Can We Help You Protect Your Ammonia Facility?

admin

We Can Help You Protect Your Ammonia Facility

We are particularly proud to have been awarded a United States Patent for the Relief Valve Monitoring and Reporting System and have several in operation.

We can identify Abnormal Pressure Vessel pressures, alarm on those pressure conditions, and in the event of a relief valve release, identify the vessel and relief valve. 
 
We also identify the start and end time of the event and the actual loss of pressurized gas in real time.  
 
We are working with gas detection sensors in an effort to cover all potential leaks or releases with one system.  It really IS the first single package, multiple condition ammonia protection system available to the pressurized gas industry.   

The Origin of the Refrigerant Relief Valve Monitoring & Reporting System© (RRVMRS)

admin

U.S. Patent Number 9,684,293

WHY ARE WE HERE?

Barrow Systems was called in to a client’s facility where several ammonia releases had been reported.  BSI was asked to evaluate what had happened and to make recommendations to prevent additional releases.

Upon review, it was discovered that some of the releases were due to monitoring devices providing “false positive” alarms and others were directly attributable to vessel over pressure conditions.  In this facility, there are several refrigerant pressure vessels with a combination of single and dual relief valves.

All relief valves are piped into a common vent header which is piped outside to a containment vessel.  There is an ammonia sensor in the vent header which detects the presence of ammonia in the header near the containment vessel.  Determination of a specific pressure vessel or relief valve experiencing an ammonia release proved impossible.  There are no operational alerts indicating a relief valve release condition and the vent header was full of ammonia vapor as a result of a release.

As a result of BSI’s site evaluation, several concerns became apparent:

  • There was no way to determine if an actual refrigerant release had occurred other than a “sniff” test.
  • There was no way to determine if an over pressure condition had existed or where it may have occurred.
  • There was no realistic method for determining and reporting the time span for a refrigerant release.
  • There was no method for accurately determining and reporting the loss of refrigerant in pounds.

BSI recommended the installation of “Tell-Tale” gauges on all pressure vessels.  These gauges would indicate if a high pressure condition had been experienced at a pressure vessel.  This approach was the most practical at this point and the only reasonably reliable option available.

Barrow Systems decided that a better way of detecting vessel over pressure conditions and Relief Valve releases was needed.  BSI proceeded to work on and develop a standalone Refrigerant Relief Valve Monitoring and Reporting System©.  It’s a twofold system.  One part monitors all pressure vessels in a system, and in doing so can reduce the potential for an ammonia relief valve release or maybe prevent it altogether, while the other part has accurate reporting capabilities in the event a relief release event does occur.

 

PREVENTION!

  • A standalone system that monitors all ammonia pressure vessels continuously 24/7 regardless of operations or shutdowns.
  • A display that shows the pressure status of every ammonia pressure vessel in the system continuously 24/7 regardless of operations or shutdowns.
  • Every pressure vessel in the ammonia system is identified by name or location.
  • Prevention of an ammonia release through a relief valve:
  • There is a vessel status screen on the HMI, as well as visual indication (stack light) for any vessel that achieves a “Pressure Above Normal” condition. This gives Operations/Maintenance personnel time to respond to the location and condition.
  • The vessel status screen on the HMI will change with a second alarm including visual indication and audible annunciation (stack light and horn) for any vessel that achieves a “High Pressure” condition. Again, this gives Operations/Maintenance personnel time to respond to the location and condition.
  • Any of these alarm conditions can be sent in real time to selected computers, cell phones, printers, overhead monitors or emergency status response systems within a facility.
  • There are interlocks from the RRVMR System that can be incorporated into the facility’s refrigeration and process control systems to suspend operations or shut equipment down in an effort to avoid an over pressure condition.
  • The RRVMR System provides real time notification of any refrigeration system pressure vessel with a status outside normal operating limits. There is no delay in response time due to lack of information about vessel location or pressure, and there is a constant update of pressure on the HMI to allow supervisors to assess the current conditions and appropriate response prior to a relief valve release event.

 

REPORTING!

