2020 RETA Breeze Jan-Feb

RETA BREEZE REFRIGERATING ENGINEERS & TECHNICIANS ASSOCIATION JANUARY / FEBRUARY 2020

5 BASIC PREVENTATIVE MAINTENANCE ACTIVITIES TO PERFORM REGULARLY

33 CHESTNUT AVE. WESTMONT, IL 6O 559 info@hantempcontrols . 6 3O- 537-IO 49

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BREEZE

5 Basic Preventative Maintenance Activities to Perform Regularly page 22

The RETA Breeze is the official publication of the Refrigerating

Engineers & Technicians Association (RETA). RETA is an international not- for-profit association whose mission is to enhance the professional development of industrial refrigeration operating and technical engineers. Don Chason Executive Editor 704-455-3551 Jim Barron Executive Director

jim@reta.com Sara Louber Senior Director, Office Operations

INSIDE THIS ISSUE

sara@reta.com Dan Reisinger Certification Manager dan@reta.com Michelle Robinson Conference Manager michelle@reta.com Dan Denton Chapter Relations Liaison ddenton@reta.com Vince Grindel Education Coordinator vince@reta.com

Message FromThe President............4 Thankful..............................................5 Message From Tim Kohrs, President Of Northern Plains Chapter of RETA Don’t Drive Through The Big Smoke....................................6 Being Safe With NH3 Epic Fail...............................................8 Oil Pot Uncertainty Conference Corner.............................10 Lets Talk About The Conference Refrigeration Historian...................12 Volume XXVIII Compliance.......................................17 Ammonia Pipe And Equipment Labeling - Part 3

Education Corner............................20 Education Saves Lives Basic Refrigeration Cycle................21 5 Basic Preventative Maintenance Activities To Perform Regularly.....22 RETA Testing Corner No. 17 v2. ...27 RETA’s Testing And ANSI Guru Certification......................................29 Honor Roll The Shade Tree Mechanic...............30 Volume XLIV

The information in this publication is based on the collective experience of industry engineers and technicians. Although the information is intended to be comprehensive and thorough, it is subject to change. The Refrigerating Engineers & Technicians Association expressly disclaims any warranty of fitness for a particular application, as well as all claims for compensatory, consequential or other damages arising out of or related to the uses of this publication. Publication of advertisements in Breeze , or any other RETA publication, does not constitute endorsement of any products, services or advertisers by RETA and shall not be considered or represented by advertiser as such. Copyright © 2020 Refrigerating Engineers & Technicians Association.

REFRIGERATING ENGINEERS & TECHNICIANS ASSOCIATION 1725 Ferry St. SW, Albany, OR 97322 Telephone: 541.497.2955 | Fax: 541.497.2966 RETA.com

RETA.com 3

2019-20 BOARD OF DIRECTORS CHAIRMAN Arlie Farley, CARO, CIRO Farley’s S.R.P., Inc. PRESIDENT Vern Sanderson, CIRO, CRST, RAI Wagner-Meinert, LLC EXECUTIVE VICE PRESIDENT Eric Teale, CARO, CRST Danfoss Industrial Refrigeration TREASURER Keith Harper, CARO Tyson Foods SECOND VICE PRESIDENT Pete Lepschat, CIRO, CRES, CRST Henningsen Cold Storage, Co. DIRECTORS Bengie Branham, CIRO Perdue Farms William Ellena Coastal Pacific Food Distributors, Inc David Gulcynski, CIRO Dot Foods Inc. Michael Hawkins Midatlantic Refrigeration, LLC Matt Hayes, CARO TJW Industrial Edward Johnson, CARO Schwans Global Supply Chain, Inc. Frank Kologinczak III Kolo Compression Jim Kovarik Gamma Graphics Bill Lape, CARO, CIRO, CRST SCS Engineers Jordan Reece, RAI Ricky Jimenez, CIRO Mericle Mechanical Inc COMMITTEE CHAIRS Gene Dumas, CARO, CIRO, CRST, RAI Nominations SCS Tracer Environmental Dave Gulcynski, CIRO , Education Dot Foods, Inc. Jim Kovarik, National Conference Gamma Graphics Lanier Technical College Raymond Urban, CARO Lineage Logistics

FROM THE DESK OF THE PRESIDENT

The Christmas rush is over and the New Year has begun. Many New Year’s

resolutions have already been broken. But if your resolution is to acquire a new RETA certification, the time is right to make that resolution a reality. Many members delay their exams because they are nervous about the possibility of failing. Education is never a failure. You will learn much by the attempt even if you fall short the first time. This may be a good time to mention that t he majority of applicants pass their certifications. Online practice exams are a great way to check your competence level prior to the “big” exam, as the questions are similar to those that will challenge you during the certification exam. Online exams are also a great preparation tool. Completing an online practice exam helps eliminate pre-exam jitters and the results of the practice exam will give you an indication of the areas you may need to study further. From personal experience, I can assure you, it is disappointing when you fall short on an exam, but the disappointment is nothing in comparison to the joy of passing an exam. I have a tendency to dance around the house waving my patch and saying “Who’s the man!” a lot and singing my rendition of Toby Keith’s “How Do You Like Me Now.” It annoys

