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Operation of Ammonia High Pressure
Receiver HPR-1
| Company Name |
Section Number: TBD |
Page 1 |
| Process Safety Management |
PSM/Standard Operating
Procedures/Review/Revision/
HPR-1 |
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Prepared by:
PSM Coordinator |
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Revision Date: 0/00 |
| Revision Approved by: Plant Engineer |
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Issue Revision |
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Objective:
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This procedure is designed to describe the
Technical Operating Specifications (TOS), and to set down the Standard
Operating Procedures for the safe operation of Ammonia High Pressure
Receiver 1 (HPR-1). |
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Purpose:
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The purpose of the TOS is to provide a description
of the High Pressure Receiver, to define the function of the receiver,
its operating conditions and limits, and consequences of deviation from
these limits; To describe controls and instrumentation and safety
systems, and set operating alignments. The purpose of the Standard
Operating Procedure (SOP) is to set down the proper steps for starting,
monitoring normal operation, and stopping and restarting the Receiver
under normal and emergency conditions. |
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Concerns:
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Very Careful attention to valve positions,
temperature, and pressure levels is extremely important to the
successful completion of these procedures. Deviations from normal
operating limits could cause personal injury or death, small to
catastrophic release of ammonia or environmental damage, or evacuation
of, or injury to, members of the public. We seek to prevent incidents
such as:
- Injury to operators and others in the area.
- Damage to the High Pressure Receiver.
- Release of any quantity of
Anhydrous Ammonia refrigerant.
The company Lockout/Tagout program shall be followed when taking the
receiver out of service, while maintaining the receiver, and while
returning it to service. If Line-Breaking is required, all
Line-Breaking precautions described in the company Line-Break Policy
shall be observed. Additionally,
proper PPE shall be immediately available, or worn in response to the
threat level posed by the work and circumstances.
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Department: |
Refrigeration |
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Operator: |
Qualified Refrigeration Operator(s) |
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Equipment: |
Ammonia High Pressure Receiver, HPR-1 outside
the south compressor room. Data from U-1-A: Vertical Receiver, Serial
Number xxxxx, National Board Number xxxxx, built in 1998, by E.L.
Nickell Company. MAWP: 250 psig @ 240°F |
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Location:
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Related Documents: |
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Initial Date of Development: |
4/1998 |
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Authorized By: |
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| Previous Revision: |
4/1/1998 |
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Annual Review By, and Date: |
9/2001 plant engineer, utilities supervisor, two
operators, the Process Safety Management (PSM) coordinator, and an outside consultant |
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Technical Operating Specifications (TOS)
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Function:
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The function of the High Pressure Receiver (HPR-1)
is to provide storage for part of the Anhydrous Ammonia liquid inventory
needed to supply the plant refrigeration loads, and recirculation
receiver loads, as required to maintain efficient operation.
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Description: |
Capacity/ Size |
Safe Operating Limits |
Consequences of Deviation |
Corrective Action |
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Vertical thermo-siphon Receiver |
7’10.5” x 19’11.75” inside |
250 psig MAWP, max capy 80 percent fill |
Over-pressurization will cause operation of
pressure relief valves. Probable risk of ammonia inhalation by nearby
Community residents and businesses. |
Shutdown the transfer pumps. Send all the liquid
produced to Refrigeration. |
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Overfilling will cause refrigerant backup into
condensers. |
Shutdown the transfer pumps. Send all the liquid
produced to Refrigeration. |
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Control failure may result in overfilling
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Shutdown the transfer pumps. Send all the liquid produced to
Refrigeration.
