Integrated Risk ManagementRMIT - Building 57CO2 Refrigeration Lab Prepared By : RDJ27/12/14 Updated: 6 Jan -15 ISECOEngineering Services PTYLikelihood Consequence Likelihood ConsequencePipe ruptureUnlikely Medium MediumCertified welders / procedures/ pressure testing . Also ensure any capped pipe work /valveswithAmmonialiquid haveprovisions to prevent over pressure liquid trapping ( i.e. check valve orrelief valve) Adequate AlwaysUnlikelyMedium Low NOCheck any capped future connections cannot trap CO2 orAmmonia Liquid - okno valves on future caps Relief valve liftPossible Medium SignificantPressure releifvent lines discharge towater tank Adequate AlwaysUnlikelyMinor Low NORoutine Maintenance required to manage tank water level & check pressure relif valves as per supplier recommendations Pressure Vessel failureUnlikely Medium MediumVessels to AS1210 & pressure tested/register with WHS and inspected annually /as per standardAS 3788 Adequate AlwaysUnlikelyMinor Low NORoutine pressure vessel inspection requiredCorrosionPossible Medium SignificantUse of stainless steel pipes,Painted vessels and copper tubing ( CO2) Adequate AlwaysUnlikelyMinor Low NORoutine Maintenance only Gland or seal leak Possible Medium Significant Valves capped / regular inspections (weekly)Adequate AlwaysUnlikelyMinor Low NORegular InspectionGauge failure Common Medium Significant Capped gauge valves to isolate gauges Adequate AlwaysUnlikelyMinor Low NOTopping up the systemPossible Medium SignificantSignage.Trained personnel. Follow correct procedures.Protective safety equipment on handAdequate AlwaysUnlikelyMinor Low NOTrained Personnel only and written procedures requiredVibration of pipe work or rubbingthrough of touching partsPossible Medium SignificantVibration isolation and appropriate pipe supports / sleaves Adequate AlwaysUnlikelyMinor Low NOReview final installation to confirm compliance -ok no excessivevibrationMechanical Impact from forklifts, vehicles etcPossible Medium SignificantPlant is not in an area subject to traffic and all items protected within enclosureAdequate AlwaysUnlikelyMinor Low NOSystem over pressure due to highambient temperatureor compressorcontrol malfunctionPossible Medium SignificantAir cooled condenser has been generously sized to operate at a low (3K) temperature differencebetween ambient air and condensing . Thus unlikely to get to relief valve discharge pressure inambient temperature range below 52 oC . Pressure switches will automatically cut off compressors if high pressure set point is exceeded.Adequate AlwaysUnlikelyMinor Low NOTestpressure switches & relief valves regularly Ammonia to glycol heat exchangerfreeze up / rupturePossible Medium SignificantGlycol system has an antifreeze system control which automatically shuts off ammonia compressor if glycoltemperature is too low . Also glycol concentrationmaintained with 6oC safety factor on freezing temperature . Do not connect mains water to automatically top upsystem ( dilution will result ) Adequate AlwaysUnlikelyMinor Low NOTest antifreeze shut down on commissioning and regularly, alsotest glycol concentration at handover and at least 2 times peryear.Confirm mains water is not connected for automatic makeup .Water supply not available toemergency spray / scrubber system Possible Medium SignificantProvide signage on valves " Warning must be open for safety system "and lock valve open .Include warning in system operating instructions not to operate if water supply is not availableAdequate AlwaysUnlikelyMinor Low NOProvide signage , lock and operating instructions Valves not plugged Possible Medium Significant Regular valves inspections, all valves capped & pluggedat initialhandover Adequate AlwaysUnlikelyMinor Low NO Routine Maintenance Only Proper signage and placardingAdequate AlwaysUnlikelyMinor Low NOGas detector installed (early warning) and plant room ventilation and water spray/ scrubbersystem installed . Also Emergency Stop Buttons provided .Adequate AlwaysUnlikelyMinor Low NORoutine calibration and testing