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HomeMy WebLinkAboutRISK MANAGEMENTPillSbury Bakeries & Foodservice Bakersfield Ammonia Refrigeration System Ope. ration Guide' Pillsbury Bakeries & Foodservi~~e - Bakersfield May 3, 1991 Refrigeration Flow Cycle Ammonia gas from the l(,w suction accumulator (LSA-1) enters the booster compressors (BC-1 & 2) where the refrigerant is drawn axially, compressed and goes tot he oil separator as a mixture of gas and oil. The oil separator ent?ains the oil and discharge gas leaves the oil separator and goes to the intercooler (IC-1) where the refrigerant is desuperheated and cooled to + 10 DF. An intermediate press. COrresponding to 10 DF in the intercooler (IC- 1) is a mixture of liquid and ammonia gas. Liquid level is controlled by a level switch that energizes a solenoid valve and allowing the refrigerant to flow from the thermosyphon receiver (TSR-1), (Operating levels will be discussed more under control strategy). Desuperheated gas from the top of the intercooler (IC-1) travels to the high stage compressors (HS-1 & 2) to be compressed to the condenser pressure. Refrigerant is then cooled to a saturated liquid and draifis back to the thermosyphon receiver (TSR-1). The thermosyphon receiver (TSR-1) acts as a supply tank of liquid refrigerant for the compressor oil coolers to maintain opera!ing oil temperature. In addition, thermosyphon receiver insures liquid supply to the plate heat exchanger iHX-2), glycol heat exchanger (HX-1), make-up liquid to the intercooler (IC-1) and controlled pressure r6ceiver (CPR-1). Flow to the controlled pressure receiver (CPR-1) will only be allowed if the level insid~ the thermosyphon receiver (TSR-1) raises beyond 6" which will open a pilot operated valve (PRV-5) dontrolled by a pilot float valve. The liquid which flows to the controlled pressure receiver has its pressure reduced to a pressure equal to +17 DF. The liquid that is flashed flows through a pressure regula!or (PRV-3) will pressurize the controlled pressure receiver to maintain recompressed by the high stage compressors (HS-1 & 2). The subcooled liquid is then drawn to the storage freezer coils and !he spiral freezer coils at a 1 ½:1 liquid overfeed ratio. Refrigerant suction (LTRB) from the storage freezer and spiral freezer enters the suction accumulator (LSA-1) as a liquid and gas mixture. Refrigerant gas at -40 DF goes to the booster compressor (BC-1 & 2) for compress!on, while liquid refrigerant flows by gravity to the dump trap (DT-1) located below the suction accumulator (LSA-1 ). The dump trap (DT-1) is ~h transfer tank that collects the liquid which settles at the bottom of the suction accumulator (LSA-1). After the liquid in the dump trap (DT-1) raises by more than two-thirds, a level switch is energized, which energizes the three-way solenoid. The three-way solenoid which acts normally as an equalizing line to thee suction accumulator (LSA~I) becomes the hot gas line pressurize the dump trap (T-1). Once the presiure of the dump trap builds up above the controlled pressure receiver (CPR-1), the liquid will transfer to ~the controlled pressure receiver. A field set timer will then shut off the three- way solenoid and liquid v~ill once again drain to the dump trap (DT-1) from the suction accUmulator (LSA-1) Emergency Safety Procedures Emergency switches are located outside the engine room and are used to operate the ammonia diffusion system and shutdown th~ entire system in the event of ammonia release or fire. The ammonia diffusion system is also operated a.htomatically by the ammonia gas sensor located in the engine room set at 200 ppm. ~ Switch No. 1 (S- 1) "Emergency Refrigeration Shutdown" Switch. Shuts off the entire refrigeration system. Switch No. 2 (S-2) "Eme. rgency Ventilation Switch". Tums on the exhaust fan. Switch No. 3 (S-3) "Horn/Silence" Switch. Silences alarm horn while scrubber system is operating. Switch No. 4 (S-4) "Mariual Scrubber System" Switch. Operates the ammonia scrubber system, Hand- Off-Auto switch normall~, in the Auto position unless manual operation is needed. Ammonia sensors are lo~ated inside the engine room and in the relief pipe header to monitor any releases. The pipe sensor will souOd an alarm in the event that ammonia is present in the relief header. The engine room area sensor which is set at 200 ppm will automatically start the scrubber system. The scrubber pump (SP-1) will turn or~ to pump water from the diffusion tank to the condenser where ammonia vapor is absorbed by Sprayed water, with the condenser fans (ECF-1 & 2) running. Ammonia/water mixture is then re-circulated back tO the diffusion tank by a 3-way valve (3V-l). Exhaust fan (EF-1) will run only if switch No. 2 is ON or thq room temperature thermostat is calling. Emergency Fire Box Operation: (Fire Department Use) Step 1 Step 2 Step 3 Step 4 Turn ventilation S~witch on (S-2) and evaluate the problem in the system. If problem is in the low side, do not push lemergency shutdown switch (S-l). If problem is in the high side of the system, push emergency ~hutdown switch (S-1). Open valve No. 3! 140 psig. Open valve No. 11 200 psig. Ammonia transfer- within the system. (Notify Tri-Com Refrigeration before proceeding with this step.) Open valv, No. 2 to transfer ammonia from the high side to the low side of the system. 2 and use the gauges to maintain the pressure on the low side of the system below and. use the gauges to maintain the pressure on the high side of the system below Section 1 - Alarms A. Low Suction Acc Refrigeration Control Strategy amulator High Level If the liquid level in the 10w suction accumulator reaches the high level float switch (LSHH-3) it sends a signal to the controller. After a 10 second delay the booster compressors will shut down and will not restart without manually ~'esetting each booster compressor. After the float switch opens, the reset button at the main control panel;~will clear the alarm horn and pilot light. Once the alarm has been cleared the booster compressors may be manually reset at the compressor control panels. There will be no indication at the compressor control panel to show high level shut down as this is indicated by the pilot light at the main control panel. : B. Intercooler High ,Level If the liquid level in the intercooler reaches the high level float switch (LSHH-1) it sends a signal to the controller. This immediately shuts down the high stage compressors which will not restart until they have been manually reset. After the high level float switch opens, the reset button at the main control panel will clear the alarm horn md pilot light. Once the alarm has been cleared the high stage compressors may be reset at the compresso~r control panels. It should be noted that if the booster compressors are running in the remote mode while afl intercooler high level shut down occurs they will shut off until the high stage compressors restart. Thel booster compressors will restart automatically after the high stage compressors have run for at least 1 mi..hute. When a high intercooler level shut down occurs, there will be no indication at the compressor panels Cs this is indicated by a pilot light at the main control panel. C. Intercooler Low I~evel If the liquid level in the ifitercooler drops below the low level float switch (LSLL-1) it sends a signal to the controller. At this time the alarm horn and the low level pilot light are energized. When the liquid level rises above the floa~ switch, the alarm may be cleared by pressing the alarm reset button at the main control panel. [ D. Intercooler Transfer If the liquid level in the ir~tercooler reaches the transfer float switch (LSH-1) it sends a signal to the controller. At this time th,'e transfer solenoid valve opens, and returns liquid to the accumulator (LSA-1) until the float switch opens. When the float switch opens the solenoid closes but the transfer pilot stays on until the alarm reset bt~tton on the main control panel is pressed. E. Compressor Failu~-e Alarms If any compressor shuts d~own due to a safety failure it will indicate by energizing the proper pilot light at the main control panel as ',well as the alarm horn. The compressor failure switches must be in the normal (on) position at all times. ',If the switches are turned off it will disable all compressor alarm functions including by-passing high level safety shut down. In addition to disabling the alarm functions leaving the switches in the offpositi,m can cause the system to defrost or feed liquid to the evaporators even after a compressor failure. The failure by-pass switches are only used for intentional shut down of the compressors. F. Horn Switch and ~larm Reset When an alarm occurs th.~ horn switch may be turned to "silence" until the alarm can be cleared. If the alarm switch is left in the "silence" position after an alarm is cleared, the hom will sound again until the switch is returned to the ?horn" position. Upon power failure to the control system, it may be necessary to reset the alarm systemI It may also be necessary to reset each of the compressors if the compressor control power is also lost... After any power failure it should be noted that the compressors may not sequence back on properly and Tri-Com should be notified immediately. Section 2 - Spiral Blast A. Cooling Mode Freezer System To activate the refrigeration to either of the spiral freezers requires that the fan switch adjacent tot each spiral is turned on. Ifth~ fans start, the fan pilot light will energize. With the fans running and the thermostat calling for co61ing, the liquid solenoids will energize along with the "Refrigeration" pilot light. The liquid solenoids wflllshut off it the thermostat satisfies or if the fans go off during this time. If both of the high stage compreisors should shut down during the cooling mode it will cause the liquid solenoids to close along with the ",Refrigeration" pilot light to go out. B. Defrost Mode '~ To initiate a defrost, the manual defrost push button must be activated. At this time ifa defrost is possible, the defrost pilo! light will come on. If the pilot light does not come on, it means that a defrost is not possible at this time due to another zone already being in defrost. During the first part of the defrost (approx. 6 minutes) the f,n switch must be on and the fans allowed to run. When the fan Pilot light goes off then the fan switch may be turned off if you do not wish for the spiral to return to the cooling mode at the end of the defrost. Ai the end of the fan delay period, the hot gas solenoid for the first half of the coil will energize along with ihe pilot suction stop solenoid. The hot gas will remain on to the first half of the coil for the length of time set on the hot gas timer located in the main control panel in the compressor room. At the end of this period the timer resets and starts again for the same period. This causes the hot gas solenoid for the secohd half of the coil to open and the hot gas solenoid for the first half to close. At the end of the time pe.fiod, the second hot gas solenoid closes and the suction stop valves reopen to equalize the coil pressure! with the plant suction pressure for approximately 3 minutes. When the pressure equalization period is over, the liquid solenoids open 10 seconds prior to the fans restarting if the fan switch is left on. During ithe defrost cycle on either spiral freezer the liquid solenoids for all 3 evaporators in the storage freezer are forced on even if the storage freezer thermostat is satisfied. This provides enough load for the hot ghs required to defrost the spiral coils. If either spiral freezer is in the defrost mode it will not allow any other zone to defrost at the same time. This means that if a defrost is scheduled by the controller for one of the evaporators in the storage freezer at this time it will be skipped. Care should be taken to p~'event defrosting a spiral coil during the time when a scheduled defrost is to take place in the storage freez6r. Tri-Com will provide a schedule of the automatic defrost times for the storage freezer. ~ C. Spiral Shut Down} Procedure Prior to shutting off the refrigeration at the end of the production, the spiral freezer should be defrosted. If possible leave the storgge freezer in cooling while the other is in defrost to provide additional load and prevent automatic shut d0~wn of the booster compressor sequencer. If the spiral freezer fan switches remain off for more than i15 minutes, the booster sequencer system shuts off the large booster compressor and allows the small boogter to run on local control. This provides for low load conditions and weekend operation at a higher suction pressure for increased efficiency. After the spiral is shut off, the evaporator coil should be inspected !o insure that it is completely defrosted. If necessary the hot gas timer may be adjusted for a longer time to allow total removal of frost. Section 3 - Storage Fre~ezer Refrigeration System A. Cooling Mode ~ Each of the 3 evaporator~, in the storage freezer (AU-2, 3 & 4) have control switches at the main control panel. The switches pro?ide for the shut down,.auto defrost; ;0r manual defrost of each evaporator individually. By placing the control switch in the "auto" position, the evaporator will remain in the cooling mode and the far~s will run continuously until a defrost cycle is initiated by the controller. During the cooling cycle the liqdid solenoids are controlled by the freezer thermostat. If the thermostat satisfies the liquid solenoids will Close unless the spiral or any one of the 3 evaporators in the freezer starts a defrost cycle. If any zon~ starts a defrost cycle it will override the thermostat and force open the liquid solenoids to the remainir~g evaporators in the freezer to provide additional load. B. Defrost Mode Defrosting of the freezer :ievaporators can occur manually or automatically via the controller. The controller uses an internal clock function to time between defrost intervals. The time of day and the number of defrosts per day can be adjusted to suit the needs of each evaporator. If any zone is already in defrost, no other zone ca,n be defrosted at the same time. This means that if a spiral or storage freezer zone is manually defrosted during the time that the controller calls for an automatic defrost the auto defrost will be skipped. ~When a defrost is initiated, the defi'ost pilot light will come on and the liquid solenoid for the proper zone will close. At this time the refrigeration pilot will go out and the fans will continue to run for approximately 4 minutes. The fans will now shut off along with the fan pilot light. At this time the hot gas solehoid will energize and the suction pressure regulator solenoid will turn off allowing the regulator to ~aise to the defrost pressure setting. The hot gas solenoid will stay energized for the length of time set on the hot gas timer located in the main control panel. At the end of the hot gas time, the suction pressur~ regulator will open and equalize the pressure for 10 seconds. Following pressure equalization, the, liquid solenoid will reopen and precool the coil for approximately 2 minutes. At the end of the precool ~period, the fans will restart if the switch is in the "auto mode. It should be noted that if hny zone starts a defrost cycle and the high stage compressors are in the remote run mode but the sequen6er has cycled them off, compressor # 1 will be forced to run to provide hot gas for defrosting. Section 4 - High Stage Compressor Sequencer The intermediate suction! pressure is controlled by a floating point pressure switch (PS-2) located adjacent to the main control panel!. The pressure switch sends a load signal to the controller if the suction pressure is above set point. If the :~suction pressure remains in the "dead band" no signal is sent to the controller. If the suction pressure fallsibelow the set point, the pressure switch sends an unload signal to the controller. Upon receiving a load signal from the pressure switch, the controller initiates a 30 second delay timer. If the load signal remains constant beyond the 30 second delay, it pulses an internal counter and sends a start signal to # 1 high stage c.bmpressor ifa "compressor ready" signal is sent from the compressor to the controller. The compres§or ready signal is only outputted from the compressor if the compressor if the compressor control circuit is reset, it is in the remote run mode, and the anti-recycle timer is reset. If the compressor ready signal hnd the load signal remain constant, the sequencer continues to pulse the internal counter and begins to ser~d 5 second load pulses to the compressor and causes the electric valve actuator to move the slide valve mad load up the machine. The sequencer will send a 5 second pulse every 30 seconds until there is no !onger a load signal or the counter reaches a value that allows the # 1 compressor to be at maximum load. If the sequencer continues to receive a load signal, it will start # 2 high stage compressor after approximately a 3 minute delay and only if a "ready signal" is sent to the controller from # 2 compressor. The # 2!high stage compressor will continue to load every 30 seconds for a period of 5 seconds if the load signa! remains on. If at any time during this cycle the suction pressure drops below the load set point, the counter will stop and hold the present value. If the load signal is again sent to the controller, it will wait t~ough another 30 second delay period to loading the compressors. The compressors unload in the same manner as above when a signal to unload remains constant for more than the 30 second delayl If # 1 and # 2 high stage compressors are both running, the sequencer will completely unload # 2 c~mpressor and then turn it offprior to a 3 minute delay before it starts to unload the # 1 compressor. The !unload signal pulses down the counter as well as unloading the compressors until the counter reaches a minimum value which shuts off the # 1 compressor. If at any time during the unload cycle the suction pressure raises above the unload set point and then the unload signal is again sent to the controller, it will Wait through a 30 second delay before unloading. All internal timers are adjustable for the delay time as well as the load pulse and interval time. If the # 2 high compressor is not in the remote mode the # 1 compressor will still function normally in the remote sequence mode. if the # 1 compressor is not in the remote mode or fails after having been started in the remote mode, theni# 2 may run in the remote mode but only after waiting through the normal time to load # 1 compressor to~ 100%. The sequence counter will reset any time after a failure or if the remote switch is placed back in the remote mode on compressor # 1. This means that if compressor # 2 is running and compressor # 1 is reset with the selector switch in the remote mode, then # 2 compressor will turn off until it is called for by the sequencer after # 1 compressor reaches 100% loaded. To restart the system afte_i' a compressor failure, push the stop button on compressor # 2 and then reset # 1 compressor with the ~elector switch in the remote mode. If the pressure switch is calling for a load signal then the time dela~ will activate and restart compressor # 1. After # 1 compressor is reset in the remote mode then # 2 may be reset and placed in the remote mode. The compressors may be switched to local control at any time if necessary but should not be put back into remote without following the procedure outlined above. Section 5 - Booster Conipressor Sequencer The low temperature suction pressure is controlled by a floating point pressure switch (PS-1) located adjacent to the main cont~ot panel. This pressure switch functions in the main control panel. This pressure switch function~ in the same manner as the PS-2 pressure switch above. The booster compressors are controlled in the same way as the high stage compressors. All features of the booster sequencer apply as in thei description of the high stage compressor sequencer with the exception of the load pulse time. The loa~l pulse time is set at 3 seconds on and 30 seconds between load pulses. This allows more time for the high stage compressors to load up and keep the intermediate suction pressure stable. During the time that the ~piral freezer is being used, the sequencer functions by starting and loading # 1 booster compressor first. If additional capacity is required, the # 2 booster starts and loads according to the same strategy as uged in the high stage sequencer. If the spiral freezer is tur~ed off for more than 15 minutes, the sequencer is overridden and # 1 booster shuts off. At the time that # 1 booster shuts off, booster # 2 changes back to local control even with the selector switch in the rerOote position. This allows booster # 2 to stop and start via the "HSP" and "LIP" switches located at the S .;ullair panel. This allows the suction pressure to be maintained at -20 DF (sst) during low lOad conditions which will be more energy efficient than the - 40 DF (sst) required when the spiral freezer is in use. 10 Section 6 - Transfer System, Condenser and Purger Controls A. Phillips Transfer System The Phillips Transfer Sy4tem utilizes gas pressure to return liquid to the controlled pressure receiver (CPR-1) from the low suction accumulator (LSA-1). The gas pressure differential must be maintained by running a high stage compressor. If a high stage compressor is not running the transfer system is locked out. During the time the ithat a high stage compressor is not running it is possible for a booster compressor to run if it is iin the local mode. The booster compressor running will allow liquid to be pulled back from the system and fill the low suction accumulator. If the transfer system is locked out during this time, it may cause a high! level in the accumulator. If the system is allowed to run in the local mode, the booster compressor should be shut off when the high stage compressors are not running. B. Condenser Controls The condenser pump is COntrolled by a "Hand-Off-Auto" switch located in the main control panel. In the hand position the pump will run continuously. If the switch is in the auto position, the pump will stop and start with any of the compressors. The condenser fan is con,trolled by a "Hand-Off-Auto" switch located in the main control panel. In the hand position the fan will run continuously in either high or low speed depending on the selector switch setting of the "High-Low;" switch located on the door of the fan starter. If the fan is placed in the auto position, it may only start if the condenser pump is nmning. If the pump is running and the fan control is in the auto position then a dual set point pressure switch (PS-3) located adjacent to the main control panel will cycle the fan. The 16w speed fan will start at approximately 155 psig discharge pressure. The low speed fan will continue tb run until the discharge pressure reaches approximately 175 psig. At 175 psig, the high speed fan will stlart and mn until the pressure drops back to 170 psig. At this point the high speed fan will turn off and a 6 s~econd timer will start. When 6 seconds have elapsed the low speed fan will start and continue to mn until ithe pressure drops below 150 psig. The 6 second delay timer is in effect whenever the low speed ~'an starts. There are pilot lights to indicate high and low speed fans as well as the condenser pump running C. Purger The Hansen Automatic purger requires high pressure liquid to be supplied to its cooling circuit to operate. The liquid feed solenoid is locked out if at least one high stage compressor is not running. This is to insure a constant supply 6f liquid to the purger as well as insure gas flow through the condenser where the noncondensible gasses axe removed. 11 Section 7 - Miscellaneohs The liquid feed solenoid bn the intercooler requires that one of the high stage compressors be running before it may energize. If the operating level float switch calls for liquid, and a high stage compressor is running then the feed solenoid may open. A circuit breaker panel itl the motor control center provides control power to the programmable controller as well as the compresso~.s. There are separate control transformers located in each starter cabinet for the remaining motors. 12 Pillsbury Bakeries and Food Services Bakersfield LO~W STAGE INTERCOOLER lilGtl STAGE COMPRESSOR VAPOR 24 PSIG VAPOR COMPRF. SSOR DU~P 'rPou' EVAPORATOR METERING DEVICE 140 PSIG VAPOR 30 PSIG I.IQIHD '1'11ERMOSYPilON [ RECL:IVER KING VALVE CONTROLLED PRESSURE RECEIVER Basic Schematic of the Ammonia Ret?igeration Systetn CONI')ENSF-P. AMMONIA REFRIGERATION COLOR CODE LEGEND FOR PIPING PBFS-BAKERSFIELD · PRECAUTION BLUE - LOW PRESS. VAPOR · POSTAL BLUE - LOW PRESS. LIQUID · INSULATION (WHITE)-LOW PRESS. LIQUID/VAPOR (THIS IS NOT A PAINT) · ALERT oRANGE - HIGH PRESS. VAPOR · FIRE RED!- HIGH PRESS. LIQUID · RADIATION PURPLE - HIGH PRESS. LIQUID/VAPOR · HI-VIS YELLOW - · 1M GRAY- · SPANISH ;TILE - · SAFETY GREEN - OIL DRAIN RELIEF VENT RELIEF LOOP INTO SYSTEM WATER ALL THE PAiNTS MENTIONED ARE FROM DUNN EDWARDS. ALL COLORS ARE OSHA SAFETY COLORS WITH THE EXCEPTION OF: · IM GRAY;! · SPANISH TILE zm ~. z SOP No. DESCRIPTION TAB SOP-103B 7 SOP-lO4 8 SOP-lO5 9 SOP-106 10 SOP-107 11 SOP-lO8 12 SOP-109 13 SYSTEM OVERVIEW 1 SOP-1 ANNUAL REVIEW SUMMARY & CERTIFICATION 2 SOP-2 STANDARD OPERATING PROCEDURES (SOP) GENERAL 3 SOP-101 CONTROLLED PRESSURE RECEIVER 4 EQUIPMENT CPR1 SOP-102 EVAPORATIVE CONDENSER 5 EQUIPMENT EC 1 & EC2 SOP-103A BOOSTER COMPRESSORS 6 EQUIPMENT BC1, BC2 & BC3 HIGH STAGE COMPRESSORS EQUIPMENT HS1, HS2 & HS3 THRMOSYPHON RECEIVER EQUIPMENT TSR1 INTERCOOLER EQUIPMENT IC 1 PUMPER DRUM EQUIPMENT DT 1 SUCTION ACCUMULATOR EQUIPMENT LSA1 AMMONIA DIFFUSION TANK EQUIPMENT ADT FIRE DIFFUSION PANEL EQUIPMENT ADP SOP-Il0 LOW TEMPERATURE EVAPORATORS 14 EQUIPMENT AU2, AU3, AU4, AU6, AU7 & AU8 SOP No. DESCRIPTION TAB SOP-Ill SHELL AND TUBE HEAT EXCHANGER EQUIPMENT HX1 SOP-112 TURBO WATER CHILLER 16 EQUIPMENT HX2 SOP-113 HANSEN AUTO PURGER 17 EQUIPMENT AP 1 SOP-114 ICE MAKER 18 EQUIPMENT IM 1 SOP-115 OIL POT 19 EQUIPMENT OP1, OP2 & OP3 SOP-2000 EVAPORATOR COIL CLEANING 20 SOP-3000 REFRIGERATING SPECIALTIES (R/S) PRESSURE 21 REGULATOR SOP-4000 SAFETY RELIEF VALVE REPLACEMENT 22 15 INTRODUCTION This Plant utilizes anhydrous ammonia, an acutely hazardous material, in quantities greater than 10,000 pounds. As per CFR 1910.119 (Process Safety Management) this quantity requires the employer, Pillsbury, to create a written, formalized document(s) to mitigate the possible release of ammonia and to create a safer workplace. Pillsbury is committed to a quality product, a safe workplace and the protection of the environment. The production schedule varies but often operates 24 hours per day 7 days per week. Regardless, the refrigeration system operates continuously to maintain the holding freezer. All accidents/incidents, regardless of severity are investigated at the Pillsbury, Bakersfield, California Facility. REFRIGERATION SYSTEM This system is considered a two-stage refrigeration system and utilizes anhydrous ammonia as the refrigerant. High-pressure liquid ammonia is feed from the Thermosyphon Receiver to the thermosyphon oil coolers, the Intercooler, the Water Chiller, the Glycol Chiller and the Controlled Pressure Receiver. The Intercooler de-superheats the discharge gas from the Booster Compressors. If too much liquid accumulates in the Intercooler, a High Level Alarm float switch will transfer the excess ammonia to the Suction Accumulator. The Water Chiller supplies chilled water for use in the Dough Mixer(s) while the Glycol Chiller supplies glycol to Air Handlers in the Dock and Production Floor for comtbrt cooling. The Glycol Chiller also supplies glycol to the Dough Mixer for cooling. The Controlled Pressure Receiver delivers the necessary sub-cooled liquid ammonia for proper operation of the evaporators in the Holding Freezer, Ice Maker, Ante Room and (2) Spiral Freezers. With exception of the Ice Maker, these evaporators are intentionally ted more ammonia than can be evaporated, (to increase the efficiency of the heat transfer surface.) This excess liquid is separated from the ammonia vapor in the Suction Accumulator. The liquid is returned to the Controlled Pressure Receiver by means of a Liquid Transfer System and the vapor is pulled off by the Booster Compressors. The Booster Compressors discharge the compressed ammonia vapor into the Intercooler where much of the heat of compression is removed before the High Stage Compressors finish the compression. The two evaporative condensers condense the ammonia vapor back into a liquid and drain into the Thermosyphon Receiver to start the cycle over again. REFRIGERATION SYSTEM (continued) An ammonia diffusion system has been installed to mitigate the release of ammonia into the atmosphere during an emergency. Each pressure relief valve is piped to a relief main, which in turn, is piped directly to the Ammonia / Water Diffusion Tank. Each vessel containing liquid ammonia is piped separately to a valve in the Fire Diffusion Panel located outside the engine room. The panel is piped directly to the Ammonia / Water Diffusion Tank. During an emergency situation, pressure can be manually and safely released from any or all vessels and safely diffused in water, from outside the building. The facility's Ammonia Detection System is currently being modified as described here and should be completed by July 1, 2001. Ammonia sensors have been installed throughout the facility in each area containing an ammonia evaporator and / or control-valve group. This system is set up to show an alarm condition at 35 PPM and create an evacuation and Fire department notification at 50 PPM. The engine room sensor will create an alarm at 50 PPM and evacuation at 150 PPM. This system works in con. junction with Fire alarm panel and utilizes visual and audible alarms. Any sensor going to alarm condition will automatically close the respective liquid and hot gas solenoid at the units and system king valve. The system can be manually operated. This facility will have a guard on site 24/7 and the Fire and ammonia system will be monitored 24/7 also. This refrigeration system has a Low Stage compressor capacity of about 344 TR (tons of refrigeration.) The High Stage compressor capacity is about 430 TR. The system equipment is described as follows: Evaporative Condenser - ECl Evapco Model: PMCA-495 Evaporative Condenser - EC2 BAC Model: C-266-L Auto Purger - AP1 Hansen Model: AP08 Thermosyphon Receiver - TSR1 RvS Model: 18" Dia. x 15' OAL Fire Diffusion Panel - ADP Ammonia Diffusion Tank - ADT Model: 15' Dia. x 30' OAH High Stage Screw Compressor - HS1 Sullair Model: A12LA231 High Stage Screw Compressor - HS2 Sullair Model: A12LA276 High Stage Screw Compressor - HS3 Frick Model: RWB II-134 Booster Screw Compressor - BC1 Sullair Model: A12LB200 Booster Screw Compressor - BC2 Sullair Model: C20LB Booster Screw Compressor - BC3 Frick Model: RDB-316 REFRIGERATION SYSTEM (continued) Intercooler - ICl RvS Model: 84" Dia. x 12' OAH Low-Temp. Suction Accumulator - LSA RvS Model: 84" Dia. x 15' OAH Pumper Drum - DT1 RvS Model: 24" Dia. x 4' OAL Control Pressure Receiver- CPR RvS Model: 72" Dia. x 18' OAH Glycol Heat Exchanger (Chiller) - HX1 RvS Model: 24" Dia. x 12' OAL Water Chiller - HX2 Turbo Model: HTDA-480601 Surge Drum - SD1 RvS Model: 42" Dia. x 10' OAL Surge Drum - SD2 Howe Model: 18" Dia. x 3'-4" OAL Ice Maker - IM1 Howe Model: 50EA Oil Pot - OP1 RvS Model: 12" Dia. x 3' OAL Oil Pot - OP2 Model: 6" Dia. x 3' OAL Oil Pot - OP3 Model: 4" Dia. x 18" OAL (Existing) Model 6" Dia. x 36" OAL (New, replacing the existing OP3 by July 1, 2001) Evaporator - AU2, AU3 & AU4 Frigid Coil Model: LTA.364-1/3-LTT-HGO-IP-PCV-PW (3 Units) Evaporator - AU6 Frigid Coil Model: S245.104X174X8R-3FPI (1 Unit) Evaporator - AU7 Frigid Coil Model: ICB- 1 H- 1910-3LRB-HGD-IPPCV (1 Unit) Evaporator - AU8 Frigid Coil Model: S230.80X272X 10R-3 FPI (3 Units) To the best of our understanding, this refrigeration system xvas built in accordance with all laws, codes, and regulations in effect at the time of construction. 