Original Condenser Magazine Before Redesign in 2012 by William Ellis

Condenser

November 2011

Published by the International Institute of Ammonia Refrigeration as a service to its members and the Industrial Refrigeration Industry

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Condenser | November 2011 | A Publication of the International Institute of Ammonia Refrigeration

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Condenser | November 2011 | A Publication of the International Institute of Ammonia Refrigeration

CONTENTS

Industry Statement: American Refrigeration Company, Inc. On January 18, 2011, our company, American Refrigeration Company, Inc., an industrial refrigeration contractor located in Andover, Massachusetts, pleaded guilty to a charge that it violated the federal Clean Water Act. The charge arose from an incident that occurred during the transfer of ammonia in connection with a refrigeration system servicing procedure for an industrial customer. Specifically, a trained ammonia service technician employed by the company knowingly discharged a mixture of anhydrous ammonia and water down a floor drain that led to a municipal wastewater treatment facility. The service technician underestimated the quantity of ammonia and the concentration of the ammonia in the mixture he was discharging and overestimated the capacity of the wastewater treatment facility to which the drain led. When it reached the wastewater treatment facility, the discharge destroyed the treatment works’ biological agents, disabling wastewater treatment and causing the treatment works to violate its own discharge permit under the National Pollutant Discharge Elimination System. As a result of this conduct, American Refrigeration Company will pay a criminal fine and be placed on probation for two years. The company must also commission, at its own expense, an audit of its environmental compliance program and comply with any compliance recommendations the auditors may make. This incident has reminded us of several things that we would like to share with the readers of this publication. First, this matter has served as a strong reminder of the importance of managing hazardous substances responsibly. Second, and more specifically, the case has highlighted for us the fundamental but sometimes overlooked principle that ammonia and other pollutants and hazardous substances should never be discharged down a drain without prior approval from local, state or federal environmental officals, regardless of the quantities believed to be involved. Finally, this matter has reinforced our awareness of our obligation to make sure that our line service technicians are properly trained and supervised in the management of ammonia and other pollutants and hazardous substances, even if they are licensed. In publishing this notice, it is our hope that others in the refrigeration industry will learn from our experience.

Industry Statement: American Refrigeration Company, Inc.

Chairman’s Message

Designing Ammonia Systems for Maintenance and Safety

IIAR Code Advocacy Update

IIAR Government Affairs

What Do You Think…?

Ammonia Refrigeration Foundation Update

Ice House Preservation Offers Glimpse of Refrigeration Industry History

From the Technical Director

International Institute of Ammonia Refrigeration 1001 North Fairfax Street, Suite 503 Alexandria, VA 22314 | www.iiar.org Phone: 703-312-4200 | Fax: 703-312-0065 Condenser Staff Publisher | Bruce Badger | bruce_badger@iiar.org

Stephen P. Gianelli, Chief Executive Officer American Refrigeration Company, Inc. Michael G. Sirois, President American Refrigeration Company, Inc.

Condenser | November 2011 | A Publication of the International Institute of Ammonia Refrigeration

Chairman’s Message by Adolfo Blasquez

he International Institute of Ammonia Refrigeration is gearing up for the 2012 IIAR Conference & Exhibition in Milwaukee, Wisconsin, an area central to the ammonia refrigeration industry in the United States. The 2012 IIAR Industrial Refrigeration Conference & Exhibition will be held in downtown Milwaukee at the Frontier Airlines Convention Center. We’ve negotiated excellent room rates with two wonderful hotels. The IIAR Conference headquarters hotel will be the Hilton Milwaukee City Center hotel. We also have rooms available in the newly-renovated, luxurious Hyatt Regency Milwaukee. Both hotels are located adjacent to the convention center and connected by covered walkways to protect conference goers from the elements. This year, we’re extending a special welcome to exhibitors and attendees with a new educational event, a full Ammonia Safety Training Day. The free event will be offered Sunday, March 18, 2012. IIAR’s Ammonia Safety Training Day can provide the annual refresher training required of ammonia refrigeration facility employees under Process Safety Management requirements in the United States, and provides a unique opportunity for enduser ammonia refrigeration facilities to work with emergency responders to develop effective emergency planning. Beyond the United States regulatory requirements for emergency planning, participation in an Ammonia Safety Training Day is an essential activity for many IIAR members who know the importance of educating response teams and our own employees and contractors – to make sure the refrigeration systems we operate and those people within the company that are trained to assist with technical support are on top of the latest safety protocols. IIAR’s Ammonia Safety Training Day program will consist of an introduction to regulatory and code responsibilities followed by an overview of emergency planning and personal protective equipment. The goal is to provide enough training

that each attendee walks away with the knowledge of what they should be doing in order to plan effectively and appropriately respond to an ammonia release event. Beyond the Safety Training Day event, IIAR is looking forward to providing the usual robust technical program and networking opportunities, establishing itself once again as the “must attend” event of the year for industrial refrigeration professionals. Attracting the most qualified business leaders and peer-topeer networking groups, the conference is the largest gathering of industrial refrigeration decision makers in the industry. Hundreds of contracting firms and thousands of end user facilities from the United States, Canada, Mexico, Latin America, Europe, Asia and Australia represent themselves and their companies at IIAR’s show. This year’s technical program includes workshops, reviews of technical papers and educational panels designed to give the most thorough update on operations, maintenance, and energy conservation within the industrial refrigeration industry. This year, IIAR’s program will focus on end-user operations as well as strategies that drive down operating cost by boosting energy efficiency. In addition to a well-rounded educational program, IIAR will also address general code issues, and United States and Canadian regulatory issues faced by the industry and how they may evolve in the near future. As an IIAR member, you have access to the best forum in the world for industrial refrigeration professionals who want to stay educated on the issues they face in their dayto-day business environment. IIAR is continuously working to broaden the scope of the industry by fostering a valuable exchange of ideas and knowledge, and the IIAR Conference & Exhibition is an important part of that effort. We hope to see you there.

Condenser | November 2011 | A Publication of the International Institute of Ammonia Refrigeration

sig

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ia S g y s tem Mai nte sf

(The goal of design and maintenance is to account for the safety of workers and the nearby community given the inherent risks of ammonia. Properly designed, maintained, and operated, these systems can be safe. The examples provided in this article highlight protective ways of meeting this goal, though there may be similarly protective alternate ways of designing, maintaining, and/or operating an ammonia system.)

Introduction roper design, maintenance and safety is critical for operator safety; ammonia system and equipment reliability, functionality and efficiency; and protecting facility assets. Although this paper does not touch on all aspects of design, it briefly highlights examples for implementing long term safety, system and equipment reliability, and efficiency. Ammonia system design should only be performed by qualified engineering companies and/or design/build contractors. When designing an engine room, location, size, equipment layout, future expansion, construction materials, future maintenance, etc. all need to be considered. The topics in this paper apply to designing a new engine room, or modifying or expanding an existing engine room. The statements in this paper do not state a company position or definitive view and are based on my personal observations during the course of my career. 4

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Safet

Initial Design

By Gary J. Webster, Kraft Foods Global, Inc.

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It is extremely important to hire an experienced and qualified engineering design firm or an ammonia design/ build contractor. In addition, during the design stage, it is important to have facility engineers, utility supervisors and refrigeration operators involved in design reviews. Consider having design reviews, with all parties involved, at various stages, such as initial, 30 percent, 60 percent and 90 percent completion. Several of these reviews can be by conference call, but face-to-face is recommended at least for a 60 percent review. It may seem excessive, but reviewing often maintains project focus with all involved parties and allows for easy modifications and revisions, typically without major expense. In the initial design stage, consider performing a Hazard Analysis for any new engine room or major modification or expansion. The Hazard Analysis can be of several methods such as HAZOP, What-if or What-if Checklist. The Hazard Analysis should be performed by a person familiar with the hazard analysis technique being used and is an excellent method for analyzing the system and eliminating potential safety hazards during the design stage. Once a qualified engineering design firm and/or design build contractor is chosen, the design team can consider engine room location options. Consider adjacent buildings Designing Ammonia Systems for Maintenance and Safety continued on page 6

Condenser | November 2011 | A Publication of the International Institute of Ammonia Refrigeration

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Condenser | November 2011 | A Publication of the International Institute of Ammonia Refrigeration

Designing Ammonia Systems for Maintenance and Safety continued from page 4

Continuous and emergency engine room ventilation fans (Figure 1) are typically required and sized per local or country rules/regulations/codes. Emergency exhaust fans are typically up- blast type with the motor located outside of the air stream. Wall louvers can be provided to allow fresh air into the engine room. Good design for an engine room layout will have fans located on one end of the engine room and wall louvers on the opposite end so air sweeps through the engine room and exhausts a safe distance from air intakes, windows and doors.