of gas detection required .Eye wash & safety showerAdequate AlwaysUnlikelyMinor Low NOConfirm Eyewash & safety shower installed -RMIT to reviewEmergency plan in place for evacuation and calling in outside assistance (Fire Brigade / police / ambulance) Adequate AlwaysUnlikelyMinor Low NOEmergency Response Plan to be developedServicing strainers / filters anddraining oilDiscomfort with breathing / sore eyes but unlikely to affect anyone outside the immediate workingareaPossible Minor MediumOnly qualified technicians to service equipment / proper procedures in place. Service personneland /or trained operators access to respirator masks / shut-off NH3 supply and isolate leakAdequate AlwaysUnlikelyMinor Low NOWritten maintenance procedure & trained personnel only .Alsoclearly identify ammonia shut off valve ( King Valve ) on liquidreceiver and ensure it is easily accessible. PPE equipment onsite.Leakage at connections to gauges ortransducers and sensorsdue tovibration , connection leakage etc. Discomfort with breathing / sore eyes but unlikely to affect anyone outside the immediate workingareaPossible Minor MediumConnectionsto be welded or designed for correct pressures and temperatures .Vibrationelimination and prevention of rubbing through to be included . All connections to be pressuretested before handoverAdequate AlwaysUnlikelyMinor Low NOCheck pressure tests have been performed at hand overAccidental contactRisk of injuryPossible Severe HighProper guards are fitted to coupling/fans etc in acc. with the Standards. E Stop buttons also fittedAdequate AlwaysUnlikelyMinor Low NOServicing equipmentRisk of injury to service personnel Possible Severe HighOnly qualified technicians to service equipment / proper procedures in place. JSAs and tag lock-out systems in place during service operationsAdequate AlwaysUnlikelyMinor Low NODevelop proceduresthat require qualified service personnelonly 4 Working at Height Servicing the condenser or ceilingmounted evaporatorsRisk of injury from fall Possible Severe HighProper ladder and service platforms Adequate AlwaysUnlikelyMinor Low NOUse standard working at height procedures 5 Heavy Equipment Removal of heavy equipment items for servicing Risk of back injury Possible Medium SignificantAdequate access for heavy lifting equipment around the unit (forklift / trolley etc.)Adequate AlwaysUnlikelyMinor Low NO6 Fire External e.g. spread from adjacent building; or electrical malfunctionRisk of injury to operator from overpressureandCO2 or Ammonia releaseUnlikely Medium Medium No significant conbustible building materials in vicinity of rack plant .Relief valves will vent any over pressure.Adequate AlwaysUnlikelyMinor Low NOMonitor to conirm no combustible storage in area of refrigeration rack 7 Electrical shock Maintenance on electrical equipment and switchboardsRisk of injury to technicians Possible Severe HighOnly qualified technicians to service equipment / proper procedures in place. JSAs and tag lock-out systems in place during service operations. Provide warning signs for all heat traced Pipework using 240 V Adequate AlwaysUnlikelyMinor Low NOCheck heat traced pipes & drains have warning labels 8 Hypothermia Accidentally trapped in Freezer orchiller rooms Injury or death Unlikely Severe SignificantEmergency lighting and exit doors with manual release mechanism as per BCA Section G1.2 Adequate AlwaysUnlikelyMinor Low NOCheck compliance with BCA G1.29 Incorrect Emergency Response Lack of Emergency Response planresulting in delayed or incorrect evacuation procedures Injury Unlikely Medium MediumDevelop Emergency response plan which also incorporates : Notification of adjacent FurnitureTech Building in event of ammoniadetection alarm or release, Security to direct buildingoccupants away from ammonia leakage (Use wind sock etc to decide which evacuation doors are safe) , notification ofFire Brigade and emergency response team of type of refrigerant andquantities , Provide signage to direct emergency response ,Clearly identify main ammonia shut