Global Cold Chain Alliance in the IIAR…The Cold

CondenserMay 2009

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

Global Cold Chain Alliance

in theIIAR…The Cold

ii Condenser | May 2009 | A Publication of the International Institute of Ammonia Refrigeration

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Condenser | May 2009 | A Publication of the International Institute of Ammonia Refrigeration 1

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2 Condenser | May 2009 | A Publication of the International Institute of Ammonia Refrigeration

International Institute of Ammonia Refrigeration

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Arlington, VA 22201 | www.iiar.org

Phone: 703-312-4200 | Fax: 703-312-0065

Condenser Staff

Publisher | Bruce Badger | [email protected]

Managing Editor | Bob Armstrong | [email protected]

Writer-Editor | Liz Milner | [email protected]

Layout & Design | Laura Dugan

Illustrator | Ron Curameng

CONTENTS

2 IIAR News

3 Chair’s Message

4 A Powerful Document: IIAR, GCCA Sign Memo of Understanding

8 IIAR Code Advocacy Update

10 IIAR Government Affairs: Hot Topics for 2009

12 What the Watchman Watches

14 Design and Operating Experience of Large Ammonia Systems with Small Refrigerant Charge

16 RMP: Where do you stand?

18 2009 Conference

20 IIAR Member of the Year

20 Honorary Life Member

21 IIAR Board of Directors

21 Joe Mandato Elected to IIAR EXCOM

22 Sight Glass Task Force Appointed

23 Andy Ammonia Awards

24 Technical Papers

28 Ammonia Refrigeration Foundation Update

IIAR News

Eric Smith named IIAR Technical Director

The International Institute of Ammonia Refrigeration announces the appointment of

Eric M. Smith, P.E., as Technical Director. Smith will officially join the staff of IIAR later this fall.

“Eric comes to us equipped with a long and broad history of involvement in the refrigeration, air conditioning and construction industry,” says IIAR President Bruce Badger. “As a youngster, he was an assistant to his father and older siblings in the family’s refrigeration and air-conditioning service company. Thus began his interest in mechanical systems and mechanisms.”

Smith worked in the family business through high school and college, where he obtained a bachelor’s degree in Mechanical Engineering at Mississippi State University. He then moved to Atlanta, GA and began his professional career, designing air conditioning, piping, plumbing and fire protection systems for consulting firms.

Smith has 17 years’ experience working with a design/build construction firm, specializing in buildings and systems tailored to the food and pharmaceutical industries. His efforts were mainly focused on the design of a multitude of industrial refrigeration systems for various applications nationwide and internationally. He became the Director of Refrigeration Engineering for the firm in 2000, and most recently, the Director of Mechanical Engineering.

“Eric is a registered engineer in over thirty states. His exposure to technical and regulatory issues nationwide, his service to end users, and work with various refrigeration contractors and manufacturers will be an asset to IIAR members. He is looking forward to promoting our industry and providing his best efforts to assist our membership,” Badger concluded.

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would be government and regulatory affairs. Lowell Randel, formerly the Deputy Assistant Secretary for Congressional Relations at the United States Department of Agriculture (USDA), has been hired to serve as our Director of Government Affairs.

While at USDA, Lowell served as the primary contact between the Department and the U.S. Congress. He was responsible for the development and implementation of a legislative strategy pertaining to the 2007 and 2008 Farm Bill as well as playing a key role in the implementation of the bill after its passage.

Prior to his work at USDA, Lowell served as a Senior Associate with Meyers and Associates, a Washington, DC-based government relations firm. While at Meyers and Associates, he assisted clients on matters of agriculture and science policy, and served as their point of contact to Congress and the Administration. He also held the position of Coordinator of Trade and Federal Issues for the Texas Department of Agriculture, as well as Assistant Legislative Director for AESOP Enterprises, an agriculture focused government relations firm in Washington DC.

As you can tell, Lowell is a veteran on Capitol Hill and has a strong background with the Washington regulatory community that will benefit our organizations on Capitol Hill. In addition to being our advocate, he will keep our organizations informed on issues of importance to IIAR members and the rest of the cold chain community. You’ll find his first column reporting on regulatory affairs in Washington on page 10.

This issue of the Condenser also includes an update on a technical paper presented by Andy Pearson at the 2003 IIAR Industrial Refrigeration Conference & Exhibition in Albuquerque. The report examines design and operating experience with low charge industrial refrigeration systems that use ammonia as a refrigerant.

Before concluding, I should also note that this issue marks the first anniversary of the Condenser as a quarterly publication. It takes a great deal of effort from the volunteers who write many of the articles that make this such a worthwhile publication. We appreciate their hard work. I also want to thank our advertisers. Without their financial support, the Condenser would not be the quality publication that it has become.

The Condenser is a valuable benefit of membership in IIAR, which reminds me to remind you that it’s time to renew your membership. Dues notices will be mailed in June. And, if you have more than five members, I would encourage your company to take advantage of the Dues Discount Program. For more information, contact Belinda Ross at IIAR Headquarters.

By Don Stroud, Kraft Foods

The 2009 Industrial Refrigeration Conference & Exhibition in Dallas this past March was another very successful event for IIAR. In spite of difficult economic times, more than 900

people attended the conference, and explored the products and services on display by nearly 110 companies and organizations in the exhibit hall. This year’s attendance was equal to the average attendance of the past five non-tradeshow IIAR exhibitions.

In this time of economic uncertainty, when many organizations are reporting significant drops in attendance at their annual meetings of 20–40%, the attendance at the 2009 IIAR annual meeting speaks well of the economic resiliency of our industry.

Why the large turn-out for the IIAR conference? The quality of the technical program, the technical papers, workshops and panels are the primary reason most people attend the conference as well as the exhibit hall. The volume of traffic in the exhibit hall speaks to value attendees place on this important element of our Annual Meeting.

Every year, I come away from the conference with many new ideas and very useful information. This year, one of the workshops focused on liquid level sight glasses, sharing the current findings on the issue of some sight glass failures that came to the forefront in 2007.

The initial reports of sight glass failures, and their subsequent investigation, led to the Sight Glass Alert that appeared in the Condenser (November 2008). The alert focused on the potential safety hazards associated with the bull’s eye type of sight glasses commonly used in industrial refrigeration systems. An update to the Sight Glass Alert is provided in this issue of the Condenser on page 22. IIAR continues to investigate the causes of reported sight glass failures as well as formulating a plan of action.

Also, during the business meeting in Dallas, IIAR signed a Memo of Understanding to become a Core Partner in the Global Cold Chain Alliance. The Partnership establishes a formal connection that will serve both organizations well in the future. This exciting new relationship is already paying dividends. The alliance allows us to share resources to provide a broader scope of services to our members and more efficiently carry out administrative functions. From a legislative and regulatory perspective, this alliance will allow us to exert greater influence in the development of the model codes and legislation at the state and federal levels.

Ever since IIAR was founded, advocacy and regulatory affairs have always been key elements of the IIAR mission. Therefore, it should be no surprise that one of the first areas for IIAR and the other core partners within GCCA to cooperate

CHAIR’S MESSAGE


A Powerful Document

IIAR, GCCA Sign Memo of Understanding

By Liz Milner, IIAR Writer/Editor

History was made during the business meeting at the 2009 IIAR Industrial Refrigeration Conference & Exhibition when representatives of IIAR and

the Global Cold Chain Alliance (GCCA) signed a Memorandum of Understanding.

This formalizes a partnership designed to enhance IIAR’s ability to be the world’s leading technical

resource and advocate for the safe, reliable and efficient use of natural refrigerants for industrial applications.

“Fellowship” rather than “partnership” might be a better way to describe this relationship since GCCA is composed of three powerful trade associations and one foundation whose combined clout, when partnered with IIAR’s technical expertise, will make the GCCA a power to be reckoned with in the world food distribution process.

“Conceptually, becoming a core partner in the Global Cold Chain Alliance allows IIAR to become part of a much larger and more

influential organization,” says Immediate Past Chair Brian Marriott. In addition to IIAR, GCCA is comprised of four Core Partners: The International Association of Refrigerated Warehouses (IARW), The World Food Logistics Organization (WFLO), The International Refrigerated Transportation Association (IRTA) and The International Association for Storage Construction (IACSC).

IIAR, GCCA continued on page 6


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GCCA is the world’s recognized cold chain authority. An umbrella organization, GCCA unites partners to be innovative leaders in the temperature-controlled products industry.

In addition to IIAR, GCCA is comprised of four Core Partners: • The International Association of Refrigerated

Warehouses (IARW). Founded in 1891, the International Association of Refrigerated Warehouses promotes excellence in the global temperature-controlled warehouse and logistics industry by sharing best practices, advising members of legislation and regulations, and assisting members in complying with U.S. and international regulations. All active members of IARW are also members of The World Food Logistics Organization.

• The World Food Logistics Organization (WFLO) is a scientific and educational foundation whose purpose is to deliver education and research to the industry and empower economic development by strengthening the global cold chain. Supported by a team of food and logistics scientists and experts, WFLO cooperates with government and private institutions in research and training activities throughout the world. WFLO also undertakes the publication and maintenance of a repository of scientific information and research for the benefit of the cold chain industry.

• The International Refrigerated Transportation Association (IRTA) was established in 1994 to meet a growing demand in the transportation industry for chilled and frozen food products. IRTA has a core international membership of companies involved in the refrigerated transportation industry that primarily includes ports and companies involved in trucking, warehousing/logistics, marine shipping, rail, and air. Members also include businesses that are engaged in refrigerated food logistics, such as attorneys, claim agents, carriers, equipment suppliers, receivers, and consignees. IRTA provides a forum for the interchange of information and ideas for companies involved with transportation of frozen or chilled perishable products such as flowers, fruits, beverages, fish, meat, poultry, or dairy products.

• The International Association for Storage Construction (IACSC). The International Association for Storage Construction provides members with a forum for innovative ideas, promotes standards of practice for the cold storage construction industry, sponsors professional education programs and promotes the interests of the industry in political, legal and regulatory arenas.

These organizations have pooled their collective expertise in an effort to create modern, integrated cold chain operations around the world through research, education, and technical support initiatives. The partners share information about new technology, best practices and benchmarking, government affairs and regulatory issues, industry trends, economic development, and investment opportunities. IIAR’s participation will help make GCCA’s coverage more comprehensive by putting the “Cold” into the Cold Chain Alliance.

IIAR, GCCA continued from page 4

IIAR Chair (2008-09) Brian Marriott (right) and GCCA President and CEO Bill Hudson (left) sign Memo of Understanding

Shortly after the signing, IIAR Board Chair, Don Stroud, stressed that the MOA with GCCA will not impair IIAR’s autonomy, saying, “It’s an alliance, not a consolidation.” Bill Hudson, GCCA’s President and CEO, elaborated, giving a detailed outline of the new relationship between IIAR and GCCA: “The whole theory of the Global Cold Chain Alliance is to bring partners together—not merge them—to create better links between them.” Members of the Alliance, “maintain their own leadership, their own resources and services, [and] their own membership.”

Hudson said that the formation of the GCCA was necessary because of the increased integration of the cold chain industry. This is a catalyst for closer relationships among all players in the supply chain. Developments such as dedicated distribution facilities and public refrigerated warehouse (PRW) investment in trucking assets bear witness to this trend.


enhanced ability to bring modern industrial refrigeration technology to the developing world. A transformation in the world food distribution system has made the GCCA an essential actor in the worldwide struggle to prevent hunger. Today, supplying food has become a global concern. A broken link in the distribution chain can have effects that spread like a ripple through water, destabilizing governments and creating widespread misery. A breakdown in distribution networks in the American Midwest, for example, is no longer a purely local problem; it is likely to have a devastating impact on communities throughout the developing world.

Bruce Badger says that the partnership could be the means for pursuing a key objective of IIAR, “to bring up-to-date industrial refrigeration technology to the developing world.

Globalization is transforming the industry through:• Increased integration of business models. Refrigerated

warehouses increasingly are managing the entire cold chain process from warehousing to logistics to trucking and customer service.

• Recognition of international business structures. In emerging economies where distribution networks are in the early stages of development, food production and food delivery are often the provenance of a single company.

• Need for core competencies—maintaining proper temperatures and instilling best practices. The cold chain has to take on the development of all links from harvest to point of sale.

In addition to the Core Partners, Hudson said that GCCA will include organizations that represent processing, cold storage, refrigerated transportation, retail, specific commodities, government, and educational institutions.

GCCA has offices in Europe, South Asia, China, and Latin America, in addition to the headquarters office in the United States.

IIAR’s president, Bruce Badger, sees the alliance as being particularly beneficial to end users. “The partnership with GCCA is a way for the end users of the cold storage warehouse community to get closer to the technical expertise of the IIAR. Conversely, it enables IIAR members to get closer to more end users.”

“We’ve always used the IIAR for their technical resources, so that we don’t have to reinvent the wheel,” agreed Mike Henningsen of Henningsen Cold Storage. “We rely on many of their existing diagrams and engineering resources to help design our systems in the most efficient and safe manner possible. We’re also very supportive of the GCCA. Tying IIAR and GCCA together gives us access to a one-stop shop.”

Brian Marriott, IIAR’s Immediate Past Chair, stressed the benefits IIAR brings to the partnership, namely “its expertise in government relations and code-related matters.”