and rooms within the property boundaries as well as buildings adjacent to the property when designing. Additional on site considerations such as main employee plant entrances, offices, parking lots, distances from property line, basement locations and confinement within production facilities are important. Where practical, remote separate buildings, far corners of properties, areas downwind of prevailing winds, and a safe distance from neighboring properties are excellent locations for engine rooms. Emergency Exhaust Fan After site location is determined, system design decisions such as built-up or package units, flooded or direct expansion (DX) units, glycol or direct ammonia to the load, process temperatures required, etc. need to be analyzed and discussed. Although not as efficient as direct ammonia SRV Header Discharge cooling, using a secondary medium such as glycol has safety advantages. Pumping glycol to the load and keeping the ammonia in the engine room minimizes potential ammonia exposure and leaks in the plant. Consider advantages and 1. Emergency Exhaust Fan Emergency Figure 1.Figure Emergency Exhaust Fan disadvantages of each option in the design. Exhaust Fan Ammoniasaving sensors strategically located in engine rooms are typically part of good design. Often During the design stage, consider evaluating energy low level sensors (sensors set to detect low ppm concentrations ammonia) are used rooms to soundare Ammonia sensors strategically of located in engine opportunities and options. They can be includedaninalarm, the design activate a strobe light outside the engine room doors and start high velocity emergency typically part of good design. Often low level sensors (sensors or bid as alternatives. Tax incentives or credits are oftenfans. In addition, low level sensors typically activate motorized wall louvers to allow exhaust fresh outside air to be drawn the engine room.concentrations of ammonia) are used set tointo detect low ppm available through local utility companies for energy saving SRV Header to sound an alarm, activate a strobe light outside the engine Discharge equipment/projects. High level ammonia sensors often activate a shunt trip on a main breaker supplying electrical room doors andthe start high velocity emergency exhaust fans. power to the engine room. Shunt tripping electrical power when the ammonia concentration Energy items to consider in the design phase include nears the explosive level eliminates electrical spark sourcestypically and reduces the risk motorized of an explosion. In addition, low level sensors activate wall proper suction pressure to run the system, a single a two If aorshunt trip system is applied, explosion proof emergency lights and emergency exhaust fans louvers to allow outside to be intothe themotorized engine room. are typically installed on a separate powerfresh source. In theair event of adrawn shunt trip, wall stage system, integral sump vs. remote sump for evaporative louvers should Ôfail open,Õ in other words, you want the Fan louvers to open. Figure 1.level Emergency Exhaust High ammonia sensors often activate a shunt trip condensers, various floor warming methods, variable frequency on a2)main breaker supplying electrical power to thebreak engine Break glass stations (Figure areinoften required If not, drives (VFD’s), over sizing condensers and evaporators, defrost Ammonia sensors strategically located engine rooms by arecode. typically partconsider of goodinstalling design. Often glass stations for immediate electrical shunt trip of all engine room power except explosion proof room. Shunt tripping the electrical power when the ammonia low level sensors (sensors set to detect low ppm concentrations of ammonia) are used to sound schedule programming, fan types, fan cycling, compressor emergency andlight exhaust fans. an alarm, activate lights a strobe outside the engine and start high velocity emergency concentration nearsroom the doors explosive level eliminates electrical spark sequencing, evaporator fin spacing, compressor cooling exhaustoil fans. In addition, low level sensors typically activate motorized wall louvers to allow sources and reduces the risk of an explosion. If a shunt trip system fresh outside air to be drawn into the engine room. method, condenser type, condenser spray nozzles, premium is applied, explosion proof emergency lights and emergency efficient motors, liquid sub cooling, heat recovery, dock doorsensors often High level ammonia activate a shunt trip on a main breaker supplying electrical Break Glass exhaust fanstheare typically installed on ammonia a separate power source. power to the engine room. Shunt tripping electrical power when the concentration types, warehouse lighting, etc. Station nears the explosive level eliminates sources the risk an explosion. In the electrical event of spark a shunt trip, and the reduces motorized wallof louvers should ‘fail If a shunt trip system is applied, explosion proof emergency lights and emergency exhaust fans open,’ in other words, you want the louvers to open. are typically installed on a separate power source. In the event of a shunt trip, the motorized wall Designs for Safety Break stations (Figureto 2) are often required by code. louvers should Ôfail open,Õin other words,glass you want the louvers open. All local, city and country rules, regulations, codes and If not, consider installing break glass stations for immediate laws need to be followed on all designs. Regardless the (Figure 2) are often required by code. If not, consider installing break glass Break glass of stations electrical of all engine room power stations for immediate electrical shunt tripshunt of alltrip engine room power except explosionexcept proof explosion examples suggested in this paper, you should follow your emergency lights and exhaustproof fans. emergency lights and exhaust fans. applicable local laws at a minimum. Figure 2. Break Glass Station If local or country rules/regulations/codes do not determine Safety relief valves (SRV) are typically piped into a properly sized common header and piped to egress, consider at least two methods of egress from an Good design locates the discharge a safe distance from all air intakes, windows and the roof. Break Glass doors and angle or engine room with at least one exit directly to outside. Exitsprotected from rain and snow by turning the pipe downward, cutting at a 45¡ Station by use of a diffuser. In addition, when terminating SRV discharge headers, consider whether from an engine room need to remain un-obstructed and free of moisture from cooling towers or evaporative condensers could enter the pipe discharge. If water clutter and debris. Strategically locate eyewashes/showers in does enter the pipe, it could freeze and break. When piping SRV headers to a from these sources unobstructed areas in the engine room. Another consideration is having an eye wash/shower outside the engine room in case the ammonia concentration is too high to remain in the engine room. It is good design to provide eyewash/safety Figure 2. Break Station Figure 2. Break GlassGlass Station showers with tepid water. 6

Safety relief valves (SRV) are typically piped into a properly sized common header and piped to the roof. Good design locates the discharge a safe distance from all air intakes, windows and Condenser | November 2011 | A Publication of the International Institute of Ammonia Refrigeration doors and protected from rain and snow by turning the pipe downward, cutting at a 45¡angle or by use of a diffuser. In addition, when terminating SRV discharge headers, consider whether

welded connections when installing equipment, including items such as float s and sight columns. Typically, float switches and sight columns are installed w the bottom connection on a float switch or sight column is typically below liqu of an ammonia leak is increased.

Safety relief valves (SRV) are typically piped into a properly sized common header and piped to the roof. Good design Installed with no locates the discharge a safe distance from all air intakes, flanges or unions to windows and doors and protected from rain and snow by eliminate turning the pipe downward, cutting at a 45° angle or by use potential leaks of a diffuser. In addition, when terminating SRV discharge headers, consider whether moisture from cooling towers or evaporative condensers could enter the pipe discharge. If water from these sources does enter the pipe, it could freeze and break. When piping SRV headers to a roof, a good design is to install a drip leg with a stainless steel ball valve Figure 3. Figure Float 3. Switch Float Switch with weep hole on the low point located in the engine room to periodically check and drain moisture. Designs for Maintenance Engine room access is typically limited to authorized It is extremely important to lay out equipment with ample personnel only. Consider posting signage on the exterior of working distances and clearances. If codes/regulations/ all doors into the engine room stating Authorized Personnel rules do not require a minimum working distance, consider a Only. To safeguard engine rooms from entry by un-authorized minimum of one meter (3.3 ft.) in front of all electrical panels personnel, doors are typically locked from the outside and and 1.2 – 1.5 meters (4 -5 ft.) between compressors, chilled access permitted only by key, badge swipe, combination water pumps, etc. Consider double doors or an overhead code or some other secure method. door into the engine room for equipment maintenance removal Alarms are a critical part of ammonia room designs, and future installations. In addition, compressor and motor especially in remote engine rooms or facilities with minimal removal for maintenance/replacement can be made easier refrigeration operators. Alarms can be installed to notify by designing lifting hoists, such as an overhead trolley and an personnel of compressor failures, ammonia leaks, fires, pump I-beam system with chain hoists. shut downs, system upsets, etc. It is important to involve Designs for Maintenance Evaporative condensers and/or cooling towers are often refrigeration operators to determine which alarms and on the roof. stairs with hand rails instead It is extremely lay out equipment with Consider ample working distances and clearances. If notification methods are preferred. System upsets can be important tolocated codes/regulations/ rules doofnotships require a minimum working distance, consider a minimum of one ladders to the roof for easier maintenance access. alarmed at security offices/gates, cell phones,meter computers, etc. (3.3 ft.) in front of all electrical panels and 1.2 Ð1.5 meters (4 -5 ft.) between If access to the roof is through the engine room by stairs, compressors, chilled water pumps, etc. Consider double doors or an overhead door into the Good design practice considers valve accessibility, piping a door onto roofinstallations. instead ofIna addition, roof hatch. In room for equipmentconsider maintenance removal andthe future methods for reducing potential leaks and futureengine expansions. compressor and motor removal for maintenance/replacement cansnow be made easiermake by designing cold weather locations ice and could opening a An example of a good design practice for future expansion lifting hoists, such as an overhead trolley and an I-beam system with chain hoists. roof hatch difficult. Galvanized structural steel platforms for includes adding a valve and bleed valve on the stub end Evaporative condensers and/or cooling towers are often located the roof. Consider with for will eliminate future on maintenance costsstairs required of pipes, thus eliminating a shutdown when expanding the of ships condensers hand rails instead ladders to the roof for easier maintenance access. If access to the roof is through the engine roompainted by stairs,steel. consider a door onto the roof instead of a roof hatch. In header. cold weather locations ice andConsider snow couldupper make opening a roofcatwalks hatch difficult. Galvanized and lower around evaporative In some situations, locating overhead valvesstructural high insteel the platforms for condensers will eliminate future maintenance costs required for condensers (Figure 4) for servicing fans, motors, pumps and painted steel. ceiling cannot be avoided. When installing overhead valves, sprays. Without easy access, maintenance and daily checks consider how the equipment located directly below the Consider upper and lower may catwalks evaporative condensers (Figure 4) for servicing fans, be around more difficult and less safe. In addition to catwalks, valve impacts valve accessibility. When it is difficult avoid motors, to pumps and sprays. Without easy access, maintenance and daily checks may be more condenser manufacturers have options such as motor/fan difficult less safe. In addition to catwalks, condenseroften manufacturers often have options such installing valves overhead or above equipment, chainand operated as motor/fan jib cranes forjib easycranes removalfor of easy fan motors. removal of fan motors. valves can be installed to improve valve accessibility. Pipe flanges, threaded connections and unions are a potential source of leakage. Consider welded connections when installing equipment, including items such as float Catwalks switches (Figure 3) and sight columns. Typically, float switches and sight columns are installed with flanges. Since the bottom connection on a float switch or sight column is typically below liquid level, the risk of an ammonia leak is increased. Figure 4. Evaporative Condenser Catwalks

Figure 4. Evaporative Condenser Catwalks

Older designs often located pipes and valve stations inside buildings and tight to ceilings and/or Designing Ammonia for Maintenance Safety continued above a false or drop ceiling. Valve access wasSystems often difficult with thisand design and shuttingon offpage 25 valves in an emergency could be dangerous. Modern design typically locates pipe mains and valve stations on roofs. This design practice allows easy access to shut off ammonia to a room Condenser | November 2011 | A Publication of the International Institute of Ammonia Refrigeration 7 and/or an evaporator in case of a leak. In addition, maintenance on valve stations located on roofs is typically easier and safer.

