2021 RETA Breeze May-June

RETA BREEZE

REFRIGERATING ENGINEERS & TECHNICIANS ASSOCIATION MAY / JUNE 2021

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BREEZE

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 sara@reta.com Stephanie Date Marketing & Events Manager stephanie@reta.com Dan Denton Chapter Relations Liaison ddenton@reta.com Vince Grindel Education Coordinator vince@reta.com 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 © 2021 Refrigerating Engineers & Technicians Association.

Corrosion Rate is (NOT) a Viable Means to Determine Life of a Component in Ammonia Refrigeration page 20

Message FromThe President........... 4 FromThe Executive Director.......... 6 Epic Fails Here's mud in your eye, good luck getting it out .......................... 8 Call for Nominations Annual awards . .................................. 11 Conference Corner 2021 Conference ................................ 12 From Microbial Haven To Safe Haven Guidelines for maintaining proper meat plant air quality ......................... 14 INSIDE THIS ISSUE Mythbuster

Corrosion Rate is (NOT) a Viable Means to Determine Life of a Component in Ammonia Refrigeration ...................... 20 Education Corner Safety Requirements Defined by ANSI/ IIAR-2 and OSHA . ............................ 22 Tier II Reporting & Avoiding Common Mistakes Part 2 ............. 24 LinkedIn and Facebook – Valuable Connections .................... 26 RETA Testing Corner No. 24.......... 28 RETA’s Credentialing Exams And Activities Certification..................................... 30 Honor Roll

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

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2020-21 BOARD OF DIRECTORS CHAIRMAN Vern Sanderson, CIRO, CRST, RAI Wagner-Meinert, LLC PRESIDENT Eric Teale, CARO, CRST Danfoss Industrial Refrigeration EXECUTIVE VICE PRESIDENT Keith Harper, CARO Tyson Foods Inc TREASURER Pete Lepschat, CIRO, CRES, CRST Lineage Logistics SECOND VICE PRESIDENT Bengie Branham, CIRO Perdue Farms DIRECTORS Alan Gervais, CARO, CIRO Western Precooling Systems Bill Lape, CARO, CIRO, CRST SCS Engineers David Gulcynski, CIRO Dot Foods Inc. Debbie Koske Calibration Technologies, Inc Edward Johnson, CARO Schwans Global Supply Chain, Inc. Jeremy Murfin AC & R Specialists Jim Kovarik Gamma Graphics Jordan Reece, RAI Lanier Technical College Michael Hawkins Midatlantic Refrigeration, LLC Raymond Urban, CARO Lineage Logistics Ricky Jimenez, CIRO Mericle Mechanical Inc William Ellena Coastal Pacific Food Distributors, Inc COMMITTEE CHAIRS Dascha Whitmore, Marketing Dave Gulcynski, CIRO , Education Dot Foods, Inc. Jim Kovarik, National Conference Gamma Graphics Lee Pyle, CARO, Certification SCS Tracer Environmental Matt Hayes, CARO, Publications TJW Industrial Michael Hawkins, Membership Midatlantic Refrigeration, LLC Jim Barron, Executive Director

FROM THE DESK OF THE PRESIDENT

Somewhere along my short journey in this life and career, I stumbled my way across a concept of the 200-year present, a concept developed by sociologist Elise Boulding. At any given moment, if you consider the life spans of the oldest and youngest individuals alive which is approximately 200 years, you begin to understand the effect and impact past actions have on the present and the effect and impact of present actions on the future. The near-term future of 2025 has the HVAC&R industry facing a shortage of Technicians in the US potentially as high as 180,000 individuals. That number is daunting alone without considering what the worldwide shortage could be. This shortage is an effect of our industry and society’s past and is coming at a time of change for our industry as other effects of our past are causing us to use refrigerants that have less of an impact on our future environment. The “why” of an individual should consider a career in our industry is well understood, good pay, potential for advancement, and it is a career that has real impact on environmental sustainability. The “how” to get people into our industry and help to eliminate the shortage is all our responsibility to figure out. One way to do that is to build your legacy. When I start to think of my legacy, I start to see how in my past, my mentors brought me into the refrigeration community where I was able to learn and grow and be a part of building the future. I have been involved at the local chapter level as volunteer leader and by just showing up and being present.

Eric Teale, RETA National President

I have shared my career story with students at Minnesota State University, Mankato to show them the possibilities that a career in refrigeration holds. I have been active in RETA and IIAR committees to share the knowledge I have gained and been given with others. I am part of building the RETA Training Institute to help bring individuals in our industry. These are the things that I am currently doing that will have effects that stretch into the future well beyond my lifetime. What are you doing to build your legacy? Are you teaching and sharing the knowledge and wisdom that you gained? Are you reaching out to local schools to help recruit? Are you being open minded to new ways of thinking and technology? Are you attending RETA meetings locally or virtual? Are you volunteering your time in committees or local chapter leadership? If you want to contribute to your legacy and contribute to building the future of RETA and RETA Training Institute, we have place for you to belong. Contact myself or RETA Headquarters to get connected. In the words the Joseph M. Marshall III, “Wisdom travels many roads and knows no boundaries. It is a fleeting gift, grasp it while you can, for it is not yours to keep, but to use and pass on.”

