2019 Nov-Dec RETA Breeze

RETA BREEZE REFRIGERATING ENGINEERS & TECHNICIANS ASSOCIATION NOVEMBER / DECEMBER 2019

THANK YOU TO EVERYONE WHO ATTENDED RETA 2019

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BREEZE

How to Properly Complete an IIAR 6 System Safety Inspection Checklist Form? page 19

The RETA Breeze is the official publication of the Refrigerating

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

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

INSIDE THIS ISSUE

sara@reta.com Dan Reisinger Certification Manager dan@reta.com Michelle Robinson Conference Manager michelle@reta.com Dan Denton Chapter Relations Liaison ddenton@reta.com

Message from the President..............4 2019/2020 Announcement...............6 Reta Officers & Board of Directors Epic Fail...............................................8 Part Deux ConferenceWrapUp..........................10 Planning for our next conference & a call for abstracts Awards Corner.................................15 Compliance.......................................16 Ammonia pipe and equipment labeling - part 2

The Shade Tree Mechanic...............18 volume XXXIII How to Properly Complete an IIAR 6 System Safety Inspection Checklist Form?............19 RETA Testing Corner No. 16..........25 RETA’s Testing and ANSI Guru Certification......................................27 Honor Roll Anniversary Milestones..................29

The information in this publication is based on the collective experience of industry engineers and technicians. Although the information is intended to be comprehensive and thorough, it is subject to change. The Refrigerating Engineers & Technicians Association expressly disclaims any warranty of fitness for a particular application, as well as all claims for compensatory, consequential or other damages arising out of or related to the uses of this publication. Publication of advertisements in Breeze , or any other RETA publication, does not constitute endorsement of any products, services or advertisers by RETA and shall not be considered or represented by advertiser as such. Copyright © 2019 Refrigerating Engineers & Technicians Association.

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

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

FROM THE DESK OF THE PRESIDENT

My first Presidents report . I want to sincerely thank the membership for their confidence in me. I will endeavor to do my best to prove your confidence in me is well founded. This month we are printing the acceptance speech from conference. It has been shortened. My “ahs” have been removed and a few stories were removed for the sake of space, and the grammar has been cleaned up. But here is the acceptance speech from October 10th, 2019. expected, ever, to be up here on this stage. I was surprised when I got the call to join the National Board. I told Dave Murphy no, he needed somebody better than me. When I got the second call, I thought “well they keep calling, maybe I should try it.” So I accepted the nomination. It has been an incredible journey. There are a few people I would like to thank. First of all, I would like to thank God. I would like to thank my wife Tonya, my daughter Sarah, and my RETA family. WMI and all of you that have spent so much time with me, thank you so much. I would like to thank some of the old Arlie, thank you very much. ... this is a very humbling experience. I never

timers such as Leroy Mosby. I would tell Leroy Mosby all the things I didn’t like and Leroy would say, “well then do something about it.” So, he started calling Jim Marella and finally I got to meet with Jim and “do something about it.” So thank you to all the old guys. Larry Kellys and TimWagner who hired a 19 year old child who didn’t have enough common sense to comb his hair before his interview. Thank you Tim. Thank you Tex Hildebrand who saw something, I will never know what it was. He spent a lot of years, the last years of his life, trying to teach me the art of refrigeration. I know this would be a very proud moment for Tex. He deserves this much more than I do. Thanks Tex. RETA is history. An old history. A

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

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history of education. A history of coming together for the good of the industry. When 4 men got together in 1909 and said we have to do something. There are operators on their own with no support. We have to do something. We have to find a way to bring everybody together. In January 1910, the four guys got back together, and two additional guys showed up. JB Embry made it his personal duty to invite every operator and engineer to the 1910 convention. He sent hundreds of letters around the country. In December 1910, the original 58 members of the organization assembled. Oh, we have a vast history. A history of helping one another. A history of coming together. Our organization has survived a lot. It survived several world wars. It survived 9/11. It survived the blackout. The organization is strong. It continues to be strong. It will be strong in the future. So what is the future? The future is better support for our members. Better support for our chapters. The future is going out and finding the people who are unaware. Who are unaware of RETA. Who are unaware of how to properly operate an ammonia refrigeration system. Those people who get up every day and take personal responsibility for the safety of themselves, for the safety of their plants, and for the safety of their community. It amazes me that we require degrees for accountants but not refrigeration operators. No one has ever died because a filing drawer leaked. Our operators take personal responsibility for their safety. They go to work in the morning, often they go to work at night. And they say nothing is going to happen to my community on my shift. We need to support those people.………

One item I would like to read. In our Constitution, Article 2 PURPOSE: The purpose of this Association shall be: To further the education, training, and technical knowledge of its Members in the art and sciences of refrigerating engineering and all phases of refrigeration; to disseminate information concerning refrigeration and refrigeration engineering; and to engage in, foster and encourage research in the field of refrigeration. Nowhere in that statement do you hear industrial. Nowhere in that statement do you hear ammonia. It says refrigeration. In 1909, there was no commercial. There was no residential. Fredrick Wolfe didn’t automate the ice box until 1915. It was the only refrigeration. I

