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REDDY ICE/ PACKAGED ICE, INC.PROCESS SAFETY MANAGEMENT/ RISK MANAGEMENT PREVENTIONSTANDARD OPERATING PROCEDURES OPERATION OF SCREW COMPRESSORS
SOP-3.1
Operation of Rotary Screw Compressors RWF 270
Objective This procedure is established to describe the Technical Operating Specifications (TOS) and to set
forth Standard Operating Procedures (SOP) for the safe operation of the compressors. Any person
that is responsible for any operation, repair or maintenance of this equipment should read and be
familiar with all elements of the Frick Manual and should daily, read the compressor log concerning
the compressor and associated equipment.
Purpose The purpose of the TOS is to provide a description of the compressor, define its function, operating
conditions and limits, consequences of deviations from operating limits, describe its controls,
instrumentation and safety systems and setting its operating alignment(s). The purpose of the SOP
is to establish the proper steps for startup, operation, and shut-down of the compressor.
Concerns Pay careful attention to suction pressure, discharge pressure, lubrication oil pressure, and
lubrication oil temperature. This is important to this procedure because compressor damage can
occur when compressors are dead-headed or when lubrication is lost. Among the incidents we are
trying to prevent are:
Injury to operator(s)
Damage to compressors due to high discharge pressure or loss of lubrication
Over-pressurization of the refrigeration system (e.g., blocked in liquid) resulting in arelease through pressure relief valves or failure or rupture of lines, tubes, or other equipment and a
subsequent release
Department Engineering
Operator/
Responsibility
Plant Engineer - Mike Cannon
Plant Manager - Steve Waters
Equipment/Location (3) Frick model RWF270, Located in the engine room (east end of building).
Related documents Inspection and Maintenance Records in the Plant Engineers office.
System Log Book in the Plant Engineers office.
Manufacturer's Installation and Operations documents in the Plant Engineers office.
Block Diagrams in the PSM/RMP Program documentPlant Engineers office.
P&IDs - in the PSM/RMP Program document Plant Engineers office.
Ammonia MSDS in Right to Know notebook located in the hall at battery charging station.
Copies of all documents Plant Managers office.
Initial SOP
development date
January 2002
Authorized by
Revision No. 0
Annual Review by
Annual Review by
REDDY ICE DALLAS Page SOP 3.1-1 Original Date: January 2002Revision Date: ___________
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REDDY ICE/ PACKAGED ICE, INC.PROCESS SAFETY MANAGEMENT/ RISK MANAGEMENT PREVENTIONSTANDARD OPERATING PROCEDURES OPERATION OF SCREW COMPRESSORS
Technical Operating Specification (TOS)
Function The compressor serves, as a pump to maintain desired suction pressure by removing ammonia vapor
from the Vogt Icemaker liquid recirculator. In the process, low-pressure ammonia vapor is compressed,
which creates heated high-pressure ammonia vapor. The high-pressure ammonia vapor then moves to
the evaporative condensers and liquefies. The Frick RWF 270 Compressor package has a side port
economizer to maintain a controlled pressure on the liquid receiver (CPR). The compressor package
also has an oil cooling thermosyphon system. The thermosyphon oil cooler on the side of the
compressor (C1-18) has chiller plates in which the oil flows. The plates are surrounded by liquid
ammonia that flows directly from the pilot thermosyphon receiver. The oil passes through the plates, the
ammonia boils and absorbs the heat from the oil, and the vapor returns to the Thermosyphon pilot
receiver.
Description Capacity/Size Operating Limits Deviations/Consequences
(3) Frick Screw
Compressors Model
RWF 270
735 HP
478.1 TR
Suction pressure: 22-30 psig
Head pressure 150-181 psig
Low suction pressure may result
in inefficient operation (and
freeze up icemakers).
Discharge pressure.
155-181psig
High discharge pressure may
result in minimizing compressor
capacity.
210 psig maximum discharge
pressure
Over-pressurization may result in
operation of pressure relief
valves.
Approximate lubrication oil pressure is
discharge pressure less suction
pressure.
