r134a testing procedures
TRANSCRIPT
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R134aREFRIGERATIONTECHNICIAN
HANDBOOK
Version2.1Updated:May10,2012
USACO
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TABLEOFCONTENTS1.0 OVERVIEW...................................................................................................................................................4
BACKGROUND............................................................................................................................................4
2.0 HANDBOOKINTRODUCTION.......................................................................................................................5
SAFETYANDENVIRONMENTALNOTES......................................................................................................5
RECEIVINGREFRIGERATEDCONTAINERSONDANGERLIST....................................................................6
HANDLINGPROCEDURESFORALLR134AREFRIGERATEDUNITS..............................................................7
3.0 IDENTIFYINGFAKE/COUNTERFEITR134AREFRIGERATEDGAS.................................................................8
4.0 R134AREFRIGERATEDCYLINDERTESTINGUNITANDPROCEDURES.........................................................9
HALIDETORCHANDVENTILATIONHOODASSEMBLY...............................................................................9
CONGLOBALGASEXTRACITONANDANALYSISRECOVERYSYSTEM(CGEARS)......................................11
PROCEDURESFOREXTRACTINGANDTESTINGR134AREFRIGERATEDGASCYLINDERS.........................12
LABELLINGANDTRACKINGTESTRESULTS...............................................................................................14
5.0 NEWSAFETYREQUIREMENTSFORSERVICINGR134AREFRIGERATEDCONTAINERS..............................16
ADDITIONALSAFEGUARDSIMPLEMENTEDATCONGLOBALINDUSTRIES...............................................17
6.0 CONGLOBALGASEXTRACTIONANDANALYSISRECOVERYSYSTEM(CGEARS).....................................19
SAMPLINGMETHODS...............................................................................................................................19
IMPORTANTPRECAUTIONS......................................................................................................................19
CGEARSMETHODTOCHECKREFRIGERATIONMACHINERYFORCHLORIDECONTAMINATION............20
PREPARATION.............................................................................................................................20
EQUIPMENT................................................................................................................................20
PREPARINGTHECGEARSDEVICE...............................................................................................22
TAKINGSAMPLESFROMREFRIGERATIONMACHINE..............................................................................23
SAMPLEPORTS............................................................................................................................23
SAMPLINGPROCESS....................................................................................................................23
FLAMETESTINGOFEXTRACTEDSAMPLES..................................................................................27
FLAMETESTRESULTS..................................................................................................................28
CLEANINGTHECGEARS..............................................................................................................29
7.0 EMPLOYEEACKNOWLEDGMENT...............................................................................................................30
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ThisR134aRefrigerationTechnicianHandbookwasdevelopedasinstructionalguidelinesforrefrigerationpersonnelofConGlobalanditsrelatedcompanies.Wehavemadethisinformationpublicsolelyasasourceofinformationtootherswhoareinterestedintheservicingofrefrigeratedcontainers.WearemakingthisdocumentavailableasinformationonlyandareNOTPROMOTINGORSUGGESTINGanyoneoutsideofConGlobalanditsrelatedcompaniesadoptanyofthemeasurescontainedinthisdocument.Anypersonnelservicingrefrigeratedcontainersshoulddotheirowninvestigationandimplementsafetypoliciessuitedtotheirspecificsituationandconditions.
Thishandbookisintendedtobeanevolvingdocumentandwillchangeasnewinformationisdiscoveredandmadeavailabletotheindustry.Commentsandsuggestionsforimprovingtheeffectivenessoftheinformationandprocedurescontainedhereinarewelcomedandencouraged.CommentsandsuggestionsshouldbedirectedtoPriscillaYataatpyata@cgini.com.
ConGlobalreservestherighttoamend,modifyandretractanyorallpartsofthiswritingasnewinformationmaydictate.
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1.0 OVERVIEW
BACKGROUND
TheRefrigeratedContainerindustryhasrecentlyexperiencedseveralinstanceswherebyrefrigeratedcontainershaveviolentlyandunexpectedlyexploded,resultinginmultipledeathsofservicetechniciansaroundtheworld.Todate,investigationsindicatethattheexplosionswerecausedbytheintroductionofcounterfeitR134arefrigerantcontaining,amongothergases,significantamountsofR40(methylchloride).Asofthiswriting,alloftheunitsthathaveexplodedreceivedarefrigerantgaschargeinVietnam.
However,anadditionalinvestigationofinstockrefrigerantgassuppliesatrepaircompaniesaroundtheworld,aswellasonboardmarinevessels,hasturnedupcounterfeitgascontainingR40.Further,inarecenteffortbymembersoftheContainerOwnersAssociation(COA)whoconductedasamplingandtestinganalysisofseveralhundredrefrigeratedunitsacrosssevenlocations,inthreedifferentcountries,involvingunitsfromtwelvedifferentSSLines(orLeasingCompanies),revealedthatsomeunitswhichwerenotservicedinVietnamwerefoundandconfirmedtohavecounterfeit/contaminatedrefrigerantcontainingseveraldifferentchlorinatedgasses,includingR40.Andasexpected,manyoftheunitsthatreceivedgasserviceinVietnamwerealsofoundtobecontaminated.Thissupportsthegrowingsuspicionthatthiscounterfeit/contaminatedrefrigerantissueisnotisolatedtounitshavingbeenservicedinVietnam,asoriginallythought.
Sincetheearlyannouncementsofthisproblemin2011,ConGlobalIndustrieshasbeeninvolvedwithaninternationalcommunityofexperts,bothinthecontinuedinvestigationaswellasthedevelopmentoftestmethodstoeffectivelyscreenunits.ConGlobal,alongwithotherindustryleaders,hasbeenadrivingforcebehindthedevelopmentofpoliciesandeducationalprogramsdesignedtosafeguardrefrigerationservicepersonnelandtopreventtheproliferationandspreadofcounterfeit/contaminatedrefrigerant.Thisissueisevolvingdaily,andwecontinuetolearnmorerelevantinformationwitheachcontaminatedcontaineridentified.
ConGlobalIndustries,Inc.andouraffiliatedservicecompaniesofUSACOinCostaRica,CoastalGreatSouthernontheU.S.EastCoast,andICAVEinMexico,areamongthelargestrefrigerationservicecompaniesintheworld.Assuch,wehavetakenaveryseriousviewoftheissue.
