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CondenserMay 2008

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

Condenser | May 2008 | A Publication of the International Institute of Ammonia Refrigeration 1

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

Member Price: $150 $100/copy Non-Member Price: $200 $150/copy

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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. A one stop reference book for the ammonia refrigeration industry. 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 in this book. Other chapters focus on General Information, Properties of Ammonia, Ammonia and the Environment, 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 Corrosion Cracking 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 sections Updated 2004 RMP revisions incorporated Revised Appendix A table values re-calculated using REFPROP Version 7

The Ammonia Data Book, 2nd EditionSave $50 per copy

Order Your Copy Today Before the Price Increase Takes effect July 1, 2008

2 Condenser | May 2008 | A Publication of the International Institute of Ammonia Refrigeration

International Institute of Ammonia Refrigeration

1110 North Glebe Road, Suite 250

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]

Technical Editor | Kirsten McNeil | [email protected]

Layout & Design | Laura Dugan

Illustrator | Ron Curameng

CONTENTS 1 Ammonia Data Book – 2nd Edition

2 What Do You Think…?

3 Chair’s Message

4 Discount Dues Program

5 Uncle Andy Wants You!

6 Membership Form

7 IIAR Code Advocacy Update

8 21st Century Approach to Refrigeration Safety Replaces Emergency Control Boxes

12 Ammonia Plant Saves Power for South African Supermarket

14 IIAR Research Project on Stress Corrosion Cracking

16 DHS Update

18 Learn More About www.iiar.org

20 Relief Valve Testing

22 Conference Collage

24 IIAR Members

25 IIAR Board/Kent Anderson

27 Sustainability Beyond Energy Efficiency – Part 2

29 2008 Conference/Call For Papers

30 Andy Ammonia Winner/ Technical Paper Abstracts

34 Ammonia Safety Day

36 ARF

38 IIAR on Display in Shanghai

45 News & Notes

With this issue of the Condenser, we introduce a new feature. We’d like to hear your ideas and commentaries on issues

and trends in industrial refrigeration. In this column, we will briefly examine a trend or idea and ask for your feedback, your thoughts, and your observations.

Is Ammonia the Right Answer? Again?Those of us who have long been committed to

anhydrous ammonia as a refrigerant for large plant systems typically regard it as “the right answer” for all of the obvious reasons: cost, energy efficiency, lower operational pressures, and environmental friendliness. Could it be that the time has come to press for a return to ammonia in other systems as well?

I was recently invited to participate in an industry think tank that is committed to reducing the carbon footprint of producing and delivering a gallon of milk to the consumer. The task is being broken down into crop production, milk production, transport to the plant, processing, packaging, distribution, and sale. I was surprised to see that refrigerants were listed as an appreciable impact under distribution, but not under processing. It was explained to me that this is the case because almost all milk is processed using ammonia as a refrigerant, but transported using HFCs. I learned that while HFCs have a much lower carbon impact than CFCs or HCFCs, they still have a considerable influence with a carbon effect per gram much greater than that of CO2, methane, or nitrous oxide. Research indicates that recovery regulations and practices notwithstanding, refrigerant loss from transport systems is significant.

Could it be that the time has come for the food industry and the IIAR to work with the large purveyors of transport refrigeration to shift this segment to ammonia? I would think that any additional cost in making the materials of construction of such units compatible with ammonia would be offset by lower refrigerant cost and fuel usage while at the same time benefiting the environment. Ammonia is also used routinely in RV refrigerators. I have heard anecdotal reports that some vehicle air conditioning systems in cars produced by Pacific Rim countries for domestic use employ ammonia while those built for export to the US use HFCs.

I would be interested to hear the thoughts of others both in the food industry and from companies that produce transport refrigeration units as to both the potential demand and feasibility of building these units for ammonia. It may be time for a change.

David E. Lattan Vice President, Engineering Prairie Farms Dairy, Inc.

What Do You Think…


attend one of these sessions if it is scheduled for your area, in order to learn more about the One Plan.

We are also launching a major new membership initiative within the pages of this issue of the Condenser. We are offering a Rewards Program for companies that recruit new regular members. Companies that successfully refer new members to IIAR can redeem their points for a free registration to the IIAR Annual Meeting. You’ll learn more about that new program on page 5. We are also making modifications to the Associate Member Dues Discount Program. Since it was introduced a couple of years ago, we have seen our IIAR membership grow by almost 20%. The new program offers additional incentives for companies to participate in this program.

On page 1 of this issue of the Condenser, you’ll see an ad for the new Ammonia Data Book, Second Edition. To complement our industry marketing strategy promoting the environmental advantages of natural refrigerants, we have added the subtitle, The Profile of a Sustainable Refrigerant. The Data Book was originally produced more than 15 years ago, and was updated about ten years ago. Don Fenton at Kansas State University and Doug Reindl at the University of Wisconsin did most of the work on this latest revision. We sincerely appreciate their efforts.

These are just a few of the new things you will see in the weeks and months ahead from IIAR. The success of this organization, the growth of our membership and the quality of our technical publications are all dependent on membership involvement. I urge you: Join a Committee; Volunteer to write a Technical Paper; or conduct a workshop at the annual meeting. Or, you could write an article for this publication. I can tell you first hand, the rewards of participation go well beyond the obvious.

The challenge of providing legislative and regulatory advocacy on behalf of our industry is ongoing. In addition, this industry is truly global and no matter where we live we cannot ignore the potential impact of decisions and events in other countries, particularly those with large economies. We will continually monitor for issues which potentially affect the interests of our Members and respond appropriately as and when necessary. This is another example of where Members with unique knowledge of local affairs can provide invaluable help by volunteering to work on the relevant committees and on Task Force assignments when these advocacy opportunities occur.

We hope you find this new look Condenser helpful and interesting. Come July, please don’t forget to renew your membership if you have not already done so!

By Brian Marriott

Greetings! These are exciting times for IIAR. Our committees have been very active and you will see the results of their efforts in the coming months.

One of the most important things that IIAR does is maintain our industry Standards. The Standards Review Committee has been busy finalizing the new edition of American National Standard for Equipment, Design & Installation of Ammonia Mechanical Refrigerating Systems—ANSI/IIAR 2-2008. It has been through public review and approval by IIAR, and we are just waiting for ANSI approval which we expect in the next few weeks. The new ANSI/IIAR 2-2008 should be available by the end of the summer.

You can get a preview of one of the major changes in the new Standard in this issue of the Condenser. Our cover story focuses on the replacement of the Emergency Control Box with the Emergency Pressure Control System. This has been a goal of the Code Committee dating back to the days when Chuck Kohlenberger was chair of that committee. Since then, Bob deVillez, Hank Saye, Larry Basel and John Collins have all championed the cause. Our code consultant Jeff Shapiro also deserves a note of thanks. He has been the man in the trenches who has done a lot of the heavy lifting in this effort. We sincerely appreciate his efforts on our behalf.

I’m very pleased to report that our efforts over the past few years to strengthen partnerships we have with our sister organizations are paying off. IIAR President Bruce Badger just recently returned from another visit to China where he made a presentation on ammonia/CO2 systems at China Refrigeration 2008 in Shanghai. A total of 16 IIAR members exhibited at that event. You’ll find a complete report on page 38.

For several years we have supported one day IIAR mini-meetings in Mexico which have disseminated some excellent technical material in Spanish to the local IIAR members and invited guests. These meetings have been made possible through generous sponsorship from several IIAR member companies. I would like to thank these sponsors and thank Adolfo Blasquez for tirelessly spearheading this ongoing initiative. By the time you read this edition of the Condenser we will have conducted this years session which adds a second day of hands-on Ammonia Safety Training in conjunction with ASTI. I extend our thanks to Gary Smith, President of ASTI and his staff for making this valuable addition to the program possible.

This ASTI activity is in addition to the Safety Day scheduled for June 18th in Baltimore, Maryland (see article on page 34). More of these ASTI Safety Days will be held in various parts of the US over the coming months and I would encourage all of you to

CHAIR’S MESSAGE


list and contact information. By designating a single point of contact and paying from a single invoice, the company will save $1,250 off the regular associate member fees. If the company chooses to pay from multiple invoices, the savings will only be $750. Example:

No Single Contact/No Dues Discount1 Reg. Member + 15 Associate Members =$275 X 15 = $4,125Total = $4,125 + (1) Regular Member

Single Point of Contact/Single Invoice1 Reg. Member + 15 Associates = $500 Savings$275 X 5 = $1,375$150 X 10 = $1,500Total = $2,875Savings $1,250

Single Point of Contact/Multiple Invoices1 Reg. Member + 15 Associate Members =$275 X 5 = $1,375$200 X 10 = $2,000Total = $3,375 + (1) Regular MemberSavings $750

The new Dues Discount Program provides each Company with greater flexibility and advantages of a lower rate structure based upon a single invoice for the regular and associate members selected to be in the Dues Discount Program. We encourage you to review this new program and take advantage of the reduced associate member rates as well as the flexibility of the program. Should you have any questions please contact Belinda Ross, Director of Member Services at 703/312-4200.

New Additional Savings Added to Associate Dues Discount Program

IIAR has modified the popular Dues Discount Program. The changes streamline the process and provide members who take advantage of the program with additional savings.Under the new program, companies that designate a single

point of contact and pay for all memberships from a single invoice will enjoy even greater savings than they receive under the current plan. By paying from a single invoice, a company can save hundreds, depending on the number of associate members you designate for your company. Here is how the new system works: The individual designated as the single point of contact for a Company is responsible for payment of the membership dues and all communication with the IIAR Membership Director regarding both regular and associate member registration. The purpose of having one corporate contact is to facilitate communication.

Payment for the single Discount Dues Program invoice can be made by check or wire transfer.

Payment of the company invoice for the Dues Discount participants must be received on or before September 15, 2008. The names of all company employees who will be associate members of IIAR need not be identified immediately; however, the entire payment must be made prior to the deadline for all of the participants that the company expects to include in the Dues Discount Program.

For example: a company may indicate it plans to have one corporate regular member and 15 associate members. The single point of contact may be the Regular Member or an Executive Assistant who will coordinate the IIAR member

DUES DISCOUNT PROGRAM


you to list your company as the Recruiting Sponsor, so that you will receive credit when the new member joins. Packets may be ordered at no charge by contacting IIAR Headquarters at [email protected].

Some examples of how this “Membership Recruiting Packet” might be used include; a contractor uses the packet to introduce IIAR when working with an end-user on a project, a manufacturer presents the packet to a contractor during a sales call who is not a member of IIAR, or an IIAR member end-user uses a packet to promote IIAR to other end-users known through other industry or trade organizations. Use of this IIAR recruiting packet helps portray your company as an involved and informed participant in the industrial refrigeration industry.

On behalf of IIAR, thank you for your efforts to make our organization stronger through the recruitment of new members. We look forward to seeing your company’s name on the Member Recruitment Recognition Board at the 2009 IIAR Conference in Dallas.

IIAR Membership Recruiting Incentive ProgramIIAR Members are encouraged to recruit new regular members to join the International Institute of Ammonia Refrigeration. For each new successful recruit, IIAR Member companies will be credited with points that may be cashed for a reward. The following rules govern the IIAR Membership Recruiting Incentive program.

Recruiting “sponsor” companies must be IIAR members and may be any IIAR membership category.

New Members must submit an application form which includes the name of the “sponsor” company at the time of submittal.

The “sponsor” company will receive credit for the new recruit upon approval of the membership application by the IIAR Board of Directors.

Sponsor credit will only be given for each new regular member from a company that has not been a Regular IIAR Member during the previous three membership years.

For each three (3) credits a “sponsor” company receives: Mention in the Condenser, on the IIAR website, and on signage at the annual convention, plus one (1) free conference registration.

By Tim Facius, Membership Recruitment Task Force Chair

It is with great pleasure that we announce a new program at IIAR to encourage the recruitment of new members into our organization. As you know, active and involved members

are the life-blood of IIAR. Our current membership is doing an excellent job of helping IIAR achieve its vision. The addition of NEW REGULAR MEMBERS will make the organization even more vital and stronger financially. It empowers IIAR to achieve even higher levels of success in leading the industrial refrigeration market, and contributes to the vibrancy of the organization.

You are a key element in this new campaign.IIAR membership has grown dramatically in the past twenty

years. In the early 1990s, IIAR had about 600 members. At last count, IIAR membership surpassed 1,800. That’s a 300% increase over the past 18 years. A significant portion of that growth occurred because IIAR members played a key roll in the success of the campaign. Contractors, Engineers and Manufacturers personally engaged in the recruiting process to encourage customers and colleagues to join IIAR.

We are asking you and your company to contribute to this important IIAR goal of broadening the membership of our organization. Besides the benefits you realize as IIAR becomes an even larger, more vibrant organization; there are additional direct benefits to your company.

The new incentive program functions in a fashion similar to a frequent flyer program. Each time a company refers a new regular member who joins IIAR and is approved by the IIAR Board of Directors, the referring company receives points that can be cashed in against conference registration. The Membership Recruiting Incentive Program rewards your company with a free registration to the IIAR annual conference for every three (3) Regular Members you recruit during a given membership year. There will also be additional recognition for your company. (See box)

A “Membership Recruiting Packet” has been developed to assist you in your efforts. It consists of a Member Benefits Brochure, a Membership Application, as well as other flyers and brochures promoting the IIAR Annual Meeting, website and publications. The Membership Application has a line for

Uncle Andy Wants You!


(Please type or print clearly)

Company Name ID#

Individual Representative Title

Address

City State/Province

Country Zip/Postal Code

Area Code & Telephone Number Fax Number

PE License (Engineers Only) Date of Application

Email Address URL: http://

Recruited by IIAR Member Company:

Membership Categories and Dues (Dues are per membership year. Membership Year is July 1–June 30)

Academic . . . . . . . . . . . . . . . . . . . . . . . . .$ 100 . . . . . . . . (Instructors, professors, researchers, etc.)