1967. RETA was already 58 years old in 1967. We need to start educating our brothers and sisters, who are starting to get into the areas of small ammonia systems. We need to find operators that are running industrial systems who don’t know about RETA. Find the operators who are not educated in our art, operators who are trying as hard as they can to keep their community safe. We need to find them, put our arms around them, and bring them into the fold. And they need to be paid for what they do. ….. They have enough problems trying to run an industrial refrigeration system without the education. So please when you find these people, put your arms around them and tell them about RETA. Tell them about what we can offer. Invite them to a chapter meeting. Educate them. Make them and their family safe. I don’t think there is a higher calling we can have as a group, then to help other fellows. I would not be standing here if there hadn’t been dozens, hundreds of people who helped me. As we go into next year, we have some great things planned. A lot of continuations of current programs. A lot of continuations of current ideas.

“I don’t think there is a higher calling we can have as a group, then to help other fellows. I would not be standing here if there hadn’t been dozens, hundreds of people who helped me.”

Arlie Farley started a lot of great things; I want to carry them on. With that, I think I have been up here long enough. Thank you very much.

have certifications from multiple organizations, but I am proudest of my CRST than any other. I think that this service technician patch is, the crowning achievement of any refrigeration career. I cried the day I received it. It’s time that the industry has one voice. Regardless of the application. Regardless of the commercial. Regardless of the industrial. It needs to have one voice, a RETA voice. The other organizations do not have the history of RETA. Some are old, RSES was founded in 1933. IIAR in

RETA.com 5

2019/2020 RETA Officers & Board of Directors Announced

Industry leaders elected to serve a three-year term on the Board of Directors are Bill Lape of SCS Engineers; Jim Kovarik of Gamma Graphics Services; Ray Urban of Lineage Logistics; and Ricky Jimenez of Mericle Mechanical Inc. Additional members of the 2019/2020 Board of Directors are Bengie Branham of Perdue Farms; William Ellena of Coastal Pacific Food Distributors, Inc.; David Gulcynski of Dot Foods, Inc; Edward Johnson of Schwans Global Supply

RETA WAS PLEASED TO ANNOUNCE the 2019/2020 Officers and Board of Directors at their Annual Business Meeting, held recently in Las Vegas, Nevada. Arlie Farley of Farley’s SRP Inc. assumed the role of the Association’s Chairman of the Board and Vern Sanderson of Wagner- Meinert, LLC assumed the role of National President. To round out the Executive Committee are Executive Vice President, Eric Teale of Danfoss

Committee Chairs for 2019/2020 are:

Certification Lee Pyle SCS Engineers Education Dave Gulcynski Dot Foods Marketing Rick Chabot ISEL, Inc

Membership Mike Hawkins Midatlantic Refrigeration, LLC National Conference Jim Kovarik Gamma Graphics Services Publications

“I AM THRILLED TO WELCOME THESE TALENTED INDIVIDUALS TO THE BOARD. THEIR UNIQUE BACKGROUNDS AND DIVERSE EXPERIENCE WILL MAKE THEM A GREAT ASSET TO RETA’S BOARD AND THE ASSOCIATION,” RETA Executive Director, Jim Barron, announced.

Matt Hayes TJW Industrial

Chain, Inc; Frank Kologinczak III of Kolo Compression; Jordan Reece of Lanier Technical College; Matt Hayes of TJW Industrial; and Michael Hawkins of Midatlantic Refrigeration, LLC.

Industrial Refrigeration; Treasurer, Keith Harper of Tyson Foods Inc; and National Second Vice President, Peter Lepschat of Henningsen Cold Storage Co.

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EPIC FAIL

While I appreciate photos of nice, clean installations as much as the next person, they really don’t make a person sit up and take notice. I’m not saying that they shouldn’t, but they don’t. What I want to try to highlight in this column is the many failures that come together to form each picture. That way, maybe we can begin to learn from these Epic Fails and start to take steps to prevent them in our plants. So here we go. PART DEUX Welcome to Epic Fails, Part Deux. It is my honor to take over the column from the esteemed Mr. Farley.

Temperature section of the Boiler and Pressure Vessel Code states that “Occasional operating temperatures colder than -20°F are acceptable when due to lower seasonal atmospheric temperature.” However, this particular vessel was OPERATING below -20°F, making it non-compliant with the Boiler and Pressure Vessel Code. Thankfully, once pointed out to the facility, they replaced it with a new vessel rated at -40°F. So what failed? To start with, the installing contractor either failed to specify the correct rating when ordering the vessel, or they failed to double check the rating when they received the vessel, and the facility failed to catch the error as part of a Pre-Startup Safety Review. If you have photos of an Epic Fail please pass them on to nh3isB2L@gmail.com. Please note that the email address has changed, although I am sure that Arlie won’t mind receiving them. Bill Lape is Project Director for SCS Engineers. Bill is a Certified Industrial Refrigeration Operator, a Certified Refrigeration Service Technician, and a member of the National Board of Directors of the Refrigerating Engineers and Technicians Association.

