that is being exhausted by the fan. The area of the duct if connected to the exhaust fan or fans shall be in accordance with the minimum duct areas as given in Table I.

3.1.4 Emergency Exit and Fire Extinguisher - Each plant room shall be provided with emergency exits and fire extinguishers of suitable type ( see *I!j:2190-1962 Code of Practice for Selection, Installation and Main- tenance of Portable First-Aid Fire Appliances).

3.1.5 First-Aid Equipment - Fist-aid equipment shall be provided in each plant room in accordance with the requirements laid down in the Indian Factories Act, 1948, and the Rules thereunder.

3.1.6 Gas Masks-One or more gas masks or breathing apparatus of suitable type shall be kept immediately outside the plant room in an accessible position. Canisters of the gas masks shall be renewed periodically.

3.2 Foundation and supports provided for condensing units or compressor units or other refrigeration equipment shall be substantially sound and vibration absorbing and of non-combustible construction.

3.2.1 All moving machinery shall be guarded in accordance with thr provisions of the Indian Factories Act, 1948, and the Rules thereunder.

3.3 Adequate clear space for inspection and servicing of condensing units or compressor units shall be provided.

l Since revised. 6

IS:660-1963

TABLE I MINIMUM AIR DUCT AREAS AND OPENINGS ( Clause 3.1.3 )

WEIGHT OF THE MECHANICAL DUCT AREA OPEN WIN DOW REFBIGEBANT DISCHARGE oa DOOR ABEA

IN THE SYSTEM OF AIR (1) (2) (3) (4) kg ms/min m2 m2

:05 3.9 7.1 0.025 0.05 812 50 11.3 0.05

1g 148 18’0 0.07 0.07 ;:;

125 20.8 0.10 ;:; 150 23.5 0.10 z: 28.5 ;:;

300 :z

0.12 0.12

0.14 22::

% 41 45 0.18 0.18 2.6 2.8 450 49 0.18 3.0 % z: 0.20 0.20 3.1

;: 66

oo:$ ;:;

1:g :; 0.20 ;:; 83 0.20

1 250 97 0.28 ;:o”

1 500 109 0.35 5.4

2000 132 2500 154 ::z ;:; 3000 173 0.50 7.7 3 500 192 0.54 8.3 4 000 210 o-58 8.8 4500 227 0.60 9.4 5000 244 0.65 9.9 6 000 275 0.70 10.8 7000 305 0.72 11.7 8 000 333 0.75 12.5 9000 361 0.78 13.3

10 000 387 0.81 140 12 000 437 0.83 153 14 000 484 0.84 16.6 16 000 529 0.86 17.7 18 000 572 188 20 000 614 Kz 20.0

~Y~TE 1 - Mechanical discharge of air and open area hnvc been derived from the following formula: taken from DIN 8975 Refrigeration Plants, Safety Principles for Their Construction, Equipment and Erection:

Open window or door area, rn? = 0.14d E Mechanical discharge of air, ms/h = 5OeD

where C is the charge in kg of the largest closed circuit of refrigerant present in the engine room.

NOTE 2 - Intermediate values may be obtained by calculation.

7

3

I8 t 660 - 1963

3.4 Condensing units~ or compressor units within enclosures shall be readily accessible for inspection and servicing.

33 Adequate illumination for inspection and servicing of condensing units or compressor units and other refrigeration equipment shall be provided.

3.6 Water supply connection shall be made in accordance with the requirements given in*IS i2065-1963 Code of Practice for Water Supply in Buildings.

3.6.1 Water used for removing heat from the refrigerating system shall not be discharged into any water supply which is likely to be used for human or animal consumption.

3.7 Electrical wiring and installation of the electrical equipment shall be in accordance with the requirements of the Indian Electricity Act, and Rules thereunder and shall also conform to the requirements laid~ down in IS : 732-1963 Code of Practice for Electrical Wiring Installations ( System Voltage Not Exceeding 650~ Volts ) ( Revised), IS : 2274-1963 Code of Practice for Electrical Wiring Installations ( System Voltage Exceeding 650 Volts ) and i,IS : 302-1960 General and Safety Require- ments for Light Electrical Appliances, as applicable.

3.7.1 Electrical interlocking of the compressor with condensing water pump and cooling tower fan ( where provided ) is strongly recommended. The switch of the compressor moter should be interlocked with the pump- ing set and fan in such a way that the compressor motor will not start until the condensing water pump and fan have started.

