WHAT S S GOING ON INSIDE MY SYSTEM? 2012 CENTRAL VALLEY CHEMICAL SAFETY DAY. Mechanical Integrity. Mechanical Integrity GLOBAL OR DISTINCT GLOBAL

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1 2012 CENTRAL VALLEY CHEMICAL SAFETY DAY WHAT S S GOING ON INSIDE MY SYSTEM? Mechanical Integrity GLOBAL OR DISTINCT Mechanical Integrity GLOBAL DAILY ROUNDS THE WALK THROUGH EQUIPMENT INSPECTIONS-HOURLY OR BY CALENDAR YEAR OR SEASONAL INTEGRITY SAFETY PLANNED MAINTENANCE UNPLANNED MAINTENANCE 5 YEAR MECHANICAL INTEGRITY INSPT. GUIDELINES/REQUIREMENTS IIAR INDUSTRY STANDARDS SITE DATA-ONGOING AND HISTORICAL CODES AND LAW A Simple Obtainable Expectation The General Duty Clause Requirements The owners and operators of stationary sources producing, processing, handling or storing such nasty substances: Have a general duty to identify hazards which may result from such releases using appropriate hazard assessment techniques To design and maintain a safe facility taking such steps as are necessary to prevent releases, and to minimize the consequences of accidental releases which do occur. Therefore We Must Create Usable, Workable Safety, Mechanical Integrity and Training Programs! 6 5/10/2012

2 General Duty Clause Requirements Elements of designing and maintaining a safe facility: Be in compliance with good engineering practices Comply with recognized industry standards Follow manufacturers recommendations for use and maintenance of equipment Basic theory and system specific operator training IS HE HIGH? DAILY ROUNDS MEET NORM OR IS HE JUST NORM? IS HE LOW? 7 5/10/2012 DAILY ROUNDS USE ALL OF YOUR SENSES! LOOK LISTEN TOUCH FEEL SMELL THINK ANALYZE ACT LOOK! NORM HIGH AND LOW LEVELS PRESSURES TEMPERATURES FROST PATTERNS/LINES SWEAT LINES RUN TIME ON OR OFF CAPACITY CONTROL LISTEN AND FEEL! NOISE VIBRATION HISS THUMP DENTIST DRILL WHAT IS NOT THE NORM

3 Typical Causes of Failure AND WE WONDER WHY THEY VISIT! Debris embedded in the main valve Teflon V-port V seat Debris in the solenoid module passages Debris packed under Teflon piston seal ring Liquid slugs damaging piston General Duty Clause Requirements Elements of designing and maintaining a safe facility: Be in compliance with good engineering practices Comply with recognized industry standards Follow manufacturers recommendations for use and maintenance of equipment International Institute of Ammonia Refrigeration (IIAR) Ammonia Machinery Room Design (Bulletin #112) Suggested Safety and Op. Proc. Tie In (#107) Water Contam.. in Amm. Refrig.. Systems (#108) IIAR Min. Safety Crit.. for Safe Amm. Refrig.. (#109) Start-Up, Insp. and Maint.. of Amm. Refrig.. (#110) Ammonia Machinery Room Ventilation (#11) Ident.. of Amm. Refrig.. Piping & Component (#114) Avoiding Component Failure in Industrial Refrigeration Systems Caused by Abnormal Pressure or Shock (#116) American Society of Mechanical Engineers (ASME ) Boiler and Pressure Vessel Code Pressure Vessels Nondestructive Examinations Refrigeration Piping Code ANSI/ASHRAE Standard 15 Safety Standard for Refrigeration Systems ASHRAE Chapters 3 & 6 System Practices for Ammonia Refrigerant Control of Moisture and other Contaminants

4 American National Standards Institute and the Compressed Gas Association ANSI K61.1 and CGA G-2.1G Safety Requirements for the Storage and Handling of Anhydrous Ammonia More of What We Look for and What We See at Facilities Mechanical Integrity Starts During The Installation and Continues For The Life Of The System IIAR Bulletin No.109, Section states that pressure relief devices should be replaced within five years of the date of manufacture, or by the date specified by the manufacture. EPA Ammonia Regulation and Findings Bradley Miller EPA, Region 8

5 IIAR Bulletin No. 112, Ammonia Machinery Room Design: : Section 4.3.f requires all ammonia vessels, equipment and piping to be labeled.. Identification of piping should include descriptive labels and flow direction. Hey Joe Close Valve 32A Hurry It s s a Bad Leak. ANSI /ASHRAE Standard , Safety Standard for Refrigeration Systems, Section requires that facility piping have hydrostatic pressure relief valves in sections of piping in which liquid ammonia could be isolated between shut-off valves.

6 IIAR Bulletin No. 110, Start-up, Inspection and Maintenance of Ammonia Mechanical Refrigerating Systems Section 6.8 requires facilities to have rapid closing valves at all oil draining points. Mechanical Integrity???!!!??? Corrosion and Breaches of Vapor Barriers

7 Pipe Pipe showing rupture 2 Pipe Wall Thickness Schedule At cut % loss At rupture % loss Thickness at pit bottoms even less IIAR Bulletin No.109; Minimum Safety Criteria for a Safe Ammonia Refrigeration System; ; Sections & requires: Uninsulated refrigerant pipe that is corroded is to be replaced or cleaned to bare pipe and painted, Insulated piping showing signs of vapor barrier failure should have the vapor barrier removed and the pipe inspected.. If corrosion is found, it should be treated as above.

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9 EPA, Region 8 Requirement Areas of piping and equipment located throughout the facility had ice build-up, up, apparent insulation vapor barriers breached, visible pipe corrosion, and other conditions that did not appear to comply with industry standards (IIAR Bulletin No.109; Minimum Safety Criteria for a Safe Ammonia Refrigeration System; ; Sections & 4.7.5). The facility shall inspect all piping and equipment and certify that it is fit for service.