Loss of compressor lubrication
may result in compressor bearing
or seal damage and a release of
ammonia.
Lubrication oil temperature: 110F High lubrication oil temperature
could result in compressor
damage and a release of
ammonia.
Discharge temperature: 150-170F High discharge temperature
could result in compressor
damage and a release of
ammonia.
REDDY ICE DALLAS Page SOP 3.1-2 Original Date: January 2002Revision Date: ___________
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REDDY ICE/ PACKAGED ICE, INC.PROCESS SAFETY MANAGEMENT/ RISK MANAGEMENT PREVENTIONSTANDARD OPERATING PROCEDURES OPERATION OF SCREW COMPRESSORS
Controls and Instrumentation
Description Item Number Function Position/Set point
Discharge Pressure
indicator
Displayed on each compressor
and on the operator interface
terminal (Panelview)
Pressure indication on
compressor discharge
155-181 psig.
Suction Pressure
indicator
Displayed on each compressor
and on the operator interface
terminal (Panelview)
Pressure indication on
compressor suction
23-34 psig.
Slide valve control set
point.
Displayed on each compressor
and operator interface panel.
(Panelview)
Internal controlled function that
allows operator to program
suction pressure set point which
will control the loading and
unloading of compressor which
will allow for precise load limits of
suction pressure.
Set to control low
temperature event and to
unload at 23-34 psig to
prevent freeze up of Vogt
Ice Maker.
Slide stop control
internal set point.
Internal function that controls the
ratio of the discharge port and
suction slide valve position formost optimal efficiency of
compress.
Located in the set point
parameters of Quantum
controller on thecompressor.
Compressor valve listing
UNIT
VAL
# SIZE
TYPE
CONN DISCRIPTION FUNTION MANUF MODEL Name
C-3,4,5 1 2" SW ANGLE VALVE ISOLATION VALVE R/S - THERM. FEED ISOLA. VALVE
C-3,4,5 2 5" BW ANGLE VALVE ISOLATION VALVE - - SUCTION ISOLA. VALVE
C-3,4,5 3 2" SW ANGLE VALVE ISOLATION VALVE - - THERM. RETN. ISOLA. VALVE
C-3,4,5 4 1/2" FLG PRES. REGULATOR MODULATION VAL R/S A2CK THERM. BYPASS ISOLA. VLV.
C-3,4,5 5 1-1/2" SW ANGLE VALVE ISOLATION VALVE R/S - SIDE-LOAD ISOLA. VALVE
C-3,4,5 6 1-1/2" FLG PRESS. REG.W/STR MODULATION VAL R/S A4AS-ST SIDE-LOAD PRES. REGULATR
C-3,4,5 7 1-1/2" FLG CHECK VALVE DIRECT CONTROL R/S CK4A6 SIDE-LOAD CHECK VALVE
C-3,4,5 8 1-1/2" FLG STRAINER DEBRIS FILTER R/S - SIDE LOAD HAND EXP. VAL.