IIAR Code Advocacy Update By Jeffrey M. Shapiro, PE., FSFPE

Fire Sprinklers and Ammonia Refrigeration…A Good Mix?

ecently, I participated in a lively email exchange among industry icons regarding the appropriateness of installing fire sprinklers in ammonia machinery rooms and in processing and storage areas of refrigerated facilities. I learned that this has been a topic of discussion and debate for decades, with opinions varying widely. I also learned that U.S. code requirements that mandate fire sprinkler system installations in refrigerated facilities, which have changed over the past two decades, are not well known. In this article, I’ll try to capture the major discussion points, competing views, and of course the code perspective to bring you up to speed on the great fire sprinkler debate. First, the code perspective. The Code Perspective. It may surprise you to learn that refrigerated facilities in the U.S. are not uniquely regulated with respect to requirements that mandate fire sprinklers. Unlike other uses of ammonia in a building, an ammonia refrigeration system will never trigger a hazardous occupancy classification, which in turn mandates a fire sprinkler system in all cases. The exception that grants this allowance for ammonia in refrigeration systems, International Building Code (IBC) Section 307.1, Exception 7, gives credit to the many safeguards that must be designed into ammonia refrigeration systems and the building areas where large quantities of ammonia are present, for example increased ventilation in machinery rooms. As is the case for any facility that processes or stores combustible goods, IBC fire sprinkler mandates for refrigerated facilities are based on certain characteristics of the building, primarily the amount of undivided floor area and the height of the building or occupancy. Factories and warehouses that handle ordinarily combustible material, including food processing and cold storage facilities, are classified by the IBC as Group F-1 and Group S-1 occupancies, respectively. Fire sprinklers are required for both occupancy classes when any of the following conditions exist: • The fire area of the occupancy exceeds 12,000 square feet. • The fire area is located more than three stories above grade plane. • The combined area of all Group F-1 or Group S-1 occupancy fire areas on all floors, including any mezzanines, exceeds 24,000 square feet. • The storage height exceeds 12 feet, which is considered high-piled storage, over a 2,500 square foot or larger

storage area (there is an option to increase this area allowance to 12,000 square feet, but there are many expensive strings attached). The term “fire area” used in these requirements has special meaning in the IBC. A building may theoretically be subdivided into multiple “fire areas” by using “fire barriers” (another term with special meaning) to remain below the foregoing fire sprinkler installation triggers. However, the concept of subdividing a large processing or storage facility into small compartments using fire-rated walls, fire-rated selfclosing doors, etc. will often be impractical. Plus, while fire sprinklers might be avoided, numerous penalties are assessed by the code for unsprinklered buildings, including reduced exit travel distances and possibly increased requirements for fire resistance of the building structure. It should also be noted that the IBC has other sprinkler system triggers that are based on overall building height and area, but the occupancy-based triggers described above for Group F-1 and Group S-1 occupancies will probably be the first to kick in. Once fire sprinklers are required to protect a building or a fire area, sprinklers must be installed in all refrigerated spaces, machinery rooms, electrical control rooms, etc. There are no exceptions allowing omission of sprinklers from these spaces. In fact, with respect to the question of putting fire sprinklers in electrical rooms, the code has made it quite clear that such protection cannot be omitted simply because the room contains electrical equipment. Section 903.3.1.1.1 states “…Sprinklers shall not be omitted from any room merely because it is damp, of fire-resistance-rated construction or contains electrical equipment.” Do We Really Want Sprinklers in an Ammonia Machinery Room? Several reported concerns have caused industry experts to disagree about the appropriateness of having fire sprinklers in an ammonia machinery room. Positions on this issue are largely split along international lines. The IBC encourages, and often mandates, that fire sprinklers be installed in all machinery rooms. Consider that IBC Table 509 entirely eliminates the required fire-resistance rating for a machinery room enclosure when fire sprinklers are installed. Without sprinklers, a one-hour rated enclosure is required (in older codes, this was three-hours). On the other hand, ISO Draft International Standard (DIS) 5149-3, Section 5-16.2.3 specifically states that fire sprinkler systems are not permitted in ammonia machinery rooms housing systems that have a charge of more than 440 pounds. The Code Update continued on page 10

Condenser | November 2011 | A Publication of the International Institute of Ammonia Refrigeration

Code Update continued from page 8

ISO/DIS 5149-3 requirement came from EN378-3, Section 5.17.2.3, which didn’t allow fire sprinkler systems in any machinery room with ammonia, regardless of the system charge. Since I did not participate in the EN378 development process, I can’t personally comment on the basis of the “no sprinkler” requirement. However, the requirement may relate to one or more of the following concerns that are sometimes expressed: • Possible dangerous reaction between sprinkler water and ammonia; • Discharge or leakage from sprinklers or sprinkler piping mixing with an ammonia spill/release and generating contaminated runoff; • Discharge or leakage from sprinklers or sprinkler piping over energized electrical equipment. With respect to these concerns, it should first be noted that accidental releases of water from fire sprinkler systems are rare, except in cases where system components were not adequately protected from mechanical injury, i.e. forklift impact. When leaks do occur, they tend to be very small. Leak-free performance is largely credited to the fact that fire sprinklers are rigorously tested prior to approval to assure quality and the fact that sprinkler piping systems are required by code to be very robust. It must also be pointed out that, if you’re concerned about sprinkler water in a machinery room, other sources of water leakage must also be considered. For example, condenser cooling equipment and other plumbing components are likely to be less robust than fire sprinkler equipment, so if we are truly concerned about the risk of water interacting with ammonia or electrical equipment, then it would follow that all aqueous systems should be banned from the machinery rooms, not just fire sprinklers (to be clear, I am NOT suggesting that). To further explore the efficacy of putting fire sprinklers into ammonia machinery rooms, here are the four primary scenarios that should be considered: 1. Fire sprinkler system is damaged or otherwise accidentally discharges water. Consequence: Because there is no ammonia release, there will not be any reaction between ammonia and water or hazardous runoff. If there is concern about electrical equipment being wetted by sprinkler discharge, the electrical equipment can be shielded (using equipment rated for a wet/ outdoor location would likely be deemed cost prohibitive), but it’s worth noting that I’ve rarely seen water shields over electrical equipment due to concern about sprinkler discharge in the refrigeration industry or others that I’ve worked in. 2. Ammonia release. Consequence: Because fire sprinklers are individually heat activated, an ammonia release will not cause sprinklers to operate, and thereby, sprinkler water will not have an impact on this event. 3. Fire occurs without an ammonia release. Consequence: Sprinklers should suppress the fire, limiting exposure of 10

refrigeration equipment and wetting/cooling vessels and piping. A fire-induced ammonia release will likely be avoided. 4. Simultaneous fire and ammonia release. Consequence: This becomes a case of the lesser of evils. While it is true that sprinkler discharge will mix with ammonia in the room, possibly creating hazardous runoff, there is a benefit of sprinklers controlling the fire. If no sprinklers are present, the best case would be the fire department putting out what would be a much larger fire (with…you guessed it, lots of water), and the worst case would be having the building burn down. So, given the choice between sprinklers controlling a smaller fire more quickly or having the fire department use master streams after the fire goes through the roof, sprinklers certainly appear to be the better alternative. What About Refrigerated Process and Storage Areas? Any concern about ammonia-water interaction would be largely reduced in process and storage areas, given the lesser quantities of ammonia found in these spaces as compared to machinery rooms. Nevertheless, questions are sometimes raised about the wisdom of installing fire sprinkler systems in areas where water in such systems might freeze. Clearly, the risk of freezing is a concern that cannot be overlooked, and there are many options available to prevent frozen pipes. These include using dry-pipe or dry-pipe/preaction systems or systems that contain antifreeze solution. In a dry-pipe system, water is kept out of the cold room by a valve that remains closed unless the air pressure in the sprinkler piping drops quickly, which would be the case if a sprinkler operated or a pipe was struck by a forklift. In such an event, the dry-pipe valve will open, water will fill the piping system, and water will be released from any openings. A dry-pipe/pre-action system is similar to a dry-pipe system, but it offers an additional safeguard of requiring an additional fire signature, such as activation of a smoke or heat detection system, to allow water to enter the sprinkler piping. Note that detection devices that might be used in this application are not typical smoke or heat detectors. They are specialty devices that are suitable for use in industrial environments. The advantage to a dry-pipe/pre-action system is that a loss of air pressure alone will not allow water to enter system piping. Instead, a loss of air pressure simply yields a trouble signal that can alert maintenance personnel to the loss of piping integrity. In the email exchange that served as the basis of this article, a twist was offered on the issue of sprinklers in freezers that I had not previously heard of. It was suggested by one expert that the discharge from a single sprinkler might cause complete collapse of an insulated box as a result of the sudden heat load caused by spraying water into the low-temperature environment. The concern is a rapid increase in air pressure that overloads available means of pressure equalization. Code Update continued on page 24