AtConGlobalandallofouraffiliatedcompanies,thesafetyofourpersonnelaswellassafeguardingourclientassetsareofparamountimportancetous.Accordingly,wedevelopedaseriesofprograms,disciplines,andpoliciesbasedonthemostreliableandcurrentinformationavailable.
Withimmediateeffect,allConGlobalrefrigerationservicefacilitiesandservicetechniciansareadoptingtherefrigerantgashandlingprotocoloutlinedinthishandbook,whichhasbeencarefullydesignedto:
1. Safeguardourcompanypersonnel2. Safeguardourcustomerassets3. Stoptheproliferationofcontaminatedgasinourindustry
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2.0 HANDBOOKINTRODUCTIONOnNovember11,2011,thecompanyissuedthefirstSAFETYBULLETINrelativetonewsthatisolatedrefrigeratedunitsaroundtheworldhadexploded,causingcasualties,includingfatalities.
TheCompany(hereinmeanttoincludeConGlobalIndustries,CoastalGreatSouthern,ContainerCareIcaveMexico,ContainerCareMexico,andUSACOCostaRica)issuedaseriesofpoliciesandprocedures,basedoninformationanddataknownatthattime,toprotectthesafetyandwellbeingofouremployeeswhohandle,andperformmaintenance,repair,andinspectionofrefrigeratedcontainers.
Agreatdealofinformationandknowledgehasbeenaccumulatedsincethatdate.ThisRefrigerationTechnicianHandbookistobeusedastheexclusivesetofpoliciesandproceduresforhandlingrefrigeratedcontainerunitswithinandbyallcompanypersonnelandsupersedesanypriorcommunication.
Eachandeveryrefrigerationtechnicianinthecompanymustbetrainedintheproceduresoutlinedinthismanualbytheirsupervisor.Inaddition,everyrefrigerationservicetechnicianwillsigntheacknowledgmentpageattheendofthismanual,confirmingtheyhavereadthemanualinitsentirety;theyhavebeentrainedbytheirsupervisor;andtheyfullyunderstandandagreetoabidebyallthepoliciesandproceduresfoundwithinthismanual.Inaddition,theGeneralManagerwillsigntheacknowledgementpage,verifyingtheemployeehasbeentrainedandissatisfiedtheemployeehastherequiredinformationandskilltosafelyworkonallrefrigerationunits.
TherewillnodeviationfromthesepoliciesandprocedureswithouttheexplicitwrittenapprovalofeitherthePresidentorDirectorofSafetyandComplianceofthecompany.ThepoliciesandproceduresfoundwithinthismanualapplytoALLR134aREFRIGERATIONUNITSservicedbyourcompany.
Anyrefrigerationtechnicianwhodoesnotfeelcompletelycomfortablecomplyingwiththepoliciesandproceduresfoundinthismanualmustexpresstheirconcernswiththeirsupervisorpriortocommencingworkonanyrefrigeratedunit.Anyrefrigerationtechnicianwhoobservesanythingoutoftheordinaryonanyrefrigerationunitmustimmediatelystopandreporttheirconcernstotheirimmediatesupervisor.
SAFETYANDENVIRONMENTALNOTES
Abyproductofburninghydrocarbonchlorideisphosgenegas,whichisalethalgasincertainconcentrations.ToensurethattheHalideFlametestcanbesafelyperformedusingtheventilationhooddescribedinthishandbook;ConGlobalcontractedanenvironmentalhygienistfromAECOMtotesttheenvironmentatvariousdistancesaroundtheventhood,includingasamplingdevicelocatedonthetestingtechnician,andattheexhaustoutlet.AECOMusedOSHAMethod61asabasisforcompletingthesample.Thesampleperiodlastedfivehoursand6burntestswereperformed,5ofwhichlastedapproximately30seconds,andthefinalburnlastingapproximately1minute.BothR22andR134arefrigerantweretested.SinceR22containschloride,itproducesphosgenegaswhenburnedallowingAECOMtotesttheairqualityandrecordtheresults.
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TheAECOMtechniciantestedairflowrates,constructionofthehoodassembly,andsmoketestobservations.TestmediahadtobeacquiredfromalabinNewYorkandwasshippedovernightunderrefrigeratedconditions.Thetestmedia,afterbeingexposedtothephosgenegas,wasreturnedtothelab,againunderrefrigeratedprotection.Thetestresultsreportedthelevelofphosgenegasat1/100oftheOSHAPermissibleExposureLimitduringa4hourtimeframeandthusnotrepresentingasignificantrisktotechniciansperformingtheflametestwithasmokehoodinuse.
RECEIVINGREFRIGERATEDCONTAINERSONDANGERLIST
Tothebestofourability,theCompanyhasloadedclientsuppliedlistsofcontainersinTEC(TerminalEquipmentControlSystem)thathavebeenservicedinVietnam.TheseunitsaredesignatedinTECasDangerUnits.Uponarrivalatoneofourdepots,refrigeratedcontainerswillbecheckedtoverifytheyarenotidentifiedinTECasaDANGERUNIT.
IfarefrigeratedunitarrivesatyourlocationandisdeterminedtobeonourDangerList,thecontainershouldbeimmediatelymovedtoanisolatedareaofthedepot,andagassampletaken(followtheCGEARSprocedurecontainedherein).ThegassampleshouldbetestedusingaHalideFlameTesttodetermineifchlorideispresentinthegas.IfaDangerUnittestspositiveforchloride,thecontainermustbemarkedwithaLARGE,REDXatthebottomcornerofthecontainer,atthedoorend,andstacked/storedwiththeunitsfacingeachotherortherefrigeratedunitblockedwithanothercontainer,preventingunauthorizedpersonnelfromtamperingwiththem.Agastestplacardshouldimmediatelybeaffixedinaconspicuouslocationtothefrontendofthecontainer.
ForDangerUnitsfailingtheHalideFlameTest,cuttheplugsoffoftheunits,closetotheplug.PutthepluginsidethecordboxonthefrontoftheunitforanyDangerUnitthattestspositiveforchloride.
Themachineryshouldbestacked/storedcloseenoughtotheblockingcontainersuchthatapersoncannotinadvertentlywalkbetweenthem.AllDangerUnitsstoredinthisfashionshouldbestoredatleast25feetfromflammableorcombustiblematerials.