Affiliate . . . . . . . . . . . . . . . . . . . . . . . . . .$ 150 . . . . . . . . (Code groups, insurance companies, regulatory agencies)

Contractor . . . . . . . . . . . . . . . . . . . . . . . .$ 695 . . . . . . . . (Principle business is installation/service/maintenance of refrigeration systems)

Engineer . . . . . . . . . . . . . . . . . . . . . . . . .$ 695 . . . . . . . . (Principle business is design of refrigeration systems)

End User I . . . . . . . . . . . . . . . . . . . . . . . .$ 695 . . . . . . . . ( User of ammonia refrigeration, e.g., refrigerated warehouse, food processor, etc.,

multiple facilities over 10,000 pounds)

End User II . . . . . . . . . . . . . . . . . . . . . . . .$ 395 . . . . . . . . (User of ammonia refrigeration, single facility with less than 10,000 pounds of ammonia)

International Organization . . . . . . . . . .$ 695 . . . . . . . . (International Trade Association)

Manufacturer . . . . . . . . . . . . . . . . . . . . .$ 975 . . . . . . . . (Manufacturers of ammonia/industrial refrigeration equipment/components)

Manufacturer’s Representative . . . . .$ 695 . . . . . . . . (Principle business is the marketing/sales of industrial refrigeration equipment)

Other . . . . . . . . . . . . . . . . . . . . . . . . . . . .$ 695 . . . . . . . . (i.e. Utility companies, Consultants, Trainers)

Retired . . . . . . . . . . . . . . . . . . . . . . . . . . .$ 100 . . . . . . . . (Retired person no longer gainfully employed in the industry on a full-time basis)

Student . . . . . . . . . . . . . . . . . . . . . . . . . .$ 25 . . . . . . . . (Please provide name of academic institution where enrolled & photo identification)

Wholesaler . . . . . . . . . . . . . . . . . . . . . . .$ 695 . . . . . . . . (Wholesaler or supplier of ammonia)

Associate Members . . . . . . . . . . . . . . . .$ 275 . . . . . . . . (To qualify for an Associate Membership, your company must already have a Regular

Membership. An Associate Member is an employee of a Member Company other

than the voting representative. There are no restrictions to the number of Associate

Members per company or to the geographical locations.)

Associate members must check one:

Contractor End User I End User II Engineer Manufacturer Manufacturer’s Representative Other Wholesaler

Please identify Regular Member Company and Representative: ____________________________________________________________________

Send Membership Application with Payment to:

Or Fax Credit Card Payment to: 703-312-0065 (fax)

MasterCard Card Number:___________________________________________________ Exp. Date: __________

Signature: _________________________________________________________ Date:__________

Should an individual leave the company, the IIAR Membership stays with the company unless the individual has personally paid for the membership. Wholly owned subsidiaries of IIAR Regular Members are considered to be independent companies and are to make separate applications for Regular Membership. Membership dues are not deductible as a charitable expense. They may be deductible as a business expense.

INTERNATIONAL INSTITUTE OF AMMONIA REFRIGERATION

MEMBERSHIP APPLICATION


machinery room ventilation requirements.” No statistical, technical or anecdotal basis was offered to justify the additional controls on machinery room ventilation system discharge. Nevertheless, the entire rewrite, including this section, was eventually approved by the International Conference of Building Officials (ICBO) membership at the time, and the provisions were duplicated into the Uniform Fire Code (UFC).

Presumably, the basis to justify adding this new requirement to the Uniform codes might have been parity with the general hazardous materials regulations for toxic gases in UFC Article 80; however, because Article 80 never required ventilation treatment for local exhaust systems in areas where ammonia is stored or used (because ammonia is not classified by fire codes as a toxic hazardous material), it makes no sense for ammonia refrigeration regulations to be more restrictive than general hazardous materials regulations for the same material.

During the drafting process for the International codes, the requirement for treatment of machinery room ventilation was initially dropped when the UMC was merged into the International Mechanical Code (IMC) and the UFC was merged into the IFC. At the time, the goal was to make the IMC and the IFC consistent with provisions in ASHRAE 15, which is the American National Standards Institute (ANSI) recognized standard governing refrigeration system safety, and ASHRAE 15 does not contain any requirement for treatment of exhaust from machinery room ventilation systems.

In the public comment process affecting the final draft of the IFC, a proposal was made to reinstate some of the old UFC provisions into the IFC, and the requirement related to treatment of machinery room exhaust found its way back into the code.

Is It Justified?Refrigeration plants in the Central and Eastern portions of the

U.S. were not required by the legacy fire or mechanical codes previously used in those regions to provide ventilation treatment systems. Justification for requiring new plants in these areas to now be burdened with the ventilation treatment requirement is not evident. Likewise, there is no apparent justification for maintaining this requirement elsewhere, given that there was no justification to support the requirement in the first place.

It’s noteworthy that IIAR has studied the complete database on releases associated with ammonia refrigeration on file with EPA, and no incident could be identified where ammonia

Are Ventilation Treatment Systems All Washed Up?

By Jeff Shapiro, International Code Consultants

It appears the requirement for scrubbing ventilation exhaust may be scrubbed from the codes. One topic in model codes receiving a lot of attention these days is the requirement

for air exhausted from ammonia refrigeration machinery rooms to be “scrubbed” prior to release to atmosphere. The regulation establishing this requirement dates back to the 1994 Uniform Mechanical Code (UMC), and it requires ventilation discharges capable of exceeding either 1) 25 percent of the lower flammable limit (LFL), or 2) 50 percent of the concentration that would be immediately dangerous to life and health (IDLH) to be provided with an approved treatment system to reduce discharge concentrations to those values or lower. With respect to ammonia, the triggering value is 50 percent of the IDLH, or 150 parts-per-million.

Because there are many machine room failure scenarios capable of exceeding this concentration, one might expect that we’d be installing scrubbers in lots of ammonia refrigeration facilities, but this is not the case. For reasons unknown, the requirement has been largely overlooked by designers and code enforcers…until recently.

When the U.S. underwent an overhaul of our model code system in 2000, the ventilation scrubbing issue began to capture increasing attention when it was conveyed from the Uniform fire and mechanical codes into the International Fire Code, which is used in more than 40 states. In what seemed like a sudden change to many in the ammonia refrigeration industry, jurisdictions began enforcing the ventilation treatment requirement in new facilities, and solutions ranging from full-blown scrubber systems all the way down to blowing machine room exhaust ducts into condenser water were applied.

With many people questioning the value of treating machine room exhaust, the industry turned to IIAR for leadership in evaluating the issue and crafting a solution. IIAR’s research into this requirement ultimately discovered that the requirement was never justified when it was originally added to the code almost 15 years ago.

The HistoryThe treatment requirement was added as part of a

complete 1994 rewrite of the UMC chapter on mechanical refrigeration, and the entire substantiation for the new provision offered by the proponent of this change was “Gives specific

IIAR CODE ADVOCACY UPDATE

Code Update continued on page 33


of ammonia into the local community. But wait, firefighters arrive on the scene, open a special box and operate a magic valve. Miraculously, in a matter of minutes, the entire ammonia charge dumps into water, and firefighters have saved the day! Who wouldn’t like that?

While those of us who specialize in refrigeration systems today recognize that a fire scenario wouldn’t play out as described above, such knowledge would have been less common 40 years ago, and it would not have affected the development of the first model fire code. At the time, fire codes were developed with little input from industry.

Years later, the emergency control box requirement became a well entrenched code requirement, which became further legitimized when ASHRAE and IIAR standards added model figures to provide design and installation guidance for this equipment. Although the intent of including these figures was only to help designers when a box was required by local authorities, code officials latched on to the industry figures as confirmation of the control box’s validity. After all, from the fire service’s perspective, why would industry standards tell you how to design an emergency control box if the concept wasn’t valid?

Charting a Course for ChangeIn 1999, the IIAR Board of Directors initiated a

comprehensive program to review and update model code requirements related to ammonia refrigeration. Among many issues identified for study was a requirement in some codes

By Jeffrey Shapiro, International Code Consultants

Four decades ago, fire chiefs in the Western U.S. completed and published the nation’s first model fire prevention code, the Uniform

Fire Code, culminating a multi-year effort to standardize fire-safety regulations over large geographic areas. The feat was somewhat remarkable, given that the new code was written on typewriters, and correspondence was circulated by U.S. mail. Modern technology used to develop today’s codes, such as computers, fax machines, email and inexpensive long distance phone calls were many years away.

At the time, refrigeration systems were still operating in the days of analog. Skilled individuals used pressure gauges, hand valves and instinct to monitor and maintain proper operation. Modern technology used to safely operate systems today, such as programmable logic controllers, refrigerant gas detectors and other electronic sensing and control equipment had yet to be invented.

By today’s standards, emergency response to hazardous materials incidents was also somewhat archaic. Emergency responders in the late-1960’s received little, if any, training on hazardous materials or systems that used them. The focus was on fires and firefighting. Nevertheless, when a hazardous materials accident happened, the local fire department was the agency who got the call for help. While poorly equipped to deal with these types of incidents, they’d do their best to protect lives and property.

With all of this in mind, it is easy to appreciate how the concept of an emergency control box for ammonia refrigeration systems would have appealed to fire chiefs and fire marshals who wrote the new code. Imagine the thought of a refrigerated warehouse on fire, threatening a release

21st Century Approach to Refrigeration Safety Replaces

Emergency Control Boxes

EPCS continued on page 10


the fire vents through the roof (which will happen quickly with today’s lightweight construction techniques).

5. Computerized monitoring and control systems used today make a major system malfunction much less likely today than 40 years ago, when the emergency control box requirement was first added to the code. Times change, and codes need to change to keep up with benefits of improving technology.

6. An informal survey of fire officials found that the operation and capabilities of emergency control boxes were not well understood by emergency responders. In addition, the control valves were rarely, if ever, tested, exercised or used. Lacking training in the process of mechanical refrigeration, the function and operation of emergency control valves, and confidence in the reliability of equipment in control boxes, emergency responders were generally uncomfortable with the thought of using this equipment.

7. With the value of ammonia as an ingredient in explosive compounds and illegal drugs, placing a live valve box on the exterior of a building, where ammonia could be extracted from a refrigeration system, was deemed to present an unnecessary security threat.

Changing Model Codes is No Easy TaskEven with a well-developed substantiation, citing many

of the reasons listed above, the challenge of removing the emergency control box requirement from model codes proved to be a significant undertaking for several reasons, not the least of which was the fact that the requirement had a 40-year history in model codes. Many regulators involved in writing today’s codes had literally grown up with the control box as a mainstay requirement for refrigeration safety, and changing the codes required an unprecedented outreach effort by the

mandating installation of an emergency control box on new ammonia refrigeration systems.

Before discussing the merits, or lack thereof, of emergency control boxes, it must be stated that, as a matter of policy, safety is fundamental to IIAR. Accordingly, accepting a position that promoted removal of a device commonly thought to benefit emergency responders didn’t come easy. However, after studying the issue, it became clear that emergency control boxes were neither an effective nor necessary safety feature.

Some of the considerations that led to this conclusion were:1. Control boxes were only required in certain regions of

the country under the old model code system, which divided the country up under three regional fire codes. Nevertheless, there was no evidence to suggest that areas of the country where emergency control boxes were not being provided suffered any adverse consequences based on the lack of this equipment.

2. Only ammonia systems associated with refrigeration processes were required by codes to have an emergency control box. Other uses of ammonia, such as industrial processes, water treatment, etc. did not require this equipment.

3. “Dump” valves in the box aren’t really capable of evacuating a refrigeration system. Required valves basically add a small evaporator to each major vessel, and once compressors have been shut off, most liquid ammonia will remain in the system, as evaporation eventually equalizes ammonia in the system with atmospheric pressure.

4. Refrigerated warehouses built today are equipped with fire sprinkler systems, and machinery rooms are prohibited from containing combustible storage not associated with system operation. This represents a significant reduction in fire risk as compared to buildings built 40 years ago. Given the large volume of fire required to cause an ammonia vessel to vent, such a fire could only occur as a result of a sprinkler system failure, and in that case, ammonia will be released through emergency vents and will be consumed by the fire plume once

Enhancements in refrigeration system control equipment associated with new technologies now make it possible to provide an automatic emergency control system to replace key functions of the traditional manual emergency control box, like the one shown above. Such automatic controls, now required by fire codes, have made manual emergency control boxes obsolete.

The security required for the Fire Control Box has grown far beyond the traditional padlock due to growing concerns from the Drug Enforcement Administration and the Department of Homeland Security.


and fully automating an additional layer of safety controls on refrigeration systems to reduce the risk of having an over-pressurized system operate emergency pressure relief valves.

Key elements of an EPCS include an overpressure sensing-shutoff system that is fully independent of and redundant to other systems, such as compressor cut-out controls or programmable logic controllers that normally manage system operation. In the event of a severe overpressure condition, where the pressure exceeds limits that should have been intercepted by other safety controls, EPCS sensors provide a last line of defense to stop compressors before ammonia is released from pressure relief valves. In addition, the EPCS includes a high-to-low cross-over valve that will immediately and automatically activate to begin dropping high-side pressure. Experimentation with the concept has shown that, left unattended, the system will eventually equalize across the valve at a pressure marginally above the starting low-side pressure.

Key aspects of requirements for EPCS components found in fire codes and the basis for these requirements are as follows:

Automatic crossover valves. Each high and intermediate pressure zone in a refrigeration system will be required to have a single automatic valve providing a crossover connection to a lower pressure zone. The requirement for a single crossover valve between systems was based on the traditional industry practice of providing a single manual crossover valve between each set of zones in an emergency control box.

ammonia refrigeration industry to educate code officials on why emergency control boxes didn’t do what they were thought to. To address this hurdle, IIAR produced a seminar aimed at educating code officials on the fundamentals of refrigeration, the properties of ammonia and the efficacy, or lack thereof, of emergency control boxes. This program has since been presented to more than 1,000 seminar attendees.

Although IIAR was ultimately successful in educating code officials to understand the limitations of emergency control boxes, many remained unwilling to support removal of the requirement from codes unless the industry volunteered a new and better approach. IIAR responded to this challenge by breaking down the capabilities of a control box into two categories. First, control boxes were provided with “cross-over” valves capable of internally relieving ammonia from high-side vessels to low-side vessels, keeping all of the ammonia within a system. Second, control boxes were provided with “dump” valves for the purpose of releasing ammonia into a water tank, diffuser or to atmosphere.

Birth of the “Emergency Pressure Control System”Conceptually, industry experts working on IIAR’s Code

Committee agreed that providing a means to relieve ammonia across zones within a system was far less objectionable than providing a means to release ammonia from the system, and the point of compromise with fire officials was to eliminate “dump” valves and create an automated system to replace the manual “cross-over” valves in emergency control boxes. The new approach was dubbed an “emergency pressure control system,” or EPCS.

The EPCS approach ultimately established common ground between the industry and fire code officials with respect to changing model codes to eliminate emergency control boxes and the “dump” valves that they housed. This level of agreement was a critical element of getting codes to change, and even industry experts who believed that emergency control boxes should just go away ultimately recognized that such an outcome wasn’t plausible.

So, with the coming of the 2009 editions of the Uniform Fire Code, Uniform Mechanical Code, International Fire Code and International Mechanical Code, all references to emergency control boxes will disappear from model codes, replaced by requirements provide an EPCS. Shortly thereafter, new editions of IIAR 2 and ASHRAE 15 will drop provisions related to emergency control boxes as well, and IIAR 2 will provide comprehensive EPCS design guidance.