The snapshot above is from the nameplate of a transfer drum that had been installed less than six months prior to the audit.

This was the vessel to which the transfer drum was attached. Except for the times when it was transferring and it was pressurized with hot gas at high side pressure, it was operating at -30°F. Now Section UG-20, the Design

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CORNER CONFERENCE

Planning for our next Conference & a call for abstracts Conference wrap up Michelle Robinson, RETA Conference Manager

prepare for our next Conference and here are a few things we are currently working on: • Quality time/ hours in Exhibit Hall • Engaged traffic in the Exhibit Hall • Technical Topics, Hands on Sessions, Workshops and Tear Downs • WiNR (Women in Natural Refrigeration) • Entertainment - My personal favorite We have started Conference planning early for success! With that being said… On behalf of RETA, the RETA 2020 Technical Conference Committee is sponsoring a Call for Abstracts relating to Industrial Refrigeration. The Committee welcomes papers on the following suggested topics: • Management Authors of accepted abstracts will present their work at the RETA 2020 National Conference, taking place from October 27-29, 2020 in Orlando, Florida. In addition, the papers will be published and given to each attendee. Both RETA members and non-members are invited to submit proposals for papers. Call Paper Timetable: Timely submission of the abstract is critical to the success of the program. The procedures and timetable enumerated below will apply. All authors will receive electronic notification indicating acceptance or decline of the submitted abstract in mid-February of 2020. • Compliance • Operations • Engineering

WOW…what an experience I had for my first RETA Conference! At the time of Conference, I had been with RETA for two months and during that time, I heard tons of amazing and encouraging comments and thoughts about this “RETA FAMILY”. Well… everyone was absolutely RIGHT! I couldn’t have felt more at home and welcomed into this family as if I was back in my home State of Texas. The support and faith of the Board of Directors, Staff, Volunteers, Sponsors, Exhibitors and Attendees was the key component to the success of the Conference. I humbly thank you for the help and patience you showed during my first RETA Conference experience.

Thank you! I am looking forward to planning our upcoming 2020 National Conference in Orlando, Florida on October 27-29th. NOW LET’S GET TO BUSINESS! During our 2019 National RETA Conference we had over 1,000 participants! Our first week back at RETA Headquarters we sent out a survey which I hope you all took the time to take. We heard what you had to say, and we plan to address your comments. On November 4, 2019 we had our first of many Conference Planning Committee meetings. We have already started to plan and

The next conference will be in Orlando, Florida.

Continue on page 12

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A twelve point selection process will be used by reviewers. It will be suggested that contributors use the 12 points as a guide before submitting an abstract. Note: Authors who do not follow these guidelines are more likely to have their work rejected. • Does the abstract capture the interest of a potential reader of the paper? • Is the abstract well written in terms of language, grammar, etc.? • Does the abstract engage the reader by telling him or her what the paper is about and why they should read it? • Does the abstract title describe the subject being written about? • Does the abstract make a clear statement of the topic of the paper and the research question? • Does the abstract say how the research was/is being undertaken? • Does the abstract indicate the value of the findings and to whom will they be of use? • Does the abstract describe the work to be discussed in the paper? • Does the abstract give a concise summary of the findings? • Does the abstract conform to the word limit of 300-350 words? • Does the abstract have between 5 and 10 keywords or phrases that closely reflect the content of the paper? • Should the abstract be accepted? Thank you for your time and effort…it is greatly appreciated! I am looking forward to a fun and informative Conference! Michelle Robinson RETA Conference Manager

Call for abstracts to share at the next Conference. Continued form page 10

your abstract. Questions may be addressed to Michelle Robinson at Michelle@reta.com ABSTRACT STRUCTURE, GUIDELINES AND SELECTION PROCESS Abstract Structure: A model abstract should contain the following elements: • A statement of the purpose of the paper. • The research methods/methodology used to arrive at your results and/or conclusions. • The results observed. • The conclusions drawn from the topic and their significance. Abstract Structure and guidelines: • The abstract should be no more than 350 words. • Purpose: Ideally in 1-3 sentences, state the primary objectives and scope of the study or the reasons why the document was written. Also state the rationale for your research. Why did you do the research? Is the topic you are researching an ignored or newly discovered one? Why is it significant? • The abstract should be void of any self or commercial promotion and/or advertisement. • An abstract template is available online.