Sincerely, Eric W. Teale, P.E., CRST RETA President 2020-2021 eric.w.teale@gmail.com

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FROM THE EXECUTIVE DIRECTOR

Hello RETA Family, You can tell it’s almost summer here in Oregon and the blue skies and warm sun have put everyone at HQ in good spirits. We hope and pray that all of you have a safe and enjoyable summer. As always, please keep an eye out for those that ride bicycles and motorcycles. We’ve already seen too many bike accidents since the weather has turned nicer so those of you that ride, please stay safe. RETA has weathered the storm of the last year, and we have all of you to thank for your continued support and commitment to RETA. It’s a testament to the importance of RETA and the work it does as a non-profit trade Association to have endured, survived, and thrived over the last 111 years. We have persisted through the Great Depression, two World Wars, the Korean War, Vietnam, Desert Storm, 9/11, Iraq, Afghanistan, Covid-19 and so much more. I can’t stress enough that we are here because of you and for you. We will continue to do the right things for the right reasons and with God at our side. Our goal isn’t to make the most money or to become the 800-pound gorilla in the room. We are often quietly in the background fulfilling our mission statement by enhancing the professional development of industrial refrigeration operating and technical engineers in order to keep the industry and communities safe. Our chapters have done a superb job at planning virtual chapter meetings during this time when it was nearly impossible to have more than 6 people in a room. It’s been so encouraging seeing faces from all over the country at each virtual meeting. If you would like to present at a virtual

chapter meeting or be involved with a chapter in any way, please contact Dan Denton at ddenton@reta.com or 541-497-2955. If you weren’t aware, RETA-Training Institute (RETA-TI) is a 501(c)(3) that RETA has developed to address the critical issues of workforce development and education that surround the industrial refrigeration industry. RETA-TI began with three programs, REDWHITEandCOOL, Women in Natural Refrigeration (WiNR) and Youth and Young Adults (YAYA). REDWHITEandCOOL helps train individuals transitioning from the military to civilian workforce in the science and art of refrigeration. Having completed the first successful cohort in April, the REDWHITEandCOOL program is steadily gaining traction and is set to start the second cohort in July at Joint Base Langley-Eustis. We would like to thank our founding sponsors Smithfield Foods, Tyson, andWagner-Meinert for supporting such an important initiative. TheWomen in Natural Refrigeration (WiNR) program is a program dedicated to improving the careers of women in natural refrigeration, engineering and skilled trades. It encourages and high- lights individuals through networking, mentoring, and education. It also enhances the refrigeration industry’s ability to recruit, develop, inspire, advocate for, and empower women. TheWiNR committee meets monthly and they have some fantastic networking plans in the works. The Youth and Young Adults (YAYA) program is still in development, and we are hoping to bring the success of Marcos Braz’s Azle High School Industrial Refrigeration Course into other high

In the photo above: Katelyn Ingram, Jim Barron, Travis O’Neill

schools across the nation. I recently proctored the CARO exam at Azle High School and was proud and honored to award CARO certifications to Junior Katelyn Ingram and Senior Travis O’Neill. Congratulations to student Jesse Mauerhan who also received his CARO certification yesterday. All of these programs were developed to nurture passion in the industry, develop life skills, inspire the next generation, aid transitioning military veterans, and help keep the industry staffed with individuals who have gained refrigeration knowledge and are ready to go to work. If you would like to become a corporate sponsor for any, or all of these, programs please contact Lois at lois@reta.com. We give a heartfelt thank you to a 501 (c)(3) foundation that unfortunately had to close its doors this year but in doing so, donated $225,000 to RETA-TI. The National Transportation Center Foundation donated their reserves to RETA-TI in order to continue the Preston Harrison Scholarship for Veterans and transitioning military in transportation.

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On a different note, RETA is seeing the light at the end of the COVID tunnel. We are running full steam ahead in the planning and execution of our RETA annual National Conference this year in Schaumburg, Illinois Nov 9-11, 2021. We are so excited to see everyone face to face once again. It has been a tough year and a half, and we really need this connection. If you are on the fence on whether you would like to sponsor or exhibit at the Conference, please don’t be. On the slim chance we need to make the difficult decision to return to a virtual Conference for one more year, we have a 100% guarantee that all exhibitors, sponsors, and attendees will receive a FULL refund for any monies paid to RETA for the live Conference. We still have some great sponsorship opportunities available so please contact Stephanie at stephanie@reta.com with any questions. We hope to see all of you in Schaumburg this November!