AsoutlinedintheCGEARSinstructions,asampleofanyunitfailingtheHalideFlametestshouldbesenttoMcCampbellAnalyticalLaboratoryinPittsburgCAforGCMStesting.
McCampbellAnalytical,Inc.(MAI)1534WillowPassRoadPittsburg,CA94565
(877) 252-9262 www.mccampbell.com
IfaDangerUnitpassestheHalideFlametest,itisconsideredsafeandcanbeservicedasdirectedbytheclient.
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HANDLINGPROCEDURESFORALLR134AREFRIGERATEDUNITS
Usethefollowingguidelinesonallrefrigeratedunits,includingthoseunitsontheDangerlistthatpasstheHalideFlametest.
1. First,visuallyinspecttherefrigeratedcontrollertoconfirmtheunitisnotsetintheEmergencyRunmode.
2. Iftheunithasasightglass,checkforanyindicationofabnormalappearance.
3. Whenstartingtheunit,nopersonnelshouldbeinfrontoftheunit,orbeinsidetherefrigeratedcontainer.
4. Duringstartup,allpersonnelshouldbenocloserthan2containerunits(approx.15feet)fromrefrigerationmachinery.
5. Beforeplugginginunit,ensuretherefrigerationunitcircuitbreakerandpowerswitchareintheonorrun(closed)position.
6. Plugtherefrigeratedunitintoapowersourcethatisnotdirectlyinfrontoftherefrigeratedunitthathasthepowersourcebreakerturnedoff.
7. Turnonthebreakeratthepowersourceandwaitfortherefrigeratedunittogothroughitsstartupprocedure,untilthecompressorhasstartedandrunsfor35minutes.
8. Ifthecompressorexhibitssoundsofimproperoperation,suchasknocking,clanging,buzzing,orotheroddsounds,duringstartup,orifthecompressorbecomesunusuallyhot,turnoffthebreakeratthepowersourceandperformtheCGEARSprocedure.AFTERALLOWINGTHECOMPRESSORTOCOOLFORATLEAST30MINUTES.AfterpassingtheCGEARSprocedure,thentroubleshootasnormal.IftheunitfailstheCGEARSprocedure,thensendthesampletoMcCampbellAnalyticallabandwaitforresults.
9. Ifaunitfailstostart,disconnectitfrompowersource.
10. Theservicetechnicianshouldthenusethepowerpluginhandrulewhenworkingonunit.Thismeansthetechnicianwillhavethepowercordplugwithhimpriortocommencinganyworkontheunit.
11. Forunitsthatdontstart,andonlyafterpowerisCONFIRMEDdisconnected,inspectalarmlogforfailureindications.
12. Forunitsthatrequirepowertoviewalarms,disconnecttheoutputpowertothecompressorpriortoconnectingpower.
13. OnANYunitthatrequiresservice,wherebygaugesmustbeconnectedtotheunit,therefrigerantmustfirstbetestedbyusingtheCGEARSextractionprocedure.IffreonpassestheHalideFlameTest,workmaycommence.IftherefrigerantfailsHalideFlameTest,noworkshallbeperformeduntilauthorizationisgiven.
14. Ifanycompanytechnicianhasanydoubtorconcernaboutsafelyworkingonanyrefrigeratedunit,theyshouldimmediatelyconsultwiththerefrigerationsupervisor.
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3.0 IDENTIFYINGFAKE/COUNTERFEITR134AREFRIGERATEDGASThereareseveralthingstolookforwhentryingtoidentifyfake/counterfeitrefrigeratedgas.Outlinedbelowaretwoexamplesofthingstolookfor.Ifyouspotoneofthesetanks,STOP,andtakeittoyourimmediatesupervisor.
Thetankontherightisacounterfeittank.SomecounterfeittanksspellDuPontasDupont(notethelowercasep).
Anotherwaytoidentifycounterfeitcylindersistheshapeofthehandlebase.Originalcylindershavestraighthandlebasesandcounterfeitcylindershavecurvedhandlebases.
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4.0 R134AREFRIGERATEDCYLINDERTESTINGUNITANDPROCEDURESThissectionoutlinestheassemblyofthehalideflameventilationhoodandthetestingproceduresfornewR134arefrigeratedgascylindersatallConGlobalrefrigerationservicefacilities.ThepurposeoftestingnewR134acylindersbeforeuseinservicingrefrigeratedcontainersistodetectwhethertheR134acylinderhasbeencontaminatedwithchlorinatedgasses,includingR40(MethylChloride).
HALIDETORCHANDVENTILATIONHOODASSEMBLY
Theunittotestrefrigeratedgasfromcylindersusesthefollowingcomponentsandmodifications:
CompactOversprayCollectorwithdimensionsof18HX22WX20D.Thispieceisreferredtoasaventhood,purchasedfromMcMasterCARR(Partnumber9559T51).
Theventhoodismodifiedbythefollowingprocedures.o Mountingtheunitontwolegsfabricatedoutofsheetmetal.
o Drillingaholeinthebottomoftheventhoodsothehalideleakdetectorcanbeinsertedthroughthebottom.
o Paintingtheinterioroftheventhoodblacksotheflamecanbeeasilyseen.
o Drillingaholeintheleftsideoftheventhoodsotheexplorationhosecanberoutedtothetankfortesting.
o Installingaplexiglasscoveronthefrontusingapianohingetocontainfumesinhoodforultimateventilation.(Note:Theopeningatthebottomoftheinstalledplexiglassisintentionaltoallowforproperairflow.)
o Outfittingtheexhaustfanmountedontherearoftheunitwithaluminumductingsotheexhaustoutletisatasufficientdistance,asrequiredbylocalworkersafetyregulations.ForConGlobalsNorthAmericanlocations,theexhaustshouldterminatesevenfeetabovetheheightofthetechnicianshead.
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Toensureconsistencyinassemblingthetestingunits,ConGlobalcentrallypurchasesventhoodsfromMcMasterCARRanddropshipstoeachlocationthatneedsatestingunit.Wealsocentrallypurchasetheplexiglassfrontcover,pianohinge,leakdetector,valves,fittingandgauges,andhoses.TheConGlobalLosAngeleslocationfabricatesthesheetmetallegs,assemblesthevalveandconnector,andassemblesthehalidetorch.Theindividuallocationonlyneedstosecuretheexhaustductingwhichisavailableatmostlocalhardwaresupplystores.