2 ~ Objective: The objective of this procedure is to audit the Standard Operating Procedures (SOP) and ensure the program is up-to-date, and correctly implemented. The Standard Operating Procedures should be updated as necessary to reflect current operating practices including but not limited to changes in technology, equipment, and/or facility changes. Purpose: PILLSBURY is committed to the safe operation of our facilities, to protect our workers, the public, and the environment. This is accomplished to a great extent, by well-developed, up-to-date, and implemented STANDARD OPERATING PROCEDURES. One of the elements of the Process Safety Management (PSM) is to ensure that our program is up-to-date, and correctly implemented. This Audit Program has been developed to ensure the Standard Operating Procedures Program meets all of its requirements. SCOPE: It is PILLSBURY policy that the Standard Operating Procedures will be kept up-to-date and implemented. The Audit Program itself shall be evaluated at least once every three years and updated as necessary. Department: Refrigeration Operator Pillsbury Refrigeration Operator - Level 3 /Responsibility: Equipment: Location: Related Documents: Initial Development August 31, 2000 Date: Authorized By: Tim Ridley Annual Review By: March 1, 2002 PROCEDURE: A meeting of a selected group will be held annually to review all Standard Operating Procedures. The attendees will include at least one representative from the maintenance and/or operations group responsible for the operation of the refrigeration system. One attendee will represent plant engineering. Additional members of the review group can be from plant operations, the plant safety director, corporate engineering staff; the installing or servicing contractor, or the PSM consultant. The review process will evaluate all existing Standard Operating Procedures for: * Correctness · Completeness · . Current Operating Practices · Current Safe Work Practices It shall evaluate the program to determine if any additional SOP's or Safe Work Practices need to be developed. The result of the meeting will be documented in Form SOP-1 attached hereto, and Form SOP-1 shall be filed and retained at least until the triennial audit. If any deficiency is found it shall be documented in Form SOP-l, which shall then be kept as an active file fbr follow-up. Upon completion o:~ all noted items, all review group members shall approve and sign the document, and approval recorded in Form SOP-1. All manuals and files shall be updated and all affected employees notified. Any additional training shall be provided as required. Facility Information Owner: Location: Department/System/Equipment: Operating Procedure Review (Use Additional pages if necessary) Attended by: Date(s): Title: All SOP's found correct. No longer needed. Some SOP's obsolete. To be updated (describe below.) If "to be updated": Affected SOP/TOS(s): Reason: Revision assigned to: To be completed by: Revision number: Approved: Revision review date: Date: 3 Purpose: The purpose of the operating procedures of the PSM program is to develop, implement, and maintain clearly written, detailed procedures, guidelines, rules and practices for the safe operation of a hazardous chemical process during all operating phases. Scope: All employees involved in the daily operation and maintenance of the ammonia refrigeration process should have a full understanding of every operating phase. This is to include an overview of the process, principles of refrigeration, operating characteristics of tine components, associated hazards, and the proper steps to execute all system related tasks in a safe manner. Training should be provided to each employee who, in the normal course of his/her work, engages in any activity associated with the operation of the ammonia refrigeration system. (Refer to 29 CFR 1910.119(g)- Training Guidelines, for more information.) Accessibility: Operating procedures shall be readily available to employees who work in or maintain a process. Copies of the operating procedures shall be provided to all affected employees. Training on all operating procedures shall be provided to all affected employees. Department: Refrigeration Operator Pillsbury Refrigeration Operator - Level 3 /Responsibility: Equipment: Location: Related Documents: See references below Initial Development August 31, 2000 Date: Authorized By: Tim Ridley Annual Review By: March 1, 2001 REFERENCES: Regulatory 29 CFR 1900 to 1910 29 CFR1910.1000 to end 40 CFR Part 68 - Accidental Release Prevention: Risk Management Programs Under Clean Air Act Section 112(r)(7), Subpart (D), Operating Procedures (68.69) · California Code of Regulations Title 8, 5189(f') Pillsbury · Ammonia PPE Policy · ME 13000 - Standards and Recommended Practices for Ammonia Refrigeration · ME 12806 - Standards and Recommended Practices for Ammonia Detection (Draft) · IC 16806 - Standards and Recommended Practices for Electrical Control Requirements for Refrigeration Systems Industry · lIAR Process Safety Management Guidelines for Ammonia Refrigeration, Chapter 6 - Standard Operating Procedures · lIAR Ammonia Data Book · IIAR Bulletin #R1 - Guide to Good Practices for the Operation of an Ammonia Refrigeration System · ANSI/IIAR 2-1992 Equipment, Design and Installation of Ammonia Mechanical Refrigeration Systems. · ANSI/ASHRAE 15-1992 Safety Code for Mechanical Refrigeration · lIAR Bulletin # 107 - Safety and Operating Procedures When making Ammonia Refrigeration Plant Tie-ins · lIAR Bulletin #109 - Guidelines for Minimum Safety Criteria for a Safe Ammonia Refrigeration System · IlAR Bulletin #110 - Start-up, inspection and Maintenance of Ammonia Mechanical Refrigeration Systems · IIAR Bulletin # 116 - Guidelines for Avoiding Component Failure in Industrial Refrigeration Systems Caused by Abnormal Pressure or Shock · ANSI/CGA K61.1 - Safety Requirements for the Storage and Handling of A~hydrous Ammonia Separate from the SOP's, the employer is responsible for developing, implementing, and maintaining certain specific information and general safe work practices that comply with the requirements of CFR 1910.110, as listed below: · CFR 1910.119 · CFR 1910.119 · CFR 1910.119 CFR 1910.119 · CFR 1910.119 · CFR 1910.119 CFR 1910.119 CFR 1910.119 · CFR 1910.119 · CFR 1910.119 CFR 1910.119 CFR 1910.119 · CFR 1910.119 · CFR 1910.119 (c) - Employee participation (d) - Process safety information (e)- Process hazard analysis (f) (1) (iii) - Safety and health consideration (f) (1) (iv) (4) - Safety systems and their function (g) - Training (h) - Contractors (i) - Pre-start-up safety review (j) - Mechanical integrity (k) - Hot work permit (1) - Management of change (m) - Incident investigation (n) - Emergency planning and response (o) - Compliance audits DEFINITIONS: Technical Operating Specifications (TOS) The TOS is a category of the operating procedures, which deals with process equipment and system information. The TOS is the document in which to list the specific operating characteristics of each piece of equipment and/or subsystem. It is also the logical repository for much of the Process Safety Information called for as part of the Process Safety Management (PSM) program. Standard Operating Procedures (SOP) The SOP is a category of the operating procedures, which deals with tasks related to the operation of the process. These tasks include start-up, normal operation, normal shutdown, emergency and temporary operations, and such activities as routine maintenance and minor repairs. Process A process is any activity involving any use, storage, manufacturing, handling, or the onsite movement of ammonia. For the purpose of this definition, any group of vessels, which are inter-connected and separate vessels that are located such that they could be involved in a potential release of ammonia, shall be considered a single process. Pump-Down (Equipment) A procedure for removing liquid refrigerant from a piece of equiplnent prior to a prolong shutdown or fbr maintenance or repair. The procedure involves emptying of the piece of equipment or subsystem of liquid, and occurring during normal operation. The lowest pressure to which the piece of equipment can be reduced, is that of the compressor network suction to which it is connected. Pump-Out A procedure for removing refrigerant fro1Tl a piece of equipment or subsystem whereby all of the liquid refrigerant is removed and the pressure within the piece of equipment or subsystem is reduced to sub- atmospheric level. This pressure reduction would allow the opening of the piece of equipment or subsystem with little or no refrigerant loss to atmosphere. The procedure requires a separate pumping system connected in such a xvay as to create a sub-atmospheric pressure in the refrigeration system in question. Initial Start-Up An initial start-up is a situation when a component or piece of equipment is being started for the first time. This covers not only a "new" piece of equipment but also a "used" piece of equipment if the start- up is taking place for the first time in that location. Temporary Operation A temporary operation is a procedure for operating a piece of equipment at conditions outside of its normal operating range. Consideration must be given to any steps necessary to insure that there are no safety ramifications. Emergency Operation Per IIAR definition, Emergency Operation of any piece of equipment requires that the Refrigeration Operator have intent and knowledge of the existing "Near Emergency Shutdown" condition that could cause system and / or component damage or could lead to a release of ammonia to the atmosphere. Operating under these conditions is not recommended. Emergency Shutdown An emergency shutdown is a situation where the specific operating safety limits have been approached or exceeded. The shutdown could be an individual component, a group of components or the entire system. Acronyms Used OAL - Overall Length OAH - Overall Height DWP - Design Working Pressure PSIG - Pounds per Square Inch Gauge "Hg. - Inched of Mercury Vacuum TR - Tons of Refrigeration PPM - Parts Per Million EM - Electro-Mechanical Control Panel N.O. - Normally Open N.C. - Normally Closed N/A - Not Applicable TD - Temperature Difference S/N - Serial number Nat'l Bd. # - National Board Number 4 Objective: This procedure is established to describe the Technical Operating Specifications (TOS) and to set forth Standard Operating Procedures (SOP) for the operation of the Controlled Pressure Receiver. iPurpose: The purpose of the Technical Operating Specifications (TOS) is to provide a description of the Controlled Pressure Receiver, to define its function, operating conditions, limits, and consequences of deviation from said operating limits and to also describe its controls, instrumentation, safety system, and setting its operating alignment(s). The purpose of the SOP is to establish the proper steps for starting, stopping, re-starting, and monitoring normal operation. Concerns: Among incidents we are trying to prevent are: · Injury to operator(s) · Over pressurization of the system · Operation of the safety relief valves · Release of ammonia to atmosphere Department: Refrigeration Operator Pillsbury Refrigeration Operator - Level 3 /Responsibility: Equipment: Controlled Pressure Receiver Vessel - CPR Location: South wall in the South Engine Room Related Documents: P&ID R-03, Manufacturers U-1A Report, lIAR Bulletin 109 and 110, and any OEM related documents. All are located in the North Engine Room. Initial Development August 31, 2000 Date: Authorized By: Tim Ridley Annual Review By: March 1, 2002 TECHNICAL OPERATING SPECIFICATIONS (TOS) Function: The function of the CPR is to receive high-pressure liquid from the Thermosyphon Receiver and low pressure, low temperature liquid from the Low-Temperature Suction Accumulator Pumper Drum and maintain this liquid at a low pressure so as to provide an inventory of liquid ammonia to supply the Spiral Freezers, the Holding Freezer and the Ice Maker. Operating Consequences Corrective Action Description Capacity/Size Limit of Deviation Vertical Pressure Vessel - 72" OD x Intended to be Any pressure Verify proper CPR 18'-0" OAH operated at above 220 operation of the 17°F/30 PSIG PSIG could condensers. DO 250 PSIG DWP result in the NOT operate the ~ 300OF lifting of the system above pressure relief 220 PSIG. valves and a consequent release of ammonia. Insure the pressure regulator CPR-02 is functioning properly and the high stage compressors are operating. CONTROLS AND INSTRUMENTATION Description Item Number Function Position/Set point Dual Safety Relief CPR-04 & CPR-05 Opens on a rise in 250 PSIG pressure to relieve over pressure to an Ammonia Diffusion Tank Valves SAFETY SYSTEMS Description Item Number Function Position/Set point Back Pressure CPR-02 This is an operational 30 PSIG Regulator valve who's function it is to maintain a low operating pressure in the CPR. STANDARD OPERATING PROCEDURES (SOP) Initial Start-up: Verify compliance with pre-start-up safety review. Verify that pressure test has been completed. Visually inspect and make sure inlet and outlet valves are open. Record all pressures, temperatures, and levels. By definition, there is no initial start-up of the Controlled Pressure Receiver, (CPR.) During the initial plant start-up, care was taken to ensure that enough liquid was in the CPR to satisfy the needs of the refrigeration system. Normal Start-up: The CPR has no normal start-up. Once initially placed into operation, the CPR is always in operation and reacts to the system's needs on a continuous basis. Normal Operation: The CPR collects and stores liquid ammonia for system's load usage. Several automatic devices maintain its function, as a "Controlled Pressure Receiver." 1. The Phillips high side control valve, (TSR-17) allows liquid to leave the Thermosyphon Receiver only when there is enough liquid to satisfy the thermo siphon oil cooling needs of the compressors. 2. The R/S / Hansen inlet pressure regulator, (CPR-02) maintains the vessel's pressure at the prescribed predetermined pressure, (30 PSIG.) 3. The R/S / Hansen outlet pressure regulator, (HGD-05) adds some high-pressure gas to the CPR should its pressure get significantly lower than 30 PSIG. 4. The CPR also receives low-temperature liquid transferred from the Low-Temperature Suction Accumulator. The CPR feeds Sub-Cooled Liquid to the Holding Freezer, the Ice Maker, the #1 Spiral Freezer and the #2 Spiral Freezers. Normal Shutdown: The CPR has no normal shutdown. Temporary Operation: Due to the pressures involved and the amount of ammonia inventory, temporary operation is not recommended. Emergency Operation: Per IIAR definition, Emergency Operation of this compressor requires that the Refrigeration Operator have intent and knowledge of the existing "Near Emergency Shutdown" condition that could cause system and / or compressor damage or could lead to a release of ammonia to the atmosphere. Operating under these conditions is not recommended. Emergency Shutdown: The CPR is always in the system. If due to a leak in the vessel or related piping, refer to the plant Emergency Response Program. STANDARD OPERATING PROCEDURES (SOP) (cont'd.) Start-up following a turn-around or after an emergency shutdown: After a shutdown of a service nature, the CPR should be returned to a pre-shutdown condition. Then, the CPR can be restarted as per the Normal Start-up instructions above. If the shutdown was due to an emergency, an investigation procedure should be followed to determine the nature of the emergency that caused the CPR to be shutdown. If the shutdoxvn was due to a safety limit being reached, it must be determined WHY that limit was reached. Whatever the cause of the shutdown, the offending situation or condition must be corrected, with an assurance that it will not re- occur, befbre the CPR can be returned to a pre-shutdown condition. Then, and only then, should the CPR be restarted as per the Normal Start-up instructions above. Objective: This procedure is established to describe the Technical Operating Specifications (TOS) and to set forth Standard Operating Procedures (SOP) for the operation of the Evaporative Condenser. Purpose: The purpose of the Technical Operating Specifications (TOS) is to provide a description of the Evaporative Condenser, to define its function, operating conditions, limits, and consequences of deviation from said operating limits and to also describe its controls, instrmnentation, safety system, and setting its operating alignment(s). The purpose of the SOP is to establish the proper steps fbr starting, stopping, re-starting, and monitoring normal operation. Concerns: Among incidents we are trying to prevent are: · Injury to operator(s) · Over pressurization of the system · Operation of the safety relief valves · Release of ammonia to atmosphere Department: Refrigeration Operator Pillsbury Refrigeration Operator - Level 3 /Responsibility: Equipment: Evaporative Condensers ECl & EC2 Location: On the roof of the Engine Rooms Related Documents: Initial Development Date: P&ID R-02, lIAR Bulletin 109 and l 10, and any OEM related document(s). All are located in the North Engine Room. August 31, 2000 Authorized By: Tim Ridley Annual Review By: March 1, 2002 TECHNICAL OPERATING SPECIFICATIONS (TOS) Function: The function of the evaporative condenser is to reject heat from the refrigerant, (heat that was adsorbed from the product / conditioned space during the various refrigerating processes, the heat of compression and the heat from the oil coolers) into ambient air. As the refrigerant gas gives up its heat, it will condenses back to a liquid state and, by gravity, will return to the Thermosyphon Receiver Operating Consequences Corrective Action Description Capacity/Size Limit of Deviation ECl EVAPCO 495 TR 220 PSIG Higher than 220 Verify condenser Model: PMCA-495 PSIG may controls and set S/N: 915260 activate the points. Single fait 7.5 HP safety relief Dual fan 15 HP valves. Verify all fans and 1750 RPM pumps are 7.5 HP operational. 1745 RPM Water pump EC2 BAC Model: C-2662-L S/N: 92200086 Single fan Dual fan Water pump 581 TR 7.5 HP 15 HP 1750 RPM 5 HP 1745 RPM Compressor and/or system shutdown will occur due to high-pressure safety. Decreased overall system capacity. Verify eliminators are clean and all water distributors are working effectively. Verify that non- condensable gases are out of the system. Shutdown system if pressure exceeds 220 PSIG. CONTROLS AND INSTRUMENTATION Description Item Number Function Position/Set point l. Control System ECl 1. Start/stop any 1. 150 PSIG 1. N/A necessary pump or 2. EC 1-001 fan according to set 3. ECl-002 point. 2. Inlet isolation valve EC2 2. Stops the High Stage 2. Normally open 1. N/A Discharge gas from 2. EC2-001 entering the 3. EC2-002 condenser. 3. Outlet isolation valve 3. Stops High Pressure 3. Normally open Liquid from leaving the condenser. SAFETY SYSTEMS Description Item Number Function Position/Set point Safety relief valve ECl 1. Open on rise in 1. 250 psig 1. ECl-014 pressure and relief EC 1-015 to a common header EC 1-017 to the Ammonia EC 1-018 Diffusion Tank. 2. 3-way valve 2. ECI-013 2. Allows isolation of 2. From seated or EC 1-016 one or the other of back seated. the safety relief EC2 valve. (Can never 1. EC2-016 isolate both at the EC2-017 same time.) EC2-019 EC2-020 2. EC2-015 EC2-018 3. Automatic Air 3. APl 3. The Automatic Air 3. See SOP-II3 Purging Purger will help keep the discharge pressure to a minimum by keeping the non- condensable gasses out of the system. STANDARD OPERATING PROCEDURES (SOP) Initial Start-up: Verify compliance with PSM Pre-Start-up Safety Reviexv. Verify that all inlet and outlet valves are open. Verify that water and control power is available. Verify that all fans and pumps are operational and with proper rotation. Verify all set points. Visually inspect fan blades and belts. Record all pressures and temperatures. Normal Start-up: Start-up of the condenser is accomplished automatically by the control system according to set point. Normal Operation: The condensers are always in the system. The control system will utilize the fans, in a sequential mode as needed, to maintain the pressure set point. The condenser water pumps remain in the MANUAL position during normal operation. Normal Shutdown: Normal shutdown will take place when set point has been satisfied, and the control system determines no fan nor pump is needed. Temporary Operation: The condenser may be manually "turned-on" during a system shutdown to allow all condensing to take place and allow manual purging of non-condensable gases. Emergency Operation: Per IlAR definition, Emergency Operation of this equipment requires that the Refrigeration Operator have intent and knowledge of the existing "Near Emergency Shutdown" condition that could cause system and / or compressor damage or could lead to a release of ammonia to the atmosphere. Operating under these conditions is not recommended. Emergency Shutdown: The condenser should never be turned off unless there is a system shutdown. Isolate if a leak is present by closing inlet and outlet valves. Verify that system will not "run". Shutdown system if pressure reaches 220 psig. Start-up following a turn-around or after an emergency shutdown: After a shutdown of a service nature, the condenser should be returned to a pre-shutdown condition. Then, the condenser can be restarted as per the Normal Start-up instructions above. If the shutdown was due to an emergency, an investigation procedure should be followed to determine the nature of the emergency that caused the condenser to be shutdown. If the shutdown was due to a safety limit being reached, it must be determined WHY that limit was reached. Whatever the cause of the shutdown, the offending situation or condition must be corrected, with an assurance that it will not re-occur, before the condenser can be returned to a pre-shutdown condition. Then, and only then, should the condenser be restarted as per the Normal Start-up instructions above. 6 OPE ,Ni~OF THE BOOSTER REY A,: ...... PAGE ~'~;;;;',;;'i~,,, COMP~SSORS: Feb. 8, 2001 10F,~5 Objective: Purpose: Concerns: This procedure is established to describe the Technical Operating Specifications (TOS) and to set fbrth Standard Operating Procedures (SOP) for the operation of the Booster Compressors. The purpose of the Technical Operating Specifications (TOS) is to provide a description of the Booster Compressors, to define its function, operating conditions, limits, and consequences of deviation from said operating limits and to also describe its controls, instrumentation, safety system, and setting its operating alignment(s). The purpose of the SOP is to establish the proper steps for starting, stopping, re-starting, and monitoring normal operation. Among incidents we are trying to prevent are: · Injury to operator(s) · Over pressurization of the system · Operation of the safety relief valves · Release of ammonia to atmosphere Department: Refrigeration Operator Pillsbury Refrigeration Operator - Level 3 /Responsibility: Equipment: Low Stage Compressors: Sullair: BC1 & BC2 Frick: BC3 Location: North & South Engine Rooms Related Documents: P&ID R-02, R-06 & R-07, the Valve & Equipment Schedules, R-08, R-09 & R-10, lIAR Bulletin 109 and 110 and any OEM related document(s). All are located in the North Engine Room Initial Development August 31, 2000 Date: Authorized By: Tim Ridley Annual Review By: March 1, 2002 Function: TECHNICAL OPERATING SPECIFICATIONS (TOS) The function of the booster compressors is to provide the necessary suction pressure to meet plant production temperature needs. Description Capacity/Size Operating Consequences Corrective Action Limit of Deviation Min. Press. 15" SULLAIR Hg. BC1 Max. Press. 45 C20LB-717-2.6 86 TR / 100 PSIG S/N: 056-R02863 HP SULLAIR BC2 A12LB 200 S/N: 056-R02864 FRICK BC3 RDB-316 S/N: S0059KFEFTHAA3 20 TR / 30 HP 238 TR / 200 HP Any pressure above 130 PSIG could result in the lifting of the safety relief valves causing a release of ammonia to the Ammonia Diffusion Tank. Ensure that the suction pressure controls are functioning correctly on both the Booster and the High Stage Compressors. CONTROLS AND INSTRUMENTATION Description Item Number Function Position/Set point Control Panel SULLAIR - BC1 Cycles the compressor Set by the operator. "on/off" according to SULLAIR - BC2 set points. FRICK - BC3 Monitors the operating conditions and shuts the compressor off if conditions are outside the specified parameters. Set by the operator and specified by the compressors' manufacturer. SAFETY SYSTEMS Description Item Number Function Position/Set point 1. Single safety relief SULLAIR- BC1 The pressure relief 1. 150 PSIG valves. 