RMP/PSM WEBINAR SERIES

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 4 Stephanie Smith, PE Sara Willman 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 Parts 1 through 3 ANSI/IIAR 2-2014 Chapter 11 Evaporators Chapter 12 Pressure Vessels Chapter 13 Piping Chapter 14 Packaged Systems and Equipment 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 4 discusses Chapters 11 to 14 DEFINITIONS Maximum Allowable Working Pressure (MAWP): The maximum pressure permissible at the top of the vessel in its normal operating position at a designated temperature. 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. Packaged System: A prefabricated and preassembled closedcircuit refrigeration system, containing all essential equipment, piping, and devices. The package can either be enclosed within its case or framework or unenclosed. Risk Management Professionals 3

DEFINITIONS Piping: The interconnecting parts of a closed circuit mechanical refrigerating system which contain and convey the refrigerant. Piping includes pipe, flanges, bolting, gaskets, valves, fittings, the pressure-containing parts of other components such as heat transfer components, expansion joints, strainers, filters, and devices which serve such purposes as mixing, separating, snubbing, distributing, metering or controlling flow, pipe hangers, supporting fixtures and structural attachments. DEFINITIONS Pressure Vessel: Any refrigerant containing receptacle in a closed circuit mechanical refrigerating system designed and manufactured under the rules of ASME Section VIII, Division 1, Boiler and Pressure Vessel Code. Exceptions: compressors, pumps, controls, condenser coils, evaporator coils, headers, piping, other components and their headers not constructed as pressure vessels. Readily Accessible: Capable of being reached safely and quickly for operation, repair, and inspection without requiring those who ready access is required to climb over or remove obstacles or to resort to the use of portable access equipment. Risk Management Professionals 4

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. Tight Construction: Solid construction with holes or openings that are either sealed or provided with tight-fitting doors to control the transfer of liquid, moisture, air, and vapor. Ultimate Strength: The capacity of a material or structure to withstand loads tending to elongate. CHAPTER 11: EVAPORATORS 11.1 General clause 11.2 Forced-Air Evaporator Coils 11.2.1 Design Minimum design pressure: Section 5.5 Ultimate strength: Section 5.13.2 Hydrostatic overpressure protection: Section 15.6 Fan speeds: manufacturer recommendation Pressure vessels: Chapter 12 11.2.2 Procedures/Testing: Coils shall be strength tested to a minimum 1.1x design pressure, subsequently leak tested, and proven tight at least at design pressure Risk Management Professionals 5

CHAPTER 11: EVAPORATORS 11.2.3 Equipment ID manufacturer s name serial number model number year manufactured design pressure direction of fan rotation (if supplied) electric motor size (if supplied) electric defrost heater and drain pan heater ratings (as applicable) electric supply (volts, full load amps, frequency, phase) 11.2.4 Installation Considerations Unobstructed airflow at inlet/outlet per manufacturer s recommended clearances Means for preventing freezing inside condensate drain lines where lines are exposed to freezing temperatures P-traps required on condensate drain for each evaporator CHAPTER 11: EVAPORATORS 11.3 Shell-and-Tube Evaporators 11.3.1 with NH 3 Shell 11.3.1.1 Design Minimum design pressure: Section 5.5 Pressure vessels: Chapter 12 Hydrostatic overpressure protection: Section 15.6 11.3.1.2 Procedures/Testing: Shall be tested in accordance with ASME B&PVC, VIII, Div. 1, but at a minimum, strength tested to 1.1x design pressure, subsequently leak tested, and proved tight at least at design pressure 11.3.1.3 Equipment ID: Manufacturer s name Shell-side max/min allowable working pressure at specific temperature Tube-side max/min design metal temperature at specific pressure Serial number Year manufactured 11.3.1.4 Installation Considerations: Section 11.3.2.4 Risk Management Professionals 6