Title Preston Harrison Scholarship for Veterans in Transportation The Program Sponsor has established a scholarship program to assist current and former military personnel to transition into and excel in transportation careers. One-time scholarships are awarded in the name of the recipient and paid directly to the school or program providing accredited training for transportation careers. Training areas may include transportation refrigeration maintenance, logistics, crane operation, forklift operation, supervision, diesel technician, electrical technician, and maintenance. This scholarship program is administered by RETA-TI, part of the RETA organization. It is part of the RedWhiteandCool program established in February 2020 by RETA-TI and sponsor Smithfield Foods to provide a training program for veterans transitioning to civilian work. Eligibility Applicants have honorably served in the United States military. They may be within 6-months of separating and eligible for transition training or have already separated. Awards If selected as a recipient, the students approved training source will receive an award of up to $10K. Multiple recipients and awards in lesser amounts are possible each year. Applications Will be sent to REDWHITEandCOOL@reta.com or contact RETA HQ at 541-497-2955. Selection of Recipients RETA and the RedWhiteandCool program are responsible for the selection of veterans for this scholarship. Payment of Scholarships RETA and the RedWhiteandCool program will process the payments. Payments are generally a one-time payment in the name of the veteran paid directly to the organization providing the accredited training.

Jim Barron RETA Executive Director

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EPIC FAILS

HERE’S MUD IN YOUR EYE, GOOD LUCK GETTING IT OUT Anyone who has worked long enough as an ammonia refrigeration operator has had to flush parts of their body with water due to a liquid ammonia exposure. Hopefully, it was simply a minor burn on a finger or wrist. However, far too often, it is an exposure that requires flushing the eyes and face, often because the operator was not wearing a full face respirator mask, or at least chemical goggles and a face shield when opening the system, or draining oil.

To help minimize the injury, the International Institute of Ammonia

Section 6.7.2 sets path of travel requirements that may increase the number of required eyewash/shower units. It states: “The path of travel within the machinery room to at least one eyewash/ safety shower unit shall be unobstructed and shall not include intervening doors. Additional eyewash/safety shower units shall be installed such that the path of travel in the machinery room is no more than 55 ft to an eyewash/safety shower unit. The path of travel to at least one eyewash/safety shower unit located outside of the machinery room shall be within 55 ft of the principal machinery room door. The path of travel shall be unobstructed and shall not include

Refrigeration (IIAR) requires that eyewash/ showers be installed inside and outside of the machinery room. Specifically, Section 6.7.1 of IIAR-2014, Addendum A, states: “A machinery room shall have a minimum of one eyewash/safety shower unit, which shall be located inside the machinery room. A minimum of one eyewash/safety shower unit shall be located outside of the machinery room.” So, this section sets a minimum number of eyewash/shower units in and around the machinery room at two.

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SO WHAT DOES Z358.1 REQUIRE? HERE IS A SUMMARY OF THE REQUIREMENTS:

SHOWERS

• A means shall be provided to ensure that a controlled flow of flushing fluid is provided at a velocity low enough to be non-injurious to the user. • Emergency showers shall be capable of delivering flushing fluid at a minimum of 20 gallons per minute for a minimum of 15 minutes. If shut off valves are installed in the supply line for maintenance purposes, provisions shall be made to prevent unauthorized shut off. • Emergency showers shall provide a flushing fluid column that is at least 82 inches and not more than 96 inches in height from the surface on which the user stands. • The spray pattern shall have a minimum diameter of 20 inches at 60 inches above the surface on which the user stands, and the center of the spray pattern shall be located at least 16 inches from any obstruction. The flushing fluid shall be substantially dispersed throughout the pattern. • Emergency showers shall be designed, manufactured and installed in such a manner that, once activated, they can be used without requiring the use of the operator’s hands. • Emergency showers shall be constructed of materials that will not corrode in the presence of the flushing fluid. Stored flushing fluid shall be protected against airborne contaminants.

intervening doors.” The most obvious criteria in this section that may increase the required number of eyewash/shower units in the machinery room is the maximum travel distance being 55 feet. However, let’s look a little more closely at this requirement. First, let’s say that we have a machinery room that is 55 feet on each side. If the eyewash/shower is installed in one corner of the machinery room, then the minimum path of travel from the other corner would be 77.8 feet, over the maximum distance of 55 feet. Let’s say for argument’s sake, that the maximum straight line path corner to corner is 55 feet, which would apply for a

room about 38.9 feet on each side. We are good, right? Maximum path of travel is 55 feet or less, so no worries, right? The key is that the path must be UNOBSTRUCTED. If equipment stands between the person and the eyewash/shower, then the path is not unobstructed and hence does not meet the requirements of IIAR2. When placing eyewash/showers distance and obstructions must be evaluated. Once we have our selected placements, IIAR2 goes on to state requirements for the eyewash/ shower installations. Section 6.7.3 states that “Emergency eyewash/safety shower unit installations shall comply with ANSI/ ISEA Z358.1.”

