Professional Documents
Culture Documents
The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
1
NOx Emission Reduction Process
What are Nitrogen Oxides?
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2
NOx Emission Reduction Process
- In reality, more than 95% of NOx from cement plants is NO, but it will
oxidize in the atmosphere to form NO2
The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
3
NOx Sources
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4
NOx Emission Reduction Process
How do they effect us?
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5
Regulatory Issues Dictating NOx Reduction
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6
US NOX Limits
•Emission levels for NOx have been set in the past on a state-by-state
basis, using BACT guidelines
The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
7
NOX Limits for India
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8
Destroying NOX
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9
NOx Emission Reduction Process
How does ammonia reduce Nitrogen Dioxide?
The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
10
NOx Emission Reduction Process
How does ammonia reduce Nitrogen Dioxide?
The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
11
SNCR Testing
- Results of testing are normalized using the molar flows of ammonia and
starting NOx
- Mole weights
- Ammonia – 17 kg/k-mole
- NOx – 46.07 kg/k-mole
The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
12
FLSmidth SNCR Short-Term Test
Results
100%
90%
80%
70%
% Reduction
60%
50%
40%
30%
20%
10%
0%
0.00 0.10 0.20 0.30 0.40 0.50 0.60 0.70 0.80 0.90
NH3/NOx Molar Ratio
The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
13
TRAINING
The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
14
Sources of Ammonia
– Chemical Processes
– Diazo Machines
– Pharmaceuticals
– Water Treatment
The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
15
MSDS
Information on the hazards associated with the
ammonia used in the SNCR process may be found on
the manufacturer’s Material Safety Data Sheet (MSDS).
The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
16
MSDS
The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
17
AMMONIA
• AMMONIUM HYDROXIDE
– Classified by OSHA, DOT and EPA as a hazardous substance.
The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
18
Physical Properties of
Ammonium Hydroxide
• Ammonium Hydroxide is a chemical compound of Nitrogen,
Hydrogen and Oxygen.
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19
Physical Properties of
Ammonium Hydroxide
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20
Physical Properties of
Ammonium Hydroxide
• 25% Aqua Ammonia is a strong alkaline.
• It’s PH varies with concentration.
• Typical values are:
– 11.7% at 1%
– 12.2 at 5%
– 12.4 at 10%
– 13.5 at 30%
• Aqua Ammonia is an excellent acid neutralizer
The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
21
Physical Properties of
Ammonium Hydroxide
• Aqua Ammonia’s vapor pressure will vary with temperature
– A 25 % w/w solution has a vapor pressure of:
• 310 mmHg @ 20°C
• 500 mmHg @ 30°C
• 720 mmHg @ 40°C
• 1100 mmHg @ 50°C
The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
22
Physical Properties of Ammonium Hydroxide
• One gallon of 25 % solution aqua ammonia weighs 7.58 lbs (3.43 kg) and
contains 1.9 lbs (0.857kg) of NH3.
The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
23
Physical Properties of
Ammonium Hydroxide
•Aqua Ammonia is produced by dissolving anhydrous ammonia
in water. The mixing will produce an exothermic reaction. The
solution is circulated through a cooling tower or chiller.
•Aqua Ammonia is tested for trace elements introduced by
water. Iron, heavy metals such as lead, chloride, carbonate,
sulfate, arsenic, zinc, and chromate are typical elements used.
The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
24
Physical Properties of
Ammonium Hydroxide
• Typical Analysis
– Appearance: Colorless and free from suspended matter or sediment
– Assay: 25 %
– Residue after Ignition: 0.0010%
– Carbon Dioxide (CO2): Less than 0.002%
– Chloride (Cl): Less than 0.002%
– Phosphate (PO4): Less than 0.002%
– Total Sulfur (as SO4): Less than 0.002%
– Heavy Metals (as Pb): Less than 0.002%
– Iron (Fe): Less than 0.002%
– Substances Reducing Permanganate: Pass
– Specific Gravity at 16°C: 0.908
The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
25
Ammonia Health Hazards
• Ammonia is irritating and corrosive to the skin, eyes, respiratory tract
and mucous membranes.