Vern, RETA National President

my wife, but she is tolerant. Recently, I was asked about the RETA Certification patches. There is power in the patch. A certification patch shows that you are among the elite in the industry. It assures those around you that you are a refrigeration professional. Your opinion is valuable, not because you say so, but because the industry says so. “You may have stayed at Holiday Inn last night, but I’m RETA Certified!” I’ve been around the industry since I was a child, and I’ve heard all of the excuses. Perhaps my favorite excuse is this “Them tests are invented by college boys who ain’t never seen an engine room. Who are they to decide what I need to know?” I can assure you that is not the case with our RETA exams.

Michael Hawkins, Membership Midatlantic Refrigeration, LLC Matt Hayes, CARO, Publications TJW Industrial Lee Pyle, CARO, Certification SCS Tracer Environmental Jim Barron, Executive Director

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Thankful As I sit writing this it is not 70°F out and sunny in Northern Minnesota. Last I looked it was -11°F with a wind chill of -30°F. We have a foot of snow on the ground, and I have a broken snow blower. But I still am thankful for not hitting any deer since the last writing. Still sitting at 49. It is the time of the year to sit back and reflect on what we have and if our needs are taken care of. Yes, I am one happy person. I have had the fortune of being around people that are kind, considerate, honest, hardworking, and the list goes on. Of course, there are the people that get under my skin but in an hour or so, I am back trying to find the good in them. When is the last time you thanked your boss for your job, your pay, your amount of vacation, and the training that the company has provided? When was the last time you thanked them for what contribution they give you to attend or participate in your RETA Chapter? When was the last time you thanked your co-workers for just being themselves and putting up with your idiosyncrasies? When is the last time you just called a family member to talk and thank them for being part of your family? When is the last time you thanked your family and friends that are directly affected for allowing you to participate in your RETA Chapter whether it be monthly or just and occasional visit? I would also challenge employers to look around and see how fortunate you are to have loyal employees that want to take time from their busy schedule and partake in their/your RETA Chapter. When was the last time you walked your facility and looked at signage in your facility? Is the exit still an exit or should it have a sign that says, “to an exit”, due to the expansion that was done a couple of years ago? How about signage for proper signatures? Some could have been there for a couple years and the person that signed it no longer works for the company. When is that last time you looked at the employee locker rooms, rest rooms, lunchrooms? Is there improvement that could be made to make them more current to the times we are living in? Could there be minor improvements done for little cost that would go a long way to improve the moral of the employees? When is the last time you did something for them just because it was Tuesday? I’m not sure why, but some sort of Danish or ice cream can go a long way. You don’t need to have an accomplishment to treat them with respect and dignity! When is the last time you looked at the benefit package to make sure it is line with the industry standard?

Other organizations may create their exams in whatever fashion they choose, but the Refrigerating Engineers and Technicians Association develop their exams utilizing the ANSI process. The exams are designed by industry professionals utilizing a process that is second to none. Surveys of refrigeration operators have determined what knowledge is vitally important and what knowledge may be less important. Every question is reviewed to assure they are fair and unbiased. RETA exams are true tests of industry knowledge. Tough but fair. Credentials that are earned not purchased. Passable not laughable. There is power in the patch. I hope to see all of you wearing your new patches at Conference! Thank you for allowing me to serve as president! Vern

Tim Kohrs President Northern Plains Chapter of RETA

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!

Don’t Drive Through The Big Smoke

Basic facts about NH3: • It is a natural chemical

Now, as a Certified NH3 Geek, I have a responsibility not only to my employees, but also to the community around my plants. Tragically we have all seen what can happen when NH3 gets out of the pipes and people are seriously injured or killed. With many facilities in this country using NH3 as a refrigerant (and not just the

THIS IS ONE OF EVERY NH3 PROFESSIONAL’S WORST NIGHTMARES external conditions just right, and you end up with a dense vapor cloud that is quickly fatal to all. And, since our vehicles runonoxygen andnot NH3, driving through the cloud is also not a survivable option. When I conduct my NH3 safety training I use that exact phrase - Don’t run through

comprised of Nitrogen and Hydrogen

• It is not a

greenhouse gas, nor does it contribute to global climate change

WHEN PEOPLE ARE PANICKED, THEY MAY THINK THAT IT IS SMOKE OR STEAM. EVEN THOUGH IT IS SELF-ALARMING, IN A PANIC SITUATION SOMEONE MAY NOT DISCOVER WHAT IT REALLY IS UNTIL IT IS TOO LATE.