C-3,4,5 9 1/4" MPT PRESSURE GAUGE MEASURE PRES. R/S Q6 SIDE LOAD PRES. GAUGE
C-3,4,5 10 1/4" FPT GAUGE VALVE ISOLATION VALVE R/S V12 SIDE LOAD GAUGE VALVE
C-3,4,5 11 1 1/2" SW ANGLE VALVE ISOLATION VALVE R/S - SIDE LOAD ISOLA. VALVE
C-3,4,5 12 1/2" SW ANGLE VALVE ISOLATION VALVE R/S - THERM BYPASS ISOL. VALVE
C-3,4,5 13 1/2" FPT GLOBE VALVE ISOLATION VALVE R/S - THERM FEED DRAIN VALVE
C-3,4,5 14 4" BW ANGLE VALVE ISOLATION VALVE - - DISCHARGE ISOL. VALVE
C-3,4,5 15 1/2" FPT DUAL RELIEF VLVS OVER PRES RELIEF SHANK 803-300 OVER PRES. RELIEF VALVES
C-3,4,5 16 1" SW ANGLE VALVE ISOLATION VALVE DANVL - SEPARATOR SERVICE VALVE
REDDY ICE DALLAS Page SOP 3.1-3 Original Date: January 2002Revision Date: ___________
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REDDY ICE/ PACKAGED ICE, INC.PROCESS SAFETY MANAGEMENT/ RISK MANAGEMENT PREVENTIONSTANDARD OPERATING PROCEDURES OPERATION OF SCREW COMPRESSORS
REDDY ICE DALLAS Page SOP 3.1-4 Original Date: January 2002Revision Date: ___________
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REDDY ICE/ PACKAGED ICE, INC.PROCESS SAFETY MANAGEMENT/ RISK MANAGEMENT PREVENTIONSTANDARD OPERATING PROCEDURES OPERATION OF SCREW COMPRESSORS
REDDY ICE DALLAS Page SOP 3.1-5 Original Date: January 2002Revision Date: ___________
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REDDY ICE/ PACKAGED ICE, INC.PROCESS SAFETY MANAGEMENT/ RISK MANAGEMENT PREVENTIONSTANDARD OPERATING PROCEDURES OPERATION OF SCREW COMPRESSORS
Safety Systems
Pressure relief valve PSV-15 Relieve excess ammonia vapor
pressure to the deluge tank
300 psig Factory Set device
Description Item Location Function Position/Set point
Low suction
pressure cutout,
operator set point.
Each Quantum Compressor
Controller and the PLC control
system monitors the low
suction pressure setting.
The low suction pressure set
point allows for compressor
shut down at the set point.
10 psig
High discharge
pressure pre-alarm
and cutout, operator
set point.
Each Quantum Compressor
Controller and the PLC control
system monitors the low
suction pressure setting.
Alert personnel and protect the
compressor from damage due
to high discharge pressure by
alarming and then shutting
down compressor
Stop Load 190 PSIG
Force Unload 200 PSIG
Alarm 210 PSIG
Shutdown 215 PSIG
5 Second delay
Low lubrication oil
temperature cutout,
internal set point.
Each Quantum Compressor
Controller monitors the low
lubrication oil temperature cut
out.
Protect the compressor from
damage due to low lubrication
oil temperature by shutting
down compressor
Alarm 55F
Shutdown 49F
5 Second delay
High lubrication oil
temperature cutout,
internal
programmed set
point.
Each Quantum Compressor
Controller monitors the high
lubrication oil temperature cut
out.
Protect the compressor from
damage due to high lubrication
oil temperature by shutting
down compressor
Alarm 144.8F
30 Second delay
Shutdown 155.0F
10 Second delay
High discharge
temperature cutout,
internal
programmed set
point.
Each Quantum Compressor
Controller monitors the high
discharge temperature cut out.
Protect the compressor from
damage due to high discharge
temperature by shutting down
compressor
Stop Load 180F
Force Unload 190F
Alarm 200F
Shutdown 195F
REDDY ICE DALLAS Page SOP 3.1-6 Original Date: January 2002Revision Date: ___________
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REDDY ICE/ PACKAGED ICE, INC.PROCESS SAFETY MANAGEMENT/ RISK MANAGEMENT PREVENTIONSTANDARD OPERATING PROCEDURES OPERATION OF SCREW COMPRESSORS
Standard Operating Procedure (SOP)Task Flow
Manual start-up procedures
|
Monitor normal operations
|Manual shut-down procedures
|
Emergency shut-down procedures
Task Step Comment
Manual start-up
procedures (during normal
operations and following
maintenance operations)
1. Visually check the compressor for
lockout/tag-out devices.
During normal operations, the
compressor will start, stop,
automatically load, and unload based on
suction pressure.
2. On initial installation or during any
maintenance procedure that involves removal
of any electrical phased conductors, removethe motor coupling and refer to the
Compressor manual for the complete checklist
on verifying motor rotation.
Never skip the step of verifying
motor rotation. Starting a screw
compressor in the wrong direction canbe extremely dangerous to equipment
and personnel.
