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. 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. 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 Engineering Plant Engineer - Mike Cannon Plant Manager - Steve Waters

Purpose

Concerns

Department Operator/ Responsibility

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 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 Authorized by Revision Annual Review by Annual Review by No. 0 January 2002

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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. Capacity/Size Operating Limits Suction pressure: 22-30 psig Head pressure 150-181 psig Discharge pressure. 155-181psig 210 psig maximum discharge pressure Deviations/Consequences Low suction pressure may result in inefficient operation (and freeze up icemakers). High discharge pressure may result in minimizing compressor capacity. Over-pressurization may result in operation of pressure relief valves.

Description

(3) Frick Screw 735 HP Compressors Model 478.1 TR RWF 270

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: 110F High lubrication oil temperature could result in compressor damage and a release of ammonia. High discharge temperature could result in compressor damage and a release of ammonia.

Discharge temperature: 150-170F

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Controls and Instrumentation Description Item Number Discharge Pressure indicator Suction Pressure indicator

Function

Position/Set point 155-181 psig.

Displayed on each compressor Pressure indication on and on the operator interface compressor discharge terminal (Panelview) 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. Slide stop control internal set point. Internal function that controls the ratio of the discharge port and suction slide valve position for most optimal efficiency of compress.

Set to control low temperature event and to unload at 23-34 psig to prevent freeze up of Vogt Ice Maker.

Located in the set point parameters of Quantum controller on the compressor.

Compressor valve listing

VAL UNIT # SIZE 2" 5" 2" 1/2" 1-1/2" 1-1/2" 1-1/2" 1-1/2" 1/4" 1/4" 1 1/2" 1/2" 1/2" 4" 1/2" 1" C-3,4,5 1 C-3,4,5 2 C-3,4,5 3 C-3,4,5 4 C-3,4,5 5 C-3,4,5 6 C-3,4,5 7 C-3,4,5 8 C-3,4,5 9 C-3,4,5 10 C-3,4,5 11 C-3,4,5 12 C-3,4,5 13 C-3,4,5 14 C-3,4,5 15 C-3,4,5 16 TYPE CONN DISCRIPTION SW BW SW FLG SW FLG FLG FLG ANGLE VALVE ANGLE VALVE ANGLE VALVE FUNTION ISOLATION VALVE ISOLATION VALVE ISOLATION VALVE MANUF MODEL Name R/S R/S R/S R/S R/S R/S R/S R/S R/S R/S R/S A2CK THERM. FEED ISOLA. VALVE SUCTION ISOLA. VALVE THERM. RETN. ISOLA. VALVE THERM. BYPASS ISOLA. VLV. SIDE-LOAD ISOLA. VALVE

PRES. REGULATOR MODULATION VAL ANGLE VALVE ISOLATION VALVE

PRESS. REG.W/STR MODULATION VAL CHECK VALVE STRAINER DIRECT CONTROL DEBRIS FILTER

A4AS-ST SIDE-LOAD PRES. REGULATR CK4A6 Q6 V12 SIDE-LOAD CHECK VALVE SIDE LOAD HAND EXP. VAL. SIDE LOAD PRES. GAUGE SIDE LOAD GAUGE VALVE SIDE LOAD ISOLA. VALVE THERM BYPASS ISOL. VALVE THERM FEED DRAIN VALVE DISCHARGE ISOL. VALVE

MPT PRESSURE GAUGE MEASURE PRES. FPT SW SW FPT BW FPT SW GAUGE VALVE ANGLE VALVE ANGLE VALVE GLOBE VALVE ANGLE VALVE ISOLATION VALVE ISOLATION VALVE ISOLATION VALVE ISOLATION VALVE ISOLATION VALVE

DUAL RELIEF VLVS OVER PRES RELIEF SHANK ANGLE VALVE ISOLATION VALVE DANVL

803-300 OVER PRES. RELIEF VALVES SEPARATOR SERVICE VALVE

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Safety Systems Pressure relief valve PSV-15 Description Low suction pressure cutout, operator set point. Item Location Relieve excess ammonia vapor 300 psig Factory Set device pressure to the deluge tank Function Position/Set point 10 psig

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. Alert personnel and protect the compressor from damage due to high discharge pressure by alarming and then shutting down compressor

High discharge Each Quantum Compressor pressure pre-alarm Controller and the PLC control and cutout, operator system monitors the low set point. suction pressure setting. Low lubrication oil Each Quantum Compressor temperature cutout, Controller monitors the low internal set point. lubrication oil temperature cut out. High lubrication oil temperature cutout, internal programmed set point. Each Quantum Compressor Controller monitors the high lubrication oil temperature cut out.

Stop Load Force Unload Alarm Shutdown 5 Second delay

190 PSIG 200 PSIG 210 PSIG 215 PSIG 55F 49F

Protect the compressor from Alarm damage due to low lubrication Shutdown oil temperature by shutting 5 Second delay down compressor Protect the compressor from Alarm damage due to high lubrication 30 Second delay oil temperature by shutting Shutdown down compressor 10 Second delay Protect the compressor from Stop Load damage due to high discharge Force Unload temperature by shutting down Alarm compressor Shutdown

144.8F 155.0F 180F 190F 200F 195F

High discharge Each Quantum Compressor temperature cutout, Controller monitors the high internal discharge temperature cut out. programmed set point.

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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 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.

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. 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.

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Task Step 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 Comment

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. 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.

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Task Step Comment During normal operations, the compressor is automatically started and stopped, and will automatically load and unload based on suction pressure.

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

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.

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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.

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Task Step Comment

Changing Refer to Frick owners 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. 8. Remove the old filter cartridges, then install new ones. 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.

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Task Step Comment

Coalescer Filter Elements When changing the coalescer filter elements, Frick Refer to Frick owners manual 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.

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Task Changing Main Oil Filters (Single/Dual) Step Follow all lockout safety procedures when changing oil filters. 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. 10. 11. Close the purge valve. Open the outlet service valve and check for leaks. Open inlet service valve. Comment Refer to Frick owners manual for full details and associated procedures.

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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