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Controls and Instrumentation
Safety Systems
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DESCRIPTION |
ITEM
NUMBER |
FUNCTION |
POSITION AND/OR NORMAL SETPOINT |
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High Level
float
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Measures
level of ammonia liquid in tank, activate warning when reached
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Less than 80 percent fill level; activates alarm
light if reached. Light is in the main compressor room |
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Low level float
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Measures level of ammonia liquid in receiver,
activate warning light |
At approximately 10 percent liquid level, activates
warning light in the main compressor room. |
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Dual Pressure Relief Valves on manifold
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Protect against over-pressurization above MAWP of
250 psig |
Top of the receiver, on dual PRV manifold, see P&ID
Sheet xx |
Standard Operating Procedure (SOP)
Task Flow Diagram
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| 1. Normal start up |
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| 2. Normal shutdown |
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| 3. Shutdown and
isolation for maintenance/repair activity |
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| 4. Emergency
shutdown and isolation |
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| 5. Startup following emergency
shutdown and isolation, or shutdown and isolation for maintenance
activities |
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Task |
Step |
Comment |
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1. Normal Start up |
1. |
The receiver is not shut down under normal
operations. Restart under normal conditions is never necessary. |
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Task |
Step |
Comment |
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2. Normal Shut Down |
1. |
The receiver would not be shut down during
operation, for any reason. This is essential to the safe operation of
the entire system. |
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3. Shutdown and Isolation for Maintenance or
Repair |
1. See Maintenance Procedures for the float
columns, floats, and alarm systems |
Isolation of the receiver itself is not
probable. Float columns and alarms can be individually isolated for
maintenance and repair. See adjunct SOP |
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4. Emergency Shutdown and Isolation |
4.1. Close HPL supply hand valve from
condensers: |
Valve number xxxx (hand valve) |
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4.2. Close EQ line hand valve |
Valve number xxxx (hand valve) |
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4.3. Close Purge line hand valve |
Valve number xxxx (hand valve) |
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4.4. Close HPL return from transfer tanks 1 AND
2 |
Valve number xxxx (hand valve) |
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4.5. Close liquid injection cooling supply line
valve |
Valve number xxxx |
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4.6. Close liquid feed to plant hand valves |
Valve number xxxx and Valve number xxxx |
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4.7. Shut down liquid transfer pumps 1 and 2 at
TT1 and TT2 in main compressor room |
Transfer Tank 1, Transfer Tank 2, per relevant
SOP for both |
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4.8. Assess situation |
If shutdown is for any period of time,
refrigeration operations will shut down as liquid supply runs out. |
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4.9 Follow instructions of Emergency Response
Personnel on scene. |
If this situation involves fire or engulfment,
evacuate immediate area of receiver and observe from a safe distance. |
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If situation involves damage to any part of the
refrigeration system, prepare to mitigate and/or contain escaping liquid
and vapor, using appropriate PPE, if trained to do so. |
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5. Startup following emergency shutdown and
isolation. |
5.1. Assess situation. Consult with Emergency
Response Personnel and Complex Management before initiating start up
after emergency and/or release. |
Determine exact extent of any damage, ascertain
that electrical power is available; ascertain that compressor room power
is available, and that compressor room and ancillary areas are habitable
under guidelines for ammonia concentration. |
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5.2. Open EQ line hand valve |
Valve number xxxx (hand valve) This equalizes
condensers and receiver to same pressure. |
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5.3. Open purge line hand valve |
Valve number xxxx (hand valve). This will align
purger and receive for normal operation. |
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5.4. Open liquid feed to plant hand valves |
Valve numbers xxxx, and xxxx (hand valves).
Visually inspect for ammonia leaks. This will supply the plant loads and
recirculators with liquid refrigerant. |
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5.5. Open the liquid injection supply hand
valves |
Valve number xxxx (hand valve). This will permit
liquid ammonia flow to cool compressor oil injection. |
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5.6. Open liquid return from TT 1, and TT 2,
hand valves |
Valve number xxxx (hand valve). This will permit
transfer of liquid ammonia from the transfer tanks to the receiver. |
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5.7. Open liquid return hand valve from the
condensers |
Valve number xxxx (hand valve). This will permit
flow from condensers to receiver. Condensers may now be started and
checked for proper operation. |
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5.8. Turn power on to transfer pumps for TT1,
and TT2 |
Refer to SOP for both Transfer Tanks |
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5.9. Begin normal startup of the ammonia
refrigeration system |
Refer to relevant SOP documents for compressors,
accumulators, and recirculators. Re-start these prior to proceeding
with full system restart. |
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Task |
Step |
Comment |
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1. Normal Start up |
1. |
The receiver is not shut down under normal
operations. Restart under normal conditions is never necessary. |
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Task |
Step |
Comment |
