Microsoft Word - SOP - Hands-On Sessions
Rev. 2 -Final
Hands-On - Ammonia Charging
STANDARD OPERATING PROCEDURE
NAME:
Charging Ammonia System Procedure
SCOPE:
This procedure details the steps to be taken during the charging of an ammonia refrigeration system.
EQUIPMENT:
Affects all valve groups connected to ammonia refrigeration systems and all interconnected ammonia piping for the equipment.
OPERATOR REQUIREMENTS:
A minimum of two (2) trained refrigeration technicians are required to perform this procedure. The training can be from on-the-job experience and classroom instruction.
PPE required:
tools/equipment required:
have within reach: full face respirator equipped with NH 3 cartridges
lock-out/tag-out equipment pipe wrenches
Teflon® tape & paste water source nearby sulfur stick ammonia monitor
Wear: chemical resistant gloves
goggles & face shield or respirator to be used whenever opening any part of the system. long-sleeve and total skin coverage attire (coveralls). radio
ventilation fan upwind if an immediate health hazard exists within 100’ of the filling operation.
Procedure: Ammonia Charging Reviewed: 10/26/2023
Page 1 of 4
Rev. 2 -Final
SPECIAL SAFETY and HEALTH CONSIDERATIONS:
Anhydrous ammonia liquid quickly vaporizes once exposed to normal atmospheric temperature and pressure. When first released while pressurized, the ammonia will begin to boil off at a temperature of -28 º F causing a dense fog to form which will stay low until the ammonia heats up. Once heated, ammonia is lighter than air at most atmospheric conditions. Rain and high moisture can combine with ammonia making it heavier and causing it to stay lower to the ground. It is highly corrosive to skin and can cause irreversible damage to eyes. Initial contact with ammonia and eyes will cause excessive watering of the eyes to the point of being blinding. Avoid inhalation, skin contact, eye contact, and ingestion. Remove from exposure, if inhaled. Flush skin or eyes with water for at least 15 minutes. Do not induce vomiting if ingested; call a poison center. In all cases, medical aid should be sought. Associates who work with ammonia must not have any physical limitations that interfere with the use of full face respirators. Contact lenses should not be worn by those working with ammonia. Ammonia may ignite in confined areas and can react violently with strong acids. Flames should be extinguished and vapors controlled with a water fog or spray. Do not put water on liquid ammonia, this will cause violent boiling. Additional information on ammonia can be found in the Safety Data Sheets (SDS) for anhydrous ammonia - NH 3
Follow Pre-Emergency Readiness Considerations:
Lockout/tag out and test or confined space policy may be needed for this procedure. This procedure requires a minimum of two trained personnel. Head pressure may have to be lowered to allow supplier to pump against it while supplying the ammonia
Make sure that ammonia sensors, relief valves, compressor cutouts, and high level controls are serviced, calibrated and ready for service.
Operating Limits : 3 in Hg to 195 psig Consequences of Deviation : 3 in Hg = compressor suction pressure cutout; 195 psig = compressor discharge pressure cutout and relief valves release at 150 psig (low side) and 250 psig (high side) Actions to Correct Deviation : 3 in Hg = unload/shut down compressor; 195 psig = shuts down compressors.
Procedure: Ammonia Charging Reviewed: 10/26/2023
Page 2 of 4
Rev. 2 -Final
Ammonia Charging
PART A:
STEP NUMBER
SAFETY AND HEALTH HAZARDS/ STEPS TO AVOID DEVIATION Line breaks must only be performed by authorized and trained refrigeration technicians.
DESCRIPTION
1
Ensure that appropriate PPE is worn at all times and a full-face respirator equipped with NH 3 cartridges is always within reach when working with ammonia. Notify/brief and obtain sign off of the Facility Emergency Coordinator or Supervisor before initiating the system charging. When the delivery truck arrives, position the truck near system, turn the truck off and chock the wheels. Setup an area which limits access to only those persons involved in the delivery. The driver and the facility person should check paperwork to make sure the amount from the shipper and the amount ordered are the same? Also, check and verify grade of the ammonia on the truck. Check the ammonia hose line on the ammonia delivery truck to make sure the green-lined hose is stamped with an expiration date or there is a test date tag. Also, check the condition of hose (no cuts). Make sure the driver has an automatic pump supply shut-off system. Locate the emergency control valves and review the shutdown procedure. This is a remove sending unit but still may have a lanyard and manual valve. Don safety equipment (gloves, goggles or face shield or APR, radio, ammonia monitor). Secure storm drainage system to prevent threat of contamination from a potential accidental release. A qualified service technician or construction personnel can now work on the system. Locate nearest safety shower, eye wash stations and emergency exits.
2
Obtain plant SOPs, line break permits, safety meeting documentation.
3
Test operation of eyewash stations.
4
Before actual line breaking occurs, cordon off work area from any traffic if necessary.
5
6
Get a copy of the delivery drivers hose inspection log.
7
8
9
and tagout.
