SOP for Ammonia Compressor and Glycol Plant

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Questions and Answers

What is the responsibility of the Maintenance Operator as per the operating procedure?

To maintain operation of the Cooling Tower and related equipment (correct)

To monitor the entire cooling process

To oversee all utility processes

To ensure accountability and compliance

Which of the following items is NOT listed as personal protective equipment (PPE) in the document?

Safety goggles

Safety mask (correct)

Nitrile gloves

Ear plugs

What type of injury may result from chemical contact according to the content?

Skin injury (correct)

Head injury

Muscle strain

Physical injury

What precaution should be taken to prevent head injuries while operating near the structures?

Wear a safety helmet with chinstrap Signup and view all the answers

Which individual is accountable for the overall operation as stated in the procedure?

Engineering Manager Signup and view all the answers

What should be ensured before starting the operation of the compressor as per the SOP?

Guards are available for compressor pulley equipment Signup and view all the answers

What hazard is associated with water spillage on the floor?

Physical injury Signup and view all the answers

What is one of the main responsibilities of the Supervisor in the operating procedure?

To monitor the entire cooling process Signup and view all the answers

What is the recommended range for suction pressure during the operation of the ammonia compressor?

31-35 psi Signup and view all the answers

What temperature should the glycol be set to for the operation process?

-1°C – 0°C Signup and view all the answers

Which parameter must be logged every hour during the operation?

Discharge Pressure Signup and view all the answers

What is the normal range for discharge pressure during the compressor operation?

150-180 psi Signup and view all the answers

What is the first step to take when starting the operation of the ammonia compressor?

Switch on the Glycol Pump Signup and view all the answers

What is the first step to initiate the operation of the ammonia compressor and glycol plant?

Switch ON the control supply to the control panel Signup and view all the answers

Before taking production, how long should the compressor be switched on?

10 minutes Signup and view all the answers

What pressure should the glycol inlet be maintained at?

1.5 bar to 2.5 bar Signup and view all the answers

Which valves should be opened on the screw compressor's evaporator side?

Glycol inlet and outlet valves Signup and view all the answers

What should be checked after switching on the cooling tower fan and pump?

Water level in the sump Signup and view all the answers

If there is a pressure drop in the evaporator or condenser, what action should be taken?

Clean the strainer in the pump and compressor Signup and view all the answers

What should be the cooling inlet pressure during operation?

1.5 bar to 2.0 bar Signup and view all the answers

What should be done to ensure proper flow in the compressor HMI?

Switch on the cooling tower fan motor and pump Signup and view all the answers

What should be done if any abnormality is found in the system?

Initiate the issue to the Supervisor Signup and view all the answers

What is the required density for Glycol?

1.03 g/cm³ Signup and view all the answers

Which of the following is NOT part of the stopping procedure?

Increase the compressor speed Signup and view all the answers

When should the compressor be switched off?

When production is completed Signup and view all the answers

What action should be taken after switching off the compressor?

Switch off the Glycol & cooling Tower Pumps Signup and view all the answers

Which component should be turned off last during the stopping procedure?

Ammonia Compressors Signup and view all the answers

What should you do with the Liquid line Solenoid coil during the stopping procedure?

Put it off Signup and view all the answers

Which of the following actions is part of the procedure after production is completed?

Stop the cooling tower pumps on SCADA Signup and view all the answers

Study Notes

Operating Procedures for Ammonia Compressor and Glycol Plant

This standard operating procedure (SOP) outlines the steps for safely operating a cooling tower, ammonia compressor, and glycol plant in a food processing facility.
The procedure applies to utility operators in the Fresh Chilled Division and is essential for the safe and efficient operation of the plant.
Safety precautions include wearing personal protective equipment (PPE) such as safety shoes, safety helmet, safety goggles, and nitrile gloves to avoid physical injury from water spillage, head injury from hitting structures, and skin injury from chemical contact.

Startup Procedure

Pre-Start Checks: Ensure all guards are in place for equipment, switch on the control supply, and switch on the compressor ten minutes before starting production.
Valve Position and Flow Checks: Open the compressor suction and discharge valves, glycol inlet and outlet valves, and cooling tower inlet and outlet valves. Check the flow of glycol and water through the evaporator and condenser, ensuring there are no blockages.
Cooling Tower System Activation: Initiate the cooling tower fan and pump, ensuring adequate water level in the sump.
Pressure and Temperature Regulation: Maintain the glycol inlet pressure between 1.5 and 2.5 bar and the cooling inlet pressure between 1.5 and 2 bar. Set the glycol temperature as per process requirements, typically between -1°C and 0°C.

Operational Monitoring

Parameter Monitoring: Continuously monitor suction pressure (31-35 psi), discharge pressure (150-180 psi), and other relevant parameters. Record these values every hour in a designated log book.
Glycol Density Control: Maintain the glycol density at 1.03 g/cm³.
Issue Reporting: If any abnormalities are observed, immediately report the issue to the supervisor.

Shutdown Procedure

Production Completion: Once production is complete, switch off the compressor, liquid line solenoid coil, glycol pump, and cooling tower pumps.
Valve Closure: Close the compressor suction valve.
System Deactivation: Stop the cooling tower pumps and fans on the SCADA (Supervisory Control and Data Acquisition) system if necessary.
Complete Shutdown (If Required): Stop the glycol pumps and ammonia compressors on the SCADA system if they are not needed.

Summary of Key Parameters

Glycol Inlet Pressure: 1.5 - 2.5 bar
Cooling Inlet Pressure: 1.5 - 2 bar
Glycol Temperature: -1°C - 0°C
Suction Pressure: 31 - 35 psi
Discharge Pressure: 150 - 180 psi
Glycol Density: 1.03 g/cm³

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Description

This quiz covers the standard operating procedures for safely operating ammonia compressors and glycol plants in a food processing facility. It includes essential safety precautions and steps for pre-start checks and valve position verification. Ideal for utility operators in the Fresh Chilled Division.