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EYEWASH

• A means shall be provided to ensure that a controlled flow of flushing fluid is provided to both eyes simultaneously at a velocity low enough to be non- injurious to the user. • Eyewashes shall be capable of delivering flushing fluid to the eyes not less than 0.4 gallons per minute for 15 minutes. If shut off valves are installed in the supply line for maintenance purposes, provisions shall be made to prevent unauthorized shut off. • Be arranged such that the flushing fluid flow pattern as described below is not less than 33 inches and no greater than 53 inches from the surface on which the user stands and 6 inches minimum from the wall or the nearest obstruction. • Eyewashes shall provide flushing fluid to both eyes simultaneously. A test gauge for making determination of a suitable eyewash pattern shall be a minimum 4 inches in length with two sets of parallel lines equidistant from the center. The interior set of lines shall be 1.25 inches apart and the exterior lines shall be 3.25 inches apart. Place the gauge in the stream of the eyewash. The flushing fluid shall cover the areas between the interior and exterior lines of the gauge at some point less than 8 inches above the eyewash nozzle(s). • Eyewashes shall be designed, manufactured and installed in such a manner that, once activated, they can be used without requiring the use of the operator’s hands. • Eyewashes shall be constructed of materials that will not corrode in the presence of the flushing fluid. • Deliver tepid flushing fluid… Definition: A flushing fluid temperature conducive to promoting a minimum 15 minute irrigation period. A suitable range is 60 -100º F. • Nozzles and flushing fluid units shall be protected from airborne contaminants. Whatever means is used to afford such

NOW, DO YOU THINK THAT THESE MEASURE UP?

protection, its removal shall not require a separate motion by the operator when activating the unit.

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.

• The eyewash shall be designed and positioned in such a way as to pose no hazard to the user. • Eyewashes shall be designed to provide enough room to allow the

eyelids to be held open with the hands while the eyes are in the flushing fluid stream.

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CALL FOR NOMINATIONS - ANNUAL AWARDS

The following awards will be given out at the annual Conference in Schaumburg, Illinois this November. They are named in honor of past RETA members who exemplified a specific strength that benefitted the RETA membership and our industry either through teaching or leadership or service. Identify who that special RETA person is and jot down some reasons you think they should be honored. Send this nomination and the supporting documentation to the Executive Director Jim Barron by email to jim@reta.com or submit it online at www.reta.com/nominations. Nominations must be received by August 31st, 2021 in order to give the awards committee adequate time to consider the nominations.

Guy R. King Memorial Award

Venneman Award Recognizes an outstanding RETA member for a career marked by leadership and service to the profession and the organization.

Recognizes outstanding job performances in education and training of members nationally and locally.

Felix Anderson Award Recognizes two individuals who have worked behind the scenes at the Chapter level and who are not on the national Board.

Elliott R. Hallowell Award Honors the member whose record of service to RETA for the current year merits special recognition and reward.

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CONFERENCE CORNER

2021 CONFERENCE By Stephanie Date, RETA Marketing & Events Manager

I hope this finds you well and healthy. We can all agree that the past 16 months have been tough due to the COVID-19 pandemic. Our commitment to you, our members, attendees, sponsors, and exhibitors, is a safe, fun and successful 2021 conference. Our efforts to provide our member- ship with RETA’s 2021 National Conference filled with hands-on training, workshops, technical presenta- tions, networking events, and an expansive exhibit hall will continue. Our educational Conference has an all-encompassing program helping you, at any level of experience and position, grow within the refrigeration industry. We have several educational topics for everyone ranging from student to expert in the industry.

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Additional networking and other organized events are scheduled throughout the conference and include, but are not limited, to:

MONDAY, November 8th

Top Golf: 12pm-3pm. Must preregister. WiNR (Women in Natural Refrigeration) Networking Event: 5pm-6pm. Must preregister. Roaring 20’s Welcome Event: 6pm-10pm

2021 Technical Topics:

COMPLIANCE: • Applying IIAR 6 to Your Facility: Apply and Use What You Already Have • Best Practices for Minimizing Ammonia System Hazards Through Your PSM Program • What to Know Before Your Next Regulatory Audit MANAGEMENT: • Keep Your Cool in an Unpredictable World with Digitized Assets • Creating an Ammonia “Checkbook” • The Art of the Investigation OPERATIONS: • IIAR 6: Should I Hire a Contractor or Keep it In-House? • Risk Based Inspections for Refrigeration Systems • Properly Developed Standard Operating Procedure(s) (SOP), the Refrigeration Operator(s) andWhy You Should Care ENGINEERING: • ASME B31.5 Piping Stress Analysis in Refrigeration Systems • Vessels Operating at Temperatures Colder than the MDMT Stamped on the Nameplate • Virtual Design and Construction: Engineering Technology as Applied to Refrigeration Systems