1. BC1 06 valves are intended to protect the oil separator SULLAIR - BC2 and will open on a rise 1. BC2 08 in pressure relieving any over pressure into a FRICK - BC3 Relief Header which 2. BC3 05 & BC3 06 discharges into the 2. Ammonia Diffusion Tank. 2. Dual safety relief 150 PSIG valves. STANDARD OPERATING PROCEDURES (SOP) Initial Start-up: A Factory Representative usually performs initial start-up. He will ensure installation is complete and that all piping and wiring connections are properly made. He will place all of the valves on the package into their normal position, set all of the operating and safety parameters, check and correct if necessary the compressor/motor alignment and run the compressor ensuring that all subsystems function as intended before turning over the operation to the Refrigeration Operator. Normal Start-up: The booster screw compressors are started (and stopped) by a signal from their control panel mounted to the compressor package. The Sullair and the Frick compressors have EM or Electro-Mechanical control panels. All panels perform the same basic functions, (insuring that all of the operating conditions are within the prescribed operating parameters.) When the compressor receives a signal to start, the external oil pump will start, (BC2 & BC3.) After a minimum oil pressure of 20 PSIG is reached, the compressor will start. The Sullair compressor, (BC1) has a shaft driven oil pump and will therefore, start as soon as it receives its "start" command. If an adequate oil pressure does not develop within a prescribed amount of time, the compressor will be promptly shut down. The TSOC cooling system will function automatically and is driven by temperature differential. Net oil pressure should be set to 40 PSIG. Normal Operation: Once nomaal start-up has been accomplished, the compressors will load and unload automatically according to system suction pressure and the control panel set points. The various pressure switches will monitor the operating conditions. Should any monitored pressure attempt to stray outside its parameter, the respective pressure switch will respond by taking the appropriate action to protect the compressor, (load, unload or fail.) Normal Shutdown: The compressors control panels can initiate the normal shutdown of the compressors based on operating conditions and set points. The operator can also initiate the normal shutdown of the compressors. If an operator initiates the shutdown, care should be taken to unload the compressor before turning it off. (This is not necessary but this practice will allow.fbr quicker re-starts since mo,s't compressors must be ./idly unloads be]bre it can be started. The compressor will unload automatically bqfore "slart", but this could take as long as 90 seconds. A slight problem with a suction check valve could allow oil lo be pumped out rtl' the compressor and into the system during this 90- secondperiod.) Temporary Operation: This phase of operation does not apply for this facility, according to the definition per lIAR. Emergency Operation: Per lIAR definition, Emergency Operation of this equipment requires that the Refrigeration Operator have intent and knowledge of the existing "Near Emergency Shutdown" condition that could cause system and / or compressor damage or could lead to a release of ammonia to the atmosphere. Operating under these conditions is not recommended. STANDARD OPERATING PROCEDURES (SOP) (continued) Emergency Shutdown: Anytime a shutdown occurs because specific operating safety limits have been reached or exceeded, is considered to be an emergency shutdown. As per definition, this shutdown could be the entire system, an individual component or group of components. The shutdown could be either manually by an operator or automatically by the plant's safety system. This will include but not limited to; high motor amperage shutdown, oil pressure/temperature shutdown, or suction and discharge higMow pressure/temperature shutdown. All booster compressors will shutdown if the High Level Float, LSA1-33 at the Suction Accumulator is energized. Start-up following a turn-around or after an emergency shutdown: After a shutdown of a service nature, the booster screw compressors should be returned to a pre-shutdown condition. Then, the booster screw compressors can be restarted as per the Normal Start-up instructions above. If the shutdown was due to an emergency, an investigation procedure should be fbllowed to determine the nature of the emergency that caused the booster screw compressors to be shutdown. If the shutdown was due to a safety limit being reached, it must be determined WHY that limit was reached. Whatever the cause of the shutdown, the offending situation or condition must be corrected, with an assurance that it will not re-occur, before the booster screw compressors can be returned to a pre-shutdown condition. Then, and only then, should the booster screw compressors be restarted as per the Normal Start-up instructions above. 7 R~ESSORS' ~ ~8:~00 I 0~5 Objective: This procedure is established to describe the Technical Operating Specifications (TOS) and to set forth Standard Operating Procedures (SOP) for the operation of the High Stage Compressors. Purpose: The purpose of the Technical Operating Specifications (TOS) is to provide a description of the High Stage Compressors, to define its function, operating conditions, limits, and consequences of deviation from said operating limits and to also describe its controls, instrumentation, safety system, and setting its operating alignment(s). The purpose of the SOP is to establish the proper steps for starting, stopping, re-starting, and monitoring normal operation. Concerns: Among incidents we are trying to prevent are: · Injury to operator(s) · Over pressurization of the system · Operation of the safety relief valves · Release of ammonia to atmosphere Department: Operator /Responsibility: Equipment: Location: Related Documents: Initial Development Date: Authorized By: Annual Review By: Refrigeration Pillsbury Refrigeration Operator - Level 3 High Stage Compressors: Sullair: HC1 & HC2 Frick: HC3 North & South Engine Rooms P&ID R-02 & R-06, the Valve & Equipment Schedules, R-08, R-09 & R-10, lIAR Bulletin 109 and 110 and any OEM related document(s). All located in the North Engine Room August 31, 2000 Tim Ridley March 1, 2002 Function: TECHNICAL OPERATING SPECIFICATIONS (TOS) The function of the High Stage Compressors is to provide the necessary suction pressure to meet plant production medium-temperature needs and to receive the Booster Compressors' discharge gas and finish compressing it to the condensing pressure. Description Capacity/Size Operating Consequences Corrective Action Limit of Deviation SULLAIR - HS1 A12LA276 S/N: 056-R02865 SULLAIR - HS2 A 12LA231 S/N: 056-R02866 FRICK - HS3 RWB II-134 S/N: S0470KFMPTHAA3 Min. Press. Any pressure Insure suction & 101 TR / 15 PSIG above 270 PSIG discharge pressure 150 HP Max. Press. could result in controls are 225 PSIG the lifting of the functioning. pressure relief valves and a consequent release of ammonia to the Ammonia Diffusion Tank. 74 TR/ 125 HP 255 TR / 30O HP CONTROLS AND INSTRUMENTATION Description Item Number Function Position/Set point Control Panel SULLAIR - HS 1 Cycles the compressor Set by the operator. N/A "on/off' according to set points. SULLAIR - HS2 N/A FRICK - HS3 N/A Monitors the operating conditions and shuts the compressor off if conditions are outside the specified parameters. Set by the operator & specified by the compressors' manufacturer. SAFETY SYSTEMS Description Item Number Function Position/Set point 1. Single safety relief SULLAIR- HS1 The pressure relief 1. 300 PSIG. valves. 1. HS1-06 valves are intended to 2. 300 PSIG. 2. Dual safety relief protect the compressor valves, package from SULLAIR - HS2 1. HS2-07 FRICK - HS3 2. HS3-05 & HS3-06 overpressure and will open on a rise in pressure relieving any over pressure into a Relief Header which discharges into the Ammonia Diffusion Tank. STANDARD OPERATING PROCEDURES (SOP) Initial Start-up: A Factory Representative usually performs initial start-up. He will ensure installation is complete and that all piping and wiring connections are properly made. He will place all of the valves on the package into their normal position, set all of the operating and safety parameters, check and correct if necessary the compressor/motor alignment and run the compressor ensuring that all subsystems function as intended before turning over the operation to the Refrigeration Operator. Normal Start-up: The screw compressors are started (and stopped) by a signal from their control panel mounted to the compressor package. The Sullair compressors have EM or Electro-Mechanical control panels. The Frick compressor has Microprocessor control panel. All panels perform the same basic functions, (insuring that all of the operating conditions are within the prescribed operating parameters.) When the compressor receives a signal to start, the external oil pump will start. After a minimum oil pressure of 20 PSIG is reached, the compressor will start. If an adequate oil pressure does not develop within a prescribed amount of time, the compressor will be promptly shut down. The TSOC cooling system will function automatically and is driven by temperature differential. Net oil pressure should be set to 40 PSIG. (The Frick compressor, HS3 has a pre-lube oil pump and operates on pressure differential, discharge to suction, to drive the oil into the compressor.) Normal Operation: Once normal start-up has been accomplished, the compressors will load and unload automatically according to system suction pressure and the control panel set points. The various pressure sensing devices will monitor the operating conditions. Should any monitored pressure attempt to stray outside its parameters, the respective pressure sensing devices xvill respond by taking the appropriate action to protect the compressor, (load, unload, cycle on/off or fail.) Normal Shutdown: A normal shutdown of the compressors can be initiated automatically by the control panel or manually by the operator. The control panel will automatically cycle the compressors off based on the suction set point parameters. If an operator initiates the shutdown, care should be taken to unload the compressor before turning it off. (This is not necessary but this practice will allow for quicker re-starts since most compressors must be fidly unloaded beJbre it can be restarted. The compressor will unload automatically b~/bre starting, but this could lake as long as 90 seconds. A slight problem with the suction check valve could allow oil to be pumped out into the system during this 90-second period.) Temporary Operation: This phase of operation does not apply for this facility, according to the definition per lIAR. Emergency Operation: Per IlAR definition, Emergency Operation of this equipment requires that the Refrigeration Operator have intent and knowledge of the existing "Near Emergency Shutdown" condition that could cause system and / or compressor damage or could lead to a release of ammonia to the atmosphere. Operating under these conditions is not recommended. STANDARD OPERATING PROCEDURES (SOP) Emergency Shutdown: Anytime a shutdown occurs because specific operating safety limits have been reached or exceeded, is considered to be an emergency shutdown. As per definition, this shutdown could be the entire system, an individual component or group of components. The shutdown could be either manually by an operator or automatically by the plants safety system. This will include but not limited to; high motor amperage shutdown, oil pressure / telnperature shutdown, or suction and discharge high/low pressure/temperature shutdown. All high stage compressors will shutdown if the High Level Float, ICl-12 at the Intercooler is energized. Start-up following a turn-around or after an emergency shutdown: After a shutdown of a service nature, the high stage compressor should be returned to a pre-shutdown condition. Then, the high stage compressor can be restarted as per the Normal Start-up instructions above. If the shutdown was due to an emergency, an investigation procedure should be followed to determine the nature of the emergency that caused the high stage compressor to be shutdown. If the shutdown was due to a safety limit being reached, it must be determined WHY that limit was reached. Whatever the cause of the shutdown, the offending situation or condition must be corrected, with an assurance that it will not re-occur, before the high stage compressor can be returned to a pre-shutdown condition. Then, and only then, should the high stage compressor be restarted as per the Normal Start-up instructions above. 8 Objective: This procedure is established to describe the Technical Operating Specifications (TOS) and to set tbrth Standard Operating Procedures (SOP) for the operation of the Thermosyphon Receiver. Purpose: The purpose of the Technical Operating Specifications (TOS) is to provide a description of the Thermosyphon Receiver, to define its function, operating conditions, limits, and consequences of deviation from said operating limits and to also describe its controls, instrumentation, safety system, and setting its operating alignment(s). The purpose of the SOP is to establish the proper steps for starting, stopping, re-starting, and monitoring normal operation. Concerns: Among incidents we are trying to prevent are: · Injury to operator(s) · Over pressurization of the system · Operation of the safety relief valves · Release of ammonia to atmosphere Department: Refrigeration Operator Pillsbury Refrigeration Operator - Level 3 /Responsibility: Equipment: Thermosyphon Receiver - TSR1 Location: South Engine Room below the roof Related Documents: P&ID R-01, Manufacturers U-lA Report, IIAR Bulletin 109 and 110, and any OEM related documents. All are located in the North Engine Room. Initial Development August 31, 2000 Date: Authorized By: Tim Ridley Annual Review By: March 1, 2002 TECHNICAL OPERATING SPECIFICATIONS (TOS) Function: The primary function of the Thermosyphon Receiver (TSR) is to receive liquid ammonia from the evaporative condensers and maintain a small reserve of that liquid ammonia for distribution to the compressors' Thermosyphon Oil Coolers. Since the condensers drain into the TSR, it also serves to distribute liquid ammonia to other points of the system, (the Intercooler, the Water Chiller, the Glycol Chiller and the Controlled Pressure Receiver.) No liquid ammonia is stored in the TSR for any purpose other than oil cooling. Description Capacity/Size Operating Consequences Corrective Action Limit of Deviation Thermosyphon Receiver - 18" Dia. x 15' 220 PSIG Any pressure Verify the proper TSR1 OAL above 220 PSIG operation of the could result in condensers. Do the lifting of the not operate the pressure relief system above 220 valves and a PSIG. consequent release of ammonia. Rated for: 250 PSIG DWP @ 00°F Insure that the high stage compressors' high pressure cut outs function properly. CONTROLS AND INSTRUMENTATION Description Item Number Function Position/Set point Phillips High-Side TSR-174 The float and valve Float is set at 6" above Float / Pilot Operated combination will drain the bottom of the vessel. Valve all liquid that attempts to collect above a pre- set level above. SAFETY SYSTEMS Description Item Number Function Position/Set point Dual Safety Relief TSR1-2 & TSR-3 Opens on a rise in 250 PS1G Valves pressure to relieve over pressure to an Ammonia Diffusion Tank. STANDARD OPERATING PROCEDURES (SOP) Initial Start-up: The initial start-up of the Thermosyphon Receiver, TSR is accomplished by insuring that the isolation valves, TSRI-11, TSRI-12 & TSRI-13, around the float are open, the stop valves TSR1-05, TSRI-15 & TSRI-16 are open allowing the automatic operation of pilot operated valve TSRI-17. Additionally, stop valves TSRI-19 & TSR1-23 should be opened to allow for the automatic operation of the outlet pressure regulator TSR1-20. The only adjustment to be made is to set TSR1-20 to maintain the desired outlet pressure. Flow through the vessel to the various parts of the system is achieved by pressure differential and gravity. If liquid ammonia is present, it will flow to the various parts of the system providing the need is there. Normal Start-up: The TSR has no normal start-up. Once initially placed into operation, the TSR is always in operation and reacts to the system's needs on a continuous basis. Normal Operation: The TSR receives liquid ammonia from the evaporative condensers and distributes that liquid to other points of the system, (the Intercooler, the Water Chiller, the Glycol Chiller and the Controlled Pressure Receiver.) A small reserve of liquid ammonia is held back for distribution to the compressors' Thermosyphon Oil Coolers. Liquid ammonia drains, by gravity to the oil coolers. Liquid and vapor return to the TSR by thermosyphon-action. The returning liquid repeats its journey and the vapor travels back to the condensers inlet to be re-condensed. Normal Shutdown: The TSR has no normal shutdown. Temporary Operation: Due to the pressures involved and the amount of ammonia inventory, a temporary operation is not recommended. Emergency Operation: Per IIAR definition, Emergency Operation of this equipment requires that the Refrigeration Operator have intent and knowledge of the existing "Near Emergency Shutdown" condition that could cause system and / or compressor damage or could lead to a release of ammonia to the atmosphere. Operating under these conditions is not recolnrnended. Emergency Shutdown: The TSR is always in the system, if due to a leak in the vessel or related piping, refer to plant emergency response program. Start-up following a turn-around or after an emergency shutdown: After a shutdown of a service nature, the TSR should be returned to a pre-shutdown condition. Then, the TSR can be restarted as per the Normal Start-up instructions above. If the shutdown was due to an emergency, an investigation procedure should be followed to determine the nature of the emergency that caused the TSR to be shutdown. If the shutdown was due to a safety limit being reached, it must be determined WHY that limit was reached. Whatever the cause of the shutdown, the offending situation or condition must be corrected, with an assurance that it will not re- occur, before the TSR can be returned to a pre-shutdown condition. Then, and only then, should the TSR be restarted as per the Normal Start-up instructions above. 9 Objective: Purpose: Concerns: This procedure is established to describe the Technical Operating Specifications (TOS) and to set forth Standard Operating Procedures (SOP) for the operation of the Intercooler. The purpose of the Technical Operating Specifications (TOS) is to provide a description of the Intercooler, to define its function, operating conditions, limits, and consequences of deviation from said operating limits and to also describe its controls, instrumentation, safety system, and setting its operating alignment(s). The purpose of the SOP is to establish the proper steps fbr starting, stopping, re-starting, and monitoring normal operation. Among incidents we are trying to prevent are: · Injury to operator(s) · Over pressurization of the system · Operation of the safety relief valves · Release of ammonia to atmosphere Department: Refrigeration Operator Pillsbury Refrigeration Operator - Level 3 /Responsibility: Equipment: Intercooler Vessel - ICl Location: South wall in the South Engine Room Related Documents: P&ID R-03, Manufacturers U-1A Report, iiAR Bulletin 109 and 110, and any OEM related documents. All are located in the North Engine Room. Initial Development August 31, 2000 Date: Authorized By: Tim Ridley Annual Review By: March 1, 2002 TECHNICAL OPERATING SPECIFICATIONS (TOS) Function: The function of the Intercooler, ICI is to maintain a reservoir of liquid ammonia through which the booster compressors' discharge vapor is passed and is de-superheated. If, for some reason an excess amount of liquid should accumulate in the ICl, a High Level Alarm float, ICl-15 will energize solenoid valve LSA1-32 and transfer the excess to the Low-Temperature Suction Accumulator, LSA1. Description Capacity/Size Operating Consequences Corrective Action Limit of Deviation Vertical Intercooler Vessel - lC 1 Rated for: 150 PSIG DWP @ 300°F 84" Dia. x 12' Intended to be OAH operated at +10°F/24 PSIG Any pressure above 130 PSIG could result in the lifting of the pressure relief valves and a consequent release of ammonia into the Ammonia Diffusion Tank. This vessel should normally operate with a liquid level of about 54" above the bottom of the vessel. If the liquid level should increase to 82", the excess will be automatically transferred to the Low Temperature Suction Accumulator. THE, ~v. - A PaGE CONTROLS AND INSTRUMENTATION Description Item Number Function Position/Set point 1. Operating Level 1. IC1-18 1. Monitors the 1. 56" above the bottom float operating level of of the vessel. ammonia liquid, energizing and de- energizing the liquid feed solenoid valve in order to maintain this level. 2. Liquid feed 2. IC1-03 2. Controls theflowof 2. N/A solenoid valve liquid ammonia into the intercooler. 3. Hand expansion 3. IC1-02 3. To create the 3. valve pressure drop required controlling the flow of ammonia into the intercooler. 4. Liquid level eyes 4. N/A 4. Visual indication of 4. liquid level. This valve should be throttled to a point that the solenoid valve will be energized about 80% to 90% of the time. LL, 32"; OL, 56"; HLA, 82"; HLS, 94". SAFETY SYSTEMS Description Item Number Function Position/Set point 1. Dual safety relief 1. IC1-06&IC1-07 1. Opens on a rise in 1. 150PSIG valves pressure and relives into a relief vent, which carries the discharge into the Ammonia Diffusion Tank. 2. High Level Alarm 2. ICl-15 2. Visual and audible 2. 82" above the bottom float alarm and initiates of vessel. the transfer of liquid to the Low Temperature Suction Accumulator. 3. High Level 3. ICl-12 3. Local visual and 3. 94" above the bottom Shutdown float audible alarm, of the vessel. which will fail the high stage compressors. The booster compressors, in turn will fail on High Discharge Pressure. 4. Low Level float. 4. IC1-21 4. Visual and audible 4. alarm which will fail the booster compressors. 32" above the bottom of the vessel. STANDARD OPERATING PROCEDURES (SOP) Initial Start-up: Verify compliance with pre-start-up safety review. Verify that pressure test has been completed. Visually inspect and make sure inlet and outlet valves are open. Record all pressures, temperatures, and levels. By definition, there is no initial start-up of the Intercooler. During the initial plant start-up, liquid ammonia was allowed to enter the lntercooler through the liquid solenoid valve, IC1-03. When the operating level float, IC1-08 was satisfied, the solenoid valve would have shut off. Normal Start-up: By definition, the Intercooler has no norman start-up; it is always in the system. Visually inspect before and after system start-up. Record all pressures, temperatures and levels. Normal Operation: During normal operation the Intercooler receives the superheated discharge gas from the booster compressors. The lower temperature liquid ammonia removes the heat of compression from the discharge gas and allows near saturated gas to pass on to the high side section. Normal Shutdown: By definition, the Intercooler has no norlnal shutdown. It is always in the system. Temporary Operation: By definition, this mode of operation does not apply. The Intercooler is required to operate the booster compressors. Emergency Operation: Per IIAR definition, Emergency Operation of this equipment requires that the Refrigeration Operator have intent and knowledge of the existing "Near Emergency Shutdown" condition that could cause system and / or compressor damage or could lead to a release of ammonia to the atmosphere. Operating under these conditions is not recommended. Emergency Shutdown: The Intercooler can only be shutdown if the booster compressors are not operating. In an emergency situation, the Intercooler can be cannot be easily isolated from the rest of the system. If shutdown & isolation is required, the entire system will need to be shut down. It will be necessary to write a specific procedure to ensure that liquid ammonia is not trapped in other isolated parts of the system where it could heat up and lift a pressure relief valve. Then, the following valves will need to be closed, (not necessarily in the order given.) CPR-01, HX1-03, HX2-03, AP1-03, IC1-04, LSA1-01, BC1-02, BC2-04, BC3-03, HS1-04, HS2-04, HS3-03. Start-up following a turn-around or after an emergency shutdown: After a shutdown of a service nature, the Intercooler should be returned to a pre-shutdown condition. Then, the Intercooler can be restarted as per the Normal Start-up instructions above. If the shutdown was due to an emergency, an investigation procedure should be followed to determine the nature of the emergency that caused the Intercooler to be shutdown. If the shutdown was due to a safety limit being reached, it must be determined WHY that limit was reached. Whatever the cause of the shutdown, the offending situation or condition must be corrected, with an assurance that it will not re-occur, before the Intercooler can be returned to a pre-shutdown condition. Then, and only then, should the Intercooler be restarted as per the Normal Start-up instructions above. 10 01. Z '11 Objective: Purpose: Concerns: This procedure is established to describe the Technical Operating Specifications (TOS) and to set forth Standard Operating Procedures (SOP) for the operation of the Pumper Drum. The purpose of the Technical Operating Specifications (TOS) is to provide a description of the Pumper Drum to define its function, operating conditions, limits, and consequences of deviation from said operating limits and to also describe its controls, instrumentation, safety system, and setting its operating alignment(s). The purpose of the SOP is to establish the proper steps for starting, stopping, re-starting, and monitoring normal operation. Among incidents we are trying to prevent are: · Injury to operator(s) · Over pressurization of the system · Operation of the safety relief valves · Release of ammonia to atmosphere Department: Refrigeration Operator Pillsbury Refrigeration Operator - Level 3 /Responsibility: Equipment: . Pumper Drum - DT1 Location: Center of South wall in the South Engine Room under the LSA Related Documents: P&ID R-03, Manufacturers U-lA Report, IlAR Bulletin 109 and 110, and any OEM related documents. All are located in the North Engine Room. Initial Development August 31, 2000 Date: Authorized By: Tim Ridley Annual Review By: March 1, 2002 TECHNICAL OPERATING SPECIFICATIONS (TOS) Function: The function of the Pumper Drum, DT1 is to receive the liquid accumulated in the Low-Temperature Suction Accumulator, LSA1 and transfer it back to the Control Pressure Receiver, CPR via pressure differential using boost from the High Stage Discharge gas, HSG. Description Capacity/Size Operating Consequences Corrective Action Limit of Deviation Horizontal Pumper Drum - DT 1 Mfg.: RvS S/N: 91143 Nat's Bd. 3706 24" Dia. x 4' 24 PSIG to OAL 220 PSIG A pressure higher than 220 psig may lift the safety relief valve causing a release of ammonia into the Ammonia Diffusion Tank. The high-pressure gas that is used to transfer liquid to the CPR is from an outlet pressure regulator that is set for 80 PSIG. CONTROLS AND INSTRUMENTATION Description Item Number Function Position/Set point 1. Operating float 1. LSA1-20 1. Initiate transfer 1. Manufacture set switch sequence through control panel. 2. 3-wayvalve 2. LSAI-16 2. Toggles between 2. N/A venting the DT back to the LSA and pressurizing the DT to affect the transfer of liquid to the CPR. SAFETY SYSTEMS Description Item Number Function Position/Set point Dual safety relief valve LSAI-17 & LSAI-18 Opens on a rise in 250 PSIG pressure to relieve over pressure to an Ammonia Diffusion Tank STANDARD OPERATING PROCEDURES (SOP) Initial Start-up: The initial start-up of the DT consists of ensuring that all of the valves are open, that should be opened and that all of the valves are closed that should be closed. The OPEN valves are, LSAI-13, LSAI-15, LSAI-16, and LSA1-22. The CLOSED valve is, LSA1-23. Ensure that the valves in the pressure regulator assembly are open and the regulator is properly set, (TSRI-19, TSR1-20, and TSR1-22.) The Float Switch, LSA1-20 should be checked to ensure that it performs the function ~br which it was intended. Normal Start-up: There is no Normal Start-up of the DT. Since the DT is an integral part of the system, once the Initial Start-up has been completed, the DT is always in the system. Normal Operation: The Normal Operation of the DT is to receive the liquid from the Low- Temperature Suction Accumulator, (LSA) and transfer it back to the Controlled Pressure Receiver, (CPR.) Normal Shutdown: Since the DT is an integral part of the system, it is always in the system and available to operate at anytime. Temporary Operation: By definition, there is no Temporary Operation. The DT is always in the system. Emergency Operation: Per IlAR definition, Emergency Operation of this equipment requires that the Refrigeration Operator have intent and knowledge of the existing "Near Emergency Shutdown" condition that could cause system and / or compressor damage or could lead to a release of ammonia to the atmosphere. Operating under these conditions is not recommended. Emergency Shutdown: By definition, there is no Emergency Shutdown. The DT is always in the system. Start-up following a turn-around or after an emergency shutdown: After a shutdown of a service nature, the DT should be returned to a pre-shutdown condition. Then, the DT can be restarted as per the Normal Start-up instructions above. If the shutdown was due to an emergency, an investigation procedure should be followed to determine the nature of the emergency that caused the DT to be shutdown. If the shutdown was due to a safety limit being reached, it must be determined WHY that limit was reached. Whatever the cause of the shutdown, the offending situation or condition must be corrected, xvith an assurance that it will not re- occur, before the DT can be returned to a pre-shutdown condition. Then, and only then, should the DT be restarted as per the Normal Start-up instructions above. 