RMP/PSM WEBINAR SERIES Webinar Starts at 08:00 PT Please call (877) 532-0806 if you are having technical issues. The background music may be used to adjust your audio volume. IIAR STANDARDS AND HOW THEY APPLY TO RAGAGEP PART 3 Stephanie Smith, PE and Max Oppedahl Risk Management Professionals, Inc. (949) 282-0123 (877) 532-0806 Risk Management Professionals 1
RISK MANAGEMENT PROFESSIONALS Key Services Process Safety & Risk Management Process Hazard Analysis (PHA) What-If? Studies Hazard & Operability (HAZOP) Studies Layer of Protection Analysis (LOPA) Safeguard Protection Analysis (SPA) Safety Integrity Level (SIL) Assessment & Verification Process Safety Management (PSM) Risk Management Program (RMP) California Accidental Release Prevention (CalARP) Program Nevada Chemical Accident Prevention Program (CAPP) Security Vulnerability Assessment (SVA) Inherently Safer Technology (IST), Hierarchy of Hazard Control Analysis (HCA), Safer Technology & Alternatives Analysis (STAA) Safety & Environmental Management Systems (SEMS) Damage Mechanism Review (DMR) Safety Case Key Services (cont.) ERP Development & Emergency Preparedness Training (NIMS-Compatible) Risk-Graph and Bow-tie Analysis QRA Services FTA & ETA Background Services to Process Industries, Utilities, & Government Since 1995 International w/us Focus Qualifications Extensive Experience Two Decades of Risk-Based Applications Engineering, Safety, Security, and Emergency Response Backgrounds Locations HQ: Irvine, CA Houston Norfolk Walnut Creek Contact info@rmpcorp.com U.S. (877) 532-0806 SUMMARY General IIAR 2 Information Overview of Part 1 and 2 ANSI/IIAR 2-2014 Chapter 8 Compressors Chapter 9 Refrigerant Pumps Chapter 10 Condensers Risk Management Professionals 2
ANSI/IIAR 2-2014 Standard for Safe Design of Closed-Circuit Ammonia Refrigeration Systems Partial purpose of the update was to compare to ASHRAE Standard 15, NFPA code, Uniform Mechanical Code, International Mechanical Code, and International Fire Code Part 3 discusses Chapters 8, 9 and 10 DEFINITIONS Compressors: A machine used to supply air or other gas at increased pressure. Ultimate Strength: The capacity of a material or structure to withstand loads tending to elongate. Refrigerant Pumps: A mechanical device using suction or pressure to raise or move liquids, compress gases and refrigerants. Maximum Allowable Working Pressure (MAWP): The maximum pressure permissible at the top of the vessel in its normal operating position at a designated temperature. Condenser: An apparatus for changing gaseous substance into a liquid substance Risk Management Professionals 3
DEFINITIONS Shall (shall not): A term used where the provision is mandatory. Should (should not): A term used where the provisions are not mandatory but are (are not) recommended good practice under most but not all conditions. Pressure Relief Device: a device designed to open in a controlled manner to prevent the internal pressure of a system from increasing beyond a specific value. Minimum Design Metal Temperature (MDMT): The lowest temperature permitted according to the metallurgy of the vessel fabrication materials and the thickness of the vessel component. CHAPTER 8: COMPRESSORS 8.1 Ammonia Refrigeration Compressors shall comply with this section. 8.2 Design Design Pressure shall comply with Section 5.5 (General System Design Pressure). Positive-Displacement Compressor with a stop valve in the discharge connection will be protected with pressure relief device that is set at the lowest MAWP of any connected equipment. Minimum size compressor relief connection shall comply with Section 12.2.3 and 15.4.2. Risk Management Professionals 4
CHAPTER 8: COMPRESSORS 8.2 Design (cont.) Compressor shall have limiting device which shuts down the compressor when there is low-suctionpressure, high-discharge-pressure and highdischarge-temperature. Protection for rotating parts shall comply with Section 5.17.2. If rotation is only in one direction, a rotation arrow shall be attached to the device. Ultimate strength requirements shall comply with Section 5.13.2. 8.3 Shall be tested for strength at 1.5 times pressure, for leaks, and proven tight at design pressure or greater. CHAPTER 8: COMPRESSORS 8.4 Equipment Identification Labels shall have the following: Manufacturer s Name, Manufacturer s serial number, Manufacturer s model number, Year manufactured, MAWP, Maximum Rotation speed in rpm and Direction of rotation if applicable. If these requirements above are not fulfilled, the compressor shall not be used. Risk Management Professionals 5