Condenser | November 2011 | A Publication of the International Institute of Ammonia Refrigeration

FREE! IIAR Ammonia Safety Training Day March 18, 2012 in Milwaukee Details coming soon

IIAR2012 INDUSTRIALREFRIGERATION

CONFERENCE&EXHIBITION milwaukeewisconsinmarch18–21

Condenser | November 2011 | A Publication of the International Institute of Ammonia Refrigeration

IIAR Government Affairs by Lowell Randell, IIAR Government Affairs Director

OSHA Prepares Rollout for National Chemical NEP

s of the time of publication, the Occupational Safety and Health Administration (OSHA) had not yet released the directive authorizing the nationwide expansion of the National Emphasis Program (NEP) for Chemical Facilities. However, all indications are that an announcement will be made in the near future rolling out the expanded program. Implementation of the new NEP will be effective immediately and regions have already received the new dynamic list of questions on which inspections will be based. The national Chemical NEP will be based largely on the pilot program that started in July 2009 with programmed inspections Region 1 (New England), Region 7 (Midwest) and Region 10 (Pacific Northwest). Many state plan states also exercised the option of adopting in the NEP pilot. According to OSHA, the chemical facility NEP was created to reduce or eliminate workplace hazards associated with the release of highly hazardous chemicals (HHCs), which includes ammonia. As previously reported in The Condenser, it is expected that the national NEP will operate much like the pilot program, with inspectors making unannounced visits to facilities to conduct programmed inspections. Facilities with more than 10,000 pounds of ammonia, the threshold quantity for Process Safety Management (PSM) will be subject to potential inspections under the NEP. Inspectors will utilize an unpublished dynamic list of questions relating specifically to PSM as a core part of the inspection. While documentation is important, it is expected that much of the focus will be on actual PSM implementation. OSHA has indicated that if a facility successfully answers the dynamic questions, then the inspection will be complete. However, if serious issues are identified during the initial inspection, a more comprehensive inspection may follow. Unlike the pilot program, state plan states will be mandated to adopt the NEP or institute an equivalent program. There was some concern that current participants in the Safety and Health Achievement Recognition Program (SHARP) and Voluntary Protection Programs (VPP) would be subject to programmed inspections under the NEP. However, OSHA has clarified that active SHARP and VPP sites will be exempt from programmed inspections under the NEP. It is important to note that all facilities under PSM, regardless of SHARP or VPP status, will be subject to unprogrammed NEP inspections, which can arise from situations such as accidents or complaints. Much like the pilot program, ammonia facilities are expected to comprise a significant proportion of programmed

inspections under the national NEP. The directive outlining the new NEP is expected to include a provision stating that 25 percent of all programmed inspections will take place in ammonia facilities. The facility target list will be compiled from the following sources: • Facilities subject to EPA’s Risk Management Program (RMP); • NAICS codes known to be PSM but not covered by RMP (limited); • Facilities identified by local (Area and Regional Office) knowledge; • Facilities identified in OSHA’s Integrated Management Information System (IMIS) database. OSHA has stated that facilities will be randomly selected within each classification and that the selection process is structured to give all identified facilities within each classification an equal chance of being inspected. According to OSHA, as of June 30, 2011, 207 inspections had taken place during the pilot. Ammonia facilities made up approximately 41 percent of all inspections (programmed and unprogrammed) through the first two years of the pilot program. Of the 207 inspections, 142 resulted in citations. For those inspections resulting in citations, an average of nine violations was cited per inspection, resulting in an average total of $30,933 in fines. Looking at the results from the pilot, the majority of citations came from PSM elements such as Process Safety Information, Mechanical Integrity and Process Hazard Analysis. However, there were a substantial number of non-PSM related citations including issues such as lockout/tagout, personal protective equipment and record keeping. The results of the pilot illustrate some key areas that facilities may want to examine within their PSM programs. IIAR members are encouraged to review their PSM plans as well as their overall safety programs in preparation for potential inspections related to the national rollout. In addition, IIAR is working with OSHA through the Alliance program to develop compliance assistance materials related to the NEP to help members better understand the NEP and how to comply. IIAR Government Affairs will continue to actively engage with OSHA regarding the NEP and work to provide members the latest information on program developments.

CFATS Program Continues Under Short Term Extension Congress has continued its struggles to pass a long term extension of the Chemical Facility Anti-Terrorism Standards (CFATS) program. The CFATS program has operated under a series of short term extensions of authority since its original authority expired in 2009. Government Affairs continued on page 14

Condenser | November 2011 | A Publication of the International Institute of Ammonia Refrigeration

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Government Affairs continued from page 12

Since then, numerous legislative proposals have been advanced, but none has received the approval of both the House and Senate and been sent to the President for signature. Last year, reauthorization attempts were unsuccessful because of controversy surrounding inherently safer technology (IST) provisions. This year, the issue of IST has taken a back seat, as committees in both the House and Senate have approved reauthorization bills that do not include any mandates for IST. Even without the controversy of IST, moving a long term CFATS reauthorization across the finish line has proven a challenge. In the House of Representatives, two committees of jurisdiction, the House Homeland Security Committee and the House Energy

Australian Carbon Tax on HFCs Approved The Australian Senate has approved a proposal for a Clean Energy Act that sets up a carbon pricing mechanism and imposes a carbon equivalent charge on hydrofluorocarbons (HFCs). The measure will go into effect July 1, 2012. Australian senators passed the package of bills by tight majority, giving the green light to establishment of carbon price and equivalent carbon pricing on HFCs, perfluorocarbons (PFCs) and sulphur hexafluoride (SF6) through amendments to the existing legislation on synthetic greenhouse gases – the Ozone Protection and Synthetic Greenhouse Gas Management Act. A carbon pricing mechanism that will initially set a fixed price on carbon from mid-2012 is a central element to the adopted plan. Around 500 of the most polluting companies will be taxed on their carbon emissions starting at $23 AUD (about €17) per ton of carbon dioxide. The price level will be gradually increased to $24.15 (about €17.67) in 2013-14 and $25.40 (about €18.71) in 2014-15. (Editor’s note: The US dollar and the Australian dollar are roughly equivalent in value.) Subsequently, the fixed pricing mechanism will move to a flexible emissions trading program with permit prices contained between a minimum price of $15 (about €11) and a maximum price of $20 (about €15) above the expected 2015 international permit price which will be decided in 2014. From 2015-2016 forword, the carbon tax levied on HFCs will be adjusted annually to reflect the existing carbon price as defined by the emissions trading program. The Australian government will also provide incentives for destruction of waste synthetic greenhouse gases from 1 July 2013. Even though Australia’s emissions account only for 1.5 percent of the world’s total, given its relatively small population the country is the developed world’s highest emitter per capita. Carbon taxation will be the main tool to achieve Australia’s target of carbon emission reduction by 5 percent by 2020 compared to 2000 levels. 14

and Commerce Committee have each considered and passed their own versions of CFATS reauthorization (H.R. 908 and H.R. 901, respectively). There are relatively minor differences between the two bills, but neither has been brought forward for full consideration by the House. In the Senate, the committee on Homeland Security and Government Affairs has approved S. 478, its version of a long term CFATS extension but again, no action has occurred in the full Senate. With none of these bills having reached the President’s desk, continued authority for the CFATS program has come by way of continuing resolutions designed to keep the federal government running. The latest continuing resolution runs until December 16, 2011. If Congress cannot find its way to pass a free standing CFATS reauthorization, it is likely that an extension will be included in the final version of the Homeland Security appropriations. This will keep the program running through the end of fiscal year 2012 and give Congress some additional time next year to finalize a longer term extension.

National Labor Relations Board Policy Issues The National Labor Relations Board (NLRB) has been very active over the last few months in considering changes to labor policies. With the change in Congressional leadership brought on by the election of 2010, passage of “card check” legislation is extremely unlikely. As a result, the National Labor Relations Board (NLRB) is attempting to use its administrative authority to implement card check like policies without legislative action. For example, the NLRB has proposed shortening the time for union elections and would restrict an employer’s ability to communicate with workers and others about issues surrounding unionization. These provisions have drawn sharp criticism from many in the business community. The NLRB is scheduled to vote on these proposals at a meeting on November 30th. In addition, the NLRB has recently finalized a rule that requires employers to display a poster outlining employees’ rights under the National Labor Relations Act regarding unionization. The poster is now available on the NLRB website and employers will be required to display to poster starting January 31, 2012. In response to NLRB actions, legislation has been introduced in both the House and Senate that would restrict the NLRB from instituting several of the controversial policies it has been advancing. The House has passed the Protecting Jobs from Government Interference Act, which would overturn an NLRB decision that could effectively restrict how and where companies decide to do business. The House is also poised to pass the Workforce Democracy and Fairness Act, HR 3094, which would stop the NLRB from encouraging "quickie elections" and allowing the creation of micro-unions. While the House is moving quickly to advance legislation, the fate of these bills in the Senate is uncertain. In addition to legislative attempts to curb NLRB policies, groups such as the Coalition for a Democratic Workforce and the U.S. Chamber of Commerce have filed lawsuits challenging the validity of some NLRB proposals.