11 Objective: Purpose: Concerns: This procedure is established to describe the Technical Operating Specifications (TOS) and to set forth Standard Operating Procedures (SOP) for the operation of the Low-Temperature Suction Accumulator. The purpose of the Technical Operating Specifications (TOS) is to provide a description of the Low-Temperature Suction Accumulator, to define its function, operating conditions, limits, and consequences of deviation from said operating limits and to also describe its controls, instrumentation, safety system, and setting its operating alignment(s). The purpose of the SOP is to establish the proper steps for starting, stopping, re-starting, and monitoring normal operation. Among incidents we are trying to prevent are: · Injury to operator(s) · Over pressurization of the system · Operation of the safety relief valves · Release of ammonia to atmosphere Department: RefrigeratiSn Operator Pillsbury Refrigeration Operator - Level 3 /Responsibility: Equipment: Low-Temperature Suction Accumulator - LSA1 Location: South wall in the South Engine Room Related Documents: P&ID R-03, Manufacturers U-lA Report, IIAR Bulletin 109 and 110, and any OEM related documents. All are located in the North Engine Room. Initial Development August 31, 2000 Date: Authorized By: Tim Ridley Annual Review By: March 1, 2002 TECHNICAL OPERATING SPECIFICATIONS (TOS) Function: The function of the Low-Temperature Suction Accumulator, (LSA1), is to receive the wet suction from the low-temperature evaporators and provide a quiet place for the liquid ammonia and vapor to separate. The booster compressors then draw off the dry ammonia vapor and the liquid is drained off to the Pumper Drum, (DT1) where it is transferred back to the Controlled Pressure Receiver, (CPR.) Description Capacity/Size Operating Consequences Corrective Action Limit of Deviation Vertical Suction 84" Dia. x 15' 150 ?SIG A high liquid Maintain a proper Accumulator- LSA1 OAH level could cause system charge. liquid carry-over to the booster compressors causing damage and a possible subsequent release of ammonia to the atmosphere. Ensure that the liquid transfer system is functioning properly. Ensure that the High Liquid Level Float Switch and safety circuit is properly functioning. CONTROLS AND INSTRUMENTATION Description Item Number Function Position/Set point Liquid Solenoid Valve LSA1-02 When a high liquid level is eminent in the intercooler, the High Level Alarm float switch, IC1-15, energizes this valve and transfers excess liquid to the Low Temp. Accumulator. This valve is Normally Closed and is powered to open. SAFETY SYSTEMS Description Item Number Function Position/Set point 1. Dual Safety Relief 1. LSA1-06 & 1. Opens on a rise in 1. 150 PSIG Valves LSA1-07 pressure to relieve over pressure to an Ammonia Diffusion Tank 2. High Level Float 2. LSA1-33 2. Detects a level of 2. About 8'-4" above the ammonia and sends bottom of the vessel. a signal that will fhil the booster compressors preventing liquid carry-over. Additionally, there will be a local visual and audible alarm. STANDARD OPERATING PROCEDURES (SOP) Initial Start-up: The initial start-up of the LSA consist of ensuring that all of the valves are open, that should be opened and that all of the valves are closed that should be closed. The OPEN valves are, LSA1-01, LSA1-02 (Automatic position), LSA1-03 (throttled), LSA1-04, LSA1-09, LSAi-10, LSA1- 12, LSA1-27, LSA1-28, and LSA1-32. The CLOSED valves are, LSAI-11, LSA1-25, LSA1-29, LSA1- 30, and LSA1-36. The High Level Float should also be checked to ensure that it performs the function for which it was intended. Normal Start-up: There is no Normal Start-up of the LSA. Since the LSA is an integral part of the system, once the initial start-up has been completed, the LSA is always in the system. Normal Operation: The Normal Operation of the LSA is to receive the wet suction from the low- temperature evaporators and provide a quiet place for the liquid ammonia and vapor to separate. The booster compressors then draw off the dry ammonia vapor and the liquid is drained off to the Pumper Drum, (DT1) where it is transferred back to the Controlled Pressure Receiver, (CPR.) Normal Shutdown: Since the LSA is an integral part of the system, it is always in the system and available to operate at anytime. Temporary Operation: By definition, there is no Temporary Operation. The LSA is always in the system. Emergency Operation: Per IlAR definition, Emergency Operation of this equipment requires that the Refrigeration Operator have intent and knowledge of the existing "Near Emergency Shutdown" condition that could cause system and / or compressor damage or could lead to a release of ammonia to the atmosphere. Operating under these conditions is not recommended. Emergency Shutdown: By definition, there is no Emergency Shutdown. The LSA is always in the system. Start-up following a turn-around or after an emergency shutdown: After a shutdown of a service nature, the LSA should be returned to a pre-shutdown condition. Then, the LSA can be restarted as per the Normal Start-up instructions above. If the shutdown was due to an emergency, an investigation procedure should be followed to determine the nature of the emergency that caused the LSA to be shutdown. If the shutdown was due to'a safety limit being reached, it must be determined WHY that limit was reached. Whatever the cause of the shutdown, the offending situation or condition must be corrected, with an assurance that it will not re- occur, befbre the LSA can be returned to a pre-shutdown condition. Then, and only then, should the LSA be restarted as per the Normal Start-up instructions above. 12 Objective: This procedure is established to describe the Technical Operating Specifications (TOS) and to set forth Standard Operating Procedures (SOP) for the operation of the Ammonia Diffusion Tank. Purpose: The purpose of the Technical Operating Specifications (TOS) is to provide a description of the Ammonia Diffusion Tank, to define its function, operating conditions, limits, and consequences of deviation from said operating limits and to also describe its controls, instrumentation, safety system, and setting its operating alignment(s). The purpose of the SOP is to establish the proper steps for starting, stopping, re-starting, and monitoring normal operation. Concerns: Among incidents we are trying to prevent are: · Injury to operator(s) · Over pressurization of the system · Operation of the safety relief valves · Release of ammonia to atmosphere Department: Operator /Responsibility: Equipment: Location: Related Documents: Initial Development Date: Authorized By: Annual Review By: Refrigeration Pillsbury Refrigeration Operator - Level 3 Ammonia Diffusion Tank - ADT Outside the engine room, to the Northeast at ground level. P&ID R-02, Manufacturers U- 1A Report, lIAR Bulletin 109 and 110, and any OEM related documents. All are located in the North Engine Room. August 31, 2000 Tim Ridley March 1, 2002 TECHNICAL OPERATING SPECIFICATIONS (TOS) Function: The function of the Ammonia Diffusion Tank is to hold 36,000 gallons of water to mitigate an emergency release of ammonia from a safety relief valve or, if necessary, to dump the entire ammonia charge with the use of the Fire Diffusion Panel. Description Capacity/Size Operating Consequences Corrective Action Limit of Deviation Vertical Atmospheric Water Tank - ADT Water Pump 15'-5" Dis. x The Ammonia Lifting of a Notify all required 30' OAH Diffusion Tank safety relief federal, state, 41,600 Gallon must hold valve constitutes county and local Total 36,000 gallons an emergency agencies Capacity of water at all situation, accordingly. Refer times, the PSM If an emergency Emergency situation exists Response Program. that would require the manual dumping of any or all of the system's charge that action would be at the direction of the Fire Department or by the Refrigeration Mechanic under the direction and consent of the Fire Department. 3-HP :::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::: ::::::::::::::::::::::::::::::::::::::::::::::: :::::::::::::::::::::::::::::::::::::::::::::::::::::::: :::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::: ~ ::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::: .... ::::::::::::::::::::::::: ........................ ::::::::::::::::::::::::::::::::::::::: .......................................... :::::::::::::::::::::::::::::::::::::::::::::::::::::~: ::: ::: :::::::::::: :::::::: :::: :::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::: .............................................................. ::: :::::::::::::::::::::::::: .............................................. ?~::::?:::: CONTROLS AND INSTRUMENTATION Description Item Number Function Position/Set point 1. Water make-up 1. N/A 1. Maintains xvater 1. 26'-4" (36,000 Gal.) valve level. 2. Water level gauge 2. N/A 2. Displays the water 2. 26'-4" (36,000 Gal.) & float level. SAFETY SYSTEMS Description Item Number Function Position/Set point The Ammonia Diffusion Tank is considered a "System Safety Component.'~' STANDARD OPERATING PROCEDURES (SOP) Initial Start-up: The initial start-up of the fire diffusion system consists of ensuring that all of the piping is complete including the City Water supply. Then, all that remains is to fill the tank with water to the prescribed level with water. Normal Start-up: By definition, there is no start-up. The Diffusion Tank just sits there holding water in the unlikely event that a relief valve will pop or an emergency will occur requiring the manual release of pressure from one of the vessels through the Fire Diffusion Panel. Refer to normal operation below. Normal Operation: Normally, this tank just sits there taking up space and holding many thousand gallons of water waiting for the unlikely event of an emergency situation. That emergency situation would most likely be the lifting of a safety relief valve. In a fire emergency, the local fire department or the Refrigeration Mechanic under the guidance of the fire department may use this tank in conjunction with the Fire Diffusion Panel to mitigate the manual release of ammonia from one or more vessels in order to relieve the build-up of excess pressure caused by fire or other such external event. Another use of the water held in this tank is to supply make-up water to evaporative condenser, ECl, in the event that there is an ammonia release in the engine room. The ammonia detectors would initiate the start of the exhaust fan, (which discharges into the air inlet to EC 1 .) At the same time, the water pump, ADT-PU would be turned on and 3-way valve, EC1-019would be energized and water would be recirculated from the Diffusion Tank to the condenser sump and overflowing back into the Diffusion Tank. The purpose again, would be to absorb the ammonia vapor from the air as it passes through the condenser. Normal Shutdown: By definition, there is no Normal Shutdown. This tank exists for the sole purpose of mitigating a release of ammonia from a safety relief valve or by other manual release through the Fire Diffusion Panel. As such, this tank must always be at the ready. The only time this tank may be off-line is while the water is being changed after an emergency release of ammonia. Temporary Operation: By definition, there is no temporary operation. Emergency Operation: By definition, the Emergency Operation of this tank IS its Normal Operation. See Normal Operation, above. If during the Normal or Emergency Operation additional water was deemed necessary, provisions have been made for the fire department to connect one of their 1 V2" hoses to one of two connections, ADT-03 or ADT-05. Emergency Shutdown: By definition, there is no emergency Shutdown. Start-up following a turn-around or after an emergency shutdown: Verify that all repairs and / or P.M's have been made. Ensure that the drain valve, ADT-01 is closed then open the City Water valve and insure that the tank is re-filled as quickly as possible. 13 CJi P" ' fils bury FinallSSUE:Draft SOP-109 EFFECTIVE DATE: OPERATION OF THE FIRE REV.- "A" PAGE NO. March 1, 2001 DIFFUSION PANEL Feb. 8, 20011 OF 4 Objective: Purpose: Concerns: This procedure is established to describe the Technical Operating Specifications (TOS) and to set forth Standard Operating Procedures (SOP) for the operation of the Fire Diffusion Panel. The purpose of the Technical Operating Specifications (TOS) is to provide a description of the Fire Diffusion Panel, to define its function, operating conditions, limits, and consequences of deviation from said operating limits and to also describe its controls, instrumentation, safety system, and setting its operating alignment(s). The purpose of the SOP is to establish the proper steps for starting, stopping, re-starting, and monitoring normal operation. Among incidents we are trying to prevent are: · Injury to operator(s) · Over pressurization of the system · Operation of the safety relief valves · Release of ammonia to atmosphere Department: Refrigeration Operator Pillsbury Refrigeration Operator - Level 3 /Responsibility: Equipment: Fire Diffusion Panel - ADP Location: Outside the North Engine Room, East of the Ammonia Diffusion Tank Related Documents: P&ID R-02, Manufacturers U-lA Report, IIAR Bulletin 109 and 110, and any OEM related documents. All are located in the North Engine Room. Initial Development August 31, 2000 Date: Authorized By: Tim Ridley Annual Review By: March 1, 2002 ---- p;Ushur , SOP-109 APCCO Final Draft EFFECTIVE DATE: OPERATION OF THE FIRE REV.- "A" PAGE NO. March 1, 2001 DIFFUSION PANEL Feb. 8, 20012 OF 4 Function: TECHNICAL OPERATING SPECIFICATIONS (TOS) The function of the Fire Diffusion Panel (ADP) is to mitigate a release of ammonia to the atmosphere. The panel can be used to equalize pressure between vessels and / or to dump part or all of the charge into the Ammonia Diffusion Tank, (ADT.) Specific operating instructions are located in the panel. Description Capacity/Size Operating Consequences Corrective Action Limit of Deviation Control Panel N/A This is not an N/A N/A ADP operation related component. It is a safety system. APCCO Final Draft EFFECTIVE DATE: OPERATION OF THE FIRE REV. - "A" PAGE NO. March 1, 2001 DIFFUSION PANEL Feb. 8, 2001 3 OF 4 CONTROLS AND INSTRUMENTATION Description Item Number Function Position/Set point 1. Crossover valves 1. 1. All crossover valves 1. Normally closed A. TSR1 to ICl A. ADP-06 will equalize B. ICl to LSA1 B. ADP-07 pressure between C. CPR to LSA1 C. ADP-08 the two (2) vessels indicated. 2. Dump globe valves 2. 2. All vessel dump 2. Normally closed. A. TSR1 A. ADP-01 valves allow B. ICl B. ADP-02 pressure to reach C. LSA1 C. ADP-03 the Main Dump D. CPR D. ADP-04 Valve-ADP-05 E. Main E. ADP-05 3. Pressure gauges 3. 3. 3. N/A A. TSR1 A. ADP-09 A. TSR1 pressure B. ICl B. ADP-10 indicator C. LSA1 C. ADP-11 B. ICl pressure D. CPR D. ADP-12 indicator C. CPR pressure indicator D. LSA1 pressure indicator SAFETY SYSTEMS Description Item Number Function Position/Set point The Fire Diffusion Panel has no safety systems. The Fire Diffusion Panel is a safety system. Pmsh U SOP-109 APCCO Final Draft EFFECTIVE DATE: OPERATION OF THE FIRE REV. - "A" PAGE NO. March 1, 2001 DIFFUSION PANEL Feb. 8, 2001 4 OF 4 STANDARD OPERATING PROCEDURES (SOP) Initial Start-up: Visually inspect and verify that the Fire Diffusion Panel is in compliance with PSM Pre-Start-up Safety Review and that all valves in panel are closed. Normal Start-up: There is no normal start-up associated with the fire diffusion system. This component is for Fire Department use or by the Refrigeration Mechanic with Fire Department's consent. Refer to the Emergency Operation below. Normal Operation: By definition, this mode of operation does not apply. Refer to the Emergency Operation below. Normal Shutdown: This is a manual operation. With all valves in the panel closed, this component is considered shutdown. Temporary Operation: By definition, this mode of operation does not apply. Emergency Operation: During an uncontrolled rise in system pressure this component will mitigate a release of ammonia to the atmosphere through the Ammonia Diffusion Tank. By means of piping and valves, the Thermosyphon Receiver, Intercooler, Controlled Pressure Receiver, and the Low Suction Accumulator can be manually equalized with each other, (refer to the Control section this SOP.) This equalization may prevent the activation of a safety relief valve. If the need to dump the system's charge becomes inevitable, (last resort), the dump valves can be open and the respective vessel pressure will be allowed to enter the Ammonia Diffusion Tank. Emergency Shutdown: By definition, this mode of operation does not apply. A shutdown is a manual operation. With all valves inside panel closed, this component is considered shutdown. Start-up following a turn-around or after an emergency shutdown: There is no start-up associated with this component. The use of this component constitutes an emergency and not a mode of operation. 14 Pillsbury ISSUE: SOP-Il0 APCCO Final Draft EFFECTIVE DATE: OPERATION OF THE LOW REV. - "A" PAGE NO. March 1, 2001 TEMPERATU~ EVAPORATORS Feb. 8, 2001 1 OF 8 Objective: Purpose: Concerns: This procedure is established to describe the Technical Operating Specifications (TOS) and to set forth Standard Operating Procedures (SOP) for the operation of the Low Temperature Evaporators. The purpose of the Technical Operating Specifications (TOS) is to provide a description of the Low Temperature Evaporators, to define its function, operating conditions, limits, and consequences of deviation from said operating limits and to also describe its controls, instrumentation, safety system, and setting its operating alignment(s). The purpose of the SOP is to establish the proper steps for starting, stopping, re-starting, and monitoring normal operation. Among incidents we are trying to prevent are: · Injury to operator(s) · Over pressurization of the system · Operation of the safety relief valves · Release of ammonia to atmosphere Department: Refrigeration Pillsbury Refrigeration Operator - Level 3 Operator /Responsibility: Equipment: Location: Related Documents: Initial Development Date: Authorized By: Low-Temperature Evaporators: AU2, AU3 & AU4 AU6 Holding Freezer AU7 AU8 Spiral Freezer # 1 Anti Room Spiral Freezer #2 P&ID R-05 & R-05, Manufacturers U-1A Report, lIAR Bulletin 109 and 110, and any OEM related documents. All are located in the North Engine Room. August 31, 2000 Tim Ridley Annual Review By: March 1, 2002 PREPARED BY:---- ,-, aPmshur' ,ssu :SOP-Il0 APCCO Final Draft EFFECTIVE DATE: OPERATION OF THE LOW REV. - "A" PAGE NO. March 1, 2001 TEMPERATURE EVAPORATORS Feb. 8, 2001 2 OF 8 Function: TECHNICAL OPERATING SPECIFICATIONS (TOS) The function of a Low-Temperature Evaporator is to cool air, which in turn, is used to cool a product or an open area. Description Capacity/Size Operating Consequences Corrective Action Limit of Deviation Frigid Coil Model: LTA.364-1/3-LTT- HGO-IP-PCV-PW AU2, AU3, AU4 Model: S245.104x174x8R- 3FPI AU6 Model: ICB-1H-1910- 3LRB-HGD-IPPCV AU7 Model: S230.80x272xl 0R- 3FPI (3 Units) AU8 5.5 TR Ea. -20°F Coil Coil Verify the suction 10°F TD temperatures pressure. higher than Operating Limits can compromise the room temperature and product integrity. 70 TR -30°F Coil 10°F TD 74.33 TR Ea. -30°F Coil 10°F TD 74.33 TR Ea. -30°F Coil 10°F TD Verify that there is proper liquid being fed to the coils. Verify that the coils are clean and free of ice. If iced over, verify that the defrost operation is functioning properly. PREPARED BY: Pillsbury SOP-110 &PCCO Final Draft EFFECTIVE DATE: OPERATION OF THE LOW REV. - "A" PAGE NO. March 1, 2001 TEMPERATURE EVAPORATORS Feb. 8, 2001 3 OF 8 CONTROLS AND INSTRUMENTATION HOLDING FREEZER - AU2, AU3 & AU4 Description Item Number Function Position/Set point 1. Liquid feed AU2 1. Liquid ON/OFF, 1. The thermostat is set solenoid 1. AU2-02 controlled by a for a return air temp. 2. AU2-09 room thermostat, of-10°F 2. Hand expansion 3. AU2-0g 2. Controls the rate 2. 2½ Turns open valve 4. AU2-05 that the liquid enters the AU3 evaporator. 3. Hot gas solenoid 1. AU3-02 3. Allows hot gas to 3. Energized during a valve 2. AU3-09 enter the pan then portion of the defrost 3. AU3-08 the coil for cycle. 4. AU3-05 defrosting. Controlled by a AU4 Defrost Time clock. 4. Suction/Defrost 1. AU4-02 4. Controls the 4. Set for 9 PSIG during regulator 2. AU4-09 pressure at which refrigeration and 75 3. AU4-08 the liquid will PSIG for defrosting. 4. AU4-05 evaporate and the pressure at which the coil will be defrosted. PREPARED BY:---- - u SOP-Il0 APCCO Final Draft EFFECTIVE DATE: OPERATION OF THE LOW REV. - "A" PAGE NO. March 1, 2001 TEMPERATURE EVAPORATORS Feb. 8, 2001 4 OF 8 CONTROLS AND INSTRUMENTATION (continued) ANTI-ROOM - AU7 Description Item Number Function Position/Set point 1. Liquid feed 1. AU7-09 1. Liquid ON/OFF, solenoid controlled by a room thermostat. 2. Hand expansion 2. AU7-11 2. Controls the rate valve that the liquid enters the evaporator. 3. Hot gas solenoid 3. AU7-13 3. Allows hot gas to valve enter the pan then the coil for defrosting. Controlled by a Defrost Time clock. 4. Suction regulator 4. AU7-02 4. Controls the pressure at which the liquid will evaporate. 5. Defrost regulator 5. AU7-05 5. Controls the pressure at which the coil will defrost. 1. The thermostat is set for a return air temp. of-20°F 2. 4 Turns open. Energized during a portion of the defrost cycle. 4. Set for 1.6" Hg. 5. Set for 80 PSIG. PREPARED BY:Pillsb,, ry SOP-110 APCCO U Final Draft EFFECTIVE DATE: OPERATION OF THE LOW REV. - "A" PAGE NO. March 1, 2001 TEMPERATURE EVAPORATORS Feb. 8, 2001 5 OF 8 CONTROLS AND INSTRUMENTATION (continued) SPIRAL FREEZER- AU6 Description Item Number Function Position/Set point 1. Liquid feed Upper Coil 1. Liquid ON/OFF, 1. The thermostat is set solenoid 1. AU6-02 controlled by a for a return air temp. 2. AU6-21 room thermostat, of-20°F 2. Hand expansion 3. AU6-24 2. Controls the rate 2. 2½ Turns open valve 4. AU6-11 that the liquid 5. AU6-12 enters the evaporator. 3. Hot gas solenoid Lower Coil 3. Allows hot gas to 3. Energized during a valve (Coil) 1. AU6-05 enter the pan then portion of the defrost 2. AU6-26 the coil for cycle. 3. AU6-29 defrosting. 4. AU6-17 Controlled by a 5. AU6-18 Defrost Time clock. 4. Suction check valve 4. Controls the 4. Set for 1.6" Hg. 6. AU6-20 pressure at which the liquid will evaporate. 5. Defrost regulator 5. Controls the 5. Set for 80 PSIG. pressure at which the coil will defrost. 6. Hot gas solenoid 6. Allows hot gas to 6. Energized during a valve (Main) enter the pan then portion of the defrost to the (2) hot gas cycle. solenoids at each coil for defrosting. PREPARED BY:---- : u SOP-Il0 APCCO Final Draft EFFECTIVE DATE: OPERATION OF THE LOW REV.- "A" PAGE NO. March 1, 2001 TEMPERATURE EVAPORATORS Feb. 8, 2001 6 OF 8 CONTROLS AND INSTRUMENTATION (continued) SPIRAL FREEZER - AU8 Description Item Number Function Position/Set point 1. Liquid feed Upper Coil 1. Liquid ON/OFF, 1. The thermostat is set solenoid 1. AUS-05 controlled by a for a return air temp. 2. AUS-07, AU8-27 & room thermostat, of-20°F 2. Hand expansion AU8-28 2. Controls the rate 2. 2½ Turns open valve 3. AU8-09 that the liquid 4. AU8-02 enters the 5. AU8-12 evaporator. 3. Hot gas solenoid 3. Allows hot gas to 3. Energized during a valve (Coil) Common to Lower 2 enter the pan then portion of the defrost Coils the coil for cycle. 1. AU8-18 defrosting. 2. AUg-20 Controlled by a 3. AU8-22 Defrost Time clock. 4. Suction check valve 4. AUg-15 4. Controls the 4. Set for 1.6" Hg. 5. AUg-25 pressure at which the liquid will 5. Defrost regulator Middle Coil evaporate. 2. AUg-30 & AUS-31 5. Controls the 5. Set for g0 PSIG. pressure at which Lower Coil the coil will defrost. 2. AU8-33 & AUg-34 SAFETY SYSTEMS Description Item Number Function Position/Set point There are no safety systems that will shutdown the evaporators. pinshur SOP-Il0 APCCO-~ll[ ~lJ ty Final Draft EFFECTIVE DATE: OPERATION OF THE LOW REV. -"A" PAGE NO. March 1, 2001 TEMPERATURE. EVAPORATORS Feb. 8, 2001 7 OF 8 STANDARD OPERATING PROCEDURES (SOP) Initial Start-up: Verify that everything is in compliance with the PSM Pre-Start-up Safety Review. Verify that all valves are properly set. Verify that the control system is operational and all set points have been correctly entered. Verify that the fans are operational and in proper rotation. Visually inspect for any sign of leakage. Verify that CPR and the LSA are operational. Record all of the operating pressures and temperatures. Normal Start-up: Normal start-up of the coils is accomplished automatically by means of the computer system. Once the chief engineer or his representative install the desired temperature set points, the computer control system will control these units according to those set points. Normal Operation: During normal refrigerating mode, the computer control system will energize or de-energize the liquid feed solenoid. When the solenoid is energized, liquid ammonia will be metered into the evaporator coils buy the hand expansion valve (HEV.) The evaporator coils are designed to be "overfeed." A minimum of 5-PSIG pressure drop is usually enough to properly feed the evaporator coils. During defrost cycle, the computer will control the defrost operation. Typically, the defrost cycle consist of a pump-down period, hot gas period, bleed period, fan-delay down period and re-start of the fans. Normal Shutdown: Normal shutdown of the units is simply accomplished by means of the computer control system according to temperature. Temporary Operation: By definition, this phase of operation does not apply. Emergency Operation: Per IIAR definition, Emergency Operation of this equipment requires that the Refrigeration Operator have intent and knowledge of the existing "Near Emergency Shutdown" condition that could cause system and / or compressor damage or could lead to a release of ammonia to the atmosphere. Operating under these conditions is not recommended. Emergency Shutdown: These units have no safety to shut them down. Refer to system Safety Overview. A manual shutdown could be accomplished by manually shutting off liquid valves, and with the fans running, allow time for the coils to pump-out, then turning off the suction valve and the fans. Shut down system if pressure in the evaporators reaches 130 PSIG. PREPARED BY:,,,- y:"s ur'' p SOP-Il0 APCCO Final Draft EFFECTIVE DATE: OPERATION OF THE LOW REV. - "A" PAGE NO. March 1, 2001 TEMPERATURE EVAPORATORS Feb. $, 2001 8 OF 8 STANDARD OPERATING PROCEDURES (SOP) (continued) Start-up following a turn-around or after an emergency shutdown: After a shutdown of a service nature, the evaporator should be returned to a pre-shutdown condition. Then, the evaporator can be restarted as per the Normal Start-up instructions above. If the shutdown was due to an emergency, an investigation procedure should be followed to determine the nature of the emergency that caused the evaporator to be shutdown. If the shutdown was due to a safety limit being reached, it must be determined WHY that limit was reached. Whatever the cause of the shutdown, the offending situation or condition must be corrected, with an assurance that it will not re-occur, before the evaporator can be returned to a pre-shutdown condition. Then, and only then, should the evaporator be restarted as per the Normal Start-up instructions above. ~5 P" sbury ill ' APCCO Final Draft EFFECTIVE DATE: OPERATION OF THE SHELL & REV. - "A" PAGE NO. March 1, 2001 TUBE HEAT EXCHANGER Feb. 8, 20011 OF 5 Objective: Purpose: Concerns: This procedure is established to describe the Technical Operating Specifications (TOS) and to set forth Standard Operating Procedures (SOP) for the operation of the Shell & Tube Heat Exchanger. The purpose of the Technical Operating Specifications (TOS) is to provide a description of the Shell & Tube Heat Exchanger, to define its function, operating conditions, limits, and consequences of deviation from said operating limits and to also describe its controls, instrumentation, safety system, and setting its operating alignment(s). The purpose of the SOP is to establish the proper steps for starting, stopping, re-starting, and monitoring normal operation. Among incidents we are trying to prevent are: · Injury to operator(s) · Over pressurization of the system · Operation of the safety relief valves · Release of ammonia to atmosphere Department: Refrigeration Operator Pillsbury Refrigeration Operator - Level 3 /Responsibility: Equipment: Shell and Tube Heat Exchanger - HX1 Location: Southwest wall in the South Engine Room above the Turbo Water Chiller Related Documents: P&ID R-03, Manufacturers U-lA Report, lIAR Bulletin 109 and 110, and any OEM related documents. Initial Development August 31, 2000 Date: Authorized By: Tim Ridley Annual Review By: March 1, 2002 PREPARED BY: ISSUE: Pillsb ry SOP-111 APCCO U Final Draft EFFECTIVE DATE: OPERATION OF THE SHELL & REV.- "A" PAGE NO. March 1, 2001 TUBE HEAT EXCHANGER Feb. 8, 2001 2 OF 5 Function: TECHNICAL OPERATING SPECIFICATIONS (TOS) The function of the Shell & Tube Heat Exchanger is to supply chilled propylene glycol the Air Handlers in the Dock and Production Floor for comfort cooling and to the Dough Mixer for process cooling. Description Capacity/Size Operating Consequences Corrective Action Limit of Deviation Horizontal Shell and Tube 130 PSIG A pressure A pressure Heat Exchanger with higher than 130 regulator controls integral knockout drum - PSIG may lift the operating HX1 the safety relief pressure in the heat Mfg.: RvS valve causing a exchanger. release of ammonia into the Ammonia Diffusion Tank. 1. Heat Exchanger 24" Dia. x 12' S/N: 91176 OAL Nat'l Bd.: 3658 2. Knockout Drum 20" Dia. x 10' S/N: 91177 OAL Nat'l Bd.: 3659 PREPA~RED BY: ~ ~e,~ ~ . : ISSUE: Pdlslbury APCCO ~ Final Draft EFFECTIVE DATE: OPERATION OF THE SHELL & REV. - "A" PAGE NO. March 1, 2001 TUBE HEAT EXCHANGER Feb. 8, 2001 3 OF 5 CONTROLS AND INSTRUMENTATION Description Item Number Function Position/Set point 1. Operating level 1. HX1-06 1. Controls the liquid 1. Manufacture set at float switch feed solenoid valve about 18" above the bottom of the heat exchanger. 2. Liquid feed 2. HXI-16 2. Feeds make-up 2. N/A solenoid valve liquid into the heat exchanger. 3. Dual pressure 3. HX1-02 3. Maintains a suction regulator constant pressure to prevent the freezing of the glycol. 3. 23.8 PSIG-Low 35.5 ?SIG - High SAFETY SYSTEMS Description Item Number Function Position/Set point 1. Dual safety relief 1. HXI-18 & HXI-19 1. valve 2. High level float 2. HX1-05 2. Opens on a rise in pressure to relieve over pressure to an Ammonia Diffusion Tank. Local Audible and visual alarm to warn of High Level. 1. 