10
Procedure: Ammonia Charging Reviewed: 10/26/2023
Page 3 of 4
Rev. 2 -Final
9
Identify the potential hot zone pattern of minimum 100’ to a maximum 500’ around the delivery hose and connections points. Locate valve which will be used to transfer the ammonia from the delivery truck to the system. The operator should verify there is enough room for the ammonia inventory that is to be charged into the system, to do this may require the transfer of ammonia from vessel to vessel. Remove the cap or plug from the valve and install proper delivery connections. Reel out enough delivery hose to reach the charging connection and hook it up. Position the refrigeration operator in the machine room near the fill location and position the delivery truck operator at the truck delivery valve. The charging process must be within sight and must be supervised/monitored at all times. The driver and responsible refrigeration person must be present during delivery. Open the delivery hose valve slowly and check for leaks (if there are no leaks go to next step). Open the system charging valve slowly at the hose connection. If there are no leaks, start the delivery process. Monitor the system until the delivery process is complete. Bleed the liquid ammonia between the delivery hose valve and system valve to an approved container. Disconnect the delivery hose and rewind it. Remove the charging connection and replace the plug or cap. Sign the shipper with the ammonia of ammonia delivered. Record the amount of ammonia received- update the Hazmat Inventory Statement. Close the delivery hose valve.
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
Procedure: Ammonia Charging Reviewed: 10/26/2023
Page 4 of 4
Rev. 1 - Final
Hands-On - Purity Test
STANDARD OPERATING PROCEDURE
NAME:
Testing R717 (Anhydrous Ammonia) for water content
SCOPE:
The refrigeration grade anhydrous ammonia specification for water content is a maximum of 100 ppm. This procedure details the steps to be taken during the opening (line break) of any valve for taking a sample of anhydrous ammonia which may need to be performed on an ammonia refrigeration system to test for water content. Could affect any valve connected to the ammonia refrigeration system that can be opened to atmosphere. It is typical for water contamination to involve the low-pressure side of the refrigeration system. A minimum of two (2) trained refrigeration technician is required to perform this procedure. The training can be from on-the-job experience and classroom instruction. It is recommended for two (2) people be present during extraction of a sample.
EQUIPMENT:
OPERATOR REQUIREMENTS:
PPE Minimum requirement:
Tools/Equipment required:
Have within reach: Full-face respirator equipped with NH 3 cartridges
sampling flask with vented cap hose or stinger water bath container pipe wrenches Teflon® tape & paste water source nearby clear path to shower/eye wash ammonia monitor industrial fan/room ventilation
Wear: neoprene or nitrile gloves
goggles & face shield or respirator to be used whenever opening any part of the system.
Procedure : Testing R717 (Anhydrous Ammonia) for water content Reviewed: 10/26/2023
Page 1 of 4
Rev. 1 - Final
SPECIAL SAFETY and HEALTH CONSIDERATIONS:
Anhydrous ammonia liquid quickly vaporizes once exposed to normal atmospheric temperature and pressure. When first released while pressurized, the ammonia will begin to boil off at a temperature of -28 º F causing a dense fog to form which will stay low until the ammonia heats up. Once heated, ammonia is lighter than air at most atmospheric conditions. Rain and high moisture can combine with ammonia making it heavier and causing it to stay lower to the ground. It is highly corrosive to skin and can cause irreversible damage to eyes. Initial contact with ammonia and eyes will cause excessive watering of the eyes to the point of being blinding. Avoid inhalation, skin contact, eye contact, and ingestion. Remove from exposure, if inhaled. Flush skin or eyes with water for at least 15 minutes. Do not induce vomiting if ingested; call a poison center. In all cases, medical aid should be sought. Associates who work with ammonia must not have any physical limitations that interfere with the use of full face respirators. Contact lenses should not be worn by those working with ammonia. Ammonia may ignite in confined areas and can react violently with strong acids. Flames should be extinguished and vapors controlled with a water fog or spray. Do not put water on liquid ammonia, this will cause violent boiling. Additional information on ammonia can be found in the Safety Data Sheets (SDS) for anhydrous ammonia - NH 3
Procedure : Testing R717 (Anhydrous Ammonia) for water content Reviewed: 10/26/2023
Page 2 of 4
Rev. 1 - Final
LINE BREAKING FOR 100ml SAMPLE
PART A:
STEP NUMBER
SAFETY AND HEALTH HAZARDS/ STEPS TO AVOID DEVIATION Live line sampling must only be performed by authorized and trained refrigeration technicians.
DESCRIPTION
1
Ensure personal protective equipment is worn at all times and a full-face respirator equipped with NH 3 cartridges is always within reach or worn when pulling the ammonia sample. Determine locations for sampling and choose the most relevant valves. Develop a sampling procedure which may need to be approved by your EH&S manager. that appropriate
2
A representative sample which needs to be tested for water content is the ammonia located on the low side of the system that interacts with the coil or heat exchanger. (Worst place to take a sample is an oil pot this ammonia will not be representative of what is in your coil or heat exchanger) Test the function of eyewash stations for proper operation.
3
Locate nearest safety shower, eye wash stations and emergency exits.
4
Follow your site sampling procedure carefully in order to obtain a representative 100 ml sample of NH 3 from the system. Then verify that all valves have been closed. (see steps 5-14 for basic order of sampling) First connect a sampling stinger or transfer hose to the service valve which will give you the best representative liquid sample. Make sure to inform fellow employees that there will be a pungent ammonia smell in your vicinity temporarily.
Before actual line breaking occurs, cordon off work area from any traffic if necessary.
5
Low-side vessels, associated pumps and piping is the best place to sample. Extra precautions can be taken such as the installation of spring closing valves. If your sampling location is indoors consider putting the ammonia alarm sensors in test mode and inform the proper authorities for your facility. Use an industrial fan or the engine room ventilation so the atmosphere is not stagnant where ammonia can concentrate. Initial liquid flow will flash as it expands, cools the sampling flask and hose or stinger. Once the tube cools then the liquid will start to collect. Note: When using a hose, you will need assistance, or a test tube holder as you operate the service valve and hold the hose or test tube under the stinger. If the ammonia is just left in the flask open to atmosphere it can attract moisture especially in humid climates and give a false reading. Cap the flask with a vented cap and boil off the ammonia. Make sure the vented cap is pointed away from you. Slowly introduce the flask to the water bath, if done too rapidly the ammonia can boil fast enough to blow the vented cap off and or shoot vapor and droplets out the vent.