Key elements of the new EPCS approachAs mentioned above, an EPCS is basically a system that

automates the “cross-over” function previously provided by manual valves in an emergency control box. The advantages of an EPCS over control boxes include taking away manual valves from possible access by untrained responders or thieves EPCS continued on page 42

Interior of an emergency control box for an ammonia refrigeration system.


The three partners (Fitos Englezakis, Stavros Phieros and Daleep Baijnath) who built the Sebokeng SuperSpar also own the SuperSpar in Alexandra, Johannesburg and are very aware of the high maintenance and power costs of having a supermarket with a refrigeration plant of 10–25 air cooled condensing units.

As the owner of other Spar franchises has many years of experience with ammonia refrigeration and it was this experience that prompted him to ask Bob Vuletic of Multistage Cooling to come up with a more environmentally friendly refrigeration system for the new Sebokeng SuperSpar.

The initial layout for Sebokeng had 27 air cooled condensing units charged with HCFC refrigerant. After careful consideration, a new layout having a central two stage ammonia refrigeration plant with 3 reciprocating compressors and an ammonia/glycol plate heat exchanger was proposed and accepted. The low stage compressor operates at a suction of –18°C and the high stage at a suction of 0°C and 33°C condensing temperature. The thermosyphon ammonia systems cool the propylene glycol solution to –14°C for the cabinets and cold room and cools water to 6°C for the air handling units for the air conditioning of trading areas.

The cooled glycol is pumped to headers with 18 supply take offs, each with a 3 way

By John Ackermann

The Spar group is one of the Big Four supermarket groups in South Africa. Spar supermarkets are franchised to the owner in one of three sizes, KwikSpar (small), Spar

Supermarket (medium) and SuperSpar (large). One of the newest of the more than 800 franchised stores, located in Sebokeng, the largest of the six townships in Vaal Triangle and located beyond Evaton on the Johannesburg/Vereeniging road, has an ammonia refrigeration system.

The Sebokeng SuperSpar opened its doors for trading in November 2007. It is the first in the Spar group to have an ammonia refrigeration plant. Temperatures in all the chill cabinets and vending areas are maintained by a central refrigeration plant with ammonia as the primary refrigerant and a propylene glycol solution as the secondary. The entire ammonia charge of 680kg is contained in the plant room and 3150 litres of propylene glycol is circulated within the supermarket and working areas. As a result, any unfortunate ammonia leak will be confined to the plant room area and not pose a danger to the supermarket working area or shoppers.

This supermarket offers a range of pre-prepared and fresh foods. Inside the machinery room.

For South African Supermarket


We asked Daleep why the decision was made to build such a large SuperSpar in Sebokeng, which is approximately 10km from Vereeniging and 40km from Johannesburg.

He explained, “Sebokeng is a well established and respected community of approximately 120,000 households. Many of the properties are paid for and this impacts on increasing the buying power of the community. With many of the residents being of mature age, Sebokeng is relatively crime free and this is a big plus for the area. The trading in our store has been encouraging and we foresee opening a second Spar in Sebokeng and adding Tops Liquor and Build It outlets to the present store. We are expecting trade to increase when the other tenants, eg. banks and service providers move into the shopping mall, as we are presently the main tenant and do not benefit much from the passing trade to other tenants in the mall.”

Maintaining the cold chain of perishables at Sebokeng is a priority. The temperature in the receiving bay is controlled and product is transferred to cabinets with the least delays. All cabinet temperatures are checked and entered in a fridge control book on a regular basis during the trading hours of 08h00 to 20h00, 7 days a week. The opening manager monitors the checks during the early part of the day and the closing manager during the later part. Remedial action is taken when any abnormal temperatures are noted.

“Power savings are now an absolute necessity because of the pending increase in the Eskom power tariffs and to reduce the national consumption to prevent outages. We have invested in a large generator to cope with outages, but running a diesel generator is very expensive and the lower power consumption of the ammonia refrigeration plant is then of even greater importance as we will see it directly in the diesel consumption,” concluded Daleep.

(This article is reprinted with permission from The Cold Link.)

valve to regulate cabinet temperatures, or room temperature, according to set levels, by mixing supply and return glycol. The plant has a total of 36 stainless steel ball valves in the different glycol branch supply and return lines.

The low stage compressor has a cooling capacity of 200kW and the high stage compressor a cooling capacity of 300kW. The third compressor is piped to operate either as the low stage or high stage compressor and the total installed compressor’s electrical power amounts to 244kW.

A total of 6 air cooled condensing units charged with 200kg of R404A (not part of the Multistage Cooling contract), provides cooling for the low temperature cabinets and some propriety upright bottle cabinets. Air cooled condensing units were preferred for the low temperature as the relatively small cooling load was not economically viable for an ammonia system and would have also required a costly low temperature solution as the secondary refrigerant.

“Our Sebokeng store has 2680m2 of trading area and 1200m2 of back up area. Although the Sebokeng store is larger than our Alexander store, which opened in June 2007, the power consumption is approximately 40% less. This power saving represents a considerable reduction in our operating costs and at the same time, we also have a refrigeration system which is much more environmentally friendly. There is also no threat of ammonia being phased out as it has a zero Global Warming Potential (GWP) and zero Ozone Depleting Potentional (ODP),” said Daleep Baijnath, Operations Director.

Compressor packages.

Receiver on roof.


loop for an electricity generation plant, and is not entirely applicable to industrial refrigeration systems. In the discussion after Dr Cracknell’s paper the audience confirmed in general that they had almost no direct experience of SCC in refrigeration systems. The ASM Materials Handbook published in 1986 states that “the problem of SCC of steel in ammonia has disappeared in the United States.” In 1996 in Germany an industry report concluded that SCC was not relevant to refrigeration systems, stating that “No evidence was found in the literature on refrigeration technology and additionally in further journals that major failures of ammonia refrigeration systems were possibly connected to SCC…therefore it can be concluded that no immediate requirement for researching SCC exists, as faults in refrigeration systems due to SCC have not been reported.”

Where failures were recognised as stress corrosion cracking in refrigeration vessels they were usually in high pressure receivers. A few cases in shell and tube condensers had also been experienced, but the general consensus in discussion with industry experts seemed to be that the failures only occurred in vessels on the high pressure side of the system.

In many of the reports produced by the extensive research into SCC failures in ammonia spheres, holding tanks and nurse tanks, post-weld heat treatment of welded vessels was recommended. Most industry experts seemed to have assumed that the benefit provided by this treatment was the reduction of stress in the vessel shell.

The connection between oxygen and SCC seems quite obvious, and so it was generally understood that keeping oxygen levels low would be a good precaution. This advice can be found in many industry standards, including IIAR Bulletin 110. However, there is no discussion in any of the literature of

By Andy Pearson, Star Refrigeration

At the annual meeting in March, the Research Committee unanimously approved the adoption of a research proposal submitted by the Danish Technological Institute

of Aarhus, Denmark and titled “Stress Corrosion Cracking.” In this article for The Condenser, Andy Pearson describes the background to the project proposal and explains why the time is right for IIAR to take the lead in a reassessment of stress corrosion cracking as it relates to the ammonia refrigeration industry.

In April 2005 an ammonia leak developed on a water chiller at a dairy near Leeds, England. The plant had been supplied by Star Refrigeration, and we were on site at the time of the failure installing phase 2 of the chilled water project; adding a third spray chiller to the two existing units which had been in service for about 18 months. The leak was not a catastrophic failure, but took the form of a short crack in the shell of the evaporator, close to the shell-to-tubesheet weld, which led to a leak of ammonia vapour in sufficient quantity to trigger the machinery room ammonia alarm. Extensive analysis of samples from the shell of the failed evaporator concluded without doubt that this was a stress corrosion crack. This finding led to a comprehensive re-evaluation of all that had been printed about SCC in ammonia plants over the past 50 years and brought us to an inescapable conclusion: most of what the ammonia refrigeration industry thought that it knew about SCC was contradicted by this failure.

What did we think we knew?

All of the academic research into SCC in ammonia systems has been related to the manufacture of ammonia, its distribution or its use in agriculture. A survey of information about SCC presented by Vern Alexander and Mike Laucks to IIAR in Long Beach in 2001 showed that the only paper presented in the period 1950 – 2000 which was specifically targeted at the refrigeration market was by Dr Alan Cracknell of ICI to the Institute of Refrigeration in London in 1983. A report produced by D.R. Pratt on behalf of Batelle Pacific Northwest Laboratories in 1976 was also for a closed circuit cooling system, but this was a high temperature thermosyphon

Location of stress corrosion cracking.


seemed to be no clear understanding of the way in which post-weld heat treatment provided a benefit.

Details of the incident in 2005

The water chilling system is configured as three identical chiller modules, each with an independent refrigeration system comprising three screw compressors, an evaporative condenser and a “spray chiller.” This is a large shell and tube kettle-type evaporator coupled with an ammonia pump. The chiller runs with a very small refrigerant charge by recirculating the ammonia through a spray nozzle system inside the chiller. The main body of the chiller is 72" diameter, with the tube bundle contained within 36" diameter sections at each end. Each chiller unit provides about 300TR when cooling the dairy water to 34°F.

The leak occurred in the 36" diameter shell not far from the tubesheet weld, slightly below the centreline of the vessel and it was found to be a short crack, about ¾", running along the length of the vessel from the weld metal. Samples of metal were cut from the vessel and analysed by Aachen University, and independently by the University of Manchester Institute of Science and Technology. Both reports confirmed that the crack was caused by Stress Corrosion, and that several more shallow cracks were found in the samples tested. To cut a long story short, once we had committed to cutting patches from the vessel to send for analysis we knew that that evaporator was scrap and would need to be replaced. This was not easy, because it was the middle of three vessels in a location from which it had not been expected to move: with a lot of careful planning and some additional building modifications the replacement was completed as quickly as possible, but it took several months in total. A further cost during this period was incurred by the need to use rental chillers for a portion of the heat load during the shortfall in capacity. In addition the system efficiency was significantly poorer during this period because to get the dairy water to the right temperature the rental chillers worked on a glycol loop with an extra heat exchanger for chilling the water to 34°F.

the effectiveness of non-condensible gas purgers. It is obvious that they cannot eliminate oxygen entirely: if air is leaking in at one point and being purged at another then there will at least always be some oxygen in transit through the system. It is highly unlikely that purgers can achieve 0.5ppm oxygen in the ammonia in the system, which is the level below which SCC will not occur. Whether they can achieve a low enough level to make water an effective inhibitor (less than 200ppm oxygen in the ammonia – see below) is not clear. Automatic purgers work by gathering the oxygen in a small chamber and venting it to atmosphere when the ammonia content is low enough so it should be obvious that the oxygen levels in the vicinity of the purger will be very high from time to time.

to ammonia

This is another of the findings from the extensive research into spheres and holding tanks which has been transferred to the refrigeration industry without any understanding of the mechanism that delivers the benefit. It was widely reported that water would prevent SCC whereas in fact the research findings were that if oxygen levels are low then water has an inhibiting effect, but if the level of oxygen is greater than 200ppm then no amount of water will prevent SCC from occurring.

When purchasing steel for general purpose use it is important to ensure that the metal is strong enough for the intended use. It is therefore common practice to specify the lowest acceptable yield strength for the steel. This figure is then used in design calculations with the certainty that the material will not yield at stresses lower than the minimum value. If higher strength steel is delivered then the factor of safety in the design is increased. Many of the papers studied state that the material specification should be for a minimum yield strength of 350MPa or less. In fact the purchaser of steel has very little control over the actual yield strength of the material supplied. Even when a low “minimum” is specified the material tests might show figures much higher than the minimum value. This steel is still in compliance with the specification, but it would also comply with a much higher minimum yield strength requirement. No explanation could be given by industry experts for the apparent importance of the 350MPa figure, nor could they explain why SCC arose when stress values were significantly lower than that figure.

There was no uniformity of opinion on heat treatment. Some purchasers insisted on it, others required it of high side vessels, or in some cases high pressure receivers only. Most did not seem to have any opinion at all. There is clearly a cost and time penalty for taking the vessel to a large furnace. These also vary widely from place to place, and are heavily dependent on the size of vessel. As mentioned above there SCC continued on page 43

Location of stress corrosion cracking.

Crack surface.


why the CFATS process will not designate many ammonia refrigeration facilities as “higher risk.” Most facilities pose little danger to the surrounding neighborhood, even under the worst-case scenarios. In keeping with this goal, the CFATS threshold was set to 10,000 lbs of ammonia; similar to the PSM/RMP threshold but with a slight difference. The CFATS regulation adds up all the ammonia which is on-site, whereas PSM/RMP only specifies an amount that is in a particular process. For security screening purposes, it does not matter exactly which process your ammonia is in, only that you have that quantity somewhere on-site where it might affect your neighbors or be disrupted in some manner.

Another goal of the Chemical Sector is to produce a protective program that reduces sector risks without hindering economic viability. DHS provided a lot of guidance for free to facilities completing the CFATS screening process, and also provided IIAR with more information to pass along to our members. While the information collection may have been time-consuming for some facilities, the goal was to use as much existing PSM/RMP data as possible to minimize the amount of new data that needed to be collected.

Among the most important goals of the Chemical Sector is information sharing. To this end, the Homeland Security Information Network was developed.

For facilities that want or need to improve their site security, the Department offers several different training programs such as “chemical boot camps” where participants learn ways to make their facilities more secure. Some facilities may be interested in the seminar on vehicle borne improvised explosive devices and how to deter these types of attacks. There is also a web-based chemical security awareness program for facilities with limited funds for traveling and attending seminars. As you can see from all of these options, DHS is committed to maintaining information sharing and training facility operators and managers to improve site security.

The Annual Chemical Sector Security Summit will be held July 21-23, 2008 in Washington DC. This is a good opportunity for ammonia refrigeration personnel to come and meet some of the DHS people involved in the Chemical Sector and learn about the latest updates to the CFATS process. IIAR will be represented at the meeting.

DHS Chemical Security Workshop and Update

At the 2008 Annual Conference and Exhibition in Colorado Springs, Amy Graydon, Chemical Sector Brach Chief at the Department of Homeland Security

(DHS), provided an overview of the sector influencing the regulation of ammonia refrigeration facilities. The Department has several layers of management above the one directly responsible for the chemical sector, including the Office of Infrastructure Protection. This office holds the responsibility for the security of the nation’s critical infrastructures and key resources. Below this level is the Sector Specific Agency for chemical facilities.