“Regulation is not going to go away,” adds Nicholas Pedneault of Congebec Logistics. “It’s just going to get tighter and tighter every year. We need a strong partner to help us out, making sure that we fully understand the extent of the regulations. And energy costs are only going to go higher as well, so we want to make sure that we have all the information available to run efficient and safe refrigeration systems.”

Jim Marella, an IIAR Board Member and OSHA/EPA Compliance Coordinator for United States Cold Storage, sees the partnership as extending IIAR’s national and international influence. “The partnership definitely will increase our visibility in Washington.”

Because GCCA’s members have offices overseas, this alliance gives IIAR greater international presence and an

The four types of Alliance Partners are:• Core. Core Partners are organizations that are managed

by the cold chain headquarters office in Alexandria, Virginia, USA and supported by a staff of association professionals. Members of Core Partner organizations have direct access to all GCCA services.

• Affiliate. Affiliate Partners are organizations that pay an affiliation fee to the GCCA. Members of Affiliate Partner organizations have access to GCCA services through the Partner.

• Strategic. Strategic Partners are organizations that participate with the GCCA in information exchange, programs, conferences, or projects and share common cold chain interests and objectives.

• Supporting. Supporting Partners are private companies that do not qualify for membership in one of the Core Partner organizations. Through a support fee to the GCCA, these companies gain access to GCCA services.

The list of GCCA’s affiliate partners reflects GCCA’s global reach: • Refrigerated Warehouse & Transport Association of

Australia • Chinese Association of Refrigerated Warehouses• Egyptian Cold Chain Association • Assosiasi Rantai Pendingin Indonesia • Japan Association of Refrigerated Warehouses • Cold Chain Association of the Philippines • Food Storage and Distribution Federation (United Kingdom) • South African Refrigerated Distribution Association • Irish Cold Storage Federation • Brancheforeningen for Danske Frysehuse (Denmark)

IIAR, GCCA continued on page 36


The goal of securing refrigerant access ports was also justified with claims that secured ports would help to prevent leaks, prevent accidental mixing of refrigerants, deter theft and reduce owner liability.

At the initial public hearing on this issue, there was sympathy towards the proponent’s cause, but in the end, ICC’s Mechanical Code Development Committee voted to recommend disapproval of the proposal based on the contention that the issue should be dealt with by equipment manufacturers, not code enforcers. However, code development committees aren’t the final word in the ICC code development process. ICC permits individuals and organizations who disagree with a committee recommendation to submit a public comment and have their issue heard by an assembly of ICC members at ICC’s annual meeting. That’s what happened in this case.

Two public comments were received on this item, both of which changed the original proposal to simply require that outdoor connections to be secured in an “approved manner.” This text would have left it up to the local inspector to decide whether an access port was or was not satisfactorily safeguarded, and it had broad support by the original proponent and other interested parties. However, use of the term “approved” in the codes is objectionable to some code enforcers, one of whom really pushed the concern, and unfortunately, this became a big issue at the final action hearing when the proposal was decided. In the end, the originally submitted text, which specifically

Code Change M91-07/08 was introduced in the last code cycle by a mother who had lost her son after he deliberately opened up a fill connection on an air conditioning system and “huffed” refrigerant in an effort to get high. Her effort to create something positive from a personal tragedy was certainly noble, and it reflected a genuine interest in public safety. The concept was seemingly simple, by requiring tamper-resistant caps on refrigerant access ports, the ability of individuals to abuse refrigerants would be inhibited.

As justification for the code change proposal, many interesting, if not enlightening, facts were offered with respect to inhalant abuse and refrigerants.• The National Institute on Drug Abuse

reports that one in five American teens have used inhalants to get high, and inhalant abuse among 8th graders is up 7.7% since 2002.

• The Partnership for Drug-Free America reports that 22% of 6th and 8th graders admitted to abusing inhalants, yet only 3% of parents think their child has ever abused inhalants.

• An analysis of 144 Texas death certificates by the Texas Commission on Alcohol and Drug Abuse involving misuse of inhalants found that the most frequently mentioned inhalant was Freon (35% / 51 deaths). Of the Freon deaths, 42 percent were students or youths with a mean age of 16.4 years.

• 55% of deaths linked to inhalant abuse are caused by “Sudden Sniffing Death Syndrome,” and 22% of inhalant abusers who died of SSDS had no history of previous inhalant abuse, i.e., they were first-time users.

Locking Caps for Refrigerant Access Ports – A New IMC Requirement

by Jeffrey M. Shapiro, P.E., FSFPE

Have you ever opened a building, fire or mechanical code to research a requirement,

read the text and asked “who the heck came up with that, and what were they thinking?” Well, you can take some comfort in the fact that you’re not alone. Having been in the code business for almost 30 years now, I’ll admit to having that reaction to reading a code requirement on many occasions.

With this in mind, I have little doubt that people in the ammonia refrigeration industry who check out the new 2009 International Mechanical Code to see what has changed since 2006 will pause when they get to Section 1101.10. This new section contains the following requirement:

1101.10 Locking access port caps. Refrigerant circuit access ports located outdoors shall be fitted with locking-type tamper-resistant caps.

And now for the questions... “Who the heck came up with that, and what were they thinking?” The “who” starts with an unusual alliance of parents and substance abuse advocacy groups led by an organization called the United Parents to Restrict Open Access to Refrigerant and ends with an individual mechanical official who was able to convince ICC’s membership to go against the advice of their code development committee and many others with an interest in this issue.

The “what were they thinking” part of the equation is quite a bit more complex, so let’s start at the beginning.

IIAR CODE ADVOCACY UPDATE


but huffing of ammonia isn’t likely to become a widespread problem. It’s pretty clear that this wouldn’t be a crime with a lot of repeat offenders.

With regard to the security risk associated with theft of ammonia, many facilities do deal with this concern by securing outdoor connections to an ammonia system in a variety of manners, such as installing a check valve on the fill line, installing a stop valve on the

filling purposes as an event that warrants replacement with new tamper resistant caps. As always, code enforcement will be up to the local inspector until you initiate a formal challenge to the inspector’s decision.

Should this new requirement really have applied to industrial ammonia refrigeration systems? Certainly, there is a recognized concern with theft of ammonia by individuals involved in the manufacturing of illegal drugs,

requires installation of a locking cap, was approved.

Based on the information presented at the code development hearings, there is certainly a preponderance of evidence that refrigerant gas in residential and light commercial air conditioning units is being abused and that such abuse too often leads to a fatality. From that perspective, the cost of locking caps, estimated in the range of $20-30 per pair for residential units, was seen as reasonable by ICC’s membership when they passed the proposal. However, the industrial refrigeration industry was also ensnared by the new requirement, and solutions are not quite as simple on these systems.

First, there’s the issue of what constitutes a “refrigerant circuit access port.” Generally, this was understood to be a fill connection; although that’s not specifically defined by codes. Theoretically, a local code official might look at other valves and appurtenances to an industrial system as “access ports.” Nevertheless, by intent, only fill connections on industrial refrigeration system are now supposed to be secured by some type of locking cap. You may be asking whether this applies to existing installations, and the answer is, as always, “it depends on the local enforcing agency.” They should be guided in the proper application of the code with respect to existing installations by IMC Section 102.2.

102.2 Existing installations. Except as otherwise provided for in this chapter, a provision in this code shall not require the removal, alteration or abandonment of, nor prevent the continued utilization and maintenance of, a mechanical system lawfully in existence at the time of the adoption of this code.

Technically, this section says that the locking cap requirement should NOT be retroactive, but some jurisdictions may consider removal of the old cap for Code Update continued on page 36


IIAR Government Affairs

effective energy efficiency improvements and significant improvements in water use and other environmental attributes.

For commercial buildings, the program would authorize cost-sharing of retrofitting designed to improve energy efficiency. For example, the language provides $.15 per square foot of retrofit area for demonstrated reductions of 20-30 percent. Cost share amounts would go up with increases in efficiency achieved, topping out at $2.50 per square foot when efficiency is improved by 50 percent or more. The language also authorizes funds (up to $1,000) to support a building audit to determine energy-reduction potential.

Chairman Waxman conducted a series of hearings the week of 20 April, and has indicated the desire for his committee to approve legislation by mid-May. Waxman said that he hopes the legislation would be considered by the full U.S. House of Representatives prior to Memorial Day. This is an aggressive schedule on a controversial subject, but there is much interest in Congress to address climate change policy. On the Senate side, Chairwoman of the Environment and Public Works Committee, Barbara Boxer has indicated that she is working on legislation, but is not as far along as her counterparts in the House.

On 17 April, in the midst of these legislative efforts, the Environmental Protection Agency (EPA) announced its proposed finding that greenhouses gases threaten public health and welfare. The six gases covered by the finding are: carbon dioxide, methane, nitrous oxide, hydrofluorocarbons, perfluorocarbons and sulfur hexafluoride. The agency’s finding is a very significant, as it will make greenhouse gases subject to regulation under the Clean Air Act. The proposed finding is now in a 60-day public comment period.

The Obama Administration’s move to regulate greenhouse gases, as well as the call for greater energy efficiency may create an opportunity for our industry to promote the positive aspects of using natural refrigerants such as ammonia. Given the fact that ammonia is not a greenhouse gas and can provide demonstrable improvements in energy efficiency, our industry is well positioned to advance ammonia as a highly efficient and climate friendly option.

Chemical SafetyThe Chemical Facilities Anti-Terrorism Standards (CFATS)

Program, which was authorized for a period of three years

by Lowell Randel

Hot Topics for 2009

As the new Director of Government Affairs for the Global Cold Chain Alliance (GCCA), I am pleased to be writing my inaugural article for the Condenser. My

arrival at GCCA coincided with the International Institute for Ammonia Refrigeration (IIAR)’s joining of GCCA. This was no accident, as I will be working closely with IIAR on government affairs issues. This is an exciting time for IIAR and GCCA and I look forward to developing an active government relations program that will advance IIAR’s priorities, as well as those of the broader alliance. One of my roles will be contributing to the Condenser and reporting on the policy issues of the day. For my first article, I would like to lay the foundation for a few high profile issues that are likely to surface this year.

Climate Change and EnergyPresident Obama has made climate change and energy

a top priority for this year. His inaugural budget proposal includes a “cap and trade” program aimed at reducing overall greenhouse gas emissions. Obama’s proposal would establish an auction system where industry would be required to purchase emissions credits. The plan would raise $646 billion over ten years and reduce emissions by 14 percent by 2020 and by 83 percent by 2050. The plan has received mixed reviews in Congress, but there are indications that climate and energy legislation will be considered this year.

Henry Waxman, Chairman of the House Energy and Commerce Committee, has released draft legislation entitled The American Clean Energy and Security Act of 2009. Waxman’s draft includes a “cap and trade” program similar to President Obama’s, but does not specify how emissions credits would be distributed. The draft also sets an aggressive course to require retail electricity suppliers to meet a certain percentage of their load with electricity generated from renewable resources, like wind, biomass, solar, and geothermal. The new Federal Renewable Electricity Standard would begin at 6% in 2012 and rise to 25% in 2025.

In addition to setting standards for reducing greenhouse gases and increasing renewable energy, the bill also includes provisions designed to improve energy efficiency. Among these provisions is Retrofit for Energy and Environmental Performance Program (REEP), which provides incentives to help industry become more energy efficient. The purpose of the REEP program is to facilitate the retrofitting of existing buildings across the United States to achieve maximum cost-


alliance with OSHA. Such an alliance would help develop stronger relationships with the agency and facilitate better communication between the agency and the industry. We will be monitoring this situation closely and work to effectively position IIAR and industry should an NEP be established.

EPA Risk Management Plan (RMP) UpdatesThe Environmental Protection Agency (EPA), acting under

the Clean Air Act requires facilities to submit Risk Management Plans (RMPs) if they use, produce or store a threshold quantity of a regulated substance in any one of their processes. These plans are required to be updated every 5 years. The initial RMP submissions occurred in June 1999, therefore June 2009 represents a 5-year update anniversary for many facilities.

To help facilitate the process, EPA has developed a new online submittal program called “E-Submit” that is now available for companies to update their RMPs. Companies that have submitted an RMP previously should have received a letter from EPA with directions regarding how to resubmit an RMP online. Additional information on the “E-Submit” process can be found on the EPA website.

In future articles we will keep you informed on the developments of the issues outlined here, as well as other hot topics impacting our industry. I look forward to serving as Director of Government Affairs and advancing the interests of IIAR and its members.

by the Fiscal Year 2007 Homeland Security Appropriations Act, is scheduled for reauthorization this year. Authority for the current program runs out in October 2009. As a result, the U.S. Congress will need to act in order to reauthorize the CFATS program. It is widely expected that Congress will move legislation to extend the program, however it is unclear the form this legislation will take. It could be a simple reauthorization of the program with no changes, or it could be a more detailed overhaul of the program.

Some in Congress are advocating a more comprehensive reauthorization of CFATS and see the legislation as a vehicle to establish a federal mandate for inherently safer technologies (IST). This approach was taken by Bennie Thompson, Chairman of the House Homeland Security Committee, last year in the form of H.R. 5577. While the bill did not move last year, the committee is again working on draft legislation. Expect a bill to be introduced and acted upon prior to the expiration of CFATS authority in October of this year.