150 PSIG Within the bottom 25% of the surge drum. APCCO~ml. llJ ff Final Draft EFFECTIVE DATE: OPERATION OF THE SHELL & REV. - "A" PAGE NO. March 1, 2001 TUBE HEAT EXCHANGER Feb. 8, 2001 4 OF 5 STANDARD OPERATING PROCEDURES (SOP) Initial Start-up: The initial start-up of the HX consist of ensuring that all of the valves are open, that should be opened and that all of the valves are closed that should be closed. The OPEN valves are, HX1-01, HX1-02 (Automatic position), HX1-03, HX1-04, HX1-07, HXl-14, HXI-15 (Throttled), HX1- 16 (Automatic position), and HXI-17. The CLOSED valves are, HX1-08, HX1-09, HXI-10, HXi-11, HXI-12, and HXI-13. The Float Switches, HX1-05 and HX1-06 should be checked to ensure that they perform the function for which they are intended. Normal Start-up: There is no Normal Start-up of the HX. Since the HX is an integral part of the system, once the Initial Start-up has been completed, the HX is always in the system. Normal Operation: The Normal Operation of the HX is to supply chilled propylene glycol to the Air Handlers in the Dock and Production area and to the Dough Mixer for process cooling. Normal Shutdown: Since the HX is an integral part of the system, it is always in operation supplying chilled glycol. Shutting the HX down would halt production. If the HX needed to be shut down for servicing or repair, start by closing the liquid isolation valve, HXI-17 and keeping the glycol pump running until all of the liquid ammonia is boiled off. If the HX needed to be taken off line for servicing or repair, refer to a specific pump down and isolation procedure. Temporary Operation: By definition, there is no Tempt)rary Operation. The HX is always in the system. Emergency Operation: Per IIAR definition, Emergency Operation of this equipment requires that the Refrigeration Operator have intent and knowledge of the existing "Near Emergency Shutdown" condition that could cause system and / or compressor damage or could lead to a release of ammonia to the atmosphere. Operating under these conditions is not recommended. Emergency Shutdown: By definition, there is no Emergency Shutdown. The HX is always in operation supplying chilled glycol. Shutting the HX down would halt production. If the HX needed to be shut down, refer to Normal Shutdown. p SOP-Ill APCCO Final Draft EFFECTIVE DATE: OPERATION OF THE SHELL & REV. - "A" PAGE NO. March 1, 2001 TUBE HEAT EXCHANGER Feb. 8, 2001 5 OF 5 STANDARD OPERATING PROCEDURES (SOP) (continued) Start-up following a turn-around or after an emergency shutdown: After a shutdown of a service nature, the HX should be returned to a pre-shutdown condition. Then, the HX can be restarted as per the Normal Start-up instructions above. If the shutdown was due to an emergency, an investigation procedure should be followed to determine the nature of the emergency that caused the HX to be shutdown. If the shutdown was due to a safety limit being reached, it must be determined WHY that limit was reached. Whatever the cause of the shutdown, the offending situation or condition must be corrected, with an assurance that it will not re- occur, before the HX can be returned to a pre-shutdown condition. Then, and only then, should the HX be restarted as per the Normal Start-up instructions above. 16 P~P~I~-D BY: ~,~l[i!]~ I~. ISSUE: APCCO ~ Final Draft EFFECTI,~E OATE: opE~TION OF THE TU~O ~V. - "A" PAGE NO. March 1,200~ WATER CHILLER Feb. 8, 2001 1 OF 4 Objective: Purpose: Concerns: This procedure is established to describe the Technical Operating Specifications (TOS) and to set forth Standard Operating Procedures (SOP) for the operation of the Turbo Water Chiller. The purpose of the Technical Operating Specifications (TOS) is to provide a description of the Turbo Water Chiller, to define-its function, operating conditions, limits, and consequences of deviation from said operating limits and to also describe its controls, instrumentation, safety system, and setting its operating alignment(s). The purpose of the SOP is to establish the proper steps for starting, stopping, re-starting, and monitoring normal operation. Among incidents we are trying to prevent are: · Injury to operator(s) · Over pressurization of the system · Operation of the safety relief valves · Release of ammonia to atmosphere Department: Refrigeration Operator Pillsbury Refrigeration Operator - Level 3 /Responsibility: Equipment: Turbo Water Chiller - HX2 Location: Southwest wall in the South Engine Room below the Shell & Tube Heat Exchanger Related Documents: P&ID R-03, Manufacturers U-lA Report, IIAR Bulletin 109 and 110, and any OEM related documents. All are located in the North Engine Room. Initial Development August 31, 2000 Date: Authorized By: Tim Ridley Annual Review By: March 1, 2002 PREPARED BY: u SOP-112 APCCO Final Draft EFFECTIVE DATE: OPERATION OF THE TURBO REV. - "A" PAGE NO. March 1, 2001 WATER CHILLER Feb. 8, 2001 2 OF 4 TECHNICAL OPERATING SPECIFICATIONS (TOS) Function: The function of the Turbo Water Chiller is to cool water for the plant's production requirements. Operating Consequences Corrective Action Description Capacity/Size Limit of Deviation Water Chiller 9.25 TR Suction Pressures lower Ensure that the Mfg.: Turbo Refrigerating Pressure than 40 PSIG suction pressure Company between 40 could cause regulator, HX2-02 Model: HTDA-480601 PSIG to 45 water to freeze is set correctly and PSIG on the plates, functioning properly. Must have a continuous supply of fresh water. Pressures higher than 45 PSIG may not be adequate for plant production requirements. P~PAREDBY: '' bury ,ssu~: ; ~. ~ i !$i i SOP-112 ~o Pill .... Final Draft EF~F=ECTIVE DATE: O~P~E~TI:O~'OF THE TURBO REV.- "A" PAGE NO. March 1, 2001 WATER CHILLER Feb. 8, 2001 3 OF 4 CONTROLS AND INSTRUMENTATION Description Item Number Function Position/Set point 1. Operating Level 1. HX2-14 1. Monitors the 1. The operating level is float operating level of set to ensure that the ammonia liquid, plates are flooded energizing and de- with ammonia with energizing the little or no liquid in liquid feed solenoid the surge drum. valve in order to maintain this level. 2. Liquid feed 2. HX206 2. Controls the flowof 2. N/A solenoid valve liquid ammonia into the intercooler. 3. Hand expansion 3. HX2-05 3. To create the 3. valve pressure drop required controlling the flow of ammonia into the intercooler. This valve should be throttled to a point that the solenoid valve will be energized about 80% to 90% of the time. SAFETY SYSTEMS Description 1. Dual pressure relief 1. HX2-08 & HX2-09 1. Opens on arise in 1. valves pressure and relives into a relief vent, which carries the discharge into the Ammonia Diffusion Tank. Item Number Function 2. Highlevel float 2. HX-13 2. Visual and audible 2. alarm. Position/Set point 150 PSIG Level is set to allow no more than 2 to 3 inch level in the surge drum. SOP-112 APCCO . Final Draft EFFECTIVE DATE: OPERATION OF THE TURBO REV.- "A" PAGE NO. March 1, 2001 WATER CHILLER Feb. 8, 2001 4 OF 4 STANDARD OPERATING PROCEDURES (SOP) Initial Start-up: Verify compliance with pre-start-up safety review. Verify that pressure test has been completed. Visually inspect and make sure inlet and outlet valves are open. Verify that water system is operable. Record operating pressure and temperature. Normal Start-up: Once water valve open and water flow has been established, liquid ammonia can be introduced into the surge drum. The chiller operates on a continuous basis and energizing of the liquid feed solenoid can be considered the normal start-up. Visually inspect the chiller before and after each start-up. Verify water is "ON." Occasionally check to ensure that ice is not accumulating on the plates. Record all pressures and temperatures. Normal Operation: During normal operation the high-pressure liquid ammonia is fed into the surge drum. The liquid ammonia flows, by gravity, to the bottom inlet of the plates. As the liquid comes in contact with the warmer plates, some of it vaporizes cooling the water that is falling over the outside of the plates. The vapor works its way up to the top of the plate, carrying along some liquid, where it enters the surge drum. In the surge drum, the liquid separates from the vapor. The vapor is pulled off by the high stage suction and the liquid falls back to the bottom of the plates to repeat the process again. Normal Shutdown: A normal shutdown is accomplished by simply de-energizing the liquid feed solenoid. Temporary Operation: By definition, this mode of operation does not apply. Emergency Operation: Per lIAR definition, Emergency Operation of this equipment requires that the Refrigeration Operator have intent and knowledge of the existing "Near Emergency Shutdown" condition that could cause system and / or compressor damage or could lead to a release of ammonia to the atmosphere. Operating under these conditions is not recommended. Emergency Shutdown: Refer to Normal Shutdown above. Shutdown if ammonia odor is present. Start-up following a turn-around or after an emergency shutdown: After a shutdown of a service nature, the Water Chiller should be returned to a pre-shutdown condition. Then, the Water Chiller can be restarted as per the Normal Start-up instructions above. If the shutdown was due to an emergency, an investigation procedure should be followed to determine the nature of the emergency that caused the Water Chiller to be shutdown. If the shutdown was due to a safety limit being reached, it must be determined WHY that limit was reached. Whatever the cause of the shutdown, the offending situation or condition must be corrected, with an assurance that it will not re-occur, before the Water Chiller can be returned to a pre-shutdown condition. Then, and only then, should the Water Chiller be restarted as per the Normal Start-up instructions above. 17 APCCO Final Draft EFFECTIVE DATE: OPERATION OF THE HANSEN REV. - "A" PAGE NO. March 1, 2001 A~UTO PURGER Feb. 8, 2001 1 OF 5 Objective: Purpose: Concerns: This procedure is established to describe the Technical Operating Specifications (TOS) and to set forth Standard Operating Procedures (SOP) for the operation of the Hansen Auto Purger. The purpose of the Technical Operating Specifications (TOS) is to provide a description of the Hansen Auto Purger, to define its function, operating conditions, limits, and consequences of deviation from said operating limits and to also describe its controls, instrumentation, safety system, and setting its operating alignment(s). The purpose of the SOP is to establish the proper steps for starting, stopping, re-starting, and monitoring normal operation. Among incidents we are trying to prevent are: · Injury to operator(s) · Over pressurization of the system · Operation of the safety relief valves * Release of ammonia to atmosphere Department: Refrigeration OperatOr Pillsbury Refrigeration Operator - Level 3 /Responsibility: Equipment: Hansen Auto Purger - AP1 Location: Southwest wall in the South Engine Room South of the Turbo Water Chiller Related Documents: P&ID R-02, Manufacturers U-1A Report, IIAR Bulletin 109 and 110, and Hansen Bulletin AP-003g, September 1998.. All are located in the North Engine Room. Initial Development August 31, 2000 Date: Authorized By: Tim Ridley Annual Review By: March 1, 2002 PREPARED BY= APCCO Final Draft EFFECTIVE DATE: OPERATION OF THE HANSEN REV. - "A" PAGE NO. March 1, 2001 AUTO PURGER Feb. 8, 2001 2 OF 5 Function: TECHNICAL OPERATING SPECIFICATIONS (TOS) The function of the Hansen Auto Purger is to remove non-condensable gas from the refrigeration system. Description Capacity/Size Operating Consequences Corrective Action Limit of Deviation Hansen Auto Purger 8 Purge Points 220 PSIG or Discharge Check condenser AP1 system safety pressures higher for proper S/N: J1067 pressures, than 220 PSIG operation. may cause the safety relief valves to lift. Ensure that the Auto Purger is functioning properly, (the purger's purpose is to remove non- condensable gases that will cause high discharge pressures.) PREPARED BY: · ~ ISSUE: ' :'i i' ~ ~ urv soP_il3 APCCO ~ Pffisib Final Draft EFFECTIVE DATE: OPERATION OF THE HANSEN REV.- "A" PAGE NO. March 1, 2001 AUTO PURGER Feb. 8, 2001 3 OF 5 CONTROLS AND INSTRUMENTATION Description Item Number Function Position/Set point Control Panel 1. Foul Gas Valve 1. AP1-001 1. Allows foul gas to 1. N.O. reach purger. 2. HPLvalve 2. AP1-002 2. Allows liquid to 2. N.O. reach purger. 3. Suction Valve 3. AP1-003 3. Allows suction to 3. N.O. reach purger. Foul gas solenoid ECl Allow non-condensable N/A valves EC 1-006 gas to reach auto- EC 1-009 purger from their respective locations. EC2 EC2-008 EC2-011 TSR1 TSR1-008 SAFETY SYSTEMS Description Item Number Function Position/Set point The Hansen Auto Purger is a manufacturer control package system. Refer to Hansen Bulletin AP- 003g, September, 1998 PREPARED BY: APCCO Final Draft EFFECTIVE DATE: OPERATION OF THE HANSEN REV. - "A" PAGE NO. March 1, 2001 AUTO PURGER Feb. 8, 20'01 4 OF 5 STANDARD OPERATING PROCEDURES (SOP) Initial Start-up: - Verify that all is in compliance with the PSM Pre-Start-Up Safety Review. - Verify that all electrical connections have been made and that control power is present and that all purge point solenoids have been connected. - Verify that the water supply and the water drain are connected. - Visually inspect the Auto Purger before opening liquid suction and foul gas lines. - Open the suction line and verify that there are no leaks. - Open the foul gas line and verify that no leaks are present. - Open the liquid line also verifying that there are no leaks present. - Note: The Hansen Auto Purger is totally automatic and electronically controlled. - Turn the purger switch on the front panel of control cabinet to the "Automatic" position. - Record all pressures and temperatures. Refer Hansen Bulletin AP-003g. Normal Start-up: Once all manual valves, (i.e. foul gas, liquid, suction) are open the Auto Purger can be started in either automatic or manual. When in automatic the electronic controller will have a cool down stage. Once evaporator reaches approximately 20°F it will sequence all purge points until no non- condensable gases are noted. When in the manual operation, the "Purger" switch located on the front panel, can be used to manually select the purge point. The timer will not operate in this manual mode. Refer Hansen Bulletin AP-003g Normal Operation: During normal operation, the Hansen Auto Purger will remove air and other non- condensable gases from the refrigeration system. By means of piping to purge point locations and an electrical solenoid at each location, the Auto Purger energizes in sequence and with an adjustable time, each purge point (if set on automatic). This allows the foul gas to enter the onboard condenser. All non- condensable gases will separated and exit the system through a water bubbler. Refer Hansen Bulletin AP-003g. Normal Shutdown: The Auto Purger should be in the system during normal operation. A shutdown of the Auto Purger can be accomplished by simply putting the "Purger" switch, located on the front panel, to the off position. Refer Hansen Bulletin AP-003g. Temporary Operation: By definition, this phase of operation does not apply. Emergency Operation: Per IlAR definition, Emergency Operation of this equipment requires that the Refrigeration Operator have intent and knowledge of the existing "Near Emergency Shutdown" condition that could cause system and / or compressor damage or could lead to a release of ammonia to the atmosphere. Operating under these conditions is not recommended. pinshur ; APCCO,~gll ,11~ ~ Final Draft EFFECTIVE DATE: OPERATION OF THE HANSEN REV. - "A" PAGE NO. MarCh 1, 2001 AUTO PURGER Feb. 8, 2001 5 OF 5 STANDARD OPERATING PROCEDURES (SOP) (continued) Emergency Shutdown: By definition, an emergency shutdown of this unit does not apply. There are no system or unit safeties that will shut this unit down. Start-up following a turn-around or after an emergency shutdown: After a shutdown of a service nature, the Hansen Auto Purger should be returned to a pre-shutdown condition. Then, the Hansen Auto Purger can be restarted as per the Normal Start-up instructions above. If the shutdown was due to an emergency, an investigation procedure should be followed to determine the nature of the emergency that caused the Hansen Auto Purger to be shutdown. If the shutdown was due to a safety limit being reached, it must be determined WHY that limit was reached. Whatever the cause of the shutdown, the offending situation or condition must be corrected, with an assurance that it will not re-occur, before the Hansen Auto Purger can be returned to a pre-shutdown condition. Then, and only then, should the Hansen Auto Purger be restarted as per the Normal Start-up instructions above. AUTO-PURGER®AP NoncondenSible Gas (Air) Refrigerant Purger Model AP08 OPERATOR INSTALLATION & INSTRUCTION MANUAL For Models AP01, AP08, AP16, AP24, and APC European Versions AP01E, AP08E, AP16E, AP24E, and APCE [ISO 9002) ~' C US HANSEN TECHNOLOGIES CORPORATION ' :~ ' Table'of Contents :~ .... · '; Section 1 Mounting and Piping Installation .................................................. 2 Section 2 Electrical Installation and Mechanical Component Operation ..................... 6 Section 3 AUTO-PURGER Operation ....................... 12 Section 4 Troubleshooting Purger Operation ....... 14 Parts List .................................. ; .................................... 18 Selecting an AUTO-PURGER ..................................... 20 Bulletin AP-OO3{I September, 1998 SECTION 1 MOUNTING The AUTO-PURGER is a totally automatic, electronically-controlled noncondensible gas (air) refrigerant purger for reducing condensing pressure. The deluxe models--AP08, AP16, and AP24mare preassembled, prewired, insulated, and include an automatic water bubbler. Installation requires piping the foul gas line, liquid line, suction line, water line, drain line, and power connection, and wiring the remote purge point solenoid valves. Purge point solenoid valves must be purchased separately and must be a minimum of %= (13 mm) port size. In addition, a computerized modelmAPC---is available where a separate plant computer or programmable logic controller (PLC) is used to start and stop the AUTO-PURGER and independently operate the various remote purge point solenoid valves. The basic AUTO-PURGER--Model AP01---is the same construction less insulation, automatic water bubbler, water solenoid valve, 7-day time clock, and sequence timer for remote multipoint purge solenoid valves. The insulation and automatic water bubbler flush system can be factory added or field upgraded. The internal surface area and flooded evaporator efficiency gives the AUTO-PURGER two to three times the foul gas condensing capacity of an Armstrong Purger and 10 times the capacity of purgers with small electric hermetic compressors. Ina system with normal noncondensible loads, all models will handle a 750 ton (2600 kW) ammonia plant at suction pressures below atmospheric pressure or a 1500 ton (5300 kW) ammonia plant at positive suction pressures. The amount of noncondensibles in the system is based on many factors including age, maintenance practices, and operating temperature. The number of purgers required for a system depends on the number of installed purge points. Twenty- four purge points is the maximum practical number per purger. For example, a system with 24 points set to purge for 10 minutes per point requires a 240 minute (4 hour) cycle. Each purge point can be purged 6 times a day. This may, or may not, be adequate. Therefore, a second purger should be used and the purge points divided equally between the two purgers. The AUTO-PURGER can operate over a wide range of condensing pressures. This is important for refrigeration systems that operate at Iow condensing pressures during cold ambient conditions. MOUNTING INSTRUCTIONS Mount the AUTO-PURGER securely on a wall or sturdy steel channels capable of supporting 450 lbs (205 Kg). Eight mounting holes in the frame are provided to support the unit. See Figure 1. The unit should be located in an accessible area, but away from moving equipment that could accidentally come in contact with the purger. Elevation with respect to condensers or high-pressure receivers is not critical. Do not punch access holes in the top of the control cabinet. Unused electrical entrances to the enclosure must be sealed to protect the controls from moisture. & PIPING INSTALLATION The AUTO.PURGER is normally installed in the compressor room where it can be monitored, but also may be installed outdoors where temperatures below freezing are not anticipated. For outdoor use, areas near falling or spraying water, or in constant high humidity areas, an optional NEMA 4 enclosure with sealed conduit wiring is recommended. PIPING INSTRUCTIONS It is extremely important to install purge points at locations sure to be liquid free. Also, no liquid traps are desirable either before or after purge point solenoid valves. See Figure 2. The line from the purge point on the condenser to the AUTO-PURGER should not pass through cold areas where further condensing of the saturated gas can occur. If this cannot be avoided, the purge line must be insulated because flooded purge point lines will flood the AUTO-PURGER with liquid, resulting in a temporary halt of noncondensibles being removed. The minimum line size for foul gas piping is 1/2~ (13 mm). The line should be pitched down toward the purger to drain any refrigerant that may condense. It is important that one purge point solenoid valve is open at all times to prevent losing foul gas pressure to the purger. An optional differential pressurestat system (DPS} can be used to safeguard against loss of foul gas pressure. FOUL GAS LINES Model AP01 For the single point purger, Model AP01, the foul gas line is brought directly from the purge point on the condenser or receiver to the purger. During operation, the AUTO-PURGER's foul gas solenoid valve (#4) located on the purger, energizes when the purger's evaporator chamber is cooled to approximately 20°F (-7°C). FOUL GAS PIPING FOR MUL TIPOINT PURGING Models AP08, AP16, AP24, and APC It is nearly impossible to predict where noncondensible gases (air) will accumulate. Therefore, purging at several points on the high- pressure side of the system is the best method for removing air from the system. For multipoint purgers, the solenoid valves may be manifolded into one line to the purger. However, only one purge point should be purged at a time. Connecting two purge points together may result in gas flowing from one condenser to another due to unequal pressure drop, even though the difference in pressure drops is very small, for example % psi (0.02 bar). The result is that even in the best of circumstances, only one point is effectively purged. The best practice is to purge each condenser and receiver circuit separately. EVAPORATIVE CONDENSER PIPING Typically, evaporative condenser outlet liquid drain lines on each circuit must drop between 4e-6¢(l.2m- 1.8m) for ammonia and 8e-12¢ (2.5m-3.7m) for halocarbons from the centerline of the condenser outlet to the centerline of highest elevation of the liquid line manifold to receiver. Preferably each circuit should have a P-trap to balance variations in pressure drop in each circuit and to prevent liquid from backing up into one or more condensers, flooding the purge point. A properly-sized equalizer line from the receiver will help drain condenser circuits into the receiver. Refer to ASHRAE guidelines or recent IlAR papers on condenser piping design. Also, consult condenser manufacturers installation instructions for additional piping and sizing information. Do not use one purge point solenoid valve to purge two circuits. This negates the P-trap on the condenser drain line and may back liquid up into one circuit. PURGE POINT CONNECTIONS Condensers should be purged at points recommended by the condenser manufacturer. This is typically at the top of each circuit's outlet header. In some cases a small, high-pressure auxiliary receiver is located at the outlet of one or more condensers. This receiver should have a purge point at the top. Where a high-pressure float regulator is used to drain one or more condensers, the top of the float valve chamber should be a purge point. Heat exchangers and horizontal shell and tube water- cooled condensers should be purged at the top, usually at the point or points furthest from the compressor discharge main inlet. Vertical condensers should be purged near the top of the vessel if possible. For certain types of oil separators where very Iow velocities may exist near the top of the vessel, purging may be advisable from a top fitting. It is not necessary to purge control pressure receivers, high pressure thermosyphon vessels, or vessels located on the Iow side of the system. SUCTION LINE A %= (20 mm) suction line should be connected to a protected main suction line or can be piped to a suction accumulator. The purger thermostat is factory set at 30°F (-1°C). To allow for temperature transfer losses between the purger evaporator and the thermostat sensor, the suction temperature should be approximately 20°F (-7°C) or below to close the thermostat. This then switches the AUTO-PURGER from its PURGER COOLING DOWN mode to its AUTOMATIC or MANUAL PURGING mode. For higher suction temperatures, consult the factory. 2.~0' IS4 MM] s 4.~0- Ul4 MM] ~ONNECTION FROM PURGE POINTS ON HIGH PRESSURE CONDENSERS AND RECEIVERS PRESSURE UQUID LINE CONNECTION 14.94' TO PROTECTED SUCTION ACCUMULATOR ~-SHUT-OFF VALVE COLUMN [~o~ MM] SHUT-OFF VALVE CONNECTION t/2' WATER LINE- CHECK VALVE [800 MM] BUBBLER __ 24.00 [610 MM]/ DRAJN CONNECTION. DO NOT INSTALL SHUT-OFF LVE IN DRAIN LINE. NOT RUN DRAIN LINE MORE THAN 10' (3 M) ABO~E BUBBLER, 1/2' FPT CONNECTION FOR PRESSURE. .53" [14 MM] MOUNTING POINT SOB~OI~ V~L~ CONNEC~ONS [~ M~ x,x,.~ ' ' [191 ~]~ ~ H~H PRESSURE~P~TOR ~ ~ TH~ BUL~ ~L D~N ~NEC~N (114' ~ ~ BE~ IN~AL~ OR L~ PR~URE SEP~R OPtiNG AUT~URGER OIL D~IN C~NEC~ON (~14' FP~ ~ Figure 1. AUTO-PURGER AP installation dimensions. WATER LINE An automatic water bubbler flush system is provided with the purger (except Model AP01). A water line must be connected to the water solenoid valve (#6). The connection is %= FPT. The water supply pressure should be 30-80 psig (3.1-6.5 bar). The clear tube of the water bubbler may become coated with mineral deposits after a period of time. These deposits can be removed by adding a cup of vinegar to the water in the bubbler and cleaning the clear tube through the top plastic tiffing with the supplied brush. A water conditioning filter housing and cartridge are available for abnormally hard water. Model AP01 comes with a plastic hose and tiffing for connection to an ammonia-absorbing water reservoir (customer supplied). This reservoir should be at least one gallon (four liters) and the water must be changed regularly. The water bubbler flush system can be added to Model AP01. OIL DRAINS Excess oil can reduce the purger capacity by lowering the evaporating or condensing rate. Oil is not typically a problem. However, any oil that may collect in the purger can be drained off through the two capped %~ valves on the purger. See Figure 1. Before draining oil, shutoff the purger and close the liquid and foul gas valves. Allow the purger to pump out, then close the suction line valve. Use normal oil draining precautions to prevent injury or property damage. LIQUID LINE A high-pressure liquid source is required for the AUTO-PURGER. This connection should be at a location where oil will not be directed into the purger. The liquid line supplies refrigerant during startup and feeds makeup liquid as required during purging. The liquid line solenoid valve (#1) on the AUTO-PURGER closes when the AUTO-PURGER is off. See Figure 11. The supply pressure must be sufficiently above the purger evaporator pressure to ensure proper operation of the level control valve. This valve supplies only 5% of the liquid refrigerant required for cooling, except at startup. The remainder of the required refrigerant is condensed from the foul gas line. This liquid is fed to the evaporator through the metering valve located downstream of the liquid metering solenoid valve (#3). CHECK VALVES There are four check valves on the purger. A I psid (.07 bar) check valve with a ~1=22 (.8 mm) diameter metering orifice is installed on the purge gas line to prevent reverse flow of water into the purger. A 30 psid (2.1 bar) check valve is installed in the liquid line to the float chamber. This limits the liquid line pressure at the purger to 30 psi (2.1 bar) less than the foul gas pressure and allows noncondensibles into the purger. A 225 psid (15.5 bar) relief check valve from the float chamber to suction line. Older purgers have a 200 psid (13.8 bar) relief check valve, The water line has a %=check valve. /t;~" PORT PURGE POINT SOLENOID (TYPICAL) COMMON PURGE POINT RECEIVER CONDENSER B~LET (TYPICAL) ~'~ /- PURGE POINT CONNECTION ON ~COON ~ I ~ TOP OF OUTLET PIPE OF EACH ,/(~, CIRCUIT IN CONDENSER ('TYPICAL) (' ~ PURGE POINT SOLENOID VALVE ~.~- I '- ' I CrYPtAL). LOCATE SOLENOID ~ I I VALVE NEAR THE PURGE POINT ~ I I AT THE SAME OR HIGHER -'~. I ELEVATION THAN 'fl-IAT DEHSER ~ ~ I OF 'I'HE PURGE POINT ~ CONDENSER OUTLET ('FYPICAL) FOUL ~A$ UNE TO PURGER ~t/2" (13 MM) HIGH-PREESURE UQUID LINE 3/4" (26 MM) MINIMUM SUCTION LINE TO PROTECTED SUCT1ON ACCUMULATOR MINIMUM OF t' (25 MM) ON HA3.0GARBON PURGER AUTO-PURGER AP {ALL MODELS) Figure 2. Typical purge point locations. 