Operator Training rsupport.com



|SECTION 5 |

|Operator Training |

|Delhaize America |

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| |Revision Date: |February 12th 2016 |

| |Total Pages: |8 |

|PURPOSE: |

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|The Occupational Safety and Health Administration (OSHA) Process Safety Management (PSM) element and the corresponding Environmental Protection|

|Agency (EPA) Risk Management Program (RM Program) element relating to Training, is to insure that proper training has been given to employees |

|who are involved with the ammonia refrigeration system. Knowledge in the safety and health hazards of ammonia, and the ammonia refrigeration |

|system is necessary for the protection of the individual, the facility employees, the citizens who live nearby, and the environment. |

|SCOPE: |

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|This document summarizes how DELHAIZE AMERICA complies with the requirements of the PSM, Training element, 29 CFR §1910.119 (g), and the EPA’s|

|RM program, Training element, 40 CFR §68.71. It requires the facility to establish a training program for all employees involved in the |

|operation, maintenance, and supervision of the ammonia refrigeration system. This program includes the following: |

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|Identity of associates to be trained |

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|Training program technical content |

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|Competency requirements |

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|Documentation requirements for demonstration of competence |

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|Schedule for initial training and refresher training |

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|Training for change |

|REFERENCES: |

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|29 CFR §1910.119 Process Safety Management of Highly Hazardous Chemicals, Paragraph (g) |

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|40 CFR Part 68 Accidental Release Prevention Requirements: Risk Management Programs under the Clean Air Act, Section 112(r)(7). |

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|40 CFR Parts 9 and 68 List of Regulated Substances and Thresholds for Accidental Release Prevention and Risk Management Programs for Chemical |

|Accidental Release Prevention; Final Rule and Notice. |

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|PROCEDURES: |

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|DELHAIZE AMERICA’s responsibility includes well defined and administered training programs. The DELHAIZE AMERICA’s responsibility includes a |

|commitment to learning, a commitment to knowing and a commitment to request further training if they feel that they are not knowledgeable about|

|any operating procedures. |

|1.0 |MINIMUM OPERATOR/MAINTENANCE PERSONNEL TRAINING |

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| |Each refrigeration technician should be knowledgeable in the following: |

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| |• Ammonia properties, safety and health hazards; |

| |• The refrigeration cycle -- how the facility operates; |

| |• Each facility component (i.e. compressors, condensers, evaporators, liquid pumps, receiver, accumulators, purge unit, stop |

| |valves, controls and control valves); |

| |• Mechanical integrity program requirements; |

| |• Normal facility operating procedures; |

| |• Fixed and portable ammonia detector use and calibration |

| |• Normal facility operating limits; |

| |• Identifying and correcting abnormal operating conditions; |

| |• Responsibilities under the Emergency Response Plan; |

| |• Facility Piping & Instrumentation Diagrams and Process Flow Diagram; |

| |• Lubricant management; |

| |• Line breaking procedures |

| |• Personal Protective Equipment |

| |• SDS for ammonia; |

| |• Safe work practices; and |

| |• Overview of the Risk Management Program and Process Safety Management. |

|2.0 |COMPETENCY REQUIREMENTS |

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| |DELHAIZE AMERICA is responsible for verifying that the maintenance personnel have understood the training requirements. This |

| |verification is obtained through observation and/or written verification. |

|3.0 |INITIAL AND REFRESHER TRAINING SCHEDULE |

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| |A schedule for initial training of associates (e.g., new hires and transfers), and future refresher training for each associates |

| |is verified by DELHAIZE AMERICA |

| |The schedule for refresher training needs was determined and confirmed by consulting with the associates. |

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| |Refresher training is currently every 3 years and as projects arise and/or as employees request it. |

|4.0 |TRAINING FOR MANAGEMENT OF CHANGE |

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| |Additions or changes (MOCs) in the facility require training of all involved maintenance personnel. |

|5.0 |TRAINING REFERENCES |

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| |The following are examples of sources of information on training resources: |

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| |A) RETA (Refrigerating Engineers and Technicians Association) |

| |Chicago, IL |

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| |B) IIAR (International Institute of Ammonia Refrigeration) |

| |Washington, DC |

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| |C) Equipment Manufacturers |

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| |D) Contractors |

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| |E) Consultants/Engineers |

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| |F) Colleges, Universities, Community Colleges, and Vocational Schools |

|DOCUMENT MANAGEMENT: |

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|DELHAIZE AMERICA maintains a training file with the following information: |

