4Q1.7-112.pdf

Reference Procedure Screening Form Manual Number Procedure Number Revision

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APPROVED FOR USE

Reference Procedure AIM Form (Rev 3-9-2016)

Activity is not complex

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– Examples of significant consequence: Errors have an immediate effect and/or significant impact on personnel health and safety or plant or equipment operability; consequences of errors will not be detected and/or corrected prior to the end of the activity and declaration of operability; error in performance will affect the Hazards Analysis (e.g., AHA, JHA, etc.) or USQ that was done on the procedure, and error could result in a new activity that wasn’t analyzed

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If the performance of the procedure meets all of the criteria listed above, then the procedure is properly categorized as a Reference Procedure.

The procedure is technically accurate and can be performed as written

If the procedure cannot be performed as written, then the procedure deficiencies must be corrected prior to release.

The required prerequisite training and/or position qualification are adequate to ensure the user has the skills and knowledge to perform the procedure in a logical sequence to accomplish the task.

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I have verified that the Reference Procedure is appropriately categorized, technically correct, and personnel are trained to allow performance of the procedure in a logical sequence.

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Categorization

Technical Content

Procedure User Training

Perry L. Byrd

William R. Tadlock

4Q1.7 112 6

F1571 Digitally signed by F1571 DN: dc=gov, dc=srs, ou=WSRC Users, cn=F1571 Date: 2016.05.05 13:48:32 -04'00'

O8594 Digitally signed by O8594 DN: dc=gov, dc=srs, ou=WSRC Users, cn=O8594 Date: 2016.05.05 14:30:48 -04'00'

Manual: 4Q1.7 Procedure: 112

Revision: 6

STARTUP, OPERATION, AND SHUTDOWN OF THE

PERMANENT BREATHING AIR SYSTEM FOR THE

RESPIRATORY EQUIPMENT FACILITY

Effective Date: 05/09/2016 Type-Class: Tech-REF Page: 1 of 6

1.0 INTRODUCTION

1.1 Purpose

This procedure provides detailed steps for operation of Respiratory Equipment Facility (REF) Breathing Air System (BAS).

1.2 Scope

This procedure provides instructions for operating the GA 37 Atlas Copco Stationary Air Compressor, Deltec Air Dryer, and performing proper valve positioning in associated airlines.

This procedure provides instructions for startup, operation, and shutdown of the REF BAS.

This is a Reference procedure. The user is not required to have this procedure present while performing the activity.

2.0 GENERAL INFORMATION

2.1 Definitions and Abbreviations

LED - Light emitting diode

2.2 Responsibilities

1. REF Lead is responsible for:

Notifying Operation Support personnel of any alarms, malfunctions, or service messages that may be experienced with the BAS, Starting and stopping the Respiratory Equipment Facility Breathing Air System

(REF BAS).

2. REF Personnel are responsible for:

Notifying REF Lead of any alarms, malfunctions, or service messages that may be experienced with the BAS, Starting and stopping the REF BAS.

3. Operations Support Personnel are responsible for:

Performing and coordinating all preventative maintenance, troubleshooting, and/or any repairs to the REF BAS.

4. Field Industrial Hygiene (IH) Personnel is responsible for:

Performing the quarterly breathing air quality check and any checks, which may be required or requested.

Startup, Operation, and Shutdown of the Permanent Breathing Air System for the Respiratory Equipment Facility

Revision: 6 Page: 2 of 6

2.3 Information

GA 37 Atlas Copco Stationary Air Compressor is a single-stage, oil-injected, screw compressor driven by an electric motor. The compressor is enclosed in sound-insulated bodywork. The front panel consists of an electronic control module including the start and stop buttons. An emergency stop button is also provided.

3.0 PRECAUTIONS AND LIMITATIONS

NOTE

The REF BAS is not to be used for work with hazardous material (i.e., painting, welding, etc.) unless the activities are planned as a part of a work package since safety features, such as a back-up air supply, are not available.

1. A hazard analysis has been performed on this task.

2. Safety Glasses with side shields, ear plugs, and gloves must be used when starting up, operating, and shutting down the REF BAS.

3. Only Operations Support personnel shall perform and coordinate compressor repairs.

4. Do NOT operate the compressor unless authorized and familiar with contents of this procedure.

5. Do NOT step on copper tubing extending from the air dryer to the floor drain.

6. Caution should be used when entering covered area housing the compressor. There are several pipes (tripping hazards) on the floor and areas that must be stepped over.

7. Additional hazard analysis may be required to ensure that facility/job specific hazards are identified and that the appropriate actions are taken to eliminate/mitigate the identified hazard(s).

4.0 PREREQUISITES

1. REF Personnel shall complete qualification training as specified in the Job Performance Standard or approved equal.

Startup, Operation, and Shutdown of the Permanent Breathing Air System for the Respiratory Equipment Facility

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5.0 PERFORMANCE

5.1 Pre-Startup Operating Instructions

CAUTION

Do not step on copper tubing extending from the air dryer to the floor drain. Use caution when entering covered area housing the compressor. There are several pipes (tripping hazards) on the floor and areas that must be stepped over.