Fortheactualhalidetorchtestingapparatus,weareusingaNRPLeakDetectorthatmountsdirectlytoaconventionalhandheldpropanebottle.Thepropanebottleismountedbetweentheventhoodstand,sotheleakdetectorunitisinsidetheventhoodandthepropanebottleisbelowtheventhood(Seediagrams#1and#1abelow).
Diagram#1 Diagram#1a
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CONGLOBALGASEXTRACITONANDANALYSISRECOVERYSYSTEM(CGEARS)
Thegaugeandconnectorassemblyconsistsofthefollowingcomponents:
A. Acme(auto)adaptortoflarefittingB. flarefemaleunionC. QuickconnectvalveD. RegulatorE. Lowpressurerefrigerantgauge(R134a)F. Lowlossline8inlengthwithballvalve,flarefittingsG. FemaleflareadaptortotubingH. coppertubingI. adaptorfromtubingtocapillarytubeJ. Capillarytube(0.054innerdiameter)K. Schraderadaptor(ThermoKingPart#669873)L. BallvalveflareconnectionsM. Doublemaleflareconnector
Diagram#2
NoteThistestinggaugedeviceisrecommendedoveratypicalmanifoldgaugesetbecausethequantityofgasisrestrictedbythedevicesize.Thiskeepsanydischarge,eitherintentionalorunintentional,toademinimuslevel,asrequiredbyU.S.EPAregulationsection608.
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PROCEDURESFOREXTRACTINGANDTESTINGR134AREFRIGERATEDGASCYLINDERS
Ifpossible,priortodoingtheactualtestwithaR134acylinder,performthesametestonaR22sample,whichcontainschlorideandwillcreatethesameflamecolorchangetogreenasacylinderofR134athatiscontaminatedwithR40,R12,orR142b.Thisprocessisrecommendedsimplytoensurethatthetestingtechnicianknowspreciselywhattolookforsincethechangeincolorcanberapid,andwilllastforonlyasecondortwo,dependingonthevolumeofrefrigerantpassingthroughthecapillarytube.Itisimperativethatthetestingtechnicianshaveexperiencewithvisuallydetectingthechangeinflamecolorbeforeconductingthelivetests.ThevideolinkbelowandthepicturesinDiagrams#3and#3aareexamplesoftheflamepriorto,andafterexposuretogasseswithchloride.
Flametestingvideolink:www.youtu.be/JDBTxSJ7H8
Diagram#3ContaminatedR134aRefrigerantGas Diagram#3aUncontaminatedR134aRefrigerantGas
Afteratestthatispositiveforchloride,andtoavoidapossiblefalsepositiveresult,beforethenextR134acylindertest,youneedtothoroughlycleanandpurgethetestinggaugeandconnectorwithcompressedairornitrogen.Ifthelinesarenotpurged,tracesofchloridemayremaininthetestinggaugecausingfalsepositivereadingswhentestingotherwisepureR134asamples.Asageneralrule,thetestinggaugeneedstobepurgedaftereachtestandparticularlyafterapositivechloridetestresultinginagreenflame.
Followtheseproceduresforflametesting.
1. ConnectapurgedandcleanedCGEARStoanitrogenbottleandpressuretestforleaks.
2. ConnectfittingAtoR134arefrigerantbottle,thenconnectSchraderadaptorL.ThenattachquickconnectvalveC.(Ifrefrigerantbottlehasfitting,connectSchraderadaptorL,andthenconnecttobottlewithquickconnectvalveC.)
3. EnsureballvalvesMandGareclosed.
4. Connecttheexplorationtubefromthehalidetorchtothebarbedfittingontheinsideofthehood.
5. Connectanotherpieceofexplorationtubetotheoutsidebarbedfitting.
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6. Raisethecleardoorofthehoodandlightthetorchwithanignitionsource.
7. Adjustthecenterflameconesothatthetipoftheflameisjusttouchingthecopperreactorplate.
8. Afterthetorchisoperatingproperly,closetheplexiglassfrontcover.
9. Lettheflameburnuntilthereactorplateisglowingred(usually23minutes).
10. Slowlyopenthevalveoftherefrigerantbottleandthenopenquickconnectvalve,thenopenballvalveGandallowpressuretoreach6080psi.(Pressuremayvarydependingonambienttemperature.)
11. Closethevalveonthebottle,alsoclosethequickdisconnectvalveandballvalveGoftheCGEARS.YouhavenowessentiallytrappedyourgastestsampleintheCGEARS.
12. DisconnecttheCGEARSfromtheR134acylinderandtaketestgaugetotheventilatedhalideflametestlocation.
13. ConnectSchraderadaptorLtomaleconnectorNandthentocapillarytubeassembly.InsertSchraderadaptorLintoquickdisconnectvalveC.
14. Insertthecapillarytubeintoasmallcontainerofwater,whilepositioningtheexplorationtubefromthehalidetorchapproximately1inchabovethewater.
15. OpenballvalveG,thenslowlyopenvalveCuntilaslightgasflowfromthecapillarytubeisvisuallyconfirmedbybubblesinthewater.Closelywatchthehalidetorchflamethroughtheslotsintheflameshieldforabrief,temporarychangeinflamecolorfrombluetogreen.
16. Ifthereisacontaminantcontainingchloride,theflamewillturngreenwithinafewsecondsandburngreenforbetween1and5seconds.Iftheflameremainsaconstantblue,thetankbeingtestedisfreeofchloridecontaminants.
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LABELLINGANDTRACKINGTESTRESULTS
Anauditableprocessfortestinggassamplesisessentialtodocumentwhichcylindershavebeentestedtopreventadditionalcontaminatedgasfrombeingintroducedtorefrigeratedcontainermachines.Whenanewgascylinderisreadytobeusedforservice,ahalidetestshouldbeperformedtodetermineifthegashasbeencontaminated.Oncethecylinderhasbeentested,thetestingtechnicianwilluseanindeliblemarkertomarkDIRECTLYONTHECYLINDER1)thedepotlocation,2)cylindernumber,3)testdate,4)testresultand5)techniciansignature.Thisinformationisthenrecordedonalogtocreateanaudittrailthatcanbeeasilysharedwithcontainerownersandauditorsuponrequest.Anexampleofthelogisattachedasreference.
