R134a Testing Procedures

R134aREFRIGERATIONTECHNICIAN
HANDBOOK
Version2.1
Updated:May10,2012
USACO
TABLEOFCONTENTS
1.0
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
ThisR134aRefrigerationTechnicianHandbookwasdevelopedasinstructionalguidelinesforrefrigeration
personnelofConGlobalanditsrelatedcompanies.Wehavemadethisinformationpublicsolelyasasourceof
informationtootherswhoareinterestedintheservicingofrefrigeratedcontainers.Wearemakingthis
documentavailableasinformationonlyandareNOTPROMOTINGORSUGGESTINGanyoneoutsideof
ConGlobalanditsrelatedcompaniesadoptanyofthemeasurescontainedinthisdocument.Anypersonnel
servicingrefrigeratedcontainersshoulddotheirowninvestigationandimplementsafetypoliciessuitedto
theirspecificsituationandconditions.
Thishandbookisintendedtobeanevolvingdocumentandwillchangeasnewinformationisdiscoveredand
madeavailabletotheindustry.Commentsandsuggestionsforimprovingtheeffectivenessoftheinformation
andprocedurescontainedhereinarewelcomedandencouraged.Commentsandsuggestionsshouldbe
directedtoPriscillaYataatpyata@cgini.com.
ConGlobalreservestherighttoamend,modifyandretractanyorallpartsofthiswritingasnewinformation
maydictate.
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Version2.1Updated:5/10/2012
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1.0 OVERVIEW
BACKGROUND
TheRefrigeratedContainerindustryhasrecentlyexperiencedseveralinstanceswherebyrefrigerated
containershaveviolentlyandunexpectedlyexploded,resultinginmultipledeathsofservicetechnicians
aroundtheworld.Todate,investigationsindicatethattheexplosionswerecausedbytheintroductionof
counterfeitR134arefrigerantcontaining,amongothergases,significantamountsofR40(methylchloride).As
ofthiswriting,alloftheunitsthathaveexplodedreceivedarefrigerantgaschargeinVietnam.
However,anadditionalinvestigationofinstockrefrigerantgassuppliesatrepaircompaniesaroundthe
world,aswellasonboardmarinevessels,hasturnedupcounterfeitgascontainingR40.Further,inarecent
effortbymembersoftheContainerOwnersAssociation(COA)whoconductedasamplingandtestinganalysis
ofseveralhundredrefrigeratedunitsacrosssevenlocations,inthreedifferentcountries,involvingunitsfrom
twelvedifferentSSLines(orLeasingCompanies),revealedthatsomeunitswhichwerenotservicedinVietnam
werefoundandconfirmedtohavecounterfeit/contaminatedrefrigerantcontainingseveraldifferent
chlorinatedgasses,includingR40.Andasexpected,manyoftheunitsthatreceivedgasserviceinVietnam
werealsofoundtobecontaminated.Thissupportsthegrowingsuspicionthatthiscounterfeit/contaminated
refrigerantissueisnotisolatedtounitshavingbeenservicedinVietnam,asoriginallythought.
Sincetheearlyannouncementsofthisproblemin2011,ConGlobalIndustrieshasbeeninvolvedwithan
internationalcommunityofexperts,bothinthecontinuedinvestigationaswellasthedevelopmentoftest
methodstoeffectivelyscreenunits.ConGlobal,alongwithotherindustryleaders,hasbeenadrivingforce
behindthedevelopmentofpoliciesandeducationalprogramsdesignedtosafeguardrefrigerationservice
personnelandtopreventtheproliferationandspreadofcounterfeit/contaminatedrefrigerant.Thisissueis
evolvingdaily,andwecontinuetolearnmorerelevantinformationwitheachcontaminatedcontainer
identified.
ConGlobalIndustries,Inc.andouraffiliatedservicecompaniesofUSACOinCostaRica,CoastalGreatSouthern
ontheU.S.EastCoast,andICAVEinMexico,areamongthelargestrefrigerationservicecompaniesinthe
world.Assuch,wehavetakenaveryseriousviewoftheissue.
AtConGlobalandallofouraffiliatedcompanies,thesafetyofourpersonnelaswellassafeguardingourclient
assetsareofparamountimportancetous.Accordingly,wedevelopedaseriesofprograms,disciplines,and
policiesbasedonthemostreliableandcurrentinformationavailable.
Withimmediateeffect,allConGlobalrefrigerationservicefacilitiesandservicetechniciansareadoptingthe
refrigerantgashandlingprotocoloutlinedinthishandbook,whichhasbeencarefullydesignedto:
1. Safeguardourcompanypersonnel
2. Safeguardourcustomerassets
3. Stoptheproliferationofcontaminatedgasinourindustry
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2.0 HANDBOOKINTRODUCTION
OnNovember11,2011,thecompanyissuedthefirstSAFETYBULLETINrelativetonewsthatisolated
refrigeratedunitsaroundtheworldhadexploded,causingcasualties,includingfatalities.