CHAPTER 11: EVAPORATORS 11.3.2 - with NH3 Tubes 11.3.2.1 Design Minimum design pressure: Section 5.5 Pressure vessels: Chapter 12 Hydrostatic overpressure protection: Section 15.6 Tube side: ASME B31.5 or ASME B&PVC, VIII, Div. 1 11.3.2.2 Procedures/Testing: Strength tested to a minimum 1.1x design pressure, subsequently leak tested, and proven tight at least at design pressure 11.3.2.3 Equipment ID: Manufacturer s name Shell-side max/min allowable working pressure at specific temperature Tube-side max/min design metal temperature at specific pressure Serial number Year manufactured Test pressure, test type (hydraulic or pneumatic) 11.3.2.4 Installation Considerations: Clearance shall be provided to accommodate maintenance and replacement of evaporator tubes CHAPTER 11: EVAPORATORS 11.4 Plate Heat Exchanger Evaporators 11.4.1 Design Minimum design pressure: Section 5.5 Ultimate strength: Section 5.13.2 Pressure vessels: Chapter 12 Ammonia side of the plate pack overpressure protection: Section 15.3 Non-refrigerant process overpressure protection: Section 15.6 11.4.2 Procedures/Testing: Shall be strength tested to at least 1.1x design pressure, subsequently leak tested, and proven tight at least a design pressure Risk Management Professionals 7

CHAPTER 11: EVAPORATORS 11.4.3 Equipment ID Manufacturer shall provide: manufacturer s name hot-side MAWP at specific temperature (where applicable) cold-side MAWP at specific temperature (where applicable) serial number year manufactured If incorporated pressure vessel is present, data shall be provided in accordance with UG section of ASME B&PVC, VIII, Div. 1 11.4.5 Installation Considerations: Clearance shall be provided for maintenance or replacement of evaporator plates. CHAPTER 11: EVAPORATORS 11.5 Scraped (Swept) Surface Heat Exchangers 11.5.1 Design Minimum design pressure: Section 5.5 Pressure vessels: Chapter 12 Ammonia side overpressure protection: Section 15.6 11.5.2 Procedures/Testing: Shall be tested in accordance with ASME B&PVC, VIII, Div. 1, but at a minimum, strength tested to 1.1x design pressure, subsequently leak tested, and proved tight at least at design pressure 11.5.3 Equipment ID manufacturer s name Shell MAWP at specific temperature Shell MDMT at specific pressure serial number year manufactured 11.5.4 Installation Considerations: Clearance shall be provided for the maintenance or replacement of equipment Risk Management Professionals 8

CHAPTER 11: EVAPORATORS 11.6 Jacketed Tanks 11.6.1 Design Minimum design pressure: Section 5.5 Ultimate strength: Section 5.13.2 Pressure vessels: Chapter 12 Ammonia side overpressure protection: Section 15.6 11.6.2 Procedures/Testing: Shall be tested in accordance with ASME B&PVC, VIII, Div. 1, but at a minimum, strength tested to 1.1x design pressure, subsequently leak tested, and proved tight at least at design pressure 11.6.3 Equipment ID Manufacturer shall provide: manufacturer s name MAWP at specific temperature serial number year manufactured If incorporated pressure vessel is present, data shall be provided in accordance with UG section of ASME B&PVC, VIII, Div. 1 CHAPTER 12: PRESSURE VESSELS 12.1 General clause 12.2 Design Minimum Pressure: Section 5.5 Design, fabrication, inspection, testing (inside diameter [I.D.] > 6 ): ASME B&PVC, VIII, Div. 1 Ultimate Strength (I.D. < 6 ): Section 5.13.2 Pressure Relief Connections I.D. > 6 and < 10 ft 3 : > ¾ piping or ½ coupling Volume > 10 ft 3 : > 1 piping or ¾ coupling Heads of pressure vessels shall be hot formed or stress relieved after cold forming (except when primarily containing oil) Vessel shall be designed and stamped with MDMT < lowest expected operating temperature When subject to external corrosion, must have > 1/16 corrosion allowance in addition to thickness required by ASME B&PVC, VIII, Div. 1 Risk Management Professionals 9

CHAPTER 12: PRESSURE VESSELS 12.3 Procedures/Testing: Shall be tested in accordance with ASME B&PVC, VIII, Div. 1 12.4 Equipment ID Manufacturer s name MAWP at specific temperature MDMT at specific pressure Serial number Year of manufacture Model number (where applicable) Stamp with MDMT that the equipment is operated in accordance with ASME B&PVC, VIII, Div. 1 12.5 Nameplate Mounting Comply with Section 5.14.4 If insulated, mounting on an approved standoff is required or the insulation at the nameplate location shall be removable CHAPTER 12: PRESSURE VESSELS 12.6 Pressure Vessel Installation Considerations 12.6.1 Access: Section 5.12 12.6.2 Physical Protection: Section 7.2.4 12.6.3 Support: Section 5.11 Service Provisions Testing Security Isolation Loading Seismic Vibration/ Movement Risk Management Professionals 10