After developing an accurate and reliable pressure monitoring system, BSI also developed a methodology for accurately determining the loss of refrigerant in pounds using ASME certified manufacturer’s relief valve flow characteristics and accepted ASME formulas for determining loss of refrigerant through a relief valve.  After extensive, full scale and real time testing, Barrow Systems applied for and received a full Patent for the ammonia Refrigerant Relief Valve Monitoring and Reporting System© (RRVMRS).  The Patented RRVMR System generates the following indisputable information that accurately defines the refrigerant release event.

  1. An accurate, measurable real time start of a relief valve release event.
  2. An accurate, measurable real time end or termination of a relief valve release event.
  3. An accurate, measurable duration of a relief valve release event.
  4. A mathematical formula that defines the quantity of refrigerant loss at each pound of pressure and the duration of time at each pound of pressure as the vessel pressure reduces until event end or termination.
  5. Accurately identifies which relief valve released the refrigerant on a dual relief valve assembly so the relief valve can be replaced when the release event is complete.

When evaluating the loss during a relief valve release event, it is important to realize that from the beginning of a release the refrigerant quantity through the relief valve is diminishing in rate as the pressure drops and will continue to diminish until the relief valve release event stops or is terminated.

Quantity appears elusive at this point because the descending slope cannot be averaged.  This is why it was determined that quantity at a pressure must be sampled more frequently during the release.  The Real Time measurement of a relief valve release event is essential to accurately account for the loss of refrigerant. There must be a specific measurement of the time that the vessel pressure is at any given pressure during the relief valve release event.  By combining the precisely measured time and the rated flow of ammonia vapor through the valve at any given pressure, an accurate accounting of the loss in pounds can be determined.

When the relief valve release event is over, accurate recorded data is available to be reported through the facility’s emergency management protocol.  There is no need for delay in reporting due to uncertainty.  The reporting information is immediately available to be compliant with the National Response Center’s/EPA’s reporting requirements.

relief-valve-monitoring-installation

Foods Production Companies Install New Relief Valve Monitoring Systems

admin

Relief Valve Wiring Installation

Two more Refrigerant Relief Valve Monitoring and Reporting Systems were brought online in December at a global Foods production company. Commissioning of the Refrigerant Relief Valve Monitoring and Reporting System went smoothly and as expected. The system mechanical and electrical installation was inspected and validated ensuring that the system components and wiring were installed correctly.

During the startup phase of the project, we validated each pressure vessel sensor and each relief valve sensor in the refrigeration system. We also validated the program functionality by simulating a relief valve release event on each pressure vessel and each relief valve. Additionally, we validated that each screen appears at the proper time and messages are correct along with validating the refrigerant loss calculations.

The Refrigerant Relief Valve Monitoring and Reporting System is real, viable and protecting our customers, their communities, and the environment.

Manage Ammonia Releases With Easier Reporting

admin

If you use a refrigeration system for your business, it is highly likely that you utilize anhydrous ammonia refrigerant in your various cooling processes. Using an effective, but toxic chemical comes with many responsibilities.

Part of this includes laws and regulations to protect from the hazards of an accidental release. The EPA obligates any business with more than 10,000 pounds of anhydrous ammonia to submit a risk management plan. Additionally, any discharge of Ammonia over 100 pounds must be reported in a detailed manner. NOTE: Some dangerous gases have lower reporting requirements for a loss or discharge.

At Barrow Systems, we offer a full scaled solution to such responsibilities. Our patented Refrigerant Relief Valve Monitoring and Reporting System© (RRVMRS) collects and reports discharge events of dangerous gasses in a way that makes it easy for government compliance.

Patented Relief Valve System:

During a relief valve release, a detailed data report is compiled together. Below is the accurate data the system gathers:

Start Time & End Time

The measured event start time, measured event end time, and date is recorded. The exact duration of the discharge is recorded as well.

Pressure Valve Location

The system identifies the exact vessel and relief device that is used during the process. This makes it easier to pinpoint the potential cause of the release during an inspection.

Amount of Ammonia Loss

The exact amount of ammonia that is released is reported in pounds.This works for other pressurized gasses that need to be monitored as well.

Barrow Systems’ Refrigeration Relief Valve Monitoring System©

admin

At Barrow Systems, we pride ourselves in making Refrigeration Systems that not just saves money, but safeguards the lives of the operators. Our patented Refrigeration Relief Valve Monitoring System © (RRVMRS) detects abnormal pressures of ammonia before you know it yourself.