OSHA and Process Safety Management (PSM)On the regulatory front, there are strong indications that

OSHA is considering the development of a National Emphasis Program (NEP) for ammonia and process safety management (PSM). While our industry is generally familiar with the PSM process, establishing a NEP would mean increased scrutiny on those facilities utilizing ammonia refrigeration. In preparation for this possible NEP, IIAR is exploring the creation of an


by Stan D’aubin, Dave Kuntz, and Vern Sanderson, Wagner-Meinert, Inc.

It is often said that rounds men and rounds women (a.k.a., “rounds persons”) should constantly be on the lookout for any indication of system upsets. But exactly what should they

look for?For most people the first answer that comes to mind is,

“thermometers and pressure gauges.” Another possible answer is, “they should be using their eyes, ears, and noses.”

An effective rounds program must use all of these in conjunction with training and reasoning skills to provide meaningful results.

Let’s look at these in detail.

EYESThe rounds people should be constantly on the lookout

for anything that looks out of place or appears different than normal. This should include both visual indicators in the systems as well and an awareness of operational and personnel behavior.

For example: While performing rounds, Jim noticed a toolbox near an ammonia screw compressor that was running. When he looked closer he noticed the coupling guard had not been reinstalled at completion of the work. By taking notice of the toolbox and giving special attention Jim was able to prevent a potentially serious accident.

Visual Thermometer ChecksThermometers allow us to check temperatures within our

refrigeration system. In many instances, we check pressures in lieu of temperatures because the pressure/temperature relationship for ammonia at saturated conditions allows us to directly infer temperature at known pressure. However, in areas of the systems where components are not operating near saturated conditions (or if conditions are suspect), the checking of temperatures is required.

Some areas where temperatures should be routinely checked are compressor suction lines, brine or glycol, condenser cooling water, and compressor discharge temperatures.

Jennifer performs the rounds upon her arrival every morning; however, she had developed the bad habit of setting her driving gloves on the reciprocating compressor to dry them while she did rounds. Imagine her surprise when she re-entered the engine room to find her gloves on fire! The fire was quickly extinguished and a major incident was averted. What do “flaming gloves” have to do with thermometers? The compressor head should not have been that hot. Two opportunities were missed. The first was that if the compressor discharge temperature had been checked, it would have indicated an unusually high temperature requiring a repair or a shutdown. Second, if the head cooling water return temperature had been monitored, the issue would have been found much earlier and a costly compressor repair could have been avoided.

Visual Pressure Gauges As noted above, pressure gauges can allow us to determine

both temperature and pressure within our system during saturated conditions. But the question arises—out of the dozens of gauges throughout the refrigeration system, how do we

What the Watchman Watches A Quick Guide to Refrigeration System Vital Signs


Visual Frost Patterns Frost patterns or lack of frost can be an indicator of the

system status.When a component normally has frost but is not frosted

during rounds, it is cause for concern. For instance, the outlet of a thermal expansion valve which is suddenly defrosted may be a sign of a failed solenoid valve. It can also be something as simple as an indication that the unit is in defrost.

Another example is frost patterns on the outlet of the liquid expansion valve during the hot gas defrost cycle. This is an indication of a liquid supply solenoid valve that has failed to open. The hazard of this situation is the cold liquid contacting the hot vapor. This releases a tremendous amount of energy.

Excessive frost on the face of an evaporator is an indication of a failed defrost cycle.

An usual frost pattern may also be an indication of a system problem. An oil pot which is frosted at the top is an indication of oil accumulating in the oil pot. Frost on the bottom (only) of an oil pot may be an indication of contaminants in the system.

What about frost shaped like a donut? If there is an ammonia leak with significant pressure it can actually create a frost pattern that looks like a donut. The hole in the middle identifies the location of the leak.

Blue ice can also be an indication of an ammonia leak into the ice. Other leaking materials into water or ice can generate different colors. It is vital that we check for any unusual coloration and investigate the cause of the discoloration.

EARSHearing protection should always be worn in hazardous

areas. Hearing protection does not prevent the rounds people from using their ears. Unusual sounds or the absence of normal sounds can be an indication of system issues. Most times a rounds person who enters the engine room to perform rounds and finds the engine room completely silent knows there are serious issues at hand. Another example is the case of Mary, a third-shift rounds person. Mary had just exited the machinery room and entered the production area. A “hissing” sound attracted her attention. She investigated the sound and found a control pneumatic control valve leaking air. Her early detection of the air leak prevented a costly production delay.

NOSEThe way a system “smells” can tell the trained rounds person

a lot about the operation of the refrigeration system. The “hot” smell of melting insulation, the pungent odor of burnt oil, even the “chemical” smell of leaking water treatment chemicals are clear signs of system problems. Larry was beginning his rounds in the engine room when he smelled an unusual odor.

determine what gauges to check during daily rounds? Do we check them all? Probably not.

Critical gauges in all refrigeration systems are: compressor discharge and suction pressure level (high stage, low stage, low-low stage, etc.). Other critical gauges may include gauges associated with critical processes.

Also, a pressure gauge should be installed and checked on a regular basis anywhere a pressure fluctuation may cause either a safety issue or an impact on production.

Lisa was conducting the refrigeration system rounds one evening in a poultry facility. A water chiller was chilling red water for an open-face bird chiller. The water returned to the chiller at about 40°F. Water exited the chiller at 34°F. As Lisa was checking the gauges, she noticed the pressure within the chiller was 31 PSIG which indicates an ammonia temperature of 18°F—a temperature too low for safe operation. Lisa de-energized the liquid solenoid and repaired the suction regulator. (It had stuck in the open position.)

Lisa’s actions prevented a severe freeze-up that would likely have resulted in crushing the chiller tubes, causing tens of thousands of dollars in equipment damage, and lost production.

Visual Sight GlassesWhile today’s modern electronic level sensors and remote

monitoring are convenient and excellent tools they should not be trusted without regular rounds verification.

Level sensors are mechanical and electrical and as such they are subject to calibration error and at some point they will fail.

Bull’s eyes and tubular sight glasses, on the other hand, are reliable—they don’t lie!

A good rounds person will use both. The level indicators are used to record an accurate level. The bull’s eye is used to ensure that the electronic level probe is reasonably accurate.

Why do we need to know what the level is anyway?Low levels may indicate make-up problems. It is better

to find the issue before high temperatures (lack of cooling) becomes an issue.

High levels may lead to slugging or indicate an overfeed situation.

Lewis was performing rounds at 3:00 p.m., the last duty of his shift. He walked past the receiver which was the last stop on his rounds. He noticed the receiver level had dropped five bulls’ eyes since his morning shift. Lewis knew this was cause for alarm. In the five years he had been doing rounds he had never seen such a drastic drop. A quick radio call to the refrigeration supervisor solved the mystery of the missing ammonia. The recirculator level had been increased in preparation for some upcoming work.

Sudden shifts in levels can indicate issues, so Lewis did the right thing. Any severe fluctuation should be reported immediately. What the Watchman Watches continued on page 31


technique for brine chilling and ice making for brewing, meat-packing, cold storage and ice-skating rinks.

Since these early beginnings there have been many developments in refrigeration; some weakening ammonia’s dominant position and others strengthening it. From an initial position of common technology, the industries in Europe and the United States have diverged, so it is not surprising to find that, one hundred and fifty years after the Carrés’ first absorption system, there are considerable differences in technologies, attitudes and legislation. In Europe from 1950 to 1980, ammonia in industrial refrigeration was almost completely superseded by CFCs and HCFCs. Latterly these systems tended to be large pumped R-22 systems, or smaller packaged R-502 plants using direct expansion or the pumpless “low pressure receiver” system. Ammonia was only retained in very old plant, or where there was a strong tradition of its use, backed with appropriate local expertise, for example in breweries. Most cold stores and food factories, and all ice rinks built in the period 1970 to 1990 in the United Kingdom used halocarbons (principally R-22). Water chillers for air conditioning of buildings were almost exclusively halocarbon based; mainly R-12 centrifugal chillers for larger capacities and R-12 or R-22 chillers with multiple semi-hermetic reciprocating compressors in the smaller sizes. In other parts of Europe the extent of the change varied; central Europe retained more ammonia plant, but France, for example,

By Dr. Andy Pearson, CEng, Star Refrigeration

(The following article was published as a technical paper by the IIAR at the 2003 Annual Meeting in Albuquerque, NM under the title, Low charge ammonia systems – why bother? The following updated version will be presented in June at the 13th European Conference on Refrigeration and Air Conditioning in Milan.)

Ammonia has been in use as a refrigerant since 1859 when the absorption process was developed by the Carré brothers in France. It was first used in the United

States during the Civil War in 1863, when four absorption ice makers were smuggled through Union blockades via Mexico and installed in the Southern States; the first being a 200kg (440lb) per day machine constructed in Augusta, Georgia. Almost a decade later, David Boyle, born in Johnstone, Scotland, installed the world’s first ammonia refrigeration compressor, in Jefferson, Texas. This pre-dates Carl von Linde, who at that time recognised the potential of vapour compression systems, but was experimenting with methyl ether. He switched to ammonia in 1876, applying a scientific rigour to the compressor and system design, and achieved new levels of success with his new design which was licensed to Augsbourg (Germany), Sulzer (Switzerland), Carels (Belgium), Morton & Burton (Great Britain) and Fred Wolf (USA). Within ten years, many more ammonia compressor manufacturers were active on both sides of the Atlantic, including De La Vergne, Frick, Vilter and York in the USA and Sterne in Great Britain. Ammonia refrigeration quickly became the preferred

Design and Operating Experience of

Large Ammonia Systems with Small Refrigerant Charge


1977 limiting the use of CFCs in aerosol, rightly regarded as “total loss systems," but no moves were made against air conditioning, and in particular car air-conditioning. At that time car a/c was effectively also a total loss system as no attempt was made to recover refrigerant during vehicle servicing. In contrast in Europe, and particularly Northern Europe, aerosols were not targetted until much later, but the refrigeration and air-conditioning market was more tightly controlled at a much earlier stage. When the Montreal Protocol was first ratified in 1986, the European Community led the campaign for stricter controls. The protocol originally sought to reduce CFC production to 50% of base (1986) levels, but the EU proposed tighter limits and a complete phase-out long before this was established as the internationally agreed stance.

It was therefore clear that the commercial and industrial refrigeration industry in Europe, which had come to depend on R-12 and R-502 would need to find alternatives. HFCs like R-134a filled the gap in the commercial market, and for a long time R-22 was promoted as “part of the solution, not part of the problem." However it eventually became clear, with increased concern about global warming, that R-22’s days were also numbered, and that this would come sooner rather than later in Europe.

HFCs were fundamentally unsuitable for larger industrial systems. They were relatively expensive, so that for the first

enacted much tighter requirements. These dictate that any system containing more than 150kg ammonia must comply with rules on plant location relative to neighbouring buildings, and must be subject to local authority registration and technical oversight. Since small systems, with less than 150kg charge, are the ones most suited to R-22, this greatly restricted the ammonia refrigeration industry in France.

In the United States, the air conditioning market was more advanced and used many R-11 centrifugal chillers, as well as R-12. The industrial sector was treated as a niche within a much larger market, and opted to continue to use ammonia in very traditional ways. These include large, site installed systems comprising two or more temperature levels, with ammonia held in large receivers and pumped to freezers, cold stores and process users. It is estimated that there are about 2,000 facilities in the United States of America with an ammonia charge exceeding 10,000lbs (4,546kg), which is the threshold for registration of the installation with the Occupational Safety and Health Administration (OSHA). The largest of these plants contains over 400,000lbs (over 180,000kg) of refrigerant.

The consequences of CFC phase outThe divergence of the European and American markets

for refrigeration and air-conditioning had a profound effect on their respective responses to the initial reports of ozone depletion. In the US legislation was enacted as early as Large Ammonia Systems continued on page 32


RMP: Where do you stand?

First, though it may be difficult to believe, some companies said they had no idea that they were required to comply with RMP/PSM. That may have been true for some individuals within an organization when these programs came into existence. However, there was a considerable effort put forth by many industry groups to inform companies within their organizations and areas of influence about the requirement to get these program in place. Unfortunately, some of companies did not realize the importance of compliance. This was one of the major reasons several companies received large fines. They had nothing in place. They had not even begun any aspect of these programs.

Second, there were some companies that received large fines that unfortunately had inadequate assistance from outside their organization in (supposedly) putting their programs in place. The assistance given was far from complete, and the organizations themselves did not make the effort to understand what was being put together to meet the regulation requirements or that continued effort on their part was required to maintain their program. In several cases an RMP Submit was completed, which indicated that there was a “complete” RMP in place and, as is required, the RMP Submit was sent to the EPA. When EPA staff visited to review how these

By Kem Russell, Double-Kold

If your company meets the criteria to have a “Risk Management Program” (RMP) in place, this could be one of the most important articles you will read for some time.

Over the past two years, there has been a significant increase in fines for non-compliance of the EPA “Risk Management Program” (40 CFR Part 68). These fines have been levied against numerous refrigerated facilities, and many have been costly. The average fine for eight companies was $85,916. Another seven companies had average fines of $4,390. It was due to significant effort on the part of these companies that the fines came down to these amounts. Since the RMP program has been in effect since June 20, 1999, how could these companies be in a situation that would result in substantial fines? I will briefly discuss many of the reasons these companies were fined. I hope that this will cause you to take a serious look at your company’s compliance with RMP. Doing this will not only to reduce the possibility of a large fine, but will also show you how compliance can improve many aspects of your refrigerated facility.

