We can provide you with the following additional PSM/RMP services...
- Material and Energy Balance
Material and Energy Balance
The material and energy balance should document the overall change in energy in the compressors, cooling evaporators, and condensers. Ideally it will provide indication that the compressor capacities exceed the projected system loads, and that the condenser capacities exceed the compressor capacities.
- Ammonia Charge Calculation
Ammonia Charge Calculation
(Maximum Intended Inventory) Calculated refrigerant inventory within the refrigeration system.
- Relief Line Calculation
Relief Line Calculation
The PSM Standard does not identify the information that should be included in the design and design basis documentation; however, in its VPP Supplement, OSHA recommended that the following items be included as part of the design and design basis documentation:
- Identification and description of each relief device.
- A listing of all equipment which will be relieved through the device.
- Design pressure.
- Set pressure.
- Listing of all sources of overpressure considered.
- Identification of the worst case overpressure scenario or relief design.
- State of material being relieved (i.e., liquid, vapor, liquid-vapor, liquid-vapor-solid, along with an identification of the material which was the basis for the relief device selection).
- Physical properties of the relieved materials, vapor rate, molecular weight, maximum relieving pressure, heat of vaporization, specific gravity and viscosity.
- Design calculations.
- Valve Index
List of all valves within the refrigeration system
Common Valve Index Lists include for each valve the location, equipment, line, tag number and the normal state (Ex. open, closed, auto).
- Field Verification of P&ID
Field Verification of P&ID
Facilities must have piping and instrument diagrams (P&IDs) for the equipment in the refrigeration system. P&IDs are detailed drawings which may contain the following items:
- A lead sheet containing a legend of the symbols and abbreviations used on the P&IDs.
- Refrigeration equipment (vessels, compressors, pumps, condensers, etc.) and a descriptive name or identification number. P&IDs should be set up to indicate relative elevations of equipment and to depict gravity and pumped flows where possible. Pre-fabricated equipment packages will typically not be shown in detail unless it is necessary for a clear portrayal of the refrigeration piping, instrumentation or utility connections.
- Equipment description blocks which often list the manufacturer, model number, capacity, design limits, and materials of construction.
- Valves, strainers, and relief valves shown schematically using the symbols on the lead sheet.
- Instruments (pressure gauges and transmitters, level gauges and transmitters, temperature gauges and transmitters, etc.) identified and numbered in accordance with the lead sheet and ISA standards. Control strategy, including associated alarms and interlocks, should be clearly indicated with instrument functions and mounting locations shown.
- Refrigeration piping contained in the system. Sections of piping typically contain a unique identification number which indicates the line size, service (contents of the line), line number (a unique number for referring to that line), pipe class (material of construction), insulation (if applicable), and heat tracing (if applicable).
- Utility tie-ins to refrigeration equipment including normal instrument air supply connections to instruments
- Refrigeration line continuations from drawing to drawing which extend to the edge of the drawing.
- Title blocks for each drawing indicating the company name, facility location, type of drawing, simplified drawing name, drawing number, person who prepared the drawing, revision number, revision date, and provisions for drawing approval.
- Materials of Construction
Materials of Construction
The materials of construction of each equipment item must be clearly documented. Items which may be used to document the materials of construction for the refrigeration systems include:
- Equipment description blocks contained on the piping and instrument diagrams.
- Piping identification systems associated with the piping and instrument diagrams.
- Equipment data forms filled out by facility personnel.
- Fabrication or installation drawings provided by the manufacturer or vendor.
- Material certificates provided by the manufacturer such as U-1, U-1A, U-2, and R-1 manufacturers data reports for pressure vessels.
- Vendor manuals
- Electrical Classifications
Areas of a facility which contain flammable or combustible materials are normally classified according to the flammability of these materials and the probability that they may be released from their normal containment system. This classification is conducted to determine the degree of protection required to prevent ignition of flammable materials by installed equipment or temporary equipment.
References which may be used to define hazardous area classifications are:
- NFPA 70, National Electrical Code, National Fire Protection Association (NFPA).
- NFPA 497A, Classification of Class I Hazardous (Classified) Locations for Electrical Installations in Chemical Process Areas, National Fire Protection Association (NFPA).
- ANSI-ASHRAE 15, Safety Code for Mechanical Refrigeration, American National Standards Institute-American Society of Heating, Refrigerating and Air-Conditioning Engineers, Inc. (ANSI-ASHRAE).
- Bulletin #111, Guidelines for: Ammonia Machinery Room Ventilation, International Institute of Ammonia Refrigeration (IIAR).
Ammonia machinery rooms may be classified as non-hazardous, unclassified locations under the National Electrical Code (NEC) if they meet the criteria for ventilation systems set out in documents such as ANSI-ASHRAE 15 and IIAR Bulletin #111. Non-hazardous classification will eliminate the requirements imposed by a Class 1, Division 2 classification.
ANSI/ASHRAE 15 2010 (8.12(h) which states: When ammonia is used, the machinery room is not required to meet Class I Division 2, of the National Electric Code providing (1) the mechanical ventilation system in the machinery room is run continuously and failure of the mechanical ventilation system actuates an alarm or (2) the machinery room is equipped with a detector that will automatically start the mechanical ventilation system and actuate an alarm at a detection level not to exceed 1,000 ppm.
- Written SOP’s
Ammonia refrigeration equipment operating procedures include:
- Objectives and Purpose.
- Safety and Health Considerations.
- Equipment Information.
- Identification and Capacity/Size
- Operating Limits.
- Safe upper and lower limits.
- Consequences of deviation.
- Steps required to correct or avoid deviation.
- Steps for each operating phase:
- Initial startup.
- Normal operations.
- Temporary operations.
- Emergency shutdown.
- Emergency operations.
- Normal shutdown
- Start up after an emergency shutdown
We can also offer training for you on your newly developed operating procedures at your location or we can offer you training through a webinar if desired. Additional cost will be applied.
- Manufacturer's Data Report for Pressure Vessels
Manufacturer's Data Report for Pressure Vessels
Certification by a national board of boiler and pressure vessel Inspector that the pressure vessel has been constructed in accordance with ASME Boiler and Pressure Vessel Code.
- Emergency Action/Respomse Plan
Emergency Action/Respomse Plan
An emergency action plan (EAP) is a written document required by particular OSHA standards. [29 CFR 1910.38(a)] The purpose of an EAP is to facilitate and organize employer and employee actions during workplace emergencies. Well-developed emergency plans and proper employee training (such that employees understand their roles and responsibilities within the plan) will result in fewer and less severe employee injuries and less structural damage to the facility during emergencies. A poorly prepared plan, likely will lead to a disorganized evacuation or emergency response, resulting in confusion, injury, and property damage.
- Vibration Analysis
The objective of a vibration analysis is to identifying noise or vibration in an operating compressor. Vibration analysis is done on motors and compressors to check for a failing element of a rotating machine such as bearing defects, motor misalignment, gear box and belt defects.
- Oil Analysis
An effective oil analysis program should focus on leading indicators that anticipate and help prevent compressor problems rather than trailing indicators that only serve to alert the user to an existing problem. These leading indicators will vary depending on lubricant type but several parameters are universally important. They include TAN (Total Acid Number), pH, viscosity, and contamination.
- Refrigerant Analysis
Analysis to determine the amount of water present in the refrigeration system .
- Block Flow Diagram
Block Flow Diagram
- Ventilation Calculation
- Written LOTO Procedures
Written LOTO Procedures
- Incident Investigation
- Loss Calculation
- Chemical Facility Anti-Terrorism Standards(CFATS)
Chemical Facility Anti-Terrorism Standards(CFATS)