The recent promulgation of the Chemical Facility Anti-Terrorism Standard (CFATS) brought renewed interest in ammonia refrigeration facilities by the federal government. In January 2008, all facilities with greater than 10,000 lbs of ammonia on-site were required to register with DHS through their online submission form. It is anticipated that only a few ammonia refrigeration facilities will be required to continue with this process, after being designated “higher risk.”

IIAR is a member of the Chemical Sector Coordinating Council which interfaces with DHS in the development and implementation of these new regulations. Working this closely with DHS, IIAR is making sure that our members receive timely updates and our portion of the industry is well represented. The Chemical Sector Coordinating Council also includes organizations such as the Compressed Gas Institute and American Petroleum Institute. The Council is responsible for identifying protection priorities, implementing the National Infrastructure Protection Plan, prioritizing critical infrastructure and key resource protection plans, and examining interdependencies within other sectors. Above the Council, DHS coordinates with other government agencies at the federal, state and local levels.

The federal government’s vision for a secure, robust Chemical Sector is: An economically-competitive industry that has achieved a sustainable security posture by effectively reducing vulnerabilities and consequence of attack to acceptable levels using risk-based assessments, industry best practices, risk-based protective measures, and comprehensive information sharing between industry and government.

Among the top goals for the Chemical Sector is a risk profile of assets that supports risk-based prioritization. This is

Department of Homeland Security Update


HSIN-CS – A Security Information Communication Network

The Department of Homeland Security provides a web-based portal, free of charge, to its security partners to encourage information sharing. The Chemical Sector Coordinating Council (SCC) has chosen to utilize the Homeland Security Information Network -Chemical Sector (HSIN-CS) as the primary information-sharing platform for the Chemical Sector. The portal is available to both public and private Chemical Sector stakeholders and is a key tool for maintaining situational awareness and sharing security information. Access to HSIN-CS enhances the ability of users to receive information and communicate during operationally significant situations within and concerning the sector and/or their commercial enterprises. The portal provides alerts and incident bulletins are posted regularly.

Participation in HSIN-CS is open to all individuals who are employed by companies that belong to trade associations that are members of the Chemical Sector Coordinating Council (SCC), and to staff for such associations. Access may be granted in unusual cases where an individual is employed by a company that (i) does not belong to one of these associations, but (ii) the Sector concludes is a part of the nation’s critical chemical infrastructure.

Members of the IIAR are invited to join the HSIN-CS network and gain access to valuable Chemical Sector security information.

How do I gain access to HSIN-CS? Interested individuals should contact Emily Miller, at [email protected], with a request for nomination that includes a name, company, and email address. Email addresses must match the company name. Email addresses from public ISPs such as AOL, Yahoo, Earthlink, etc. will not be accepted. Once nominated, registrants will receive an electronic link generated by HSIN to an application for completion.

2008 Chemical Sector Security SummitJuly 21–23, 2008

The 2008 Chemical Sector Security Summit, co-sponsored by IIAR and other members of the Chemical Sector Coordinating Council and the Department of Homeland Security, will offer presentations on chemical security standards, maritime security transportation regulations, security assessments and best practices.

IIAR member companies are invited to register for the 2008 Chemical Sector Security Summit. There is no registration fee associated with this event. Space is limited and we expect high interest again this year, so please register early!

WHO SHOULD ATTEND?Chemical and related industry professionals involved with:

Corporate and facility security Environment, Health & Safety Transportation and distribution of chemical products

WHY SHOULD I ATTEND? Better understanding of the Regulations covering High-Risk Chemical Facilities

Meet and interact with key Department of Homeland Security and other relevant government agency officials

Discuss options for meeting Risk-Based Performance Standards from your peers and experts in the field

Network with your industry peers on best practices

WHERE IS THE SUMMIT LOCATED?Bethesda North Marriott Hotel and Conference Center, 5701 Marinelli Road, Bethesda, MD 20852 | Reserve a sleeping room and mention you are attending the 2008 Chemical Sector Security Summit | Online: http://www.marriott.com/hotels/travel/wasbn-bethesda-north-marriott-hotel-and-conference-center/ | Phone: 301-822-9200 or 1-800-859-8003

HOW DO I REGISTER?The registration form is available at www.dhs.gov. Email the form to [email protected]. Form requires the name of the registrant(s), organization, job title, phone number, and email Due to space constraints, each organization and company will be limited to two registrants. Please provide a list of registrants in order of preference for entry. The first two names listed will be given priority registration, while the other(s) will be placed on a waiting list. If your participants wish to be placed on an attendee list that will be distributed at the 2008 Summit, please indicate your agreement to be included on the roster. The attendee list will not include your email or phone number.Please note, registration is not confirmed until you receive a response email including a confirmation number.

QUESTIONS?Please contact Amy Graydon or Aprilgrace Aytona at [email protected].


This will take you to an on-line form that will allow you to review the contact information currently on file for you on the website. Make any changes that need to be made on this form and click submit. The on-line Membership Directory will be updated after your modifications have been reviewed by an IIAR staff member.

To look up the contact information for an IIAR Member, click on the Membership Directory button on the navigation bar on the left side of the members home page. You will know you are logged in by the Welcome Back message in the upper left corner.

www.iiar.org is your website.

As a member of IIAR, the website is where you will find many web-based member benefits. In this new column we will take you on a tour of the re-designed

IIAR website. This month we feature the On-Line Membership Directory.

Before we look at the Directory itself, this would be a good time for you to make sure that your membership information is up-to-date. To update your member information, first log in to the website. You will need your member ID and password.

Click on the My IIAR button, and then click on the Member update tab on the pull down menu.


Your search results will come up in a window that looks like this.

Verify the name of the person you are looking for and click on the link. It will open up a page like the one below that contains all of the contact information for that individual.

The On-line membership directory is available exclusively to IIAR members. It contains the most up-to-date information, and is significantly more current than the old printed directory replaced by this site several years ago. New members are added monthly, and you can update your own information at any time.

This screen allows you to search for your fellow members by name, location, company or member type. You can narrow the search down to a specific State in the United States or province in Canada, or by other countries around the world. You can sort through a complete list of member companies, or narrow the search based on a specific member category like contractor, end user or manufacturer. In this example, we are searching all companies and all membership categories based on the member’s last name.


By Jack Piho, Piho Engineering

Pressure relief devices are commonly one of two types: rupture discs or spring loaded valves. Rupture discs are membranes which burst at a set pressure and cannot reseal. Once ruptured, these membranes must be replaced. The spring loaded valve opens to relieve pressure when a set pressure is exceeded; when the pressure falls the valve closes again (but should thereafter every six months be checked for leakage as resealing may not be complete). In some relief valves, the spring loaded pressure element is a replaceable cartridge form.

Pressure relief devices shall be visually inspected every six months for corrosion or accumulation of scale and for leaks. Vent lines shall be inspected to ensure that they are clear, that they discharge to a safe place and are protected against ingress of moisture, which could freeze.

At least every five years pressure relief valves (or cartridges) shall be removed and replaced with new or with overhauled and recalibrated valves (or cartridges).

Relief valves that have discharged in service due to temporary excessive overpressure should be replaced at the first opportunity even though they may be, temporarily, maintaining a pressure tight seal. Valves may be returned to the manufacturer for reconditioning and re·setting service if avail able.

All replacement pressure relief devices shall be correctly selected in accordance with ANSI llAR 2 1992 (see 7.1) and ANSVASHRAE 15-1992 (see 7.2).

The IIAR Board of Directors approved a revision to Bulletin 110, Section 6.6.3 on November 2, 2001, which stated in part:

When a component reliability program is in place to verify relief valve functionality and longevity by history, testing, disassembly and inspection, and periodic statistical review of these activities, relief valves may be replaced at any interval justified by the findings of such a program. In the absence of such a program, each relief valve shall be replaced at the

A workshop presented at the 2007 IIAR Conference and Trade Show in

Nashville, Tennessee described relief valve testing methods and how IIAR is advancing this issue in the industry. A spreadsheet was presented that IIAR members can utilize when testing their relief valves. IIAR members are encouraged to review the spreadsheet (see figure below) and submit comments on its content.

The goal of the program is to develop a consistent test method for the industrial refrigeration industry, so that data may be compared between different types of service, temperature loads, frequency of use, type of equipment it protects, and other environmental factors. The debate has raged over whether tested valves should be placed back in service after testing. Many different factors can affect the life and operation of your relief valves, too many to list here. Major effects can be seen if the valves are sprayed during wash-down, if moisture seeps in from the outdoors, or if the valves sustain mechanical damage.

The IIAR Research Committee Chaired by Bruce Nelson was charged with re-examining the relief valve testing issue after the 2006 IIAR Annual Meeting. The committee’s scope was to review the wording in Bulletin 110 Start-up, Inspection and Maintenance of Ammonia Mechanical Refrigeration Systems, Section 6.6.3 and to consider revising the 5 year replacement policy.

OSHA CitationsThe provision stating that relief valves shall be replaced

every five years in the absence of a “component reliability program” or manufacturers’ recommendations to the contrary has resulted in OSHA citations issued to IIAR members alleging violations of the mechanical integrity provisions of the Process Safety Management standard, 29 C.F.R. § 1910.119. In addition, IIAR members have had a difficult time proving to OSHA that they have an adequate component reliability program because verification of “relief valve functionality” does not typically include pressure testing or disassembly of valves. In other words, when an IIAR member is performing their yearly MI, how can they determine that the relief valve is OK and does not need to be tested or replaced until its 5 year interval?

First: Some History of Bulletin 110 Section 6.6.3.The original wording from 1993 of Section 6.6.3 reads in part:

Relief Valve

Testing


3) The manufacturer’s recommendations on replacement frequency of pressure relief devices shall be followed.Exception: Relief devices discharging into another part of

the closed-loop refrigeration system are not subject to the relief valve replacement practices. All replacement pressure-relief devices shall be correctly selected in accordance with current editions of ANSI/IIAR 2 and ANSI/ASHRAE 15.

ASME National Board Part RB -In-service Inspection of Pressure-Retaining Items

The Bulletin 110 Section 6.6.3 is based in part on ASME National Board Part RB -In-service Inspection of Pressure-Retaining Items Section RB-8410 Recommended Inspection and Test Frequencies. Section RB-8410 States in part:

Frequency of test and inspection of pressure relief devices for pressure vessel and piping service is greatly dependent on the nature of the contents and operation of the system and only general recommendations can be given. Inspection frequency should be based on previous inspection history. If valves are found to be defective or damaged by system contents during inspection, intervals should be shortened until acceptable inspection re sults are obtained. Where test records and I or inspection history are not available, the fol lowing inspection and test frequencies are suggested: Pressure Relief Valves in Combination with Rupture Disks (5 Years), Propane, Refrigerant, (5 Years).

Typically IIAR Members do not disassemble, inspect, and recertify their ASME relief devices after 5 years. They will simply replace the valves because it is more cost effective.

Relief Valve Task Force UpdateThe task force reviewed the history of relief valve testing and

replacement history and discovered that the 5 year inspection

frequency recommended by the relief valve manufacturer. In the absence of both a component reliability program and manufacturers’ recommendations, relief valves shall be replaced every five years if not indicated earlier at annual inspection.

The IIAR Board of Directors approved another revision to Bulletin 110 Section 6.6.3 on May 24, 2007. This is the current version of the Bulletin, including the modification, which states in part:

Pressure-relief devices are generally one of two types: rupture discs or spring-loaded valves. Rupture discs are membranes that open at a set pressure and cannot reseal. Once ruptured, these devices must be replaced. Spring-loaded relief valves open to relieve pressure when a set pressure is exceeded. After opening, these valves are designed to re-seat when pressure in the protected component drops below the valve’s closing pressure. If a spring-loaded relief valve opens, the valve shall be replaced or recertified in a safe and timely manner. If re-seating is not complete, the valve shall be taken out of service immediately.

Relief valve vent lines shall be visually inspected annually to ensure that the vent line piping is intact and that vent outlets terminated to atmosphere are unobstructed and piped to prevent foreign matter from entering the vent line piping. If equipped, drip pockets shall be checked for water accumulation.

Pressure relief devices shall be replaced or recertified in accordance with one of these three options:1) Every five (5) years from the date of installation. IIAR

originally recommended (in 1978) that pressure relief valves be replaced every five years from the date of installation. This recommendation represents good engineering practice considering the design and performance of pressure relief devices; or

2) An alternative to the prescriptive replacement interval, i.e., five years, can be developed based on documented in-service relief valve life for specific applications using industry accepted good practices of relief valve evaluation; or

Relief Valve Testing continued on page 33


2008 AMMONIA REFRIGERATION CON


COLORADO SPRINGS, CONFERENCE & EXHIBITION


“Honorary Life Membership in IIAR is an award extended to individuals whose services to the organization extend well beyond the traditional terms of office and who contributions exceed well beyond those expected of the most dedicated members,” said 2007-08 IIAR Chairman Jeff Welch (right). “These awards are not made every year, but today I am very pleased to present honorary life membership to an individual who has made immeasurable contributions to the ammonia refrigeration industry.”

Nambudiripad, a long time member of the IIAR Safety Committee, has been a tireless worker. He has authored several technical papers and championed IIAR, promoting membership in the organization both inside and outside the company he worked for.

Nambudiripad, who recently retired from his position with General Mills, also played a key roll in the organization of the first End User corporate engineering meeting ever held in conjunction with an annual IIAR meeting.

Blasquez Elected to IIAR EXCOM

Adolfo Blasquez, President of A. Blasquez E. Refrigeracion Industrial has been elected to the IIAR Executive Committee. The election was held during the 2008 IIAR Ammonia Refrigeration Conference & Exhibition in Colorado Springs.

Blasquez joins the Executive Committee as Treasurer of IIAR. The Executive Committee also includes Chairman Brian Marriott, Frick/JCI; Chair-elect Don Stroud, Kraft Foods Global; Vice-chair Peter Jordan, Senior Principal Engineer for MBD Risk Management; and Immediate Past-chair Jeff Welch, Freeze-Pro.

Blasquez has been a member of IIAR for 28 years. He obtained the title of professional engineer (P.E.) in Mexico in 1977 when he graduated from the Ibero-American University. He has served for three years on the IIAR Board of Directors and has been working since 2005 on the strategic plan objective to increase awareness of IIAR in Mexico and promote the benefits of implementing programs such as the ARM (Ammonia Refrigeration Management) program. He has also promoted IIAR standards and guidelines for the ammonia refrigeration industry in Mexico. Blasquez has also worked on several IIAR task forces and Committees.

Dennis Halsey, Nick Kawamura, Joe Paul, Kem Russell, Mark Stencel, Doug Sweet, and Gary Webster were elected to serve on the IIAR Board of Directors. Jim Marrella was elected to his second term on the Board.