The RMP contains three main elements: a hazard assessment, a prevention program, and an emergency response program. In addition, once the RMP is in place it must be submitted to the EPA via the RMP Submit program. Although the fines issued by the EPA were for various non-compliances of the RMP, this program (the prevention program portion) also requires compliance with OSHA’s program “Process Safety Management” (PSM) found in CFR 1910.119. There are 15 elements that must be properly addressed to comply with RMP. Considering this, let me first review two reasons why companies were levied large fines. RMP continued on page 30


Conference & Exhibition

March 14–17, 2010 San Diego, California www.iiar.org

2010 Industrial Refrigeration


Conference Attendance Bucks National Trends; Good Reviews From Attendees

If attendance at the 2009 IIAR Industrial Refrigeration Conference & Exhibition is an indication, the industrial refrigeration industry is holding up well in difficult economic times. More than 900 industrial refrigeration industry professionals attended the conference, an amount slightly below the average attendance (948) at the last five similar IIAR events.

“We are very pleased to report the economy apparently had only a small impact on conference attendance,” said IIAR President Bruce Badger, “Many other organizations are reporting declines in conference attendance in the 20–40% range. It’s gratifying to note that attendance at the IIAR Conference & Exhibition was down less than five percent. That is about on par with recent non-tradeshow events. That kind of turn out speaks well for the economic resiliency of our industry.”

An overwhelming majority (90%) of attendees rated the 2009 Conference & Exhibition as good or better, according to a post event survey in which 20% of those who attended the Conference & Exhibition participated. More than half (54%) gave the conference a very good rating. The same survey indicated that 89% of all attendees agree with the statement, “Attending the IIAR Conference & Exhibition benefits me and my company.” Only 3% disagreed. The balance (8%) had no opinion. A break out of exhibitors shows similar results.

“IIAR has a long history of excellent reviews from conference-goers,” says Badger. “We are very proud of that history and strive to maintain that high standard. However, the survey over the past couple of years indicates an erosion in the conference reviews. More people are rating the conference very good, with a small fall off in the number of excellent ratings. That means some areas of the conference require some attention to further enhance the conference experience for those who participate.”

According to the survey results, there is a desire among many attendees for more time in the exhibit hall. The opinion is reflected about evenly in the comments from a significant number of exhibitors and conference attendees. There is also some concern about the logistics relating to some of the meals.

“During the coming months, as we prepare for the 2010 Conference & Exhibition that will be held in San Diego, we will re-examine the format and explore some options that will address the concerns that have been expressed and enhance the conference for as many people as possible,” Badger concluded.

Condenser | May 2009 | A Publication of the International Institute of Ammonia Refrigeration 19A Publication of the International Institute of Ammonia Refrigeration 19

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March 22–25, 2009Dallas, Texas


Marketing Engineer, Application Engineer, and Sales Engineer. He graduated in 1979 from the University of Maine with a B.S. Degree in Mechanical Engineering. He also obtained a journeyman electrician’s license while attending college. Upon graduation he completed York’s Graduate Engineer Training Program, and has been passionately involved in the industrial refrigeration business every since.

In addition to starting the Atlanta chapter of RETA, Jeff is a member of ASHRAE and currently sits on the Board of Directors of IIAR.

Larry Basel Named

Honorary Life Member

Jeff Welch (left), former IIAR chair (2007-08), has been named IIAR Member of the Year for 2008-09.

The award was presented to Welch by Brian Marriott (right), IIAR Chair (2008-09) at the 2009 IIAR Industrial Refrigeration Conference & Exhibition in Dallas, Texas. Marriott described Welch as “an enthusiastic and active contributor to the success and growth” of IIAR.

Welch has “demonstrated extraordinary leadership qualities in several projects that qualify him for this high honor. Many of these projects culminated during the past year,” said Marriott.

Welch has been instrumental in the successful leadership transition that IIAR has undergone during the past year. “From first-hand experience, I know that his steady hand was essential to

Jeff Welch Named

IIAR Member of the Year

Larry Basel (left) attained the highest honor an IIAR member can achieve when he was given an honorary Life

Membership at the Association’s 2009 IIAR Industrial Refrigeration Conference and Exhibition.

Honorary Life Memberships aren’t given out every year. They are reserved for members whose service extends well beyond their term of office and who have made extraordinary contributions to IIAR and the industry. In presenting the award, 2008-2009 IIAR Chair Brian Marriott (right) described Basel as “an individual who has made immeasurable contributions to the ammonia refrigeration industry and IIAR.”

“He’s been a tireless worker and a ready volunteer since he joined IIAR. Most recently, he has been a leader in state level advocacy efforts, especially in New Jersey,” Marriott added.

the process that led to the selection of a qualified new leader to continue IIAR’s growth and success in the future,” Marriott added.

In addition, Welch has been a longtime champion of the concept of an Ammonia Refrigeration Foundation. His tireless efforts led to the formation of the Foundation in 2007. Welch served as Chair of the Foundation during the past year.

When he is not leading IIAR through new, exciting changes, Jeff devotes himself to his company, Freeze-Pro, Inc., which he founded in 1985. Jeff is owner and president of Freeze-Pro which sells industrial refrigeration equipment to contractors in the tri-state area of Florida, Georgia, and Alabama.

Before founding Freeze-Pro, Jeff worked for York International and FES where he held the positions of Product

Basel, who is Director of Safety/Risk Management Midwest Region for Dean Foods, has served IIAR in a number of positions. He is a former Board Chair (2004-05), Executive Committee member and Treasurer. He was first elected to the IIAR Board of Directors in 1999. He became active in IIAR in the early 1990s, attending his first convention in St. Louis to learn more about the new Process Safety Management (PSM) Standard.

Basel’s work has been instrumental in promoting safety within our industry. He chaired the taskforce that developed the PSM Guidelines. More recently, he served as co-chair of the Ammonia Refrigeration Management (ARM) task force. He is a former chair of the code committee and a spirited advocate of IIAR, promoting membership within and outside of Dean Foods.


excellent opportunities to get to know the people who buy his products. He adds that he is fortunate in that his company, EVAPCO, has always been a strong supporter of IIAR and that being involved in IIAR is a part of EVAPCO’s corporate culture.

Now, as he embarks on his term on the Executive Committee, Mandato brings a strong background in sales, marketing and business management to the treasurer’s position as well as strong organizational skills that will enable him to “drive on-going programs to successful conclusions.”

Mandato says that “Being active, involved and of service is the best way to utilize my membership. It’s an honor to be on the executive committee; an opportunity to learn and give something back to IIAR.”

He summarized his vision for IIAR’s future by saying,

Joe Mandato, EVAPCO Senior Vice President for Worldwide Industrial Refrigeration, has been elected to

IIAR’s Executive Committee where he will serve as treasurer. The election was held at the 2009 IIAR Industrial Refrigeration Conference & Exhibition in Dallas, Texas.

Mandato, who has served on IIAR’s Board of Directors since 2006, became an IIAR member in the late 1990s. EVAPCO had transferred him from the company’s air conditioning side to its refrigeration side and he joined IIAR to educate himself on refrigeration issues. As a sales and marketing manager he knew that broadening his knowledge of the industry would make him more effective in his job and better able to serve his customers. He quickly discovered that IIAR is also a great networking and sales venue. He found that service to IIAR provided him with

“To meet the challenge of a member-based association, IIAR must be more proactive in developing new initiatives that advance the industry. The association needs to provide quantifiable goals for members and make members aware when these goals are achieved. Support for the work of ARF is critical because research and training are what moves the industry forward. It is especially important to draw talented young people to careers in our industry and membership in IIAR.”

Seated: Adolfo Blasquez, Peter Jordan, Don Stroud, Joe Mandato, Brian Marriott

Front Row: Rudy Nechay, Kem Russell, Nick Kawamura, Jim Marrella, Bob Port

Second row: Ron Miller, Chuck Taylor, John Collins, Dennis Halsey, Bob Shriver, Bruce Nelson, Tim Facius, John Ansbro, Marcos Braz

Back Row: Paul Bishop, Doug Sweet, Mark Stencel, Gary Webster, Bruce Badger, Jim Adler, Bob Czarnecki, Larry Gilliland

Absent: Joe Paul

Joe Mandato

Elected to IIAR EXCOM

IIAR Board of Directors


recommendation for preference of borosilicate glass to soda-lime glass reported in the previous sight glass alert.

Following the presentation, open discussion was held with more than 100 workshop participants. Although no one offered other cases of catastrophic sight glass failures in the field, those in attendance were attentive to actions that can and should be taken to maintain the safety of industrial ammonia refrigeration systems. At the present time, IIAR is considering what additional action is required for follow-up on this matter.

Pending the report from the Task Force and based on the information obtained to-date, the following suggestions have been made regarding sight glasses installed in industrial refrigeration systems:1. Ammonia refrigeration end-users should incorporate sight

glasses into their mechanical integrity programs. a. Liquid level sight glasses should be visually inspected

at least annually to ensure they are free of damage or any other abnormality. This includes etching, scratching, cracks, any other surface damage, any imperfections (large bubble inclusions), discoloration and lack of clarity. Immediately replace any glasses that are damaged or suspect.

b. To avoid damaging the exterior face of a sight glass, absolutely no sharp metal objects should be used to remove frost or clean the sight glass retaining ring.

A special task force has been appointed to examine potential safety hazards associated with bull’s eye sight glasses used in industrial refrigeration systems. Marcos Braz,

Jacobs, will chair the Sight Glass Task Force which will consist of Steve Yagla, HA Phillips; John Yencho, Hansen Technologies; Niels Vestergaard, Danfoss; Todd Metsker, Refrigeration Specialties; Doug Reindl, Industrial Refrigeration Consortium; Bent Wiencke, Nestle; Bob House, WalMart; Rowe Bansch, RVS; and Thomas Quick, Summit Refrigeration.

“The Task Force will conduct a comprehensive review of all aspects of sight glass manufacture, installation and use,” said IIAR Chair Don Stroud. “In the coming months, the Task Force will examine many sight glass related issues, including liquid transfer systems and hydraulic shock. The Task Force has been charged with developing recommendations that will enhance industry safety including possible changes to IIAR Standards if they are necessary.”

Last fall, an industry alert concerning potential safety hazards associated with bull’s eye sight glasses used in industrial refrigeration systems was published in the Condenser (November, 2008). The subject was also addressed in a workshop at the 2009 IIAR Industrial Refrigeration Conference & Exhibition. During this workshop, presentations were made by Bent Wiencke, Nestlé and Doug Reindl, IRC.

Wiencke’s presentation highlighted a sight glass failure that occurred in a large facility with a low temperature refrigeration system. The sight glass failure was both unexpected and unprecedented. The subsequent investigation suggested that possible factors that contributed to the sight glass failure were damage to the glass itself either during installation or while in-service or a combination thereof.

Reindl’s presentation provided a broader overview of sight glasses used in industrial refrigeration systems. He also presented the results of a somewhat small survey of end-users and their experiences with sight glasses. Among other items, the survey sought to find out how many end-users had catastrophic failures of sight glasses in the past. None of the forty plants surveyed reported experiencing catastrophic sight glass failures; however, four of the forty plants did indicate their experience with smaller leaks from sight glasses attributable to hairline crack in the sight glasses or gasket leaks. Reindl also reported on a search of the literature which brought into question the

Sight Glass Task Force Appointed

Sight Glass continued on page 36


Pearson is Managing Director for Contracts at Star Refrigeration and chair of the Institute of Refrigeration’s Technical Committee and the European Carbon Dioxide Interest Group. Pearson was IIAR’s member of the year in 2007.

Don Faust of Gartner Refrigeration and Andy Pearson of Star Refrigeration were presented with Andy Ammonia Awards for excellent technical presentations

at the 2009 IIAR Industrial Refrigeration Conference. The Andy Ammonia Award, which was first created in 1996, is awarded to the presenters who score highest on the evaluation forms submitted by session attendees.

Don Faust is vice president of Gartner Refrigeration, located in Plymouth, Minnesota. An engineering graduate of Purdue University with over 20 years of experience in the design and installation of ammonia refrigeration systems, Faust is a member of the IIAR Standards Review Committee.

Don Faust’s presentation, Pumped Recirculators vs. CPR Feed, demonstrated a structured approach to analyzing refrigeration system performance by using thermodynamic tables.

Star Refrigeration’s Andy Pearson won his award for a presentation entitled, Calculating Freezing Times in Blast and Plate Freezers. In his presentation, Pearson presented several methods of modeling the freezing process that can be used in a simple spreadsheet to help explain the benefits of using a correctly designed system with carbon dioxide as the refrigerant.

CALL FOR PAPERS2010 IIAR Industrial Refrigeration Conference & Exhibition

March 14–17, 2010 • San Diego, CA

Help IIAR expand the knowledge base for natural refrigerants. Share your best practices, insights and perspectives on industrial refrigeration with your colleagues and help define the natural refrigeration industry for the 21st century. A technical paper submission positions you and your company at the forefront of the industry.

IIAR seeks papers that describe ideas and techniques that have successfully been used to advance the state of the art in refrigeration design, installation, operation and maintenance. The papers will be presented at the 2010 IIAR Industrial Refrigeration Conference & Exhibition in San Diego, CA, March 14–17, 2010.