off valve ( king valve ) on outlet of liquid receiver and ensure its easy to access with BreathingApparatus on. Adequate AlwaysUnlikelyMinor Low NODevelop procedures and install windsock or equal to show winddirection10 Environmental contamination Release of water containing ammonia and oil to stormwater or trade wastedrainsInjuryPossible Medium SignificantReview possibility & consequence of water from ammonia scrubber entering stormwater or tradewaste drains and provide bunded collection if required. Adequate AlwaysUnlikelyMinor Low NORMIT accept one off limited discharge in event of emergency situation .11 Carbon Dioxide leak in Freezer and or adjacentclass roomPipe rupture or valve/ component failure allowing CO2 to leak into anenclosed freezer room or adjacent class room. Cold burnsto eyes and skin . High concentrations inair can lead to asphyxiationPossible Medium SignificantPipe work and equipment to be located above normal head height.Students entering coldrooms/freezer room to wear PPE.Automatic CO2 detector to be installed at low level in Freezer room to activate alarm and ventilation systems if alarm levels exceeded (15,000 ppm).Also ensure any capped pipe work /valveswith CO2 liquidhaveprovisions to prevent over pressure liquid trapping ( i.e. check valve or releif valve).Adequate AlwaysUnlikelyMinor Low NODevelop PPE procedure for students & staff.Test CO2 detectionat commissioning and regularly as perdetector manufacturer recommendations. 12 Carbon Dioxide discharge fromplantskid Pipe rupture or valve/ component failure allowing CO2 to leak into plant skid areaCold burnsto eyes and skin .Possible Medium SignificantStudents entering plant skid area to wear PPE.Also must be with trained plant operator who alsohas PPE .Because plant area is open at sides , unlikely to build up significant CO2 concentrationin event of leakage.Pressure relief valves installed on all vessels and piped to safe location.Adequate AlwaysUnlikelyMinor Low NODevelop PPE procedure for students & staff. Confirm pressurerelief valve discharge to safe location.Ammonia detectors fail to operate , Co2 detectors fail to operate , Possible Medium SignificantDetectors to be monitored via fail safe contacts into Security Systemwhich has battery back upAdequate AlwaysUnlikelyMinor Low NOChecked ok durring commissioningAmmonia plant does not restart in correct sequencewhen power resumedPossible Medium SignificantCheck during commissioning that all drives and controls restart automatically or go to safe status when power is restored. Also check all tx valves remain closed until the relevant compressoris operating Adequate AlwaysUnlikelyMinor Low NOChecked ok durring commissioningCarbon dioxide plantdoes not restart in correct sequence when power resumedPossible Medium SignificantCheck during commissioning that all drives and controls restart automatically or go to safe status when power is restored. Also check all tx valves remain closed until the relevant compressoris operating Adequate AlwaysUnlikelyMinor Low NOCheck during commissioningLow temperature carbon dioxide receiver pressurerelief valve lifts when vessel contents rise above -4.5oC Possible Medium SignificantThe vessel is insulated andhas a back up refrigeration unit but this also need mains power tooperate. The vessel relief valve will lift automatically if pressure is exceeded. The valve is discharged to a safe location outside of buildings . Adequate AlwaysUnlikelyMinor Low NOPossible Medium1 Major NH3 leak(Note full charge is 12 kgs )Comment Level ofrisk ratingFurthertreatmentrequiredAssessment ReassessmentDetails of existing controlsAdequacy ofexisting controlsImplementation of existing controlsLevel ofrisk ratingReviewed By: JEF 25/3/15Minor NH3 leak13 Supply failure or isolation of powersupply to refrigeration switchboardExtended Mains Poweroutage 3 Rotating machinery2SignificantRef Risk How can it happen What can happenAny of the aboveExposure to NH3 vapour or liquid causing danger topeople in the immediate working area andsurroundings