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NH3 Refrigeration

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NH3 Refrigeration
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For Official Use Only

Ammonia Refrigeration RAGAGEPs

For Official Use Only

Objectives Gain a basic understanding of: RAGAGEPs unique to Ammonia Refrigeration Equipment-specific RAGAGEP requirements

Again, this is an overview discussion.There is usually an exception to most rulesSlide 2

RAGAGEP Organizations ASME ANSI /ASHRAE IIAR NB NIOSH RMASlide 3

ASME / NB BPVCDesign, fabrication, inspection, testing and certification of vessels operating above 15 psig (internal and/or external)

B31.5Refrigeration Piping and Heat Transfer Components

NBIC NB-23In-service inspections, repairs, alteration, reratesSlide 4

ANSI / ASHRAE ANSI/ASHRAE 15Safety Standard for Refrigeration Systems

Slide 5

IIAR Process Safety Management Guidelines forAmmonia Refrigeration (update coming soon)

Ammonia Refrigeration Piping Handbook Ammonia Data Book(chemical and technology PSI resource)

Oil D Draining i i G Guidelines id li

Slide 6

IIAR ANSI/IIAR Standard 2Equipment, Design, and Installation of Closed-Circuit Ammonia Mechanical Refrigeration Systems

Bulletin No. 107Suggested Safety and Operating Procedures When Making Ammonia Refrigeration Plant Tie Tie-Ins Ins

Bulletin No. 108Guidelines for Water Contamination in Ammonia Refrigeration SystemsSlide 7

IIAR Bulletin No. 109Guidelines for IIAR Minimum Safety Criteria for a Safe Ammonia Refrigeration System

Bulletin No. 110Guidelines for Start-Up, Inspection, and Maintenance of Ammonia Mechanical Refrigeration Systems

Bulletin No. 111Guidelines for Ammonia Machinery Room VentilationSlide 8

IIAR Bulletin No. 112Guidelines for Ammonia Machinery Room Design

Bulletin No. 114Guidelines for Identification of Ammonia Refrigeration Piping and System Components

Bulletin No. 116Guidelines for Avoiding Component Failure in Industrial Refrigeration Systems Caused by Abnormal Pressure or ShockSlide 9

NIOSH Publication No. 79-120Working Safely with Anhydrous Ammonia

Publication No. 79-119A Guide for Developing a Training Program for Anhydrous Ammonia Workers

Slide 10

RMA Publication IP IP-14 14Specifications for Anhydrous Ammonia Hose

Publication IP-11-2Hose Technical Bulletin - Manual for Use Use, Maintenance, Testing, and Inspection of Anhydrous Ammonia Hose

Slide 11

Slide 12

ANSI/ASHRAE 15Safety Code for Mechanical Refrigeration

Establishes safeguards for personnel andproperty

Applies to: Design, construction, test, installation, operation, and inspection Modifications (non-RIK) Subst Substitutions tut o s of o refrigerants e ge a tsSlide 13

ANSI / IIAR Standard 2Standard for Equipment, Design & Installation of Ammonia Mechanical Refrigerating Systems

Applies to closed-circuit mechanicalrefrigeration systems

Provides minimum requirements for: Equipment Machinery room design Installation of systemsSlide 14

IIAR Bulletin No. 109Minimum Safety Criteria for a Safe Ammonia Refrigeration System

Identifies mandatory safety requirements Provides safety inspection checkliststo be performed annually

References e e e ces ot other e codes a and d sta standards da ds asbasis for checklists

Slide 15

IIAR Bulletin No. 110Start Up, Inspection, and Maintenance of Start-Up, Ammonia Mechanical Refrigerating Systems

StartupPSSR, Evacuation, Dehydration, Leak Checking, Charging Testing Protective Devices Charging,

I&MSystem Log/inspection, Log/inspection Compressors Compressors, PVs PVs, and HEs, Pumps, Valves, Piping, Oil, Motors Provides example ITPM planSlide 16

IIAR Bulletin No. 110 System log/inspection at least daily(example in Appendix I)