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|Name of associate; |

|Date of training; |

|Subject matter; |

|Means used to verify understanding of training (written test); |

|Signature of associate; and |

|Signature of trainer. |

DELHAIZE AMERICA

AMMONIA REFRIGERATION TRAINING CERTIFICATION FORM

Trainee Name:_________________________________

Trainee Signature______________________________ PSID#___________________

Date of Training: _____ This Training is:

Name of Trainer: θ Initial θ Refresher

|Training Topics Covered (check all that apply): |

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| |Anhydrous Ammonia Properties, Safety and Health Hazards (SDS’s) |

|θ |Identification |

|θ |Physical Data |

|θ |Reactivity Data |

|θ |Health Hazard Data |

|θ |Special Protective Data |

|θ |Special Precautions or Other Data |

|θ |Ingredients & Exposure Limits |

|θ |Fire & Explosive Hazard Data |

|θ |Spill or Leak Procedure |

|θ |Emergency First Aid Procedure |

|θ |Refrigeration Cycle Operation, including normal operating parameters |

|θ |Compressor Operation |

|θ |Condenser Operation |

|θ |Evaporator (Air Unit) Operation |

|θ |Ammonia Liquid Pump Operation |

|θ |Receiver Operation |

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|θ |Purger Operation |

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|θ |Accumulator Operation |

| |Review of Standard Operating Procedures (SOP’s): |

|θ |Ammonia Refrigeration System Relief Valve Replacement |

|θ |Shutdown of Ammonia Refrigeration System |

|θ |Startup and Operation of Ammonia Refrigeration System |

|θ |Defrost of Evaporator Units |

|θ |Emergency Shutdown of Ammonia Refrigeration System |

|θ |Power Failure |

|θ |Oil Draining from Ammonia Refrigeration System |

|θ |Isolation and Pumpout of Liquid Ammonia Pumps |

|θ |Isolation and Pumpout of Screw and Reciprocating Compressors |

|θ |Review of Mechanical Integrity Program |

|Training Topics Covered (check all that apply): |

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|θ |Emergency Response Plan (ERP): |

|θ |Evacuation Procedures |

|θ |Review of Emergency Response Plan |

|θ |Review of Ammonia Detection System: Fixed and portable use and calibration |

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|θ |Review of Ventilation System including manual and automatic operation |

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| |Review of Electrical Shutdown Switches |

| |Safe Work Practices: |

|θ |Lockout/Tagout Procedures |

|θ |Personal Protective Equipment |

|θ |Hot Works Permits |

| |Equipment Operation: |

| |(fork lifts, pallet jacks, sweeper/scrubber, scissor lift, and utility carts) |

|θ |Daily Inspection Log Sheet |

|θ | |

|θ |Overview of the Process Risk Management Program and Process Safety Management Program |

|θ |Other: |

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|θ | |

|θ | |

|Associate Name |Associate Signature |Test Score |

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I hereby certify that the above list of associates were tested by me on the above checklist of topics and have passed, to my satisfaction, the training requirements.

Date:_________________________________

Trainer Signiture:_____________________________________________

Delhaize America Ammonia Refrigeration OPERATOR TEST

Name:_______________________________________________ Date:______________

PSID#_______________

There are six pages to this exam. Please ask questions if a question is unclear.

PART I

TRUE OR FALSE

1. The refrigeration system uses ammonia as the refrigerant.

2. Temperature and pressure indicates the amount of heat present in the

refrigerant.

3. A hand expansion valve in the pumped liquid line is used for isolation.

4. Ammonia liquid in a pipe or coil and will boil off leaving a layer of

frost on the outside surface.

5. Ammonia is corrosive.

6. When refrigerant evaporates or boils off it absorbs heat.

7. An evaporative condenser operates by using air and water to

condense liquid.

8. According to guidelines established by the IIAR, all system safety

relief valves should be replaced every 5-years.

9. In a system using screw compressors with thermosyphon oil cooling

the oil is cooled using high pressure liquid.

10. Ammonia is classified as a toxic hazardous substance having low

flammability.

11. Ammonia vapor is lighter than air.

12. Typical refrigerant solenoid valves stop the flow of refrigerant in

in both directions.