The abnormal pressure detection in any pressure vessel and “Early Bird” alarm to attract the attention of the operator is a highlighted feature of the RRVMRS. With real-time detection, our system minimizes downtime and helps the operator address potential high-pressure conditions before they become a problem.

RELIEF VALVE PATENT SYSTEM:

Emergency Alarm System

Elevated pressures trigger the system alarm to alert relevant personnel. A preventative measure this way solves the problem before the pressure relief valve is lifted.

Accurate Data

Every pressure location is displayed on an HMI screen. The data captured during a release event includes not just the time and date, but also the exact location and quantity of the release.

Real-Time Detection

Regardless of the time of day, the relief system continues to monitor and report the status of the refrigeration systems vessels. This leaves your safety to us while increasing your productivity.

Click to Learn More About Our Patented Relief Valve Monitoring System

refrigerant-relief-valve-monitoring-reporting-system-ammonia

Refrigerant Monitoring and Environmental Concerns

admin

Refrigeration is important in our daily lives. Keeping product at specific temperatures is required for industrial processes as well as preservation of various food items.

Ammonia refrigeration by design is a mechanical pressurized system containing a Hazardous Material.  By law these systems are required to meet minimum safety regulations that include a detailed reporting protocol for any unexpected release of ammonia. If an overpressure condition occurs, Relief Valves are designed into the system by code to relieve the overpressure condition, either to atmosphere or secondary containment.  In any case, a release event must be reported to the National Response Center in a timely manner with details of the event. When reporting a release event, the required information must include the start, the end and the duration of the event as well as the estimated quantity of ammonia released.

Compliance with reporting of a release event has been a subjective process at best because in large ammonia systems with many vessels and multiple processes it is virtually impossible to determine where the release originates or when it occurred. Without a defined start time the reporting is inaccurate. Without a known origin of a release, it is unlikely that the end of the event can be defined. Without the timing of the event, duration is unknown and so is the loss of ammonia in pounds.

Many times there is a delay in reporting a refrigerant release because of confusion about what vessel was experiencing high pressure and subsequent release, how many pounds of refrigerant were lost, etc.  Resulting fines from Federal, State and Local governments for late reporting have been very costly to these facilities.

Actual case #1:  Article excerpted from U.S. local news papers

More than 6,000 pounds of anhydrous ammonia spewed from a refrigeration building at the plant  for about seven hours. Environmental regulations require plants to immediately notify the National Response Center, the state Department of Environmental Protection and local emergency planning offices if a plant leaks more than 100 pounds of anhydrous ammonia.

 The U.S. Environmental Protection Agency is seeking a penalty of $46,408 against (company name withheld)  for not immediately reporting a chemical leak to the proper authorities, officials said.

Actual case #2:  Article excerpted from U.S. local news papers

The U.S. Environmental Protection Agency today announced a settlement with food processing company (company name  and location with held). The company has agreed to pay $157,900 for violations of federal regulations including failing to notify the proper officials immediately following the release of anhydrous ammonia, failure to submit a required Risk Management Plan, and inadequate chemical accident prevention.

Actual case #3:

BSI was called in to a client’s facility where several ammonia releases had been reported. BSI was asked to evaluate what had happened and to make recommendations to prevent additional releases.

Upon review, it was discovered that some of the releases were due to Leak Detector monitoring devices (sniffers) providing “false positive” alarms. There were also other releases directly attributable to vessel over pressure conditions. There are a good number of refrigerant pressure vessels with a combination of single and dual relief valves in this facility.

All relief valves were piped into a common vent header (in compliance with national codes) which was piped outside to a containment vessel. There was an ammonia sensor (sniffer) in the vent header which detected the presence of ammonia in the header near the containment vessel. Determination of a specific pressure vessel or relief valve experiencing an ammonia release proved impossible. There were no operational alerts indicating a relief valve release condition, only a vent header full of ammonia vapor as a result of a relief valve release.

As a result of BSI’s site evaluation, several concerns became apparent:

  • There was no way to determine if an actual refrigerant release had occurred other than a “sniff” test.
  • There was no way to determine if an over pressure condition had existed or where it may have occurred.
  • There was no realistic method for determining and reporting the time span for a refrigerant release.
  • There was no method for accurately determining and reporting the loss of refrigerant.