TUESDAY, November 9th

Exhibit Hall Welcome Reception: 4:45pm-6:45pm Chapter Leaders Reception: 7pm-8:30pm RETA After Hours: 7pm-11pm RETA Rumble and Breakfast: 7:15am-9:15am Sip n Dip: 6:30pm-7:30pm Awards Banquet: 7:30pm-9:30pm RETA After Hours: 9pm-11pm

WEDNESDAY, November 10th

Big Ticket Items Drawing in Exhibit Hall: 12:30pm-2pm

THURSDAY, November 11th

Exhibitor Booths and Sponsorship Opportunities Still Available:

If you opt to continue with your sponsorship for 2021 but are unable to attend, RETA will honor your sponsorship. RETA will ensure your company name is represented during the Conference, even if you are not physically there. Exposure is everything! RETA HQ is committed to you and our membership and will continue to keep you informed of any changes or actions that need to be taken. Until then, planning for an in-person 2021 National Conference will continue to move forward. I look forward to seeing you in Schaumburg, Illinois!

There is still room for you at the 2021 RETA National Conference! Our sponsors and exhibitors are what makes the RETA National Conference a success! We hope that you will continue to be a part of our conference this year either as a sponsor, exhibitor, or both. This is a no risk commitment. 100% refund guaranteed if the 2021 RETA Conference goes virtual!

The Conference will have several Hands-On and Manufacturing Sessions to choose from. There is something for everyone.

• Chapter Gift Card • Big Ticket Items

These sessions will not only be worth 1-2 PDH credits, but you will gain invaluable information and knowledge from a trained professional instructing the class. Each hands-on and manufacturing session will be held twice during the conference.

• Special Events & Networking Options • Media & A/V Advertisement Options • Hot Point & Visibility Options • Custom Opportunities

Stay safe and healthy, Stephanie Date RETA Marketing & Events Manager

RETA.com 13

FROM MICROBIAL HAVEN TO SAFE HAVEN: GUIDELINES FOR MAINTAINING PROPER MEAT PLANT AIR QUALITY By Jim Adler, Manager of Refrigeration Engineering, Hixson

Studies have shown that microbial growth is inhibited by keeping meat processing facilities cold and dry. Such studies are part of the reason why the North American Meat Institute (NAMI) established guidelines #4 and #5 of the Sanitary Design Principles for Meat Processing Facilities. Specifically:

• Principle #4 recommends that plants keep room temperatures cold to control microbial growth and to keep rooms dry to prevent condensation from forming (including managing fog during the sanitation process). • Principle #5 recommends that facilities ensure airflow moves from the most clean to least clean areas, with proper facility air balance/pressurization, while maintaining air quality and controlling contaminants. Following these recommendations can be a significant challenge in an environment which is hard to control and constantly changing. Fortunately, getting your facility to conform to the design principles – while sometimes complicated – is not impossible, particularly if you know the steps to take and what you’re looking for along the way. Whether you’re trying to solve existing temperature and condensation issues or prevent problems from occurring, the first step in the process involves understanding existing room conditions in four key areas: room temperature, humidity levels, pressurization and filtration. This article describes what to look for in these areas and provides a broad overview of the issues to be considered when solving a temperature or condensation issue.

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MICROBIAL HAVEN TO SAFE HAVEN

RoomTemperature is the First Key Room temperature is, perhaps, the most obvious component of temperature and condensation problems. To understand how room temperature creates issues within an area in your facility, begin by cataloguing a history of the temperature control problems. Does it only get warm during a certain time of day? Is the temperature problem localized within the room (e.g., one area within the room is warmer than others)? Answers to these questions may point to an undersized refrigeration system. Next, look at how the room is being used. Are forklift users or others who have business in the room leaving doors open for convenience sake? You’ll also need to look at the recommended storage or process condition for the room, a factor typically set by a Quality Control (QC) or Quality Assurance (QA) department. How does the temperature of the room compare to that number? Finally, you’ll need to identify the temperature of all the surfaces within the room, identifying any cold surfaces that may promote the formation of condensation (i.e., surface temperatures that are below the dew point temperature of the air). RoomHumidity Another Likely Culprit Because it can lead to condensation, increased room humidity is the next piece of the temperature/condensation puzzle. Just like room temperature, you need to begin by understanding when the increased humidity is occurring. Is it seasonal (e.g., more condensation during the summer), or does condensation only occur at a particular time of day? Location is also important. Is there condensation throughout the room or is there condensation only on certain surfaces? To understand how the room is being affected by humidity, you must calculate the dew point temperature (see “Helpful Definitions,” page 4) of the room air at various locations and during various times