The abstract submission deadline is June 1, 2009. Apply online at www.iiar.org or fax your proposal to (703) 312-0065. The primary author of each accepted paper receives complimentary conference registration. The two highest rated presentations receive the Andy Ammonia Award and the primary author receives a complimentary registration for the following year. IIAR also requests proposals for technical projects to be presented in Spanish. For additional information, visit www.iiar.org.

Don Faust and Andy Pearson Win Andy Ammonia Awards

Andy Pearson (left) and Don Faust (right) accept Andy Ammonia Awards from 2009 IIAR Industrial Refrigeration Conference & Exhibition Chair Peter Jordan (center).


IIAR members can access these papers in the elibrary beginning on September 1, 2009. The elibrary, which is exclusively available to IIAR members, is an online resource

that contains more than 400 documents. The elibrary can be accessed through the IIAR web site, www.iiar.org.

Technical Paper #1ASME-ARF Low Temperature Pipe Research ProjectMartin Prager, Pressure Vessel Research Council

An investigation of the impact test exemption curves of ASME Section VIII, USC-66, in order to extend them to lesser thicknesses. Specifically, the purposes of the investigation included:• Extension of the curves (particularly curves for material

groups A and B) to lower temperatures and to thicknesses less than 0.394 inches

• To understand the technical and historical origin of these curves

• To expand in a more systematic and complete way the several exceptions to these curves, namely USC-66(d) and UG-20(f)

• Evaluation of data and history in light of modern steel production methods, which produce materials that are less prone to low temperature failures

Technical Paper #2Energy Penalties for CO2 Systems vs. AmmoniaJ.W. Pillis, P.E., Frick by JCI

CO2 cascade systems have been used in refrigeration for many years and are growing in popularity for a number of reasons. Reduction in ammonia charge, reduced cost of refrigerant, reduction in compressor size, reduced risk of air ingress, and reduced energy consumption are all cited as possible advantages with CO2 cascade. This study takes a detailed look at energy consumption using CO2 cascade systems to determine whether they are in fact energy competitive with two stage ammonia systems or other possible systems over the range of temperatures normally encountered in food freezing and storage applications.

Technical Paper #3Designing an Inherently Safer Ammonia Refrigeration SystemPeter Jordan, MBD Risk Management Services

After approximately 12 years of research, the FAA announced a new requirement in July 2008 which is designed to make airline travel inherently safer. This requirement mandates the use of nitrogen in airline fuel tanks to eliminate the potential for a flammable atmosphere in these tanks. The ammonia refrigeration industry has been emphasizing the use

of inherently safer designs for many years. Examples include the use of secondary refrigerants and the elimination of ammonia piping manifolds in processing areas.

The processes used to evaluate design options, however, have tended to be relatively informal and qualitative in nature. This technical paper will describe a formalized method that has been used to quantitatively and qualitatively evaluate different options in ammonia refrigeration systems to determine which option is inherently safer. The method involves adding additional questions to Process Hazard Analysis (PHA) studies to stimulate discussions on potentially inherently safer designs. The method also involves the use of actual ammonia accident investigation data that has been collected over a three year period, published equipment and human failure rate data, and ammonia dispersion analyses to evaluate various design alternatives. The end result is a prioritized list of recommendations which are designed to make the ammonia refrigeration system inherently safer.

Technical Paper #4Natural Refrigerant Applications in North American SupermarketsDavid K. Hinde, and Shitong Zha, PhD., Hill PHOENIX

Recent achievements with the application of CO2 secondary and cascade systems in North American supermarkets are presented. Practical information gained through start-up and operation of these systems as well as customer experiences is included. The results of a detailed analysis are presented. These results focus on impacts of distribution piping, material costs, and heat gain compared to conventional direct expansion systems using HFC refrigerants. An energy and TEWI comparison is made between several system types including CO2 secondary and cascade, as well as various primary refrigerants. Projects successfully containing the refrigerant charge in the mechanical room renew the possibility of using ammonia in these systems. A discussion of the potential of commercial ammonia systems in the U.S. is added, highlighting needed developments for successful implementation in the future.

Technical Paper #5Calculating Freezing Times in Blast and Plate FreezersAndy Pearson, Star Refrigeration

Recent experiences using carbon dioxide have shown remarkable improvements in freezing times. Close analysis of the freezing process has shown that this improvement is a result of the elimination of hindrances which handicap traditional freezer designs such as high suction line pressure drops, intolerance of off-design operation and internal fouling.

2009 Technical Paper Abstracts


• vertical versus horizontal air flow• evaporator capacity as a function of face velocity, gross

and net capacity• evaporator design for low room dehydration• effect of liquid overfeed rate on evaporator performance• gravity flooded coils and the optimization of surge drum

height• circuit orifices – when are they needed and how are they

sized• frost catch for evaporator coils

Technical Paper #8Probability in Risk Assessment for Ammonia RefrigerationAnders Lindborg, Ammonia Partnership AB

Designers and users of ammonia in refrigeration and heat pumps consider it a safe and economical refrigerant. The number of accidents and lethal accidents are extraordinarily rare compared to other risks in society. This is not generally known and myths which depict ammonia as very dangerous continue to influence regulators and society at large. This paper demonstrates that ammonia’s dangers have been greatly exaggerated.

Programa en español

Trabajo técnico #1Amoníaco como el refrigerante sostenible: Una comparación amoníaco-halocarburo Alex Gooseff, ALTA Refrigeration y Jamie Horton, ElectroMotion Refrigeration

Cuando se considera la pregunta “¿nuestra instalación debe usar un sistema de refrigeración con amoníaco o con halocarburo?” un inversionista debe efectuar un análisis financiero detallado de ambos sistemas. La primera diferencia de costo de ambos sistemas puede ser recuperado fácilmente a través de los ahorros en costos de operación y los beneficios de largo plazo pueden ser significantes. Para el caso de estudio de este trabajo, la inversión original de $208,000 para un sistema de amoníaco resultó en una recuperación simple de la inversión de alrededor de 1.7 años y un ahorro total de alrededor de $4.9 millones durante 20 años. En general las siguientes reglas generales aplican para una aplicación de instalación de distribución: menos de 50,000 pies cuadrados de espacio refrigerado, sistemas de circuito dividido de halocarburo normalmente son aceptados. Un espacio refrigerado de 50,000 a 200,000 pies cuadrados de espacio refrigerado, sistemas de circuito dividido de halocarburo y sistemas centralizados de refrigeración con amoníaco son comunes. Más de 200,000 pies cuadrados de espacio refrigerado, el uso de sistemas centrales de refrigeración con amoníaco es lo más común.

The paper presents several methods of modeling the freezing process which can be used in a simple spreadsheet, and which helps to explain the benefits which can be gained by using a correctly designed system with carbon dioxide as the refrigerant.

The paper will provide an explanation of the theory behind the freezing process and will convert this into a methodology which can be implemented in a standard spreadsheet. For more advanced users the option of automating the spreadsheet by using macro programs will be explained.

Technical Paper #6Pumped Recirculators vs. CPR FeedDon Faust, Gartner Refrigeration

The controversy over CPRs vs. pumped recirculators has gone on for many years. Despite numerous articles and papers, each claiming energy savings for its approach, the problem has not been fully analyzed from a fundamental standpoint. Using the simple concept of conservation of mass, and employing thermodynamic properties of refrigerants, a mass and energy balance can be modeled for each type of system. This approach yields equations which can then be used to predict the mass flows required for each type of system. This allows the systems to be compared to each other in a scientific manner. The paper will illustrate how feeding cold liquid to the evaporators lowers pressure drops and increases overall system efficiencies.

Technical Paper #7Extended Surface Air Coolers for Industrial Refrigeration Plants – the Contractor’s PerspectiveStefan S. Jensen, Scantec Refrigeration Technologies

Considering the very large range of evaporator coil geometries, coil material combinations, coil defrost methods and circuiting options available, the industrial refrigeration contractor often faces considerable difficulties deciding which evaporator design to use for a certain application.

The paper analyzes:• the impact of coil geometry on overall heat transmission

coefficient (u-value)• the impact of material selection and fin thickness on overall

coil performance• the importance of correct circuiting of air coolers• performance differences between NH3 and CO2 • air pressure drop as a function of coil geometry• vertical versus horizontal headers• parallel flow versus counter flow and the impact on coil

performance• the impact of internal (oil) and external (frost) fouling on the

performance of various coil geometries and materials• high heat flux air coolers for cooling of fresh air supply to

food processing facilities


instalación incluyendo condiciones de almacenamiento, capacidad de almacenamiento, planes de almacenamiento, configuración y trazado de la instalación, ubicación y planificación de local. Se ofrece información básica sobre el diseño de estructuras de instalaciones de almacenaje refrigerado, incluyendo el diseño de estructuras de soporte, paredes, techos, suelos, puertas y plataformas de embarque (muelles). Se da atención especial al diseño de aislamiento y retardadores de vapor, incluyendo la junta de la pared y el techo, así como el cimiento, sistemas de calentamiento del suelo y tipos, tamaños y sellos de puertas. También se presenta una discusión de la gestión de instalaciones de almacenamiento refrigerado, incluyendo puesta en marcha y entrenamiento, inspección y mantenimiento, análisis de costo de ciclo de vida y estrategias de energía.

Trabajo técnico #5Métodos de enfriamiento de aceiteWayne Wehber, P.E., Jean-Louis Picouet y Mike Nielsen, Vilter Manufacturing

Sistemas de refrigeración que usan compresores de tornillo requieren algún método de enfriar los compresores. Normalmente esto se logra enfriando el aceite lubricante antes de inyectarlo de vuelta al compresor. Este trabajo provee un guía para todos los métodos de enfriamiento de aceite utilizados en compresores de tornillo del pasado hasta el presente, incluyendo una evaluación de las ventajas y desventajas de cada método.

Trabajo técnico #6Integridad mecánica e inspección no destructiva para sistemas de refrigeración con amoníacoJim Kovarik, Lixi

Establecer los requisitos específicos para probar e inspeccionar las tuberías ha desafiado a los usuarios finales. Desde la perspectiva del usuario final se establecen las siguientes preguntas: ¿Qué métodos de pruebas pueden ser aplicados? ¿Qué clases de fallas son las más comunes? ¿Qué tipos de equipos de inspección son los más adecuados? Este trabajo examina las diferentes tecnologías de inspección disponibles para evaluar la condición del equipo de refrigeración con amoníaco y destaca las ventajas y desventajas de cada método. Asimismo se discuten los elementos para mantener un programa viable de Administración de la seguridad del proceso (PSM) y los puntos que se tienen que considerar cuando se está seleccionando un inspector.

Trabajo técnico #2Integrando controles avanzados en los procesos de planta y programas de administracíonPaul H. Stiller, P.E., Rockwell Automation, Power and Energy Management

Una variedad de avances tecnológicos recientes en sistemas de control de refrigeración prometen mejorar la eficiencia, efectividad y confiabilidad. Ahora la gestión de los servicios públicos puede ser una parte integral del proceso de fabricación. Las tecnologías de sensor permiten un planeamiento de acción de mantenimiento más eficaz. Además, los operadores pueden hacer decisiones basadas en información a tiempo real. La energía de enfriamiento puede ser dirigido como otros factores de producción. Usuarios finales tienen una oportunidad para controlar y ajustar los sistemas con precisión como nunca. Disfrutan del poder de la informática moderna que facilitará dirigir los costos de energía como parte del proceso de fabricación. Este trabajo trata de las oportunidades y presenta ejemplos específicos de aplicaciones de informática y tecnología de automatización en el proceso de la planta de refrigeración y dirección de manufactura.

Trabajo técnico #3Eficiencia de energía y rendimiento mejorado aplicando impulsores de velocidad variable a compresores de tornillo rotativoJohn C. Cosner, Frick by JCI

Este trabajo trata de la aplicación de impulsores de velocidad variable a compresores de tornillo rotativo desde dos sentidos: 1) ahorros de energía por medio de mejor eficiencia de carga parcial y 2) el rendimiento mejorado proveído por un impulsor de velocidad variable respecto al control de capacidad rápido y preciso.

Trabajo técnico #4Mejores prácticas en el diseño, construcción y gestión de instalaciones de almacenaje refrigeradoBryan R. Becker, Ph.D., P.E. y Brian A. Fricke, Ph.D., University of Missouri

El diseño de instalaciones de almacenaje refrigerado supone una variedad de tareas, incluyendo planificación, financiamiento, selección de emplazamiento, diseño arquitectónico y estructural, diseño del sistema de refrigeración, selección del equipo e instalación, construcción, inspección y mantenimiento. Además, hay otras consideraciones que aumentan la complejidad del procedimiento de diseño como los códigos de construcción y seguridad, la eficiencia de operación y la rentabilidad. Este trabajo trata de un buen número de estos asuntos así como tendencias establecidas actuales en el diseño de instalaciones refrigeradas. También se trata de especificaciones de la


Yes, I want to order the Ammonia Data Book, 2nd Edition

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Fax your order with credit card information to 703-312-0065, or Mail your order to: IIAR Data Book, 1110 North Glebe Road, Suite 250, Arlington, VA 22201

The Ammonia Data Book is the only publication of its kind. It is the most complete reference ever published on ammonia for the refrigeration industry. It contains essential resource data for the safe and efficient operation of any ammonia refrigeration facility. U.S. regulatory requirements for ammonia and other valuable compliance information about federal regulations, such as the Community Right to Know Act, are featured. Other chapters focus on General Information, Properties of Ammonia, Ammonia and the Environment, and Ammonia Safety Data and U.S. Regulatory Requirements.