!

• It is a very efficient refrigerant

the big cloud! The reasoning behind that is when people are panicked, they may think that it is smoke or steam. Even though it is self-alarming, in a panic situation someone may not discover what it really is until it is too late. As a long time Safety Professional, it was my job to keep my employees safe at work. Send them home in the same condition they came to work in, except a few hours older!

PSM plants, as even a smaller quantity of NH3 can lead to the same issue), we are all doing a pretty good job of keeping everyone safe. I think we can still do better, and continue to reduce the number of releases through improvements in technology, training, vigilance, and good old fashioned hard work. I look forward to the day when I can realistically stop telling my students: Don’t Run Through the Big Cloud!

• It is inexpensive • It can kill you if you are exposed to it

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EPIC FAIL

Section U-1 of the Boiler and Pressure Vessel Code exempts vessels that have an internal diameter of six inches or less. This oil pot is an eight inch elbow. Hence, it is subject to the Boiler and Pressure Vessel Code. Were calculations performed to determine proper dimensional requirements, including metal thickness and head curvature to withstand the pressures it would operate at? For that matter, was a maximum allowable working pressure and a minimum design metal temperature calculated for the vessel? Was it tested according to the code’s requirements? Were the welders certified to weld pressure vessels? Was it inspected by an authorized inspector? Without a nameplate with an ASME stamp, it is a safe bet that the answer to these questions were no. So what do you do in a situation such as this? The easy answer is to replace it with a proper one that is either UM or This oil pot was built back in the 1960’s, according to the those who were familiar with this piece of equipment. It is a pipe elbowwith caps welded to each end, and while it is an ingenious conserver of floor space, it is an example of an Epic Fail. Oil Pot uncertainty

U stamped, meaning that it is built to meet the Boiler and Pressure Vessel Code requirements. When you replace the vessel, be sure to follow your Management of Change procedures, which will include filing the manufacturer’s data report (U1, U1A, or U3) and the certified drawing of the vessel in your Process Safety Information. It should also be noted that this is an Epic Fail regardless of how many pounds of ammonia are in your system and which regulations that you must follow. If you have photos of an Epic Fail please pass them on to nh3isB2L@gmail.com. Bill Lape is Project Director for SCS Engineers. Bill is a Certified Industrial Refrigeration Operator, a Certified Refrigeration Service Technician, and a member of the National Board of Directors of the Refrigerating Engineers and Technicians Association.

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CONFERENCE CORNER

I hope everyone had a Happy and Safe New Year! RETA’S Conference Committee and I are in full swing and meeting goals for a great upcoming Conference. We met our first deadline for the Call for Abstracts which were due January 13, 2020. I am very excited to announce that we had a great response with a 25% increase of abstracts submitted from previous years. We also had a great variety of titles in each of the four topics. All abstracts have gone out to our peer LET’S TALK ABOUT THE CONFERENCE Michelle Robinson, RETA Conference Manager

WE ARE WORKING DILIGENTLY ON “WHAT’S IN IT FOR YOU” AND ARE FOCUSING ON BENEFITS OF INTEREST SUCH AS UPDATING OUR WEBSITE TO GET YOU INFORMATION AS SOON AS POSSIBLE.

The website will be updated with the most current information by the end of the month. We are also finalizing quality time in the Exhibit Hall, Hands on Sessions, Workshops, WiNR (Women in Natural Refrigeration) and Entertainment. Minette and I have finalized our Sponsorship Brochure and Exhibitor Commitment forms. Please be on the look out for an email with that information. We have added several new sponsorship opportunities and a Bingo Jeopardy which is open to the first 75 exhibitors who secure a spot. Bingo Jeopardy is designed to bring more foot traffic to your booth by providing 3 educational questions pertaining to your business. Attendees will answer one of your questions. Once one of your three questions have been

review committee members for grading. Papers are graded for Technical Merit, Readability, Relevance, Originality, Formatting, Acceptance and Confidence. The deadline for peer review is February 11, 2020 and authors will receive an email from me on or before February 17, 2020 as to whether it was accepted. I personally want to thank everyone who took the time and effort to submit their abstract. RETA’s Conference Committee and I will be meeting this month for our 4th time and are making great progress toward our upcoming Conference. We are working diligently on “What’s in it for you” and are focusing on benefits of interest such as updating our website to get you information as soon as possible.

