Operation of Rotary Screw Compressors RWF 270

Transcription

REDDY ICE/ PACKAGED ICE, INC.
PROCESS SAFETY MANAGEMENT/ RISK MANAGEMENT PREVENTION
STANDARD 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 a
release 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 Engineer’s office.
System Log Book – in the Plant Engineer’s office.
Manufacturer's Installation and Operations documents – in the Plant Engineers office.
Block Diagrams – in the PSM/RMP Program document –Plant 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 2002
Revision Date: ___________
Technical Operating Specification (TOS)
Function
Description
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.
Capacity/Size
(3) Frick Screw
735 HP
Compressors Model 478.1 TR
RWF 270
Operating Limits
Deviations/Consequences
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 Loss of compressor lubrication
discharge pressure less suction
may result in compressor bearing
pressure.
or seal damage and a release of
ammonia.
Lubrication oil temperature: 110°F
High lubrication oil temperature
could result in compressor
damage and a release of
ammonia.
Discharge temperature: 150-170°F
High discharge temperature
could result in compressor
damage and a release of
ammonia.
Page SOP 3.1-2
Controls and Instrumentation
Description
Item Number
Function
Position/Set point
Discharge Pressure
indicator
Displayed on each compressor Pressure indication on
and on the operator interface compressor discharge
terminal (Panelview)
155-181 psig.
Suction Pressure
indicator
Displayed on each compressor Pressure indication on
and on the operator interface compressor suction
terminal (Panelview)
23-34 psig.
Slide valve control set Displayed on each compressor Internal controlled function that
point.
and operator interface panel. allows operator to program
(Panelview)
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.
Located in the set point
parameters of Quantum
controller on the
compressor.
Internal function that controls the
ratio of the discharge port and
suction slide valve position for
most optimal efficiency of
compress.
Compressor valve listing
VAL
UNIT
#
C-3,4,5 1
C-3,4,5 2
TYPE
SIZE
2"
5"
CONN DISCRIPTION
FUNTION
MANUF MODEL Name
SW
ANGLE VALVE
ISOLATION VALVE
R/S
-
THERM. FEED ISOLA. VALVE
BW
ANGLE VALVE
ISOLATION VALVE
-
-
SUCTION ISOLA. VALVE
ISOLATION VALVE
-
-
THERM. RETN. ISOLA. VALVE
C-3,4,5 3
2"
SW
ANGLE 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
Page SOP 3.1-3
DANVL
SEPARATOR SERVICE VALVE
Page SOP 3.1-4
Page SOP 3.1-5
Safety Systems
Pressure relief valve PSV-15
Relieve excess ammonia vapor 300 psig Factory Set device
pressure to the deluge tank
Description
Item Location
Low suction
pressure cutout,
operator set point.
The low suction pressure set
Each Quantum Compressor
Controller and the PLC control point allows for compressor
shut down at the set point.
system monitors the low
suction pressure setting.
Function
Position/Set point
10 psig
High discharge
pressure pre-alarm Controller and the PLC control
and cutout, operator system monitors the low
set point.
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
Force Unload
Alarm
Shutdown
5 Second delay
190 PSIG
200 PSIG
210 PSIG
215 PSIG
Low lubrication oil Each Quantum Compressor
temperature cutout, Controller monitors the low
internal set point.
lubrication oil temperature cut
out.
Protect the compressor from Alarm
damage due to low lubrication
Shutdown
oil temperature by shutting
5 Second delay
down compressor
55°F
High lubrication oil
temperature cutout,
internal
programmed set
point.
Protect the compressor from Alarm
damage due to high lubrication 30 Second delay
oil temperature by shutting
Shutdown
down compressor
10 Second delay
Controller monitors the high
lubrication oil temperature cut
out.
High discharge
temperature cutout, Controller monitors the high
internal
discharge temperature cut out.
programmed set
point.
Protect the compressor from Stop Load
damage due to high discharge
Force Unload
temperature by shutting down
Alarm
compressor
Shutdown
Page SOP 3.1-6
49°F
144.8°F
155.0°F
180°F
190°F
200°F
195°F
Standard Operating Procedure (SOP)
Task Flow
Manual start-up procedures
|
Monitor normal operations
|
Manual shut-down procedures
|
Emergency shut-down procedures
Task
Step
Manual start-up
1. Visually check the compressor for
procedures (during normal lockout/tag-out devices.
operations and following
maintenance operations)
2. On initial installation or during any