Zhao, Shriver — IIAR Members of the Year

IIAR recognized two industry leaders as Members of the Year at the 2008 IIAR Ammonia Refrigeration Conference & Exhibition in Colorado Springs. Zhao Lianjie and Bob Shriver were honored for outstanding contributions to the ammonia refrigeration industry through extraordinary service to IIAR during the course of the past year.

“These two men have been enthusiastic and active contributors to the success and growth of IIAR,” said 2007-08 Chair Jeff Welch.

Zhao Lianjie was recognized for the key role he has played in the rapidly developing relationship between IIAR and the Chinese Association of Refrigeration (CAR).

“Lianjie has been IIAR’s ambassador on the ground in China, organizing meetings, coordinating special seminars and successfully promoting the adoption of IIAR’s standards by the CAR,” Welch added.

Bob Shriver was recognized for his work as Chair of the IIAR Standards Review Committee (SRC).

“Bob holds one of the most important positions in IIAR,” said Welch. “As a technical organization, IIAR relies heavily on the work done by the SRC. As Chairman, he has lead a significant re-write of IIAR 2 which we expect to publish later this year. At the same time, he has lead the committee in the development of a suite of standards that will soon be released for public review.”

“Unfortunately, Bob Shriver was unable to attend the conference in Colorado Springs. We wish him well and look forward to seeing him next year in Dallas,” said Welch.

Nambudiripad Named IIAR Honorary Life Member

Honorary Life membership in IIAR was extended to Godan Nambudiripad at the 2008 IIAR Ammonia Refrigeration Conference & Exhibition held in Colorado Springs at the Broadmoor Hotel.

IIAR Members

Zhao Lianjie

Bob Shriver


Anderson also played a key role in IIAR regulatory affairs activities. For the past two years, Anderson represented IIAR on the Chemical Sector Advisory Council which serves as the

sounding board for the Department of Homeland Security in the development of the new chemical facility anti-terrorism security (CFATS) regulation.

M. Kent Anderson was recognized during the annual Business Meeting at the 2008 IIAR Ammonia Refrigeration Conference & Exhibition for his service to the International Institute of Ammonia Refrigeration. Anderson was recognized with a plaque and posed for a photo with the the Past Chairs of IIAR and Honorary Life Members of IIAR. Anderson announced his retirement in December 2007 and currently holds the position of President Emeritus with IIAR. Anderson was also honored with a video tribute that recognized his contributions to IIAR.

During Anderson’s tenure, first as Executive Director and later as President, IIAR membership grew nearly five fold. Membership benefits have expanded to include the largest on-line technical resource library, publication of the Piping Handbook and the Ammonia Data Book. IIAR also developed a training library of 12 DVDs, of which almost half of them are also available in Spanish, the Process Safety Management and Risk Management Program, and the training guideline.

2008-09 IIAR Board of Directors

Seated: Peter Jordan, Vice-Chair; Don Stroud, Chair-Elect; Brian Marriott, Chairman; Adolfo Blasquez, Treasurer; Jeff Welch, Immediate Past Chair.Second row: Bob Port, Joe Mandato, Rudy Nechay, Mark Stencel, Doug Sweet, Nick Kawamura, Gary Webster, Bruce BadgerBack Row: Joe Paul, Dennis Halsey, Jim Wright, Jim Marrella, Tim Facius, Marcos Braz, Larry Gilliland, Chuck Taylor, Kem Russell, Bob Czarnecki, Ron Miller, John Collins, Paul Bishop, Bruce Nelson, John Ansbro (Absent: Bob Shriver)

Anderson Recognized for Tenure at IIAR Helm

Pictured Left to Right – Seated: Will Stoecker, Jeff Welch, Morris Eisert, Bill Bowles, Kent Anderson, Hank Bonar, Chuck Toogood, Anders Lindborg, Don Ballou. Standing: Don Siller, David Grong, Larry Basel

Kent Anderson accepts a plaque to commemorate his service to IIAR from Bruce Badger, Anderson’s successor as President.


speech, “sustainability is not only the right thing to do...it is also good business...it contributes to an improved

bottom line.”At IIAR headquarters,

our publications and mailings are printed by a local company, HBP Inc.

This company is yet another example of how you can bring

sustainable options to your customers, while still increasing your bottom line. HBP is a member of the Rainforest Alliance and the Forest Stewardship Council. These

organizations work together with suppliers and customers to generate environmentally-friendly

printing options. This issue of the Condenser is printed on paper certified by the Forest Stewardship Council, making you a part of the sustainability trail already. By doing our part at IIAR, we are hoping to facilitate improvements in our members’ businesses.

For example, this issue of The Condenser uses 1525 lbs of paper which has a postconsumer recycled percentage of 25%. By selecting the paper it is printed on, IIAR preserves 2.69 trees for the future, saves 1,143 gallons of wastewater flow, conserves 1,905,488 BTUs energy, eliminates 126 pounds of solid waste that would have otherwise been deposited in a landfill, and prevents the release of 249 lbs net of greenhouse gases.

The Mechanical Contractors Association of America has also started a website www.greencontractors.us that gives real options to building contractors for how they can make their buildings more green. The US EPA has started a program called GreenChill in which they are helping supermarkets reduce their impact on global warming. Several IIAR members are founding partners of the GreenChill project. These programs along with Energy Star Partners are great ways to market the sustainability side of your business.

PART 2

By Bruce Badger, IIAR President

In the last issue of the Condenser, we reported how consumers are increasingly demanding products that are

manufactured, designed and distributed in a sustainable manner. In this issue, we address how the sustainability marketing scheme can benefit your business, whether you are a refrigeration design engineer, contractor, end user, operator or manager.

As the concept of sustainability becomes more popular and more widely-recognized, more high profile examples exist in the marketplace. At the 2008 IIAR Ammonia Refrigeration Conference and Exhibition in Colorado Springs, the keynote speaker, Steve Yucknut, VP of Sustainability for Kraft Foods, provided some examples of this concept already being implemented in the consumer marketplace. His examples included concentrated laundry detergent, reduced plastic

beverage containers, and high efficiency light bulbs. These products have found marketing success based on a sustainability message and environmentally-friendly designs. This model can be applied to marketing ammonia refrigeration as the sustainable option for your facilities which also enhances your product’s position in the consumer market. As Yucknut mentioned in his

beyond Energy Efficiency

Steve Yucknut, VP of Sustainability for Kraft Foods Sustainability continued on page 41


2009 IIAR Industrial RefrigerationConference & Exhibition

March 22–25, 2009 Hyatt Regency Dallas Dallas, Texas

www. iiar. org


“The survey identified some areas that we do need to focus on for next year,” said 2009 Conference Chair Peter Jordan. “While most attendees like the change in the banquet schedule, there was some concern about the banquet format. We will take that into consideration when we plan next year’s event.”

“The survey also identified significant support for changes to the exhibit hall in Dallas. Almost half of the people who responded to the survey said they wanted larger exhibits in Dallas. The support was pretty even across the board from end users, contractors, engineers, consultants, and manufacturers.

“We don’t plan for a complete tradeshow next year, but we do plan to look at our rules to allow larger booths and larger exhibits for those companies that want to participate to that extent. We’ll review our ideas with members of the exhibitor advisory committee and announce any changes in the coming weeks. We are also considering a plan to add more exhibit hall hours without conflicting with the technical program,” Jordan concluded.

The 2009 IIAR Industrial Refrigeration Conference & Exhibition will take place in Dallas on March 22-25, 2009 at the Hyatt Regency Dallas.

2008 IIAR Conference & Exhibition Rated Big Success

By all standards, the 2008 IIAR Conference & Exhibition was a tremendous success. Attendance was up over previous years and the attendees gave

the annual meeting very high marks.As a non-tradeshow, attendance at the annual event

in Colorado Springs was up almost ten percent over the conference in Reno. Total attendance topped 1,030, which represents about a minimum of an 8% increase in attendance over each of the past five non-tradeshow events.

“We are very pleased with the success of the conference,” said Conference Chair Don Stroud. “And it appears that attendees feel the same way. According to the post-conference survey, almost everyone who responded to the survey gave the conference a rating from good to excellent.”

A total of 172 conference goers responded to the on-line email survey, a response level of 17%. More than 90% of the people who responded to the survey gave high marks to the workshops, technical papers, technomercials, exhibit hall, and Plenary Speaker Steve Yucknut of Kraft Foods.

Of the 66 respondents who identified themselves as exhibitors, 97% rated the conference as good or better, 42% rated the conference as very good and 30% gave it an excellent rating.

Each year, IIAR conducts a post conference survey to assist with planning future meetings. The decision to move the Conference Banquet to Monday night and the Exhibitor’s Reception to Tuesday evening was based on previous surveys. The change was well received by this year’s attendees: 90% of those responding approved of the change to the Banquet schedule and 94% approved of the Tuesday Night Reception schedule. In both cases, more than 60% of attendees rated the change as very good or excellent.

You are invited to share your unique insight and perspective on a topic of interest to the industrial refrigeration industry. Abstracts are being sought for papers defining ideas and techniques that have successfully been used to advance the state of the art in refrigeration design, installation, operation and maintenance.

Submit your abstract online at www.iiar.orgThe primary author of each accepted paper receives a “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 papers to be presented in Spanish. You may also fax your proposal to 703-312-0065. For additional information, visit www.iiar.org.

2009 IIAR Industrial RefrigerationConference & Exhibition

March 22–25, 2009 Hyatt Regency Dallas Dallas, Texas

www. iiar. org

CALL FOR PAPERS IIAR 2009 Industrial Refrigeration Conference & Exhibition March 22–25, 2009 | Dallas, Texas


“Bent’s presentation received an almost perfect score from attendees. Some even attempted to give the presentation a six on a scale of 1–5. In our memory, that hasn’t happened since the initial Andy Ammonia Award was presented to Milt garland in 1996,” Stroud added.

Wiencke Wins Andy Ammonia Award

The Andy Ammonia Award, created to recognize excellence

in the IIAR annual meeting program, was presented to Bent Wiencke, Corporate Engineer for Nestlé USA, Inc. and Nestlé Canada, at the 2008 IIAR Ammonia Refrigeration Conference & Exhibition. His presentation of a Technical Paper, A Case Study of Pipework Fracture due to Hydraulic Shock in an Ammonia System, received the highest score on the evaluations forms submitted by those who attended the sessions.

“By all standards, this year’s Andy Ammonia Award winner stands head and shoulders above all of the other presentations,” said Conference Program Chair Don Stroud. “The evaluation form comments included words like insightful, courageous, and eye-opening.”

The paper was presented twice during the conference. The combined total attendance at both sessions was almost 400, which is about 40% of the total conference attendance.

Bent Wiencke, Corporate Engineer for Nestlé USA, Inc. and Nestlé Canada accepts Andy Ammonia Award from 2008 Conference Chair Don Stroud of Kraft Foods.

WIENKE

2008 Technical Paper Abstracts

These papers will be available to IIAR members in the eLibrary on Sept 1, 2008. The eLibrary is an on-line resource at www.iiar.org that contains more than 400

technical documents that is available exclusively to IIAR Members.

Tech Paper #1Computer Modeling of Central Ammonia Systems vs. The Economics of Impact-Tested Pipe and FittingsPhil Golden and Reid McNally Jr.

This paper documents the requirements of the 2006 ASME B31.5 Code for Pressure Piping, “Refrigeration Piping and Heat Transfer Components,” related to piping and fittings. The selection by the owner of: 1.) the currently followed industry practices, or 2.) the alternative design guidelines set forth in the ASME B31.5 piping code, will have a financial impact

on the cost of each project. In this paper we examine these alternatives, review impact testing implications, examine several money saving concepts that can be implemented in the design and construction of refrigeration piping systems and, finally, review the procedures required to comply with the B31.5 piping code requirements.

Tech Paper #2Energy Efficiency and Enhanced Performance by Applying Variable Speed Drives to Rotary Screw CompressorsJohn Cosner

This paper covers the application of variable speed drives to rotary screw compressors from two directions: 1) energy savings through better part load efficiency and 2) the enhanced performance provided by a variable speed drive in regard to rapid and precise capacity control.


Tech Paper #6A Case Study of Pipework Fracture due to Hydraulic Shock in an Ammonia SystemBent Wiencke

In June 2007 a deflagration occurred at a frozen food factory. The incident investigation identified a ruptured coil located in a spiral freezer as the source of the ammonia leak. Within a 20 minute time frame, the ammonia concentration in the room surrounding the freezer enclosure increased to a flammable level and subsequently a deflagration occurred. The arcing found in a wire inside a drinking fountain was the likely ignition source. This freezer design, including the control valve group and liquid transfer vessel, is very typical for the refrigeration industry. The freezer and its associated refrigeration infrastructure were in operation for more than 10 years and underwent 3 Process Hazard Analyses. The incident investigation concluded that a hydraulic shock caused by a vapor propelled liquid slug generated enough of a transient pressure spike to cause coil rupture. A detailed analysis of the control valve group and liquid transfer vessel design and system dynamics, in conjunction with a metallurgic fracture analysis, was used to develop a mathematical model to describe and reconstruct the mechanism of this incident. The results are quite startling and support the fact that a seemingly insignificant system upset has the potential of leading to a catastrophic event. The incident investigation identified additional safeguards that could have prevented this incident.

Tech Paper #7Estimating Refrigerant Release QuantitiesTodd Jekel PhD, P.E. and Doug Reindl PhD, P.E.

End users are continuing to make strides toward increasing refrigeration system safety. Programs such as OSHA’s Process Safety Management (PSM) standard and EPA’s Risk Management Program (RMP) have provided a framework for end users to drive continuous improvement in plant refrigeration system safety. Nevertheless, incidents and accidents involving the unintended and uncontrolled loss of refrigerant from pressure-containing parts of a system can and do occur. In this paper, we review techniques suitable for use in estimating the quantity of refrigerant lost as a result of a leak. First principles models are presented for vapor-only, liquid-only, and flashing liquid leak scenarios. Qualitative indications as to what constitutes a reportable quantity of ammonia lost during an incident are also provided. The paper concludes by providing a number of examples of leak quantity estimates for various leak scenarios.

Tech Paper #3Ammonia as the Sustainable Refrigerant: A Comparison of Central Ammonia and Packaged Halocarbon SystemsJamie Horton and Alex Gooseff

When contemplating the question “Should our facility utilize an ammonia or halocarbon refrigeration system?” an owner should perform a detailed financial analysis of the two systems. The first cost difference of the two systems may be easily returned via the savings in operating costs and the long term benefits can be significant. For the example Case Study, the original investment of $208,000 for an ammonia system resulted in a simple pay-back of about 1.7 years and a total savings of about $4.9 million over 20 years. In general the following rules of thumb apply for a distribution facility application: Less than 50,000 sq. ft. refrigerated space, halocarbon split circuit systems are normally accepted. A 50,000 to 200,000 sq. ft. refrigerated space, both halocarbon split circuit systems and central ammonia systems are common. Over 200,000 sq. ft. refrigerated space, central ammonia refrigeration systems are most common.