Condenser | November 2011 | A Publication of the International Institute of Ammonia Refrigeration

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What Do You Think… P

eriodically, the Condenser publishes articles that present an author’s point of view and commentary on a topical issue of interest to the industrial refrigeration industry. In this column, we will briefly examine a trend and ask for your feedback, your thoughts, and your observations. In this issue, we take a look at…

The Case for Qualification and Certification of Mechanical Integrity Inspectors By Keith A. Tyson It is time for your plant to have a third-party inspection. How do you decide who to use? Before an inspector is hired, the owner/manager of the equipment has a right – and a responsibility – to know answers to the following: • What assurance is there that the inspector has the knowledge and ability to perform the inspections or tests? • Does the inspector have enough experience and training to support the report’s conclusions? • What makes the report on equipment condition credible? • Can a report that recommends the repair or replacement of equipment to meet safety requirements be trusted? • Can I sleep at night believing a report that states no harm or damage is likely to result from continued use of the inspected equipment? • Is there a system that allows me to have confidence in an inspector’s methods, procedures, and reports? These questions are common to most industries. Dependable answers are provided by a standardized written program and procedure for the qualification, training, and certification of inspectors. Other industries have requirements for inspectors. Nearly all pressure vessels and exchangers have ASME certifications which denote, at some point in their assembly, the inspection or testing by a person holding specific credentials. The methods of training, qualification, and certification for these inspectors are codified and well known. This assures the owner that that equipment is suitable for the conditions in which it will operate. Ammonia refrigeration systems are required to be inspected and tested in order to comply with OSHA’s PSM mandates. These duties must be performed in accordance with “recognized and generally accepted good engineering practice”. This is commonly interpreted as conforming to ANSI/IIAR-2, Bulletin 109, and Bulletin 110 which provide 16

the basis for inspections and tests. The IIAR bulletins stipulate only that the inspector must be “competent”. Bulletin 109, paragraph 5.3, states that “A more thorough inspection…should be conducted by a competent ammonia refrigeration engineer … every five years.” Bulletin 110 adds, in paragraph 6.4.4.1,“…the annual inspection of the vessels and heat exchangers shall be carried out by a competent person independent of immediate commercial and production pressures for that installation…” No other requirements for the inspector are provided. There is a growing awareness by auditors that the industry standard does not adequately address inspector qualifications. In fact, recent OSHA audits of refrigeration systems have found persons previously thought “competent” to be inadequately equipped for inspection duties. If the question is “How do we know the inspector is competent?” The logical response is “An inspector should be qualified, trained, and certified to perform the inspection and tests.” The process begins with the development of written inspection and test procedures. Although details of these are beyond the scope of this article, the documents should state inspection goals as well as the minimum qualifications for inspectors —including a certification level. The procedures ought to specify whether the inspector may be a facility employee or must be an independent contractor. If the inspection requirements are clearly stated, then the final report will yield relevant information.

Qualification of the Inspector A written inspection program defines the amount of training required based on the combination of education and experience. This is known as qualification. The training required for an individual factors in educational level, previous training, and related work experience. A new hire with a high school education and no ammonia refrigeration experience requires a great deal more instruction than an operator who has had refrigeration training and work experience. A person with pertinent higher education, such as an engineering degree, will likely not need as much preparation. It is useful to observe the training programs required for individuals who perform inspections and tests in other industries, such as petroleum or chemical. The employers of such inspectors use The American Society for Nondestructive Testing, Inc Recommended Practice No. SNT-TC-1A. This guideline provides a standard methodology for the qualification, training, and certification of inspectors. Most

Condenser | November 2011 | A Publication of the International Institute of Ammonia Refrigeration

design codes including ASME Section VIII, Div. 1, Unfired Pressure Vessels, contain reference to this document for inspectors who perform certain non-destructive examinations. Inspections and tests are not valid unless the inspector is certified in accordance the written practice of the inspector’s employer, which must meet SNT-TC-1A standards. A written practice that uses SNT-TC-1A guidance will categorize inspectors into three levels identified by Roman numerals I, II, and III. It will stipulate the amount of training, in hours, that are needed for each level of certification based on the educational and work experience of the candidate. Higher levels of education or experience will usually require fewer hours of training. A person who has not yet attained Level I is known as a trainee. A Level I inspector can perform certain aspects of the test but may not be able to sign off on the results. A Level II can perform all inspection duties and may also assure that the Level I’s work was proper and certifies the test results, in other words, supervise a Level I. A Level III is the person who writes the procedures and examinations, performs training and qualification, and certifies a person as meeting the requirements for inspector Level I or II. The Level III is also responsible for development of the training and certification program which is known as the Written Practice. SNT-TC-1A is simply a guide. It does not address the details of the required training. It does not contain a “how to” about training or even materials for the candidate to study. It only offers recommendations on the number of hours and topics that should be discussed as part of the training. It is the duty of the employer or the Level III to develop the required training programs and certifications. Therefore, a Level III inspector must be knowledgeable of the inspection or test method that will be used and in the requirements of the code or standard that must be met. It is clear that the Level III must have extensive experience along with comprehensive knowledge of the codes and standards used in ammonia refrigeration. There are guidelines in the SNT-TC-1A for the certification of a person as Level III. The American Society of Nondestructive Testing conducts tests on a national scope to certify Level III inspectors in various inspection methods. A person holding this ASNT Level III certification can be either the company’s employee or a contractor. To use a contractor as Level III the company generally creates a document known as a “letter of appointment” that gives the person, by name, the authority to be a Level III. Another approach is to generate a certification test, usually by a contracted ASNT Level III, to test a person employed by the company to hold a Level III position. The Level III’s certification is limited to the employer only and usually cannot be transferred to another company. Another requirement for certification as an inspector is that of a physical or eye examination. We want to determine that a candidate has good eyesight in order to conduct the

inspections to ascertain that they can see print of a certain size which may be important in reading nameplates or drawings. The eye examination may determine that the candidate may only perform the tests with corrective eyewear and this becomes a condition of the work performed. The eye examination may be conducted by the Level III using standard eye charts, or the candidate may be tested by a local optometrist. Eye examinations are required annually.

Training of the Inspector Obviously, ammonia refrigeration experience is a plus for candidates who will perform inspections. The more knowledge they have of the refrigeration process and associated equipment, the more they will understand and identify any deficiencies. A facility-employed operator can be a good candidate for inspector if that person is capable of looking at the system with an eye towards compliance. On the other hand, flaws can be overlooked because of familiarity with the system. For example, a component may have been installed improperly or without a required safety device. If the condition has been such the entire time the operator has known it, that flaw may be overlooked as a compliance issue. It is not uncommon to point a deficiency out to a long-term operator and hear him say, “I never noticed that before”. The inspector will receive training based on the qualification level as described earlier. Less qualification means more training; more qualification allows advanced topics. Training will cover three basic areas, namely, the “how to’s” of the inspection method; all requirements of the associated codes and standards; and the acceptance criteria. Once training is completed, the inspector should be able to perform the test properly and determine the results correctly. There are numerous inspections and tests that are used in mechanical integrity. Inspections are performed by humans using a visual means of observation, either directly or indirectly with a scope or camera of some sort. Tests are performed with some instrument, gauge, or logic used to determine that an object meets a minimum standard such as material thickness, system tightness or expected action. A test may be monitored by humans, computers, or some other means (think canaries). Inspection methods or tests may require specialized equipment or techniques such as ultrasonic thickness testing, vibration analysis, or thermographic imaging. The inspector must receive adequate training to perform these examinations properly. He must be knowledgeable of the testing equipment, how to conduct the test, and how to interpret results. SNTTC-1A provides a guideline on how much training each test method should reasonably require. The training would also include a number of hands-on, or OJT, hours under the supervision of a trainer or a qualified inspector as tests are conducted on actual equipment.

Condenser | November 2011 | A Publication of the International Institute of Ammonia Refrigeration

Once the inspector knows how to perform the test, training then moves to why the inspection or test is being performed. The specific code or standard is introduced and the requirements are explored. The standard may state briefly that “an annual inspection” must be conducted. This becomes mandatory and the inspection must be performed. Our industry uses the checklists provided in Bulletin 109 to document those inspections. The training should cover all the codes and standards relevant to the system to glean the minimum requirements or acceptance criteria. The inspection checklist is also a guide for the inspector in conducting the inspection. The inspector must have knowledge of the construction codes in order to perform the inspection completely. Once the training hours have been met, the candidate is then qualified to be an inspector. The person has the prerequisite education or work experience, the required training hours, and the prescribed field experience conducting the test. The candidate is now ready for certification.