Slide 17

IIAR Bulletin No. 110Appendix G Typical Inspection and Maintenance Plan

Slide 18

IIAR Bulletin No. 111Ammonia Machinery Room Ventilation

Ventilation DesignEAC, Emergency Vent Rate EAC Rate, Fan Selection & Layout, Detectors, Controls

Operation & MaintenanceFans/Intakes, Room Pressure, Detectors, Controls

Slide 19

IIAR Bulletin No. 111

Slide 20

IIAR Bulletin No. 114Identification of Ammonia Refrigeration Piping and System Components

Comprehensive labeling scheme Label size Colors Locations Label material requirements

Slide 21

Equipment-specific Requirements

Slide 22

Alarms & Detectors Each machinery room is equipped withammonia detection that alarms and starts ventilation at a concentration of no higher than 1,000 ppm (ASHRAE-15, 8.11.2.1)

Detector alarms annunciate with visualand audible means both inside and outside each entrance to machinery room (ASHRA-15, 8.11.2.1)

Alarm is triggered when the continuousventilation system fails (IIAR-111, 3.5.3)Slide 23

Alarms & Detectors A high high-range range detector will automaticallyshut down all unclassified equipment in the machinery room at no more than 15,000 ppm (IIAR-111, 3.5.2)

Must be manual reset type with the resetlocated inside the refrigerating machinery room (ASHRAE-15, 8.11.2.1)

The meaning of each alarm shall beclearly marked by signage near the annunciators (ASHRAE-15, 8.11.2.1)Slide 24

Compressors Fitted with high pressure cutoutsthat unload the machine at 90% of the pressure relief valve set pressure (ASHRAE-15, 9.9)

Moving parts are guarded(ASHRAE-15, 8.2)

Located such that there isunobstructed access for both normal and emergency tasks (ASHRAE-15, 8.3)Slide 25

Compressors Must have both suction and dischargeshut-off valves (ASHRAE-15, 9.12.4)

Fitted with nameplates that include:manufacturer, identification number, design pressures pressures, and refrigerant used (IIAR-2, 6.1.4)

Each must be identified with signage withlettering greater than 0.5" in height (ASHRAE-15 (ASHRAE 15, 11 11.2.2) 2 2)Slide 26

Compressors Each compressor has a high dischargetemperature and pressure cutout (IIAR-2, 6.1.2.2)

Each compressor has a low suctionpressure cutout (IIAR-2 (IIAR 2, 6 6.1.2.2) 1 2 2)

Each compressor package with an oilpump has an oil flow failure indicator (more than just checking oil pressure and DP) (IIAR (IIAR-2 2, 6 6.1.2.2) 1 2 2)Slide 27

Design Pressures High High-side side components on systems 250 psig - evaporative condensing 300 psig air-cooled air cooled condensing (IIAR-2, 6.1 and 9.1)

Low-side components are rated forMAWPs of 150 psig or greater (IIAR-2, 9 1) 9.1)

Slide 28

Machinery / Engine Room Head room of at least 7.25 ft below equipmentsituated it t d over passageways (ASHRAE (ASHRAE-15, 15 8.11.1)

Self-closing, tight-fitting doors that openoutward (ASHRAE-15, 8.11.2)

No other wall penetrationsthat would allow ammonia to other parts of building (ASHRAE-15, ( , 8.11.2) )Slide 29

Machinery Room Emergency ventilation amount is greaterthan 100 times the square-root of the charge of refrigerant in pounds (ASHRAE-15, 8.11.5)

Continuous ventilation amount is at least0.5 cfm/ft2 or 20 cfm/person (ASHRAE-15, 8.11.5 and IIAR-111, 3.2.3)

Slide 30

Machinery Room Does not permanently contain equipmentwith continuous operating surface temperatures in excess of 800F [ASHRAE-15, 8.12(a)]

Walls are noncombustible and at leastone-hour fire resistive construction [ASHRAE-15, 8.12(c)]