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2. Normal Shut Down |
1. |
The receiver would not be shut down during
operation, for any reason. This is essential to the safe operation of
the entire system. |
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3. Shutdown and Isolation for Maintenance or
Repair |
1. See Maintenance Procedures for the float
columns, floats, and alarm systems |
Isolation of the receiver itself is not
probable. Float columns and alarms can be individually isolated for
maintenance and repair. See adjunct SOP |
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4. Emergency Shutdown and Isolation |
4.1. Close HPL supply hand valve from
condensers: |
Valve number xxxx (hand valve) |
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4.2. Close EQ line hand valve |
Valve number xxxx (hand valve) |
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4.3. Close Purge line hand valve |
Valve number xxxx (hand valve) |
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4.4. Close HPL return from transfer tanks 1 AND
2 |
Valve number xxxx (hand valve) |
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4.5. Close liquid injection cooling supply line
valve |
Valve number xxxx |
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4.6. Close liquid feed to plant hand valves |
Valve number xxxx and Valve number xxxx |
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4.7. Shut down liquid transfer pumps 1 and 2 at
TT1 and TT2 in main compressor room |
Transfer Tank 1, Transfer Tank 2, per relevant
SOP for both |
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4.8. Assess situation |
If shutdown is for any period of time,
refrigeration operations will shut down as liquid supply runs out. |
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4.9 Follow instructions of Emergency Response
Personnel on scene. |
If this situation involves fire or engulfment,
evacuate immediate area of receiver and observe from a safe distance. |
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If situation involves damage to any part of the
refrigeration system, prepare to mitigate and/or contain escaping liquid
and vapor, using appropriate PPE, if trained to do so. |
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5. Startup following emergency shutdown and
isolation. |
5.1. Assess situation. Consult with Emergency
Response Personnel and Complex Management before initiating start up
after emergency and/or release. |
Determine exact extent of any damage, ascertain
that electrical power is available; ascertain that compressor room power
is available, and that compressor room and ancillary areas are habitable
under guidelines for ammonia concentration. |
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5.2. Open EQ line hand valve |
Valve number xxxx (hand valve) This equalizes
condensers and receiver to same pressure. |
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5.3. Open purge line hand valve |
Valve number xxxx (hand valve). This will align
purger and receive for normal operation. |
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5.4. Open liquid feed to plant hand valves |
Valve numbers xxxx, and xxxx (hand valves).
Visually inspect for ammonia leaks. This will supply the plant loads and
recirculators with liquid refrigerant. |
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5.5. Open the liquid injection supply hand
valves |
Valve number xxxx (hand valve). This will permit
liquid ammonia flow to cool compressor oil injection. |
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5.6. Open liquid return from TT 1, and TT 2,
hand valves |
Valve number xxxx (hand valve). This will permit
transfer of liquid ammonia from the transfer tanks to the receiver. |
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5.7. Open liquid return hand valve from the
condensers |
Valve number xxxx (hand valve). This will permit
flow from condensers to receiver. Condensers may now be started and
checked for proper operation. |
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5.8. Turn power on to transfer pumps for TT1,
and TT2 |
Refer to SOP for both Transfer Tanks |
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5.9. Begin normal startup of the ammonia
refrigeration system |
Refer to relevant SOP documents for compressors,
accumulators, and recirculators. Re-start these prior to proceeding
with full system restart. |
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Special Cautions and Procedures
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Tremendous risk
is involved in the complete shutdown and isolation of the High Pressure
Receiver unless it is for an extreme emergency involving risk of injury
or death to personnel, and/or community residents.
Assess the risks and benefits carefully,
in consultation with complex management and emergency services
personnel.
For maintenance, repair or inspection procedures
requiring opening of this, or any component of the Ammonia Refrigeration
System to the atmosphere, the company line-breaking policy and
procedures shall be strictly followed. Among the procedures and
steps that are required are:
- A line break permit shall be obtained.
- Only qualified Refrigeration personnel shall
perform the work
- The line to be opened shall be isolated, and
isolation valves secured with locking devices appropriate to type
shall be applied. Isolation valves must be logged by number, and a
copy of this log kept in the maintenance office to preclude loss.
- The portion of the line to be opened shall be
evacuated (pumped down, into a vacuum). Operators shall test that the
vacuum condition is holding, and hold the level of vacuum for a
minimum of 30 minutes.
- Prior to the opening of the line, operators
shall don appropriate PPE, (APR), and wear the PPE until it is evident
to the senior operator that no danger of ammonia flow exists.
- Mechanical integrity of all lines, valves,
and other component parts affected by the line break related work
shall be maintained.
- At the conclusion of the work process, the
assembled line, valves, or other constituent parts shall be first
vacuum tested, then pressure tested.
- When such testing is successfully completed,
all valves shall be restored to the original alignment conditions.
The original log shall be consulted to ensure that all valves
originally listed have been returned to original alignments, and all
tags and biscuits have been removed, and the work area restored to
previous conditions.
The area of the line break shall be observed
periodically to ensure leakage-free operation, and proper refrigeration
function.
See also S-xx, Section xx, bid specification for
acceptable parts and procedures for repair and replacement of component
parts.
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