10 RETA.com

answered correctly you will stamp your logo, which will be on one of the bingo squares. Once the attendee has a bingo black out, they will be entered to win a big ticketed item and 1PDH hour. If you have not sponsored or been an exhibitor at a previous RETA National Conference and would like more information, please call me anytime at 541-497-2955 or email me at Michelle@RETA.COM. Lastly, please SAVE THE DATE for October 27-29, 2020 and remember to come early for pre-conference activities. Saturday-Monday, October 24-26, 2020 we will have the Review Courses which include the Train the Trainer Course and the CARO, CIRO, CRST, CRES Review Courses. Please note there is a separate fee to register for a review course. Sunday, October 25, 2020 we will have a Chapter Leaders Reception from 5pm-6pm and a Welcome Reception for Exhibitors and Sponsors from 6pm-8pm. Monday, October 26, 2020 we will have Workshops from 8am-5pm, at no additional cost. Monday will also have TopGolf offsite from 1pm-4pm for an additional fee and a WiNR (Women in Natural Refrigeration) Happy Hour Networking event from 4pm- 6pm. We will end the day on Monday at the RETA After Hours Lounge from 5pm-10pm. The RETA National Conference provides a unique gathering of networking, learning, and fun into a single platform.

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The Refrigeration Historian Volume XXVIII

WHAT IS HEAT? It seems such a simple concept today. The first chapter of any treatise on Refrigeration clearly defines heat. What about the bygone days before heat? Or more correctly, should I say before heat was defined. Heat, much as any of the concepts we hold dear, has no origin, only a time of definition. The first sunrise was witnessed before definition. Sir Isaac Newton defined gravity, but hardly discovered it. Prior to Isaac, people didn’t float off into the heavens. Much is the story of heat. Robert Mayer may be credited as the discoverer of the mechanical equivalent of heat. Joule certainly drew conclusions as to the relation of heat and motion. The “American Knight”, Benjamin Thompson, also known as Count Rumford may be rightly credited with determining the mechanical equivalency of heat. Benjamin was born in 1752 in the town of Woburn Massachusetts. A small town north west of Boston, now a full fledge metropolitan suburb of the same. He received a humble education and became an apprentice to a merchant at age 12. He self-studied in the fields of engineering and chemistry and he would ultimately try his hand as a teacher. In 1767, Benjamin would take over as Headmaster in the village of Rumford, New Hampshire. By 1772, he had wooed a local widow of some means and they married. Their union would produce a daughter before her death. At the outbreak of the American Revolution, Benjamin requested a commission. Ultimately it was denied. Allegations of Toryism were made, most probably true.

.2 g.2

Benjamin would ultimately migrate to England where he worked for the English government where his service to the crown earned him a knighthood. In 1784, he would migrate to Munich. Which was then part of Bavaria. He would take the position of Chamberlain to the Prince of Bavaria. Benjamin would lead major reforms in Bavaria. His skills lent themselves to military tactics which he found to be overly complicated. These tactics were then simplified. Benjamin would also modify the Bavarian soldier. Strict military code would bring about a more disciplined military. A school for soldier’s children was established. The school concentrated on the industrial sciences. He worked to improve the conditions of the working class though education and housing initiatives which is something that would remain a passion for the rest of his years. These deeds would earn him the title of Count from the Holy Roman Empire, thus becoming the Count of Rumford. But his greatest accomplishment to the thermodynamic world would come from his work in arms manufacture. While in Bavaria, he worked with the development and production or armaments, including heavy artillery. His discovery would come while boring brass cannon.

ything g ready, oceeded to e the

riment I had jected, in the

lowing nner:”

/ The Refrigeration Historian

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Per the paper Benjamin Thompson

As most stories begin, while hard at work one day. Benjamin asked himself “Whence comes the heat produced in the mechanical operations of boring cannon? Is it furnished by the metallic chips which are separated from the metal?” This began, the quest for the answer. Traditional thought being that the boring process was releasing latent heat in the brass. Experiments proved this to be false as the amount of latent heat which could be absorbed by a pound of brass was the same whether previously bored or not. In his next experiment Benjamin, horizontally mounted a cylinder. He then bored a 1.75” radius hole in the end. He inserted a flat piece of hardened steel 4” inches long, .63” thick, and nearly 3”wide. This provided a 2.5” area of contact. A small hole was then cut in which he inserted a mercury thermometer. This allowed Benjamin a means by which the heat could be measured. Using a weight to create pressure and thus assure friction, he spun the cylinder at 32 Revolutions per minute. The temperature made prior to the rotation was 60 degrees. After 30 minutes and approximately 960 rotations, the temperature of the cylinder was 130 degrees. The experiment was a success. He would perform further experiments to determine the mechanical equivalency of heat As a point of reference, it should be noted that at the time of the American Revolution, the Royal Society of England was one of the most prestigious Science organizations in the world. For one’s work to obtain legitimacy, it must be submitted and subjected