3. Check to ensure a sufficient quantity of the
evaporative condenser(s) are enabled to
operate at desired pressure range depending
present load.
4. Remove tags as valves are opened or as
from the closed position during the shutdown
or maintenance procedure.
5. Manually open the suction valve C-02
slowly to (full open) to the compressor.
6. Manually open the discharge valve C-14
on the compressor.
7. Ensure that the manual valves on the
thermosyphon oil cooler line are open.
8. Turn on or reset any disconnects that was
turned to the off position.
Also remove-warning tags (DO NOT
OPERATE) from disconnects as they
are reset or closed.
REDDY ICE DALLAS Page SOP 3.1-7 Original Date: January 2002Revision Date: ___________
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REDDY ICE/ PACKAGED ICE, INC.PROCESS SAFETY MANAGEMENT/ RISK MANAGEMENT PREVENTIONSTANDARD OPERATING PROCEDURES OPERATION OF SCREW COMPRESSORS
Task Step Comment
9. Check the oil level in the compressor using the
two sight glasses. The level should be in the middle of
the top sight glass when the compressor is shut
down. The level should be in the middle of the bottom
sight glass when the compressor is running. (Visually
check separator sight glass, verify there is no oil in
coalescer section of the oil separator)
10. Start the compressor in the manual mode,
operate slide valve, slide stop in the manual mode
(increase & decease the position) to verify that the
compressor operates correctly and then place the
operator interface terminal (Panelview) and Quantum
panel switch to remote.
The compressor will start, oil
pressure will begin to increase as
the discharge pressure increases
and the suction pressure
decreases
11. Monitor analog data on the microprocessor to
ensure that all the parameters are within the
acceptable range.
Check proper operating
parameters as recorded on each
compressor log-sheet clipboard.
12. Monitor the system for ammonia/oil leaks. If any unusual conditions
(ammonia or oil leaks, noises, or
vibration) are observed. Stop
compressor, make corrections
and restart compress.
13. Verify that all electrical or mechanical access
covers are replaced that were removed or opened
during the shutdown or maintenance procedure.
Monitor normal operations 1. Check compressor at least once every hour
for normal operation. The compressor log sheet
should be filled out once per shift.
Compressor is checked more
frequently if it operates outside
acceptable parameters.
The Frick Compressor logsheet should be filled out
once per shift. The sheets
will be collected by the Plant
Engineer, reviewed, signed
and filed daily. The logbook
will remain on file in the
Plant Engineers Office.
Check lubrication schedule
daily for any listed
equipment due for
lubrication.
2. Steps to Operate within Desired Ranges: Suction pressure: check position of slide
valve and adjust settings using the compressor
microprocessor or panelview.
Discharge pressure: check position of
discharge valve and check operation of evaporative
condenser.
Lubrication oil pressure and temperature,
discharge temperature: position of oil valves.
Read and be familiar with theFrick manual and operating
procedures furnish by Frick.
There is wealth of valuable
learning material included in the
material.
REDDY ICE DALLAS Page SOP 3.1-8 Original Date: January 2002Revision Date: ___________
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REDDY ICE/ PACKAGED ICE, INC.PROCESS SAFETY MANAGEMENT/ RISK MANAGEMENT PREVENTIONSTANDARD OPERATING PROCEDURES OPERATION OF SCREW COMPRESSORS
Task Step Comment
Normal manual shutdown. 1. Go to Frick Quantum Micro processor and go to
compressor mode, select manual stop. Compressor will
unload and then will stop.
During normal operations,
the compressor is
automatically started and
stopped, and will
automatically load and
unload based on suction
pressure.
Manual shutdown for
compressor maintenance
procedures that do not
require evacuation of
ammonia from compressor
2. Before starting any maintenance on the compressor
follow the lockout/tag out procedures described in the
lockout / tag out manual to lockout the appropriate
disconnects.
Manual shutdown for
compressor maintenance on
a selected section of the
compressor.
3. After performing steps 1 and 2 follow steps listed in the
Frick manual to isolate the section where the maintenance
procedure will be performed.
Manual shutdown forcompressor maintenance
procedure that do require
evacuation of ammonia from
compressor.