1. Deadline for Abstracts January 13, 2020, Authors to submit an abstract. 2. Acceptance or Decline of submit- ted Abstract February 17, 2020, Authors will receive an email of acceptance or decline 3. Deadline for White Papers June 1, 2020, Authors will submit completedWhite Paper 4. White Paper Peer Review June 1- July 1, 2020, Peer review of White Paper and Authors revision 5. Distribute PowerPoint Presenta- tion Template and Guidelines for White Papers to Authors July 1, 2020 6. Peer Review for PowerPoint Presentation of White Papers August 1- Sept. 1, 2020, Peer review of PowerPoint Presentation and Authors revision 7. Deadline for PowerPoint Presen- tation of White Papers September 2, 2020 The RETA Technical Conference Committee looks forward to receiving abstract proposals in response to the call and is happy to respond to inquiries from interested parties. Please visit https://reta.com/ page/2020-conference-abstract for further information and to submit

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Thank you to all of the 2019 National Conference Exhibitors

1 Stop Compliance LLC. AC&R Specialists Acorn Surfaces & Treatments Acuren Inspection Airfoil Impellers Airgas Specialty Products Alfa Laval Inc. Ammonia Refrigeration Service, Inc. Analytical Technology Inc. Apex Refrigeration & Boiler Co. Applied Process Cooling Corporation (APCCO) APSM ASTI Azane Inc. Bacharach Inc. Baltimore Aircoil Company Bassett Mechanical Benshaw, Inc. BITZER U.S. Inc. C&L Refrigeration Cal-Therm Inc. Calibration Technologies Inc. (CTI) California Controlled Atmosphere dba CCA- Technologies Camco Lubricants Carnot Refrigeration Inc. Castel Srl CIMCO Refrigeration Inc. Climate By Design International, Inc. (CDI) Colmac Coil Manufacturing, Inc.

Cyrus Shank Company Danfoss Inc. DeHart Construction Services Inc. Delta Tee International Inc. Draeger Inc. Dual Temp Clauger Evapco Farley’s S.R.P. Inc. Fisher Refrigeration Inc. Frick Industrial Refrigeration Frick Industrial Refrigeration Parts FrostPoint LLC Garratt Callahan Company Gartner Refrigeration & Manufacturing Inc. GCAP - Garden City Ammonia Program GEA North America General Refrigeration Company GGS - Gamma Graphics Services Guntner US LLC H.A. Phillips & Co. Hansen Technologies Corporation Hantemp Controls Heatcraft Refrigeration Products Hermetic Pumps Inc. Hill Brothers Chemical Company Hillphoenix Howden Roots dba Howden Compressors HT Industrial Ltd. FLSmidth Inc. Frascold USA

Industrial Consultants Industrial Refrigeration Parts Industrial Refrigeration Technical College (IRTC) Insul-Therm International Inc. Integrated Circuit Systems, Inc. Intercool USA, LLC International Institute of Ammonia Refrigeration (IIAR) ISEL, Inc. Jamison Door Company JAX Refrigeration Joe White Tank Co. Kerco, Inc. Kolbi Pipe Marker Co. Lanier Technical College LEWA-Nikkiso America, Inc. Lineage Logistics Logic Technologies, Inc. Logix M&M Refrigeration Mac Rak Incorporated Marking Services Inc. Mayekawa USA/MYCOM MIRO Industries Morris & Associates, Inc. Motortronics MRBraz & Associates, PLLC MTH Pumps Multi-Wing America, Inc. Nexus Refrigeration Nitto, Inc. Northwest Technical Institute Owens Corning Parker Phoenix Air Systems Polyguard Products, Inc.

Powered Aire Inc. Process & Safety Solutions, LLC Process Cooling Magazine; BNP Media Co. PRUFTECHNIK PSM RMP Solutions Refrigerated Mechanical Solutions Republic Refrigeration, Inc. RETA HQ Risk Management Professionals Inc. Rooftop Anchor Refrigeration Systems Construction and Service Inc. (RSCS) Safety Products Group SCS Engineers ServiceTrade SGS Refrigeration, Inc. Shambaugh & Son, L.P. Stellar Sterling Industrial Refrigeration Summit Summit Refrigeration Group Synergy Refrigeration Tecogen Inc. Teikoku USA Inc. VaCom Technologies Vapor Armour Vilter Manufacturing LLC Wagner-Meinert LLC Warrender, Ltd.

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AWARDS CORNER

THE FOLLOWING AWARDS were bestowed at the 2019 RETA National Conference. The awards are named in honor of past RETA members who exemplified a specific strength that benefitted RETA membership and our industry through teaching, leadership, or service. A big congratulations and thank you to all of the Award Recipients. The following were honored for their service to the Association and the Industry.

The Earl J. McMichael Award was presented to the Central Valley Chapter for the best growth performance of the previous 12 months.

The Venemann Award was presented to John Shish for his outstanding efforts in advancing the aims and ideal of the Association and for his contribution to the education and inspirational betterment of the Association throughout his career.