At least one door opens directly outsidebut not under a fire escape/open stairway [ASHRAE-15, 8.12(d),(e)]Slide 31

Machinery Room Emergency shutdown control of is locatedimmediately outside of the machinery room door [ASHRAE-15, 8.12(i)]

Emergency ventilation fans are on aseparate electrical circuit and have a control switch immediately outside of the machinery room door [ASHRAE-15, 8.12(i)]

Slide 32

Machinery Room Signage indicating Name and address of installer Refrigerant number and amount Lubrication identity and amount Field test pressure (ASHRAE-15, 11.2.1)

Access ccess is s limited ted to aut authorized o ed pe personnel so e o only, y,signage indicating MACHINERY ROOMAUTHORIZED PERSONNEL ONLY at each door (ASHRAE-15, 8.11.8 and 11.2.4)Slide 33

Machinery Room Personnel Safety ANSI Z358.1 Z358 1 eyewash/safety e e ash/safetshower located in close proximity outside of the machinery room (IIAR-2, 13.3.1.4)

ANSI Z358.1 Z358 1 eyewash/shower h/ hstation should be located inside the machinery room within 50 ft of any point in the room (IIAR-2, 13.3.1.4)

Slide 34

Piping All refrigerant piping less than 6" NPS is atleast schedule 40 (B31.5)

All refrigerant piping less than 2" 2 NPS is atleast schedule 80 (B31.5)

Refrigerant piping must be fabricated bycertified welders-WPS/PQR/WQR (B31.5)

All piping mains, headers, and branchesare identified including the refrigerant's physical state state, relative pressure level level, and the direction of flow (IIAR-2, 10.5, IIAR-114)

Slide 35

Piping

Slide 36

Piping

Main shut-off valve(s) (i.e., kingvalves) should be readily accessible and identified with a prominent sign (IIAR-109, 4.10.3)

Slide 37

Pumps Pumps are protected from hydrostaticoverpressure with an relief device (IIAR-2, 6.2.1.2)

All exposed rotating parts of the pump areguarded (IIAR (IIAR-2 2, 6 6.2.1.4) 2 1 4)

Liquid refrigerant pumps are equipped withlow liquid level pump cut cut-out out

Slide 38

Relief Devices Pressure relief devices protecting ASME ratedcomponents are stamped with a UV or VR symbol (ASHRAE -15, 9.4.2)

If a stop valve exists on the discharge of apressure relief device device, it is full-port full port and locked open (ASHRAE-15, 9.4.7)

Pressure relief device set pressure is equal to orless than the maximum allowable working pressure of the protected component(s) (ASHRAE-15 and ASME Sect. VIII)Slide 39

Relief Devices The capacities of the relief devicesprotecting liquid containing vessels are equal to or exceed ASHRAE 15 requirements

The inlet and outlet piping of the relief deviceand the protected component is at least the same size as the relief device inlet and outlet connections (ASHRAE-15, 9.7.6 and 9.7.8.4)Slide 40

Relief Devices Discharge from relief device(s) are greaterthan 15 ft above the adjoining ground level (verify vent does not put people in "harms way") (ASHRAE-15, 9.7.8)

Discharge from relief device(s) are greaterthan 20 ft from windows, ventilation intakes or building exits (ASHRAE-15, 9.7.8)

Replaced or cleaned/inspected tested every5 years (IIAR (IIAR-109 109, 4 4.9.7) 9 7)Slide 41

Pressure Vessels Pressure Press re vessels, essels incl including ding shell and t tube beexchangers must have a nameplate (IIAR-2 (IIAR 2, 7 and 9)

Liquid level indicators should be protectedf from physical h i ld damage (IIAR (IIAR-109, 109 4 4.6) 6)

Inspected During daily rounds Annually Every 5 yearsSlide 42

Review We covered Ammonia Refrigeration RAGAGEPs Some equipmentspecific requirements i t

Slide 43

Q Questions ti

Slide 44

Chad Patschke

Manager, Mechanical Integrity Services ABS Consulting [email protected] 281 685 0988 281-685-0988

Slide 45

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