“A quadrangular oblong deal box (Fig. 1) watertight, 11.5 English inches long, 9.4 inches wide, and 9.6 inches deep (measured in the clear), being provided with holes, or slits, in the middle of each of its ends, just large enough to receive, the one, a square iron rod, to the end of which the blunt steel borer was fastened; the other, a small cylindrical neck,

presented to the Society:

which joined the hollow cylinder to the cannon, when this door (which was occasionally closed above by a wooden cover, or lid. moving on hinges) was put into its place; that is to say, when by means of the two vertical openings, or slits, in its two ends (the upper parts of which openings were occasionally closed by means of narrow pieces of wood sliding in vertical grooves), the box (g, h, I, k, Fig.2) was fixed to the machinery in such a manner that its bottom (I, k) being in the plane of the horizon, its axis coincided with the axis of the hollow metallic cylinder, it is evident from the description that the hollow metallic cylinder would occupy the middle of the box without touching it on either side, and that, on pouring water into the box, and filling it to the brim, the cylinder would be completely covered, and surrounded on every side, by that fluid. And, farther, as the box was held fast by the strong square iron rod in which passed in a square hole in the center of one of its ends (a, fig. 1) while the round or cylindrical neck, which joined the hollow cylinder to the end of the cannon, could turn round freely on its axis in the round hole in the center of the other end of it, it is evident that the machinery could be put in motion without the least danger of forcing the box out of its place, throwing the water out of it, or rearranging any part of the apparatus.”

“Everything being ready, I proceeded to make the experiment I had projected, in the

following manner:”

“The hollow cylinder having been previously cleaned out and the inside of its bore wiped with a clean towel till it was quite dry, the square iron bar, with the blunt steel borer fixed to the end of it, was put into its place,

14 RETA.com / The Refrigeration Historian

to the scrutiny of the society. Something Benjamin would do in 1798. Since the heat produced was accurately measured, it would be determined as to how large of fire would have been required to produce the same amount of heat and thus the expenditure required to produce the same heat. The driving force behind the contraption was a simple horse, harnessed to the device. This experiment demonstrated that this device could be used as a portable heat generator. A horse could spin the cylinder and produce heat. Thus, the concept of horsepower per hour in thermal units. With failing health, Benjamin would return to England in 1798. Back in England, his health improved and he continued his study of heat as well as other philanthropical pursuits. His accomplishments include: • Construction of a modern fireplace. Increasing efficiency by over 12% in some cases 50% • Determining the amount of heat generated by burning various fuels • The thermos It can be argued that Benjamin was the father of the concept of convection heat. Having fully recovered, the next stage of Benjamin’s life would take him to France. In 1804, Benjamin would marry the widow Lavoisier and retire to her villa at Auteuil, He would die 10 years later.

the mouth of the bore of the cylinder being closed at the same time, by means of the circular piston, through the center of which the iron bar passed.” “The result of this beautiful experiment was very striking, and the pleasure it afforded me amply repaid me for all the trouble I had had in contriving and arranging the complicated machinery used in making it.” “The cylinder, revolving at the rate of about thirty two times a minute, had been in motion but a short time when I perceived, by putting my hand into the water, and touching the outside of the cylinder, that heat was generated, and it was not long before the water which surrounded the cylinder began to be sensibly warm.” “At the end of one hour I found, by plunging a thermometer into the water in the box (the quantity of which fluid amounted to 18.77 lbs. avoirdupois, 2.25 wine gallons), that its temperature had been raised no less than 47°, being now 107° of Fahrenheit’s scale.” “When thirty minutes more had elapsed. or one hour and thirty minutes after the machinery had been put in motion, the heat of the water in the box was 142°” “At the end of two hours, reckoning from the beginning of the experiment, the temperature of the water was found to be raised to 178°.” “At two hours and twenty minutes it was at 200°, and at two hours and thirty minutes it actually boiled!” “It would be difficult to describe the surprise and astonishment expressed in the countenances of the bystanders, on seeing so large a quantity of cold water heated, and actually made to boil, without any fire. “Though there was, in fact, nothing that could justly be considered as surprising in the event, yet I acknowledge fairly that it afforded me a degree of childish pleasure, which, were I ambitious of the reputation of a grave philosopher, I ought, most certainly, rather to hide than to discover.”

The Refrigeration Historian /

RETA.com 15

“The result of this beautiful experiment was very striking, and the pleasure it afforded me amply repaid me for all the trouble I had had in and arranging the complicated machinery used in making it.”

His contributions are seemingly countless. Humanitarian and science awards across the globe are named in his honor. Even a lunar crater bears his name. All have benefited from his work and Count Rumford will never be forgotten. This article offers only a small window into the story of Benjamin Thompson. The breadth of The Count’s accomplishments deserves much more fanfare than the author could provide. Harvard University Press has preserved his collected works in five volumes available through their press. A worthwhile read for those interested in any of the social or thermodynamic sciences for which he is credited. The Refrigeration Historian roams, the library of Vern M. Sanderson (Wagner-Meinert LLC), often dusting old tomes and lamenting the early days of refrigeration. The information used to generate this article is believed factual. Should you have any corrections or additional information pertaining to this article please forward them to the editor.