Certification of the Inspector Certification is the process of testing the inspector in order to verify proficiency in the test method as well as the ability to actually conduct the examination and interpret the results correctly. The Level III is responsible for the testing and certification of all inspector candidates. Tests are generated to demonstrate that the candidate has a good knowledge of the codes and standards, the correct method for performing the test, and suitable acceptance criteria. The formal test will be proof that the person is qualified to conduct the test or inspection and, thus, the reported results can be trusted. The tests to be administered to the candidate are broken into the following three areas: General, Specific, and Practical. Each section of the test contains a prescribed number of questions relating to the inspection method. The questions may be generated from industry guidelines or specifically written by the Level III. SNT-TC-1A provides guidelines for the number of questions to be administered in each area and the minimum number of correct answers, stated as a percentage. The final score of the test is a weighted average of the three sections. Each section must be passed independently, with the final score reaching a minimum level. The following example demonstrates the number of required questions and minimum passing percentages for a candidate performing visual inspections: • General Questions 40 Pass 70 percent • Specific Questions 20 Pass 70 percent • Practical Questions 20 Pass 70 percent A failing grade in any area reveals a weakness that must be addressed in order to have an inspector whose tests can be fully trusted. More training is provided in the areas that were failed and then the candidate may be retested. Failure of one or more sections usually requires a retest of all sections. 18

General questions pertain to the inspection method as well as problems that may be encountered in real life. The questions should demonstrate a broad knowledge of refrigeration conditions that can be detrimental to mechanical integrity. For ammonia refrigeration, the questions should cover corrosion and what conditions can cause it, insulation applications that are likely to be observed, and different types of equipment. Various valves and conditions that may be encountered are also areas that could be addressed. Specific questions are generated directly from the codes and standards that are used in ammonia refrigeration. These questions may be along the lines of such topics as minimum thickness, pressure rating, or hanger spacing. This portion of the test is “open book,” meaning that the candidate will need to know where the paragraph exists and demonstrate the ability to interpret correctly the meaning of the test. The answers are required to have a reference to the paragraph by number to show that the candidate is not working from memory. The practical test is an actual inspection or test of a component to demonstrate the candidate can observe and interpret discrepancies in a real object. The test can be with real components or, more effectively, photographs of components with a number of problems. A photograph of a piece of equipment can be presented and the candidate is asked questions about the object to demonstrate that the discrepancies can be discerned. The Level III reviews and scores the test. The scores are recorded on forms and then signed by the Level III which becomes the inspector’s certification. The certification is usually good for three years and a retest is required at that time. Also, the Level III may require retesting if he has cause to doubt the inspector’s abilities.

Conclusion The training, qualification and certification of the inspector is a crucial element of any mechanical integrity inspection. It may not have been an issue in the past, but recently there have been OSHA audits questioning the credentials of certain ammonia refrigeration inspectors. This, in turn, undermines the validity of any report generated by an inspector of dubious suitability. A roadmap has been developed by ASNT that has served other industries well. This can be readily applied to our industry to yield reliable results in inspections and tests. Begin with a thorough review of your inspection requirements and develop the guidelines that will provide the integrity of your mechanical integrity program. If these functions are performed in-house, define the qualifications needed and develop training and certification procedures. If these duties are contracted out, stipulate requirements to those contractors. Above all, obtain certification documents for all inspectors who provide mechanical integrity reports. In the end, the process will be structured, based on solid practices, repeatable, and reliable. Then we all sleep better.

Condenser | November 2011 | A Publication of the International Institute of Ammonia Refrigeration

Ammonia Refrigeration Foundation UPDATE

ARF Announces Scholarship Award

he Ammonia Refrigeration Foundation, which supports research and education programs benefiting the industrial refrigeration industry, has named an ARF scholarship recipient, University of Wisconsin – Madison, senior, Laura Young. Young will graduate with a degree in mechanical engineering this year, and has spent the fall working closely with Doug Reindl, Professor at the University of Wisconsin and Director of the Industrial Refrigeration Consortium. As part of the ammonia refrigeration-specific focus of her scholarship, Young will participate in courses on ammonia refrigeration and tour IIAR member plants to experience the dynamics of large refrigeration systems at work in the food industry. The Ammonia Refrigeration Foundation has also awarded scholarships in support of vocational programs at Erie Community College and Louisiana Technical College. Don Stroud, Chairman of the Ammonia Refrigeration Foundation and Infrastructure Program Manager at Kraft Foods said students like Young represent the future of the industry. “As in every economic sector, the older generation leaves the industry and takes years of experience with them. There is a need for the younger generation to come in and fill that void to carry on the wealth of knowledge built by previous generations of professionals,” Stroud said. “With the phase out of CFC and HCFC refrigerants, there are many new opportunities for natural refrigerants such as ammonia and CO2. The ARF scholarship program’s goal is to encourage young engineers to pursue careers in industrial refrigeration and help develop the new opportunities for natural refrigerants,” Stroud said.

“We’re trying to raise the visibility of our industry to engineering students. The ARF scholarship is a tool to get undergraduates engaged in, aware of, and pursuing careers in the industrial refrigeration world before they graduate,” said Reindl. “We’ve had so many ammonia refrigeration professionals say, ‘hey, there are a lot of bright kids coming out of our schools these days, how do we build a pipeline and bring them into our industry? This scholarship is a way to harness some of that talent and move it forward into our profession.” The Ammonia Refrigeration Foundation is a non-profit research and education foundation that was originally organized by members of the International Institute of Ammonia Refrigeration to promote educational and scientific projects related to industrial refrigeration and the use of ammonia and other natural refrigerants. “All of us in this industry are passionate about our field, and we want to make sure the contributions we’ve made in our time will continue to enrich the next generation of professionals as they build on the foundation of technology, research and education that made our livelihood possible,” said IIAR Education Committee Chair Gary Webster. The Ammonia Refrigeration Foundation Scholarship attempts to do that by rewarding mechanical engineering undergraduates that have an interest in the thermal sciences. Scholarship awardees then complete an independent study on an industrial refrigeration-related project. In addition to supporting engineering education, the ARF scholarship aims to attract future engineering graduates to pursue careers in industrial refrigerationrelated positions.

Condenser | November 2011 | A Publication of the International Institute of Ammonia Refrigeration

Don Stroud, ARF Chairman and ARF Scholarship Recipient Laura Young

This year’s recipient, Laura Young, previously completed a summer internship with the Trane Company at the Trane corporate headquarters in Lacrosse, WI. Reindl said Young was a particularly good candidate because she had expressed an interest in sustainability, an issue that is “very relevant to ammonia refrigeration and to our industry.” Reindl, who has been involved in the ammonia refrigeration industry for over eighteen years, said a mechanical engineering degree is such a broad degree, there are often many directions open to graduates, especially in the ammonia refrigeration industry. “Depending on their technical interests, there are many places within our industry where they can contribute meaningfully. If they are interested in thermodynamics – that’s what our ARF continued on page 24 19

Ice House Preservation

Offers Glimpse of Refrigeration Industry History By Andrea Fischer, IIAR Staff Writer

t’s not every day that an entire town turns its attention to the preservation of a unique piece of ammonia refrigeration history, but that’s exactly what happened in Waynesboro, Georgia, where city officials and community leaders worked together to save one of the nation’s few remaining ice plants built at the turn of the century. The Waynesboro Ice Plant, once in danger of demolition, was opened to the public as a museum on Sept 8, 2011, and has been met with enthusiasm from Waynesboro residents and members of the ammonia refrigeration industry alike. “We’ve had quite a few retired refrigeration industry professionals coming down to look at this place since we opened and that’s really nice to see because most people who visit don’t necessarily know what they’re looking at,” said City Manager Jerry Coalson. “This is one of the few places the beginnings of the refrigeration industry are being preserved.” Among other equipment, the plant’s two original ammonia compressors were preserved as well as the traveling bridge crane along one ceiling and a diesel engine, forged in 1933, that provided mechanical power for ice making and generated electricity for streetlights. “We were very excited that we were able to save two of the ammonia pumps – one is displayed outside and one 20

inside,” said Coalson, adding that the Ice Plant “brought a big change in the way of life for the people who lived here.” The Waynesboro Ice Plant opened in 1905 when many cities in the South began to make their own ice instead of importing it from the North by rail. As the use of compressed ammonia refrigeration spread in the early 1900s, most households added "iceboxes," and cities that once imported ice from northern lakes began to make their own. Because it was located near the railroad tracks, the plant quickly became one of the city's most important facilities, supplying ice to the surrounding areas and operating for almost seventy years. “Before this plant was built, people didn’t have access to ice,” said Coalson. The advent of Waynesboro’s refrigeration industry also brought new affluence to the tiny town, which saw over nineteen thousand dollars in profits from ice sales, “the most paying proposition that the city has,” according to an October 11, 1925 report in the Augusta Chronicle. The plant remained in operation until the early 1970's, but by 2000, the Waynesboro Ice Plant had fallen into disrepair and was crumbling away. The City planned to demolish it but when the bids to do so were all too high it was not torn down. "Fortunately, all the Ice House Preservation continued on page 23

Condenser | November 2011 | A Publication of the International Institute of Ammonia Refrigeration

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Ice House Preservation continued from page 20

bids came in too high," Coalson said. "When the building was not torn down, we started to save it." Plans for the site's resurrection began in 2005, when a series of Transportation Enhancement Act grants were awarded to help transform the building as part of a new greenway project. Today after undergoing a $1.1 million renovation, the 7,000 square foot building not only houses the Offices of Planning and Development for the City of Waynesboro, but serves as a museum and meeting space. With the help of architects from Athens, Ga., planning firm Armentrout Matheny Thurmond, the plant has been remodeled to offer visitors a glimpse into the city's industrial past. "When it was open, you could come to the window and buy ice – blocks, shaved, any way you wanted," Coalson said. "There was a big porch where people waited in line to pay." Now, said Coalson, people will be able to visit the plant once more to enjoy the displays and vintage photos tracing the plant’s history and commemorating the beginnings of the refrigeration industry.