4 DRAIN LINE A 1= (25 mm) PVC socket/l= FPT water drain connection is located at the bottom of the bubbler. The water should flow to a suitable drain or container. If the drain line is run overhead, the fitting on the top of the water bubbler must be sealed, including the 1/~= NPT vent connection in the fitting, and a protective mesh installed around the clear tube. Do not run the line more than 10¢(3 m) above the height of the bubbler because the pressure on the water bubbler could be excessive. Support the drain line to prevent undue stress on the water bubbler. Also, do not install a shutoff valve in this line. Since Model AP01 comes less the bubbler, no drain is necessary on this model. Initially, fill water bubbler with water through the 3 = (75 mm) plug located on top of the tube. Keep the plug lubricated and hand tight. Check for leaks at the hose fittings. MODEL APF AUTO-PURGERS Model APF AUTO-PURGERs are for use in halocarbon refrigeration systems. The installation and operation of these AUTO-PURGERs are similar to that of an ammonia AUTO-PURGER. PIPING HALOCARBON AUTO.PURGERS The halocarbon liquid line and foul gas line piping and sizing .details are the same as for an ammonia AUTO-PURGER. However, the suction line size for halocarbon purgers should be 1 = (25 mm) for suction temperatures down to -20°F (-29°C), and 1%= (32 mm) for-20°F (-29°C) to -60°F (-51°C) suction temperatures. Condenser drain lines on halocarbon evaporative condensers must be trapped and drop vertically 8e-12¢(2.5m-3.Tm), or per manufacturer recommendations. This is to prevent possible backflow of liquid into one or more condenser circuits resulting in a flooded purge point. While the air indicating column (water bubbler flush system) is included, the water line and drain line are not required. Purge points are at the same locations as for an ammonia purger. See Figure 2. For evaporative condensers, the purge points are on the top of the outlet drain line. Although noncondensible gases are lighter than halocarbon gas, they still collect at, or near, the outlet. FILTER-DRYER CONDITIONING SYSTEM The special construction for APF AUTO-PURGERs includes a filter-dryer conditioning system for the foul gas and liquid line. See Figure 3. Water vapor, as well as noncondensible gas, may be present at each purge point. The filter-dryers remove this moisture before it can enter the purger. Both dryers are used to protect the purger internally from freezing water, but they also supplement water removal of the primary refrigeration system liquid line dryers. Moisture indicating sight glasses located downstream of the filter-dryers indicate when the filter-dryer cores are saturated with water and must be replaced. Isolation shut-off valves are included for change out of the filter-dryer cores, and access valves allow evacuation of the refrigerant from the filter-dryer shell. Another feature is a small filter-dryer prior to the liquid metering valve (or metering orifice on European purgers). This small filter-dryer protects the expansion orifice by capturing particles and any moisture present in the purger. It should be replaced during normal maintenance. AIR INDICATING COLUMN Model APF AUTO-PURGERs are equipped with an air indicating column (ammonia models have a water bubbler). Fill the clear tube to the marked line with water or a lightweight, clear oil. Noncondensibles released from the purger bubble up through the column, indicating proper operation. As with ammonia purgers, the counter inside the control cabinet keeps a record of how many times the purge gas solenoid valve (#5) opens to release noncondensibles into the column. FOUL GAS LINE IN 518" ODS CUSTOMER-SUPPLIED 5/8" ODS COPPER PIPE (TYPICAL*. -- LIQUID LINE IN 5/8" ODS ITEM 1 2 SUCTION LINE OUT 4 1" SW~, 5 ~ 6 o ~ NOTES: THE VALVES AND ACCESSORIES ARE SHIPPED SEPARATELY TO BE PIPED IH THE FIELD TO SUIT THE LOCATION. USE 5/8' ODS COPPER PIPE TO CONNECT BALL VALVES, FILTER-DRYERS, AND MOISTURE-INDICATING SIGHT GLASSES. Figure $. AUTO-PURGER APF filter-dryer conditioning system for halocarbon refrigerants. DESCRIPTION SUCTION LINE SHUT-OFF VALVE ASSEMBLY FLANGE ADAPTER 112' FLANGE X 518" ODS 518' ODS BALL VALVE MOISTURE-INDICATING SIGHT GLASS, 5/8' ODS REPLACEMENT FILTER-DRYER CORE, 5/8' ODS ACCESS VALVE, 114" MPT MOUNTING BRACKETS SECTION 2 ELECTRICAL INSTALLATION MECHANICAL COMPONENT OPERATION ELECTRICAL CONNECTIONS The standard AUTO-PURGER requires a 115V 50/60Hz electrical supply. Also, AUTO-PURGERs requiring 230V 50/60Hz are available. The circuit should be fused to 15 amps. Model AP01 has a %2 (13 mm) knockout on the side of the control cabinet to access the power connection terminal strip. Any unused knockout holes must be sealed to prevent splashing water, dust, and debris from entering the control cabinet. AUTo-PURGERs other than Model AP01 have an additional %: (20 mm) knockout for individual purge point solenoid valves. Wires from each purge point solenoid valve should be brought to the purger control cabinet. Any additional access holes should be made on the side of the control cabinet. All access holes into the control cabinet must be sealed to prevent moisture, dust, and debris entering the cabinet. Connect one line from each purge point solenoid to the corresponding screw terminal located near the top inside the control cabinet. The numbers on the terminal strip correspond to the numbers on the lights located on the door of the control cabinet. Connect the remaining wire from each purge point solenoid to the ground terminal inside the control cabinet. Remote purge point solenoid valves must be the same voltage as the purger. An internal transformer provides 12V DC to the electronic control circuits and the door panel wiring. This transformer normally does not need to be serviced. PURGE GAS SOLENOID VALVE TIME DELAY CUTOUT The AUTO-PURGER is equipped with a one hour fixed-time-delay relay which controls the purge gas solenoid valve (#5). This valve meters noncondensible gases to the water bubbler when the purger is operating. See Figure 11. This relay closes the purge gas solenoid valve (#5) after one hour of continuous noncondensible gas release into the water bubbler. In the unlikely event of a float switch malfunction, electrical fault, or system malfunction, this prevents excess amounts of refrigerant being released. However, during startup of a new purger or under high noncondensible removal conditions, it is sometimes advantageous for the purge gas solenoid valve (#5) to remain open continuously. The delay relay is equipped with an on/off switch to bypass the time delay function. Simply turn the relay to OFF until the high volume of noncondensible gas is removed when. When noncondensible gas is being removed at short intervals, the time-delay relay should be switched ON for normal operation. If during normal operation the delay relay time is exceeded, the magnet will not make contact with the float switch tube and gas will not be released into the water bubbler. To reset the relay, turn the switch to OFF and back to ON. This resets the delay relay for another hour. SETTING THE GRASSLIN TIME CLOCK A Grasslin Mil 72 Series time clock is used in the AUTO-PURGER since 2/98. To set the correct day, remove the transparent cover and rotate the outer dial until the day is aligned with the triangular marker on the inner dial. TO set the time, rotate the minute hand clockwise until the time is correct. AM and PM are indicated on the outer dial. See Figure 4. If running the purger continuously, push all clock tabs out or set the manual override switch out from the middle position (up or down). If the purger is to run intermittently, such as shutting down at night or on the weekend, set the run time by pushing the clock tabs out for each period that the purger is to be on. Make sure the manual override switch is in the middle. Each tab represents two hours. Tabs pushed to the center represent when the purger is off. For AUTO-PURGERs shipped before 2198, a discontinued Grasslin time clock was used. These have red and green tabs. To set the time and day on these clocks, rotate the minute hand on the circular dial. Once the correct day and time are set, the amount of run time per day must be determined and set. Set the ON time using the green tabs and the OFF time using the red tabs. Use a green tab and red tab for each day of the week. To run the purger 24 hours per day, pull all the red pins from the circular dial or turn the small knob in the upper- right corner of the time clock to the on position. The purger should not operate when the refrigeration compressors are stopped. Terminal connections are provided for an interlock to shut down the purger while the Grasslin Time Clock continues to operate. Manual switch tabs Out = On In = Off Figure 4. Grasslin Time Clock, Mil 72 Series. (Hansen Part# 20-2226) MANUAL PURGE POINT OPERATION There is a switch on the front panel of the control cabinet (except AP01) to manually select the current purge point, and to turn the purger to AUTOMATIC and OFF. If it is desired to purge from only one point, turn the switch to that purge point. The purger will go through automatic startup with the switch in either the AUTOMATIC or MANUAL position. However, air must be present for the purger to purge. OPERATION OF THE METERING VALVE Note: European AUTO-PURGERs do not have a metering valve. Instead, a metering orifice is used. See the next section. The metering valve meters condensed liquid refrigerant from the high-pressure side of the purger into its flooded evaporator. The flow to the metering valve, part number 20-1714, is controlled by the %= liquid metering solenoid valve (#3). This valve is energized when the purger is in AUTOMATIC or MANUAL operation. The refrigerant is filtered through a small flanged strainer prior to the metering valve, which removes any particles that might block the orifice. An indication of proper operation of the*metering valve is a frosted liquid feed line from the float switch chamber through the solenoid valve, strainer, and metering valve to the evaporator, if the stainless steel line is not frosted when the purger is in AUTOMATIC or MANUAL operation, then the flow of refrigerant through the line may be blocked due to dirt in the metering valve, strainer, or solenoid valve. The metering valve is set and held in place by a locking knob. Unlock this knob using the .0352 hex key wrench provided inside the purger control cabinet. To clean the orifice of the metering valve, fully open the metering valve to flush out any particles. Then, close the valve and reopen six turns. This is the proper operating setting for both the ammonia and halocarbon metering valve. On halocarbon purgers shipped prior to 1/91, the metering valve setting is 2 turns open. These older valves are easily recognized by their green metering knobs. If the line still does not frost, check the liquid metering solenoid valve (#3) for operation. If the solenoid valve appears to be operating normally, then pump out the purger and inspect the solenoid, strainer, and metering valve. OPERATION OF THE METERING ORIFICE ON EUROPEAN AUTO-PURGERS The metering orifice meters condensed liquid refrigerant from the high-pressure side of the purger into its flooded evaporator. The flow to the metering orifice, part number 70-0213, is controlled by the 1/, = liquid metering solenoid valve (#3). This valve is energized when the purger is in AUTOMATIC or MANUAL operation. The refrigerant is filtered through a small flanged strainer prior to the metering orifice which removes any particles that might block the orifice. An indication of proper operation of the metering orifice is a frosted liquid feed line from the float switch chamber through the solenoid valve, strainer, and metering orifice to the evaporator. If the stainless steel line is not frosted when the purger is in the AUTOMATIC or MANUAL operation, then the flow of refrigerant through the line may be blocked due to dirt across the orifice or in the strainer or solenoid valve. OPERATION OF COUNTER The counter inside the control cabinet displays the number of times the purge gas solenoid valve (#5) opens. This valve bleeds noncondensibles into the water bubbler. The counter does not monitor the duration of the purge time, only the number of times the purger has been emptied of air. The counter can be used to measure noncondensible gas activity. If a daily or weekly record is logged, any abnormal changes in the number of times the purge gas solenoid valve (#5) is operated can be noted. This directly relates to the amount of noncondensible gases released. An abnormal increase may indicate a problem with the system, such as a leak. An abnormal decrease in the operation of the purge gas solenoid valve (#5) may indicate a problem with the purger. In either case, action can be taken to correct the problem. Resetting the counter to zero On 115V AP purgers, the counter has a push-button reset. In order for the counter to reset, the purger must be OFF. When the purger is off, push the knob on the face of the counter to reset to zero. On 230V AP purgers, the counter has a thumb wheel reset. The purger can be either ON or OFF. To reset the counter, simply turn the thumb wheel until the counter displays zero. See Figure 5. COUNTER RESET Figure 5. Resetting the purge gas solenoid valve counter. LEAK TEST Use standard refrigeration procedures to check the AUTO-PURGER for leaks before placing it in service. To confirm a leak-free AUTO-PURGER, manually open the foul gas solenoid valve (#4) on the purger by removing the lower seal cap and turning the stem in (clockwise). Next, manually open one remote purge point solenoid valve, if there is one. Manually open the foul gas shut-off valve and allow pressure inside the purger to build to condensing pressure, as shown on the pressure gauge. Then, turn the foul gas valve off. Turn the purger switch on the front panel to AUTOMATIC. This opens the vent solenoid valve (#2) and pressurizes the evaporator section of the purger. Check for leaks. Return all solenoid manual- opening stems to the automatic position. SETTING PURGE POINT TIMER Each purge point timer board contains eight relays which energize the remote purge point solenoid valves. These relays operate in sequence when the AUTO-PURGER is set to AUTOMATIC PURGING. Wire the remote purge point solenoids in sequence. Do not skip any purge point terminals. The amount of time eaCh purge point relay is active can be adjusted from I to 60 minutes. To adjust the time, rotate the screw on the timer clockwise to increase or counterclockwise to decrease. The screw rotates approximately 270° with a linear time increase/ decrease with rotation. See Figure 6. These are factory set at approximately 1 minute. When on AUTOMATIC PURGING, the purge sequence begins at purge point #1, continues to purge point ~2, and so on. When the final purge point is completed, the timer circuit returns to purge point #1 and repeats the sequence. This continues as long as the purger front panel switch is set to the AUTOMATIC position. The Jumper Select connector indicates the final purge point. See Figure ?a. In Figure 7a, only six of eight purge points are desired. With the Jumper Select connector installed as shown, the purge point sequence returns from purge point #6 to purge point #1 and repeats the purge cycle, omitting purge points #7 and #8. To change the final purge point, simply move the Jumper Select connector to the numbered pins corresponding to the final purge point. All purge points up to and including the one where the Jumper Select connecter is installed are included in the sequence. All purge points after the one where the Jumper Select connecter is installed are omitted from the sequence. See Figure 8. If changing the 30 MINUTES 45 MINUTES number of purge points is expected, keep this in mind when wiring the added purge point solenoids. Model AP08 has one purge point timer board. Model AP16 has two purge point timer boards electronically tied together. Model AP24 has three purge point timer boards electronically tied together. For models AP16 and AP24, jumpers A and B are used to electronically tie the purge point timer boards together. On Model AP08, the jumpers remain in both the A and B positions. On Models AP16 and AP24, jumper A is located on the final timer board to return the purge point sequence to the initial timer board. Jumper B is located on the initial timer board.. When jumper A returns the sequence to the initial timer board, jumper B resets the solid state electronics to the beginning of the sequence. The purge timer boards automatically cascade from one board to the next board. Therefore, the middle board on an AP24 (points 9 through 16) has neither the A nor B jumper installed. See Figure 7b and 7c. If the number of active purge points is decreased so that one or more of the purge point timer boards are not used, move jumper A to the last board in the sequence. This may also be the initial board. Install the Jumper Select connector on the pins corresponding to the purge point that is the last in the sequence. Also, disconnect the timer cable, part number 20-1349, from the unused timer board(s). By temporarily disabling one or more purge point timer boards, in effect an AP24 becomes an AP16 or AP08 and an AP16 becomes an AP08. This may be useful when planning for future system expansion. 15 MINUTES PURGE POINT #1 TIMER 1 MINUTE -- 6O MINUTES -- SCREWDRIVER SLOT TO ADJUST PURGE POINT TIME FROM 1 MINUTE TO 60 MINUTES (270* ROTATION) -- Figure 6. Setting the purge point timer. 8 AP08 Purge Point Timer -- Purge Time Adjusl~ent Knob* Juml~r on 'B' Posltion7 270' Rotation .... n ~(I mln to 60 miR) Jumper on A Positi~.7/ ~.1'1 2 3 4. $ 6 7 81 OC'OOO0.1 1. Use a small screwdriver to a~Just purge time: Minimum time 1 minute, Max]mum t~me 60 minutes. 2. Jumper posit~ns on pu~e point timer board: Jumper oa 'A' and "B' positions, Jumper Select on Desired number of purge points (6~ posit~on shown}. 3. MammJly skip through purge IX~nts by depn~ssing Advance Buttor~ Figure 7a. AP08 purge point timer board. Figure 7b. AP16 purge point timer boards. Figure 7c. AP24 purge point timer boards. These purge points will be energized in the purge sequen~ / F' These purge points will / ! be omitted from the , / / purgesequence. c~ 12345678 A B 2 3 4 5 6 7 8I 12345678 0000000000 /---- These purge points / will be energized in the purge sequence. / ~- This purge point will / / be omitted from the ,/ ~urge sequence. 12345678 A B I I 2 3 4 5 6 7 8I 12345678 0000000000 Figure 8. Changing the final purge point. OPERATION OF PURGE GAS ORIFICE Purgers shipped after January 3, 1989 incorporate a metering orifice disc inside the 1 psid (0.07 bar) check valve in the purge gas line to the water bubbler. See Figure 9. This ~ (0.8 mm) diameter orifice meters the noncondensible gas into the water bubbler to prevent over or under feeding. The %= NPT gauge valve should be fully open during operation and closed for pump out or maintenance. The orifice is sized to remove approximately 2 ft3 (0.06 m3) of noncondensible gas per minute. Purgers shipped prior to 1989 use the gauge valve, set at 1/s turn open, as an orifice to bleed adequate noncondensibles to the water bubbler. More than ¥8 turn open causes excessive action. OPERATION OF LEVEL CONTROL VALVE The purpose of the level control valve is to maintain the liquid level in the evaporator chamber. During startup, the liquid line solenoid valve (#1) energizes to feed liquid refrigerant to the level control valve, which feeds the purger until the level in the flooded evaporator reaches the level of the sensor. During operation of the purger, the level control valve acts as a makeup device to maintain the liquid level. However, approximately 95% of the liquid used in the evaporator is liquid condensed from the foul gas line and recirculated through the liquid line metering valve. 114" PURGE GAS GAUGE VALVE WIDE OPEN DURING OPERATION CLOSED FOR SERVICING PURGER II I (U.07 BAR) ~ SOLENOID VAL~ M~ERING ORIFICE DISC INSTALLED IN THE CHECK VALVE PURGE GAS TO WATER BUBBLER OR TO CUSTOMER SUPPLIED WATER BO'I-rLE Figure 9. The purge gas solenoid valve (#5). LIQUID DRAINER The liquid drainer separates any liquid condensed in the purge point piping. This liquid is fed into the purger's flooded evaporator. Therefore, only foul gas--no liquid---enters the condensing section of the purger. However, if too much liquid comes down the foul gas line due to improper piping, corrective action must be taken. Too much liquid is indicated by continuous frost on the stainless steel line running from the outlet of the liquid drainer into the purger's flooded evaporator. During normal operation, this line should frost and defrost as small amounts of liquid are released into the flooded evaporator. If the line is continuously frosted, one or more purge points are flooded with liquid. WATER BUBBLER Models AP08, AP16, AP24, and APC AUTO-PURGERs are equipped with a water bubbler. Noncondensible gas from the AUTO-PURGER flows through the water bubbler where residual ammonia is absorbed into- water. The water, with absorbed ammonia, flows to a drain. The water solenoid valve (#6) opens to automatically replenish water to the bubbler each time the purge gas solenoid valve (#5) energizes. The water solenoid valve (#6) remains energized for 30 seconds after the purge gas solenoid valve (#5) de-energizes (float switch magnet pulls in). Small, 1= (25 mm) diameter bubbles in the water bubbler indicate proper operation. 10 STARTUP Make sure all piping, electrical connections, and settings are complete as described in this bulletin. Open the foul gas, liquid, and suction line shut-off valves. Open the purge gas gauge valve and water shut-off valve. On Models AP08, AP16, and AP24, turn the purger switch located on the front panel of the control cabinet to the AUTOMATIC position. Be sure the Grasslin 7-Day Time Clock is ON. The AUTO-PURGER begins with a COOL DOWN stage. The PURGER COOLING DOWN light illuminated on the front panel indicates correct operation. This stage cools the purger to a temperature where efficient separation of noncondensible gas and refrigerant can occur. The AUTO-PURGER will not condense nor allow any foul gas into the water bubbler until the temperature of the purger evaporator reaches approximately 20°F (-7°C). This should take 5 to 15 minutes, depending on suction line temperature. PURGER PUMP OUT PROCEDURE, WITH AUTO-PURGER ON 1) Close the purge gas gauge valve to the water bubbler. 2) Close the liquid line shut-off valve. 3) Close the foul gas line shut-off valve. 4) Close the water line valve. The purger will pump down in several hours. To accelerate the process, attach ammonia hoses to the oil drain valves and pump out into a suction line. Close the suction line to isolate the purger. With electricity on, the pressure in the purger should remain at zero. This process should be completed only by knowledgeable refrigeration technicians. IQL4 WATI~ I.V, - OPTIONAL APOg J~ I.IM~T PIIONT PANIq ~ OAIEI; TOA~ i.8 UMiT IIUROE POIfT 1 Illfl IlltTi~f ~ ~,.AY RB.AY TA D~,,AY Mi. BQ Idl4/TB ~ DELAY R~.AY P.81 ROTARY 811nTCI( F~ONT PANII, Figure 10. Ladder diagram for AUTO-PURGER AP operation. Also, refer to the wiring schematic supplied with the purger for the purger control cabinet. SECTION 3 AUTO-PURGER OPERATION The AUTO-PURGER is designed to automatically startup and operate without the assistance of plant personnel. Beginning at startup, the following is a description of the refrigerant flow through a purger when all connecting shut-off valves are open. Refer to Figure 11. STARTUP On startup, the AUTO-PURGER enters a COOLING DOWN stage. In this stage, liquid refrigerant fills and cools the purger. Both the flooded evaporator and high-pressure air separator chamber are filled simultaneously. The liquid line solenoid valve (#1) energizes to feed refrigerant to the liquid level control valve, which opens to fill the Iow-pressure flooded evaporator. The liquid level sensor located in the suction separator chamber senses when the flooded evaporator is full and closes the liquid level control valve. At the same time the flooded evaporator is filling, liquid refrigerant fills the float ball chamber and the air separator chamber through the liquid line and the 30 psid (2.1 bar) check valve. The refrigerant gas that is formed is vented to suction through the vent solenoid valve (#2). When the float switch chamber fills with liquid refrigerant, the float ball rises and pulis in the float switch magnet, de- energizing the vent solenoid valve (#2). The purger continues to cool down. A thermostat with a sensor bulb attached to the flooded evaporator senses temperature. At approximately 20°F (-7°C) evaporator temperature, the thermostat switches the purger from the COOLING DOWN stage to AUTOMATIC or MANUAL, as indicated by the purger switch and lights on the control cabinet. OPERATION When the purger is in AUTOMATIC operation, the foul gas solenoid valve (#4) and liquid metering solenoid valve (#3) are energized, allowing a mixture of noncondensible gas and refrigerant into the purger. In addition, the thermostat energizes the timer board to operate the first purge point solenoid valve. The thermostat also allows solenoid valves (#5) and (#6) to open when the float ball is down (magnet away from tube). If the switch on the front panel of the control cabinet is set to MANUAL (single purge point), then that purge point solenoid valve energizes. The purger purges only from that point as long as the switch is positioned to that purge point. The foul gas carries a certain amount of condensed refrigerant, which is captured by the liquid drainer before it enters the purger's condenser coil. From the liquid drainer, the liquid is fed directly into the flooded evaporator chamber. If this separation does not occur, liquid refrigerant will fill the purger's condenser and limit the condensing capacity of the purger. The liquid-free foul gas enters the purger condensing coil, which is submerged in the flooded evaporator. The refrigerant condenses inside the coil. The condensed refrigerant and noncondensible gas then flow through a check valve and back into the air separator chamber. The condensed liquid refrigerant is removed from the high-pressure air separator chamber through the liquid metering solenoid valve (#3), strainer, metering valve (located in the liquid feed line), and then into the flooded evaporator. Note: European purgers have a metering orifice instead of the metering valve. Meanwhile, the noncondensible gas travels along the top of the air separator chamber and into the float ball chamber where it collects. As more noncondensible gases collect, the liquid level gradually falls, causing the float ball to fall. This changes the SPDT switch position of the liquid level float switch and energizes the purge gas solenoid valve (#5) and the water solenoid valve (#6), allowing noncondensible gas to bleed through the orifice plate into the water bubbler (except Model AP01). As air is released into the water bubbler, the liquid refrigerant level in the purger float ball chamber rises. The purger timer board operates each specified remote purge point solenoid valve in sequence, as long as the purger switch on the front control cabinet is on AUTOMATIC and the ;'-day time clock is on. See the Setting Purge Point Timer section on page 8 for details. WATER BUBBLER FLUSH SYSTEM The water flush system consists of the water bubbler, water solenoid valve (#6), water check valve, and shut-off valve. This is an option that can be added to the AP01. Water is automatically fed to the water bubbler through the water solenoid valve (#6). Noncondensible gas and water mix, absorbing residual amounts of ammonia into the water. The ammonia-laden water is flushed to the drain through the overflow tube. The water solenoid valve (#6) remains energized an additional 30 seconds after the float switch magnet pulls in. This fills the water bubbler with fresh water for the next purge cycle. 12 LIQUID %" WATER UNE ~/~" FOUL GAS LINE %' HIGH-PRESSURE LIQUID UNE RELIEF CHECK VALVE - CONNECTION FOR oP'nONAL PRESSL ORIFICE - 1 PSID (0,07 BAR) CHECK VALVE- SUCTION LINE ~~ GAUGE VALVE SWITCH OVERFLOW TUBE -- WATER c o o o o o METERING VALVE* liD LEVEL CONTROL SENSOR DRAINER /--- THERMOSTAT SEPARATOR CHAMBER I P-HAMBER OIL DPJUN AND PUMP OUT I" DRAIN TO SEWER CHECK VALVE OIL DRAIN AND PUMP OUT *EUROPEAN PURGERS (AP=E) HAVE A METERING ORIFICE IN PLACE OF THE METERING VALVE Figure 1 1. AUTO-PURGER AP flow diagram. Solenoids: #1 Liquid Line #4 Foul Gas #2 Vent #5 Purge Gas #3 Liquid Metering #6 Water SECTION 4 REASON 1 The 30 psid (2.1 bar) check valve is stuck open. CHECK Close the liquid line shut-off valve. The pressure gauge on the purger should read close to system condensing pressure and should not change when the liquid line is closed. Leave the foul gas line open. Next, open the liquid line shut-off valve and close the foul gas line. The pressure should drop 20--30 psi (1.4-2.1 bar). If not, the 30 psid (2.1 bar) check valve is stuck open. ACTION Pump out the purger and clean or replace the 30 psid (2.1 bar) check valve (20-1184). REASON 2 The relief check valve is leaking or stuck open. CHECK Look for frost on the check valve. If operating properly, there should be no frost. ACTION Replace or repair the check valve. REASON 3 The vent solenoid valve (#2) is leaking or stuck open. CHECK Look for frost on the outlet of the solenoid valve. If operating properly, there should be no frost. ACTION Repair or replace the solenoid valve. REASON 4 The metering orifice in the I psid (0.07 bar) check valve inside the purge gas solenoid valve (#5) is plugged. See Figure 9. CHECK Make sure the purge gas solenoid valve (#5) is energized, then look for noncondensible gas release. ACTION If noncondensibles are not released, then clean or replace the I psid (0.07 bar) check valve (20-1183). REASON 5 The foul gas line is not open. SYMPTOM The pressure gauge on the purger is reading 20-30 psi (1.4-2.1 bar} below system condensing pressure. CHECK Close the foul gas line shut-off valve. If the reading on the purger pressure gauge falls 20-30 psi (1.4-2.1 bar}, the foul gas line was open. If the pressure remains the same, then: ACTION Check for individual purge point solenoids not energized or stuck closed. Check for closed shut- off valves. Verify proper operation of the foul gas solenoid valve (~4}. To check for a sticking solenoid valve, use the manual-opening stem to temporarily open the valve. Observe if the TROUBLESHOOTING PURGER OPERATION .