4. After performing steps 1 and 2 then close and tagisolation valves C-02 located in the compressor suction line.
5. Close and tag the isolation valve C-14 located in the
compressor discharge line.
6. Close and tag the isolation valves C-1 & C-3 located in
the compressor thermosyphon oil cooler line
7. Close and tag the isolation valve C-11 on the side port
connection.
8. Connect a hose that is verified to be with in date and is
the appropriate type for ammonia service from the pumpdown valve C-16 located on the compressor to the service
valve PRG 04 on the Purger.
9. Open the service valve C-16 and Purger valve PRG-04
allowing the residual ammonia vapor to be evacuated as low
as possible with suction from purger then use jet pump to
finish the evacuation, see SOP 10 for jet pump operation.
10. Evacuate the residual ammonia from the compressor,
until the pressure indicator located in the compressor
microprocessor reads 0psig.
11. Remove jet pump and open service valve C-16 to
atmosphere to verify there is not vapor remaining in
compressor before starting work.
REDDY ICE DALLAS Page SOP 3.1-9 Original Date: January 2002Revision Date: ___________
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REDDY ICE/ PACKAGED ICE, INC.PROCESS SAFETY MANAGEMENT/ RISK MANAGEMENT PREVENTIONSTANDARD OPERATING PROCEDURES OPERATION OF SCREW COMPRESSORS
Emergency shutdown
procedures
1. Shut off the compressor by pushing the
RED/Stop button on the compressor
microprocessor control panel or at the panelview. If
the button cannot be reached, use the Emergency
Stop button located at the south, and the east
entrance to the compressor room as well as thenorth entrance to the icemaker room.
Use these procedures if there are leaks
on the compressor skid or if there is any
mechanical damage to the compressor.
2. Follow the lockout/tag-out procedures
described in the lockout / tag-out manual to lockout
the appropriate disconnects and valves as
necessary.
3. Close and tag the isolation valve C-02 located
in the compressor suction line
4. Close and tag the isolation valve C-14 located
in the compressor discharge line.
5. Close and tag the isolation valves C-01 & C-
03 located in the compressor thermosyphon line if
appropriate.6. Close and tag the isolation valve C-11 on the
side port connection.
REDDY ICE DALLAS Page SOP 3.1-10 Original Date: January 2002Revision Date: ___________
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REDDY ICE/ PACKAGED ICE, INC.PROCESS SAFETY MANAGEMENT/ RISK MANAGEMENT PREVENTIONSTANDARD OPERATING PROCEDURES OPERATION OF SCREW COMPRESSORS
Task Step Comment
Changing
Compressor Oil
1. Shut down the unit when changing oil. Follow all lockout
tagout procedures. At the same time all oil filters cartridges must be
changed and oil strainers elements removed and cleaned.
Continue the following procedure is as follows.
Refer to Frick owners manual
for full details and associated
procedures.
2. Press he STOP key on the microprocessor panel to the
compressor unit.
3. Open the disconnect switch for the compressor motor starter
and install safety lockout tag.
4. Close the suction and discharge service valves. Also close the
liquid injection and economizer service valves where applicable.
5. Slowly vent separator to low-side pressure using the bypass
line on the suction trap. Transfer all ammonia vapor to available
auxiliary suction on air purge unit or other operating unit suction.
Use water jet pump to evacuate any residual ammonia vapor. (See
Sop 11 for proper use of water jet)
6. Use drain valves located on the underside of separator to
drain oil.
Contain all oil, don't allow any
oil to escape to any floordrains.
7. Remove the old filter cartridges, then install new ones.
8. Remove, clean, examine, and reinstall strainer elements.
9. Evacuate the unit to 28 inches of Hg vacuum using
refrigeration type vacuum pump to remove air.
10. Open the suction service valve, pressurize the unit with
suction pressure only and check for leaks.
11. Add oil by attaching a hose suitable for ammonia oil transfer
to the oil-charging valve located on top of the separator. Using a
pressure type oil pump and approved ammonia refrigeration grade
oil, fill the separator until the oil level is midway in the top sight
glass.