The Felix Anderson Award was presented to Pat Bates of the Monterey Bay Chapter and Steven Mesner of the Western Wisconsin Chapter for their exemplary contribution to the development, growth and strength of their chapters.

The Guy R. King Award was presented to Jeff Sloan for his outstanding performance in the education and training of members nationally and locally.

The Outstanding Chapter President Award was presented to Gordon Rascoe, Jr of the Ft. Wayne Chapter.

The Elliot. R. Hallowell Award was presented to Raymond Urban, Jr whose record of service to RETA for the current year merits special recognition and reward

RETA.com 15

COMPLIANCE

AMMONIA PIPE AND EQUIPMENT LABELING PART 2

By Bill Lape, SCS Engineers IN PART I OF THIS SERIES, I described some options that facilities have when choosing their RAGAGEP for pipe and equipment labeling. Even though the specific colors and abbreviations called out in Bulletin 114 from the implemented as part of a facility’s labeling program, most facilities in the food processing and cold storage industries that use ammonia as a refrigerant follow it, or at least claim that they do. In this issue, we will look closely at the pipe label recommendations found in Bulletin 114, highlighting some of the changes that have been made to the document over the last 18 years, and we will discuss some of the areas where facilities find themselves tripped up. Bulletin 114 calls out label colors, sizes, and placement of labeling on pipes and equipment in ammonia refrigeration systems. It also calls out specific wording used for the state of the refrigerant, the pressure of the refrigerant, and for the function of the refrigerant in the pipe. Bulletin 114 was first published in 1991. At that time, the primary background color for the label was Safety Yellow. Starting in 2014, Bulletin 114 made a change to Safety Orange to more closely align with ASME A13.1, which calls out Safety Orange as the color for corrosives and toxics. International Institute for Ammonia Refrigeration are not required to be

In 1991, a label for a High Pressure Liquid line would look something similar to this:

Starting in 2014, the label would look something like this:

One thing to note is that the 1991 edition made no mention of a specific color for the state and pressure band text. Starting in 2014, it specifies black text for those bands. Another change that occurred was in the vapor state band. The pictures below show how it has changed over the years.

1991, 2014, 2017 Editions

2018 Edition

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One area that has consistently tripped up many a facility is the function abbreviations for the pipe. Remember, there is NO requirement that the abbreviations that are called out in Bulletin 114 be used. However, if abbreviations are used on labels that are not called out in Bulletin 114, then your Process Safety Information (PSI) MUST list those abbreviations that differ or are not found in Bulletin 114. Does the top image on this page SSS mean Single Stage Suction? In the bottom left image, does CD mean Condenser Drain as called out in Bulletin 114? In one picture, it actually means Condensate Drain, while in the other it means Condenser Drain. Can you tell which one? A refrigeration operator would pick out the Condensate Drain line to be the insulated one. Here’s the problem. How does the new guy tell the difference? How does a first responder? Also, if you look closely, the pressure band on the Condensate Drain is wrong. It should be LOW, as it operates under 70 psig. Also, the state bands should be both LIQ and VAP since two phase flow occurs in that pipe. Regardless of the abbreviations used, your employees must be trained on them through documented training. This is an easy finding for an auditor. Remember, if

Does SSS mean Single State Suction? In which image does CDmean Condenser Drain or Condensate Drain? Can you tell?

you state in your PSI that you follow Bulletin 114, then you must do so.

Which brings us to our last topic for this issue. Do you have to switch to the newer Bulletin 114 color schemes? The answer is no, BUT if you wish to continue to use the yellow labels on your piping then you must state in your PSI that you follow IIAR Bulletin 114-1991. If you don’t specify a year, auditors and regulators will look to the most recent edition. In the next issue, we will discuss the recommendations found in Bulletin 114 for pipe colors and equipment labeling. Bill Lape is Project Director for SCS Engineers. Bill is a Certified Industrial Refrigeration Operator, a Certified Refrigeration Service Technician, and a member of the National Board of Directors of the Refrigerating Engineers and Technicians Association.

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SERVICE

The Shade Tree Mechanic volume XXXIII

Sharing Secrets My second shift maintenance

So accordin to them business guys, news needs to come from a feller’s direct supervisor. Who woulda thought, huh? So what Bobby has been doin is tellin the guys what’s comin, because Bobby thought they would believe that the changes needed made if the news comes from him. But ya see he was also hedgin his bets. Ifin the change proved to be a bad idea, well I officially announced it, so it was on me. That struck me as a bad idea. But Bobby explained that having me be the bad guy was also good for me. Ya see, since everybody trusts Bobby then Bobby can kinda explain that I’m not a bad sort, just misguided on whatever the bad change was. He could kinda explain things to everybody. He says he can be a friend to both sides. His reports and his manager. I’m thinkin I need to think on this a little more over a beer. I get that even though it seems like sharin secrets and releasin information early is wrong, it does kinda get everybody used to what’s come down the pipe.