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26
Exposure Limits
– Parts
– Per
– Million
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27
Exposure Limits
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28
Exposure Limits
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29
Exposure Limits
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30
Routes of Entry
• Ingestion
• Injection/Puncture
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31
Routes of Entry
• Absorption
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32
Routes of Entry
• Inhalation
– The most rapid route into the body, immediately introducing toxic
chemicals to respiratory tissues and the bloodstream.
– Once admitted to the blood through the lungs, these chemicals are
quickly transported throughout the body.
The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
33
Routes of Entry
• Ingestion
– Materials get into the mouth through hand to mouth contact and
through coughing when inhaled particulate material is removed from
the lungs to the throat and then swallowed.
The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
34
Routes of Entry
• Injection
– The best precaution is wear protective clothing and observe safe work
habits.
The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
35
Effects of Overexposure
• Chronic
– Several small exposures over a period of time cause no immediate
effect.
• Acute
– A large, single dose received over a short period of time may or may
not produce an immediate effect.
The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
36
Effects of Overexposure and Emergency Aid
• Emergency Aid:
– Flush the eye with copious amounts of water for a minimum of
15 minutes.
– Eyelids should be held apart and away from the eyeball for
thorough rinsing.
37
Effects of Overexposure and Emergency Aid
The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
38
Effects of Overexposure and Emergency Aid
The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
39
Effects of Overexposure and Emergency Aid
The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
40
Effects of Overexposure and Emergency Aid
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41
Effects of Overexposure and Emergency Aid
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42
Fire and Explosion Hazard Data
• Flashpoint: None.
The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
43
Ammonia Fire-Fighting Procedures
•Use water spray or fog to extinguish flames and cool down fire exposed
containers.
•Use water spray or fog to control ammonia vapors; dike or contain run-
off.
The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
44
Chemical Reactivity of Ammonia
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45
• Selection and Use of Personal Protective
Equipment
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46
Personal Protective Equipment (PPE)
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47
Personal Protective Equipment (PPE)
• Face Shield – protects against splash exposures.
– Highest risk is when making and breaking connections.
– Should be worn when a danger exists of contact with liquid
or vapor ammonia.
– Should be worn with goggles, not as a substitute.
• Rain Gear – protects against splash exposures
– Rubber rain coat or suit.
– Should be worn when a danger exists of contact with liquid
or vapor ammonia.
• Hard Hat – for head protection.
– Should be worn where head exposures exist.
The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
48
Levels of PPE
• Level D:
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49
Determining Levels of Protection
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50
Levels of PPE
• Level C:
– Rubber Gloves, Hard Hat, Chemical Suit with Hood, Full Face Cartridge
Respirator and Chemical Boots.
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51
Determining Levels of Protection
– The direct contact with the contaminant will not be harmful to the
skin.
– The type of contaminant has been identified and measured and meet
the air-purifying respirator criteria.
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52
Levels of PPE
• Level B:
– Level B Protective Suit with Hood, SCBA, Hard Hat, Rubber Gloves and
Chemical Boots.
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53
Determining Levels of Protection
The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
54
Levels of PPE
• Level A:
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55
Determining Levels of Protection
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56
Levels of PPE
• Level C:
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57
Respirator Types
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58
Respirator Types
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59
Respirator Types
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60
Respirator
61
Respirator
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62
Respirator
The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
63
Respirator
• Cleaning
– Remove cartridge
– Wash with warm water and soap or alcohol
– Rinse with clean warm water
– Allow respirator to dry to prevent decay in storage.
The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
64
Respirator
• Inspection
– Once a month.
– Inspect rubber for cracks, wrinkles, distortions and holes.
– Check both inhalation and exhalation valves and they are clean.
– Check lens for scratches, looseness and cracks.
– Inspect straps they should not be losing elasticity or breaking.
– Check that buckles and attachments work properly.
– Assure there is no damage to the respirator.
– Check cartridge expiration, type and condition.