~'~: pressure increases to condensing pressure. Also, ensure that the plastic shipping cap has been · removed from the foul gas line flange. REASON 6 The time-delay relay time limit has been exceeded. SYMPTOM The magnet on the float switch is away from the steel tube, the water solenoid is energized, and the NONCONDENSIBLE GASES TO ATMOSPHERE light is illuminated. CHECK Verify that the one hour time delay limit for the purge gas solenoid valve (#5) has been exceeded. ACTION Turn the delay relay off momentarily to reset the time delay. For more information see Section 2, Purge Gas Solenoid Valve Time Delay Cutout. REASON 7 No noncondensibles are present in the system. CHECK Compare the refrigerant liquid temperature from the condenser with the condensing pressure. The pressure/temperature relationship should be within 2 to 3 psi (0.14 to 0.21 bar) to indicate no noncondensibles present. REASON 8 The liquid feed line is plugged. SYMPTOM The purger appears to be operating properly, but the liquid feed line is not frosted CHECK Look for a restriction in the metering valve (metering orifice on European purgers). ACTION Unlock the metering valve knob using the .0352 hex key wrench provided inside control cabinet. Open the valve wide to clear any dirt plugging the orifice. Close the metering valve and reopen 6 turns (2 turns for halocarbon purgers shipped prior to 1/91; these have a green knob). CHECK Make sure the liquid line solenoid valve (#3) is energized and frosted. ACTION No frost means the strainer or line is plugged. Disassembled and remove the blockage. See Purger Pump Out Procedure on page 10. REASON 9 The foul gas line is flooded with liquid. SYMPTOM The stainless steel line from the bottom of the liquid drainer to the inlet of the purger evaporator is always frosted. During proper operation, this line should periodically frost and defrost. CHECK Refer to Piping Instructions in Section 1. REASON 10 The liquid line pressure at the purger is 20 psi (1.4 bar) or more higher than the condensing pressure. 14 CHECK Verify the pressure at the liquid line and the foul gas line using pressure gauges. Check for a high static head of liquid and/or a pump boosted liquid line pressure. ACTION For a high static head, install a pressure reducing differential pressure regulator (Hansen's HA2BL} in the liquid line. For a pump boosted.liquid line, install the liquid line before the pump. REASON 11 The purge point solenoid coil is shorted. SYMPTOM The 2 amp (1 amp on 230V purgers} fuse is blown. Do not increase the amperage of the fuse. CHECK Verify the resistance in each coil to find the shorted coil. QUICK CHECK Replace the blown fuse. Advance purge points with the advance button until the new fuse blows. The faulty coil or wiring is now pinpointed. ACTION Replace the faulty coil or repair the wiring. Install a new fuse. SYMPTOM Small bubbles are present in the water bubbler and the water bubbler assembly is violently shaking. REASON 1 The foul gas line is not open. SYMPTOM The pressure gauge on the purger is not reading within 2-5 psi (0.14-0.34 bar) of system condensing pressure. CHECK Close the foul gas line shut-off valve. The pressure should fall 20-30 psi (1.4-2.1 bar), as indicated on the pressure gauge on the purger. ACTION Check for a blown 2 amp fuse (1 amp for 230V purger) in the control cabinet. This indicates a burned out purge point solenoid coil. Next, check for a closed valve and a plugged strainer in the foul gas line. Ensure that the plastic shipping cap has been removed from the foul gas line flange. REASON 2 The purge gas solenoid valve (#5) seat is leaking. SYMPTOM Bubbles are slowly being released in the water bubbler with the NONCONDENSIBLE GASES TO ATMOSPHERE light not illuminated and the float switch magnet pulled in against tube. CHECK Look for dirt or a worn seat in the purge gas solenoid valve (#5). ACTION Lift the float switch assembly momentarily to open the valve. This may clear any dirt on the seat. If not, pump out the purger and repair the valve. REASON 3 Oil in the purger. SYMPTOM No frost is present around the bottom oil drain valve. Normally, liquid is present here and the valve frosts. ACTION Drain any oil through the valves located on the bottom and left end of the purger, as described in the Oil Drains section on page 4 of this bulletin. REASON 4 The relief check valve is leaking or stuck open. CHECK Look for frost on the check valve. If operating properly, no frost should be present. ACTION Repair or replace the check valve. REASON 5 The vent solenoid valve (#2) is leaking or stuck open. CHECK Look for frost on the outlet of the solenoid valve. If operating properly, there should be no frost. ACTION Repair or replace the solenoid valve. REASON 6 The liquid level control valve is not operating. SYMPTOM The suction line and the outlet flange of the liquid level control valve are not frosted. CHECK Verify the resistance of the heater. Proper resistance of the 115V heater is 900 ohms, for the 230V heater 3,600 ohms, both +10%. ACTION Replace the heater if the circuit is open. CHECK The power element charge may be lost. Check the capillary tube for breaks. ACTION Replace the power element. The purger must be isolated from the refrigeration system and the purger pumped out before replacing the power element. Follow the pump out procedure described on page 10. REASON 7 The foul gas solenoid valve (#4) is not open. SYMPTOM The foul gas line is frosted or cold where the line enters the insulated purger vessel. CHECK Verify the voltage to foul gas solenoid coil (fi4) at terminal 32. CHECK Manually open the foul gas solenoid valve (#4). The pressure should rise 20-30 psi (1.4-2.1 bar), as indicated on the pressure gauge on the purger. ACTION If the pressure does not rise, pump out the purger and clean or replace the foul gas solenoid valve (#4). 15 REASON 8 A purge point or purge point solenoid is not connected. SYMPTOM Foul gas pressure is being lost. CHECK Examine the physical connections to each purge point. Verify proper wiring to the purge solenoid valve remote line connections in the control cabinet. Verify continuity of all wiring to coils. ACTION Properly install the purge point. Refer to Purge Point Connections in Section 1. Properly connect the purge point solenoid. Refer to Electrical Connections in Section 2. REASON 1 The suction temperature is above 20°F (-7°C). CHECK Verify the suction temperature at the purger suction line connection. ACTION If not cold enough, move the suction line to lower temperature suction, or reset the thermostat to a higher temperature. Call the factory before changing the thermostat setting. REASON 2 The evaporator is not filled with refrigerant. CHECK The float switch magnet should make contact in 5 to 15 minutes after turning the purger on. ACTION If the magnet does not pull in, check for a restriction at the liquid line shut-off valve, verify voltage at the liquid line solenoid valve (#1) (115V at terminal 28 or 230V for 230V purger), verify continuity of the liquid line solenoid coil, check for a blockage in the liquid line strainer, and ensure that the plastic shipping cap has been removed from the liquid line flange. REASON 3 The liquid level control is not working. CHECK Verify frost at the outlet flange of the liquid level control valve. If no frost is present, check for 115V at terminal 35 (or 230V for 230V purger). Check continuity of the heater. Proper resistance of 115V heater is 900 ohms, 3600 ohms for the 230V heater, both _+10%. Check for broken or pinched capillary tube. ACTION Replace the power element 20-1441 (115V) if the capillary tube is damaged. Replace the heater if the resistance is incorrect (115V heater, 20-1752; 230V heater, 20-1753). REASON 4~ A restriction in.the suction pressure. CHECK Verify the line size and shut-off valves. The suction line should be a minimum of %' (20 mm) for ammonia and 1, (25 mm) for halocarbons. On new installations, ensure the plastic shipping cap has been removed from the suction line flange. ACTION Remove restriction or install the correct line size. REASON 1 Solenoid valve faulty. CHECK Verify coil is operation or look for dirt in the valve. REASON 2 No voltage to the timer board. SYMPTOM The red LED on the timer board is not illuminated. CHECK Verify 12V DC on cable 20-1197 leading from the purger board. The white wire is neutral and the black and gray wires should have 12V DC when the purger .is in the AUTO position. ACTION ' Repair the cable. If 12V DC is present, gO to the next CHECK step. CHECK If cable 20-1197 is OK, check for 12V DC at terminal 4 on the door panel. Terminal 7 on door is neutral. ACTION If no voltage is present, check wire 4 for continuity and repair if necessary. REASON 3 A fault in the timer board cable 20-1196. SYMPTOM In AUTOMATIC, the purge point lights do not operate but the purge point solenoids are operating. CHECK Verify the continuity of each lead from the timer cable, 20-1196. ACTION Repair the fault. REASON 4 A fault in the purger board to timer board cable 20-1197. SYMPTOM In AUTOMATIC, either all purge point lights are dimly illuminated or no lights are illuminated. CHECK Verify the continuity of each lead. ACTION Repair the fault. 16 REASON 5 A purge point solenoid valve is not operating. CHECK Verify continuity through the two amp fuse (one amp for 230V purger). ACTION · If faulty, replace the fuse. CHECK Verify the voltage at terminal RL. The voltage should be 115V (230V for 230V purger). If no voltage is present, check the continuity of lead 42. ?DOWN REASON 1 No power to the purger. SYMPTOM The ON and pURGER COOLING DOWN lights are not illuminated. CHECK The LINE and NEUTRAL terminals inside the control cabinet should have 115V (230V for 230V purger} across the terminals. REASON 2 The 7-Day timer is not on. CHECK Verify the time setting on the timer. ACTION Set the time according to the instructions on page 6-of this bulletin. REAS°N 3 NO poWer to the Purger board 20-1773. SYMPTOM The red LED on the purger board is not illuminated. CHECK Verify voltage to the board. The voltage between terminals RL and COMMON should be 115V (230V for 230V purger). REASON 4 A fault in the wiring to the purger board. CHECK Verify continuity between leads 36, 37, 39, and 46. ACTION Repair if defective. REASON 5 The transformer is faulty. SYMPTOM The red LED on the purger board is not illuminated but there is power at terminal RL. CHECK Verify 24V AC between leads 43 and 44. ACTION If no voltage between the leads, replace the transformer. If voltage is present, go to reason 6. REASON 6 A short in the 12V DC circuit. SYMPTOM The red LED on the purger board 20-1773 is not illuminated if there is a short. On purgers shipped 17 between 7/88 and 11191, the purger board has a built-in fuse. If the fuse is blown, replace it after completing the following CHECK step. CHECK Disconnect purger cables 20-1195 and 20-1197, and terminal plug connections 22 through 26. The red LED should now be illuminated. ACTION If the LED does not illuminate, replace the purger board 20-1773. If the LED illuminates, plug in each cable separately until the red LED goes out to determine which circuit has a ground short. REASON 7 A fault in the purger cable 20-1195. SYMPTOM The ON light not illuminated but the red LED on purger board is illuminated. CHECK Verify 12V DC between terminal I and terminal 7 (neutral) on the door. ACTION If no voltage between the terminals, check the continuity of cable 20-1195 and repair. If voltage is present, go to reason 8. REASON 8 A faulty rotary switch (purger switch). SYMPTOM Look for no voltage at door terminal 2 when the rotary switch is set to the AUTOMATIC position. ACTION If no voltage is present, check wiring leads I and 2, and the rotary switch for faults. If voltage is present, go to reason 9. REASON 9 A fault in the purger cable 20-1195. SYMPTOM The ON light and red LED On the purger board are illuminated but the purger is not operating. CHECK Verify the voltage between lead 2 and neutral on the purger cable 20-1195. ACTION If no voltage is present, then replace the purger cable 20-1195. If voltage to the purger board through lead 2 on the door panel is 12V DC, then there is a fault on the purger board. Replace the purger board 20-1773. water excesSive mineral . ,ii!ii REASON Hard water in the water bubbler. ACTION Switch the water line to softened water or install the optional water conditioning housing and cartridge. Parts List Mechanical Part Standard Number Description (US) European 20-1179 Level Control Valve w/Power Element (115 Volt) 20-1647 Level Control Valve w/Power Element (230 Volt) 20-1441 Power Element, Level Control (115 Volt) 20-1739 Power Element, Level Control (230 Volt) 20-1752 15 Watt Heaterfor Level Control (115V} 20-1753 15 Watt Heater for Level Control (230V) HLLSW Float Switch Assembly HLLSWE Float Switch Assembly 20-1738 Float Ball Assembly Kit, includes: 20-1142 Float Ball Assembly 20-1212 Gasket-Top Adapter 770037 Screws (2) 20-1772 Water Bubbler Assembly, antisyphon (w/end connections) 20-1186 Metering Valve 20-1198 Metering Valve Seal Kit 70-0213 Metedng Orifice 20-1648 Metering Valve Strainer 20.1648 Metering Orifice Strainer 20-1737 Screen Assembly Replacement lot for above strainers, includes: 20-1535 Screen Assembly 78-0016 Strainer Gasket 70-1059 Plunger Kit for all purger solenoid valves 20-1183 Check Valve, 1 psid (.07 bar) 20-1184 Check Valve, 30 psid (2.1 bar) 20-1185 Check Valve, 225 psid (15.5 bar)---Replaces older 200 psid (13.8 bar) check valve 20-1214 Check Valve Seal Kit, for 1, 30, and 2001225 psid ( .07, 2.1, and 13.8/15.5 bar) check valves 20-1776 Air Indicating Column for halocarbon purger 20-1311 Uquid Drainer PURGE POINT SOLENOID VALVES For the customer-supplied purge point solenoid valves, Hansen recommends our HS8 with close- coupled strainer. This is a ~/=: port, heavy-duty, pilot-operated solenoid valve with stainless steel piston. The purge point solenoid valve must be a minimum of 1/22 port size to avoid excess pressure drop across the valve. The standard molded coil is for 115V, 2081230V, or 24V. Flange connections available are ~12=, 314,, and 3/8~ FPT, socket weld, and weld neck. Also available is 8182 ODS. To order, specify catalog number HS8ST, required connection style and size, and volts. Specify DIN plug solenoid connection if needed. HS8ST %= Solenoid Valve with Close- Coupled Strainer HS8ST %~ Solenoid Valve with DIN Plug Connection and Close-Coupled Strainer 18 Parts List Electrical Part Standard Number Description (US) European 20.1202 LED Light--Red 20-t203 LED Light--Yellow 20-1204 LED Light--Green 70-1064 Solenoid Coil, Junction Box--115V, 50160 Hz, 16 Watt 70-1063 Solenoid Coil, Junction Box--230V, 50160 Hz, 16 Watt 70-1055 Solenoid Coil, Din Plug--115V, 50/60 Hz, 16 Watt 70.1054 Solenoid Coil, Din Plug---230V, 50160 Hz, 16 Watt 20-2226 7-Day Time Clock (115 Volt, 50/60Hz) ,/ v' 20-2227 7-Day Time Clock (230 Volt, 50/60Hz} Purger Control Board Lees Plug-in Connector, 115 Volt or 230 Volt 20'1773 Replaces 20-1130 & 20-1536 Purger Control Board with Plug-In Connectors 20-1499 (Replaces Older Boards with Screw Terminals) 20-1131 8-Point Timer Board, Less Plug-In Connectors 8-Point Timer Board with Plug-In Connectors 20.1500 (Replaces Older Boards with Screw Terminal) 20-1205 Transformer, 115V124VAC 20-1602 Transformer, 230V/24VAC 20-1307 Thermostat 20-1498 Time-Delay Relay, 1 Hour Fixed, Off Switch (115 Volt) 20-1528 Time-Delay Relay, 1 Hour'Fixed, Off Switch (230 Volt) 20-1280 4-Digit Counter with Reset, 115 Volt 20-1473 6-Digit Counter with Reset, 230 Volt HS2B(10) HS2 (Brass) Water Solenoid Valve Only (Less Coil), 1/4" FPT (#6) HS2(10) HS2 Solenoid Valve Only (Less Coil), %" FPT (#2 and #3) 70-0208 HS2 Flanged Solenoid Valve Only (Less Coil), (~r2 and ~3) HS2(30) HS2 Uquid Une Solenoid Valve Only (Less Coil), 112" FPT (#1) 700208 HS2 Flanged Uquid Line Solenoid Valve Only (Lees Coil), (#1) HS2N(10) HS2 Purge Gas Solenoid Only (Less Coil) with Neoprene Seat 1/4" FPT (#5) 70-0208 HS2 Flanged Purge Gas Solenoid Only (Less Coil), (#5) HS8(10) HS8 Foul Gas Solenoid Valve Only (Less Coil) (~4) As(x) Solenoid #8262C80N, V4" Connection 115 Volt 20-1182 (Older model, indicated by a green coil housing) 20.1538 Repair Kit for Asco Solenoid, Asco Part ~302-020 (Older model, indicated by a green coil housing) 20-1349 Cable, Timer to Timer Board 20-1197 Cable, Purger Board to Timer Board 20-1195 Cable, Purger Board 20.1279 Fuss, 2 amp, 115V Purger 20.1281 Fuse, 5 amp, 115V Purger 20.1694 Fuse, I amp, 230V Purger 20-1695 Fuse, 3 amp, 230V Purger 20-1697 Fuse, 2 amp, 115V Purger 20.1699 Fuse, 5 amp, 115V Purger 20-1696 Fuse, 1 amp, 230V Purger 20-1698 Fuse, 3 amp, 230V Purger v Replacement control cabinets are available for both standard (US) and European purgers. Contact the factory for selection. ,IQ CAUTION Hansen purgers are for refrigeration systems only. These instructions and related safety precautions must be read completely and understood before selecting, using, or servicing these purgers. Only knowledgeable, trained refrigeration technicians should install, operate, or service these purgers. Stated temperature and pressure limits should not be exceeded. Purger components should not be removed from the purger unless the system has been evacuated to zero pressure. See also the Safety Precautions in the current List Price schedule and the Safety Precautions Sheet supplied with this product. Escaping refrigerant can cause injury, especially to the eyes and lungs. WARRANTY Electrical and electronic components are guaranteed against defective materials and workmanship for 90 days F.O.B. our plant. All other components are guaranteed against defective materials or workmanship for one year F.O.B. our plant. No consequential damages or field labor is included. STANDARD (US) AUTO-PURGER AP CONSTRUCTION VERSUS EUROPEAN AUTO-PURGER APE CONSTRUCTION The standard (US) AP and European APE operate in the same manner, except as noted in this bulletin. The basic differences in construction between the two versions are outlined in the chart below. Component Standard (US) European Construction Constn~ction Piping NPT Threaded Pipe Welded Pipe 1/4' NPT Threaded Valves Connections {except Welded/Flanged ~4, ¥2" Flanged) US Electrical European Electrical Electrical Standards Standards Solenoid Coils Junction Box DIN Connection ~/2" NPSM Float Switch DIN Connection Connection Expansion Device Metering Valve Metering Orifice DEFINITIONS Noncondensible gases: These gases, primarily air, cannot be condensed by the normal system operating temperature and pressure. They cause higher-than-necessary head pressure. Noncondensible gases can enter a refrigeration system through vacuum leaks, break down of oil and refrigerant, and during service repair~ and system charging. Foul gas: A vapor mixture of noncondensible gases and refrigerant gas. High-pressure liquid: Refrigerant liquid source from a condenser or receiver. P-trap: A piping arrangement, typically in condenser drain lines, to prevent passage of gas while enabling liquid to proceed. Purge point= A location on the refrigeration system above the liquid level where foul gas is taken from and piped to the purger. Purge gas= The noncondensible result of the separation of refrigerant gas from the foul gas by the purger. Normally passed into a water bubbler or water reservoir. © 1998 Hansen Technologies Corporation Printed in USA SELECTING AN AUTO-PURGER* In addition to the AUTO-PURGER* AP, Hansen Technologies offers two other versions--the compact AUTO-PURGER* APM and the Nonelectrical AUTO-PURGER* (NEAP). Use the following descriptions to help select the best AUTO-PURGER for your needs. For additional assistance, contact the factory. AUTO-PURGER AP This is the original AUTO-PURGER. It has solid- state control and is ideal for larger systems, up to 1500 tons (5300 kW) ammonia. This is two to three times the air removal capacity of the Armstrong purger. With models available to purge up to 24 points, the AP features automatic startup with electronic control. The purge cycles can be individually adjusted to meet system requirements. The AP includes an automatic water bubbler. *An optional NEMA 4 rated enclosure is available. A European option is available that features all-welded construction and conformance to European electrical standards. For ammonia and halocarbon refrigeration systems. As- sembled, tested, and ready to run. AUTO-PURGER APM A more compact version of the original AP, the AUTO-PURGER APM is ideal for medium-size systems, up to 200 tons (700 kW). Like the AP, the APM features automatic star/up with electronic control. Designed for up to four purge points, an electronic "brain" searches for noncondensible gases in the' system and purges at those points when air is present. The APM includes an automatic water bubbler and comes standard with a NEMA 12,13 control cabinet. For use with ammonia refrigeration systems. Assembled, tested, and ready to run. NONELECTRICAL AUTO-PURGER (NEAP) The Nonelectrical AUTO-PURGER (NEAP) is ideal for small systems, up to 100 tons (350 kW). The nonelectrical design also makes the NEAP ideal for explosion proof applications. The simple design of the NEAP features easy startup and is generally used to purge a single point. For use with ammonia refrigeration systems. Assembled, tested, and ready to run. 20 HANSEN TECHNOLOGIES CORPORATION 6827 High Grove Boulevard Burr Ridge, Illinois 60521 U.S.A. Telephone: (630) 325-1565 Toll-free: 1-800-426-7368 FAX: (630) 325-1572 18 PRE:PA~R3ED BY: . · :, ISSUE: ry SOP-114 Pdi}sbu Final Draft REV. - "A" PAGE NO. EFFECTIYE DATE: 'OPERATION OF THE ICE MAKER Feb. 8, 2001 1 OF 3 Ma~reh, !, ~00~ Objective: Purpose: Concerns: This procedure is established to describe the Technical Operating Specifications (TOS) and to set forth Standard Operating Procedures (SOP) for the operation of the Ice Maker. The purpose of the Technical Operating Specifications (TOS) is to provide a description of the Ice Maker, to define its function, operating conditions, limits, and consequences of deviation from said operating limits and to also describe its controls, instrumentation, safety system, and setting its operating alignment(s). The purpose of the SOP is to establish the proper steps for starting, stopping, re-starting, and monitoring normal operation. Among incidents we are trying to prevent are: · Injury to operator(s) · Over pressurization of the system · Operation of the safety relief valves · Release of ammonia to atmosphere Department: Refrigeration Operator Pillsbury Refrigeration Operator - Level 3 /Responsibility: Equipment: Ice Maker - IM1 Location: Roof above the Production Area Related Documents: P&ID R-04, Manufacturers U-lA Report, IlAR Bulletin 109 and 110, and any OEM related documents. All are located in the North Engine Room. Initial Development August 31, 2000 Date: Authorized By: Tim Ridley Annual Review By: March 1, 2002 PREPARED BY:---- p;nsh u SOP-114 APCCO Final Draft 5FFECTIVE DATE: OPERATION OF THE ICE MAKER REV. - "A" PAGE NO. March 1, 2001 Feb. 8, 2001 2 OF 3 Function: TECHNICAL OPERATING SPECIFICATIONS (TOS) The function of the Ice Maker is to make flaked ice for use in production. Description Capacity/Size Operating Consequences Limit of Deviation Corrective Action Ice Machine 130 PSIG A pressure Ensure that the Mfg.: Howe higher than 130 suction pressure Model: 50EA PSIG may lift regulator, IM1-06 S/N: 5285 the safety relief is properly valve causing a adjusted and release of functioning as ammonia into intended. the Ammonia Diffusion Tank. CONTROLS AND INSTRUMENTATION Description Item Number Function Position/Set point 1. Phillips high-side 1. IMl-12 1. Maintains the 1. Manufacture set. float operating level of ammonia in the 2. IM1-06 surge drum. 2. Manual control. 2. Liquid solenoid 2. Used to turn the valve 3. IM1-01 liquid ON and OFF. 3. 12 PSIG 3. Controls the 3. Suction pressure operating pressure regulator in the IM. SAFETY SYSTEMS Description Item Number Function Position/Set point Dual safety relief valve IM1-02 & IM1-03 Opens on a rise in pressure to relieve over pressure to an Ammonia Diffusion Tank 150 PSIG ~PREPA. R~ED BY: ~ · ;e,; L~ '. ISSUE: PrHsbury SOP-114 APCCO Final Draft REV. - "A" PAGE NO. EFFECTIVE DATE: OPERATION OF THE ICE MAKER Feb. 8, 2001 $ OF :3 March 1, 2001 STANDARD OPERATING PROCEDURES (SOP) Initial Start-up: Ensure that all electrical, water and ammonia connections are made tested and in proper order. Turn on the water valve for the IM1 and start the motor. Ensure that the three oil drain valves are CLOSED, IM1-08, IM1-09, and IMI-10. OPEN valve IM1-05 and ensure that the suction pressure regulator and the liquid solenoid valves are in the Automatic position. Normal Start-up: Normal Start-up is accomplished by turning the IMlon from the control panel. Normal Operation: During normal operation, the ON/OFF toggle switch simultaneously energizes the liquid solenoid valve, IM1-06, and the pressure regulator, IM1-01 as well as the water pump and the electric motor that drives the drum. Liquid Ammonia is fed through the float valve, IMl-12, which maintains a level in the surge drum. Liquid ammonia flows from the surge drum through the evaporator drum and back to the surge drum by thermosyphon action. Water is pumped into the water reservoir where it is distributed to the outside of the evaporator drum. After the water has frozen to the drum surface, a stainless steel blade scores the ice, which then drops off into the storage container below. The Ice Maker operates as needed to meet the Production Department's needs. Normal Shutdown: Normal shutdown can be accomplished by turning off control panel. Temporary Operation: By definition, this mode of operation does not apply. Emergency Operation: Per IlAR definition, Emergency Operation of this equipment requires that the Refrigeration Operator have intent and knowledge of the existing "Near Emergency Shutdown" condition that could cause system and / or compressor damage or could lead to a release of ammonia to the atmosphere. Operating under these conditions is not recommended. Emergency Shutdown: Turn off control power to control panel. To isolate the IMlfrom the rest of the system, turn off liquid valve, SCL-02 located in the Sub-cooled Liquid main and the suction stop valve IM1-05. Start-up following a turn-around or after an emergency shutdown: After a shutdown of a service nature, the IMlshould be returned to a pre-shutdown condition. Then, the IMlcan be restarted as per the Normal Start-up instructions above. If the shutdown was due to an emergency, an investigation procedure should be followed to determine the nature of the emergency that caused the IMlto be shutdown. If the shutdown was due to a safety limit being reached, it must be determined WHY that limit was reached. Whatever the cause of the shutdown, the offending situation or condition must be corrected, with an assurance that it will not re- occur, before the IMlcan be returned to a pre-shutdown condition. Then, and only then, should the IMlbe restarted as per the Normal Start-up instructions above. 19 PREPARED BY: p. sbury APCCO ~lll SOP-115 Final Draft EFFECTIVE DA.~E: O~E~.T~ON O,F THE OIL POT REV. - "A" PAGE NO. MarCh 1, 20071 Feb. 21, 2001 1 OF 9 Objective: Purpose: Concerns: This procedure is established to describe the Technical Operating Specifications (TOS) and to set forth Standard Operating Procedures (SOP) for the operation of the Oil Pot. The purpose of the Technical Operating Specifications (TOS) is to provide a description of the Oil Pot, to define its function, operating conditions, limits, and consequences of deviation from said operating limits and to also describe its controls, instrumentation, safety system, and setting its operating alignment(s). The purpose of the SOP is to establish the proper steps for starting, stopping, re-starting, and monitoring normal operation. Among incidents we are trying to prevent are: · Injury to operator(s) · Over pressurization of the system · Operation of the safety relief valves · Release of ammonia to atmosphere Department: Refrigeration Operator Pillsbury Refrigeration Operator - Level 3 /Responsibility: Equipment: Oil Pots - OP1, OP2 and OP3 Location: OP1 & OP2 are located in the South engine room OP1 along the South wall in front of LSA1, OP2 along the West wall in front of HX2. OP3 is located on the roof below SD2. Related Documents: P&ID R-03 & R-04, Manufacturers U-IA Report, IIAR Bulletin 109 and 110, and any OEM related documents. All are located in the North Engine Room. Initial Development August 31, 2000 Date: Authorized By: Tim Ridley Annual Review By: March 1, 2002 PREPARED BY:---- - apms 'ur' SOP-115 APCCO Final Draft ~FFECTIVE DATE: OPERATION OF THE OIL POT REV. - "A" PAGE NO. March 1, 2001 Feb. 21, 2001 2 OFr 9 Function: TECHNICAL OPERATING SPECIFICATIONS (TOS) The function of the oil pot is to collect oil from various parts of the system, where oil is likely to collect, allow for the separation of the oil from the liquid ammonia and facilitating the safe removal of the oil from the system. Description Capacity/Size Operating Consequences Corrective Action Limit of Deviation 1. Oil Pot- OP1 1. 