TheCompany(hereinmeanttoincludeConGlobalIndustries,CoastalGreatSouthern,ContainerCareIcave
Mexico,ContainerCareMexico,andUSACOCostaRica)issuedaseriesofpoliciesandprocedures,basedon
informationanddataknownatthattime,toprotectthesafetyandwellbeingofouremployeeswhohandle,
andperformmaintenance,repair,andinspectionofrefrigeratedcontainers.
Agreatdealofinformationandknowledgehasbeenaccumulatedsincethatdate.ThisRefrigeration
TechnicianHandbookistobeusedastheexclusivesetofpoliciesandproceduresforhandlingrefrigerated
containerunitswithinandbyallcompanypersonnelandsupersedesanypriorcommunication.
Eachandeveryrefrigerationtechnicianinthecompanymustbetrainedintheproceduresoutlinedinthis
manualbytheirsupervisor.Inaddition,everyrefrigerationservicetechnicianwillsigntheacknowledgment
pageattheendofthismanual,confirmingtheyhavereadthemanualinitsentirety;theyhavebeentrainedby
theirsupervisor;andtheyfullyunderstandandagreetoabidebyallthepoliciesandproceduresfoundwithin
thismanual.Inaddition,theGeneralManagerwillsigntheacknowledgementpage,verifyingtheemployee
hasbeentrainedandissatisfiedtheemployeehastherequiredinformationandskilltosafelyworkonall
refrigerationunits.
Therewillnodeviationfromthesepoliciesandprocedureswithouttheexplicitwrittenapprovalofeitherthe
PresidentorDirectorofSafetyandComplianceofthecompany.Thepoliciesandproceduresfoundwithinthis
manualapplytoALLR134aREFRIGERATIONUNITSservicedbyourcompany.
Anyrefrigerationtechnicianwhodoesnotfeelcompletelycomfortablecomplyingwiththepoliciesand
proceduresfoundinthismanualmustexpresstheirconcernswiththeirsupervisorpriortocommencingwork
onanyrefrigeratedunit.Anyrefrigerationtechnicianwhoobservesanythingoutoftheordinaryonany
refrigerationunitmustimmediatelystopandreporttheirconcernstotheirimmediatesupervisor.
SAFETYANDENVIRONMENTALNOTES
Abyproductofburninghydrocarbonchlorideisphosgenegas,whichisalethalgasincertainconcentrations.
ToensurethattheHalideFlametestcanbesafelyperformedusingtheventilationhooddescribedinthis
handbook;ConGlobalcontractedanenvironmentalhygienistfromAECOMtotesttheenvironmentatvarious
distancesaroundtheventhood,includingasamplingdevicelocatedonthetestingtechnician,andatthe
exhaustoutlet.AECOMusedOSHAMethod61asabasisforcompletingthesample.Thesampleperiodlasted
fivehoursand6burntestswereperformed,5ofwhichlastedapproximately30seconds,andthefinalburn
lastingapproximately1minute.BothR22andR134arefrigerantweretested.SinceR22containschloride,it
producesphosgenegaswhenburnedallowingAECOMtotesttheairqualityandrecordtheresults.
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TheAECOMtechniciantestedairflowrates,constructionofthehoodassembly,andsmoketestobservations.
TestmediahadtobeacquiredfromalabinNewYorkandwasshippedovernightunderrefrigerated
conditions.Thetestmedia,afterbeingexposedtothephosgenegas,wasreturnedtothelab,againunder
refrigeratedprotection.Thetestresultsreportedthelevelofphosgenegasat1/100oftheOSHAPermissible
ExposureLimitduringa4hourtimeframeandthusnotrepresentingasignificantrisktotechnicians
performingtheflametestwithasmokehoodinuse.
RECEIVINGREFRIGERATEDCONTAINERSONDANGERLIST
Tothebestofourability,theCompanyhasloadedclientsuppliedlistsofcontainersinTEC(Terminal
EquipmentControlSystem)thathavebeenservicedinVietnam.TheseunitsaredesignatedinTECasDanger
Units.Uponarrivalatoneofourdepots,refrigeratedcontainerswillbecheckedtoverifytheyarenot
identifiedinTECasaDANGERUNIT.
IfarefrigeratedunitarrivesatyourlocationandisdeterminedtobeonourDangerList,thecontainershould
beimmediatelymovedtoanisolatedareaofthedepot,andagassampletaken(followtheCGEARS
procedurecontainedherein).ThegassampleshouldbetestedusingaHalideFlameTesttodetermineif
chlorideispresentinthegas.IfaDangerUnittestspositiveforchloride,thecontainermustbemarkedwith
aLARGE,REDXatthebottomcornerofthecontainer,atthedoorend,andstacked/storedwiththeunits
facingeachotherortherefrigeratedunitblockedwithanothercontainer,preventingunauthorizedpersonnel
fromtamperingwiththem.Agastestplacardshouldimmediatelybeaffixedinaconspicuouslocationtothe
frontendofthecontainer.