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COMPLIANCE

AMMONIA PIPE AND EQUIPMENT LABELING part 3

IN THIS SERIES, we have been discussing ammonia refrigeration pipe and equipment labeling. In Part I, I highlighted the possible choices for applicable good engineering practices that pertain to such labeling, highlighting the American Society of Mechanical Engineers (ASME) A13.1 and the International Institute of Ammonia Refrigeration (IIAR) Standard 2. In Part II, I began to delve into the details of IIAR’s Bulletin 114, and how it has changed over the years. I limited the discussion in Part II to Bulletin 114’s guidelines for piping labels. In this article, we will review the pipe color guidelines in Bulletin 114, along with component, or equipment labeling. BY BILL LAPE, SCS ENGINEERS

The first thing to note is that in the original edition of Bulletin 114, published in 1991, no recommendations were made as to pipe color. Most facilities simply assumed that painted ammonia pipe would match the yellow of the label without referring to any other RAGAGEP. Even if they had referred to ASME A13.1 as it read at that time, yellow would have been the color of choice.

RETA.com 17

In 2007, ASME updated A13.1 to call out orange as the preferred color for toxic and corrosive fluids and limited the use of yellow to flammable and oxidizing fluids. In 2014, IIAR updated Bulletin 114 to more closely align with A13.1. The preferred paint color for liquid ammonia over 70 psig is orange. Note that these color schemes are guidelines. Should a facility choose to use a different coloration scheme, that is allowable under the Process Safety Management standard and the Risk Management Program rule. If this route is chosen, be sure to do the following: 1. Document the chosen color scheme that is being followed 2. Train affected employees and contractors on the selected color scheme 3. Document this training including proof of understanding

Liquid Ammonia Piping > 70 psig Vapor ammonia over 70 psig is called out as yellow. In 2018, a clarification was added that Booster Discharge lines should be yellow regardless of discharge pressure.

Vapor Ammonia Piping > 70psig Low pressure, high temperature vapor or liquid lines, such as HTRL or MTS lines are called out as light blue.

Low Pressure, High Temperature Liquid andVapor Piping Low pressure, low temperature vapor or liquid lines, such as LTRL or LTS lines are called out as dark blue.

Low Pressure, LowTemperature Liquid and Vapor Piping Low low pressure, low low temperature vapor and liquid lines, such as LLTRL and LLTS are called out as purple.

Low Low Pressure, Low LowTemperature Liquid andVapor Piping Pressure relief vent piping is called out as gray.

Pressure Relief Piping Water for condensers or auto-purgers, along with brine or glycol secondary coolant piping is called out as water green, aligning it with ASME A13.1.

18 RETA.com

“Do I need to make the outer jacket of my pipe insulation match the appropriate color for the pipe service?”

AU-2

LOW

Bulletin 114-1991 Component Marker Example

One question that is asked a lot is “Do I need to make the outer jacket of my pipe insulation match the appropriate color for the pipe service?” The answer is NO. A facility MAY choose to use insulation jacketing of different colors, but it is perfectly allowable to use a simple white PVC jacket or gray aluminum jacket, as long as the labeling conforms to the chosen good engineering practice. Another question that gets asked frequently is “Does the label background color need to match the recommended pipe color?” Again the answer is no. In fact, it has been argued that a label with an orange background is awful hard to read on an orange pipe. This is a valid concern and could be a good argument for developing your own internal standards for pipe colors and labeling. Now on to equipment, or component markers. The 1991 edition called out a yellow background for the component markers with red or green pressure bands for high and low pressures, respectively. In 2014, the background was updated to orange with the same pressure bands. In 2018, the pressure band was REMOVED from the label. Bulleting 114, calls out identifying the equipment by name or abbreviation. For instance, an air unit would have the text “air unit” or “AU” on its label. However, take note that this naming convention can cause issues under a number of government regulations. If your equipment no longer has the original manufacturer’s nameplate with the equipment serial number, then any label applied to the equipment must uniquely identify it. Even if the Original Equipment Manufacturer (OEM) nameplate is still on the equipment and is still readable, it is advisable to use unique nomenclature on this additional labeling. The best approach is to use the unique identifier that should be on your piping & instrumentation diagrams (P&IDs) for your system. In the case above, we may label the equipment as “AU-2” if it has that designator on the P&IDs.

AU-2

LOW

Bulletin 114-2014, 2017 Component Marker Example

AU-2

Bulletin 114-2018, 2019 Component Marker Example

Regardless of what standard or recommendation you choose to use as your facility’s good engineering practice, be sure to document, document, document. Document the chosen color and labeling schemes. Document that the affected employees and contractors have been trained on the chosen color and labeling scheme. Document that those trained on the chosen color and labeling scheme understood their training and can properly identify piping and equipment. Bill Lape is Project Director for SCS Engineers. Bill is a Certified Industrial Refrigeration Operator, a Certified Refrigeration Service Technician, and a member of the National Board of Directors of the Refrigerating Engineers and Technicians Association.