CHAPTER 13: PIPING 13.1 Design, fabrication, examination, and testing shall comply with ASME B31.5, unless otherwise specified in this section 13.2 Pipe, Tubing, Fittings, and Flanges 13.2.1 Material: ASME B31.5, except: ASTM A53-Type F pipe and cast iron or wrought iron pipe shall not be used for pressure-containing side of closedcircuit ammonia refrigeration systems Zinc, copper, and copper alloys shall not be used in contact with or for containment of ammonia (includes copper-containing anti-seize and/or lubricated compounds) 13.2.2 Minimum Pipe Wall Thickness: Shall be based on the properties of selected pipe material, design working pressure, and comply with ASME B31.5 13.2.3 Tubing: Wall thickness shall be based on properties of selected material and the greater of the design working pressure or the requirement specified by the manufacturer of the compression ferrule used for the fitting connection CHAPTER 13: PIPING 13.2.4 Pipe Fittings Butt weld fittings shall match pipe schedules All forged and cast steel socket weld and screwed fittings shall be minimum Class 3000 per ASME B16.11 Threaded joints shall not be used for refrigerant piping larger than 2 diameter 13.2.5 Pipe Flanges When in accordance with ASME B16.5, flanges shall comply with ASME B31.5. Flange class shall be based on the design working pressure and maximum working temperature at the design working pressure. Gaskets shall be correctly dimensioned for the flange set in accordance with ASME B16.20 or B16.21 Risk Management Professionals 11

CHAPTER 13: PIPING 13.3 Refrigerant Valves & Strainers 13.3.1 Required Shut-Off Valve Locations Shall be installed at each location: Inlet/outlet of positive-displacement-type compressor, compressor unit, or condensing unit Main feed inlets/outlets of individual refrigeration equipment loads Refrigerant inlet/outlet of pressure vessel containing liquid ammonia and having an internal gross volume > 3 ft 3 Exceptions 13.3.2 Valves in Equipment and Safety Design Where a required orientation of a valve is provided by the manufacturer (vertical, horizontal, or rotational), the system design shall indicate the required orientation Where a valve is deliberately specified for use with an indicator opposite the direction of flow, the system design shall specify the intended installation direction Valve gasket materials shall be in accordance with manufacturer s specifications and the thickness specified CHAPTER 13: PIPING 13.3.3 Pressure relief shall be provided where a check valve is installed upstream of other automatic valves Provision for liquid removal downstream of check valve shall be required. Hydrostatic protection: Section 15.6 13.3.4 Valve groups shall accommodate ammonia removal to facilitate strainer maintenance 13.3.5 Shut-off valves used to isolate equipment or devices from other portions of the system shall be capable of being locked out (by design or alternate method) 13.3.6 Shut-off valves connecting ammonia-containing equipment or piping to the atmosphere shall be capped, plugged, blanketed, or locked closed during shipping, testing, operating, servicing, or standby when not in use. 13.3.7 Valves required for emergency shutdown shall be accessible and identified in accordance with Sections 5.14.3 and 6.3.3.2; other valves must comply with Section 6.3.3.1 if located in the machinery room Risk Management Professionals 12

CHAPTER 13: PIPING 13.4 Piping, Hangers, Supports, and Isolation 13.4.1 Piping hangers and supports shall carry the weight of the piping and any additional expected loads 13.4.2 Refrigerant piping shall be isolated and supported to prevent damage from vibration, stress, corrosion, and physical impact 13.4.3 Threaded hot-rolled steel hanger rods shall be permitted 13.4.4 Anchors, their attachment points, and attachment methods shall be designed to support applied loads 13.4.5 Mechanically expanded concrete anchor bodies shall not be adjusted or axially spun after being set 13.5.6 For insulated piping, supports shall be designed or the insulation shall be selected to avoid damage to the insulation from compression CHAPTER 13: PIPING 13.5 Location of Refrigerant Piping 13.5.1 Refrigerant piping crossing walkway areas in a building shall be > 7.25 above the floor (exception: when piping is placed against the ceiling of such space) 13.5.2 Shall not obstruct a means of egress 13.5.3 Shall not be placed in a shaft containing a moving object (e.g., elevator shaft, dumbwaiter shaft, etc.) 13.5.4 Shall not be installed in a stair, landing, or means of egress that is enclosed or is accessible to the public 13.5.5 Shall be permitted to be installed underground provided that the piping is protected from corrosion 13.5.6 If installed in concrete floors, piping shall be encased in pipe duct Risk Management Professionals 13

