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Questions and Answers
What is the responsibility of the Maintenance Operator as per the operating procedure?
Which of the following items is NOT listed as personal protective equipment (PPE) in the document?
What type of injury may result from chemical contact according to the content?
What precaution should be taken to prevent head injuries while operating near the structures?
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Which individual is accountable for the overall operation as stated in the procedure?
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What should be ensured before starting the operation of the compressor as per the SOP?
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What hazard is associated with water spillage on the floor?
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What is one of the main responsibilities of the Supervisor in the operating procedure?
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What is the recommended range for suction pressure during the operation of the ammonia compressor?
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What temperature should the glycol be set to for the operation process?
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Which parameter must be logged every hour during the operation?
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What is the normal range for discharge pressure during the compressor operation?
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What is the first step to take when starting the operation of the ammonia compressor?
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What is the first step to initiate the operation of the ammonia compressor and glycol plant?
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Before taking production, how long should the compressor be switched on?
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What pressure should the glycol inlet be maintained at?
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Which valves should be opened on the screw compressor's evaporator side?
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What should be checked after switching on the cooling tower fan and pump?
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If there is a pressure drop in the evaporator or condenser, what action should be taken?
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What should be the cooling inlet pressure during operation?
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What should be done to ensure proper flow in the compressor HMI?
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What should be done if any abnormality is found in the system?
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What is the required density for Glycol?
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Which of the following is NOT part of the stopping procedure?
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When should the compressor be switched off?
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What action should be taken after switching off the compressor?
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Which component should be turned off last during the stopping procedure?
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What should you do with the Liquid line Solenoid coil during the stopping procedure?
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Which of the following actions is part of the procedure after production is completed?
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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.