The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
65
Ammonia Detection
66
Ammonia Detection
• Maintenance
– Response test before each use
– Calibration every six months
– Keep plugged into charger when not in use
– Flow meter check before each use
– Filter check every six months
– Typical sensor life is 3 years, return to manufacturer
– Detector should be stored in air conditioned office to preserve sensor
life
The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
67
Ammonia Detection
• Sensor
– When cell becomes depleted, sensor will not respond and must be
returned to manufacturer
– Sensor life will shorten due to:
• A long period of time
• Exposure to high temperatures
• Exposure to varying concentrations of NH3 gas
• Exposure to high moisture
The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
68
• Ammonia Incidents
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69
Hazardous Material Incident
• Definition:
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70
Emergency Response Plan Elements
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71
OSHA’s Emergency and Fire Prevention Plan
(29 CFR 1910.111)
• Emergency Program
– Must have clear escape procedures and escape route
assignments. Retreat to designated areas or Shelter – In –
Place.
– Must have well defined procedures for employees who
remain to operate critical procedures. Plant procedures and
shut down of equipment.
– Procedures to account for all employees Count Heads
– A list of workplace hazards use proper methods of storage
and handling.
– A list of possible ignition sources Responsible personnel
knowing control procedures.
The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
72
Training Levels
• OSHA 29 CFR 1910.120 (q) and ANSI K- 61.1-3.1 state that all employees
must be trained to their specific job level.
• There are five levels of Ammonia training
• 1. Awareness Level
• 2. Operations Level – your training level
• 3. Technician Level
• 4. Specialists
• 5. Incident Commander
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73
Awareness Level
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74
Operations Level
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75
Technical Level
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76
Specialist Level
• Act as liaison with Federal, State and other governing agencies in regard to
site activities.
The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
77
Incident Commander Level
78
Standard for Professional
Competence of Responders to
Hazardous Material Incidents
NFPA 472
• First Responders at Operational Level
– First responders at the operational level are those persons
who respond to releases or potential releases of hazardous
materials as part of the initial response to the incident for
the purpose of protecting nearby persons, the environment,
or property from the effects of the release. They shall be
trained to respond in a defensive fashion to control the
release from a safe distance and keep it from spreading.
The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
79
First Responders at Operational Level
• Goals
1. Analyze a HAZMAT incident
• Survey the incident
• Identify Hazardous Material
• Container labels
• Container shapes
• Visual, odor
• Consequences
• MSDS
• CHEMTREC, Shipper, Manufacturer
• Predict likely behavior of the material
• Estimate potential harm at the HAZMAT Incident
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80
First Responders at Operational Level
• Goals continued
2. Plan an initial response
• Objective is to control events as they occur or
keeping even more severe events from occurring.
• Establish communications
• Take defensive action; diking, placing a pail under a
leaking valve, closing a valve.
• Understand the limitation of PPE at this level.
• Identify decontamination procedures if personnel
were exposed.
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81
First Responders at Operational Level
• Goals continued
3. Implement the response
• Establish and enforce scene control.
• Initiate the IMS (Incident Management System)
• Don PPE correctly
• Perform defensive controlled functions
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82
First Responders at Operational Level
• Goals continued
4. Evaluate the progress of the actions taken
• Are the defensive actions taken having the desired
results.
• Communicate the status of the response to IC
(Incident Commander).
The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
83
OSHA’s Storage & Handling of
Anhydrous Ammonia
•
(29 CFR
A list of fire protection equipment
1910.111)
Responsible personnel maintaining
the equipment Facilities which manufacture or use NH3 as a refrigerant
only are exempt.
The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
84
PPE Requirements
OSHA 29 CFR 1910.132-.134
• Employers are responsible for supplying safety equipment to employees to
protect the eyes, face, head and extremities from hazardous contact.
• OSHA requires the use of PPE when working with or around ammonia.