1. DON eye, ear, and hand protection prior to performing Pre-Startup Operations.

2. ENSURE the following valves are in the required position:

when stem is out, the valve is open when the stem is in, the valve is closed

Valve Function Required Position

C-705000-BA-V-001 Connection for portable BAS to the

REF CLOSED

C-705000-BA-V-002 Pressure Gauge OPEN C-705000-BA-V-003 Ball Valve at Compressor Unit OPEN

C-703000-BA-V-011

Receiver tank drain strainer isolation valve at bottom of receiver tank

OPEN

C-705000-BA-V-012 Receiver tank blowdown valve CLOSED C-705000-BA-V-005 Receiver tank OPEN C-705000-BA-V-006 Receiver tank pressure gauge OPEN

C-705000-BA-V-007 Valve overhead coming off receiver tank OPEN

C-705000-BA-V-008 Air Dryer bypass valve CLOSED C-705000-BA-V-009 Air Dryer inlet valve OPEN C-705000-BA-V-010 Air Dryer outlet valve OPEN

3. IF the valve is not in the required position, THEN

MANIPULATE the valve to the required position indicated in the table found in Step 5.1.2.

4. CHECK the digital control panel daily for service messages and/or alarms.

Normal operation, the main display is shown indicating the compressor outlet pressure, the status of the compressor, and the abbreviations of the functions of the keys below the display.

Startup, Operation, and Shutdown of the Permanent Breathing Air System for the Respiratory Equipment Facility

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5.1 Pre-Startup Operating Instructions, (cont.)

5. CHECK the display, AND

ENSURE that the trouble alarm LED is not illuminated or blinking. The display will also show a service message if one of the monitored components is to be serviced.

A. IF a service message or an alarm is observed, THEN

NOTIFY the REF Lead.

6. ENSURE the pointer of the compressor oil level indicator is within the green to orange range.

A. IF the pointer of the level indicator is NOT within the green or orange range, THEN

DISCONTINUE proceeding with the startup.

B. NOTIFY the REF Lead.

5.2 Air Compressor and Air Dryer Startup

1. START the air compressor by pressing the "I" start button.

2. WAIT for the green automatic operation LED to light up once the compressor starts running, THEN

WAIT on the digital display to change from "Auto Unloaded" to "Auto Loaded".

3. VERIFY the voltage indicator light is illuminated.

4. OBSERVE the digital display until the compressor air pressure reaches 100 psig.

5. WHEN air compressor reaches 100 psig, THEN

A. STEP over to the air dryer

B. TURN the air dryer on by turning the on/off switch clockwise to the ON position.

Startup, Operation, and Shutdown of the Permanent Breathing Air System for the Respiratory Equipment Facility

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5.3 Air Dryer Operation

NOTE

Be aware of overhead piping and piping at the floor level.

1. PRESS AND RELEASE the air dryer filter automatic water drain test buttons numbered #1 on the top of the automatic water drain to drain the air dryer filter, AND

LISTEN for the sound of releasing air.

2. PRESS AND RELEASE the air dryer filter automatic water drain test button numbered #2 on the top of the automatic water drain to drain the air dryer filter, AND

LISTEN for the sound of releasing air.

3. IF the sound of releasing air is not heard, THEN

SHUTDOWN the REF BAS.

4. NOTIFY the REF Lead.

5.4 Shutdown Instructions

5.4.1 Standard Shutdown Instructions

1. DON eye, ear, and hand protection prior to Shutdown Operations.

NOTE

There may be a 30-second delay before the compressor shuts off once the Stop “O” button is pressed.

2. PRESS the Stop "O" button to shut the compressor down, AND

WAIT for the message "Programmed stop" to appear on the display.

3. TURN the air dryer off by turning the on/off switch counter-clockwise to the OFF position.

4. OPEN valve C-705000-BA-V-012, AND

DRAIN the receiver tank completely.

Startup, Operation, and Shutdown of the Permanent Breathing Air System for the Respiratory Equipment Facility

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5.4.2 Emergency Shutdown Instructions

CAUTION

In the event of an emergency stop, the air compressor shall not be restarted until qualified personnel have reviewed the problem.

1. DISCONTINUE compressor operation by pressing the large, red STOP button, AND

NOTIFY the REF Lead.

5.5 Maintenance

1. PERFORM AND COORDINATE all compressor maintenance and troubleshooting by authorized and qualified Operations Support personnel and their subcontractors.

5.6 Post Maintenance Activities

1. ENSURE the valves have been placed back into their proper settings.

6.0 REFERENCES

Atlas Copco Stationary Air Compressors Instruction book, 1998-04

Hazard Analysis INF-25371

User Manual for Electronic Regulator Gas Up to GA75 Compressor, 1996-09

7.0 RECORDS

Records generated as a result of implementing this procedure are maintained in accordance with Manual 1B, Procedure 3.31, Records Management.

8.0 ATTACHMENTS

None