6
7
Put on the proper PPE then use the stinger or hose to fill the 100 ml evaporation test tube.
8
Once the flask has reached the 100 ml mark, the service valve can be secured and the sample is ready for evaporation.
9
Use a water bath as the heat source for vaporizing the ammonia sample.
Procedure : Testing R717 (Anhydrous Ammonia) for water content Reviewed: 10/26/2023
Page 3 of 4
Rev. 1 - Final
STEP NUMBER
SAFETY AND HEALTH HAZARDS/ STEPS TO AVOID DEVIATION
DESCRIPTION
10
The boil off will take approximately 15 to 20 minutes using a water bath depending on the water temperature. If the flask is left in the air for boil off it could take up to an hour of course temperature dependant.
The water bath will become colder and colder so changing out the water will keep the vaporization more consistent rather than slowing as the water approaches freezing. Ice will form on the outside of the test tube and look like the tube is cracking but this is typically not the case.
11
As the flask contents either approach dryness or stops boiling a bare hand rubbing the flask measuring nipple for extra heat will drive off any remaining ammonia in the sample. The flask measuring nipple will then have your reading which typically reads between 0 and .5 which equates to 100 to 99.5% purity. If the level is above the nipple pour into a measuring cylinder for an accurate accounting. Remove the sampling stinger or hose from the service valve.
Do not sniff or drink.
12
14
Check for leaks and re-tighten all valves, plugs or caps.
Procedure : Testing R717 (Anhydrous Ammonia) for water content Reviewed: 10/26/2023
Page 4 of 4
Rev. 2 - Final
Hands-On - Liquid Line Break
STANDARD OPERATING PROCEDURE
NAME:
Line Breaking
SCOPE:
This procedure details the steps to be taken during the opening (line break) of any valve group or piping for service or maintenance which may need to be performed on an ammonia refrigeration system.
EQUIPMENT:
Affects all valve groups connected to ammonia refrigeration systems and all interconnected ammonia piping for the equipment.
OPERATOR REQUIREMENTS:
A minimum of one (1) trained refrigeration technician is required to perform this procedure. The training can be from on-the-job experience and classroom instruction.
PPE required:
tools/equipment required:
have within reach: full-face respirator equipped with NH 3 cartridges
lockout/tagout equipment pipe wrenches Teflon® tape & paste water source nearby sulfur stick ammonia monitor
Wear: chemical Resistant gloves
goggles & face shield or respirator to be used whenever opening any part of the system.
SPECIAL SAFETY and HEALTH CONSIDERATIONS:
Anhydrous ammonia liquid quickly vaporizes once exposed to normal atmospheric temperature and pressure. When first released while pressurized, the ammonia will begin to boil off at a temperature of -28 º F causing a dense fog to form which will stay low until the ammonia heats up. Once heated, ammonia is lighter than air at most atmospheric conditions. Rain and high moisture can combine with ammonia making it heavier and causing it to stay lower to the ground. It is highly corrosive to skin and can cause irreversible damage to eyes. Initial contact with ammonia and eyes will cause excessive watering of the eyes to the point of being blinding. Avoid inhalation, skin contact, eye contact, and ingestion. Remove from exposure, if inhaled. Flush skin or eyes with water for at least 15 minutes. Do not induce vomiting if ingested; call a poison center. In all cases, medical aid should be sought. Associates who work with ammonia must not have any physical limitations that interfere with the use of full face respirators. Contact lenses should not be worn by those working with ammonia. Ammonia may ignite in confined areas and can react violently with strong acids. Flames should be extinguished and vapors controlled with a water fog or spray. Do not put water on liquid ammonia, this will cause violent boiling. Additional information on ammonia can be found in the Safety Data Sheets (SDS) for anhydrous ammonia - NH 3
Procedure: Line Breaking Reviewed: 10/26/2023
Page 1 of 3
Rev. 2 - Final
LINE BREAKING
PART A:
STEP NUMBER
SAFETY AND HEALTH HAZARDS/ STEPS TO AVOID DEVIATION
DESCRIPTION
1
Ensure that PPE is worn at all times and a full-face respirator equipped with NH 3 cartridges is always within reach when working with ammonia. Verify water source is nearby and operational. Determine isolation valve locations and develop a pumpdown procedure which may need to be approved by the service project manager, depending on project size or equipment that is being pumped out. Inform all affected personnel of intentions to perform a pump out and verify your supervisor is aware of your intentions. Follow pumpout procedure carefully in order to isolate the desired piping, valves or equipment from the system. Then re-walk the isolated section to verify that all valves have been closed and there are no other valves requiring attention. (see steps 5-9 for basic order of pumpout) First, stop liquid flow and then remove all liquid ammonia from piping or equipment according to pumpdown procedure. Drop pressure as much as possible and then close suction (or downstream) isolation valves. Connect an ammonia rated transfer hose to service valve on isolated piping or equipment and blow down remaining pressure into a bucket of water or through a Jetpump. Remove hose from water source as soon as pressure has dropped to 0 psig to prevent water from being pulled into the system by a vacuum or ammonia vapors. Monitor open service valve for 15 minutes to verify that all valves are holding and there is no pressure coming from the valve. If there is no pressure rise, work may begin on the cleared portion of the system.