3.7.2 It is recommended that as far as practicable the high pressure switches, low p:essure switches, and other electrical control apparatus used in connection with a mechanical refrigeration system be operated on a voltage not exceeding 250.

3.8 No open flame or apparatus to produce open flame or hot surface above 425°C shall be permitted in a plant room having one or more refrigeration machines with a total refrigerant charge exceeding that mentioned in Table II for each cubic metre of room volume.

3.9 No open flame shall be applied to refrigerating system or refrigerant vessel when the system or vessel is charged with refrigerant.

3.10 In the case of refrigerating system using in@nmable refrigerants, such as methyl chloride; ethane, etc, all electrical installations for refrigerating system shall generally conform to the requirements given

*Since rcviscd. *‘Third revision in 1967

8

IS : 660- 1963

TABLE II MAXIMUM PERMISSIBLE QUANTITIES OF INFLAMMABLE REFRIGERANTS

( Clause 3.8 )

NAME

Butane

Ethane

Ethyl chloride

Ethylene

Isobutane

Methyl chloride

Methyl formate

Propane

CHEMICALFOIIMULA

Coho

C&4 CsHsCI

C&4

(CH313CH CH,CI

HCOOCH,

C3Hs

MAXIMUMQUANTITY

g/m3 40

40

100

32

40

160

110

40

in IS : 1646-1961 Code of Practice for Fire Safety of Buildings (General): Electrical Installations, where applicable, and any othere fire safety requirements laid down by the appropriate authority.

3.11 No refrigerating system or piping shall be installed in a passage doorway, below a staircase, or in any public place, except when suitably guarded.

3.12 Charging of Refrigerant - While charging, a gauges hould be provided between the refrigerant container and the machine to know the pressure at which the system is being charged. This pressure should not exceed the discharge pressure at which the compressor has to work with particular type of refrigerant.

3.13 For each installation of refrigerating system, t’le following information, mounted on a frame, should be clearly posted in the plant room :

a> b) Cl 4 4

Name and make of the condensing unit; Model of condensing unit; Name and full charge of refrigerant; Full charge of oil; Quantity of refrigerant and oil charged in the system with clatc of charging;

f > Pressure at which the system is tested after installation; and

d Change of refrigerant, if any, with date.

9

ISr660-1963

4. REFRIGERATING SYSTEM AND EQWMENT

4.1 Refrigerant piping, valves, fittings, their related parts and all material used in the construction and installation of refrigerating system shall be suitable for the refrigerant used. No material which would deteriorate due to chemical action of the refrigerant or the oil or the combination of both and moisture shall be used. Aluminium, zinc or magnesium shall not be used in contact with methyl chloride. Magnesium alloys shall not be used in contact with chloro-fluoro derivatives of methane and ethane. Copper and copper alloys shall not be used in contact with ammonia.

4.2 AU joints shall be readily accessible.

4.3 Joints from refrigerant copper pipe and fittings made with solder or other alloys shall have melting point of :

a) not less than 260°C for pipe sizes up to 32 mm, and

b) 540°C for pipe sizes above 32 mm and for all the sizes on hot gas lines.

4.4 Stop valves shall be installed on all systems other than those using centrifugal compressors, containing more than 10 kg of refrigerant. The location of the stop valves shall be as given in 4.4.1.

4.4.1 Stop valves shall be provided at the inlet and outlet ends of each of compressor, receiver and evaporator.

4.5 Test Pressures - All stop valves, piping, joints, flanges and fittings shall withstand test pressures as given in Table III after completion of installation and before operation.

4.6 All refrigerant piping should be supported by means of hangers, bracket straps, clamps, clamps of pedestals in such a manner as to relieve joints of harmful strains and vibrations.

4.1 Colour identification of refrigerant pipe lines shall be in accordance with the colour identification given in IS : 2379-1963 Colour Code for Identification of Pipe Lines.