Major Updates of the Ammonia Data Book, 2nd Edition• Updated Ammonia production and emission statistics• New Stress Cracking Corrosion section added• Updated EPA Toxics release inventory reference• Expanded content focuses on the Code of Federal

Regulations• Updated ATSDR Toxicological Profile for Ammonia that

extensively references a new 2004 report• New Data using ISCST2 model on downwind distance

and concentration• Updated IDLH references• Additional new section addressing State Plan States:

state-specific safety programs• Updated PSM requirements focused on employee

involvement, lockout/tagout, pre-start-up safety reviews, ongoing maintenance of PSM program etc.

• New NIOSH,REL and IDLH section• Updated 2004 RMP revisions incorporated• Revised Appendix A table values re-calculated using

REFPROP Version 7

The Ammonia Data Book, 2nd Edition


ARF’s 2010 Golf Tournament to be held in San Diego!Make plans to come out to San Diego early and support the refrigeration

industry by participating in this important fundraiser. The date of ARF’s Golf Tournament will be Saturday, March 13, 2010. Up to the minute news regarding this event will be posted on the ARF website at http://www.nh3foundation.org/.

Ammonia Refrigeration Foundation UPDATE

ARF PhilanthropistsIn appreciation for their

generous donations, the Ammonia Refrigeration Foundation recognized the Philanthropists of the Year. This honor went to Bill Kahlert (the award was accepted by Joe Mandato on Kahlert’s behalf) as the 2008 Individual Donor of the Year and to Star Refrigeration Ltd., as the 2008 Corporate Donor of the Year.

2008 Individual Donor of the Year: Joe Mandato (left) accepting on behalf of Bill Kahlert, Jeff Welch (right), ARF Chair 2008–2009

2008 Corporate Donor of the Year: Dr. Andy Pearson (left), Star Refrigeration Ltd., Jeff Welch (right), ARF Chair 2008–2009

Dear Colleague: We have all benefited from

ammonia refrigeration. Beyond the industry’s many contributions to our modern lifestyle and the preservation of our environment, ammonia refrigeration has enriched our lives personally, through friendships developed over the years, and financially, through careers in all areas of the industry.

As beneficiaries of the growth and success of ammonia refrigeration, we have a responsibility to reinvest in the industry to promote its continued prosperity. We can do that by making tax deductible contributions to the Ammonia Refrigeration Foundation. ARF is a new organization, committed to education and research that expands the science and technology associated with ammonia refrigeration, enhances the industry’s already strong performance in the cold chain and expands its profile as an environmentally responsible industry.

The mission of the Ammonia Refrigeration Foundation is to raise financial resources and to use these resources in the support of educational programs and research that benefit the industrial refrigeration industry.

Your support is critical to the success of the foundation and its mission. There are many ways to contribute. Many individuals and companies already have.

Your support of the Ammonia Refrigeration Foundation is greatly appreciated.

Regards,Brian Marriott2009–2010 Chair

ARF Century Club Fundraising Campaign

The Century Club members are the first 100 contributors of $1,000 or more to the Ammonia Refrigeration Foundation. The Century Club is open to individuals and corporations who believe in the future of ammonia refrigeration and are committed to the Foundation’s goals.

In the two years since its inception, ARF has become fully operative and self-sustaining. The generous participation by 80 individual and corporate sponsors in the Century Club campaign now has the Foundation secured with an endowment of over $ 250,000 with an additional $ 50,000 in pledges. This level of endowment permits ARF to be self-sustaining and to fund modest projects. Your donation can help ARF to take its work to the next level and fund more ambitious research projects, scholarships and training programs. You still have time to become a Century Club Member. Join today! Membership information is available at http://www.nh3foundation.org/.


all of the mandatory income distribution. Your Benefits: Avoids income tax on that charitable distribution amount. The transfer does not generate taxable income nor an itemized deduction, you benefit even if you do not itemize your tax deductions.

Gift of Life Insurance: Make a large gift with little cost to yourself. Buy a life insurance policy in ARF’s name or contribute an existing life insurance policy. Your Benefits: Current income tax deduction. Possible future deductions through gifts to pay policy premiums.

Bequest In Will: Defer a gift during your lifetime. Name ARF in your will (designate a specific amount, a percentage or a share of the residue).Your Benefits: Donation is exempt from federal estate tax. Control of assets during your lifetime.

Revocable Living Trust: Make a revocable gift during your lifetime. Name ARF as the beneficiary of assets in a living trust. Your Benefits: You maintain control of the trust for your lifetime. Gift in trust is exempt from federal estate tax.

Charitable Remainder Trust: Create a hedge against inflation over the long term and supplement your retirement income. Create a trust that pays a fixed percentage of the trust’s assets as revalued annually. Your Benefits: Receive a variable income for life. Immediate income tax charitable deduction.

Charitable Remainder Annuity Trust: Secure a fixed income and supplement your retirement funds. Create a charitable trust that pays you a set income annually. Your Benefits: Immediate income tax deduction. Fixed payments for life.

Planned Giving: Planned giving is a wonderful way to support ARF. Many people think of it as deferred giving because the most common gift is made through a will, living trust or other estate document.

Benefactor and Stakeholder Contributions: Become a Benefactor with a $1,000 contribution or become a Stakeholder for a $50 contribution. Simply write a check or use a credit card. Your Benefits: Immediate income tax deduction. Removes property from estate.

Gift of Cash: Make a quick and easy gift by simply writing a check or use a credit card. Your Benefits: Immediate income tax deduction. Removes property from estate.

Memorial Gifts: Many ARF donors make gifts to honor the memory of friends and loved ones. This is a wonderful tribute.Your Benefits: Immediate income tax deduction. Removes property from estate.

Gift of Retirement Assets: Avoid the twofold taxation on IRAs or other employee benefit plans. Name ARF as the beneficiary of the remainder of the assets after your lifetime. Your Benefits: Make the gift from the most highly taxed assets, leaving more for family. Avoids income and estate tax.

Gift of Securities: Avoid tax on capital gains. Transfer stock or appreciated securities from your brokerage account to ARF’s brokerage account. Your Benefits: Immediate charitable deduction of full fair market value. Avoids capital gains tax.

Over 70-1/2 Years of Age?: Make a gift to avoid income tax on mandatory IRA distributions. Transfer a gift up to $100,000 to ARF in lieu of taking part or

Naturally Green: ARF’s March 2009 Golf Tournament

The March 2009 ARF golf tournament which was generously sponsored in its entirety by EVAPCO, Inc., was held on March 21, 2009 before the start of the annual IIAR conference and took place at the Bear Creek Golf Club in Dallas, Texas.

Jeff Nank, 2009 Golf Chair, organized the format for the March golf outing which differed from the typical “scramble” type of play and allowed everyone to play their own ball throughout the match. This unique scoring system for the event challenged the avid golfers to compete for the prize of individual champion while allowing the more casual golfers an opportunity to have fun while helping their foursome compete for team prizes.

TAKE PRIDE IN AMMONIA: Donate to the Ammonia Refrigeration Foundation

ARF Board of Directors 2009–2010

Seated: Don Stroud, Secretary; Brian Marriott, Chair; Dennis Carroll, TreasurerStanding: Bruce Nelson, Research Committee Chair; John Hendrickson, Director-At-Large; Chuck Taylor, Director-At-Large; Gary Webster, Education Committee Chair

Jeff Nank, 2009 Golf

Chair thanking the golfers for

their support of the Foundation

Good day to golf

Sizing up the putt


organizations were doing with their program, there was no program in place, no documentation, and no records of any kind other than the RMP Submit. Pleading they did not know and that they thought everything was in place was no excuse for inaction and total disregard for the purpose of RMP. Large fines followed.

There were a number of reasons smaller fines were given:• Some companies did have many elements of the RMP

“generally” in place; however, what had been used to develop each element was not specific to the facility. There was no information, nor documentation that applied to the particular company and facility, nor the individuals at the facility.

• Some companies had not updated their “Hazard Assessment” using the most current population data available. This indicated the program was no longer being kept current, and potentially not as effective as it could be in dealing with an ammonia release, its impact on employees, the public and the environment.

• Some companies had information specific to the ammonia system, but this information was not current. For example:• Changes had been made to the system but no

“Management of Change” (MOC) documentation existed for the changes, although there was a section in the company’s program describing how the MOC program would be accomplished.

• An initial “Process Hazard Analysis” (PHA) had been done, but the follow-up documentation showing resolution of any recommendations was not completed.

• The required five-year PHA review was not done.• The “Compliance Audit” element was described in the

program, but no audit had been done or could not be found. A key point here is that program elements must not only be in place, but must be easily located. The RMP should be well organized and all elements and associated materials easily located and available.

• Drawing information was not kept current with the existing system.

• Piping & Instrumentation Diagrams (P&ID’s) were available and had equipment and valves in the system identified, however, on field inspection, equipment and/or valves were not identified or the identification was missing.

• Past ammonia incidents were indicated in the documentation by “Incident Investigation,” but reports were incomplete and there was no documentation of resolution of any recommendations.

• Relief system design basis was incomplete and out of date.

• Training records were not kept. There was no information to show that operators were qualified to perform their work. For cases where it would have been applicable to “Grandfather” an operator based on prior experience and training, no “Grandfather” document existed.

• Standard operating procedures were either not well developed, or had not been written.

• Mechanical integrity information for the ammonia system had not been developed, or was not current.

• The “Management System,” which is a key element in how the program will be carried out and shows defined responsibly for assuring all parts of the program are actively being done was described. However, the position and person responsible for the entire RMP was not identified, nor was the position(s) or person(s) responsible for individual elements of the program identified.

• Many companies did not have a well-developed or up-to-date emergency plan. In many cases companies did not understand the difference between an “Emergency Response” plan and an “Emergency Action” plan. The majority of companies fined did not have the people or equipment to have a “Response” plan so they had to have an “Action” plan. However, this was not properly developed. Responsibilities within the program were not clearly defined, nor were actions to be taken in the event of an emergency described. Also, where companies could not “respond” to an ammonia emergency they should have coordinated and worked with local emergency services who could respond. Again there was no coordination. Further, no evacuation drills were conducted and no emergency training was given to employees.

All of the companies that were fined could have received significantly smaller fines or no fine at all if they would have been actively working to keep their program “living.” The RMP must be an integral part of the company culture. It must be actively used, and that use must be properly documented. The primary reason for the RMP is to prevent accidental releases of hazardous substances, in our case ammonia, and to minimize the impact of a release should it occur.

Companies that have (after being stimulated by a fine) put their program in place have said they would have done what is called for by the program had they realized what the program was. They now see the value of the information that is readily available, the improvements in their operations, and the knowledge that they are much better prepared to deal with an emergency should one occur. These companies are now diligently working to have good, active programs in place. Will the EPA be back to visit? The answer comes from a popular movie quote, “I’ll be back.” Are you ready?

RMP continued from page 16


When he investigated, he found a calcium chloride brine leak from the brine chiller. Had he ignored the odor and accepted it as normal, the results could have included severe corrosion of several pipe nipples and an isolation valve. Larry’s investigation prevented a potentially costly pipe replacement or disruption of service.

Another example is the failure to investigate a faint odor of ammonia during condenser inspections. The result was the loss of thousands of pounds of ammonia through a relatively small leak because the leak was masked by the cooling water flowing over the coils and subsequently allowed to continue for weeks after first being detected.

The Hidden Keys to Success

Transfer CountsFacilities which use automatic transfer systems should

monitor transfer counts on a regular basis. There is an ideal number of transfers for every system. In some systems, three to four transfers are normal. A single wing recirculator may have several hundred transfers a day. The important thing for the rounds person is the ability to recognize a variance from normal.

An increase in transfers is a sign of an overfeed condition somewhere in the system. A decrease in transfers may be an indicator of a lack of normal liquid feed.

The rounds person should be aware of the current refrigeration load and weather conditions. These may have a bearing on transfers.

Mechanical failures of the transfer system may also result in a change in transfer counts.

Remember the variance from the norm is the important distinction.

Purge CountsIf the facility is equipped with an automatic purger, the

purge times and counts can be a strong indicator of problems in the system. An increase in purges is an indication of air being drawn into the system. A lowering of purge counts can also give us a clue to the operation of the system.

As we’ve discussed with other rounds issues, we are looking for a variance from normal. However, we must not get complacent. Normal may not be correct. Just because it “always looks that way” doesn’t mean it should. We will discuss this in greater detail in the future.

MiscellaneousEach system component has specific items to be checked

on a regular basis.System control panels and ammonia detection panels

should be checked to assure there are no active alarms. The

rounds person should also check the alarm history since the last round.

Evaporators should be checked for failed motors, missing fan blades, and icing.

Much like evaporators, condenser fan motors should be checked daily.

Sump tank levels should be checked to assure adequate water is available for cooling.

Chillers may require a check for brine concentrations, suction pressure, liquid levels and pump pressures.

Compressors may require checks of suction pressures, discharge pressures, discharge temperatures and oil levels. Each compressor micro panel should be checked to assure it is operated in the correct mode (remote or local). Slide valve position should also be checked to assure that it loads and unloads automatically. Each microprocessor should be checked to assure that there are no active alarms.