12. Open the suction and discharge service valves and the liquid
injection and economizer service valves, if applicable.
13. Close the disconnect switch for the compressor motor starter
and remove lock out tags.
14. Start the unit and monitor unit to verify normal operation.
REDDY ICE DALLAS Page SOP 3.1-11 Original Date: January 2002Revision Date: ___________
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REDDY ICE/ PACKAGED ICE, INC.PROCESS SAFETY MANAGEMENT/ RISK MANAGEMENT PREVENTIONSTANDARD OPERATING PROCEDURES OPERATION OF SCREW COMPRESSORS
Task Step Comment
Coalescer Filter Elements When changing the coalescer filter elements, Frick
recommends that the oil be changed, cartridges in the
filters be changed and the applicable strainers elements
be removed and cleaned.
Refer to Frick owners manual
for full details and associated
procedures.
Follow all safety procedures for electrical lock out and
tag out.
When opening vessel, follow all confined space access
safety rules set out in the Reddy Ice Safety Manual and
the Frick Owners Manual.
At least 2 persons must be
present when reaching into
manway.
1. Refer to Oil change procedure for oil change steps
1 through 8.
2. Loosen manway cover and cover gasket. Discard
cover gasket.
3. Remove retain nut securing coalescer filter
retainer.
4. Remove retainer, coalescer filter element and two
(2) o-rings. Discard filter elements.
5. Install new coalescer filter elements. CAUTION -
Seat elements in center of locating tabs on the
separator bulkhead.
6. Replace coalescer filter retainer and nut. Do nut
over tighten nut.
7. Install a new manway gasket and replace manway
cover.
8. Tighten manway bolts. NOTE: When the
compressor unit is re-pressurized, re-tighten bolts,
since manway bolts will loosen.
9. Refer to oil changing steps 9 though 14.
REDDY ICE DALLAS Page SOP 3.1-12 Original Date: January 2002Revision Date: ___________
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REDDY ICE/ PACKAGED ICE, INC.PROCESS SAFETY MANAGEMENT/ RISK MANAGEMENT PREVENTIONSTANDARD OPERATING PROCEDURES OPERATION OF SCREW COMPRESSORS
Task Step Comment
Changing Main Oil
Filters (Single/Dual)
Follow all lockout safety procedures when changing oil
filters.
Refer to Frick owners manual
for full details and associated
procedures.
1. If a single oil filter is installed push the Stop key on the
microprocessor panel to shutdown the unit.
2. Open the motor starters disconnect switches for both
the compressor and the oil pump.
3. Close the outlet and then inlet service valves for filter
being serviced.
4. Connect a hose that is approved for ammonia service
work to the bleed valve and purge pressure from the oil filter
cartridge in to a auxiliary suction on the purger suction line
or connect a water jet pump (follow SOP 11) for proper use.
5. Open the drain valve or remove drain plug and drain oil
into a container.
6. Remove cover plate and gaskets, pull filter assembly
from canister. Discard cartridges.
7. Flush filter body with clean refrigeration oil and wipe dry
with a clean lint free cloth. Close drain valve or re-install
drain plug.
8. Place new cartridges in filter assembly, insert filter
assembly with new gasket, then fill with new refrigeration oil.
9. Close the purge valve.
10. Open the outlet service valve and check for leaks.
11. Open inlet service valve.
12. Remove lockout tags, close disconnects for
compressor and oil pump.
13. Put unit back in service and verify that compressor
functions normally.
14. Verify that floor is free from oil and discarding of oil
and filter cartridges is completed properly.
REDDY ICE DALLAS Page SOP 3.1-13 Original Date: January 2002Revision Date: ___________
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REDDY ICE/ PACKAGED ICE, INC.PROCESS SAFETY MANAGEMENT/ RISK MANAGEMENT PREVENTIONSTANDARD OPERATING PROCEDURES OPERATION OF SCREW COMPRESSORS
REDDY ICE DALLAS Page SOP 3.1-14 Original Date: January2002
Revision Date:___________