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EDUCATION CORNER

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Education Saves Lives I want to convey what an honor it is for me to have been chosen as your On May 24, 1998 my focus changed somewhat when a young worker at BY VINCE GRINDEL

accomplished when we, as a group, work together to produce a product dedicated to education, efficiency, and professional development. I invite all RETA members, to involve yourself as much as possible with the development of the RETA study courses. Your experience and expertise are what makes the RETA training materials great. Get involved at the Chapter level and at the national level. Ask questions, seek answers. RETA as an organization only works when you become involved. Right now, RETA is in the process of developing, editing and improving the study materials on an ongoing basis and

new Education Coordinator. My history with RETA dates back to 1976 when I was a student at Linn-Benton Community College, in Albany, Oregon. There I had the distinct pleasure of meeting, working with and becoming friends with the 1971 RETA National President, Larry Benedict, aka “Purging Benedict”. Larry would sometimes get to missing the smell of ammonia so he kept a spray bottle full of purger water handy and he would spray it in the office and shop area until my eyes would water. He called it “air freshener”. Back then we organized and started a newWillamette Valley RETA Chapter where I served as the Chapter Vice President and then Chapter President. We used the RETA texts as training materials at our Chapter meetings. After college I spent a number of years in a service van as a refrigeration service technician working on all kinds of refrigeration systems and some more years as an ammonia plant operator riding herd on a 5000 hp, 2-stage ammonia refrigeration system. Back then, the operator was the control system. Eventually, the company decided to install a new computer control system.

a plant, who we knew and had trained with, was killed by an ammonia release that was caused

by a lack of training, written procedures and a complete

understanding of the refrigeration system. This tragic event was totally preventable!

I was a member of RETA’s National Board of Directors from 2003 to 2007 and was Vice Chair of the Certification Committee while RETA was going through the initial ANSI accreditation process helping to develop the CARO and CIRO certification tests. The goal for RETA, as an organization, is to never have another preventable injury. Everyone goes home safe at the end of their shift. My goal is to make the RETA training materials as good as possible. This can only be “ The goal for RETA, as an organization, is to never have another preventable injury. Everyone goes home safe at the end of their shift.”

we can use your help. Please contact me or your various

Education Committee members to find out how you can get involved.

Vince Grindel RETA Education Coordinator vince@RETA.com

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The Basic Refrigeration Cycle

GORDON RASCOE, CIRO, CRST, RAI CHAPTER PRESIDENT FORT WAYNE CHAPTER

VARIOUS METHODS OF cooling product and spaces have been around for a long time. However, it wasn’t until the development of the Closed-Loop Refrigeration System that cooling products and spaces became feasible, efficient, and practical. Most closed-loop systems work the same basic way, with the differences being the addition of extra components and controls to make the systemmore efficient and to accomplish the task at hand. This article discusses the four (4) basic components and their function, the state of refrigerant at each component, and the relative pressure in each section of the closed-loop system. The first component in this system is the Compressor. The Compressor provides the motive force by taking a low- pressure vapor, compressing it into a high-pressure vapor, and sending it to the Condenser. Compressors can be a Positive Displacement type, such as a Reciprocating Compressor, a Screw Compressor, or a Rotary Vane Compressor. A Positive Displacement Compressor traps a volume of vapor and moves it to the discharge side. If that volume of air is blocked, either by a shut off valve or some other obstruction, then the pressure keeps building until something gives; that could be a relief valve or something in the line that

breaks. A Centrifugal Compressor is a non-positive displacement Compressor. It uses an impeller to increase the velocity of the vapor, thus allowing it to be compressed a certain amount. If the discharge is blocked, then the pressure only increases to a certain point. The impeller still rotates but won’t move the vapor. This causes excessive heat to build up causing damage to the Compressor. The next component is the Condenser. The condenser rejects the heat that the refrigerant obtained from the evaporator, piping, and the Compressor, and transforms the vapor back into a high-pressure liquid. Condensers can be 1) Air-Cooled, which moves air across a coil to cool the refrigerant; 2) Evaporative, which uses air and the evaporation of water across a coil to cool the refrigerant; or 3) Water-Cooled, which uses water through tubes or plates to cool the refrigerant. As refrigerant moves through the condenser, it condenses into a liquid, but the pressure stays relatively constant. The liquid then travels through an Expansion Device that takes the high- pressure liquid and reduces it to a low-pressure low-temperature liquid. The expansion device can be as simple as an orifice or small-diameter tubing, or as complicated as a TXV (thermo