Refrigerant pumps should have oil levels checked. It may also be necessary to check pump discharge pressures or differential pressure.

Each vessel will have a specific list of items to check based on its use. A receiver may require a level check where a recirculator may require a level check as well as a pressure check.

A rounds log does not have to be specific to the refrigeration system. A facility which uses air compressors should be regularly checking the oil level within the air compressor. These types of checks should be incorporated in the rounds log. In most cases it is not logical to force employees to perform two simultaneous rounds.

This list is certainly not complete. There are many components so there are many items to check. The manufacturer’s information should be consulted. Additionally, industry references, such as IIAR Bulletin 110, should also be used.

OrganizationRounds sheets should be organized to provide a thorough

walkthrough. Remember the “eyes, nose and ears.” By organizing the sheet to guide the rounds person through the system, the person has opportunities to use eyes, nose and ears.

What does the future of rounds hold? Imagine portable electronic rounds devices, automatic trending and rounds logs on demand (The ability to print a rounds sheet listing the status of equipment and the computerized reading. These are then verified by the rounds person).

Rounds are a vital part of the safety and reliability plan for any facility. They should be given the importance they deserve. The ability of the rounds people to react to changes seen while performing the rounds will ultimately result in a safer and efficient compressor room.

What the Watchman Watches continued from page 13


If a plate condenser is also used, in conjunction with a cooling tower or dry air cooler, then the specific ammonia charge can easily be reduced to 0.1kg/kW (0.8lb/TR). Chillers of this type are used in very large sizes; up to 10MW (2,850TR) for mine cooling in South Africa; and have been applied for large cooling projects in public buildings such as Heathrow Terminal 5 and Oslo’s Gardermoen airport.

There are several ways in which “nearly dry” operation of the plate evaporator can be achieved, including using a thermostatic or electronic expansion valve to control suction superheat or using a low pressure receiver vessel with “high side float” control. There are several types of packages now on the market using superheat control, but there is always a risk of liquid carryover to the compressor if a suction pot is not fitted, particularly under rapidly varying load conditions. The low pressure receiver system is “critically charged” and excess charge cannot get back to the compressor. It offers the efficiency and reliability of the gravity flooded system, but the receiver can be positioned anywhere relative to the evaporator, offering greater flexibility in packaged chiller design.

The plate and shell heat exchanger is a variant of plate heat exchanger suited for applications with high pressure on the secondary side. This comprises a stack of circular corrugated plates, laser welded on the seams and compressed into a steel shell. It gives a very compact arrangement, but unlike the plate-in-frame exchanger, it is not so easy to strip for cleaning. If a low charge evaporator is required, but cleaning of the secondary side is essential then a spray chiller should be considered. This is a shell and tube vessel, but with a pump feeding liquid to a sparge pipe above the tube bundle. The shell contains almost no liquid, but the tube surfaces are fully wetted, giving efficient operation across a wide range of capacities. There is virtually no risk of liquid carryover under any circumstances.

Extruded or fabricated “microchannel” heat exchangers have been developed for refrigeration applications, particularly as evaporators for carbon dioxide systems and condensers for R-134a chillers. To date these novel heat exchangers have not been applied to ammonia chillers, but the prospect is very appealing, as it should be possible to achieve the specific charge ratio of a plate to plate chiller without the penalty of a condenser water circuit on the heat rejection side of the chiller. One possible difficulty in the use of microchannel condensers with ammonia would be the behaviour of immiscible oil in the condenser, where the refrigerant passages are typically less than 1mm diameter. Another concern is the corrosion resistance of these all-aluminium heat exchangers as the expectation for operating life of ammonia equipment is generally longer than for commercial chillers.

time in the history of refrigeration the charge of an industrial plant would represent a significant proportion of the total capital investment in the plant. HFCs required the use of new lubricants, none of which was really suitable for use in a large system. They also seemed somehow to be more prone to leakage than their predecessors. In a short time, ammonia was “rediscovered” in Europe, and adopted with enthusiasm by the industrial market. However end-users were unfamiliar with ammonia, and service technicians were more used to “fully automatic” halocarbon plants, with automatic air purgers and oil return. It was not possible to return to the traditional ammonia systems, as were still being installed in the USA, and therefore European contractors developed new techniques. These included the use of ammonia in packaged chillers with low charge evaporators and the adaptation of the CFC-based low pressure receiver system to make it suitable for ammonia.

The influence of heat exchanger type on chiller system charge

Traditional water and glycol chillers use a shell and tube evaporator. For dry expansion operation the refrigerant is inside the tubes, but most ammonia chillers operate “flooded,” with the water or glycol in the tubes and the ammonia liquid on the shell side. There are several advantages to this arrangement, but it results in a large ammonia charge relative to the cooling capacity. When air-cooled or evaporative condensers are used they also contain a significant quantity of liquid refrigerant, and so a traditional style of chiller, with flooded shell and tube evaporator and direct condenser, may contain as much as 1kg/kW (7.7lb/TR). If the liquid level in the flooded chiller is controlled (“low side float system”) and a high pressure receiver is fitted, then the specific charge could rise to 1.5kg/kW (11.6lb/TR). Several alternative types of heat exchanger can reduce these figures. The most common is the plate heat exchanger, where thin corrugated sheets, usually of stainless steel, are compressed between thick steel endplates in a supporting frame. These exchangers were originally developed for liquid/liquid heat exchange in process industries, but required minimal adaptation for use as evaporators or condensers. Smaller units can be nickel brazed or even copper electro-tinned for use with ammonia, but above about 100kW (30TR) capacity the plate and frame configuration is necessary. In a standard gravity-fed system the plates and wet suction riser are nearly full of ammonia liquid, with gas bubbles rising through it. In the worst case, the specific charge of a gravity fed plate heat exchanger will not be much less than for a shell and tube even though the internal volume of the plate pack is relatively small. However if the plates are operated with a dry, or nearly dry suction line then the specific charge is likely to reduce to about 0.5kg/kW (3.9lb/TR) with a direct condenser (air-cooled or evaporative).

Large Ammonia Systems continued from page 15


the unit would be adversely affected. This would either cause the efficiency to be impaired, or it would require immediate attention from a technician to trace and fix the leak. As there was no high pressure receiver, if the expansion valve was controlled by a float on the low pressure side of the system then any excess charge in the plant would tend to back up into the plate type condenser. This would cause the unit to run inefficiently with a high discharge pressure. The idea of a unit in which the efficiency was so tightly dependent on achieving and maintaining exactly the right charge did not find favour with plant operators. Instead the concept of “optimum charge” was developed. It was recognised that it was not sensible to make the ammonia charge absolutely as low as it could be if this had adverse effects on reliability or efficiency. The optimum charge was that which was as low as it could be without risking gross inefficiency if a small amount of charge was lost. The low pressure receiver system described above achieved this goal. In normal operation there is a slight overfeed from the plates, typically 3–5% in a water chiller. This is collected in the low pressure receiver, where it is evaporated by subcooling the liquid feed from the condenser. If the unit is under-charged then the flow through the plates evaporates to dryness, and there is no overfed liquid available for sub-cooling. This gives a clear and easily recorded signal that the unit is undercharged, but has no significant effect on efficiency until a greater quantity of refrigerant has been lost. If the system is overcharged, the excess will lie in the low pressure receiver, and has no effect on efficiency or reliability unless the overcharge is so excessive that the receiver fills up and liquid returns to the compressor. In practice this requires so much additional refrigerant that it is highly unlikely. Optimum charge systems have become very common, and a benchmark specific charge of 0.1kg/kW (0.8lb/TR) seems to be generally accepted as a sensible target. A large system with plate evaporators and condensers was installed for Roche Pharmaceuticals at Welwyn Garden City in England. There are three water chillers, each of 2,500kW (720TR), which each required 238kg (524lb) ammonia at commissioning. It was stipulated in the specification that the charge was to be less than 250kg (550lb) per chiller. The use of low pressure receivers and plate heat exchangers has now been extended to a standard range of packaged water chillers with two compact screw compressors and capacities in the range 200kW to 800kW. These air cooled chillers are designed for outdoor location, with the control panel, compressors, oil system, receiver and evaporator incorporated within the body of the condenser which comprises two vertical coils and a fan deck.

Optimum charge in cold stores and freezersThe low pressure receiver, originally developed to provide

compact packaged units using R-502 for cold stores, is also

In air cooler applications, such as cold storage and freezing, a recent development has been the use of an internal enhancement to improve the wetting of the inner surface of the tube. This effect is important for direct expansion evaporators and those in low pressure receiver systems, and it becomes increasingly significant as the operating temperature is lowered. In chill applications there is no difficulty in establishing wavy or annular flow in the cooler tubes, but in cold stores and blast or spiral freezers, where the mass flux is low compared to the volume flow, the flow regime is almost always stratified, and typically only 10–20% of the tube surface is wetted. Coupled with the use of aluminium tubes this arrangement can offer a significant improvement in system efficiency, of the order of 10%, while reducing the amount of liquid ammonia held in the evaporator during operation. Superheat control through thermostatic expansion valves is not preferred for ammonia air coolers because of the risk of leakage at the valve, and because prolonged operation with ammonia can cause valve seat erosion (wire drawing), leading to erratic and unreliable operation. Problems can also be caused on a large system if several DX coolers are defrosted together, particularly with large volumes of liquid returning in the supposedly “dry” suction at the end of defrost. The use of the enhanced aluminium coolers together with the low pressure receiver system eliminates these problems.

Minimum charge vs optimum charge chillersIn the early 1990’s, as the European refrigeration

industry looked to apply ammonia to water chillers for building services, there was a spate of development of so-called “minimum charge” chillers. The objective was to encourage operators previously unfamiliar with ammonia to use it in large chiller systems where the fluorocarbon alternatives were unacceptable. Most of these designs used plate heat exchangers as evaporator and condenser, but every other component in the system was also analysed and modified where possible to reduce the unit charge. A typical configuration used a gravity feed arrangement for the evaporator, but with the level controlled in the drop leg rather than in the receiver. The high pressure liquid from the condenser was expanded through an ejector into the plate inlet. The overfeed from the plates was fed to the side port of the ejector, creating a slight suction which was sufficient to overcome the pressure loss through the plates and induce flow from the receiver back to the plate inlet. There was no high pressure receiver on the unit; the low side receiver was sufficient to carry the total unit charge. With this arrangement it was possible to achieve a specific charge as low as 0.025kg/kW (0.2lb/TR), resulting in a charge of only 25kg (55lb) in a 1000kW (285TR) unit. However this type of unit attracted some criticism for several reasons. If there was any leak of ammonia, no matter how slight, the performance of


now used for ammonia plants. Initially it was thought that the very high latent heat of ammonia made it fundamentally unsuitable for this type of system. However careful design of some key components and attention to detail in installation have proved that such systems can be engineered to be cost effective in capital and revenue terms. Such systems on ammonia have been built in the United Kingdom since 1988, and over this twenty year period some significant development refinements have been introduced. The high latent heat means that the overfeed ratio in an ammonia low pressure receiver system is less than it would be in an equivalent R-502 system. As a result it is more difficult to ensure even distribution between evaporators and between individual tubes in an evaporator. However, using special distributors with careful design of evaporator circuits and enhanced aluminium coolers, good results can be achieved.

The low refrigerant charge in the low pressure receiver system is the result of a combination of several factors. The receiver only contains gas in normal operation, provided the plant is charged correctly. The liquid line from the condenser to the plantroom is full of liquid, but it is usually short and like all ammonia liquid lines is small diameter. The expansion valves are mounted on the receiver package, which is usually located in the compressor plantroom, so the liquid line from the package to the evaporators contains a mixture of flash gas and liquid in the form of froth. The coolers typically contain a smaller amount of liquid than in a pumped circulation system, and the wet suction line, if the plant is charged correctly will carry about 10% liquid by mass (about 1% by volume). There is no high pressure receiver at the condenser outlet, and the system charge can be held in the low pressure receiver for maintenance. An ancillary glycol circuit is provided in the evaporative condenser to provide a simple but effective method of oil cooling, and automatic air purging is achieved with a small liquid pot at the condenser outlet which doubles as the high pressure float control chamber. Oil is returned automatically from the low pressure receiver to the compressor.

The result of these measures is best illustrated by reference to a typical installation. This case study is a composite distribution centre built in 2001. The centre provides distribution facilities for chilled and frozen produce to supermarket stores in the south-east of England, and comprises four temperature controlled chambers. The largest of these is 123m (410ft) at its widest point and 120m (400ft) long, and is held at +2°C(36°F). There are two smaller chill chambers, one at –1 °C (30°F) and one at +10°C (50°F). They are both 65m (215ft) wide and are 45m (158ft) and 75m (258ft) long respectively. All the chill ceilings are at 7m (23ft) and the total chill duty is 2600kW (750TR). The cold store is 110m (365ft) long and 80m (264ft) wide and has an 11m (36ft) ceiling. It is held at –25°C (–13°F) and has a calculated duty of 1150kW (330TR).