4.8 Emergency I)ischarge Line - Each refrigeration system of ammonia and sulphur dioxide having a charge of 10 kg or more should be equipped with emergency discharge line. The discharge line should be connected directly on top of the receiver or the condenser receiver. The emergency

10

IS : 660 - 1963

TABLE III MINIMUM FIELD REFRIGERANT LEAK TEST

PRESSURES

( Clauses 4.5 and 5.3 ),

NAME OF CHEMICAL REBRIOERANT FORMULA

Ammonia

‘Carbon dioxide

Dicblorodifluoromethane

Dichloroethylene

bichloromethane (methylene chloride)

Dichloromonofluoromethane

Dichlorotetrafhroroethane

Ethane

‘Methyl chloride

Monochlorodifluoromethane

l Sulpbur dioxide

Tricbloromonofluoromethane

Trichlorotrifluoroethane

MINIMUM FIELD REBRIQERANT LEAK TEST PREBSUBEB,

kg/cm2 GAUCJE ~------A------\

High Pressure Low Pressure Side Side

NH3 20

CO2 100

CC12F2 16

C2HzC12 2

CH2C12

CHC12F

C2C12F4

C2He CH,Cl

CHClF2

so2 CCI,F

C2C13F3

2 2

5 3

3.5 3.5

85 50

15 8.5

20 10.5

12 6

2 2

2 2

‘Not recommended for new installations.

10.5

70

10

2

valve should be placed immediately outside the plant room and there should be no valve between the emergency valve and the receiver so that in case of an emergency the valve can be operated from outside without entering the plant room. Adequate precautions should be taken to see that the emergency valve is not tampered with by any unauthorized person. The emergency valve should be covered preferably with a glass fronted box. The emergency discharge pipe should be so connected outside the building that it does not affect the surrounding locality.

5. PRESSURE DEVICES

5.1 High Pressure Switch

5.1.1 AIl*condensing units or compressor units above the sizes normally used for domestic refrigerators shall be fitted with automatic high pressure switches.

11

ISt660-1963

5.1.2 The hi h pressure switch shall always be fitted on to the discharge side o tg the compressor before the discharge shut-off valve.

5.1.3 For condensing units about 7.5 ‘kw the cut-in cycle of the high pressure switch shall not be automatic, that is, after tripping, the compressor motor shall require to be started manually.

5.2 Low Pressare Switch - Low pressure switch should be fitted, wherever practicable, to all compressors other than those used for domestic refrigerators when the compressors are used for producing low temperature conditions below 0°C. , 5.3 Pressure Relief Devices or Fusible Plugs - These shall be provided on the l$gh side above the refrigerant liquid level on all condensing units. The discharge for the relief valve should be so connected that it should discharge without affecting the surrounding locality outside the building. Ammonia and sulphur dioxide refrigerants shall be discharged in vessels containing wat& and brine, respectively. The pressure relief valves shall be set to blow at pressures 75 to 80 percent of those specified for minimum field refrigerant leak test pressures ( on the high pressure side ) given in Table III.

6. PRESSURE VESSELS

6.1 All refrigerant-containing pressure vessels’ shall be hydrostatically tested and thoroughly examined periodically as required under the Factories Act, 1948, and the Rules thereunder.

6.2 All refrigerant-containing pressure vessels having a net volume of 0*15m3 or more, and which may be shut off by valves, shall be equipped with pressure relief devices or fusible plugs.

7. MAINTENANCE

7.1 Each refrigerating system after installation shall be checked for refrigerant leaks every three months.

7.2 Pressure devices, pressure gauges and all other refrigerant controls on both the high side and low side shall be checked periodically, the time between two such inspections not exceeding six months. shall be inspected once every three months.

Fusible plugs

7.3 Moulds, cans, tanks, etc, shall be checked frequently for chemical action and corrosion from hygienic and sanitary point of view.

7.4 Electrical installation shall be checked periodically for insulation leakage, etc, in accordance with the Indian Electricity Act, 1910, and

12

18:660-1963

the Rules thereunder and IS : 732 - 1963 Code of Practice for Electrical Wiring Installations (System Voltage Not Exceeding 650 Volts) ( Rmid ) and IS : 2274 - 1963 Code of Practice for Electrical Wiring Installations ( System Voltage Exceeding 650 Volts ).

7.5 All repairs shall be duly recorded and a record of all tests carried out after repairs shall be maintained. The record should be signed by the mechanic and the engineer or officer-in-charge.

7.6 Proper precautions shall be taken that no gas other than what is in the system is charged.

7.7 Open flame shall never be applied to the gas cylinder or to the system when it is charged with refrigerant.

7.8 In a plant room in which refrigerating system containing more than 25 kg of refrigerant is installed, a card shall be placed conspicuously near the compressors giving directions for the operation of the refrigerating system including precautions to be taken in the case of a breakdown or leak and instructions for shutting down the refrigerating system in case of emergency.

13

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is 660 (1963): safety code for mechanical refrigeration

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