CHAPTER 14: PACKAGED SYSTEMS AND EQUIPMENT 14.1 General 14.1.1 Packages shall be permitted to be enclosed or unenclosed; Must comply with Section 5.16 14.1.2 Shall be designed, constructed, and installed in accordance with Chapters 4 through 7, as applicable 14.1.3 Shall be ventilated based on the intended operation; Emergency mechanical ventilation shall be provided where required by the following: Any packaged system in machinery room shall follow requirements for emergency ventilation in machinery rooms (Section 7.3.1) Any packaged system located indoors and outside machinery room (per Section 4.2.3, item 5) shall follow requirements in Section 7.3.1 Any packaged system located outside that are designed for human occupancy shall follow Section 7.3.2 14.1.4 Equipment and devices incorporated into packages systems shall comply with Chapters 8 through 17, as applicable CHAPTER 14: PACKAGED SYSTEMS AND EQUIPMENT 14.2 Design 14.2.1 Structure shall be designed to support the operating weight of the included equipment. 14.2.2 Structure of the package shall be designed to withstand the stresses cause by shipping and rigging Temporary supports and bracing are permitted Rigging instructions must be provided to accommodate the installation of the structure 14.2.3 Structure of the package shall be designed to withstand loads or stresses imposed on the package after installation and start-up 14.2.4 Shall have valved pump-out connections to remove ammonia 14.2.5 Shall be designed for use in both the lowest and highest expected ambient temperatures in which they will operate Risk Management Professionals 14

CHAPTER 14: PACKAGED SYSTEMS AND EQUIPMENT 14.2.6 Access shall be provided for manually operated valves Isolation valves used for emergency shutdown procedures shall comply with Section 6.3.3.1 Valve tagging shall comply with Section 5.14.3 14.2.7 Pipes shall be marked in accordance with Section 5.14.5 14.2.8 Equipment shall be labeled in accordance with Section 5.14.2 14.2.9 Shall be equipment with lighting, or the area with refrigeration equipment shall be equipped with light fixtures delivering a minimum of 30 foot-candles (320 lumens/m 2 ) at the working level (36 above ground surface) 14.2.10 Enclosed packages that require entrance for service, maintenance, inspection, or operation shall have lighting control located at entrances CHAPTER 14: PACKAGED SYSTEMS AND EQUIPMENT 14.3 Fabrication 14.3.1 Equipment shall be set on the package in accordance with manufacturer s recommendations 14.3.2 Equipment/piping shall be supported to withstand transporting and rigging; Temporary supports and bracing are permitted 14.3.3 Stationary or temporary rigging points shall be provided as required to position the package 14.3.4 Piping shall be pressure tested after fabrication, and leaks shall be repaired 14.3.5 Electrical equipment and wiring shall be installed in accordance with the Electrical Code 14.3.6 Gas fuel devices and equipment used with refrigeration systems in the package shall be installed in accordance with Mechanical Code. Risk Management Professionals 15

CHAPTER 14: PACKAGED SYSTEMS AND EQUIPMENT 14.4 Alarms and Detection Detection and alarms for packaged systems shall comply with the following: If located in machinery rooms, they shall be included as machinery room equipment and comply with Section 6.13 If located indoors and outside of the machinery room, they shall be provided with Level 2 detection and alarms in accordance with Section 17.7.2 If located outdoors, not intended for human occupancy, they shall not require ammonia detection or alarms WHAT S NEXT? Chapter 15 Overpressure Protection Devices Chapter 16 Instrumentation and Controls Chapter 17 Ammonia Detection and Alarms Appendix Overview * This agenda may be changed based on information presented and time allotted for the next webinar. Risk Management Professionals 16

UPCOMING WEBINARS / CONFERENCES June 1, 2017 Webinar DHS CFATS Regulations and How to Prepare for an Audit presented by Nicholas Cabrena and Carine Black June 27, 2017 Webinar Using HAZOP/LOPA to Create an Effective Mechanical Integrity Program presented by Steven Maher, PE and David Childs Sept 26-29, 2017 RETA National Conference (Hershey, Pennsylvania) Sponsor and Exhibitor Oct 5, 2017 Webinar Solid & Powder Dispersion Modeling in Accordance with CalARP/RMP/PSM Regulations presented by Nicolas Cabrena Stephanie Smith, PE Sara Willman Stephanie.Smith@RMPCorp.com Sara.Willman@RMPCorp.com Risk Management Professionals, Inc. (949) 282-0123 (877) 532-0806 Risk Management Professionals 17