maintenance procedure that involves removal
of any electrical phased conductors, remove
the motor coupling and refer to the
Compressor manual for the complete checklist
on verifying motor rotation.
Comment
During normal operations, the
compressor will start, stop,
automatically load, and unload based on
suction pressure.
Never skip the step of verifying
motor rotation. Starting a screw
compressor in the wrong direction can
be 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 Also remove-warning tags (DO NOT
turned to the off position.
OPERATE) from disconnects as they
are reset or closed.
Page SOP 3.1-7
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 Check proper operating
ensure that all the parameters are within the
parameters as recorded on each
acceptable range.
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 Compressor is checked more
for normal operation. The compressor log sheet
frequently if it operates outside
should be filled out once per shift.
acceptable parameters.
The Frick Compressor log
sheet 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.
Page SOP 3.1-8
Read and be familiar with the
Frick manual and operating
procedures furnish by Frick.
There is wealth of valuable
learning material included in the
material.
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.
Manual shutdown for
compressor maintenance
procedures that do not
require evacuation of
ammonia from compressor
During normal operations,
the compressor is
automatically started and
stopped, and will
automatically load and
unload based on suction
pressure.
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.
3. After performing steps 1 and 2 follow steps listed in the
Manual shutdown for
compressor maintenance on Frick manual to isolate the section where the maintenance
procedure will be performed.
a selected section of the
compressor.
4. After performing steps 1 and 2 then close and tag
Manual shutdown for
isolation valves C-02 located in the compressor suction line.
compressor maintenance
procedure that do require
evacuation of ammonia from
compressor.
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 pump
down 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.
Page SOP 3.1-9
Emergency shutdown 1.
Use these procedures if there are leaks
Shut off the compressor by pushing the
procedures
on the compressor skid or if there is any
RED/Stop button on the compressor
microprocessor control panel or at the panelview. If mechanical damage to the compressor.
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 the
north entrance to the icemaker room.
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 & C03 located in the compressor thermosyphon line if
appropriate.
6.
Close and tag the isolation valve C-11 on the
side port connection.
Page SOP 3.1-10
Task
Step
Comment
Changing
Refer to Frick owner’s manual
1. Shut down the unit when changing oil. Follow all lockout
Compressor Oil tagout procedures. At the same time all oil filters cartridges must be for full details and associated
procedures.
changed and oil strainers elements removed and cleaned.
Continue the following procedure is as follows.
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.
7.
Remove the old filter cartridges, then install new ones.
8.
Remove, clean, examine, and reinstall strainer elements.
Contain all oil, don't allow any
oil to escape to any floor
drains.
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.
Page SOP 3.1-11
Task
Step
Comment
Coalescer Filter Elements When changing the coalescer filter elements, Frick
recommends that the oil be changed, cartridges in the for full details and associated
filters be changed and the applicable strainers elements procedures.
be removed and cleaned.
Follow all safety procedures for electrical lock out and At least 2 persons must be
tag out.
present when reaching into
When opening vessel, follow all confined space access manway.
safety rules set out in the Reddy Ice Safety Manual and
the Frick Owners Manual.
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.
Page SOP 3.1-12
Task
Step
Comment
Changing Main Oil
Filters (Single/Dual)
Follow all lockout safety procedures when changing oil
filters.
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.
Page SOP 3.1-13
2002
Page SOP 3.1-14
Original Date: January
Revision Date:
___________

Operation of Rotary Screw Compressors RWF 270

Transcription

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