Currently,gascylindersdonothaveuniqueserialnumbersthatcanbeusedforidentification.Therefore,repairfacilitiesneedtocreateauniquenumberforeachcylinderthatistested.AtConGlobalIndustries,thecylindernumberwilladheretothefollowingformat.Itstartswithathreealphacoderepresentingthedepotcompanyname;followedbyathreealphacoderepresentingthetestinglocation;andendswithasequentialthreenumbercode.UsingCGISEA001asanexample,CGI=ConGlobalIndustries;SEA=Seattle,Washington;and001=sequentialnumber.Ifacylinderisnotlabelledwithall5piecesoftestinginformationlistedabove,itshouldnotbeused.
Afteratankisempty,thevalveshouldbeknockedoff.Besurethetankisemptyandproperlyevacuatedbeforeknockingoffvalve!Thetankcanthenbescrapped.Crushingthetankmayberequiredbysomerecyclers.Checkwithyourlocalscrapmetalrecyclerfortheirspecificrequirement.Afterdestruction,notethedestructiondateontheGasBottleTestingLogSheetunderthecommentssection.
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REFRIGERATEDCONTAINERGASCYLINDERHALIDETESTINGLOG
DEPOT LOCATIONCYLINDERNUMBER
FLAMETESTDATE
PASS/FAIL
TESTERNAME COMMENTS
ConGlobalIndustries Seattle,WA CGISEA001 3/1/2012 Pass MikeA destructiondate:3/3/2012
ConGlobalIndustries Seattle,WA CGISEA002 3/1/2012 Pass MikeA destructiondate:3/3/2012
ConGlobalIndustries Seattle,WA CGISEA003 3/10/2012 Pass MikeA
ConGlobalIndustries Seattle,WA CGISEA004 3/10/2012 Pass MikeA
ConGlobalIndustries Seattle,WA CGISEA005 3/10/2012 Pass MikeA
ConGlobalIndustries Seattle,WA CGISEA006 3/26/2012 Pass MikeA
ConGlobalIndustries Seattle,WA CGISEA007 3/26/2012 Pass MikeA
ConGlobalIndustries Seattle,WA CGISEA008
ConGlobalIndustries Seattle,WA CGISEA009
ConGlobalIndustries Seattle,WA CGISEA010
ConGlobalIndustries Seattle,WA CGISEA011
ConGlobalIndustries Seattle,WA CGISEA012
ConGlobalIndustries Seattle,WA CGISEA013
ConGlobalIndustries Seattle,WA CGISEA014
ConGlobalIndustries Seattle,WA CGISEA015
ConGlobalIndustries Seattle,WA CGISEA016
ConGlobalIndustries Seattle,WA CGISEA017
ConGlobalIndustries Seattle,WA CGISEA018
ConGlobalIndustries Seattle,WA CGISEA019
ConGlobalIndustries Seattle,WA CGISEA020
ConGlobalIndustries Seattle,WA CGISEA021
ConGlobalIndustries Seattle,WA CGISEA022
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5.0 NEWSAFETYREQUIREMENTSFORSERVICINGR134AREFRIGERATEDCONTAINERS
Theinvestigation(s)ofthecontainersthathaveexplodedindicatethatoneofthepossibleconditionscausingtheexplosionsistheintroductionofafreshR134arefrigerantchargeintoacontaminatedsystem.Inanefforttokeepourservicetechnicianssafe,withimmediateeffect,anyrefrigeratedcontainerusingR134arefrigerantthatrequirestheconnectionofamanifoldgaugesetforanyreason,including::
AR134arefrigerantgascharge, TheevacuationofR134arefrigerantgasforanyreason(i.e.systemrepair),OR Simplepressurecheck.
willfirstberequiredtoundergoaRefrigerationgashealthandsafetycheck.ThisprocesswillentailthatasmallsampleofrefrigerantgasbeextractedbymethodscarefullydevelopedbyConGlobal,andfieldscreened/testedbyeitherHalideflametestorbyRRAChloridetesttube.ThecostforthisfieldscreeningisminimalandisavailabletoConGlobalclientsuponrequest.
(AvideooftheHalideflametestcanbeviewedathttp://youtu.be/JDBTxSJ7H8)
TheresultsforallrefrigerantsamplestestedwillbecommunicatedtotheclientsandwillberecordedwiththeConGlobalservicehistoryfortheunit.Iftherefrigerantgassamplepassesthefieldscreentest,thenourservicetechnicianswillaffixaR134arefrigeranttestdecaltotheunit(seebelowformoredetails)andproceedwiththenormalserviceroutine.
However,anyR134arefrigerantgasfailingthefieldscreentestwillbesubjecttoaGasChromatographyMassSpectrometry(GCMS)openscanlabtestbeforeanyfurthermachineryrepairsarecarriedout.Thecosttoourclientforthisadditionalrequiredsafetytestwillnotbeincurreduntilapprovalbytheclientisreceived.ThedetailedresultsoftheGCMSopenscanwillbeprovidedelectronicallytothecontainerclient/ownerfortheirrecordsandwillalsobekeptintheunitservicefilesatConGlobal.
Note:GCMStestresultsindicatinganydetectablelevelsofR40(methylchloride),TrimethylAluminum(TMA),Tetramethylsilane(TMS)oranyotherpyrophoricgasorsubstancewillresultintheunitbeingclassifiedaspotentiallydangerousandallserviceworkwillSTOPuntilconsultationwiththeownerregardingneutralizationmeasuresaretakenandtheaffectedcontainercanbesafelyreturnedtoserviceordestroyed.
ConsistentwithARI700refrigerantstandards,anyGCMSresultsindicating>.5%(1/2of1%)ofothernondangerouscontamination,i.e.R142b,R12,R22,etc.,willresultintheunitbeing1)completelyevacuated,purged,orcleanedwithdrynitrogen,2)oilremovedandreplaced,3)anewfilterdrierinstalled,and4)thesystemrechargedwithnewR134arefrigerant.Afterrechargingtheunitandrunningitfor30minutes,anotherrefrigerantgasscreentest(HalideorRRATubetest)willbeperformedtoconfirmtheeffectivenessoftheprocess.