ForDangerUnitsfailingtheHalideFlameTest,cuttheplugsoffoftheunits,closetotheplug.Puttheplug
insidethecordboxonthefrontoftheunitforanyDangerUnitthattestspositiveforchloride.
Themachineryshouldbestacked/storedcloseenoughtotheblockingcontainersuchthatapersoncannot
inadvertentlywalkbetweenthem.AllDangerUnitsstoredinthisfashionshouldbestoredatleast25feet
fromflammableorcombustiblematerials.
AsoutlinedintheCGEARSinstructions,asampleofanyunitfailingtheHalideFlametestshouldbesentto
McCampbellAnalyticalLaboratoryinPittsburgCAforGCMStesting.
McCampbellAnalytical,Inc.(MAI)
1534WillowPassRoad
Pittsburg,CA94565
(877) 252-9262
www.mccampbell.com
IfaDangerUnitpassestheHalideFlametest,itisconsideredsafeandcanbeservicedasdirectedbythe
client.
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HANDLINGPROCEDURESFORALLR134AREFRIGERATEDUNITS
Usethefollowingguidelinesonallrefrigeratedunits,includingthoseunitsontheDangerlistthatpassthe
HalideFlametest.
1. First,visuallyinspecttherefrigeratedcontrollertoconfirmtheunitisnotsetintheEmergencyRun
mode.
2. Iftheunithasasightglass,checkforanyindicationofabnormalappearance.
3. Whenstartingtheunit,nopersonnelshouldbeinfrontoftheunit,orbeinsidetherefrigerated
container.
4. Duringstartup,allpersonnelshouldbenocloserthan2containerunits(approx.15feet)from
refrigerationmachinery.
5. Beforeplugginginunit,ensuretherefrigerationunitcircuitbreakerandpowerswitchareintheon
orrun(closed)position.
6. Plugtherefrigeratedunitintoapowersourcethatisnotdirectlyinfrontoftherefrigeratedunitthat
hasthepowersourcebreakerturnedoff.
7. Turnonthebreakeratthepowersourceandwaitfortherefrigeratedunittogothroughitsstartup
procedure,untilthecompressorhasstartedandrunsfor35minutes.
8. Ifthecompressorexhibitssoundsofimproperoperation,suchasknocking,clanging,buzzing,orother
oddsounds,duringstartup,orifthecompressorbecomesunusuallyhot,turnoffthebreakeratthe
powersourceandperformtheCGEARSprocedure.AFTERALLOWINGTHECOMPRESSORTOCOOL
FORATLEAST30MINUTES.AfterpassingtheCGEARSprocedure,thentroubleshootasnormal.Ifthe
unitfailstheCGEARSprocedure,thensendthesampletoMcCampbellAnalyticallabandwaitfor
results.
9. Ifaunitfailstostart,disconnectitfrompowersource.
10. Theservicetechnicianshouldthenusethepowerpluginhandrulewhenworkingonunit.Thismeans
thetechnicianwillhavethepowercordplugwithhimpriortocommencinganyworkontheunit.
11. Forunitsthatdontstart,andonlyafterpowerisCONFIRMEDdisconnected,inspectalarmlogfor
failureindications.
12. Forunitsthatrequirepowertoviewalarms,disconnecttheoutputpowertothecompressorpriorto
connectingpower.
13. OnANYunitthatrequiresservice,wherebygaugesmustbeconnectedtotheunit,therefrigerant
mustfirstbetestedbyusingtheCGEARSextractionprocedure.IffreonpassestheHalideFlameTest,
workmaycommence.IftherefrigerantfailsHalideFlameTest,noworkshallbeperformeduntil
authorizationisgiven.
14. Ifanycompanytechnicianhasanydoubtorconcernaboutsafelyworkingonanyrefrigeratedunit,
theyshouldimmediatelyconsultwiththerefrigerationsupervisor.
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3.0 IDENTIFYINGFAKE/COUNTERFEITR134AREFRIGERATEDGAS
Thereareseveralthingstolookforwhentryingtoidentifyfake/counterfeitrefrigeratedgas.Outlinedbelow
aretwoexamplesofthingstolookfor.Ifyouspotoneofthesetanks,STOP,andtakeittoyourimmediate
supervisor.
Thetankontherightisacounterfeittank.SomecounterfeittanksspellDuPontasDupont(notethelower
casep).
Anotherwaytoidentifycounterfeitcylindersistheshapeofthehandlebase.Originalcylindershavestraight
handlebasesandcounterfeitcylindershavecurvedhandlebases.
