Project Background and Problem
A client operating an ammonia (NH₃) refrigeration system for gas liquefaction sought to assess and optimise their toxic gas detection layout. The system included NH₃ compressors in a semi-enclosed building, with other equipment outdoors, within a complex site with high personnel occupancy. Given the toxicity of ammonia, the client wanted to ensure the gas detection system met modern risk- and performance-based standards.
Solution
Equinox Automation was engaged to conduct a detection gap analysis and recommend an updated layout. Following ISA-TR84.00.07-2018, we carried out a risk assessment to identify likely NH₃ release scenarios and prioritise high-risk equipment. This formed the basis for setting coverage targets for gas detection.
We then modelled ammonia dispersion under various failure conditions to understand potential toxic exposure zones. Using 3D fire and gas mapping software, we analysed the existing detector layout and identified gaps in both the compressor building and surrounding areas.
Optimisation involved relocating several point detectors to eliminate blind spots and improve coverage. We also introduced open-path toxic gas detectors to cover key perimeters and high-traffic areas, providing broader protection and early detection.
Results
Targeted Risk Assessment: Quantified NH₃ hazards and prioritised detector placement by risk.
Enhanced Coverage: Improved detection in critical zones and high-occupancy areas.
Optimised Layout: Reduced overlap, maximised effectiveness, and avoided unnecessary costs.
Advanced Technology: Integrated open-path detection to protect key access routes and boundaries.
Verified Design: Delivered a detailed report and layout drawing aligned with best practice.
By applying a structured risk-based approach, Equinox Automation helped the client significantly improve ammonia detection performance, safety, and compliance.
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Figure 1: Designing Ammonia Compressor Toxic Gas Detector Layouts with 3D F&G Mapping Tools Example
Figure 2: Hazard Analysis – Ammonia Toxic Gas Dispersion Modelling
Figure 3: NH3 Workplace Threshold Table