Credit: Rainier Ehrhardt, The Augusta Chronicle

Visitors to the Ice Plant will find some of the original equipment on display; including a trove of antique tools, railroad parts and even pieces of the original galvanized piping. “We did everything we could to preserve every aspect of this system that remained intact,” said Coalson.

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Condenser | November 2011 | A Publication of the International Institute of Ammonia Refrigeration

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Code Update continued from page 10

I must admit that it’s beyond my expertise to calculate the consequences of this type of event, but even if such an event were possible, I go back to three points offered above: 1) Activation of a fire sprinkler without a fire is a very rare event; 2) If sprinklers are activated as a result of a fire, putting water on the fire quickly is still the best approach, given the alternative of an uncontrolled fire; and 3) Dry-pipe/Pre-action sprinkler systems are very effective in preventing accidental release of water from a sprinkler system if the concern is limited to an accidental release scenario. Finally, it’s important to know that all fire sprinkler systems are not equal with respect to the level of protection provided. Storage height, the stored commodity and the use of racks versus stacked pallets are among many factors that must be considered in matching a sprinkler system design to an expected fire intensity. Changes in any of these factors, particularly adding racks to an unracked structure, can result in a sprinkler system being unable to control a fire. Think of fire sprinkler systems as being analogous to refrigeration systems. If the cooling capability of sprinklers is inadequate to

absorb the heat load created by a fire (which varies by factors such as those mentioned above), the system will not perform satisfactorily. Any changes in the facility that will affect the “fire load” should trigger a review of the continued suitability of the fire sprinkler system design. Conclusion. While the risk and consequences of an ammonia release are always important concerns, fire represents a much greater threat to a refrigerated facility. With the exception of individuals who were intimate with an ammonia release, long-term injuries and fatalities associated with ammonia releases from refrigeration systems are rare, and facilities that experience such a release will typically be able to resume operations in a relatively short period of time. In contrast, there have been a number of major fires at refrigeration facilities have resulted in catastrophic property damage, so the threat is very real. It is simply unrealistic to expect that firefighters will be able to suppress a large fire in a cold storage or processing facility, particularly given today’s climate of reduced staffing and equipment budgets. So, fire sprinklers are the prudent choice for firesafety.

ARF continued from page 19

industry is about. If they are interested in sustainability, then we have a sustainable refrigerant they can identify with,” said Reindl. “Once we give students a glimpse of our industry, they see that no matter what their interests are, there are needs in the industry where they can make a contribution.” But perhaps more than anything, the economic stability of ammonia refrigeration is what attracts students like Young to the industry. “I think there’s a general concern about job outsourcing these days, but we’re always going to manufacture food in this country, and this industry is always going to be relevant. I think a lot of students pick up 24

on that, this industry is going to be here for their future.” ARF represents a large group of professionals eager to invest in the future of their own industry, and the Foundation Scholarship Award is a great first step, said Reindl. “It’s great that the foundation is thinking about the future and supporting education, hopefully this is the beginning of something that will really have a positive long term impact on our industry.” ARF said earlier this year that the Foundation will take steps to accelerate project and scholarship funding and to build a reserve of protected principle for the Foundation’s long-term viability. Condenser | November 2011 | A Publication of the International Institute of Ammonia Refrigeration

Designing Ammonia Systems for Maintenance and Safety continued from page 7

Older designs often located pipes and valve stations inside buildings and tight to ceilings and/or above a false or drop ceiling. Valve access was often difficult with this design and shutting off valves in an emergency could be dangerous. Modern design typically locates pipe mains and valve stations on roofs. This design practice allows easy access to shut off ammonia to a room and/or an evaporator in case of a leak. In addition, maintenance on valve stations located on roofs is typically easier and safer. If installing valve stations on a roof, consider using galvanized steel pipe supports and keeping all pipes a minimum of 0.3 meters (1ft.) off the roof for future roof repair or replacement. To avoid damaging pipe and insulation, consider installing walkway bridges over the pipe (Figure 5) and paving block walkways on the roof (Figure 6) to reduce wear and damage to roof material surfaces. Valve stations typically are not insulated since valve and strainer maintenance would require removal of insulation. Consider stainless steel valves and pipe for outside un-insulated valve stations and pipe.

Maintaining an Ammonia System A good preventative maintenance (PM) program for ammonia refrigeration systems and equipment provides safety, reliability and longevity of the system. Proper maintenance will extend the life of equipment, thus reducing and prolonging future capital spending. In addition, a good PM program will help system energy efficiency and reduce unplanned equipment downtime. No doubt, a good PM program requires planning, staffing and time to effectively execute. Most PM programs today are

Figure Figure5.5.Walkway WalkwayBridge BridgeOver OverPipe Pipe

Figure 5. Walkway Bridge Over Pipe

computerized maintenance management systems (CMMS), but a simple paper system can also be effective. When writing PMs a good starting point is the manufacturers’ recommendations and suggested maintenance intervals. In addition, consider past history of like or similar equipment; experience, knowledge and staffing of refrigeration operators; production scheduling; and requirements when developing written PMs, maintenance intervals and maintenance plans. It is important to have detailed steps on how to inspect, test and repair equipment. One way of conveying that information is through the PM itself. Detailed steps on PMs and training on the maintenance procedures will help assure consistency among refrigeration operators when performing the PMs. With a computer based PM system, equipment maintenance history can be recorded for future use. You can also track equipment history manually in a maintenance logbook. Often facilities contract with a refrigeration service that performs maintenance. If your facility hires a contractor, it is good to verify that the contractor has done the analysis above for PMs (i.e., starting with the manufacture’s maintenance schedule) and keeps accurate records. You may also want to have the contractor include additional PMs according to facility requirements. Consider including daily round sheets performed by refrigeration operators to record items such as suction pressures, discharge temperatures, water sump levels, oil levels, oil pressures, emergency fan checks, etc. With today’s automated systems, ammonia equipment such as compressors, pumps, condensers, etc. can often be monitored remotely and/or from a control room. In addition, staffing is often

Figure Figure6.6. Paving PavingBlock BlockWalkway Walkway

Figure 6. Paving Block Walkway

Condenser | November 2011 | A Publication of the International Institute of Ammonia Refrigeration

Maintaining Maintainingan anAmmonia AmmoniaSystem System

reduced to minimal operators. Regardless of the monitoring and staffing situation, daily rounds performed by trained and qualified refrigeration operators can provide an additional safety factor. By walking through the entire engine room and all areas of the facility where ammonia is present, including roofs, refrigeration operators can become familiar with sights, sounds and feel of equipment during their daily rounds, something that cannot be accomplished or replaced by electronics. Besides the daily round sheet, consider maintaining a daily log book. The log book can be used by each shift operator to record highlights of daily activities such as equipment problems, adjustments or corrections made, equipment put on line or taken off line during the shift, utility problems, etc. This information (whether in a log book or otherwise conveyed) is very beneficial for an operator on following shifts or when returning from longer absences to gain an understanding of events that occurred while they were away. In addition, it can be valuable information for future equipment maintenance.

Condensers

• Check sump water level • Check conductivity daily to verify water treatment is in control • Check water pump discharge pressure • Check water flow and clean strainer • Check bleed-off-valve for proper operation • Check make-up water valve and control system • Check chemical pumps to ensure primed • Check for blow-down valve proper operation • Check float switch function • Make-up water solenoid function • Lubricate and service pump and fan bearings • Check fan belt condition & tension • Check fans screens for obstruction • Check drift eliminators • Check that eliminators are secured and free from biological contamination • Check condenser spray nozzles • Calibrate & clean the conductivity meter • Visually inspect all condenser pipes • Drain and clean condenser pans and remote sump • Exercise inlet and outlet valves and lubricate stems • Check for non-condensables in the condensers • Inspect the condenser sheet metal • Check all structural steel supports, catwalks, ladders, etc. for corrosion • Replace safety relief valves on a frequency per good engineering practices

Exhaust Fans

• Visually verify the continuous exhaust fan is running • Test-run the engine room emergency exhaust fans • Check fan belts for wear and tension • Check mounting bolts on motor for tightness and alignment • Grease motors • Check fan shroud for cracks, and fan mounting • Check area around updraft fans on roof for clearance and cleanliness

Emergency Response Equipment

• Take inventory of equipment on the emergency HAZMAT cart and re-stock any missing items • Take inventory of emergency response equipment located throughout the facility, such as ladders, flashlights, ropes, P&IDs, radios, etc • Inspect SCBA units, Level A suits & canister respirators • Calibrate portable hand held ammonia detectors • Conduct hydrostatic test of fiberglass wrapped and Kevlar wrapped SCBA tanks • Conduct hydrostatic test of carbon wrapped composite SCBA tanks

Evaporators

• Perform visual check of coils and fans • Visually inspect evaporator roof piping and valve stations • Drain oil (if applicable) • Periodically review defrost schedules to determine if the length of time between defrosts can be increased to save energy • Check air temperature difference across coils • Check/clean coils and pans for excessive dirt • Check evaporator supports, motor mounts, fans and guarding • Replace safety relief valves on a frequency per good engineering practices; in the U.S. that is currently 5 years

Preventative Maintenance Note: The following is a list of equipment and examples of preventative maintenance tasks to perform. The equipment list is not intended to be an all inclusive list, since each facility is unique. Moreover, each task may not be appropriate for a given facility. In developing a preventative maintenance (PM) program, you will need to seriously consider all aspects of your given facility. However, this list can serve as a starting point for developing a PM program. The frequency of each task depends on the manufacturer’s recommendations, equipment history, facility history and knowledge. Refer to the manufacturer’s preventative maintenance recommendations when developing a PM program. EQUIPMENT