CHAPTER 8: COMPRESSORS 8.5 Compressor Installation Must have a valved connection. If the area has low ambient temperature, then condensation in compressor must be prevented. Designs will include foundations. If a variable frequency drive is used, then follow all manufacturer s instruction and make sure all frequencies are stable. Shall be operated within manufacturer's design limitations. Shall have a check valve to avoid back flow of ammonia mixtures. CHAPTER 8: COMPRESSORS 8.5 Compressor Installation (cont) Any used compressors shall be checked for any manufacturer design alterations, especially those which may affect integrity of casting. Shall have pressure and temperature indicating devices like gauges or readouts which show suction pressure, discharge pressure, oil pressure and discharge temperature. If compressor is connected to vessel and if High liquid level alarm of vessel activates, then the compressor will have control to shutdown. Risk Management Professionals 6
CHAPTER 9: REFRIGERANT PUMPS 9.1 Refrigerant pumps covered 9.2 Design Minimum design pressure must comply with Section 5.5. Means of protecting pumps and piping from hydrostatic overpressure shall be provided. Must comply with ultimate strength requirements from Section 5.13.2. Must be protection from exposed rotating parts from Section 5.17.2. Pumps must be suitable for the service. Refrigerant pumps shall be provided with isolation valves. Pump supports and foundation must comply with Section 5.11. CHAPTER 9: REFRIGERANT PUMPS 9.3 Refrigerant pumps shall be strength tested to a minimum 1.5 times the design pressure, subsequently leak tested and proven tight at pressure greater than or equal to design pressure by manufacturer. 9.4 Name plate requirements: Manufacturer s Name, Manufacturer s serial number, Manufacturer s model number, Year manufactured, MAWP, Maximum Rotation speed in rpm, and Direction of rotation. 9.5 Pumps shall have a way to remove ammonia. Risk Management Professionals 7
10.1 Condensers are covered. 10.2 Tube-and-fin and micro-channel type air-cooled condensers and air cooled de-superheaters are covered by this section. Minimum design pressure must comply with Section 5.5. Must comply with ultimate strength requirements from Section 5.13.2. If inlet and outlet piping can be isolated, then there will be a hydrostatic overpressure protection complying with Section 15.6. Must be protection from exposed rotating parts from Section 5.17.2. Fan speeds shall not exceed manufacturer s recommendations for speed limit. Shall be strength tested to a minimum 1.1 times the design pressure, subsequently leak tested and proven tight at pressure greater than or equal to design pressure by manufacturer. 10.2 Air-cooled condensers and air-cooled de-superheaters (Cont.) Permanent label required with the following information: Manufacturer s Name, Manufacturer s serial number, Manufacturer s model number, Year manufactured, Design Pressure, Direction of fan rotation, Electric motor power, and Electrical supply: volts, full load amps, frequency (Hz), phase. Air-cooled condensers shall be installed with manufacturers minimum clearances. Risk Management Professionals 8
10.3 Evaporative condensers are covered by this section Minimum design pressure must comply with Section 5.5. Must comply with ultimate strength requirements from Section 5.13.2. Pressure vessel attached or used in the evaporative condensers system must comply with Chapter 12. If inlet and outlet piping can be isolated, then there will be a hydrostatic overpressure protection complying with Section 15.6. Must be protection from exposed rotating parts from Section 5.17.2. Fan speeds shall not exceed manufacturer s recommendations for speed limit. 10.3 Evaporative Condensers (Cont) Shall be strength tested to a minimum 1.1 times the design pressure, subsequently leak tested and proven tight at pressure greater than or equal to design pressure by manufacturer Shall be labeled with the following information: Manufacturer s name, Manufacturer s serial number, Manufacturer s model number, Year manufactured, Design pressure, Direction of fan rotation and water-circulating pump, Electric motor rating for fans and water-circulating pump, and Electric supply: volts, full load amps, frequency (Hz), phase Risk Management Professionals 9