of the day. Does that dew point temperature of the air fluctuate or remain constant? You may also want to calculate the percentage of relative humidity (see “Helpful Definitions,” page 4). If surface temperatures are lower than the dew point temperature of the air, then condensation will form on those surfaces. Some typical surfaces that could be below the dew point temperature of the room air include: • Cold product transfer lines • Refrigerant or chilled water lines that are inadequately insulated • Supply air ducts/diffusers • Unit cooler casing and drain pans • Floors and door frames that connect to a colder adjoining room • Room ceilings and walls which are cold due to refrigerated supply air Surfaces that are below the dew point temperatures of the air may need to be insulated or heat traced. Sanitation is another big factor contributing to room humidity. Is the room a fog bank during the sanitation cycle? If so, this is creating saturated

room conditions, leaving all surfaces wet and requiring a longer time to dry out. You also need to determine exactly how long it takes for the room to dry out after sanitation. If the room never gets drier, then the unit coolers may not be sized properly or the extra latent heat load (see refrigeration system to handle. The Importance of Air Flow and Pressurization Room temperature and condensation issues caused by sanitation, room openings/doors and improperly insulated or heat traced pipes and equipment aren’t the only reasons why rooms inside meat plants can be at less-than-ideal conditions. Air flow and room pressurization are also important factors to consider. To understand air flow, you’ve first got to measure it. Which direction is the air flowing? How much? How fast? What are the sources of air coming into the room? Are there doors being left open? Are there exhaust fans creating areas of negative pressure? “Helpful Definitions,” page 4) being generated may be too high for the

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MICROBIAL HAVEN TO SAFE HAVEN

Achieving the proper balance between supply air and exhaust air is critical to proper system operation and control. When done correctly, airflow should move from the cleanest to the least clean areas and outside air make up should be supplied to exhausted areas so as not to create negative pressure zones within the building. Because both airflow and the sources of air can be hard to control during processing conditions, it’s best to set up a hierarchy using relative pressurizations. Don’t Forget About Air Filtration Air filtration is the fourth component in the good air quality mix. Air needs to be adequately filtered to maintain air quality levels and control contaminants as directed by the QA/QC department. To determine whether your filters are acceptable, check whether pre-filters and final filters are installed on your equipment. If not, where are they missing? If so, what are the MERV ratings (see “Helpful Definitions,”page 4) of those filters? Optimizing the Room Once you’ve compiled the data from the four components outlined above, you’ll then need to determine the most likely source(s) of your temperature/ condensation issues. Is it an undersized refrigeration system? Is there too little insulation? Are doors being left open? Is there air infiltration or are cold surface temperatures causing the problems? After determining likely problem areas, you’ll want to identify what the optimal state for the room would be in terms of temperature, humidity, pressurization and filtration: • Heat and Moisture Loads. Calculate heat and moisture loads as well as the outside air requirements that the room should have based on a typical day. Room load calculations should take into consideration sensible heat and latent heat (see “Helpful Definitions,” page 4) and air infiltration. At this point, you’ll also need to determine the dew point temperature of the room air as well as the temperature of the supply air

coming into the room. The room air should not have a higher dew point temperature than the surface temperatures within the room or condensation will form. • Pressurization. As mentioned, air should move from cleanest to least clean areas and make up air must be brought in as needed to achieve proper pressurization. To calculate required air volume, determine the free opening areas in the room – full openings and 1/4" crack around doors – for total area (in square feet – sq. ft.), then multiply by 50 to 100 (in feet per minute - fpm) out openings/cracks plus air required for exhaust make up (in cubic feet per minute - cfm). • Air Filtration. Identify the air filtration needs (which equipment and at what MERV rating) for the room. From a design perspective, Hixson recommends that packaging area equipment have pre-filters with MERV ratings of 7-8 and final filters with ratings of 13-14. • Purge Cycle. Keep in mind the sanitation purge cycle necessary for cleaning and start up requires a 2 to 2.5 minute air change rate (per Hixson recommendations). This rate will help keep the fog cleared and help dry the room out faster. To assist in this, the chart included at the end of this article outlines standard conditions for typical rooms found within the meat plant setting. Note that these will not be perfect for every meat plant but are intended to be used as guidelines for typical “ideal” conditions. Consider theWhole Facility! By comparing the data collected and other calculations with the information found in the table, you should be able to identify any new air handling equipment and/or other fixes required to keep rooms cold and dry. However, before instituting changes in any room, you’ll need to assess the impacts those changes may have on rest of the facility:

• Will a domino effect occur? Adding outside air to solve pressurization and condensation issues adds to your overall cooling load and can create the

need for additional compressors, condensers, etc. How will these

additional systems affect other systems and rooms within your facility? Will you have room for this new equipment? Will even more equipment be required down the road? • What is the air balance and pressurization throughout the facility? It is virtually impossible to maintain a positive pressurization in a particular area if the adjoining area air system is not properly balanced. Plus, adding too much outside air in one area may affect the air balance of the facility and create adverse pressurization (preventing doors from closing), which can ultimately have an impact on the goals you’re trying to achieve. • Is your solution cost-effective? Remember that it is more economical to provide make up air to ambient areas being exhausted, than to allow outside air to be brought in through refrigerated areas. When All Else Fails This information is intended to help you understand what problems you may have within the facility and the solutions that may help address those challenges. Because every facility is different, this information may not solve every problem and some challenges may require a more complex, in-depth examination by a professional engineer. However, these guidelines are a good place to start when attempting to apply the AMI principles and make effective cost-to-value decisions within your facility.

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HELPFUL DEFINITIONS • Dry bulb temperature (°F). The temperature of the room air taken with a standard thermometer. • Relative Humidity (% RH). The percentage of water vapor (at a given dry bulb temperature) present in the air as compared to how much water vapor could be present if the same air was totally saturated. • Dew Point Temperature (°F). The temperature at which a given air-water vapor mixture will become completely saturated (i.e., 100% RH) and water vapor will start to condense. • Vapor Pressure (inches Hg). Each water molecule in a given air-water vapor mixture exerts pressure on the

surrounding environment. Vapor pressure is the measure of this pressure caused by the amount of water vapor in the air-water mixture. Moist air = higher vapor pressure; Dry air = lower vapor pressure. • Minimum Efficiency Reporting Value (MERV). A system used to rate the efficiency of an air filter. The higher the MERV, the more efficient – and more expensive – the filter will be. • Latent Heat. The amount of heat absorbed or released by a substance undergoing a change of phase (e.g., ice changing to water or water to vapor) at constant temperature and pressure. • Sensible Heat. Heat conveyed by a substance which has a greater temperature than its surroundings.

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MYTHBUSTER

CORROSION RATE IS (NOT) A VIABLE MEANS TO DETERMINE LIFE OF A COMPONENT IN AMMONIA REFRIGERATION By Jim Kovarik, VP NDT Technology, Gamma Graphics Services (GGS) and LIXI, Inc.

As a rule, for industries that manage a piping condition monitoring system to support operations, corrosion rates can be used to estimate the remaining life of equipment such as piping, pressure vessels, reactors, distillation columns, etc. A corrosion rate determines the speed at which metal deteriorates in a specific environment.

Accurate, usable corrosion rates require the following characteristics to be present: 1. A systematic process in which conditions are controlled, repetitive and routine. 2. Corrosion or erosion occurs internally (on the inside wall) of the equipment. 3. The ability to measure process metrics that affect the reaction between the process chemical (including pressure, velocity, temperature, conductivity, diffusion, etc.) and the piping or other equipment.

For example, in the Oil and Gas industry, hydrocarbons pump through the pipes at a consistent, calculable temperature, pressure and velocity. The chemical itself at a given pressure and velocity wears the piping overtime, and the chemical is contained within the pipe. This systematic process is generally uninterrupted by environmental or other influences that may disrupt or change the process pattern. As a result, the oil and gas industry is capable of measuring the rate of internal corrosion on their piping and they know that internal erosion/corrosion factors will deteriorate the piping long before external factors will cause leaks.

In contrast, ammonia does not degrade metal. Ammonia is not a corrosive chemical to carbon steel or stainless-steel piping. Consequently, piping in closed- circuit ammonia refrigeration systems is generally not susceptible to internal corrosion. The damage mechanism that thins pipe wall in ammonia refrigeration systems occurs on the outside of piping. Corrosion Under Insulation (CUI) occurs when water or condensation breaches the vapor retarder and rests in the insulation against the surface of the pipe metal. Piping with moisture in the insulation becomes corroded and eats away the metal on the pipe surface, thinning the pipe wall.

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conducted 12 months prior, and assumptions that ‘old’ components would be the first ones needing to be replaced. Their first task was to remove insulation on the piping associated with the 12 oldest blast cells in the system. Based on visual inspection of older in-service piping (primarily visual evidence of corrosion), new piping was prefabricated, and work began to replace this older piping and equipment. Before completing the replacement work, they decided to have non-destructive testing performed to justify the work that was being done. The data from testing revealed a different story. The replacement of the ‘oldest’ piping associated with the 12 blast cells did not minimize risk to the plant. The testing results revealed that at a 40% wall loss replacement threshold, 9 of the blast cells did not need to be replaced, resulting in an unnecessary expenditure totaling $675k. The results redirected their strategy for the remainder of the first phase. They were able to make decisions based on concrete data instead of forecasting and assumptions. Their resulting cost avoidance equated to half of their original $10M budget. Deciding to Keep or Replace If you are documenting procedures for your Process Hazard Analysis (PHA) or need to document that your equipment (piping, vessels, valves, etc.) are working in a safe condition for your PSM or RMP program: 1. DO NOT try to calculate a future state, estimate damage, or assume degradation based on age. 1. DO evaluate and make decisions based on the present state. 2. DO consistently evaluate per the recommended 1- and 5-year PSM cycles. 3. DO make equipment keep/replace decisions based on remaining wall thickness measurements, not presence of corrosion.