TASK

Ammonia Detectors

• Calibrate each sensor with certified calibration gas • Make sure the cell reacts to ammonia and will trip the alarm • Verify all proper alarms and cutouts are operational

Ammonia Pumps

• Check for abnormal vibration or noise • Check pump oil level where applicable • Test and/or rotate back-up pump • Check the operation of the pump differential switch or pump controller • Check drive belts for wear and lubricate bearings where applicable • Drain any oil from the pump low point • Examine the pump exterior and adjacent lines for damage and corrosion • Verify minimum flow orifices and/or regulators are open and properly adjusted

Condenser | November 2011 | A Publication of the International Institute of Ammonia Refrigeration

Eyewash/ Safety shower

• Clean and check that area around eyewash station is clean and eye wash station for blockage and obstructions • Verify proper signage is posted to identify eyewash station • Verify eye wash/shower station is operational • Clean eye wash/shower with a mild detergent • Inspect eye wash/shower components for rust or corrosion

Gauges

• Inspect all system gauges for cracked face plate, broken indicator needle, excessive needle movement, damage to housing, oil level (if applicable), presence of water infiltration, etc. • Test and recalibrate critical gauges and pressure transducers

Engine Room Housekeeping

• Sweep and mop engine room floor • Wipe down compressors • Perform an engine room clean-up and inspection for safety, operational cleanliness, and to help extend asset life • Things to adjust or eliminate may include: • Oil on the floor • Jackets, tool belts, electrical cords, hoses, etc, hanging on valves, compressors, etc. • Boxes, garbage cans, etc., stored next to or on ammonia compressors • Clearance in front of all electrical panels • Open electrical panels • Un-labeled electrical panels • Hoses and/or electrical cords on the floor • Water on the floor • Used filters, old equipment parts, pipe, etc., on the floor • Brooms, mops, shovels, etc., are hanging • Burned out light bulbs

HVAC & Air Make Up Units

• Inspect belts • Check fan and motor pulleys • Inspect combustion air blower (if applicable) • Inspect filters and replace as needed • Check & clean drain pan • Check & clean coils • Inspect damper linkage and lube • Inspect and lube fan and shaft bearings • Inspect fan motor mounts • Check condition of structural steel supports • Check condition of ducts • Inspect door seals • Inspect and test duct smoke sensors

Pipe, Insulation • Perform a walkthrough visual inspection of roof piping, and Roof valve stations, insulation, insulation jacket, painted Valve Stations pipe, valve station leakage • Signs to look for include: ice buildup on insulated pipe, torn or punctured insulation, sagging pipe, broken hangers, and missing valve tags • Perform a thorough inspection of all un-insulated piping and associated components such as flanges and supports for any damage to or deterioration of the piping or its protective finish • Check accuracy of P&ID’s • Perform non-destructive testing of large diameter piping Purger

• Clean bubbler • Check for proper operation of all lights • Drain oil • Inspect and clean metering orifice

Reciprocating Compressors

• Visually check for abnormal noise/vibrations • Perform a vibration analysis • Perform oil analysis • Inspect refrigerant lines • Grease motor bearings • Calibrate pressure and temperature sensors • Inspect oil lines • Lubricate all valve stems • Check tightness of motor anchor and compressor package foundation bolts • Check V-Belt (if applicable) • Replace oil filters if necessary • Replace safety relief valves on a frequency per good engineering practices

Screw Compressor

• Visually check amount of seal oil in bottle or pan • Check oil sight glass in second stage of oil separator; no oil should be present • Adjust load/unload solenoid valves • Check oil pressure regulator • Perform a vibration analysis • Perform oil analysis • Calibrate pressure and temperature sensors • Inspect refrigerant lines • Grease motor bearings • Replace oil filters if necessary • Clean oil pump suction strainer • Check operation of oil heaters • Clean package and paint if needed • Exercise and lubricate all valve stems • Check tightness of motor anchor and compressor package foundation bolts • Replace safety relief valves on a frequency per good engineering practices

Valves

• Inspect SRV discharge lines for wasp nests, debris, etc. • Open SRV discharge header drain valves (if so equipped) to eliminate any water in the header • Clean, lubricate valve stems, and exercise all critical system valves such as three way valves on relief headers, king liquid and hot gas shut-off valves, condenser isolation valves, etc. • Check valve tags on all critical valves

Vessels

• Perform visual inspection of equipment • Monitor transfer cycle on transfer vessels • Inspect vessel oil pot to determine if oil needs to be drained • Inspect insulation integrity • Check float switches for proper operation • Check high and low level cut-outs • Inspect pipe hangers and supports for tightness • Inspect condition of sight glass • Exercise the sight glass shut-off valves and lubricate stems • Check condition of insulation and paint • Check vessel valve tags • Replace safety relief valves on a frequency per good engineering practices

Water/Brine Chiller (shell & tube, plate & frame, falling film)

• Inspect oil pot to determine if oil needs to be drained • Inspect insulation integrity • Check valve group integrity • Check supports and guarding • Check pumps (if applicable), check water pumps, rotate to spare, grease • Replace safety relief valves on a frequency per good engineering practices

Condenser | November 2011 | A Publication of the International Institute of Ammonia Refrigeration

From the Technical Director by Eric Smith, P.E., LEED AP, IIAR Technical Director

pinions – everyone’s got one. While much of the technology surrounding industrial refrigeration has long been settled, the industry is far from consensus on whether and how to approach several technical issues related to handling, preventing, and avoiding exposure to ammonia releases. One of the main responsibilities of your technical association is to gather the opinions, facts, evidence and research to formulate appropriate, industry vetted guidance how to design, install, use and maintain industrial refrigeration systems and equipment. Forty years ago, IIAR was formed because several industry leaders decided that too many decisions about ammonia refrigeration were being made by people who were not familiar with the substance or the practice. The IIAR proceeded to publish IIAR-2, and numerous bulletins and guidelines that are referenced by many people with a material interest. While some very good work has been done thus far, no one would argue that improvements to IIAR materials could not be made. Some areas for investigation and improvements were recently addressed at the Standards Review Committee in July, and the Board of Directors meeting in October. The following outlines some key issues that were discussed and will require consensus building efforts on the part of the industry. Shunt tripping of the electrical equipment in engine rooms upon ammonia detection has been proposed. Proponents say that this is the safest bet, and easy to implement on new construction. An additional argument is that if electrical equipment is shunted, engine rooms can be used to hold ammonia vapor (in the event of an engine room release) which might be advantageous in an urban setting. And some propose (and practice) shunt tripping all equipment except for ventilation. Opponents of this strategy argue that it is not necessary, because with adequate ventilation, ammonia is very difficult to ignite. Also, it is very difficult if not impossible to remove all sources of ignition which can include static electrical discharge, lighting capacitors, circuit board capacitors, and obviously electrical contacts. Mandating shunt tripping could imply that engine room equipment should be mandated to be rated Class I, Division 2 (explosion proof) which would add considerable expense. Opponents also argue that it may be beneficial to have some equipment (compressors) running to mitigate a release or an over-pressure scenario. Further, if the objective of shunting is to “bottle up the ammonia vapor”, how will the room be cleared later? Will all of the expense

and effort for shunt tripping actually help considering that many releases occur outside of engine rooms? Shunt tripping can have implications on process rooms also. If there is ammonia equipment in a process room (which is another issue discussed later) should all lighting and electrical equipment in the process room be de-energized? Is there a viable method of scrubbing ammonia vapors (or converting them) from an airstream that will eliminate or greatly reduce off-site consequences? New water misting technology is available that could provide the means to do this. This could be part of a solution for concerns in densely populated areas. Are ammonia diffusion tanks connected to the relief valve system affective? What becomes of the aqueous ammonia solution within the tanks? Does the additional handling of the remains impose further risks? If diffusion tanks are considered effective, should there be safeguards developed to mitigate their negative aspects, such as additional training, or a requirement to have dry tanks? Again, one must consider if relief valve releases constitute a minority of all releases, are they worth the effort and expense? Do they provide a false sense of security? Should process equipment using pumps or hot gas transfer be allowed in occupied process rooms? Current codes and standards do not actually allow for such equipment to be located in any room that is not designated a machinery room (reference Jeff Shapiro’s article in the August 2011 Condenser). Should a set of standards be developed to address occupied process rooms that have ammonia equipment in them? Or should the industry avoid this type of scenario altogether, relying instead on new technologies that could remove the need for such equipment in a process room? With the increasing focus on small charge and packaged systems, should language be developed to exempt these types of systems from regulations designed for large custom built systems? If so, what standards should apply? There is no doubt that there are many other aspects surrounding the issues above. And there are other issues not mentioned that are also important to address. It is up to the IIAR and our industry to steer the direction on these issues. To this end, the IIAR staff and conference committee is making plans for the annual conference in Milwaukee. We encourage you to attend the final panel session on Wednesday, March 21, 2012 in which these issues will be discussed and audience participation will be encouraged.

Condenser | November 2011 | A Publication of the International Institute of Ammonia Refrigeration

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Original Condenser Magazine Before Redesign in 2012

Articles inside

Ammonia Refrigeration Foundation Update

From the Technical Director

Chairman’s Message

IIAR Government Affairs

What Do You Think…?

Designing Ammonia Systems for Maintenance and Safety

Ice House Preservation Offers Glimpse of Refrigeration Industry History

IIAR Code Advocacy Update