A system does exist that can take the guesswork out of the event details when reporting an ammonia overpressure relief valve release event.  Such details include “Which vessel had the high pressure release,” “Which relief valve released,” “The start time of the release,” “The end time of the release,” “The duration of the release,”  and “The pounds of ammonia loss during the release.”

Prevention of an ammonia release is the primary goal with this system, however if a release of refrigerant (anhydrous ammonia) does occur, this system is designed to provide the facility with pertinent information necessary to comply with the E.P.A.’s reporting requirements.

This technology is designed to give facilities the tools to make reporting a refrigerant release quick, accurate and easier than ever before.  This system solves so many reporting issues when a refrigerant high pressure event takes place.

 

Refrigerant Relief Valve Checklist

admin

Safety

Safe practices when working around relief valves.

  • Wearing safety glasses,  full face shield or both when working with relief valves.
  • Having breathing apparatus available in case of emergency when working with relief valves.
  • Use valve handle “lock out-tag out” procedures, to safely service relief valves in system.
  • Knowing the location of and having access to safety showers, bubbler fountains, water hoses, exits, and first-aid equipment when working with relief valves on ammonia systems.

Basics:

  1. Relief valves must be replaced every 5 years whether they have blown or not.
  2. If a relief valve blows it must be replaced. It does not matter if the relief valve reseats. Once a relief blows the relief valve blow setpoint can change causing:

Unexpected loss of refrigerant due to:

Seeping through the relief valve because valve did not fully reseat

Relief setpoint typically shifts to a lower setting, therefore valve could release or simmer at a lower pressure.

Inadequate protection of pressure vessel due to setpoint change.  Typically the setpoint shifts low but not always.

Reliability.  In time of emergency, you need to be sure your relief valve will operate properly.

 

Proper sizing of relief valves:

The minimum required discharge capacity of the pressure relief device for each pressure vessel shall be determined by the following:

C = ƒDL                      Where

C = minimum required discharge capacity of the relief device in pounds of air per minute.

D = outside diameter of vessel in feet.

L = Length of vessel in feet.

ƒ = factor dependent upon type of refrigerant. (ammonia (R-717)  = .5) and (freon 22 (R-22) = 1.6)

NOTE:  When combustible materials are used within 20 ft. of a pressure vessel, multiply the value of ƒ by 2.5

Tips

A number of guidelines for pressure relief Valve service and maintenance exist to ensure that pressure relief valves work correctly. Some tips in brief include the following.

Industry-Accepted Tips

  • Atmospheric discharge lines should have adequate rain and moisture protection, and be capable of draining condensate and rainwater.
  • Check to make sure the relief valve exit stays unobstructed.
  • Routine maintenance of pressure relief valves should include visual inspection of the relief valve and discharge piping every six months.
  • Relief valves should be replaced at intervals of no longer than five years of service.
  • Maintain pressure relief valve data in an inven­tory record, including location, size, set pres­sure, manufacturer, capacity, date installed, dates of inspections, and latest date for replacement.
  • Pressure relief valves should not be discharged during installation or start-up.
  •  Replace pressure relief valves once they have discharged.

Hansen’s Technologies Additional Tips

  • Never expose your face or body to a connected relief valve exit.
  • Avoid trapped ice build up between valves and other equipment.
  • Reduce inlet pressure to zero before attempting to install or replace any pressure relief valve. Preferably, and as required by most codes, use a three-way dual shut-oft valve to isolate relief valves for individual inspection or replacement.
  • Check the nameplate or installation date tag to be sure the time-in-service does not exceed five years.
  • Look for corrosion and leaks. If there is any doubt about the internal condition of a relief valve, remove and inspect it internally. If there is any question about a valve’s condition, replace it.

Ammonia Safety Tips

admin

While ammonia is not a poisonous gas, it does severely irritate the mucous membrane of the eyes, nose, throat and lungs.  A very small concentration of ammonia is easily detected in the air by its sharp, pungent odor.  This serves as a warning.  Prolonged exposure to air containing 100 parts per million (ppm) of ammonia is not harmful but concentrations exceeding 700 ppm will cause irritation of the eyes and may cause permanent injury.  Concentrations of 5,000 ppm or more may be fatal causing spasm or inflammation of the larynx.