12" Dia. x 3' OAL 1. 130 PSIG Any pressure Ensure that the oil 150 PSIG DWP above 130 PSIG pot is never (220 PSID for isolated from the the new OP3) rest of the system could result in with liquid 2. Oil Pot- OP2 2. 6" Dia. x 3' OAL 2. 130 PSIG the lifting of the ammonia in it. 150 PSIG DWP pressure relief valves and a 3. OilPot-OP3 3. 4'Dia. xl~/2'OAL 3. 130PSIG consequent 150 PSIG DWP release of ammonia. Note: By 7/1/01 OP3 will be replaced with... 6" Dia. x 3' OAL 300 PSIG DWP 220 PSIG NOTE: For the remainder of this SOP, any reference to OP3 will be referring to the new 6" Dia. x 3' OAL oil pot. p SOP-115 APCCO . Final Draft EF'FECTIVE I)A~E: OPE~TIOH OF THE OIL POT REV. - "A" PAGE NO. March.l, 2001 ' Feb. 21, 2001 3 OF 9 CONTROLS AND INSTRUMENTATION Description Item Number Function Position/Set point 1. OP1 - Oil heater 1. N/A 1. Heat the oil in thc 1. N/A pot thereby boiling off any remaining ammonia. 2. OP2-N/A 2. N/A 2. N/A 2. N/A 3. OP3-N/A 3. N/A 3. N/A 3. N/A SAFETY SYSTEMS Description Item Number Function Position/Set point 1. OP1-Single safety 1. LSA1-31 relief valve 2. OP2 - Single safety 2. HX2-18 relief valve 3. OP3-Dual safety 3. IMl-15 & IMl-16 relief valve Any pressure above 1. 130 PSIG (220 PSIG for OP3) could result in the lifting of the 2. pressure relief valves. o 150 PSIG 150 PSIG 250 PSIG pillsbury, SOP-115 APCCO_~lll ltJ ~ Final Draft ;FFECTIVE DATE: REV. - "A" PAGE NO. OPERATION OF THE OIL POT March 1, 2001 Feb. 21, 200:14 OF 9 STANDARD OPERATING PROCEDURES (SOP) Initial Start-up: Ensure that the oil drain valves are closed, that the oil heater .in OP1 is covered, (visible in the lower sight glass) with clean fresh refrigeration grade oil before introducing ammonia to the oil pot. Additionally, make sure that the valves between the vessels the oil pots are draining from and venting to, are open. Normal Start-up: After the Initial Start-up, as stated above, there is no Normal Start-up. Normal Operation: Under Normal Operation, the oil pots will collect any oil that finds its way into the LSA1, SD1 & SD2. Along with the oil, liquid ammonia will also find its way into the oil collection pot. Oil, being heavier that liquid ammonia, will collect at the bottom of the oil pot displacing the liquid ammonia. After a sufficient amount of oil has accumulated in the oil pot, it can be drained. Follow the proper procedure for draining oil for the specific oil pot in question, (further on in this SOP.) NOTE: The oil draining procedures are similar, but significantly different for each oil pot. Normal Shutdown: The oil pot needs to be shut down, or valved out of the system, each time it needs to be drained of oil. Again, refer to the specific oil draining procedure for the specific oil pot in question. Temporary Operation: By definition, there is no Temporary Operation of the oil pot. The oil pot is an integral part of the system; it is either in operation collecting oil or out of operation being drained of oil. Emergency Operation: Per IIAR definition, Emergency Operation of this equipment requires that the Refrigeration Operator have intent and knowledge of the existing "Near Emergency Shutdown" condition that could cause system and / or compressor damage or could lead to a release of ammonia to the atmosphere. Operating under these conditions is not recommended. Emergency Shutdown: See Normal Shutdown. Start-up following a turn-around or after an emergency shutdown: After a shutdown of a service nature, the Oil Pot should be returned to a pre-shutdown condition. Then, the Oil Pot can be restarted as per the Normal Start-up instructions above. If the shutdown was due to an emergency, an investigation procedure should be followed to determine the nature of the emergency that caused the Oil Pot to be shutdown. If the shutdown was due to a safety linfit being reached, it must be determined WHY that limit was reached. Whatever the cause of the shutdown, the offending situation or condition must be corrected, with an assurance that it will not re- occur, before the Oil Pot can be returned to a pre-shutdown condition. Then, and only then, should the Oil[ Pot be restarted as per the Normal Start-up instructions above. i ,e"~ ISSUE: APCCO Final Draft EFFECTIVE DATE: OPERATION OF THE OIL POT REV. - "A" PAGE NO. March 1, 2001 Feb. 21, 2001 5 OF 9 The following is an excerpt from the lIAR Recommended Oil Draining Guidelines. The instructions that follow are in accordance with that guideline. CAUTION: Draining oil from an ammonia refrigeration system is a potentially dangerous process and should only be performed by properly trained personnel. Before beginning the procedure for draining oil, be familiar with: 1. The exact oil draining procedure for the system being drained. 2. The Emergency Response Procedures. 3. The location of the nearest eye wash/shower station. 4. The location of all of the valves that would be required to isolate the oil pot in the event of a problem. 5. Ammonia first aid procedures (refer to the lIAR First Aid Poster or similar first aid procedure.) 6. Basic training on oil draining and all process equipment. 7. Plant Lock Out/Tag Out Procedures. II. Before beginning the procedure, assemble the following equipment: 1. Elbow-length rubber gloves. 2. Splash goggles and a face shield. 3. Clean bucket for oil to drain into. 4. Valve wheel wrench for closing and opening valves. 5. Closed-Valve markers. 6. Emergency service bucket containing: b. Full-face piece type gas mask. c. Eye wash bottle. d. Pipe wrench. DO NOT APPLY HEAT EXTERNALLY TO AN OIL POT PREPARED BY:---- aPmshur ' SOP-IlS APCCO ' Final Draft EFFECTIVE DATE: OPERATION OF THE OIL POT REV. - "A" PAGE NO. March 1, 2001 Feb. 21,200! 6OF 9 OIL DRAINING INSTRUCTION FOR OP1 STEP COMMENT 1. Close the liquid inlet valve from the LSA1 - LSA1-27. Mark this valve with a CLOSED valve marker. Turn the oil heater ON and allow the liquid ammonia to evaporate. When the oil pot has warmed up to ambient conditions, all traces of liquid ammonia should be gone. Turn OFF the oil heater. After turning the oil heater OFF, the vent valve should be closed - LSA1-32. Mark this valve with a CLOSED valve marker. The pressure in the pot must be above atmospheric pressure otherwise no oil draining will take place. With a positive pressure in the oil pot, it is now safe to drain the oil. Remove the pipe plug and slowly open the oil pot isolation valve, LSA1- 30. Then, slowly drain the oil into the bucket containing water through valve LSA1-29. 1. Once the inlet valve is closed, time must be allotted to evaporate the liquid ammonia. 2. This process may take an hour or so. 3. The oil heater MUST be turned OFF before proceeding. Closing valve LSA1-32 will isolate the oil pot from the rest of the system. There should be a positive pressure in the oil pot before preceding with step 5 otherwise the water will be drawn into the oil pot and no draining will take place. If pressure is below atmospheric pressure, raise the pressure to a positive value before proceeding. This can be accomplished by admitting a very small quantity of liquid ammonia through valve LSA1-27 then closing it again. Once this process is started, you must NOT WALK AWAY! NEVER open the drain valve all the way. The oil may be very thick and may not readily drain. Patients will win the day here. When the draining is complete, close the oil pot isolation valve, LSA1-30 and allow the drain line to drain before closing valve LSA1-29. (You want to be extremely careful not to trap liquid between the two valves.) Then, replace the pipe plug, OPEN the vent valve, LSA1-32 and the inlet valve LSA1-27. The oil pot is back in operation. Ensure that the oil drain valve is closed before opening either of the remaining valves otherwise ammonia will be released into the atmosphere. i~ ~ :: SOP-115 APCCO . i../,~ll~ ~,~. Final Draft EFFEcTiVE D~TE: :~P~ ' ~Nw ~~ we ~v THE OIL POT ~V.- "A" PAGE NO. March 1,200~ Feb. 21, 2001 7 OF 9 OIL DRAINING INSTRUCTION FOR OP2 STEP COMMENT 1. Close the liquid inlet valve from the SD1 - 1. Once the inlet valve is closed, time must be HX2-17. Mark this valve with a CLOSED allotted to evaporate the liquid ammonia. valve marker. 2. Allow the contents of the oil pot to warm up to 2. ambient conditions over a period of several hours. 3. When the oil pot has warmed up to ambient 3. conditions, all traces of liquid ammonia should be gone. At this time, the vent valve should be closed HX2-21. Mark this valve with a CLOSED valve marker. 4. The pressure in the pot must be above 4. atmospheric pressure otherwise no oil draining will take place. 5. With a positive pressure in the oil pot, it is now 5. safe to drain the oil. Remove the pipe plug and slowly open the oil pot isolation valve, HX2- 19. Then, slowly drain the oil into the bucket containing water through valve HX2-20. This process may take several hours. If the oil pot is a ball of ice, carefully removing the ice will speed up the process some. Closing valve HX2-21 will isolate the oil pot from the rest of the system. The pressure in the oil pot should be monitored. There should be a positive pressure in the oil pot before preceding with step 4 otherwise the water will be drawn into the oil pot and no draining will take place. If pressure is below atmospheric pressure, raise the pressure to a positive value before proceeding. This can be accomplished by admitting a very small quantity of liquid ammonia through valve HX2-17 then closing it again. Once this process is started, you must NOT WALK AWAY! NEVER open the drain valve all the way. The oil may be very thick and may not readily drain. Patients will win the day here. 6. When the draining is complete, close the oil pot 6. isolation valve, HX2-19 and allow the drain line to drain before closing valve HX2-20. (You want to be extremely careful not to trap liquid between the two valves.) Then, replace the pipe plug, OPEN the vent valve, HX2-21 and the inlet valve HX2-17. The oil pot is back in operation. Ensure that the oil drain valve is closed before opening either of the remaining valves otherwise ammonia will be released into the atmosphere. ---- - a p;Ush u ISSUE: SOP-115 APCCO Final Draft EFFECTIVE DATE: OPERATION OF THE OIL POT REV. - "A" PAGE NO. March 1, 2001 Feb. 21, 20018 OF 9 OIL DRAINING INSTRUCTION FOR OP3 After OP3 is replaced, (by July 1, 2001) this page will become obsolete. The procedure on the following page should be followed for the NEW OP3. CAUTION! PLEASE USE EXTREME CAUTION WHEN DRAINING OIL FROM THIS OIL POT. THERE ARE NO VALVES TO ISOLATE IT FROM THE SYSTEM. THIS OIL POT WILL REMAIN CONNECTED TO A LIVE SYSTEM AND MOST LIKELY WILL CONTAIN LIQUID AMMONIA AT ALL TIMES DURING THE OIL DRAINING PROCESS. STEP COMMENT 1. Ensure that there is NO frost on the oil pot. 1. Frost is not necessarily an indication of the presents of liquid ammonia. Mostly, it simply indicates that the contents are below freezing. Exercise extreme caution. 2. Remove the pipe plug and slowly open the oil 2. pot isolation valve, IM1-09. Then slowly drain the oil into the bucket containing water through valve IM 1-10. Once this process is started, you must NOT WALK AWAY! NEVER open the drain valve all the way. The oil may be very thick and may not readily drain. Patients will win the day here. o When the draining is complete, close the oil pot isolation valve, IM1-09 and allow the line to drain before closing valve IM1-10. (You want to be extremely careful not to trap liquid between the two valves.) Then replace the pipe plug. If ammonia should spurt out, stop draining and wait a while before continuing. Cold oil drains very slowly. Draining it too quickly could cause liquid from the surface of the oil to be pulled down through the oil to the drain point. After several minutes try draining again. Keep in mind that there was liquid ammonia at the drain valve when you stopped last time so proceed with caution again. The use of hot water on the oil pot could speed this process. Continue is this manor until you are reasonably sure that the oil has been drained. Ensure that the oil drain valve is closed before opening either of the remaining valves otherwise ammonia will be released into the atmosphere. PREPAID BY: Pillsbury SOP-115 A~PCCO ~ Final Draft EFFECTIVE DATE: REV. - "A" PAGE NO. OPERATION OF THE OIL POT March !, 2001 Feb. 21, 2001 9 OF 9 OIL DRAINING INSTRUCTION FOR OP2 This procedure should be sued with the new OP3, which should be installed by July 1, 2001. STEP COMMENT 1. Close the liquid inlet valve from the SD2 - 1. Once the inlet valve is closed, time must be IMI-13. Mark this valve with a CLOSED allottedto evaporate the liquid ammonia. valve marker. 2. Allow the contents of the oil pot to warm up to 2. ambient conditions over a period of several hours. 3. When the oil pot has warmed up to ambient 3. conditions, all traces of liquid ammonia should be gone. At this time, the vent valve should be closed - IMl-17. Mark this valve with a CLOSED valve marker. 4. The pressure in the pot must be above 4. atmospheric pressure otherwise no oil draining will take place. 5. With a positive pressure in the oil pot, it is now 5. safe to drain the oil. Remove the pipe plug and slowly open the oil pot isolation valve, IM1-09. Then, slowly drain the oil into the bucket containing water through valve IM1-10. This process may take several hours. If the oil pot is a ball of ice, carefully removing the ice will speed up the process some. Closing valve IMl-17 will isolate the oil pot from the rest of the system. The pressure in the oil pot should be monitored. There should be a positive pressure in the oil pot before preceding with step 4 otherwise the water will be drawn into the oil pot and no draining will take place. If pressure is below atmospheric pressure, raise the pressure to a positive value before proceeding. This can be accomplished by admitting a very small quantity of liquid ammonia through valve IM 1-13 then closing it again. Once this process is started, you must NOT WALK AWAY! NEVER open the drain valve all the way. The oil may be very thick and may not readily drain. Patients will win the day here. 6. When the draining is complete, close the oil pot 6. isolation valve, IM1-09 and allow the drain line to drain before closing valve IMI-10. (You want to be extremely careful not to trap liquid between the two valves.) Then, replace the pipe plug, OPEN the vent valve, IMl-17 and the inlet valve IMl-13. The oil pot is back in operation. Ensure that the oil drain valve is closed before opening either of the remaining valves otherwise ammonia will be released into the atmosphere. 20 C~ Z P~PARED BY: Pi' sbury ISSUE: Final Draft EFFECTIVE DATE: REV. -"A" PAGE NO. EVAPORATOR COIL CLEANING March 1, 2001 Feb. 8, 2001 1 OF 3 Objective: Purpose: Scope: The objective of this document is to describe and set forth Standard Operating Procedure (SOP) for the cleaning of the ammonia evaporator coils throughout this facility. The purpose of this procedure is to ensure that all personnel follow the proper steps when cleaning an ammonia evaporator coil. Following this procedure will prevent damage being inflicted on the coils during the cleaning process. The procedure covers cleaning any ammonia evaporator coil in the facility. Concerns: Careful attention to valve position is important to this procedure to ensure that liquid ammonia is not trapped in the evaporator during cleaning. Among incidents we are trying to prevent are: · Injury to operator(s) * Over pressurization of the system · Operation of the safety relief valves · Release of ammonia to atmosphere Department: Refrigeration Operator Pillsbury Refrigeration Operator - Level 3 /Responsibility: Equipment: Low-Temperature Evaporators: AU2, AU3 & AU4 AU6, AU7 AU8 Location: Holding Freezer Spiral Freezer #1 Anti Room Spiral Freezer #2 Related Documents: P&ID R-04 & R-05, Manufacturers U-1A Report, IIAR Bulletin 109 and 110 and any OEM related document(s). All located in the North Engine Room Initial Development August 31, 2000 Date: Authorized By: Tim Ridley Annual Review By: March 1, 2002 APCCO Final Draft EFFECTIVE DATE: REV. - "A" PAGE NO. EVAPORATOR COIL CLEANING March 1, 2001 Feb. 8, 2001 2 OF 3 Procedures: Only the refrigeration mechanic is authorized to prepare an ammonia evaporator coil for cleaning. The following procedures ~vill be followed. PRIOR TO CLEANING ANY EVAPORATOR COIL: The "ON DUTY" refrigeration mechanic will contact the Production Supervisor and inform that person of the area and evaporator coil(s), which need to be cleaned. The refrigeration mechanic will: Inspect the area to be cleaned and ensure that no product or equipment is in danger of being damaged or contaminated by the cleaning process. The evaporator coil(s) will be put into a manual defrost cycle to melt as much ice from the coils, fins and pan as possible. · When the defrost cycle is finished, the liquid feed switches will be shut off and tagged. · All fans will be allowed to run for an additional 10 to 15 minutes, to boil off as much ammonia liquid as possible, after which they will be turned off, locked and tagged. · The area and evaporator coils will be re-inspected to ensure that everything is OK and that no liquid ammonia is left in the coils. · When the refrigeration mechanic is satisfied, he will contact the Supervisor and inform that person that the coils are ready to be cleaned. · The maintenance worker(s) will inspect the area to be cleaned and reassure that no product or and/or equipment is in danger of being damaged or contaminated. · The maintenance mechanic will add his/her locks and tags to the evaporator fan disconnect(s). · The maintenance mechanic will ensure that the evaporator(s) fan motor(s) are wrapped in plastic to prevent water damage. Plant Lockout/Tag out and Safe Practice Programs will be followed when taking a unit or system out of service, maintaining and/or returning equipment to service. Refer to plant programs for details. (Continued on next page) ry pffi . o _ ooo APCCO ~ U Final Draft EFFECTIVE DATE: EVAPO~TOR COIL CLEANING REV. - "A" PAGE NO. March 1,200I Feb. 8, 2001 3 OF 3 The Cleaning Process: Maintenance shall ensure that ALL of the above items have been complied with prior to cleaning any ammonia evaporator coil. Only after they are satisfied, should they begin the cleaning process. While cleaning the evaporator coil(s), care must be taken so as not to damage the coils, fins, pan or outer surface. ·Acid or alkaline base cleaners should never be used on the evaporator coil, fins or surrounding surface/frame. · Never use over 60 PSIG water pressure on any coil surface. · Water temperature should not be over 120°F. · Never use ANY object other than water to remove ice or other debris from the evaporator coil(s). · Avoid spraying water into ANY motor. ·Maintenance shall notify the "On Duty" Refrigeration Mechanic when they are finished cleaning the area and evaporator coil(s). ·The Maintenance Mechanic will inspect the area and remove the plastic from motors prior to removing his/her lockout/tag out. ·The Refrigeration Mechanic will remove his lockout/tag out and return the evaporator unit to normal operation. · The Refrigeration mechanic, will immediately re-inspect evaporator(s) to assure that it/they are working properly. 21 PREPARED BY: ~ ~, ISSUE: uFy SOP-3000 Pfllsb Final Draft EFFECTIVE DATE: R:EFRIG~E~TI-*NG SPECIALTIES REV.- "A" PAGE NO. March 1,200,1 (~S) P~ESSURE REGULATOR Feb. 8, 2001 1 OF 3 Objective: Purpose: Concerns: The objective of this document is to describe and to set forth Standard Operating Procedures (SOP) for the operation of the Parker-Refrigerating Specialties (R/S) Pressure Regulator. The purpose of this procedure is to ensure all personnel follow the proper steps when operating the R/S Pressure Regulator, and to set forth the proper steps for assembly, disassembly and monitoring of normal operation. Careful attention to valve position is important to this procedure. It is the regulator that provides proper equipment pressure for temperature control. Among incidents we are trying to prevent are: · Injury to operator(s) · Over pressurization of the system · Operation of the safety relief valves · Release of ammonia to atmosphere Department: Refrigeration Operator Pillsbury Refrigeration Operator - Level 3 /Responsibility: Equipment: Refrigerating Specialties Pressure Regulating Valves Location: Throughout the facility Related Documents: P&ID R-02 - R-07, Manufacturers U-lA Reports, IIAR Bulletin 109 and 110 and any OEM related documents. All are located in the North Engine Room. Initial Development August 31, 2000 Date: Authorized By: Tim Ridley Annual Review By: March 1, 2002 Plant Lockout-Tag out and Safe Practice Programs should be followed when taking a unit or system out of service; maintaining and/or returning equipment back to service. Refer to plant programs for details. Note: The following procedures have been adopted in whole or in part from the Parker-Refrigerating Specialties Division - Bulletin 23-05. PREPARED BY: ISSUE: Pillsbury so _ 000 APCCO Final Draft EFFECTIVE DATE: REFRIGERATING SPECIALTIES REV.- "A" PAGE NO. March 1, 2001 (R/S) PRESSURE REGULATOR Feb. 8, 20012 OF 3 Scope: The scope of this procedure is to ensure that all personnel follow the proper steps when operating and/or maintaining the R/S Inlet Pressure Regulator (A4A). And, to ensure that the operation and maintenance of the, R/S Inlet Pressure Regulator, will be done by qualified refrigeration mechanic, and that said mechanic has a full understanding of every operating phase. Description: All A4A regulators are pilot operated using upstream pressure for the opening force and requires a minimum of 2 psig pressure drop to fully open. They are compact, heavy duty, iron alloy (ASTM A126 Class B). These regulators come in three (3) pressure ranges. · Range · Range · Range A- 0 to 150 PSIG V - 20in. Hg to 120 PSIG D - 75 to 280 PSIG Principles of Operation: The R/S A4A Inlet Pressure Regulator modulates the flow of refrigerant liquid and/or vapor to maintain constant upstream (inlet) pressure, despite load fluctuation. The A4A Inlet Pressure Regulator opens if the inlet pressure rises above the valve's set point and closes if the inlet pressure drops below its set point. Manual Opening Stem: A manual opening stem is provided with all A4A regulators. This stem is located on the bottom of the valve protected by a seal cap. To manually open the regulator, the stem must be turned out (counter-clockwise) until it stops. To put the regulator into automatic mode, turn the stem in (clockwise) until only the wrench-flats on the stem protrude from the packing nut. Adjustments: In order to properly adjust the R/S A4A Inlet Pressure Regulator, you must first install art accurate pressure gauge in the gauge port. Then... 1. Back the adjusting stem all the way out. (This will reduce the set point to its lowest level and cause the valve to open wide.) 2. Start the system. 3. When suction pressure is about the desired pressure/temperature turn the adjusting stem in, (clockwise) until pressure gauge shows a slight rise in the inlet pressure. 4. Continue turning the adjusting stem clockwise or counter clockwise as needed to raise or lower pressure to the desired setting. 5. Monitor system and the set pressure and follow its operation for a period of time before any final adjustment. General Procedures: Before regulator is removed from the system or disassembled in place, make sure that all refrigerant pressure has been removed from the regulator. The regulator must be properly isolated from the rest of the system in a safe manner. Isolation valves must be closed, tagged and locked out per the facility's Lockout-Tag out and Safe Practice Programs. Refer to plant programs for details. When pumping down to remove the refrigerant pressure, the manual opening stem MUST be turned out (counter clockwise) to make sure the valve is open equalizing pressure on both sides of the w~lve. · *~ ~ ~' · SOP-3000 APCCO i~l~s~ Final Draft EFFECTIVE DATE: REFRIGERATING SPECIALTIES REV. -"A" PAGE NO. March 1, 2001' (~S~).~RESSURE REGULATOR Feb. 8, 2001 3 OF 3 Disassembly: 1. Back the adjusting stem all the way out to remove any pressure from range spring. 2. Remove bonnet by carefully removing cap screws. Note: Take care not to damage diaphragm or the follower. 3. Remove adapter by removing cap screws. 4. Turn manual opening stem all the way in (clockwise) until the flats on the stem barely protrude from the stuffing box nut. 5. Push piston down and check that it moves freely down and returns by the spring force. 6. If piston sticks or is jammed remove bottom cap assembly and using a hardwood dowel rod inserted through the bottom of the valve and tap the piston upward and out. 7. Thoroughly clean all parts. 8. Check piston and bore, and remove any burs. Inspect the seating area of the modulating plug for damage or erosion. 9. Inspect all gaskets and O-rings for damage. 10. Inspect pilot seat top seating surface for dirt, wear or damage. 11. Examine diaphragm for dirt, heavy scratches or corrosion. Note: If diaphragm cannot be easily wiped clean it should be replaced. 12. Replace any damaged part where necessary. Assembly: When reassembling the valve, all internal parts should be clean, dry and lightly oiled with refrigerant oil, except O-rings. (Silicone grease should be used for the O-rings.) Note: Gaskets should be oiled very lightly with refrigerant oil. 1. Install bottom cap assembly and tighten in place. 2. Carefully replace the piston. Note: Never force in place. 3. Align the adapter gasket with the proper holes with the adapter and valve body. 4. Fasten adapter in place. Note: Before assembling the bonnet, be sure the adjusting stem is turned all the way up. 5. Place diaphragm and both gaskets in the adapter. Note: The raised center of the diaphragm must be towards the bonnet. 6. Stack diaphragm follower, lower spring rest, spring and upper spring rest on top of diaphragm. 7. Carefully lower bonnet in place and tighten screws. 8. Tighten cap screws evenly. Note: Recommended tightening torque is 11 ft. lbs. Note: For range "D" uses two (2) diaPhragms. The valve is now ready to be adjusted for normal operation. If a strainer is used, it should be cleaned before putting valve back in operation. The regulator must be tested for leaks with refrigerant gas or other appropriate gas before the system is put into operation. 22 PREPARED BY: .e~i ISSUE: ~ :',! i~,! ,S~ SOP-4000 Pill ,bury Final Draft EFFECTIVE DATE: SAFETY RELIEF VALVE REV. - "A" PAGE NO. March 1, 2001 REPLACEMENT Feb. 8, 2001 1 OF 2 Objective: The objective of this document is to describe and to set forth Standard Operating Procedures (SOP) for the replacement of the safety relief valves. Purpose: The purpose of this procedure is to establish a process for which safety relief valves are to be replaced. Following this procedure will ensure the safe replacement of the safety relief valves and minimize the potential for release of ammonia during the valve replacement. Scope: The scope of this procedure is to ensure that all personnel follow the proper steps when replacing the safety relief valves. And, to ensure that the operation and maintenance of the safety relief valves will be done by qualified refrigeration mechanic, and that said mechanic has a full understanding of every operating phase. Department: Refrigeration Operator Pillsbury Refrigeration Operator - Level 3 /Responsibility: Equipment: Pressure Relief Valves Location: Located on all pressure vessels Related Documents: P&ID Set, IIAR Bulletin 109 and 110, and any OEM related documents. All located in the North Engine Room Initial Development August 31, 2000 Date: Authorized By: Tim Ridley Annual Review By: March 1, 2002 PREPARED BY:--Ill' ~t/~P;~s~ur'~ ,ssu : o . ooo APCCO Final Draft ~FFECTIVE DATE: SAFETY RELIEF VALVE REV. - "A" PAGE NO. March 1, 2001 REPLACEMENT Feb. 8, 2001 2 OF 2 General Procedures: TASK STEP COMMENT A. Isolate the Safety relief 1. Verify safety relief that will Have all of the necessary valve be replaced, equipment, tools and parts on 2. Close port to safety relief hand prior to starting the job. valve to be replaced. All 3-way valves will close the inlet port when stem seated towards the port. B. Cap the open outlet line 1. C. Replace the Safety Relief D. Re-connect the relief line E. Date the Safety Relief 3. 4. 1. 2. Purge relief line and verify that there is no residual ammonia in the vent line. Disconnect line from the safety relief. Remove the union. Cap the open vent line. Remove the old Safety Relief. Install the new Safety Relief. 1. Remove Cap installed in relief vent line. 2. Re-install the union. Mark the new Safety Relief with the date of installation. Record all information particular to the new valve and advise chief engineer of completion. Careful attention should be given to the pressure of residual ammonia in the vent line and a positive shut-off from the 3-way valve is imperative. Verify again, that the replacement valve is of like kind. Advise chief engineer of any discrepancy. Re-connect the previously capped line. Always use ammonia grade fittings, Sch. 80, seamless. Any question should be referred to the chief engineer immediately. Only use paint or other marking material that will NOT be affected by time or weather. 23 24