Line breaks must only be performed by authorized and trained refrigeration technicians.
2
3
Informing others that may be affected will reduce the chance of false leak reports and lets others know where you are while working by yourself. Before actual line breaking occurs, cordon off work area from any traffic if necessary.
4
5
Water may be applied to help boil out remaining liquid.
6
May lower compressor setpoints or purge pressure into other parts of the system.
7
Depending on volume of vapor to be blown down.
8
Condensing vapors can cause a vacuum to form.
9
If pressure is still present, repeat valve isolation tasks to assure tightness of the valves and repeat the pump out. Leave service valve open to atmosphere to prevent pressure from building up and tagout.
Procedure: Line Breaking Reviewed: 10/26/2023
Page 2 of 3
Rev. 2 - Final
PART B:
START UP AFTER LINE BREAK
STEP NUMBER
SAFETY AND HEALTH HAZARDS/ STEPS TO AVOID DEVIATION
DESCRIPTION
1
Close the service valve and reinstall the plug.
2
Evacuate piping or equipment thoroughly with vacuum pump.
Air left in the system will add to head pressure causing an increase in head pressure and possible lifting of relief valves causing an ammonia release.
3
Watch for 10-15 minutes for a rise in the pressure which would be indicative of a leak. Repair any leaks and once tight, proceed to Step 4. Slowly open isolation valve/s downstream of line break to pressurize the piping or equipment with vapor and then leak check all repairs. When certain there are no leaks, return all control valves to their normal operating positions.
4
If possible, leak check at 5-10 psig first and then again at full system pressure.
5
6.
Slowly open isolation valve/s upstream of line break.
Verify that all tags have been marked from the tagout log.
7.
Place equipment back into operation and then monitor closely to verify proper operation with correct operating pressures and temperatures.
Re-check for leaks and re-tighten all flange bolts after they cool down.
Procedure: Line Breaking Reviewed: 10/26/2023
Page 3 of 3
Rev. 2 - Final
Hands-On - Liquid Line Break
STANDARD OPERATING PROCEDURE
NAME:
Line Breaking
SCOPE:
This procedure details the steps to be taken during the opening (line break) of any valve group or piping for service or maintenance which may need to be performed on an ammonia refrigeration system.
EQUIPMENT:
Affects all valve groups connected to ammonia refrigeration systems and all interconnected ammonia piping for the equipment.
OPERATOR REQUIREMENTS:
A minimum of one (1) trained refrigeration technician is required to perform this procedure. The training can be from on-the-job experience and classroom instruction.
PPE required:
tools/equipment required:
have within reach: full-face respirator equipped with NH 3 cartridges
lockout/tagout equipment pipe wrenches Teflon® tape & paste water source nearby sulfur stick ammonia monitor
Wear: chemical Resistant gloves
goggles & face shield or respirator to be used whenever opening any part of the system.
SPECIAL SAFETY and HEALTH CONSIDERATIONS:
Anhydrous ammonia liquid quickly vaporizes once exposed to normal atmospheric temperature and pressure. When first released while pressurized, the ammonia will begin to boil off at a temperature of -28 º F causing a dense fog to form which will stay low until the ammonia heats up. Once heated, ammonia is lighter than air at most atmospheric conditions. Rain and high moisture can combine with ammonia making it heavier and causing it to stay lower to the ground. It is highly corrosive to skin and can cause irreversible damage to eyes. Initial contact with ammonia and eyes will cause excessive watering of the eyes to the point of being blinding. Avoid inhalation, skin contact, eye contact, and ingestion. Remove from exposure, if inhaled. Flush skin or eyes with water for at least 15 minutes. Do not induce vomiting if ingested; call a poison center. In all cases, medical aid should be sought. Associates who work with ammonia must not have any physical limitations that interfere with the use of full face respirators. Contact lenses should not be worn by those working with ammonia. Ammonia may ignite in confined areas and can react violently with strong acids. Flames should be extinguished and vapors controlled with a water fog or spray. Do not put water on liquid ammonia, this will cause violent boiling. Additional information on ammonia can be found in the Safety Data Sheets (SDS) for anhydrous ammonia - NH 3
Procedure: Line Breaking Reviewed: 10/26/2023
Page 1 of 3
Rev. 2 - Final
LINE BREAKING
PART A:
STEP NUMBER
SAFETY AND HEALTH HAZARDS/ STEPS TO AVOID DEVIATION
DESCRIPTION
1
Ensure that PPE is worn at all times and a full-face respirator equipped with NH 3 cartridges is always within reach when working with ammonia. Verify water source is nearby and operational. Determine isolation valve locations and develop a pumpdown procedure which may need to be approved by the service project manager, depending on project size or equipment that is being pumped out. Inform all affected personnel of intentions to perform a pump out and verify your supervisor is aware of your intentions. Follow pumpout procedure carefully in order to isolate the desired piping, valves or equipment from the system. Then re-walk the isolated section to verify that all valves have been closed and there are no other valves requiring attention. (see steps 5-9 for basic order of pumpout) First, stop liquid flow and then remove all liquid ammonia from piping or equipment according to pumpdown procedure. Drop pressure as much as possible and then close suction (or downstream) isolation valves. Connect an ammonia rated transfer hose to service valve on isolated piping or equipment and blow down remaining pressure into a bucket of water or through a Jetpump. Remove hose from water source as soon as pressure has dropped to 0 psig to prevent water from being pulled into the system by a vacuum or ammonia vapors. Monitor open service valve for 15 minutes to verify that all valves are holding and there is no pressure coming from the valve. If there is no pressure rise, work may begin on the cleared portion of the system.