share that secret. But maybe the little ones are ok. The tough part may be decidin what secrets are ok to share and which ones ain’t. So, I and Bobby figured out a system. If I think that it’s ok to share something unofficially, I let Bobby know. If it isn’t I let him know not to say anythin. And you know if it’s really important for him not to tell someone, maybe I just don’t tell Bobby. Regardless, I’m not tellin anyone about dad’s car. The shade tree grows outside of the little town of Broughton, Ohio. Where everyone is always welcome, the beer is always cold, and something is always needin fixin.

supervisor drives me crazy. Not because what he does is harmful. What’s done is actually beneficial, but it seems wrong. So Bobby is always sharing secrets. Nothin earth shatterin, but he can’t seem to keep things quiet. Every time, we decide to change somethin in maintenance, like a procedure or sumpin, he tells everybody. Not officially mind you. Oh no, I still gotta hold a meetin to tell everyone officially. But usually Bobby has told everyone and no one is surprised. So’s I told Bobby last week that if keeps doin that, I’m tradin him to the eviscerating supervisor for a Budweiser. Bobby just looked at me and smiled. “Just helpin ya out bossman”. So I shot back “How exactly does that help me?” That’s when I learned that there was more to Bobby than I thought. He started telling me about these business books he’s been readin. How to manage change, how to build teams, how to make everythin run smoother. Well heck, I’m all for things runnin smoother. So I asked him to fill me in. Here is what I learned. See them business fellers did a study and figured out that most fellers trust their supervisor more than their supervisors’ boss. They trust their supervisors’ boss more than the head man at the plant, heck almost nobody trusts him.

It also lets them know that their supervisor (Bobby) is in the know and lookin out for em. Now I’m not thinkin it’s a good idea to share everythin. I mean, when I was a lot younger, my brother

accidently scratched dad’s car one night sneakin out to see his girlfriend, who was my other brother’s ex-girlfriend. I don’t think it would be a good idea to

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How to Properly Complete an IIAR 6 System Safety Inspection Checklist Form? Juan Parra Sr. Project Professional at SCS Engineers

THIS STANDARD INCLUDES the following two requirements, among others: Under “Section 5.1 *ITM Program Requirements”: “5.1.1.3 Each inspection and test performed shall be documented and include the following information: 1. Date of inspection or test; 2. Name of the individual or individuals who performed the inspection or test; 3. Serial number or other identifier of the equipment on which the inspection or test was performed; 4. Description of the inspection or test performed; 5. Recommended corrective action(s) for each deficiency identified; Earlier, this year, the “International Institute of Ammonia Refrigeration” (IIAR) released the“Standard for Inspection, Testing and Maintenance of Closed-Circuit Ammonia Refrigeration Systems”, ANSI/IIAR 6-2019.

6. Description of corrective action(s) for each deficiency identified; 7. Identification of each designated responsible person assigned and authorized to remedy each deficiency identified; 8. Results based on the conditions at commencement of the inspection or test, including instrumentation readings; 9. Expected activation set points (+/-) including functional description of the control logic; 10. Results based on the conditions after

present a conflict of interest and shall report instances of deficiencies.” ii

The term “ qualified inspector ” is defined by the standard as “a person who is experienced with close-circuit ammonia refrigeration systems, has knowledge of the process, and has demonstrated proficiency and understanding to perform inspections” iii . ANSI/IIAR 6-2019 Appendix B provides a series of forms known as “Ammonia Refrigeration Safety Inspection Checklists” . These checklists are considered an acceptable way of complying with ANSI/ IIAR6-2019 5.1.1.3 and ANSI/IIAR 6-2019 5.4.2 of this standard. It must be understood that ANSI/IIAR 6-2019 does not require the use, specifically, of the forms provided in Appendix B. A facility may elect to meet requirements from IIAR 6-2019 5.1.1.3 and ANSI/IIAR 6-2019 5.4.2 by other means. For the purpose of this paper, we will focus on understanding how to fill out the forms provided in ANSI/IIAR 6-2019 Appendix B and realizing the benefit the information in the forms provide the facility. In general, each of the forms provided in ANSI/IIAR 6-2019 Appendix B can be broken down in to two sections. A first

completion of the inspection or test, including instrumentation readings,

11. Expected completion date(s); 12. Actual completion date(s).” i Under “Section 5.4 Inspection Requirements” it states:

“5.4.2 *Equipment inspections shall be performed by a qualified inspector(s). Every fifth (5th) year, at a minimum, the annual inspections shall be conducted by a qualified inspector who shall not be influenced by the facility’s record keeping, operations, maintenance, or management. This person shall not