Insulated piping does not corner the market on vulnerability; uninsulated piping is also susceptible to corrosion. For example, moisture creeps into the cracks in paint on the surface of pipe forming corrosion blisters underneath the paint that continue to get worse over time. This damage mechanism, external corrosion due to exposure to the elements, presents a non-controllable variable. There is no way to determine how quickly the moisture will accumulate or advance along piping. Because steel only corrodes in the presence of liquid water, temperature plays a significant role in the corrosion rate of piping and vessels in ammonia service: • If water is in contact with steel above the freezing temperature, corrosion will occur. • Warm steel corrodes faster than cooler steel. • If ice forms at the steel surface, corrosion will stop until the steel becomes warm enough to allow the ice to melt.

Temperature variations can be due to process cycles like defrosting an evaporator or can be environmental like seasonal snow and rain exposure. External corrosion occurs at a very inconsistent rate, and therefore, the rate at which external corrosion thins pipe wall in an ammonia refrigeration system to find remaining life of the pipe is not calculable. Field Example To illustrate how assumptions and age of equipment are not a reliable means to establish the integrity of your system, consider this case at a food manufacturing plant in Arkansas: The system, built in the 1960’s with parts transferred and installed over the years, needed a full evaluation. The size of the system (300,000+ lbs. of ammonia) called for a phased approach. The core team at the facility decided to address what they assumed to be the biggest area of weakness first – the oldest piping and valves associated with 36 blast cells. The facility’s strategy was to assess based on age, assuming the oldest components presented the largest threat. Funding was allocated based on results of the MI audit

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EDUCATION CORNER

A

B

D

C

SAFETY REQUIREMENTS DEFINED BY ANSI/IIAR-2 AND OSHA

AMMONIA DETECTION LEVELS AND REQUIRED ACTIONS 25 ppm – This is 50% of the OSHA 8-hour (TimeWeighted Average) maximum permissible exposure level of 50 ppm. This level is an indication of abnormal operation condition requiring: • audible alarm - heard over ambient noise level, • visual alarm indication, • alarm notification to monitored location, • activate occupied ventilation. A

Recent Safety Day questions were asked about engine room security, ammonia detection and alarm levels, and safety controls requirements. So here is a run-down of some of the requirements defined by ANSI/IIAR-2 and OSHA. Always consult with your local inspecting authority, LEPC, fire department or emergency responders, keep in mind, the requirements may be different in your location.

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Appendix J describes for machinery room door signage, all entrances to a machinery room include the following information: 1. Refrigeration Machinery Room 2. Authorized Personnel Only 3. Caution – Ammonia R-717 4. Caution – Eye and Ear Protection Required 5. NFPA 704 – Ammonia Fire Diamond (Blue-3, Red-3, Yellow-0) Standards require a clearly identified, tamper resistant break-glass type, global system shut-down emergency stop switch, to be located outside and adjacent to the designated principal machinery room exit door(s). The E-Stop switch must immediately shut down compressors, refrigerant pumps, and the normally closed refrigerant control valves. Additional switches may be co-located to activate the emergency ventilation fans or other emergency equipment. D Emergency Stop andVentilation Switches

Note: Monitored location is defined as a means of continual oversight such as pager, on-site staff, third party alarm service, or a responsible party. And, for areas where ammonia is utilized, which is not part of the main machine room, such as evaporators in cold rooms, loading docks, production areas, etc.: • shutdown hot gas and liquid feed solenoids and fans. 150 ppm – This is 50% of the IDLH for ammonia. APR/SCBA - PPE required; Machine Room activate emergency ventilation capable of providing not less than 30 air changes per hour. 40,000 ppm – This is 25% of the LEL/LFL for ammonia (or maximum reading on the highest reading sensor), whichever is less. Shut down all power to the area except emergency ventilation and telemetry. ALARM SIGNAGE Ammonia detection alarm signage shall be placed next to the actual audio / visual alarms that identify these alarms as part of B

the ammonia detection system. Appendix J describes for machinery room door signage, that all entrances to a machinery room include the following information: Warning –When Alarms Are Activated, Ammonia Has Been Detected a. Leave room immediately when alarms are activated. b. Do not enter except by emergency trained personnel only. c. Do not enter without personal protective equipment. Machinery room entrances shall be provided with signage which: (1) restricts the area to authorized personnel only, (2) indicates the proper NFPA 704 designation. C Machinery RoomDoor Signage

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