Line breaks must only be performed by authorized and trained refrigeration technicians.
2
3
Informing others that may be affected will reduce the chance of false leak reports and lets others know where you are while working by yourself. Before actual line breaking occurs, cordon off work area from any traffic if necessary.
4
5
Water may be applied to help boil out remaining liquid.
6
May lower compressor setpoints or purge pressure into other parts of the system.
7
Depending on volume of vapor to be blown down.
8
Condensing vapors can cause a vacuum to form.
9
If pressure is still present, repeat valve isolation tasks to assure tightness of the valves and repeat the pump out. Leave service valve open to atmosphere to prevent pressure from building up and tagout.
Procedure: Line Breaking Reviewed: 10/26/2023
Page 2 of 3
Rev. 2 - Final
PART B:
START UP AFTER LINE BREAK
STEP NUMBER
SAFETY AND HEALTH HAZARDS/ STEPS TO AVOID DEVIATION
DESCRIPTION
1
Close the service valve and reinstall the plug.
2
Evacuate piping or equipment thoroughly with vacuum pump.
Air left in the system will add to head pressure causing an increase in head pressure and possible lifting of relief valves causing an ammonia release.
3
Watch for 10-15 minutes for a rise in the pressure which would be indicative of a leak. Repair any leaks and once tight, proceed to Step 4. Slowly open isolation valve/s downstream of line break to pressurize the piping or equipment with vapor and then leak check all repairs. When certain there are no leaks, return all control valves to their normal operating positions.
4
If possible, leak check at 5-10 psig first and then again at full system pressure.
5
6.
Slowly open isolation valve/s upstream of line break.
Verify that all tags have been marked from the tagout log.
7.
Place equipment back into operation and then monitor closely to verify proper operation with correct operating pressures and temperatures.
Re-check for leaks and re-tighten all flange bolts after they cool down.
Procedure: Line Breaking Reviewed: 10/26/2023
Page 3 of 3
Hands-On - Oil Draining
P-015
Maintenance Procedure Non-Standard Oil Draining
Page 1 of 20
User: Refrigeration Operators, Approved Contractors Authorized for use by:
Date:
This procedure is to be used to prepare for and perform draining oil from non-standard locations within the Ammonia Refrigeration System. OBJECTIVE: Maintenance Procedures are designed to give general guidance when performing maintenance activities. No procedure is appropriate for every situation. Maintenance Personnel should not attempt any procedure which is beyond their training. CONCERNS: Careful attention to Operating Conditions and valve positions are extremely important during this procedure. The primary incidents we are trying to prevent are injury to personnel. Additionally, our goal is to avoid the hazards associated with hydrostatic lock. REFERENCES: Additional information is available to personnel performing opening procedures. This information is not required to be reviewed, nor is it required to be onsite. However, those employees wishing further information may seek these sources out. International Institute of Ammonia Refrigeration (IIAR) Recommended Oil Draining Guidelines (poster) . International Institute of Ammonia Refrigeration (IIAR) Removing Oil from an Ammonia Refrigeration System (video). Anhydrous Ammonia SDS EQUIPMENT / MATERIALS REQUIRED: Personal Protective Equipment (PPE) appropriate for mechanical repair per the Personal Protective Equipment Policy. Recommended items are: ◦ Standard Mechanics tools ◦ Ammonia Detector(s) Portable and / or Stationary ◦ Refrigeration Wrench ◦ Ammonia Refrigeration Equipment Standard Operating Procedures ◦ Fittings and valves as need for the job. ◦ Oil drain bucket ◦ 2 x pipe wrench’s (adequately sized) ◦ Pipe dope (rated for Ammonia) ◦ ¾” Ammonia rated hose (as short as practical) ◦ *Do not use malleable iron fittings (MI)
Revision 1, November 1, 2023
This Copy Printed: November 1, 2023
MP-015 Non-Standard Oil Draining.doc Last Reviewed: October 30, 2023
P-015
Maintenance Procedure Non-Standard Oil Draining
Page 2 of 20
Operation
Previously)
3.d. Returning Alternate Configurations Not Listed Previously to Normal
2.d. Oil Draining Alternate Configurations (Not Listed
3.c. Returning a
2.c. Oil Draining
Configuration “ C” to Normal Operation
Configuration “ C”
TASK FLOW DIAGRAM
1. Preparing for Non-Standard Oil Draining 2.b. Oil Draining
3.b. Returning a
Configuration “ B” to Normal Operation
Configuration “ B”
4. Concluding Non-Standard Oil Draining Procedure
3.a. Returning a
2.a. Oil Draining
Configuration “ A” to Normal Operation
Configuration “ A”
Revision 1, November 1, 2023
This Copy Printed: November 1, 2023
MP-015 Non-Standard Oil Draining.doc Last Reviewed: October 30, 2023
P-015
Maintenance Procedure Non-Standard Oil Draining
Page 3 of 20
1. Preparing for Non-Standard Oil Draining STEP/ACTION 1. Ensure a Maintenance Work Order has been prepared and authorized. If you are a visiting Refrigeration Service Technician, ask your facility contact for all forms and authorization needed for the scope of your work. 2. From time to time, it may become necessary to drain oil at a location that is not a normal drain (non-standard). Since the nature and complexity of such a procedure is totally unique to the program or plan at the time, it is not possible to anticipate every possible potential location; therefore, it is not possible to provide complete step by step instructions for such a procedure, in advance. 3. If the oil drain is in preparation for a change requiring a Management of Change procedure, prepare a Management of Change Form including complete Engineering Design Review for any change and a preliminary Safety and Health Review or Process Hazard Analysis as required. 4. Verify the delivery of materials necessary for the work. (Fittings, valves, etc.).