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Some of the information required on the first section of the safety inspection checklists may be readily available; Often, it may be obtained from the equipment’s nameplate. At a minimum, a typical nameplate will have the equipment’s manufacturer, serial number and model number. Most, if not all, of the operating parameters can be obtained from observations throughout the inspection, discussion with operators, etc. When dealing with equipment packages, it is important to understand that the serial number or other identifier of the specific pieces of equipment being inspected is required. Checklists in ANSI/IIAR 6-2019 Appendix B also ask for model number. For example, when filling out an ANSI/IIAR 6-2019 safety inspection checklist for a compressor from a compressor package, the serial number or other identifier and model number of the compressor unit is requested by the form. There is added value of including the package model and serial number, but the model and serial number of the specific piece of equipment, not the package, is the requirement. An obvious question that will present itself is: If a refrigeration equipment nameplate is not present or not legible, should a recommendation be made? The answer is yes. Per current ANSI/IIAR 2-2014 Standard for Safe Design of Closed- Circuit Ammonia Refrigeration Systems section 5.14.4.1 which states: “Equipment shall have a nameplate with minimum data that describes or defines the manufacturer’s information and design limits and purpose as specified in Chapter 8 through Chapter 16.” iv Furthermore, previous Standard ANSI/IIAR 2-2008, also had nameplate requirements on refrigeration equipment. ANSI/IIAR 6-2019 safety inspection checklist do not specify compliance for any specific year of IIAR 2. An inspector should consider the age of the equipment when making nameplate related recommendations. At a minimum, legible nameplates is considered RAGAGEP. Hence, the owner or designated representative should be aware. The above question is in fact the question a) “Equipment labeled and name plate legible per ANSI/IIAR 2?” v of most current

section, typically page 1, which gathers the facility information, equipment data (application, manufacturer, serial number, model number, etc.), operating parameters (pressures, temperatures, etc.), related safeties (relief valve data, safety device set points, etc.), among others. A second section contains at the inspection items themselves. The first thing that needs to happen is knowing what equipment must actually be inspected. It is very common in the ammonia refrigeration industry to find equipment packages. Typically, such packages will be composed of several pieces of equipment which need to be individually inspected. Packages may have specific serial and model numbers tied to them; however, the pieces of equipment composing the package will most likely have their own model, serial number and may very well be manufactured by a different company than the package manufacturer. equipment specific. This means that several checklists will need to be filled out for a single refrigeration equipment package. To better explain this, below are three examples of different packages commonly seen in Safety inspection checklists are supposed to be refrigeration

the industry, each of them requiring more than one equipment specific checklist to be filled out during an inspection. A thermosiphon oil cooled rotary screw compressor package: Checklist 1. Compressor unit Checklist 2. Oil cooler heat exchanger Checklist 3. Oil separator vessel

A dual pump recirculator package: Checklist 1. Recirculator vessel

Checklist 2. Pump 1 Checklist 3. Pump 2 Checklist 4. Oil Pot vessel

A flooded he a t exchanger package: Checklist 1. Surge drum vessel Checklist 2. Heat exchanger Checklist 3. Oil pot vessel

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ANSI/IIAR 6-2019 equipment Safety Inspection Checklists. However, the information needed to complete some of the equipment information, may go in to much more detail for each piece of equipment. For example, when motors are part of the refrigeration equipment, the motor information (manufacturer, hp, rpm, FLA, Hz, voltage, phase, service factor, frame size, belt quantity, belt size and motor quantity) will typically be required in the checklist forms. Another example is that air cooling evaporator, heat exchanger and condenser safety inspection checklists all ask that the material for the heat exchanger surface(s) (galv. steel, stainless steel, aluminum, or other) be checked or indicated. This type of information may not be readily available; it is not uncommon that equipment motors cannot be freely accessed or their nameplate is no longer legible; the material of the heat exchanger surface is often not marked on the equipment itself. An inspector should not freely guess this information but rather the equipment manufacturer specifications will be needed to properly verify it. Ideally, a facility owner or designated representative will be able to provide the information that is not readily available to an inspector before an inspection. When the information is not available, the owner or designated representative may choose to have the inspector research missing information. Depending on what information is needed, the amount of research may be extensive and will consequently have a cost associated with it. The good thing is that once the manufacturer’s data sheets, drawings, cut sheets, or manuals are obtained, the research will not have to be conducted again. When the data gathered, on the first section of an equipment specific safety inspection checklist is correct and up to date, it may be used as a quick reference tool for simple tasks, such as ordering replacement parts, such as ordering an air cooling evaporator fan motor. Or it may be used to aid more complex tasks, such as replacement of the air cooling evaporator itself. Gathering all this information for the first time may require an original investment of time and effort, but once is completed it can save maintenance and operations staff time when the information is needed. Rather than having to look for this data repeatedly on the equipment, or in the equipment documentation, every time it is needed, it will be readily available by simply referencing the checklists. This can represent significant savings in time and money over the life span of an ammonia refrigeration system. When filling out equipment specific checklists it is very important to read in detail what is actually required.