Tech Paper #4Saving Energy Using Variable Frequency Drives Applied to Screw Compressors and Reciprocating CompressorsGary Schrift and Greg Klidonas

With energy prices on the rise, more emphasis is being placed on improving the operating efficiency of industrial refrigerating systems with a focus on the largest energy users, the compressors. As a result, the use of variable speed drives to control the capacity of screw compressors is becoming more popular. However, the use of a speed controlled screw may not be the best solution as the potential efficiency gains are influenced by many external factors. This paper will analyze and compare those factors and their impact on energy saving practices being recommended and applied to today’s compressor installations.

Tech Paper #5Air Cooled Ammonia Condensers as an Alternative to Evaporative CondensersHeinz Jackmann and Ian Runsey

This paper provides an overview of the regions in which ammonia refrigerating plants utilizing air-cooled condensers are a possible alternative to evaporative condensers, based on today’s technology. Different types of ammonia condensers can offer advantages in ambient temperature limits for ammonia refrigerating plants with air-cooled condensers depending on the compressor type, application and region. A comparison of energy and water consumption as well as investment and operating costs in different regions is explored. Technical Papers continued on page 32

ANDY AMMONIAAward Winner


y eficiente es una parte esencial del sistema. Algunos tipos de congeladores también requieren un ciclo de deshielo para sacar el producto al final del proceso de congelación. Este trabajo describe sistemas refrigeración con dióxido de carbono donde algunos métodos tradicionales de deshielo no pueden ser usados. El empleo de una variedad de técnicas alternativas es posible, cada una con ventajas y desventajas. La experiencia práctica con algunos métodos de deshielo menos comunes es descrita en este trabajo y se proveen consejos de diseño.

Trabajo técnico #3Procedimientos de operación y entrenamientoLawrence F. “Tex” Hildebrand, Vern M. Sanderson and Michael D. Axthelm, Presentado por Oscar Gomez

Mantener un buen equilibrio entre sencillez y meticulosidad en descripciones de procedimientos de operación normales (PONs) y también en entrenamiento de operadores puede ser muy difícil. A veces, los PONs pueden terminar tan sencillos que son peligrosos para un operador sin experiencia, o alternativamente, tan minuciosos que no son prácticos para usar. Este trabajo explica el desarrollo y la aplicación práctica de PONs y los programas de entrenamiento para operadores. Este trabajo utiliza un enfoque novedoso, en el cual, los procedimientos de operación son tratados desde cuatro puntos de vista: un consultor, un contratista, un usuario final, y un auditor regulador. El trabajo revisa técnicas para reducir costos, aumentar la seguridad, racionalizar operaciones, y ayudar a mejorar la retención de operadores. Este trabajo también sugiere lo que debe ser el contenido de los PONs, incluyendo recomendaciones sobre niveles de precisión operacional, que debe ser incluido, y lo que no debe ser incluido. La discusión de PONs es seguida por una discusión de tópicos de entrenamiento. Finalmente, el trabajo provee recomendaciones prácticas sobre como, cuando, donde, quien, y cuanto entrenar que los asistentes pueden implementar inmediatamente.

Trabajo técnico #4Corrosión de equipo y tuberías bajo el aislamientoPatrick J. Dunn and Richard NorsworthyPresentado por Victor de la Fuente Salazar

Este trabajo trata de los principios básicos de corrosión y métodos para moderar la corrosión. La corrosión bajo el aislamiento es un problema grave, ya sea que la tubería u otra estructura esté enterrada o en el exterior. Tres de los cuatro elementos para que ocurra la corrosión están presentes en cada metal. El cuarto elemento es un electrolito, que está presente en aislamiento térmico húmedo. La utilización de barreras de vapor, revestimientos y materiales aislantes de buena calidad, técnicas de instalación, y mantenimiento adecuados contribuyen al control de los problemas de corrosión en las tuberías.

Tech Paper #8Design Considerations for an NH3 System utilizing CO2 Brine in Tokyo, JapanKelly Sasaki, Kuniaki Kawamura, et al.

Ammonia is one of the oldest refrigerants in industrial use today. It is a natural refrigerant with excellent thermal properties. However, most ammonia refrigeration systems in Japan are of the indirect type using secondary refrigerants such as propylene glycol or water. Most of the conventional secondary refrigerants have poor heat transfer characteristics and high pressure losses at low temperatures thus offering low system coefficients of performance (COPs). Carbon dioxide is being promoted as a secondary refrigerant because carbon dioxide is a natural refrigerant (ODP=0, GWP=1), non toxic, non-flammable and has good transport properties which results in low pressure losses in the pipes. The COP of the system, therefore, can be improved. This paper reports on development and application of a 2000kW ammonia refrigeration system with carbon dioxide as the secondary refrigerant which operates at three different temperatures.

Trabajo técnico #1Integridad mecánica para recipientes de presión y tuberías para sistemas de refrigeración con amoníacoRonald Cole and Godan NambudiripadPresentado por Manuel Alarcón Lopez

Integridad mecánica es un asunto que no se entiende universalmente dentro de la industria de refrigeración con amoníaco. La guía disponible actualmente para nuestra industria sobre este asunto parece ser basado en la experiencia de la industria química y petroquímica. Hay poca duda que nuestra industria puede mejorar en esta situación, especialmente para tuberías y recipientes. El trabajo incluye un caso de estudio en el cual los autores abordaron todos los asuntos prácticos relacionados con crear y desarrollar un programa de integridad mecánica para instalaciones desde el comienzo hasta el final. Entonces los autores revisan el método desarrollado utilizando un acercamiento racional, y reparten partes significantes del mismo. El trabajo muestra un programa rentable de integridad mecánica diseñado específicamente para sistemas de refrigeración con amoníaco, concentrando en áreas críticas y de alto riesgo.

Trabajo técnico #2Tipos de deshielo para sistemas con dióxido de carbonoAndy Pearson, C.Eng., Ph.D.Presentado por Juan Manuel Quintanar Quintanar

Para muchos sistemas de refrigeración no se requiere un sistema de deshielo. Sin embargo, para sistemas con refrigerante evaporando por de bajo de 0ºC (32ºF) donde el evaporador está enfriando aire, un sistema de deshielo eficaz

Technical Papers continued from page 31


The IIAR Research Committee is developing a document to guide end users on how to test relief valves. Proper testing ensures that the results can be compared fairly. Once this testing method is complete, it will be circulated to IIAR members and some consistent data can begin to be collected. As detailed in the figure, three tests are conducted on each valve and the relief pressure (when the valve begins to function) is recorded. The condition of the valve, including the presence of stress cracks is also noted. Recording the vessel type, ambient temperature, and discharge location provides insight into why the valve operates the way it does. A very corrosive environment or outdoor discharge can explain why a valve may fail.

The data will be kept confidential and manufacturer’s names and model numbers will not be distributed to members. Data on relief functionality will be presented to the members. With this data we can propose revisions to Bulletin 110, ASME National Board Inspection Requirements, and have supporting data for regulators on when relief valves need to be inspected, recertified or replaced.

The FixHaving concluded that treatment of machine room

ventilation constitutes an excessive requirement for model codes given the lack of substantiation for such a regulation, IIAR proposed to the IFC, UFC and UMC to delete this requirement for ammonia systems, beginning with the 2009 editions of these codes. I am pleased to report that code development committees for overseeing all of these documents have approved these proposals, and these actions should soon be finalized, subject to ratification by the respective memberships of the International Code Council, the National Fire Protection Association and the International Association of Plumbing and Mechanical Officials later this year.

IIAR recognizes that some owners and/or designers may still choose to install ventilation treatment systems on a case-by-case basis, and such voluntary decisions will remain permissible regardless of whether ventilation treatment systems are mandated by code.

Code Update continued from page 7

Relief Valve Testing continued from page 21

from machinery room ventilation was the source of off-site consequences. Since treatment of ventilation systems is very uncommon, even in newer facilities, it is unlikely that any facilities reflected in this favorable incident history had ventilation exhaust treatment systems.

Also, it is noteworthy that the simple way of avoiding the requirement to provide machinery room exhaust treatment is to place refrigeration machinery outside of the building, where no such requirement applies. It simply makes no sense for the code to penalize the safer condition of putting machinery in an enclosed space by requiring treatment of room exhaust when an outdoor installation is at greater risk of a release to atmosphere.

And finally, it’s is important to point out that scrubbing ammonia to 150 parts-per-million won’t eliminate the unpleasant odor that may result in an excessive emergency response. The old concept of “if is smells bad, it must be dangerous” still prevails today in the minds of many.

and replacement wording predates IIAR. We were unable to determine a scientific basis of how the 5 year interval was established. Further discussions with the National Board resulted in the agreement that if IIAR can establish test criteria and a suitable sample population, we can petition ASME for revision of the National Board RB.

Several IIAR members have instituted testing programs to comply with OSHA. The purpose of the IIAR task force is to make these test programs uniform and adhere to established test criteria. This will also allow IIAR to develop a scientific basis for the interval between replacement/recertification.

The task force determined that the best approach is to establish a common test procedure based on ASME Performance Test Code PTC-25 Pressure Relief Devices. This uses the same test procedure used by relief valve manufacturers, but only addresses the opening or pop pressure as compared to the actual valve setting. No flow data is required. In addition, IIAR needs to know where a valve was used, years in service, condition and manufacturing date (see figure).

Trabajo técnico #5Ahorro de energía utilizando impulsores de frecuencia variables aplicados a compresores de tornillo y compresores de pistónGary Schrift and Greg KlidonasPresentado por Mauricio Quiroga

Con el incremento de los precios de la energía, más énfasis se pone a mejorar la eficiencia operativa de un sistema de refrigeración enfocándose en los usuarios más grandes de energía en un sistema: los compresores.

Consecuentemente, el uso de la velocidad variable para controlar la capacidad de los compresores de tornillo está llegando a ser más popular. Sin embargo, el uso de un compresor de tornillo controlado por velocidad puede no ser la mejor solución puesto que las mejoras potenciales de eficiencia son influenciadas por muchos factores externos. Este trabajo analizará y comparará esos factores y su impacto en las prácticas de ahorros de energía que son recomendadas y aplicadas a las instalaciones de compresores actualmente.


installations to world class safety standards. However, all refrigeration systems are dependent on human operation and maintenance, and when accidents happen emergency responders are called to the task.

“We as an industry have to convince the public, including facility owners and code officials, that the risk associated with ammonia is minimal AND a fair trade-off for the environmental benefits of this “future proof” refrigerant,” said former IIAR Chairman Jeff Welch (2007-08) “The best way to do that is to minimize the amount of accidents and their consequences. ASTI is on the cutting edge of that effort with their ONE PLAN concept and it’s promotion through regional safety days. By training the emergency responders, BEFORE an accident occurs, they are better equipped and educated to respond quickly and effectively. As we reduce the consequences of ammonia accidents, the public perception of ammonia WILL improve. Then the natural refrigerant will become the overwhelming natural choice.”

Most emergency events last for an average of 3 hours and some require the evacuation of downwind populations, the smell of ammonia creates community unrest; this is unacceptable. A prepared operator can stop most ammonia incidents through preventative action. Should a release occur, the operator (with proper PPE) can take steps to stop the incident when it is small (incidental response mode). Should the incident become an emergency event the relationship with public safety and the regulators becomes very critical. Unified command and appropriate incident action plans and safety plans should lead to a safe and effective control of the emergency event.

Recently, the Ammonia Safety Day Training Sessions have expanded nationwide through the support of the International Association of Fire Chiefs (IAFC), the International Association

(The One Plan — Coordinating Emergency Events Effectively)

By Gary Smith, ASTI President

The first Ammonia Safety Day organized by the Ammonia Safety & Training Institute (ASTI) occurred 20 years ago. Approximately 150 people showed up to learn about

the safety and emergency response concerns associated with ammonia. ASTI — headquartered in Watsonville, California — collaborated with the Montery Bay Chapter of the Refrigerating Engineers and Technicians Association (RETA) to host the first Safety Day at the Santa Cruz County Fairgrounds. This year, approximately 600 emergency response personnel, refrigeration operators and technicians, and regulators will come from areas within a day’s drive, from Sacramento to Bakersfield to attend the event in Salinas which is now organized by the Salinas Valley Safety Day Committee.

The Ammonia Safety Day sessions advocate release prevention as the first line of defense. In the event of a release, the next priority is to act quickly and effectively to control the release and prevent it from getting out of hand. And always be certain to wear the appropriate level of PPE when performing service, maintenance, a leak investigation, and a response to emergency events. The sessions also focus on the One Plan, which coordinates emergency events effectively; promoting the Incident Command System (ICS), and Unified Command between facility and public safety responders.

For many years, the Industrial Refrigeration business has recognized that ammonia is the best refrigerant for industrial applications and many others. Over the past 25 years, significant strides have been made to raise the designs and

AMMONIASAFETY DAY


Materials Technicians in fully encapsulated protective suits entered the facility and turned off valves to stop the ammonia flow and start ventilating the area.

“Due to proper actions by all involved, from the initial detection of the leak to the closing of valves and ventilation, there were no injuries,” said Mike Erfert, Public Information Officer, City of Yuma Fire Department. “Situations like this are the subject of frequent training, and the focus of the annual Ammonia Safety Day training conference.”

During the second quarter of 2008, Safety Days are scheduled in Los Angeles, California, May 14, 2008; Baltimore, Maryland, June 18, 2008, and Mt. Pleasant, Texas, August 23, 2008. Sponsors are being sought fpr Safety Days in Chicago, Illinois; Gainesville, Florida; Charlotte, North Carolina; Kansas City, Nebraska; New York, Arkansas, Madison, Wisconsin; and St. Paul, Minnesota.

Contact Gary Smith at ‘[email protected]’ or 831-724-7665 if you are interested in attending any of the Safety Days or if you want to sponsor a Safety Day in your area.

of Refrigerated Warehouses (IARW), the International Institute of Ammonia Refrigeration (IIAR), the Refrigerating Engineers Technicians Association (RETA) and the support of a grant from OSHA.

A Susan Harwood Safety Training Program grant from OSHA will fund a minimum of twelve Safety Days across the country. The agendas are organized by ASTI which also sets up instructors and training simulations. The grant pays for everything except the food; the sponsors and vendors work together to cover that cost. The targeted Safety Day locations are as follows: During the first quarter of 2008 Safety Days took place in Portland, Oregon; Pasco, Washington; Yuma, Arizona, and Salt Lake City, Utah; a total of over 850 people attended these Safety Day events.