expansion valve) or a motorized expansion valve. During this process, some vapor is created while cooling the liquid. This vapor is called Flash Gas. The pressure of the system is now near that of the suction pressure of the Compressor. The expansion device also regulates flow through the evaporator. If the expansion device lets through too much liquid, then the evaporator won’t be capable of turning all the liquid to a vapor; therefore, liquid can flow back to the Compressor, which can cause damage to the Compressor. The final component is the Evaporator. The evaporator removes heat from the room through the process of evaporating liquid ammonia flowing through the evaporator tubes. If flow is set properly, then all the liquid should evaporate before it leaves the component. Fins are built on the coils to assist in heat transfer by increasing the surface area. The fins must be kept clean, straight, and unbroken to keep the unit working efficiently. The results of a dirty evaporator could be an area not cooled sufficiently or liquid flowing back to the Compressor. This is the basic operation of a simple refrigeration system seen in home refrigerators or a window AC unit. As the size of the system grows, more components and controls are added to increase efficiency, reliability, and safety.

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Basic Preventative Maintenance Activities to Perform Regularly 5

BY DAVID PILLER INNOVATIVE REFRIGERATION SYSTEMS, INC P reventative Maintenance (PM) is critical to the function and lifespan of all industrial refrigeration systems. Without a proper PM schedule, maintenance becomes reactive instead of proactive. Compared to reactive maintenance, PM increases uptime and extends the life of equipment, saving businesses time and money in the long run. The International Institute of Ammonia Refrigeration (IIAR) sets the standards of PM for ammonia refrigeration, but there are other basic PM measures one should take on any industrial refrigeration system 1. Compressor Maintenance In refrigeration, the compressor is the single most important piece of equipment. On top of the standard IIAR inspections, it’s important to also follow Original Equipment Manufacturer (OEM) maintenance recommendations, perform vibration analysis, oil analysis, and oil filter changes regularly. Vibration analysis determines the conditions of the bearings and other internal components of the compressor. Routine vibration analysis catches issues before they manifest into a more serious problem. A certified Vibration Specialist performs this analysis after review of logged data to determine if there has been a change in normal operating parameters. Oil analysis involves pulling a sample of oil from the compressor and testing it to check for oil quality. Testing will tell the contaminants and viscosity of the oil.

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Oil analysis is essential to determining the overall oil life of the system, ensuring that oil is changed before equipment is jeopardized. Vibration analysis and oil analysis should be performed twice a year minimum. Oil filters should be changed based on manufacturer specifications or

once a year, whichever comes first. 2. Condenser Maintenance

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Condenser systems should have a good water treatment program that includes a monthly inspection by a trained water treatment provider. It’s important to control the solids (conductivity) and pH level within the water to maintain maximum heat transfer and a long life of the condenser. If the conductivity in the water gets too high for the chemicals that inhibit scaling, you will run the risk of scaling your tower. To keep the conductivity under control, you bleed off the condenser water and replace it with fresh water, which lowers the conductivity level to an acceptable level to ensure scaling does not occur. An ideal pH range is 7.1-7.8; anything above or below this range is outside of optimal operating conditions and could create corrosion issues and adversely affect the lifespan of the condenser. If the pH is above 7.8 you will run the risk of white rust forming on the galvanization, and if it drops below 7 you run the risk of losing the galvanization off of the steel and exposing bare metal. Towers should be cleaned twice a year, and belts changed once a year for proper condenser maintenance. Standard condenser inspections and following OEM recommended maintenance will increase the life of the unit and prevent early equipment failure.

3. Evaporator Maintenance Evaporators are relatively easy to maintain one would think. You should follow OEM maintenance recommendations and IIAR checklists, which include routine greasing of the motors and inspection of the fan blades and motor mounts for cracks. One area that is overlooked at times is regular cleaning of the evaporator. This includes: coil, fan, fan shroud, drain pan, IMP ceilings, and drain line cleaning. We recommend cleaning the dock units twice a year and the coolers once a year at a minimum.

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4. Refrigerant Maintenance An annual Ammonia Purity Test or Refrigerant Analysis is highly recommended to ensure that the refrigerant itself falls within specifications. Refrigerants need to maintain their purity in order to transfer heat efficiently. Common impurities are moisture (H2O), oil, and acid. All of these factors can cause equipment issues and heat transfer issues.

annually anti-seize the valve caps. When you have an operational event, the functionality of these valves is the difference between an emergency and a busy day! Lastly, keep up with painting of the valve stations on an annual basis to protect the stations from corrosion. By performing these tasks, you will keep your valves operating smoothly for 30 plus years to come. Review Setting up a good PM schedule, making sure to follow IIAR checklists, following manufacturers recommendations, and completing the steps mentioned above for all Preventative Maintenance will lower your odds of equipment failure, extend the life of the equipment, and reduce downtime. This will save you money in the long- run and lead to a more efficient and profitable facility.

5. Valve Maintenance Proper maintenance on your valves and regulators is just as important as a compressor or evaporator. To ensure proper flow of refrigerant and operation of the valves, make sure to lube and manually cycle the valve stems as required by OEM, and

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