RFABC Safety Leadership: Responsibilities & Plant Maintenance - - PowerPoint PPT Presentation

RFABC

Safety Leadership:

Responsibilities & Plant Maintenance

November 7, 2019

• 1. Regulatory Requirements
• 2. Refrigeration Maintenance Guideline
• 3. Engagement Session

AGENDA

2

Who is Technical Safety BC?

Technical Safety BC is the regulatory body that administers: The Railway Safety Act (RSA) The Safety Standards Act (SSA) If you are installing, operating, manufacturing, altering, maintaining

• r selling equipment in any of the

technologies we regulate, you are likely within our jurisdiction.

Products and Services Technical Safety BC offers

• Installation permits
• Operating permits
• Licensing for contractors
• Certification of individuals
• Education (tech talks, events)
• Review & approval of product designs
• Incident investigation
• Inspection based on risk
• Audit & enforcement

AMMONIA REFRIGERATION & PLANT REQUIREMENTS

Plant Supervision

Scope Terminology and references provided in this presentation on plant supervision are applicable to refrigeration plants in public occupancies such as ice rinks and curling rinks.

Plant in Operation

For the purposes of plant supervision, a plant is deemed to be in

• peration if any part of the refrigeration system contains refrigerant

(e.g. ammonia, Freon, etc.) at a pressure greater than 15 psig, unless:

• the refrigerant charge is pumped down and contained in a liquid

receiver, or parts of a system designed for that purpose,

• provided with over-pressure protection, and
• isolated to prevent the circulation of refrigerant.

Plant Supervision / Common Requirements

The regulation sets out the requirements for the supervision of refrigeration plants:

• that exceed 50 kW total capacity (Group A3, B2 and B3 refrigerants).

Ammonia plants fall under this category.

• that exceed 200 kW total capacity (Group A1, A2, and B1 refrigerants).

Freon plants fall under this category.

Plants can be operated as Continuous Supervision or Risk Assessed Status.

Classification of Refrigerants

REFRIGERANT CLASSIFICATIONS LOWER TO TOXICITY HIGHER TOXICITY HIGHER FLAMMABILITY A3 B3 LOWER FLAMMABILITY A2 B2 NO FLAME PROPAGATION A1 B1

Ethane Propane Isobutane Carbon Dioxide Ammonia Freon

Plant Supervision / Common Requirements

Person in charge of a refrigeration plant The owner of a refrigeration plant must designate a person to be in charge of the plant that is responsible for the plant at all times that it is in operation. The owner must report incidents and hazards to Technical Safety

• BC. Information Bulletin IB-BP 2017:

https://www.technicalsafetybc.ca/alerts/information-bulletin-incident- and-hazard-reporting-boilers-pressure-vessels-piping-and

Plant Supervision / Common Requirements

The person in charge of a plant that is Continuous Supervision or Risk Assessed Status refrigeration plant is required to hold a:

• 4th Class Power Engineer (PE) (or higher), or
• Refrigeration Operator (RO) certificate

Note – a PE or RO are also qualified to be in charge of a shift

Plant Supervision / Common Requirements

Ice Facility Operator (IFO)

• can be the person in charge of a shift in a Continuous

Supervision or Risk Assessed Status refrigeration plant that does not exceed 1000 kW total capacity Note – an IFO is not qualified to be the person in charge of a plant

Plant Supervision / All Plants

• the person in charge of a shift shall be in the immediate

vicinity of the plant premises at all times that the plant is in

• peration
• the person in charge of a shift is not intended to be within

the refrigeration machinery room at all times, but must be

• n-site, within the plant premises

CONTINUOUS SUPERVISION STATUS PLANTS

Plant Supervision / Continuous

Means that the plant is required to be under continuous supervision at all times that the plant is in operation Supervision is not required when:

• the plant is not in operation
• the plant does not exceed 50 kW total capacity (Group A3, B2

and B3 refrigerants e.g. ammonia)

• the plant does not exceed 200 kW total capacity (Group A1, A2,

and B1 refrigerants e.g. Freon)

Plant Supervision / Continuous

Person in charge of a shift A person in charge of a shift in a Continuous Supervision Status plant is required to hold a:

• 4th Class Power Engineer (or

higher),

• Refrigeration Operator, or
• Ice Facility Operator certificate

SUPERVISION / RISK ASSESSED: RISK ASSESSED STATUS PLANTS

Supervision / Risk Assessed

Section 56 of the regulation provides the requirements for a Risk Assessed Status Plant

• limited to refrigeration plants up to and including 1000

kW capacity

• Plant must meet additional technical specifications

including remote monitoring and alarms

• Provides for reduced supervision when the plant is in
• peration and the premises are not occupied

Supervision / Risk Assessed

Supervision of a risk assessed plant is required at all times when:

• The plant is in operation, and
• The premises are occupied (by any person)

Supervision of a risk assessed plant is not required when:

• The plant is not in operation, or
• The plant is in operation and the premises are

unoccupied

Supervision / Risk Assessed

The person in charge of a shift for a minimum of 7 hours in any 24 hour period is required to hold a:

• 4th Class Power Engineering (or higher), or
• a Refrigeration Operator certificate

The person in charge of the remaining shifts in any 24 hour period is required to hold a:

• PE (4th class or higher), RO, IFO, or
• a Refrigeration Safety Awareness certificate

Supervision / Risk Assessed

Refrigeration Safety Awareness Certificate The regulation was recently amended to remove the requirement for a RSA certificate to name the plant on the certificate. However, it is now the responsibility of the owner of the plant to ensure that the RSA certificate holder is trained in the safety procedures for that specific plant prior to being assigned to the shift schedule

MAINTENANCE GUIDELINES

Ammonia Refrigeration Incidents

• Upward incident trend
• 39 injuries
• 3 fatalities
• Two area evacuations
• One state of emergency
• 75% of incidents caused by:
• Equipment Failure
• Inadequate procedure

Fernie Memorial Arena – Multiple Areas of Failure

Employee Turnover

FERNIE

OCTOBER 17, 2017

3 Fatalities 95 Residents

Knowledge & Expertise Unclear Roles Competing Priorities Maintenance programs Hazards and Risk

WHY SHOULD YOU CARE?

Why should you care?

Cost of an incident Well being of your people

1

• Financial loss
• Productivity loss
• Legal costs
• High internal turnover
• Incidents can cause

injuries, or even death

• Complying and

following safety procedures leads to:

• Employee confidence
• Less downtime
• Healthier workplace

2

Why should you care?

Your legal responsibility It’s good for your business

3

• Installation permit
• Licensed contractors

& certified individuals

• Asset Owners
• Qualified individuals
• New designs, newly

built equipment

• Reporting
• Positive reputation
• Hiring
• Longevity and

reliability of equipment

• Reduces risks of

shutdowns

• Reduces

legal/regulatory issues and costs

4

Summary of responsibilities

Maintenance Requirements:

• Act and Regulation
• CSA B51
• in-service inspection must be performed to determine

the condition and fitness to continue to operate safely

• f pressure vessels, piping and fittings in a

refrigeration system

• CSA B52
• owner must maintain the refrigeration system to

preserve the operating efficiencies, equipment integrity, personal protection and protection of the building and natural environments

• NBIC, Part 2

Maintenance Strategies and Practice

Strategy Description

Corrective

Inspections, repairs, replacements carried out following detection of anomalies.

Preventative

Inspections, repairs and replacements are scheduled at pre- determined intervals.

Predictive

Regularly assess condition and repair

• r replace prior to estimated failure.

Reliability Centered

Analyze failure modes and customize inspections, repairs and replacements based upon desired reliability.

PURPOSE OF MAINTENANCE GUIDELINE

Provide guidance and basic information for the development of a maintenance and inspection program and operational procedures

Guideline Objectives

• Provide support to industry in response to the report’s

recommendations

• Provide direction and guidance to owners, contractors, training

providers & operators

• Improve the management and oversight of:
• maintenance programs
• inspection
• perational emergency procedures

Industry Standards and Guidelines

Limited resources (specific to ammonia refrigeration systems)

• standards
• guidance
• information

Refining and Petrochemical API:

• RP 571 (Damage Mechanisms Affecting Fixed Equipment in the Refining Industry)
• RP 574 (Inspection Practices for Piping System Components)

Goal of proposed guidelines is to fill this gap

Ammonia Refrigeration Maintenance Guideline

• 1. Main Body and general information: Equipment Integrity

Management Program

• 2. Appendix A: Sample of an integrity management manual
• 3. Appendix B: Damage mechanisms and inspection approaches

Plant Equipment Integrity Planning in 3 parts:

Ammonia Refrigeration Maintenance Guideline

• Scope
• Definitions
• Owners responsibilities
• Equipment integrity management

program requirements

• Mandatory codes and regulations

Main Body and General Information:

Ammonia Refrigeration Maintenance Guideline

• Statement of authority and

responsibility

• Manual control
• Training and competency
• Document and records admin
• Procedures
• Installation, repair and alteration

methods

• Materials

Equipment Integrity Management Program Requirements:

Ammonia Refrigeration Maintenance Guideline

• Corrosion
• Erosion
• Cavitation
• Damages specific to certain

refrigeration equipment: Piping,

Compressors, Condensers, Heat exchangers, …

Appendix A: Sample of an integrity management manual Appendix B: Damage mechanisms and inspection approaches

ENGAGEMENT SESSION

Technical Safety BC would like your input:

1. What steps has your organization taken in the last 2 years to improve maintenance practices and ongoing operations? 2. What were some of the challenges faced during the implementation of those improvements? What’s your top tip to share with others? 3. What do you need from Technical Safety BC?

Every table reports back with a 3 - 5 minute summary

PROVIDING FEEDBACK

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Group Discussions

• The maintenance guideline consultation is closed but you can

provide input by email

• A feedback summary will be posted by the end of the year
• Next steps will be posted on Technical Safety BC’s website

Questions?

Please contact us at engage@technicalsafetybc.ca Thank you for inviting us today

NEXT STEPS

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QUESTIONS?

THANK YOU