The training paid off as recently as April 28 when a report of an ammonia release prompted an evacuation at Pacific Cooling and Yuma fire Department personnel, including Hazardous Materials Technicians and the Special Operations Response Vehicle, responded to the scene. Hazardous

Baltimore/Washington Ammonia Safety Day (Lunch and Snacks provided)

“Prevent Them All Or Stop Them Small”Does your facility have an emergency action plan in case of an ammonia release? Are your employees trained to recognize and respond to an ammonia release? If an incident occurs, it will be handled effectively to mitigate potential injuries and damage?

The 1st Annual Baltimore/Washington Ammonia Safety Day offers the raining required to prevent or mitigate ammonia release incidents. Instruction will focus on methods to: Prevent releases Recognize and determine the severity of a release Respond to a release Coordinate with emergency responders Learn what the requirements are of various regulatory agencies in

reporting a release.

Course Goals | Safely approach with proper PPE when performing service, maintenance, leak investigation, and response to emergency events | Use the “One-Plan” to coordinate the emergency event effectively; promoting the Incident Command System (ICS), and “Unified Command” between facility and public safety responders.

Why You Should Attend | You will receive a copy of the “Glove Box” Emergency Response Cards (a checklist of key things to remember during an emergency event) and a workbook full of great recommended methods

of preventing, mitigating, and preparing for an emergency event. At the end of the day we will give you a certificate showing that you attended the Safety Day production.

Free 8 Hour Course | For individuals likely to witness or discover an ammonia leak; teaches “Defensive” response strategy and hands-on participation, as well as classroom time. Topics Covered: Effects of Ammonia & First Response, Shelter/Evacuation Plans, Assist in Decon and Medical Zones, Connecting PSM to ERP, Downwind and Downstream Effects, Fire & EMS Support, and ERP Reporting Requirements.

List Your Personnel Attending | Contact us with the names of those attending or list them below and return by mail or fax by June 6, 2008. (An acknowledgement will be sent back to you with an agenda, map and more information).Company Name ______________________________________________Address ______________________________________________________Name _______________________ Name ________________________Name _______________________ Name ________________________Name _______________________ Name ________________________

Please send to: Industrial Refrigeration Service, Inc., P.O. Box 70019,

Or Fax to: (410) 686-4094

This seminar is FREE to all attendees, and is made possible by the generous support of the following companies and organization:


ARF Reception at the Cheyenne Lodge in Colorado Springs, Colorado

More than 100 people attended a special reception at the Cheyenne Lodge in Colorado Springs in conjunction with the annual IIAR Conference & Exhibition to launch the Ammonia Refrigeration Foundation. In addition to honoring the members of the Century Club, the reception celebrated the creation of the Foundation and recognized Will Stoecker and Evapco as the Foundation Philanthropists of the Year.

“I sat down at one time and said “what were the organizations that were important to me professionally?” One of them is the University of Illinois where I spent my career, another organization is IIAR because there was the opportunity for doing technical work and there was a need for it and I felt some appreciation of it. I am just delighted that the Ammonia Foundation is getting started because I have seen many times when there is project work that could be done to benefit the industry, but we didn’t quite have the money to do it then. To be able to have an endowment which would provide a continuous source of money is a vehicle by which we can advance the industry,” said Professor Will Stoecker who was recognized as the 2007 Individual Donor of the Year.

Evapco was recognized as the 2007 Corporate Donor of the Year. “(We) made a $25,000 contribution to the Ammonia Refrigeration Foundation because we believe it will be a significant benefit to our industry. The mission of the Foundation is to provide funding for scholarships and also funding for industry related research projects which no doubt will benefit everyone involved in the industry. We also hope that by making our contribution as we did, we would allow other people to reflect on that and also consider making a significant contribution to the Foundation,” said Evapco Senior Vice President Joe Mandato.

Corporate ContributorsA. Blasquez E. Refrigeracion IndustrialAC & R SpecialistsAirfoil ImpellersALTA RefrigerationAmerican RefrigerationAmmonia Safety Management Baltimore AircoilC & L RefrigerationCarlson and Stewart RefrigerationCIMCO RefrigerationColmac Coil ManufacturingDelta Tee InternationalEngineered Refrigeration Supplies

ARF Century Club Fundraising Campaign

Foundation Chair David Grong (2007-08) welcomes Century Club Golf Clinic participants

Century Club Golf Tournament Chair Bill

Bowles works on his putting technique during the Century

Club Golf Clinic

The Ammonia Refrigeration Foundation Century Club fundraising campaign is off and running. Since mid-October 2007 through May 1, 2008 the Foundation

has received donations totaling $208,500.00. The Century Club members are the first 100 contributors of $1,000 or more to the Ammonia Refrigeration Foundation. Membership in 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. To date, the Century Club has a total of 70 members.

ARF Golf Clinic at the Broadmoor Hotel in Colorado Springs, Colorado

In appreciation for each Century Club donation of $1,000, contributors were invited to play in the Inaugural Ammonia Refrigeration Foundation Golf Tournament that was scheduled in conjunction with the 2008 IIAR Ammonia Refrigeration Conference & Exhibition at the Broadmoor Hotel in Colorado Springs.

Unfortunately the weather did not cooperate. Instead of the golf tournament taking place, the Century Club contributors participated in a Golf Clinic that was conducted by five golf pros. The clinic matched up each golfer with other golfers of the same skill level and analyzed every facet of their golf game using state-of-the-art equipment and professional observation. The golfers also took advantage of a massage in between swings!


EvapcoFES MidwestFES SystemsFreeze-ProFrick IndiaGarden City Ammonia ProgramGartner RefrigerationGeneral RefrigerationHansen TechnologiesIndustrial Refrigeration ServiceInternational Institute of Ammonia Refrigeration(in memory of Chuck Kohlenberger)IsothermLoTemp EquipmentMBD Risk Management ServicesMcNeil RefrigerationMid-States Refrigeration SupplyNorth Atlantic Refrigeration SpecialtiesParker HannifinRealcold Milmech USARefrigerating Engineers & Technicians AssociationRefrigeration Components CanadaRefrigeration Design & ServiceRefrigeration Equipment SpecialistRefrigeration Systems CompanyRepublic RefrigerationStanton and AssociatesStar RefrigerationStellarStrong Refrigeration ConsultantsUF Ammonia ServicesUnited States Cold StorageVilter FoundationWagner-Meinert

Individual ContributorsAnderson, KentBadger, BruceBonar, Henry IIBowles, JWBraz, MarcosCarroll, DennisCole, Hinda(in memory of Ron Cole)Eisert, MorrisGilliland, LarryGooseff, Alex

Professor Will Stoecker accepts the 2007 Individual ARF Donor of the Year Award from Foundation Chair (2007-08) David Grong

Evapco Senior Vice President Joe Mandato accepts the 2007 Corporate ARF Donor of the Year Award from Foundation Chair (2007-08) David Grong

ARF Mission StatementThe 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.

Grong, DavidHendrickson, JohnLoyko, LaneMarriott, BrianNechay, RudolfNelson, BrucePaul, JoePiho, JackSiller, DonaldSloan, JeffSt. Jean, Bob

2008-09 ARF Board of Directors

Seated: Dennis Carroll, Treasurer ; Jeff Welch, Chair; Brian Marriott, Secretary.Standing: Bruce Badger, IIAR President; Jeff Nank, Director-At-Large; Bruce Nelson, Research Committee Chair; Gary Webster, Education Committee Chair; (Absent: Chuck Taylor, Director-At-Large)

Stoecker, WillTaylor, ChuckTragethon, DonWilliams, RandyYencho, John


Shanghaion Display in

IIAR President Bruce Badger presented a special seminar prior to the trade show on the NH3/CO2 cascade system installed at the US Cold Storage facility in Bethlehem, Pennsylvania. This seminar was sponsored by IIAR and CAR and also supported by the National Electrical Manufacturers Association (NEMA), the American Chamber of Commerce in the P.R. of China, the United States Trade and Development Agency, and the US-China Standards and Conformity Assessment Cooperation Program.

Around 100 attendees, including Chinese engineers and business owners came to learn about cascade technology in the US. Many showed great interest in cascade systems and how they can be implemented in China effectively. Members of the IIAR Board of Directors also attended the trade show and related events representing IIAR. Dennis Halsey of GEA-

FES Systems, Joe Mandato of Evapco, and Mark Stencel of Vilter Manufacturing met with leaders of the CAR, further solidifying the growing relationship between the two organizations.

Also making an appearance at the trade show were the infamous ozone-depleting, global

warming refrigerants R-12 and R-22. These refrigerants are quickly being banned in China and throughout Asia, but were

China Refrigeration 2008 in Shanghai brought together HVAC&R companies from all over the world in one of the largest trade shows ever. Over 900 exhibitors

packed 6 halls and 5 tents at the enormous Shanghai New International Expo Center in Pudong.

Co-sponsor of the event Chinese Association of Refrigeration (CAR) claimed it was their biggest trade show ever, with more than 40,000 attendees expected. Many booths contained an upper level with a meeting room to make business deals right there on the trade show floor. Lasting three days, the show also provided a technical program, and several IIAR member companies made presentations.

IIAR President Bruce Badger gave a presentation on cascade systems.

Shanghai New International Expo Center.


still being featured by some companies.

To counterbalance this, a presentation by Greenpeace China and several other organizations promoting natural refrigerants was very well attended. Hydrocarbons, CO2 and ammonia featured prominently in the developing research and advocacy behind the drive for natural refrigerants in all applications.

The Refrigerants, Naturally! Initiative was also featured during this presentation. This initiative is a consortium of large food companies who have made the switch to natural refrigerants in their point of sale units. So far the initiative boasts The Coca-Cola Company, McDonald’s, PepsiCo, Unilever, Carlsberg and IKEA as members. This initiative is supported by the United Nations Environment Programme and Greenpeace. It is not surprising that several IIAR members are found in this list and their subsidiaries.

IIAR member companies exhibiting at China Refrigeration 2008: Alfa Laval, BAC, Bitzer, Danfoss, Dow Chemical, Evapco, GEA Ecoflex, Guntner, Hansen Technologies, Henry Technologies, Honeywell, Mayekawa, Munters, Parker Hannifin, Tranter, and Vilter. Many also gave technical presentations. This presence at the largest HVAC&R trade show in Asia is just one example of how IIAR is expanding its international influence, and helping our members grow their businesses internationally.

R-12 and R-22 are still for sale in China.

IIAR member companies exhibited at China Refrigeration 2008.


McCormick Place North & South HallsChicago, Illinois

January 26-28, 2009

Endorsed by:

For Information on Exhibiting Contact: , 15 Franklin Street, Westport, CT 06880

Phone: (203) 221-9232 Fax: (203) 221-9260 E-mail: i

The World’s Largest HVAC&R MarketplaceReturns to Chicago!

For Information on Attending: www.ahrexpo.comCo-sponsors: Honorary sponsor:

Monday – WednesdayJanuary 26–28, 2009

MARK YOUR CALENDAR!Look for a

FREE VIP Invitation to attend in theNovember issue


and specifications influence the way plants operate for the lifetime of the equipment. Consequently, when a manufacturer incorporates the basic ideas of sustainability into their products, the entire industry can benefit. Yucknut talked about how this process is happening with Kraft Foods in his keynote address. They redesigned a product jar to be manufactured out of plastic instead of glass and subsequently saved money on manufacturing, shipping, storage space (the package was smaller and lighter) and reduced greenhouse gases, all while maintaining their customer base. The ability to transform the back end of their production while satisfying customers on the front end is a model that all manufacturers implementing sustainable practices can follow.

One final example will give you inspiration to take the sustainability plunge. Another IIAR member in Florida was recently showcased in the magazine Sustainable Facility for their upgrades that have lead to big savings. Tropicana Products worked with the Florida Power & Light company to utilize incentives for energy efficiency. The total dollar value that Tropicana estimates it has saved by implementing upgrades to lighting, higher efficiency compressors, and other improvements is over $6.4 million! Take advantage of any incentive programs your local utility company may be offering to leverage these into big savings to your bottom line, and a positive company profile.

(Bob Armstrong, VP – Communications and Kirsten McNeil, Deputy Director of Technical Publications also contributed to this article.)

As a contractor, IIAR has prepared several different resources for you to use when helping customers decide whether they should install an ammonia refrigeration system or a system with halocarbon refrigerants. At the 2008 conference, a paper was presented by two IIAR members detailing the cost analysis of this dilemma.

The cost to keep this ice cream frozen with a halocarbon system is $0.23, but the cost is only $0.16 with an ammonia system. The figures are based on the assumptions made in a technical paper presented at the 2008 IIAR Ammonia Refrigeration Conference & Exhibition in Colorado Springs by Alex Gooseff and Jamie

Horton. The ammonia refrigeration system may cost more initially, but with energy savings, the payback period is only 1.7 years! This paper is available free to the public through the “About Ammonia Refrigeration” section of the IIAR website.

This cost savings also translates into environmental savings. At an electricity rate of $0.08/kWh and a utilization factor of 75%, the ammonia system saves you $162,225 each year, which is 309 kWh. This kWh savings keeps 650 pounds of CO2 from entering the atmosphere if your electricity is generated by coal!

As a manager of a refrigerated facility, you are in a unique position to contribute to the sustainability of your company. You probably have already been tasked with saving energy because the refrigeration system can be a large energy consumer. However, you can also promote sustainable practices in other areas of your business.

As Yucknut pointed out in his keynote presentation, “the time to act is now!” You may or may not have the resources immediately available to devote to capital improvements in your facility, but changing the mindset can go a long way. Existing construction, maintenance, repairs and strategic replacement of equipment are probably the areas you should focus on. In addition to these, areas like employee training, office normal practices, and general awareness can be first steps in the process of greening your business and operations.