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checklist is asking if it is “ Free of ”while previous IIAR B109 checklist was asking if it “ Has been ”. Furthermore, the second part of IIAR Bulletin 109 Compressor Safety Inspection Checklist question, “If yes, has casing been recertified and documented?” v has been separated into a question by itself in the current ANSI/IIAR 6-2019 Compressor Safety Inspection Checklist, Question o), which reads; “If, No has it been pressure tested and documentation filed?” iv . Again, the questions are very similar in nature but the same yes or no answer to each of them will have opposite meaning. This scenario is not specific to the compressor safety inspection checklist; similar questions are contained within the safety inspection checklists for pressure vessels and heat exchangers. An experienced inspector who is used to filling out a B109 checklist may assume that these questions are the same, when in reality they are similar but opposites. Another important detail, which should not be overlooked, is the possibility of selecting the Not Applicable (N/A) box on ANSI/IIAR 6-2019 Safety Inspection Checklists. There are questions on the forms that are linked together. Looking at the same ANSI/IIAR 6- 2019 Compressor Safety Inspection Checklist questions n) and o): • “n) Free of modifications, alterations, iv IIAR 2014. Chapter 5. General System Design Requirements. ANSI/IIAR 2-2014 Standard for Safe Design of Closed-Circuit Ammonia Refrigeration Systems. Revision 2014 pp 15 v IIAR 2019. “Appendix B. Ammonia Refrigeration Safety Inspection Checklist. Air Cooling Evaporators”. ANSI/IIAR 6 Standard for Inspection, Testing and Maintenance of Closed-Circuit Ammonia Refrigeration Systems. Revision 2019 pp 85 vi IIAR 2019. “Appendix B. Ammonia Refrigeration Safety Inspection Checklist. Compressors”. ANSI/ IIAR 6 Standard for Inspection, Testing and Maintenance of Closed-Circuit Ammonia Refrigeration Systems. Revision 2019 pp 89 damage or repairs such that casing integrity is or has been affected?” iv

• “o) If, No has it been pressure tested and documentation filed?” iv When checking the “Yes” box to question n), consequently, the “N/A” box should be checked on question o). The same does not question o) may require further review of related information and a recommendation may be required. In summary, when filling out the ANSI/IIAR 6-2019 Ammonia Refrigeration Safety Inspection Checklists, located in appendix B, some of the information required may not be readily accessible. When answering the checklist questions, a “Yes” answer does not generally require a recommendation inspector should be familiar with current applicable standards (ANSI/ IIAR 2, and ANSI/IIAR6 as a minimum), industry recognized and generally accepted good engineering practices (RAGAGEP), ammonia refrigeration industry applicable regulations (GDC, PSM, RMP, CalARP, NDEP CAPP, among others) and they must meet the “ qualified inspector ” definition per ANSI/IIAR 6-2019. When information required to complete a checklist information field, or to answer a question, is missing or not accessible , the inspector should consider applicable standards, RAGAGEP, regulations, and experience to determine what recommendation is appropriate and when. apply if the “No” box is checked on question n). In this case, answering and a “No” answer usually requires a recommendation viii . The qualified vii IIAR 1997. “Section 7. Inspection Checklist”. IIAR Bulletin No. 109. Guidelines for: IIAR Minimum Safety Criteria for a Safe Ammonia Refrigeration System. Revision 10/97 viii viii IIAR 2019. “Appendix B. Ammonia Refrigeration Safety Inspection Checklists.3.”. ANSI/IIAR 6 Standard for Inspection, Testing and Maintenance of Closed-Circuit Ammonia Refrigeration Systems. Revision 2019 pp 83

Even though this seems simple and obvious, an otherwise qualified inspector who is unfamiliar with the checklists may record the wrong information simply because they failed to fully read and understand a question. For example: • Q uestion n) of the current ANSI/IIAR 6-2019 Compressor Safety Inspection Checklist reads; “Free of modifications, alterations, damage or repairs such that casing integrity is or has been affected?” vi • Question e) of the previous IIAR Bulletin 109 Compressor Safety Inspection Checklist reads; “Has compressor been modified, altered, damaged or repaired such that casing integrity is affected? If yes, has casing been recertified and documented?” vii These questions are very similar, however answering yes or no on each of them have opposite meaning. ANSI/IIAR 6-2019 REFERENCES: i IIAR 2019. “Chapter 5. General, Section 5.1 ITM Program Requirements”. ANSI/IIAR 6 Standard for Inspection, Testing and Maintenance of Closed-Circuit Ammonia Refrigeration Systems. Revision 2019 pp 9. ii IIAR 2019. “Chapter 5. General, Section 5.4 Inspection Requirements”. ANSI/IIAR 6 Standard for Inspection, Testing and Maintenance of Closed-Circuit Ammonia Refrigeration Systems. Revision 2019 pp 13. iii IIAR 2019. “Chapter 2. Definitions, qualified inspector”. ANSI/IIAR 6 Standard for Inspection, Testing and Maintenance of Closed-Circuit Ammonia Refrigeration Systems. Revision2019 pp4.

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