R134a REFRIGERATION TECHNICIAN HANDBOOK

R134aREFRIGERATIONTECHNICIAN

HANDBOOK

Version2.1Updated:May10,2012

USACO

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

3|Page Version2.1Updated:5/10/2012

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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.

www.youtu.be/JDBTx-SJ7H8


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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 CGISEA008
















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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.

www.youtu.be/JDBTx-SJ7H8


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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.

Besuretodischargeanystaticelectricitybytouchingtheunitframeimmediatelypriortoextractingthegassample.

Enforceanonsmokingzoneofatleast25.

ProvideaClassC(drypowder)andClassDfireextinguisherintheimmediateworkarea.

TechnicianshouldalwayswearPPEsafetyglassesandfaceshield,gloves,andhighvisibilityvest.

EQUIPMENT

CGEARSextractiondevice

Vacuumpump

Bottleofdrynitrogenwithregulator


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HFCR134aquickconnectors

Spannerwrench

MAIGassampletubewithPHpaper(availableatMcCampbellAnalyticalPittsbug,CAwww.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.

http://youtu.be/81DrmrzdQmM


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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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EmployeesName(Print)EmployeesSignature

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LocationTodaysDate

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SupervisorsNameSupervisorsSignature

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Documents

R134a REFRIGERATION TECHNICIAN HANDBOOK