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GCMStestresultsindicating99.5%R134aorbetter,withnodetectableamountsofR40,TMS,TMAorotherpyrophoricgassesorsubstances,willbedeemedsafeandroutineservicewillproceed.AsmallGASTESTPlacard,liketheonepicturedbelow,willbeappliedtoallcontainermachinerywhen:
Fieldscreentest=PASSOR CGMStest=99.5%+R134a(withnodetectablelevelsofpyrophoricgas,orofR40,TMS,
TMA
ADDITIONALSAFEGUARDSIMPLEMENTEDATCONGLOBALINDUSTRIES
ConGlobalIndustries,Inc.hasalsodevelopedspecificpractices,policies,anddisciplinesdesignedtopreventtheproliferationandspreadofcounterfeitorcontaminatedR134arefrigerantwhileservicingcontainersatallofourservicelocations.Thesepracticesinclude:
FlametestingandcreatingapapertrailforallnewandexistingstocksofR134arefrigerant,confirmingitspurityandthatitisfreeofchlorideatlevels>300ppm(thelevelofsensitivityforaflametest).
Aseriesofhygieneprotocolrequiringthenitrogencleansingandflameretestconfirmationofservicegaugesandreusablerecoverybottles,whenpriorrefrigerantgaspurityiseitherunknownorpositivelyconfirmedbyflametestorRRAtesttocontainchloride.
Thedestructionanditsdocumentationofdestructionofalldisposable,nonrefillableR134abottles.Thisisintendedtoensurethatthebottlesarenotretrievedandusedinthecounterfeitmarket.
Nomixingofrefrigerantfromoneunittoanother.Anyrefrigerantevacuatedandrecoveredfromacontainer,afterflametesting,canonlybereturnedtothesamecontainerthatitwaswithdrawnfrom
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andwillnotbemixedwithrefrigerantfromanyotherunit.Ifforsomereasontherefrigerantwithdrawnfromaunitisnotreplacedinthesameunit,therefrigerantwillberecycled,reclaimedorincineratedratherthanusedinanotherunit.ThispolicyisintendedtoincludeALLcontainersinEVERYcircumstanceincludingsaleandscraprefrigeratedcontainers,whereitiscommoninsomerepairfacilitiestoevacuatetherefrigerantwiththespecificintentofresale.
TheestablishmentandimplementationofarecordkeepingsystemforallR134arefrigerantsusedtoservicearefrigeratedcontainerthatcanbetracedbacktothebottleoforigin.Whencombinedwiththenewbottletestingprotocoldescribedearlier,unitspecificservicerecordscaneasilybetracedbacktoaflametested/purityprovenR134arefrigerantsource.
ThetrainingofeveryConGlobalrefrigerationservicetechnicianandpartsreceivingpersonnelastothecharacteristicsthatmightindicatearefrigerantcylindermaybeacounterfeitedproduct.
AsaconditionofemploymentatConGlobaloraffiliatedcompanies,everyservicetechnician,theirsupervisors,andfacilityGeneralManagerswillacknowledgereceiptofthesepolicies;acknowledgetheircompleteunderstandingandtheintentionsofthesepolicies;andpledgetofollowtheprotocolandrefrigeranthandlingprocedures.Additionally,thishandbookshouldbeincludedintherefrigerationpersonnelnewhirechecklist.
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6.0 CONGLOBALGASEXTRACTIONANDANALYSISRECOVERYSYSTEM(CGEARS)
SAMPLINGMETHODS
ConGlobalsrefrigerationgassampling,testmethodology,andproceduresaredescribedinthisdocument.
1. Samplemethodtosafelyextractgasandtofieldcheckrefrigerationmachineryforchlorinecontamination.
2. TakingasamplefromarefrigerationmachineforlaboratoryanalysisMAIsampletube.
IMPORTANTPRECAUTIONS
Itisadvisableforalltechnicianstoconsiderthatarefrigerationmachinesystemmightbecontaminatedbeforeturningthepoweronandbeforeanyattemptismadetotakeagassample.
Currently,thesimplestandmostreliabletestfordetectingthepresenceofchloridecontaminationistheHalideFlameTest.Itshouldnotbeusedwithoutfollowingdetailedinstructionsandtakingsuitableprecautions.TheHalideFlameTestissensitivetoapproximately300ppmforchloride(0.03%)anditisthereforelikelytodetectifasystemhasbeencontaminatedwithachloroalkanesuchasR40orHCFCssuchasR22,R12orR142b.
ItshouldberememberedthatthetestisforchlorideandnotatestfortheverydangerousgasTMS(Trimethylsilene)orTMA(Trimethylaluminium),whichifpresent,wouldbealiquidinthecrankcase.ThemeltingpointofTMAis15oC.ItisremotelypossiblethatevenwhereaHalideFlameTesthasnotdetectedthepresenceofchlorideinagassampletakenfromarefrigerationmachine,theremaystillbecontaminationresiduesinthecompressorthatcouldbehazardous.Techniciansshouldremainvigilantandcautiouswhenworkingontherefrigerationsystem.
WhenrefrigerationsystemsarecontaminatedwithR40,harmfulchemicalsmayhavealsoformedinthesystem.Insomecases,thesechemicalsmayburnspontaneouslyinaironcontactwithwater.Techniciansareadvisedtowearprotectiveclothing,gloves,eyeprotection,keepingskincoveredasmuchaspossibleandtoavoidanycontaminatedchemicalcomingintocontactwiththeskinorbeinginhaled.
Todate,therehavebeenfourinstanceswherecompressorshaveexplodedwhilebeingworkedon.ItissuspectedthatthismighthavebeenaresultofR134arefrigerantbeingintroducedintothecompressorduringchargingorwhenthemachinepowerwasturnedonallowingrefrigeranttoreturntothecompressor.Othersuspectedconditionsthatmanyexpertssuspectmayleadtoexplosionsaretheintroductionofair,oxygenormoistureintoacontaminatedsystem.Inaddition,unusuallyhighcompressortemperaturesand/orpressureswhilerunningshouldalsobeofseriousconcern,andmaycauseorcontributetoapotentialexplosion.
