Screw Compress

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REDDY ICE/ PACKAGED ICE, INC.PROCESS SAFETY MANAGEMENT/ RISK MANAGEMENT PREVENTIONSTANDARD 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 arelease 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 Engineers office.

System Log Book in the Plant Engineers office.

Manufacturer's Installation and Operations documents in the Plant Engineers office.

Block Diagrams in the PSM/RMP Program documentPlant 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 2002Revision Date: ___________


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Technical Operating Specification (TOS)

Function 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.

Description Capacity/Size Operating Limits Deviations/Consequences

(3) Frick Screw

Compressors Model

RWF 270

735 HP

478.1 TR

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

discharge pressure less suction

pressure.

Loss of compressor lubrication

may result in compressor bearing

or seal damage and a release of

ammonia.

Lubrication oil temperature: 110F High lubrication oil temperature

could result in compressor

damage and a release of

ammonia.

Discharge temperature: 150-170F High discharge temperature

could result in compressor

damage and a release of

ammonia.



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Controls and Instrumentation

Description Item Number Function Position/Set point

Discharge Pressure

indicator

Displayed on each compressor

and on the operator interface

terminal (Panelview)

Pressure indication on

compressor discharge

155-181 psig.

Suction Pressure

indicator


and on the operator interface

terminal (Panelview)

Pressure indication on

compressor suction

23-34 psig.

Slide valve control set

point.


and operator interface panel.

(Panelview)

Internal controlled function that

allows operator to program

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.

Internal function that controls the

ratio of the discharge port and

suction slide valve position formost optimal efficiency of

compress.

Located in the set point

parameters of Quantum

controller on thecompressor.

Compressor valve listing

UNIT

VAL

# SIZE

TYPE

CONN DISCRIPTION FUNTION MANUF MODEL Name

C-3,4,5 1 2" SW ANGLE VALVE ISOLATION VALVE R/S - THERM. FEED ISOLA. VALVE

C-3,4,5 2 5" BW ANGLE VALVE ISOLATION VALVE - - SUCTION ISOLA. VALVE

C-3,4,5 3 2" SW ANGLE VALVE ISOLATION VALVE - - THERM. RETN. ISOLA. 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 DANVL - SEPARATOR SERVICE VALVE



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Safety Systems

Pressure relief valve PSV-15 Relieve excess ammonia vapor

pressure to the deluge tank

300 psig Factory Set device

Description Item Location Function Position/Set point

Low suction

pressure cutout,

operator set point.

Each Quantum Compressor

Controller and the PLC control

system monitors the low

suction pressure setting.

The low suction pressure set

point allows for compressor

shut down at the set point.

10 psig

High discharge

pressure pre-alarm

and cutout, operator

set point.


Controller and the PLC control

system monitors the low

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 190 PSIG

Force Unload 200 PSIG

Alarm 210 PSIG

Shutdown 215 PSIG

5 Second delay

Low lubrication oil

temperature cutout,

internal set point.


Controller monitors the low

lubrication oil temperature cut

out.

Protect the compressor from

damage due to low lubrication

oil temperature by shutting

down compressor

Alarm 55F

Shutdown 49F

5 Second delay

High lubrication oil

temperature cutout,

internal

programmed set

point.


Controller monitors the high

lubrication oil temperature cut

out.


damage due to high lubrication

oil temperature by shutting

down compressor

Alarm 144.8F

30 Second delay

Shutdown 155.0F

10 Second delay

High discharge

temperature cutout,

internal

programmed set

point.


Controller monitors the high

discharge temperature cut out.


damage due to high discharge

temperature by shutting down

compressor

Stop Load 180F

Force Unload 190F

Alarm 200F

Shutdown 195F



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Standard Operating Procedure (SOP)Task Flow

Manual start-up procedures

|

Monitor normal operations

|Manual shut-down procedures

|

Emergency shut-down procedures

Task Step Comment

Manual start-up

procedures (during normal

operations and following

maintenance operations)

1. Visually check the compressor for

lockout/tag-out devices.

During normal operations, the

compressor will start, stop,

automatically load, and unload based on

suction pressure.

2. On initial installation or during any

maintenance procedure that involves removal

of any electrical phased conductors, removethe motor coupling and refer to the

Compressor manual for the complete checklist

on verifying motor rotation.

Never skip the step of verifying

motor rotation. Starting a screw

compressor in the wrong direction canbe 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

turned to the off position.

Also remove-warning tags (DO NOT

OPERATE) from disconnects as they

are reset or closed.



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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

ensure that all the parameters are within the

acceptable range.

Check proper operating

parameters as recorded on each

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

for normal operation. The compressor log sheet

should be filled out once per shift.

Compressor is checked more

frequently if it operates outside

acceptable parameters.

The Frick Compressor logsheet 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.

Read and be familiar with theFrick manual and operating

procedures furnish by Frick.

There is wealth of valuable

learning material included in the

material.



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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.

During normal operations,

the compressor is

automatically started and

stopped, and will

automatically load and

unload based on suction

pressure.

Manual shutdown for

compressor maintenance

procedures that do not

require evacuation of

ammonia from compressor

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.

Manual shutdown for

compressor maintenance on

a selected section of the

compressor.

3. After performing steps 1 and 2 follow steps listed in the

Frick manual to isolate the section where the maintenance

procedure will be performed.

Manual shutdown forcompressor maintenance

procedure that do require

evacuation of ammonia from

compressor.

4. After performing steps 1 and 2 then close and tagisolation valves C-02 located in the compressor suction line.

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 pumpdown 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.



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Emergency shutdown

procedures

1. Shut off the compressor by pushing the

RED/Stop button on the compressor

microprocessor control panel or at the panelview. If

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 thenorth entrance to the icemaker room.

Use these procedures if there are leaks

on the compressor skid or if there is any

mechanical damage to the compressor.

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 & C-

03 located in the compressor thermosyphon line if

appropriate.6. Close and tag the isolation valve C-11 on the

side port connection.



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Task Step Comment

Changing

Compressor Oil

1. Shut down the unit when changing oil. Follow all lockout

tagout procedures. At the same time all oil filters cartridges must be

changed and oil strainers elements removed and cleaned.

Continue the following procedure is as follows.

Refer to Frick owners manual

for full details and associated

procedures.

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.

Contain all oil, don't allow any

oil to escape to any floordrains.

7. Remove the old filter cartridges, then install new ones.

8. Remove, clean, examine, and reinstall strainer elements.

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.



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Task Step Comment

Coalescer Filter Elements When changing the coalescer filter elements, Frick

recommends that the oil be changed, cartridges in the

filters be changed and the applicable strainers elements

be removed and cleaned.



procedures.

Follow all safety procedures for electrical lock out and

tag out.

When opening vessel, follow all confined space access

safety rules set out in the Reddy Ice Safety Manual and

the Frick Owners Manual.

At least 2 persons must be

present when reaching into

manway.

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.



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Task Step Comment

Changing Main Oil

Filters (Single/Dual)

Follow all lockout safety procedures when changing oil

filters.



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.



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REDDY ICE DALLAS Page SOP 3.1-14 Original Date: January2002

Revision Date:___________

Documents

Screw Compress