COMMENT
Work orders are required for all maintenance activities. Consult your supervisor or facility contact if you have questions.
See the “Management of Change Policy”, located in the PSM/RMP Program.
The materials must conform to the design standards. See the Appendix 9B “Ammonia System Design Specifications” located in the PSM/RMP Program. NOTE: The operation of motorized lift trucks requires specialized training. Work performed on the Ammonia Refrigeration System must be performed by trained ammonia refrigeration operators or Ammonia Refrigeration Technicians. See the “Contractor Qualification Program”, located in the PSM/RMP Program. NOTE: Make sure welding done on the Refrigeration System is done only by welders certified for the work to be accomplished.
5. Verify the training and certification, if applicable, of the Operators that will be utilizing the equipment and working on the system.
6. Verify the qualifications of the contractors and individual contract employees that will be working on the system.
Revision 1, November 1, 2023
This Copy Printed: November 1, 2023
MP-015 Non-Standard Oil Draining.doc Last Reviewed: October 30, 2023
P-015
Maintenance Procedure Non-Standard Oil Draining
Page 4 of 20
1. Preparing for Non-Standard Oil Draining STEP/ACTION 7. Instruct the appropriate individuals on the Safe Work Practices, Operation and Maintenance manuals of the equipment to be used, and with the detailed isolation procedure developed in the Refrigeration System Standard Operating Procedures. 8. Review Emergency Procedures including notification and Evacuation Procedures. 9. Notify all affected departments and personnel about the operation to be performed including Plant Personnel, Contractors and Visitors. 10. Familiarize all members of the team opening the system with eyewash and safety shower locations. 11. Verify that all safety equipment and Personal Protective Equipment which may be required, is available and functional. 12. If appropriate, isolate the component utilizing “Shutdown <
COMMENT
If outside Contractors are being utilized, ensure they are aware of the Safe Work policies, Operation and Maintenance manuals of the equipment to be used.
Refer to the Facility Emergency Action Plan located in the PSM/RMP Program. Plant Personnel, Contractors and Visitors should be trained on the dangers associated with ammonia, including early exposure detection techniques.
See the Personal Protective Equipment Program.
See the Volume 4 Index for a complete listing of facility Standard Operating Procedures. If services of outside contractors are to be utilized, all contractor operations are to be supervised by our personnel per the “Contractor Qualification Program”. NOTE: When performing this procedure, the prevention of hydrostatic lock is of extreme importance. The Technician in charge of this procedure must field verify piping to assure shutdown will not create safety or operational issues.
Diagram
Actual Valve Number
Valve “A” Valve “B”
Revision 1, November 1, 2023
This Copy Printed: November 1, 2023
MP-015 Non-Standard Oil Draining.doc Last Reviewed: October 30, 2023
P-015
Maintenance Procedure Non-Standard Oil Draining
Page 5 of 20
1. Preparing for Non-Standard Oil Draining STEP/ACTION 14. After reviewing the figures in the task flow diagram, proceed with the proper oil drain procedure. Go to “2.a. Oil Draining Configuration “A”, ”2.b. Oil Draining Configuration “B”, “2.c. Oil Draining Configuration “C”, or “2.d. Oil Draining Alternate Configurations Not Listed Previously” as appropriate.
COMMENT
See Task #2.a., 2.b, 2.c, or 2.d. of this Maintenance Procedure as appropriate. See the Plant Engineer if you have questions.
2.a. Oil Draining Configuration “A”
STEP/ACTION
COMMENT
1. Confirm that Task #1 “Preparing for Non Standard Oil Draining” has been completed. If not completed, do so now before continuing with this maintenance procedure.
NOTE: If the possibility exists that the conditions may have been altered after preparation of the plan, you must repeat task #1 “Preparing for Non-Standard Oil Draining” procedure. See the associated Standard Operating Procedure or Lockout / Tagout Program for details. Refer to the PPE Assessment for Mechanical Repair for a list of appropriate PPE.
2. Verify the isolation of other forms of energy to the valves being worked on.
3. Don Personal Protective Equipment.
4. Confirm equipment power source is off, locked and tagged. 5. Confirm valve “A” is closed. 6. Carefully remove the plug from valve “A”. 7. Install a ¾” nipple into the outlet of valve “A”.
It may be necessary to use a bushing or reducer. NOTE: It may be beneficial to leave this valve installed at the end of this procedure. A Management of Change Procedure will be required.
8. Install a vented self-closing (spring return) valve “B” in the outlet of valve “A”.
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Maintenance Procedure Non-Standard Oil Draining
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2.a. Oil Draining Configuration “A”
STEP/ACTION
COMMENT
9. Install a ¾” nipple, 90 deg elbow and additional nipple into the outlet of valve “B”. 10. Place the oil recovery container below the outlet of valve “B”. 11. Throttle Valve “A” open ¼ turn.
NOTE: The use of any device which bypasses the automatic closing feature of valve “B” is a violation of company policy and grounds for dismissal. CAUTION: Opening valve “A” too fast or too far can cause splatter of ammonia and oil mixture from oil recovery container. NOTE: When the flow of oil stops, then continue.