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Thereisapossibilitythatacontaminatedrefrigerationsystemcouldhaveanegativepressurerelativetotheatmospherewhenitisnotrunning.Thiscanhappeniftherefrigerationsystemwascontaminatedwithalargeamountofmethylchloride(R40).TheR40mighthavebeenconsumedbyachemicalreactionwithaluminiumcomponentsinthecompressor,thusreducingthepercentageofR40andthelatentpressureinthesystem.
Conversely,theextremehightemperaturesandpressuresthatacompressorcanreachwhilerunning,ifcontaminatedwithcertainnon134arefrigerants,(whichhasbeensimulatedinlaboratoryconditions)isofparticularconcernandmayalsoberelatedtothepotentialexplosionofarefrigerationcompressor.
CGEARSMETHODTOCHECKREFRIGERATIONMACHINERYFORCHLORIDECONTAMINATION
Thistechniqueisintendedtoenableservicetechnicianstoquicklyandsafelycheckarefrigerationmachineinatypicalrepairdepotenvironmentforchloridecontaminationtodetermineifitissafetoworkontheunit.
Ifaunitiscontaminated,itispossiblethatthegasintherefrigerationsystemmayviolentlyreact,smoke,combustorevenexplodewiththeintroductionofair,water,freshR134a,oranelectricalspark.
Itisveryimportanttoensurethatnoair,moisture,orwatercanenterintothesystemwhileextractinggas.Similarlyitisimportantnottoallowanysystemrefrigeranttoleakintotheatmospherewhileextractinggasforsampling&testingpurposes.
Allconnectionsmustbecompletelydry. Priortotheextractionprocess,confirmtheunitisunpluggedbeforeproceeding.
Onsomesystemsthatarecontaminated,thesightglassmaybeadarkgreyorbrowncolorandnoteasytoseeinto.Ifthisisthecase,extracautionshouldbetakenwhenremovingsamples.
PREPARATION
EnsureallconnectionsarecleananddryonboththeCGEARSextractiondeviceandrefrigerationmachinery.
Positiontherefrigerationunittobetestedfromtheflamesource. Besuretodischargeanystaticelectricitybytouchingtheunitframeimmediatelypriortoextracting
thegassample.
Enforceanonsmokingzoneofatleast25. ProvideaClassC(drypowder)andClassDfireextinguisherintheimmediateworkarea. TechnicianshouldalwayswearPPEsafetyglassesandfaceshield,gloves,andhighvisibilityvest.
EQUIPMENT
CGEARSextractiondevice Vacuumpump Bottleofdrynitrogenwithregulator
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HFCR134aquickconnectors Spannerwrench MAIGassampletubewithPHpaper(availableatMcCampbellAnalyticalPittsbug,CA
www.mccampbell.com)
HalideflametorchandCGIventilationhood SafetyglassesorFaceShield ProtectiveGloves
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FIGURE1
CGEARSExtractionManifold
PREPARINGTHECGEARSDEVICE
1. Cleaningandflushingconnectthedevicetoaregulatedsupplyofnitrogenandpurge/flushtheCGEARSdevicetocleananypreviouscontaminantsfromthedevice.
Note:itisveryimportanttoavoidanypossiblecrosscontaminationfromtheprevioustest,whichshouldbeconfirmedbyaHalideflametest,usingaknownsourceofpureR134a.
2. Pressuretest,withnitrogen,theCGEARSsystem(includingMAIsampletube)to6070psiandcheckforleaks,thenreducetheregulatorpressureandsetat20psi.
3. PurgenitrogenfromCGEARSandconnectthedevicetoanewsupplyofR134a,knowntobefreeofchloridecontamination,andtakearefrigerantsample.
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4. HalideflametestthissampleofknowncleanR134atoinsurethereisnochloridepresentintheCGEARSdevice.
5. CheckthePHPapertoconfirmneutralPHlevelof4to8onthecolorscale.
6. EvacuateCGEARSintoavacuumof2930in/HG.Aftershuttingvacuumpumpoff,andclosingthequickconnectvalve,confirmvacuumismaintainedfor30seconds,confirmingnoleaksintheCGEARSdevice.
TAKINGSAMPLESFROMREFRIGERATIONMACHINE
SAMPLEPORTS
GassamplescanbetakenfromeithertheHighPressure(HP)orLowPressure(LP)sideofanidleunitthatisdisconnectedfromapowersource.Therecommendedaccessportisgenerallydescribedasaserviceportlocatedasfarfromthecompressoraspossiblebothitsphysicallocationinproximitytothecompressorandthefarthestpipingdistancefromthecompressor.Thisrecommendationisintendedtoallowservicetechnicianstobeasfarfromthecompressoraspossible(physicaldistance)whileaffordingtheleastlikelychanceofencounteringTrimethylAluminium(TMA),whichmayhaveformedinthecompressorandmigratedtootherpartsoftherefrigerationsystem.InthecaseofaCarrierNTmachinetherecommendedaccessportistheKingValve.
SAMPLINGPROCESS
Afterproperlycleaning,pressuretesting,andleakcheckingbyvacuum,thegassamplingprocesscanbegin.
TheCGEARSdeviceshouldbeina2930in/HGvacuum. Choosetherefrigerationunitsamplingportbasedonthecriteriaabove(samplingports).
1. Ensureaccessportiscleananddry.
2. Withthequickconnectandservicevalvesclosed(backseated)attachthequickconnectvalveoftheCGEARStotheserviceport.
NOTE:IMPORTANTINFORMATIONRELATEDTOSCHRADERVALVES
AportionofintermodalrefrigerationunitsareequippedwithRefrigerationAccessValves,commonlyreferredtoasSchraderValves,whichisonemanufacturerofthesetypesofvalves(seephotobelow).Thesevalvescanbefoundonthedischargeservicevalve,suctionservicevalve,andatvariouspointsintherefrigerantplumbinglines.
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TheRefrigerationAccessValveisaflareconnectorfitting.WhenconnectingordisconnectingalinefromaSchraderValveoranyotherbrandofRefrigerationAccessValve,adischargeofrefrigerantisnormallyreleased.
SeeSchraderValveVideo:http://youtu.be/81DrmrzdQmM
IftheR134arefrigerantthatisdischargedhadpreviouslybeencontaminatedwithchloridecontaminants,thereisapossibilitythatotherdangerousgassesmayhaveformedandthatapyrophoricreaction(spontaneousignition)orexplosioncouldoccurifgasisreleasedintotheatmosphere.