The cold store is served by three low pressure receiver systems, each with a Howden WRVi 255 compressor and evaporative condenser sized to meet one third of the plant capacity. The ammonia charge in each of these systems is 300kg (660lb), making less than one tonne charge for the total cold store, which has a volume of just less than 100,000m3 (3.5 million cubic feet). The chill chambers are fed with a chilled glycol system, again with three independent packs. Each pack has a low pressure receiver and plate heat exchanger, connected to two Howden WRV204 compressors and an evaporative condenser. The charge of each glycol chiller is 250kg (550lb). Thus the maximum charge in any single section of this large distribution centre is 300kg (660lb), and the total plant ammonia inventory is 1,650kg (3,600lb).

It is estimated that the equivalent pumped ammonia system comprising booster and high stage compressors, low stage pump set, intercooler, evaporative condensers and high pressure receiver would contain about 14,000kg (31,000lb) owing to the long liquid lines, large number of evaporators and size of suction accumulator and intercooler. In the United States market, the central plant system would be subject to the full requirements for hazard analysis and risk management under the OSHA regulations which have a lower threshold of 4,545kg (10,000lb). The low charge system however, would be within the limits by a factor of three, even when the total charge of all the systems on site is considered.

Options for larger industrial systemsNot all installations are suitable for the direct ammonia

low pressure receiver system described above. Where there are a large number of chambers, where liquid distribution is expected to be difficult or simply where there are too many evaporators to suit the low pressure receiver then a central plant approach is preferred. It is still possible to achieve low charge by using ammonia in conjunction with another fluid. Traditionally for chill plant this would be ethylene or propylene

Figure 1 – Low charge low pressure receiver system for air cooling


glycol, and more recently in Europe for low temperature plant other salt solutions including potassium formate and potassium acetate have been introduced. However it has been recognised that additional benefits can be obtained by using carbon dioxide together with ammonia. In chill systems the carbon dioxide is used as a “volatile secondary” refrigerant, pumped at high pressure to the heat load, evaporated and returned to the condenser at a nominally steady temperature. For lower temperature applications, particularly in freezer plant, the carbon dioxide from the evaporator is compressed to a suitable high pressure before returning to the condenser.

This technique has been used over the last ten years in cold stores, distribution warehouses, plate freezer plants, blast freezer plants, tunnel freezers and spiral freezers. Four distribution centres similar in size and style to the plant described above have been completed in the United Kingdom. In comparison with the previous case study, the ammonia refrigerant charge is reduced by about 40%. Each system comprised a central pumped carbon dioxide system, feeding refrigerant at –5°C (23°F) to the chill areas and at –31°C (–24°F) to the low temperature cold store. The carbon dioxide is condensed in cascade with two independent ammonia systems to provide resilience in the event of a major ammonia system failure. Each ammonia system has a charge of approximately 500kg (1,100lbs) giving a total ammonia content of 1 tonne (2,200lbs).

Similar systems have been installed for blast and plate freezing. The specific ammonia charge in all cases is approximately 0.3kg/kW (2.4lb/TR) but this could be reduced significantly by using plate and shell ammonia condensers and cooling towers for the heat rejection, probably offering the same specific charge as the plate-plate water chillers of 0.1kg/kW (0.77lb/TR). On this basis the maximum refrigeration capacity of a system falling below the United States OSHA threshold of 10,000lbs (4,546kg) would be 128,000 TR (36 MW). The French threshold of 150kg would allow installation of a 500kW (150TR) system without any government restrictions on location, and 5 MW (1,500TR) without application of the stricter controls for ammonia systems.

Future possibilitiesIt is unlikely that current regulations governing the use of

ammonia in industrial refrigeration plants will be relaxed in the near future. Possible exceptions are in France and Italy, where regulations might be brought more in line with the rest of Europe to gain benefit from the superior efficiency possible with industrial ammonia systems; however, even this small step is improbable. It is much more likely that the requirements for safety systems, personal protection and the associated documentation will become stricter. One example of this type of legislation is the recent introduction in the US of “Homeland Security” legislation requiring end-users to

safeguard their installations against criminal or terrorist activity. At the same time construction standards will become more international. This has already happened in Europe where EN 378, Refrigerating Systems and Heat Pumps—Safety and Environmental Requirements has replaced the old national standards such as BS4434. It is possible that the international standard ISO 5149 will in the near future replace EN378 and ASHRAE 15. There is also the prospect of the introduction of more rigorous building code requirements associated with the use of ammonia. In this case the argument for low charge ammonia systems becomes very simple. If it is possible to avoid much of the difficulty and expense of designing and operating systems with large tonnage charges, then the market in the US will probably follow the Europeans down the low charge route, either with pumpless low pressure receiver systems, or with carbon dioxide/ammonia cascades. It is important to note that the very success of these new systems could be the trigger which initiates legislative moves against large ammonia charges. However on a more positive note, the market in Britain has embraced the low charge concept because it is inherently simpler, easier and therefore safer, and because when used appropriately it need not be any more expensive to install or to operate. There is no legal requirement for specific risk management measures, offsite consequence analysis or process safety management in Britain, provided the charge is less than 30 tonnes (66,000lbs), so the preference for low charge systems in Britain, and to an extent in the rest of Europe, would seem to be driven by economic and ease-of-use considerations, not legal restrictions.

ConclusionIt is possible to achieve significant reductions in ammonia

charge in chillers and industrial systems through the adoption of a range of strategies. These do not carry any significant penalty in capital cost, although they place some constraints on the ways in which the system can be configured. Experience in the United Kingdom engineering these systems over the last twenty years demonstrates clearly that the charge reductions can be achieved provided there is a willingness to accept the constraints and modify traditional attitudes to system design. The energy efficiency of these systems is, on paper, no worse than traditional pumped circulation systems and in practice the use of reverse cycle defrost eliminates much of the additional energy penalty inherent in large pumped circulation systems, enabling these systems to achieve excellent energy consumption figures.

AcknowledgementsThanks are due to the directors of Star Refrigeration for

permission to publish this paper, and to the colleagues and clients who assisted in collecting the information on installations.


fill line that is located inside of the building or locating the fill connection in a secured area, as opposed to using locking caps. These alternative solutions to keeping refrigerant in the system make more sense for industrial facilities. However, lacking a direct allowance in the code for such alternatives, companies will have to seek relief at the local level via an administrative ruling or an appeal that recognizes these allowances under IMC Section 105 for code modifications or alternative methods of compliance.

Although we were unable to get this provision satisfactorily amended before it found its way into the new code, IIAR plans to work with others in the upcoming code development cycle in an effort to bring some clarity to Section 1101.10 in the

in the preservation of its food. The UN estimates that there is a 40% loss of food from harvest to consumption in the developing world due to the wastage that occurs as the result of an inefficient distribution network. We can bring the latest technology for creating a more dependable food supply. This will result in reduced world hunger, improved yields and a more efficient use of water and land resources. It will also demonstrate that our members are actively involved in solving the problem of hunger. The result will be the across-the-board betterment of the world community.

The partnership with GCCA is not just a matter of altruism. Alliance with GCCA’s influential organizations gives IIAR a louder voice in regulatory issues. Since the combined membership of GCCA is over 3,500 it also gives IIAR a greater reach in the industry with more channels for distributing its publications and training materials. Best of all, it strengthens links with partner organizations while preserving IIAR’s autonomy.

The Global Cold Chain Alliance already has a track record of successes in this area.

Though IIAR has been unabashedly North America centered from its inception, our member companies’ businesses are increasingly expanding to the developing world. This is a trend that’s impossible to ignore. We need to go where the business is. Whatever you do in the industry, you need to follow the end users.”

GCCA already has offices in Guatemala City, Amsterdam, New Delhi, Shanghai, and St. Petersburg with headquarters in Washington, DC. In addition to this infrastructure of offices, GCCA also has networks of local contacts, so that IIAR can hit the ground running.

By joining the Global Cold Chain Alliance, the IIAR and its member companies benefit directly in the expansion of this new technology to the developing countries, according to Badger. The developing world provides a plethora of long-term business opportunities for our members, and the developing world, in turn, will benefit from our assistance

IIAR, GCCA continued from page 7

Code Update continued from page 9

Sight Glass continued from page 22

2012 edition of the IMC to address concerns of the ammonia refrigeration industry.

SPECIAL NOTICE: The International Code Council has recently changed their code development procedures, and there will no longer be two code development cycles between 3-year editions of the codes. Now, ICC will conduct only one cycle between code editions. As a result, any changes desired for the 2012 International Codes must be submitted by June 1, 2009. IIAR members seeking to fix issues involving the International Codes are encouraged to contact IIAR staff as soon as possible so that these matters may be brought to the attention of IIAR’s Code Committee.

2. On new sight glass installations or replacement of existing sight glasses, adhere to your plant’s procedures as well as those provided by the sight glass manufacturers for installation—including torque specifications for retaining rings.a. During installation, if the sight glass itself is dropped or

experiences other shocks or shows any type of damage (chipping, irregularities, imperfections, any other type of surface damage), it should be discarded.

b. Verify that gaskets are correctly installed.3. Take appropriate action to insure that sight glasses are

protected from physical damage as required by IIAR 2-2008 (§12.1.1).

4. Pay particular attention to all phases of operations as well as equipment designs that may create conditions leading

to hydraulic shock events as indicated by piping vibrations and loud noises. Immediate remedies should be sought to eliminate hydraulic shock when it is known to have occurred either intermittently or regularly. For further information, consult IIAR Bulletin 116.

5. Be sure that the design pressure of the sight glass meets or exceeds the maximum allowable working pressure for the vessel it is connected to.

6. Consider removing sight glasses that are no longer in use or needed – especially in high traffic areas. Sight glasses removed should be plugged.

7. At the present time, there appears to be no cause to restrict sight glass materials only to borosilicate glass.

Industrial Refrigeration Systems Energy Efficiency GuidebookDouglas T. Reindl, Ph.D., P.E., Todd B. Jekel, Ph.D., P.E., and James S. Elleson, P.E.Industrial Refrigeration Consortium, University of Wisconsin-Madison

As the price of energy continues to rise, its fiscal impact on food production and storage facilities is of growing global concern. Because the operation of industrial refrigeration systems in these facilities represents a major energy consumer, end-users are increasingly seeking opportunities to improve their efficiency to control plant energy costs.

This Guidebook is intended to be a “desk reference” for refrigeration plant operators, engineers, utility managers, consulting engineers, and contractors with the information needed to identify, evaluate, and implement measures that will improve the energy efficiency of industrial refrigeration systems. In addition to the energy efficiency opportunities, the Guidebook discusses potential barriers that may block implementation of the efficiency improvement strategies. Understanding these barriers is a first step toward removing them and clearing a path for success.

The contents of the Guidebook are included in seven chapters: Chapter 1 – Introduction, Chapter 2 – Overview of Systems and Equipment, Chapter 3 – Evaluating Refrigeration System Performance, Chapter 4 – High-Side Efficiency Improvements, Chapter 5 – Low-Side Efficiency Improvements, Chapter 6 – Compressors, and Chapter 7 – Other Considerations.

The International Institute of Ammonia Refrigeration (IIAR) has entered an agreement with the Industrial Refrigeration Consortium (IRC) to offer two IRC publications for sale through IIAR. The IRC is a collaborative effort between the University of Wisconsin Madison and industry. The publications can be found in the online store at www.iiar.org under Industry Books. Each book sells for $195 plus shipping.

Engineering Safety and Energy Efficiency Guidebooks Available at www.iiar.org

Engineering Safety Relief Systems GuidebookDouglas T. Reindl, Ph.D., P.E. and Todd B. Jekel, Ph.D., P.E.Industrial Refrigeration Consortium, University of Wisconsin-Madison

Relief systems are a critical engineering control aimed at enhancing the safety of industrial refrigeration systems. In 2000, ASHRAE made significant changes to the calculations required for sizing vent lines for refrigeration-related safety relief systems in its Standard 15, Safety Standard for Refrigeration Systems. These changes coupled with PSM requirements for end-users to have documentation for the design and design basis of their safety relief systems motivated the development of this Guidebook.

The Engineering Safety Relief Systems Guidebook:• Providesbackgroundontheoperatingprinciplesof

pressure relief valves.• Reviewscodesandstandardsthatrelatetopressure

relief systems.• Introducesmethodsforsizingpressurereliefvalvesfor

equipment other than vessels and positive displacement compressors.

• Presentsadetailedapproachtoengineeringsafetyrelief vent piping for manifolded (headered) relief systems.

• Introducesmethodsforestimatinginletlossestopressurerelief devices.

• Illustratestheapplicationofmethodspresentedusingexamples.

If you are involved with evaluating existing relief systems for compliance, documenting the design and design basis for new and existing relief systems, or engineering new relief systems, this Guidebook is for you.

for sizing vent lines for refrigeration-related safety

energy consumer, end-users are increasingly seeking opportunities to improve their

University of Wisconsin-Madison

global concern. Because the operation of industrial refrigeration systems in these facilities represents a major energy consumer, end-users

University of Wisconsin-Madison

global concern. Because the operation of industrial refrigeration systems in these facilities represents a major energy consumer, end-users

GEA Refrigeration

GEA FES, Inc.3475 Board Rd., York, Pennsylvania 17406Tel: 800-888-4337Tel: 717-767-6411Fax: 717-764-3627Email: [email protected]

Microprocessor Control SystemKEEPING YOU IN “TOUCH” WITH YOUR REFRIGERATION SYSTEM

GEA FES, Inc.

Global Cold Chain Alliance in the IIAR…The Cold

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