Liquid ammonia should never come in contact with skin because it freezes tissue, subjecting it to caustic action.  Symptoms of such a burn are similar to a thermal burn.

Employees working where ammonia hazards exist should be trained in the following:

A. Being familiar with the system design, the components, pressures in different areas of the system and location of isolation valves in a system.

B. Safe practices when working with ammonia.

  1. Wearing safety glasses,  full face shield or both when working with ammonia.
  2. Wearing special gloves when working with liquid ammonia.
  3. Having and wearing breathing apparatus around higher concentration of ammonia.
  4. Proper procedures when handling ammonia, purging oil from an ammonia system and charging ammonia.
  5. Use normal electrical “lock out-tag out” procedures.
  6. Use “lock out-tag out” procedures on all necessary ammonia service valves to safely service components in     system.

C. Methods for properly handling ammonia containers and equipment.

D. Location of safety showers, bubbler drinking fountains, water hoses, exits, and first-aid equipment.

E. The urgency of immediately reporting any unusual odor of ammonia.

F. Proper behavior in an emergency until the doctor or other emergency specialists arrive, including:

  1. Washing eyes immediately.
  2. Removing any ammonia-saturated clothing instantly.
  3. Getting patient to lie down and provide him with fresh air.
  4. Provide oxygen if patient’s breathing is weak or administer artificial respiration if breathing has ceased.

Recommended Procedure On Changing Oil On Vilter Compressors

admin

CAUTIONRemember to always use safe practices when working with ammonia by:

  • Wearing safety glasses, full face shield or both when working with ammonia.
  • Wearing special gloves when working with liquid ammonia.
  • Having and wearing breathing apparatus around higher concentrations of ammonia.
  • Using proper procedures when handling ammonia, having control of oil purge valve and purge hose.
  • Using normal electrical “lock out/tag out” procedures.
  • Using “lock out/tag out” procedures on all necessary ammonia service valves to safely service the compressor.
  • Using methods for properly handling ammonia containers and equipment.
  • Knowing location of safety showers, bubbler drinking fountains, water hoses, exits, and first-aid equipment.

A.)   Perform a normal oil change on the compressor.

  1. Open motor disconnect to disable compressor drive motor.
  2. Turn off crankcase heater.
  3. Close compressor suction valve, discharge valve and oil return valve to isolate compressor from refrigeration system pressures.
  4. Drain the oil into an acceptable container using the compressor ammonia pressure to help facilitate the oil draining process. Caution should be exercised during this procedure.
  5. Pump down the compressor to atmospheric pressure by dissipating the remaining ammonia into a bucket of cold water. Caution should be exercised during this procedure.
  6. Remove hand hole cover from compressor and dip out all remaining oil.
  7. Remove oil sump screen and clean screen.
  8. Wipe inside of compressor clean with “lint free” rags. Visually inspect inside of compressor for anything abnormal, i.e.  wear, pieces of metal in case, or water laying in bottom of compressor.
  9. Reinstall cleaned oil sump screen.
  10. Remove oil filter canister. Remove soiled filter cartridge from spool assembly and clean canister and spool assembly.
  11. Install new oil filter on spool assembly and insert assembly into canister.
  12. Reinstall oil filter canister.
  13. Reinstall hand hole cover with a new hand hole cover gasket.
  14. Close compressor crankcase oil drain valve.

Procedure for Changing Oil on Vilter Compressors – Continued

B.)   Check oil return float assembly for proper operation and make sure all oil is drained from oil separator

C.)   Charge compressor with new Camco 717 HT oil, either through oil pressure gauge port or through crankcase oil drain valve until oil level is approximately 5/8 full in sight glass.

NOTE:   Vilter Compressor crankcase and oil filter should require 7 gallons

D.)   Slowly open suction valve and check for oil and ammonia leak

E.)   Slowly open discharge valve and oil return line from oil separator

F.)   Turn crankcase heater on

G.)   Close motor disconnect to enable compressor drive motor

H.)   Run compressor, check oil pressure, check oil level in crankcase sight glass and recheck for leaks.