13. Copper tubing is acceptable for ammonia.

_____ 14. Never isolate liquid ammonia in a pipe between two isolation valves.

_____ 15. Always try and stop the leak soon as you observe one.

_____ 16. When oil draining the ventilation system should be turned off.

_____ 17. Always add heat using a torch or heater to warm the oil in an oil pot.

_____ 18. Reliefs should be replaced or recertified every 5 years per IIAR.

_____ 19. Ammonia vapor and liquid is colorless.

PART II

MULTIPLE CHOICE & FILL IN THE BLANK (Circle The Best Answers)

1. The saturated pressure of -28F from the ammonia tables is:

a. 4.6 PSIG

b. 31.4 PSIG

c. 0.0 PSIG

d. None of the above

2. What happens in a closed vessel or air unit that is isolated when the temperature of the

ammonia increases?

a. Pressure increases inside.

b. Pressure increases and blows relief where installed.

c. Pressure decreases.

d. Nothing happens.

3. Liquid ammonia at atmospheric (sea level) pressure laying on the ground or roof is at:

a. -40 deg F

b. -40 deg C

c. -28 deg F

d. +95 deg F

4. The heat associated with a refrigerant when it changes phase is:

a. Sensible heat.

b. Latent heat.

c. Vaporization heat.

d. Heat of fusion.

5. For most ammonia systems, the best pressure set point for the defrost

relief regulator is:

a. 50 to 60 psig.

b. 65 to 75 psig.

c. 90 to 100 psig.

d. 80 to 90 psig.

6. Compressor oil which has migrated into an ammonia refrigeration system

will normally accumulate in:

a. Condensers

b. Evaporators

c. High temperature vessels

d. Low temperature vessels

7. The flammable limits of ammonia vapor in air are:

a. 10% to 20%

b. 16% to 28%

c. 10% to 25%

d. 15% to 30%

8. When ammonia liquid or vapor leaks into a room it may (select all that apply):

a. Displace the oxygen

b. Form a visible cloud.

c. Ignite if mixed with oil and an ignition source is available.

d. Ignite between 16% and 28% if and ignition source is available.

9. You are caught in a ammonia release. What do you do?

a. Run.

b. Sound the alarm and go upwind to staging area.

c. Use the eye wash shower station for 15 minutes.

d. Try and isolate the leak.

10. High discharge or head pressure may be caused by:

a. Computer system failure

b. Fans not operational

c. Water pumps not operational.

d. Non-condensibles in the system.

11. Who must be notified when you observe an abnormal situation?

_______________________________________________________________

12. A service valve is "back-seated" when:

a. Completely open.

b. Completely closed.

c. The packing nut is tightened.

d. None of the above.

13. The Hansen Auto Purger automatically removes non condensibles from what part of the system?

a. Condenser HSD

b. Condenser CD at outlet.

c. Pump Recirculator PR-1

d. Main CD at HPR

14. Emergency fan ventilation switch for the engine room is located where?

_________________________________________________________________

15. Emergency stop buttons for the compressors are located where?

_________________________________________________________________

16. What does the Hansen level indicator do?

A) Provide the quantity of ammonia vapor in the vessel.

B) Provide the liquid level in the vessel in inches

C) Provide the liquid level as a percent of probe length.

D) It doesn’t do anything unless calibrated.

17. The compressors operate based on what?

A) What the computer tells them to do?

B) Load.

C) Suction pressure changes in the system.

D) The set points in the Microprocessor and computer.

18. The valve stem on a 3-way manifold connected to a dual relief valve assembly must

be set at the midway position.

A) True

B) False

19. What is the normal operating level for the high pressure receiver HPR?

______________________________________________________

20. Match the following P&ID abbreviation with the appropriate explanation.

A) LTRS ___ Liquid Solenoid Valve

B) HG ___ Strainer

C) HTRS ___ Low Temperature Re-circulated Suction

D) HTS ___ Hot Gas

E) HTRL ___ High Temperature Re-circulated Suction

F) HPL ___ High Temperature Suction

G) RV ___ Hand Expansion Valve

H) ST ___ Relief Vent

I) LSV ___ High Pressure Liquid

J) HXV ___ High Temperature Re-circulated Liquid

K) HSD ___ High Stage Discharge

L) DR ___ Condenser Drain

M) TSS ___ Thermosyphon Supply

N) CD ___ Defrost Relief or Return

O) TSR ___ Thermosyphon Return

21. Pressure vessels isolated from the refrigeration system should not be filled with liquid

refrigerant beyond 80% of their internal volume.

A) True

B) False

22. In the event of an ammonia leak in the engine room, the system compressors

will shut down at what concentration?

A) 50 ppm

B) 100ppm

C) 500ppm

D) 250ppm

23. The King Liquid Solenoid valve is used for what purpose.

_____________________________________________________________

24. What proper PPE should be worn when working on the ammonia refrigeration system

on a day to day basis? Not oil draining.

____________________________________________________________________

25. What PPE should be worn when entering the system or draining oil?

____________________________________________________________________

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