10.3 Evaporative condensers (Cont) Air-cooled condensers shall be installed with manufacturer s minimum clearances. Condenser and piping near condenser must be protected from the water getting frozen in order to prevent damage. The waste water and overflow from the evaporative condenser needs to be drained properly in order to avoid hazard. 10.4 Shell-and-Tube Condensers are covered by this section. This includes horizontal and vertical condensers with closed water and open water passes. Minimum design pressure must comply with Section 5.5. Must comply with ultimate strength requirements from Section 5.13.2. Pressure vessel attached or used in the evaporative condensers system must comply with Chapter 12. If inlet and outlet piping can be isolated then there will be a hydrostatic overpressure protection complying with Section 15.6. Protection against hydrostatic overpressure from the secondary inlet and outlet cooling will be provided in accordance with Section 15.6. Risk Management Professionals 10
10.4 Shell-and-Tube Condensers (Cont) Shall be strength tested to a minimum 1.1 times the design pressure, subsequently leak tested and proven tight at pressure greater than or equal to design pressure by manufacturer. Shall be labeled with the following information: Manufacturer s name, Shell-side MAWP and temperature, Tube-side MAWP and temperature, Shell-side MDMT and pressure, Tube-side MDMT and pressure, Manufacturer s serial, and Year Manufactured. Where possible clearance shall be provided for maintenance to service the condenser. 10.5 Plate Heat Exchanger condenser are covered by this section including plate and shell type and plate and frame type. Minimum design pressure must comply with Section 5.5. Must comply with ultimate strength requirements from Section 5.13.2. Pressure vessel attached or used in the evaporative condensers system must comply with Chapter 12. Inlet and outlet piping of the plate containing ammonia can be isolated allowing the ammonia side of plate to have pressure relief protection according to Section 15.3. Risk Management Professionals 11
10.5 Plate Heat Exchanger Condenser (Cont.) The nonrefrigerant process fluid lines of plate packs shall be protected from hydrostatic overpressure in accordance to Section 15.6 Shall be strength tested to a minimum 1.1 times the design pressure, subsequently leak tested and proven tight at pressure greater than or equal to design pressure by manufacturer. Shall be labeled with the following information: Manufacturer s name, Hot-side MAWP and temperature, Cold-side MAWP and temperature, Hot-side MDMT and pressure, Cold-side MDMT and pressure, Manufacturer s serial, and Year Manufactured. Clearance is given for plate maintenance. 10.6 Double-Pipe condensers are covered by this section including double-pipe with closed-water passes. Minimum design pressure must comply with Section 5.5. Must comply with ultimate strength requirements from Section 5.13.2. Pressure vessel attached or used in the evaporative condensers system must comply with Chapter 12. If inlet and outlet piping of the double-pipe condenser can be isolated, then the refrigerant side of plate will have pressure relief protection according to Section 15.3. If there is a second cooling piping system of doublepipe condensers and can be isolated, then it shall be protected from hydrostatic overpressure according to Section 15.6. Risk Management Professionals 12
10.6 Double-Pipe Condenser (Cont.) Shall be strength tested to a minimum 1.1 times the design pressure, subsequently leak tested and proven tight at pressure greater than or equal to design pressure by manufacturer. Shall be labeled with the following information: Manufacturer s name, Shell-side MAWP and temperature, Tube-side MAWP and temperature, Shell-side MDMT and pressure, Tube-side MDMT and pressure, Manufacturer s serial, and Year Manufactured. Construction shall follow ASME B&PVC, Section VIII, Division 1. Shall have clearance allowing the replacement or removal of condenser pipes. WHAT S NEXT? Chapter 11 Evaporators Chapter 12 Pressure Vessels Chapter 13 Piping * This agenda may be changed based on information presented and time allotted for the next webinar. Risk Management Professionals 13
Feb. 23, 2017 UPCOMING WEBINARS / CONFERENCES Sponsor and exhibitor at the event. Central Valley Chemical Safety Day Feb. 27, 2017 Attendee IIAR National Conference March 21, 2017 Webinar PSM/RMP Modernization Programs in California New 2016 Developments and Correlation to Evolution at the Federal Level Presented by Steve Maher, PE and Aleks Metulev April 6, 2017 Webinar Nevada CAPP Regulations and How to Prepare for an Audit Presented by David Childs April 28, 2017 Sponsor and exhibitor at the event. LA RETA Safety Day QUESTIONS? Stephanie Smith, PE and Max Oppedahl Stephanie.Smith@RMPCorp.com Max.Oppedahl@RMPCorp.com Risk Management Professionals, Inc. (949) 282-0123 (877) 532-0806 Risk Management Professionals 14