Assuch,anytimeaSchraderValve,orsimilarRefrigerationAccessValveisbeingconnectedordisconnected,thetechnicianmustfirstuseaquickconnectadapter,toavoidthelossofrefrigerantintotheatmosphere(seephotobelow).ThequickconnectcouplercommonlyusedatCGIandouraffiliatedcompanies,canbepurchasedfromThermoKing.
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3. Keepingtheservicevalveclosed,openthequickconnectvalvetoensurethatanypossibleairremainingintheconnectionareabepulledintotheCGEARSdevicevacuumandconfirmingtheconnectionisairtight.TheCGEARSshouldmaintaina28+HGvacuum.
4. Reclosequickconnectvalve.
5. Inadditiontothequickconnectvalve,ensurethetwoothervalvesontheCGEARSdeviceandthesampletubeareclosed.
6. Openservicevalve.
7. Openthequickconnectvalve.ThiswillallowgasatsystempressuretoflowintotheCGEARS.
Note:Ifavacuumismaintainedafteropeningthequickconnectvalve,closeallvalves(CGEARSandserviceport)andcontactHQforconsultation.ThisconditionmayindicatetheRefrigerationsystemisinavacuum,aconditionlikelyindicatingthepresenceofdangerousgasses.DONOTruntheunitorattempttoreusetheCGEARSdevice.
8. OpentheCGEARSstage2valveandtheMAIsampletubevalve.Ifsetcorrectly,theregulatorwilllet20psiofgasflowintothesampletube.
9. RecloseMAIsampletubevalvetrappingagassampleintheMAIsampletube.
10. Closetheservicevalve.
11. Closethequickconnectvalve.
12. DisconnecttheCGEARSandmoveawayfromtheunit.
13. WatchthePHpaperintheMAIsampletubefor30secondsforanyacidicreaction.Ifnoreactionoccurs,proceedwiththeflametest(Note:TheCGEARSgaugeshouldnowread20PSI).
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PHPaperChart.
Note:ThisisasampleofthePHpaperchart.RefertophysicalPHpaperforcolorcomparisonwithgassample.
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FLAMETESTINGOFEXTRACTEDSAMPLES
WithasampleofgassafelyextractedandtrappedintheCGEARSdeviceandtheMAIsampletube,aflametestforchloridecontaminationcannowbeperformed.
1. ConfirmthatnoreactiontothePHpaperintheMAIsampletubehasoccurred.IfthePHpaperhasreactedDONOTflametestthegassample.ContactHQforconsultationanddonotopenorreusetheCGEARS.
2. ConfirmthattheMAIsampletubevalveisclosed.
3. AttachcapillarytubewithquickconnecttotheCGEARSquickconnectvalve.
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4. InaConGlobalHalideFlameteststationwithanegativeventilationfan,conductaHalideFlametestasoutlinedinConGlobalIndustriesflametest/bottletestsection.
Flametestingvideolink:www.youtu.be/JDBTxSJ7H8
Note:IftheCGEARSgaugereadsgreaterthan20PSI,slowlybleedatinysampleuntil20PSIisachieved.ReopentheMAIsampletubevalveandreclosetoensure20PSIisintheMAIsampletube.This20PSIreadingisaveryimportantQCmeasureforMcCampbellAnalyticalLab.
FLAMETESTRESULTS
Iftheflametestindicatesnochloridecontaminationover300PPM(BlueFlame)thentheCGEARSandtheMAIsampletubecanbevacuumpurgedandreusedimmediatelyfortestinganotherunit(nonitrogenpurgeisnecessary,thoughrecommended).
Iftheflametestindicateschloridecontaminationat300PPMorgreater(GreenFlame),thenthesampleintheMAIsampletubeshouldbetaggedwiththecontainernumberandsenttoMcCampbellAnalyticalLaboratory(MAI)forGCMSanalysis.Sampletubesshouldhavebrasscapinstalledassecondaryleakpreventionanda
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chainofcustodydocumentshouldaccompanyeachsample(multiplesamplescanbeincludedonasingleCOCform.)Sampletubesshouldbeplacedinasealableplasticbag(asaddedleaksurety)andbesafelypackagedandsentviaovernight(FedEXorDHL)toMcCampbellAnalyticalinPittsburg,Ca.
Note:McCampbellAnalyticalwillclean,verifyintegrity,andreturnsampletubestoCGIforreuse,aftereachgasanalysis.
CLEANINGTHECGEARS
Afteranyfailedflametest(GreenFlame)itiscriticalthattheCGEARSbethoroughlycleanedanditschloridefreeconditionbeconfirmedpriortoreusing.Thisprocesswillgenerallytakelongerandbemoredifficultthanimagined.Experienceindicatesthatthecleaningdifficultywilldependonthetypeandamountofchloridecontamination.Minorcontaminationcangenerallybecleanedwithtwominutesofnitrogenpurgingathighpressureandthreeminutesofvacuumcleaning,repeatingeachsteptwice.Moreseverecontaminationwilltakemoreeffort.
AftercleaningtheCGEARS,flametestaknowncleansampleofR134atoensurethedeviceischloridefreeandreadyforreusewithnopossibilityofafalsepositiveresult.
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7.0 EMPLOYEEACKNOWLEDGMENTIhavereadandfullyunderstandtheinformation,policiesandprocedures,andinstructionsoutlinedintheRefrigerationTechnicianHandbook.
Ifullyunderstandallthespecificissuesrelatedtoreceiving,handling,startup,bottletesting,gashandling,andgasextractionmethodologiesreferencedinthehandbook.
IagreethatifIhaveanyquestionregardingthesepolicies,procedures,andinstructions,Iwillimmediatelyaskmyimmediatesupervisorforadviceorinstruction.
Ifullyunderstandtheimportanceoffollowingallpoliciesandprocedurerelatedtorefrigerationserviceworkandagreestonotcircumventanypolicy,procedureorinstructionfoundinthehandbook.
IacknowledgeIhavebeenfullyinstructedandtrainedinthenewproceduresoutlinedinthehandbook,andfurtheracknowledgeIunderstandthosepoliciesandprocedures.
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