12. Open and hold open valve “B”.
13. When finished draining oil, close valve “A”. 14. Allow valve “B” to close.
Continue immediately, delays may lead to hydrostatic damage.
15. Slowly reopen valve “B” to relieve any pressure buildup, then allow valve “B” to close. 16. Remove the oil recovery container.
Oil containing Ammonia, drained from an Ammonia Refrigeration System may be considered hazardous. The disposal of refrigeration oil is strictly regulated. Waste oil is left outside the Engine Room to gas off for 2-4 hours, then measured and the quantity recorded in the Master Maintenance Log. Then the oil can be disposed of properly. Please see the Maintenance Planner if you have questions concerning proper disposal.
17. Document amount of oil drained in log.
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Maintenance Procedure Non-Standard Oil Draining
Page 7 of 20
2.a. Oil Draining Configuration “A”
STEP/ACTION
COMMENT
18. Log oil draining of < equipment drained > into the Master Maintenance Log and Daily Rounds Log.
Log entries must contain the name of a person making the entry as well as the time, date, and pertinent details of the entry. Be specific!
19. If a Management of Change has been initiated to make the addition of valve “B” permanent, complete the pre-start-up safety review and proceed with Task #3.b. “Returning a Configuration “B” to Normal Operation.” 20. Go to Task #3.a. “Returning a Configuration “A” to Normal Operation.”
See Task #3.a. of this Maintenance Procedure.
2.b. Oil Draining Configuration “B”
STEP/ACTION
COMMENT
1. Confirm that Task #1 “Preparing for Non-Standard Oil Draining” has been completed. If not completed, do so now before continuing with this Maintenance Procedure.
NOTE: If the possibility exists that the conditions may have been altered after preparation of the plan, you must repeat the “Preparing for Non-Standard Oil Draining” procedure. See the associated Standard Operating Procedure or Lockout / Tagout Program for details. Refer to the PPE Assessment for Mechanical Repair for a list of appropriate PPE.
2. Verify the isolation of other forms of energy to the valves being worked on.
3. Don Personal Protective Equipment.
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This Copy Printed: November 1, 2023
MP-015 Non-Standard Oil Draining.doc Last Reviewed: October 30, 2023
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Maintenance Procedure Non-Standard Oil Draining
Page 8 of 20
2.b. Oil Draining Configuration “B”
STEP/ACTION
COMMENT
4. Confirm equipment power source is off, locked and tagged. 5. Confirm valve “A” is closed. 6. Confirm valve “B” is closed. 7. Carefully remove the plug from valve “B”. 8. Place the oil recovery container below the outlet of valve “B”. 9. Throttle Valve “A” open ¼ turn.
NOTE: The use of any device which bypasses the automatic closing feature of valve “B” is a violation of company policy and grounds for dismissal. CAUTION: Opening valve “A” too fast or too far can cause splatter of ammonia and oil mixture from oil recovery container. Note when the flow of oil stops then continue.
10. Open and hold open valve “B”.
11. When finished draining oil, close valve “A”. 12. Allow valve “B” to close.
Continue immediately, delays may lead to hydrostatic damage.
13. Slowly reopen valve “B” to relieve any pressure buildup, then allow valve “B” to close. 14. Remove the oil recovery container.
Oil containing Ammonia, drained from an Ammonia Refrigeration System may be considered hazardous. The disposal of refrigeration oil is strictly regulated.
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Maintenance Procedure Non-Standard Oil Draining
Page 9 of 20
2.b. Oil Draining Configuration “B”
STEP/ACTION
COMMENT
15. Document amount of oil drained in log.
Waste oil is left outside the engine room to gas off for 2-4 hours, then measured and the quantity recorded in the Master Maintenance Log. Then the oil can be disposed of properly. Please see your supervisor if you have questions concerning proper disposal. Log entries must contain the name of a person making the entry as well as the time, date, and pertinent details of the entry. Be specific! See Task #3.b. of this Maintenance Procedure.
16. Log oil draining of < equipment drained > into the Master Maintenance Log and Daily Rounds Log.
17. Go to Task #3.b. “Returning a Configuration “B” to Normal Operation.”
2.c. Oil draining Configuration “C”
STEP/ACTION
COMMENT
1. Confirm that Task 1 “Preparing for Non-Standard Oil Draining” has been completed. If not completed, do so now before continuing with this Maintenance Procedure.
NOTE: If the possibility exists that the conditions may have been altered after preparation of the plan, you must repeat the “Preparing for Non-Standard Oil Draining” procedure. CAUTION: This particular configuration is potentially hazardous. A Management of Change shall be initiated to add a positive shut-off valve prior to spring return oil drain valve.
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Maintenance Procedure Non-Standard Oil Draining
Page 10 of 20
2.c. Oil draining Configuration “C”
STEP/ACTION
COMMENT
2. Verify the isolation of other forms of energy to the valves being worked on.
See the associated standard operating procedure or Lockout / Tagout Program for details. Refer to the PPE Assessment for Mechanical Repair for a list of appropriate PPE.
3. Don Personal Protective Equipment.
4. Confirm equipment power source is off, locked and tagged. 5. Confirm valve “A” is closed. 6. Carefully remove the plug from valve “A”. 7. Place the oil recovery container below the outlet of valve “A”. 8. Slowly throttle valve “A” open.