Refrigeration system design engineers and manufacturers greatly affect the front-end of this process. Their products

Halocarbon System: $0.23 Ammonia System: $0.16 *operating cost only, based on Alex and Jamie’s paper assumptions

Sustainability continued from page 27

Ammonia as the Sustainable Refrigerant: An Ammonia-Halocarbon Comparisonby: Alex Gooseff, ALTA Refrigeration and Jamie Horton, ElectroMotion RefrigerationPresented at the 2008 IIAR Annual Conference & Exhibition in Colorado Springs, CO

Abstract:When contemplating the question “Should our facility utilize an ammonia or halocarbon refrigeration system?” an owner should perform a detailed financial analysis of the two systems. The first cost difference of the two systems may be easily returned via the savings in operating costs and the long term benefits can be significant. For the example Case Study, the original investment of $208,000 for an ammonia system resulted in a simple pay-back of about 1.7 years and a total savings of about $4.9 million over 20 years. In general the following rules of thumb apply for a distribution facility application: Less than 50,000 sq. ft. refrigerated space, Halocarbon split circuit systems are normally accepted. A 50,000 to 200,000 sq. ft. refrigerated space, both halocarbon split circuit systems and central ammonia systems are common. Over 200,000 sq. ft. refrigerated space, central ammonia refrigeration systems are most common.


automatically mitigated. The incident considered most likely to cause a low-side overpressure incident was a control valve stuck in the open position while transferring hot gas to defrost low-side components. In such a situation, stopping the compressor should disengage the pressure source for the defrost system.

ConclusionEliminating emergency control box requirements from model

fire codes favorably resolves long-standing industry concerns regarding the potential for harm caused by an untrained person operating valves in an emergency control box, as well as concerns that such control boxes were not an effective investment in safety. IIAR advocates that there is no condition under which manual removal of refrigerant from a refrigeration system by the fire service is considered advisable. In contrast, automatic transfer of excess pressure to another zone of a system in conjunction with stopping the pressure source (compressors), through the use of an emergency pressure control system, provides an effective means to safely mitigate an overpressure condition that has not been intercepted by other safety controls.

It must be pointed out that elimination of the emergency control box based on the addition of an EPCS does not automatically eliminate other code requirements related to water diffusion tanks. Such tanks may still be requested or required in some cases by designers, owners or local authorities for the purpose of diffusing releases from overpressure relief devices.

IIAR is pleased to have had the opportunity to work cohesively with fire, building and mechanical officials from throughout the country who were willing to rethink more than 40 years of history to develop a modern-day approach to improving refrigeration safety. This exercise truly emphasizes the ability of industry experts and regulators to come together and craft effective solutions for the betterment of public safety.

Overpressure limit set point. Automatic crossover valves will be required to automatically relieve excess system pressure to a lower pressure zone if the pressure in a high or intermediate pressure zone rises to within a predetermined set point for emergency pressure-relief devices. Initially, in the 2006 editions of model codes, the predetermined set point was 15 psi below the rating of pressure relief valves (PRV); however, that will be changed in the 2009 codes to be not less than 10 percent below PRV ratings. The 10-percent figure provides a wider safety margin to allow an EPCS to operate before a PRV, given that the pressure at which PRVs will unseat can vary significantly from rated pressures.

Manual operation. When required by a local code official, the emergency cross-over valves must be capable of manual operation, presumably by an approved switch or button. Although this was not regarded as necessary from a safety perspective, the manual operation reference was provided because it was recognized that some fire departments would be reluctant to completely give up manual controls.

Operation of an automatic crossover valve and system shutdown. Operation of an automatic crossover valve will be required to cause all compressors on the affected system to immediately stop. Dedicated pressure-sensing devices located immediately adjacent to crossover valves are permitted as a means for initiating operation of a valve. To ensure that the automatic crossover valve system provides a redundant means of stopping compressors in an overpressure condition, high-pressure cutout sensors associated with compressors are not permitted as a basis for triggering a crossover valve.

Overall, the intent of these provisions is for the emergency pressure control system to have a fully redundant means of stopping compressors. Although compressors are ordinarily provided with their own automatic high-pressure cutout controls, fire code requirements will not permit these controls to be used as a means of initiating the EPCS. An additional set of controls is considered necessary to serve as a back-up means of preventing a severe overpressure condition that could result in operation of a PRV.

Overpressure control for the lowest pressure zone. In lieu of a full EPCS, the lowest pressure zone in a refrigeration system will be required to have a dedicated means of determining a rise in system pressure approaching operation of PRVs serving that zone. The maximum initiating pressure will be limited as described in “Overpressure limit set point” above, and once a severe overpressure condition has been identified, compressors on the affected system must be stopped.

The approach to managing the lowest pressure zone is different because this zone cannot be arranged to bleed pressure to another system zone. Nevertheless, by providing a redundant emergency stop control to disengage the compressor, an overpressure condition in the lowest pressure zone should be

Emergency pressure control systems reduce the likelihood that pressure relief devices will discharge flammable, toxic, or highly toxic refrigerants or ammonia to the atmosphere. This is accomplished through the use of an automatic cross-over valve, such as the one shown above, that internally relieves excess pressure from high-pressure equipment to other portions of a refrigeration system before an atmospheric release occurs. This photo illustrates a “crossover” valve arrangement interconnecting the high-side with the low-side after the pressure has essentially equalized.

EPCS continued from page 11


water levels, when sampled, were within the accepted range for inhibition. Similar vessels had been in use for many years all over the world. We also found that the actual yield strength of the material was 370MPa and that the vessel had not been post-weld heat treated.

What questions remained unanswered?

The cracks seem to form almost as soon as the system is charged with ammonia, with the rest of the time to failure taken up by the crack propagation process.

It was noticeable that all of the other cracks which we identified were less than 1/16” (1.5mm) deep. If the crack growth was random and was due to factors such as crack tip radius then we would have expected to see each crack at a different stage of growth, with some just forming and others close to failure. Of course only one would reach failure because the vessel is taken out of service as soon as the leak occurs. Likewise if the crack initiation was a random event which could happen at any time in the life of the vessel then we would expect to see some surface cracks much less than 1/16” deep, but this was not the case.

If the end view of the chiller is compared to a clock face then the cracks were all grouped around the 4 o’clock and 8 o’clock positions. We checked the manufacturing process and found nothing in the construction of the chiller that would explain this grouping, however we noted that the liquid level, although fairly active, tends to lie in this region.

The idea of water reducing the risk of corrosion is difficult to take on board. Water is a reactive fluid, which is normally seen as a source of corrosion. If water is making a difference when added to the system, particularly in such small amounts, then it must be because it is somehow involved in a chemical reaction on the surface of the metal. However there was no sign of rust or any other discoloration on the inside of the vessel shell, only the diffraction coloring on the crack face. The rainbow colors from diffraction were not evident on the inside surface of the shell.

Like the question about water, this is counter-intuitive. The shell did not appear to be highly stressed, and higher strength material in any event would be expected to improve the situation. This also seems to point to the involvement of some other material with different material properties.

The questions about water and higher strength steel suggest that there is another material, probably a compound of

A photograph of the crack surface is shown. The brightly coloured bands look like oil stains, but they were not removed by detergent, and a mass spectrograph showed it to be a thin layer of an unidentified oxide. The coloration is produced by the same diffraction effect which produces rainbow colours when oil is spilled onto water and indicates that the layer is only one or two molecules thick. The diffractive surface layer was not identified by either of the laboratories. Closer examination of the crack surface reveals a series of striations – the beach marks which are typically identified with fatigue failure. Unlike normal fatigue however these marks are not circular but are extended into an oval. This indicates that the failure was progressive,

like fatigue, but that it did not start from a single point. It was generated from a line running parallel to the main axis of the vessel shell. This starting line seems to be in the parent metal of the shell, not in the shell-to-tubesheet weld or the heat affected zone. As the crack propagated it spread through the weld metal, creating a split which was 2” long on the inner surface of the vessel and ¾” on the outside.

The other cracks which were identified by the analyses had not grown beyond about 1.2mm deep. They were all at approximately the level of the liquid surface and had appeared at both ends of the chiller and on both sides.

There were no flaws in the weld metal and nothing in the design, fabrication, installation or operation of the vessel to indicate that SCC was likely. Oxygen levels in the ammonia in the evaporator were low, but not less than 0.5ppm, and

SCC continued from page 15

SCC continued on page 44

Depth of crack.

Internal cracking along same crack line.

Outer surface of crack.


to specify a maximum value for the steel, only a minimum. The actual value can be checked – it will be found on the mill certificate supplied with the batch of steel. If it is above 350MPa then post weld heat treatment is strongly recommended.

If an alternative treatment can be identified that could be used during manufacture to provide a protective layer on the inner surface of the vessel then it will be possible to protect vessels which are unsuitable for post-weld heat treatment.

This would be great – unfortunately if a crack has grown to the point that it produces an ammonia leak and it is evident that there are other smaller cracks inside the shell it is unlikely that an adequate repair mechanism can be found. Complete replacement of the vessel on day 1 might be a cheap alternative compared to regular callbacks to chase repaired cracks or new leaks around the vessel. Studies in ammonia storage spheres showed that they needed regular inspection, and where cracked plates in the wall of the sphere had been ground out and rewelded, fresh cracks appeared within a year.

Some of the information in official documents is wrong but relatively harmless – in other cases it is wrong and could be dangerous. In the European Standard for Refrigeration Pressure Vessels EN14276 for example it states that “For vessels containing ammonia, stress corrosion cracking does not occur if vessels are made from steel with ReH 360 N/mm2 and the refrigerating system is designed, operated and maintained according to EN378-1 to EN378-4.” The system installed by Star Refrigeration in Leeds complied in all respects with parts 1 to 4 of EN378, which carry no reference to SCC, so the intent of EN14276 is not clear. Most codes and standards are not this far wrong – many of them, like EN378, simply don’t refer to stress corrosion cracking.

ConclusionThe ARF Stress Corrosion Cracking project is an opportunity

for ARF to facilitate a major advance in the understanding of stress corrosion cracking as it applies to ammonia refrigeration systems, and to establish ARF documents as the foremost world authority on the prevention of stress corrosion cracking in refrigeration plants. Benefits to manufacturers, contractors and end-users will be the reduction of the risk of failure and hence avoidance of the severe financial consequences which usually follow. A further benefit to all IIAR members is the chance for the Institute to gain recognition for significant, novel research work at a global level, with implications for industries far beyond industrial refrigeration.

ammonia, oxygen and iron, which forms on the surface. If so then it is likely that 350MPa is significant for that material.

If the logical conclusion of the comments on water and yield strength is that another material is involved in the process then it is likely that the major benefit of post-weld heat treatment is actually that it modifies the inner surface before the ammonia gets there, and hence prevents the SCC mechanism from getting started. This would explain why heat treatment is effective irrespective of the level of stress placed on the vessel.

What did we learn?One of the authors of the American-based researches of

the mid 1970s was Prof D.A. “Denny” Jones who worked at that time for the Bethlehem Steel Company. Latterly he headed a materials science team in the Department of Chemical and Metallurgical Engineering at Nevada State University in Reno, and published a text book titled “Principles and Prevention of Corrosion,” in 1992 with a second edition in 1996.

In the second edition Denny Jones suggests that stress corrosion cracking occurs when a corrosive environment creates a non-reactive layer of corrosion product on the surface of steel. If the yield strength of the layer is less than the yield strength of the steel then “fissures” will immediately appear in the layer, running perpendicular to the direction of applied stress, provided the sum of the applied and residual stresses exceeds the yield strength of the layer. As the layer is less reactive than the steel it is possible for a galvanic corrosion cell to occur, causing the crack to grow in line with the original fissure without any widening or turning. In theory the galvanic corrosion will continue right through the parent material, much like the pitting corrosion caused by copper particles on galvanised steel tubes.

Where do we go from here?

– it reduces residual stress – but it also scales the inner surface of the vessel

Unfortunately some equipment cannot be exposed to the high furnace temperatures required for post-weld heat treatment, either because of incompatible materials such as the rubber flow baffles used in plate and shell heat exchangers, or because they would distort, or simply because they are too large and there is no suitable facility within the area.

It is important to emphasise that this is the actual strength of the material used, not the specified minimum value. It seems to be harder than ever to source lower yield strength steels, perhaps because steel mill quality control has improved so that the yield strength of batches is much less variable than it used to be. Unfortunately it is not possible for a steel plate purchaser

SCC continued from page 43


chain as well as comfort cooling. Sponsored by ASHRAE TC 10.1, Custom Engineered Refrigeration Systems. Tuesday June 24, 8am – 9:30am in Room D of the Salt Palace Convention Center, Salt Lake City, Utah.

IIAR Passes 5 Year ANSI AuditIIAR has received confirmation that our 5 year American

National Standards Institute (ANSI) audit has been approved by the ANSI Executive Standards Committee, granting re-accreditation as a standards-writing body. IIAR is accredited by ANSI and follows their guidelines of balance, consensus, openness and other principles in the development of industry standards. Every 5 years ANSI audits the procedures of IIAR standards development to ensure that these principles are being followed. The successful completion of this audit confirms that IIAR is developing standards in the recommended manner. This audit was especially important for the organization as we continue to develop our new suite of standards, the first of which, IIAR 5 Start-up and Commissioning of Ammonia Refrigerating Systems, should be published later this year.

Breaking News! Cascade System Installed in Supermarket

SARATOGA, N.Y. — A CO2 cascade refrigeration system has been installed in a renovated Schenectady, N.Y. supermarket. The system will be used for low-temperature refrigeration in the frozen food and ice cream departments of a Price Chopper Supermarket, according to Hill Phoenix, the Conyers, Georgia-based company that supplied the system.

According to Hill Phoenix, advocated the system because carbon dioxide is far less expensive than HFC refrigerant (50 cents per pound compared with $7 or $8 per pound) and enables the system to use smaller line sizes and less copper piping. In addition, the global warming potential for carbon dioxide is one, compared with that of 3,300 for HFC refrigerant, enabling Price Chopper to reduce its carbon footprint, said Hill Phoenix.

IIAR Seminar at ASHRAE Salt Lake CityIIAR is sponsoring a seminar at the upcoming ASHRAE

conference in Salt Lake City June 21-25. “Natural Refrigerant Applications with IIAR” is a reformulated version of the old “Taste of IIAR” session that features an in-depth look at ammonia refrigeration design for the food industry and uses of ammonia in air conditioning. An important application that many may not be aware of is ammonia refrigeration in central air conditioning plants. This seminar focuses on the central plant of a community college in a major metropolitan area. Both designer and end user present their experience with the system. Come learn about how ammonia is playing an important, environmentally-friendly role in our food safety cold

NEWS & NOTES

Coming in the August 2008 CondenserSummary of the revisions in ANSI/IIAR 2-2008 Troubleshooting Evaporators Post-harvest cooling in Saudi Arabia Optimizing refrigeration system operation for energy savings. System controls and sustainability And Much More!

KEEPING YOUIN 'TOUCH' WITH YOUR

REFRIGERATION SYSTEM

Refrigeration Division

FES Systems Inc.3475 Board Road York, PA 17406

Tel: 800-888-4337 717-767-6411Fax: 717-764-3627

[email protected]

condenser - iiarweb.iiar.org/membersonly/condenser/5-2008.pdf · condenser may 2008 published by...

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