The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
85
Process Safety Management (PSM)
29 CFR 1910-38
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86
Process Safety Management
Elements
• 14 Elements
1. Employee Participation
2. Process Safety Information
3. Process Hazard Analysis
4. Emergency Planning and Response
5. Operating Procedures
6. Employee Training
7. Contractor Qualification
The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
87
Process Safety Management
Elements Continued
8. Pre-Startup Safety Review
9. Mechanical Integrity
10. Hot Work Permits
11. Management of Change
12. Incident Investigation
13. Compliance Audits
14. Trade Secrets
The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
88
EPA’s Risk Management Plan
• Purpose is to prevent accidental chemical releases or to
minimize their impact to the community and environment.
– A process is regulated if a listed substance is present above
the threshold quantity. NH3 = 10,000 lbs (4525 kgs) ;
NH4OH = 20% or greater = 20,000 lbs (9050 kgs).
– Perform hazard assessments.
– Worst-case scenarios and alternative release scenarios.
– Set up an Accident Prevention Plan.
– EPA’s version of Process Safety Management.
– Emergency Response Program
– Intended for those facilities that will have employees
responding to emergencies; if not, coordinate with local
responders.
The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
89
EPA’s Form “R”
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90
Ammonia Spill Planning
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91
Ammonia Spill Planning
• Release Prevention
• Incident Command System
• Communications
• Planning for Natural Disasters
• Power Outages
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92
Emergency Planning
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93
Aqua Ammonia Storage Tanks and Fittings
• Tanks
– Stationary storage tanks are regulated by department of labor (29 CFR
1910.111)
• Safety Relief Valves
– Are designed to relieve pressure, liquid or vapor, that exceeds 30 psig
(2 bar) on storage tanks.
• Vacuum Breakers
– Are designed to prevent the tank from being exposed to substantial
vacuum.
The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
94
Aqua Ammonia Storage Tanks and Fittings
• LIQUID CONNECTION:
– Used for charging the tank with liquid.
• VAPOR CONNECTION:
– Used to recover vapor from the tank and equalize pressures between
the delivering tanker and a storage tank.
The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
95
Aqua Ammonia Storage Tanks and Fittings
• BALL VALVE
– Designed to isolate flow.
• Thermocouple
– Designed to measure the liquid’s temperature.
The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
96
Task Specific Training
For
Operation of the FLS SNCR Rig
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97
FLS Test Rig
• FLS can provide a temporary test rig to customers for use with 19%
ammonia solution for SNCR trials
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98
FLS Test Rig
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99
FLS SNCR Test Rig
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100
Filters
- Note that inlet filters are located on the rig between the connection to the
truck and the pump
- Tanks may have particulate due to reactions with minerals in the water –
filters are to prevent damage to pump and clogging of injectors
- If flow rates are very low even with the line to the injectors fully open, the
strainer may be clogged
- The strainer may be removed and cleaned with water and/or air
The information contained or referenced in this presentation is confidential and proprietary to FLSmidth and is protected by copyright or trade secret laws.
101
Connections to Truck
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102
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103
Connections to Tote
- The tote must have a vacuum breaker installed so that the tote walls do
not “suck in”
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104
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105
Safety When Making Connections
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106
Containment
• - Both the ammonia vessel (tanker or tote) and the rig should be placed on
a flat area and contained
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107
Containment
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108
Containment
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109
Containment
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110
Housekeeping
- Always hoist and lower supply lines to tower using a strong rope
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111
Housekeeping
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112
Housekeeping
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113
Housekeeping
Poor Sealing – Not
recommended
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114
Recommended sealing
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- Ensure that eyewash stations and shower locations are known and
accessible in case of emergency
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116
Additional Safety
- Place safety tape around areas where ammonia exposure can occur
- Levels of injection
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117
Entry Warnings
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118
Starting Test Rig
• Check the rotation of pump prior to start of unit with ammonia – reverse
direction if necessary
• Do not start pump with “dead-heads” – ensure path for ammonia is open
for start
• Ensure adequate heating of lines in cold weather once water has been run
through the lines
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119
Running Test Rig
• Monitor flow and tank level to ensure that pump does not run dry
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120
Clean-up
• Run water through lines prior to disconnecting ammonia for the last time
Clean equipment prior to storage (wipe down hoses, coil and secure for
transport, etc)
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121
Questions?
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122