RETA National Conference San Antonio, Texas Nov. 6-10 Summary of Classes Guide to NEP Audits, John Sherrill, RETA Educ. Committee 1. History of compliance from 1915, to building codes, self regulation, industry safety standard, chemical safety standards to EPA and OSHA Enforcement. 2. NEP trial in 2009, extension in 2010, permanent in 2011. 3. Criteria: Safety violation, complaints, accidents, random. 4. Inspector or assistant trained in NH3 and PSM. 5. Contractor does not equal Limit to Liability. 6. Procedure: Opening conf., document presentation, safety plans, walk through, process ident., contractors, history, citations. Condensation Control. Jim Your, ITW Insulation Syst. 1. Reasons to control condensation (damage, health, safety, etc. 2. Causes, dewpoint dictated. 3. Wind effect (higher, less) 4. Components: Emissivity, insul. Factor, geometry (convective) 5. Design dewpoints, use 80-90% relative humidity at design dry bulb. 6. Can be mitigated with emissivity changes. Dehumidification with NH3 and reheat. Bill Ritzer, RC&E 1. Purpose: Reduce condensation, defrost loads, bacteria and mold, product damage. 2. Use refrigeration and reheat above 36dF room applications. 3. Use desiccant and refrigeration below 36dF. Optimum Fan Power on Condensers. Jeff Welch, Welch Eng. 1. High HP fans on low cost condensers greatly benefit from VFD use. Low HP fans on large condensers may not. 2. Never use a VFD on a pump. dP is the square of the drop in RPM and reduces flow. 3. Calculatable optimum fan power for a given area. High WB areas benefit most for unit upsize. Use average WB, not design for calc. 4. Wet bulb following: Design TD should be a function of actual capacity at various WB, SCT conditions. 5. Minimums dictated by separator velocities, liquid feed systems, hot gas needs. Development and Maint. Of a PSM Program. Eric Girven, Cargill 1. OSHA Req.: All employees working on, around, or near must be trained in ammonia awareness at hiring and once yearly. 2. Training must take place at every change in process prior to implementation. 3. Techs need specific P&ID, SOP, and design training. 4. Tests for competancy. 5. Review SOP at every action/change and every 3 years. 6. Training as part of every MOC and PSSR. Using Controls to Mitigate Leaks. Lee Trautman, Logix. 1. 2. 3. 4. 5. 6. Ammonia Leak! Panic ensues. Controls installed to save energy only, right? IMC & IFC, NH3 detectors only in machine room. Practice is MR, vent, every 10k SF, and each room. Use relays to shut solenoids, open compressor contactors. Use PLC to record/doc. PPM, shut king valves, keep on or shut off compressors, turn on fans, visual/sound alarms, force compressors to 0 PSIG, etc. Ammonia Effects on the Body. Gene Dumas, Hunter Farms. 1. 2. 3. 4. 5. 6. In an emergency, assess your safety in helping first. Review of the characteristics of NH3. Lungs, burning, constriction, edema. Skin, frost bite, chemical burns, frozen clothes. Eyes, burning, blindness. Feet, frozen toes in boots. Knowledge of Power. Wayne Vander Gailien, AEC 1. Refrigeration uses 50-80% of power at a facility. 2. Training/knowledge is key to controlling power. 3. Know your energy bill: kWh costs, time of use costs, demand charges, taxes, infrastructure, and rebate allotments. 4. Peak demand charges, shoulder peak, off peak. 5. During high demand, smooth out the demand charges. Long Term Consequences of Water Contamination. Tex Hildebrand, Wagner-Meinert LLC 1. Lower SST, higher power costs, higher mass flow (more HP), higher runtime (maint), increase SCT, acids, sludge, dirt, oil breakdown, TXV problems, etc. 2. Testing methods, distillation tubes. 3. Test each year, record data to spot trends. 4. Sources of water (maint., below 0 PSIG operation, bad evacuation. 5. Signs: Cloudy SG, red/brown oil, feed problems. 6. Oil testing detects water. 7. Distillation or replacement only method to remove. 8. Do not use halocarbon refrigerant driers. Managing MR Safety Programs. Troy Baker, Honeywell 1. 2. 3. 4. 5. Safety starts with design and code compliance. Partner with experts in both safety and refrigeration. Safety Plan = Opportunities for savings, not a cost only. OSHA recommended training. Common issues: Floors, lighting, signage, hangers, chemical storage, vibration, gauge lines, electrical equip., detector maintenance. 6. Senior leadership is key. Mechanical Integrity. Kent Harmon, Industrial Consultants 1. 2. 3. 4. 14 PSM elements, MII is just one. One per year, plus 5 year indenpendant. OSHA rules on integrity maintenance. 4 requirements: Purpose and Scope, List of Equipment (109 forms or equiv.), P.M Procedures/Matrix, and MII NDT. 5. Do NDT where indicated or starting at 10 year, every year. Moisture Loads. Leon Breun, 6 Step Refrigeration 1. First half was a Psychometric Chart lesson. 2. Example of a cooler and the moisture loads delivered to the refrigeration system through an 8’ x 10’ doors. 3. Latent (vapor to fluid), Latent (fluid to solid), Sensible Loads at 75/50% to 35/90% to 32 TR or $72 per day in energy costs. 4. Main causes of structural and product damage. Non Destructive Testing (NDT), Jim Kovarick, Gamma Graphics 1. Should be done at install and every 5 years. 2. Types: Vibration Analysis, oil analysis, magnetic particle, liquid penetrant, pressure tests, eddy current, ultrasound, long range US, radiography, computed RT, flouroscope, radiometric profiling, shearwave UT, wet particle, acoustic emmissions. 3. UST: Ice problems, couplant problems, pits, scale. 4. RT. Large pipe only one wall, area cleared of people. 5. Real time RT: Insulation only. 6. Long range UST: Lots of pipe, flange, change in sched. 7. Rad. Profiling: Low radiation, slices across entire system, less than 24” assembly. Effects of Pressure Changes. Gary Dunn, APPCO 1. Pressure changes move the refrigerant. Increase in compressors, pumps, static head. Decrease in pipes, valves, heat exchangers, pressure vessels. 2. Pressure Regulator sizing effects. 3. Medium temp suction pipe sizing effects. 4. Low temp suction pipe sizing effects. 5. Low temp suction valve sizing effects. 6. Discharge line sizing effects. 7. Liquid line/sub cooling sizing effects. Proper Pipe Installation 1. 2. 3. 4. 5. 6. 7. 8. ANSI/IIAR 2, ANSI/ASME B31.5, ANSI/ASHRAE 15 Pipe grades and size application. Thread versus weld sizes Weld penetration, passes, methods of welding, pipe protection. Valve types and standards. Installation methods, stress, slopes, traps. Pipe supports, seismic, wind, penetrations. Insulation systems, vapor barriers, staggered layers, sealants. Other Topics: Pipe Corrosion, End User Experience, Ed Alderton, Wawa Dairy. Troubleshooting your System, David Gulcynski, Dot Foods Refrigeration Overview (Basics), Chistopher Kapsha, IceKap Engineers. Certification: The Buck Stops Where? Jeanne Emmons, SCS Tracer.