NOTE: The use of any device which bypasses the automatic closing feature of valve “A” is a violation of company policy and grounds for dismissal. CAUTION: Opening valve “A” too fast or too far can cause splatter of ammonia and oil mixture from oil recovery container. Note when the flow of oil stops then continue.
9. When finished draining oil, close valve “A”. 10. Remove the oil recovery container.
Oil containing Ammonia, drained from an Ammonia Refrigeration System may be considered hazardous. The disposal of refrigeration oil is strictly regulated.
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This Copy Printed: November 1, 2023
MP-015 Non-Standard Oil Draining.doc Last Reviewed: October 30, 2023
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Maintenance Procedure Non-Standard Oil Draining
Page 11 of 20
2.c. Oil draining Configuration “C”
STEP/ACTION
COMMENT
11. Document amount of oil drained in log.
Waste oil is left outside the engine room to gas off for 2-4 hours, then measured and the quantity recorded in the Master Maintenance Log. Then the oil can be disposed of properly. Please see your supervisor if you have questions concerning proper disposal. Log entries must contain the name of a person making the entry as well as the time, date, and pertinent details of the entry. Be specific! See Task #3.c. “Returning a Configuration “C” to Normal Operation” of this Maintenance Procedure.
12. Log oil draining of < equipment drained > into the Maintenance Log and Daily Rounds Log.
13. Go to Task 3.c. “Returning a Configuration “C” to Normal Operation”.
2.d. Oil Draining Alternate Configurations Not Listed Previously
STEP/ACTION
COMMENT
1. Confirm that Task #1 “Preparing for Non-Standard Oil Draining” has been completed. If not completed, do so now before continuing with this Maintenance Procedure.
NOTE: If the possibility exists that the conditions may have been altered after preparation of the plan, you must repeat the “Preparing for Non-Standard Oil Draining” procedure.
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Maintenance Procedure Non-Standard Oil Draining
Page 12 of 20
2.d. Oil Draining Alternate Configurations Not Listed Previously
STEP/ACTION
COMMENT
2. Prepare a proper plan.
Prepare a detailed plan, including written alternate oil draining procedures. Items to include: valve numbers, Lockout / Tagout isolation points, order of isolation, etc. Identify and verify locations for purging / draining. Check the Manufacturer’s Operation and Maintenance Manuals for information or special instructions to be followed for isolation. If the services of outside contractors are to be utilized, all contractor’s operations are to be supervised by our personnel per the “Contractor Qualification Program”. NOTE: When performing this procedure, the prevention of hydrostatic lock is of extreme importance. The technician in charge of this procedure must field verify piping to assure shutdown will not create safety or operational issues See The Lockout / Tagout Program for details. Refer to the PPE Assessment for Mechanical Repair for a list of appropriate PPE.
3. Have the individuals isolating the piping field verify the isolation procedures and isolation points for affected piping or systems.
4. Verify the isolation of other forms of energy to the valves being worked on.
5. Don Personal Protective Equipment.
6. Close or confirm the drain valve identified in the isolation procedure is closed. 7. Carefully remove the plug from the drain valve identified in the isolation procedure. 8. Install a ¾” nipple into the outlet of drain valve identified in the isolation procedure.
It may be necessary to use a bushing.
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This Copy Printed: November 1, 2023
MP-015 Non-Standard Oil Draining.doc Last Reviewed: October 30, 2023
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Maintenance Procedure Non-Standard Oil Draining
Page 13 of 20
2.d. Oil Draining Alternate Configurations Not Listed Previously
STEP/ACTION
COMMENT
9. Install a vented self-closing (spring return) valve in the outlet of drain valve identified in the isolation procedure.
NOTE: It may be beneficial to leave this valve installed at the end of this procedure. A Management of Change Procedure will be required. Alternately, the use of a hose may be necessary.
10. Install a ¾” nipple, 90 deg elbow and additional nipple into the outlet of drain valve identified in the isolation procedure. 11. Isolate the inlet valves as identified in the plan developed above. Look for the flow arrows on the piping. Apply Lockout/Tagout per the Lockout/Tagout Program. 12. If automatic valves are located within the section of the Ammonia Refrigeration System being worked on, change the automatic valve(s)’s manual operating stem to the “MANUAL OPEN” operating position for any automatic valve in the isolated piping. 13. If possible, allow the section of the system / piping with the control valve to pump down by isolating the liquid feed while maintaining the refrigeration suction. 14. Lower the pressure in the isolated section of the piping to the lowest pressure available.
NOTE: If the automatic valve is a motorized valve, a special tool is required to change the position of the valve when it is de energized. Please see the Manufacturer’s Operation and Maintenance procedures for specific requirements. See the Operation and Maintenance Manuals in the PSM / RMP Program.
NOTE: Any frost on exposed portions of the pipe or valves should disappear with the liquid ammonia in the system. NOTE: If the isolated piping is in a vacuum, take precautions to prevent water being drawn in when purging the piping. NOTE: DO NOT ISOLATE SECTIONS OF LIQUID PIPING UNDER PRESSURE. THIS CAN CREATE A HYDROSTATIC LOCK, AND CAN RESULT IN RUPTURED PIPING AND A RELEASE OF AMMONIA!
15. Isolate the outlet valves, as identified in the plan above, of the section of the Ammonia Refrigeration System being worked on. Apply Lockout / Tagout per the Lockout / Tagout Program. 16. Place the oil recovery container below the outlet of drain valve identified in the isolation procedure.
Revision 1, November 1, 2023
This Copy Printed: November 1, 2023
MP-015 Non-Standard Oil Draining.doc Last Reviewed: October 30, 2023
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