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4.0 R134AREFRIGERATEDCYLINDERTESTINGUNITANDPROCEDURES
Thissectionoutlinestheassemblyofthehalideflameventilationhoodandthetestingproceduresfornew
R134arefrigeratedgascylindersatallConGlobalrefrigerationservicefacilities.Thepurposeoftestingnew
R134acylindersbeforeuseinservicingrefrigeratedcontainersistodetectwhethertheR134acylinderhas
beencontaminatedwithchlorinatedgasses,includingR40(MethylChloride).
HALIDETORCHANDVENTILATIONHOODASSEMBLY
Theunittotestrefrigeratedgasfromcylindersusesthefollowingcomponentsandmodifications:
CompactOversprayCollectorwithdimensionsof18HX22WX20D.Thispieceisreferredtoasa
venthood,purchasedfromMcMasterCARR(Partnumber9559T51).
Theventhoodismodifiedbythefollowingprocedures.
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Mountingtheunitontwolegsfabricatedoutofsheetmetal.
Drillingaholeinthebottomoftheventhoodsothehalideleakdetectorcanbeinserted
throughthebottom.
Paintingtheinterioroftheventhoodblacksotheflamecanbeeasilyseen.
Drillingaholeintheleftsideoftheventhoodsotheexplorationhosecanberoutedtothe
tankfortesting.
Installingaplexiglasscoveronthefrontusingapianohingetocontainfumesinhoodfor
ultimateventilation.(Note:Theopeningatthebottomoftheinstalledplexiglassisintentional
toallowforproperairflow.)
Outfittingtheexhaustfanmountedontherearoftheunitwithaluminumductingsothe
exhaustoutletisatasufficientdistance,asrequiredbylocalworkersafetyregulations.For
ConGlobalsNorthAmericanlocations,theexhaustshouldterminatesevenfeetabovethe
heightofthetechnicianshead.
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Toensureconsistencyinassemblingthetestingunits,ConGlobalcentrallypurchasesventhoodsfrom
McMasterCARRanddropshipstoeachlocationthatneedsatestingunit.Wealsocentrallypurchasethe
plexiglassfrontcover,pianohinge,leakdetector,valves,fittingandgauges,andhoses.TheConGlobalLos
Angeleslocationfabricatesthesheetmetallegs,assemblesthevalveandconnector,andassemblesthehalide
torch.Theindividuallocationonlyneedstosecuretheexhaustductingwhichisavailableatmostlocal
hardwaresupplystores.
Fortheactualhalidetorchtestingapparatus,weareusingaNRPLeakDetectorthatmountsdirectlytoa
conventionalhandheldpropanebottle.Thepropanebottleismountedbetweentheventhoodstand,sothe
leakdetectorunitisinsidetheventhoodandthepropanebottleisbelowtheventhood(Seediagrams#1and
#1abelow).
Diagram#1
Diagram#1a
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CONGLOBALGASEXTRACITONANDANALYSISRECOVERYSYSTEM(CGEARS)
Thegaugeandconnectorassemblyconsistsofthefollowingcomponents:
A. Acme(auto)adaptortoflarefitting
B. flarefemaleunion
C. Quickconnectvalve
D. Regulator
E. Lowpressurerefrigerantgauge(R134a)
F. Lowlossline8inlengthwithballvalve,flarefittings
G. Femaleflareadaptortotubing
H. coppertubing
I.
adaptorfromtubingtocapillarytube
J.
Capillarytube(0.054innerdiameter)
K. Schraderadaptor(ThermoKingPart#669873)
L. Ballvalveflareconnections
M. Doublemaleflareconnector
Diagram#2
NoteThistestinggaugedeviceisrecommendedoveratypicalmanifoldgaugesetbecausethequantityof
gasisrestrictedbythedevicesize.Thiskeepsanydischarge,eitherintentionalorunintentional,toade
minimuslevel,asrequiredbyU.S.EPAregulationsection608.
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PROCEDURESFOREXTRACTINGANDTESTINGR134AREFRIGERATEDGASCYLINDERS
Ifpossible,priortodoingtheactualtestwithaR134acylinder,performthesametestonaR22sample,which
containschlorideandwillcreatethesameflamecolorchangetogreenasacylinderofR134athatis
contaminatedwithR40,R12,orR142b.Thisprocessisrecommendedsimplytoensurethatthetesting
technicianknowspreciselywhattolookforsincethechangeincolorcanberapid,andwilllastforonlya
secondortwo,dependingonthevolumeofrefrigerantpassingthroughthecapillarytube.Itisimperativethat
thetestingtechnicianshaveexperiencewithvisuallydetectingthechangeinflamecolorbeforeconductingthe
livetests.ThevideolinkbelowandthepicturesinDiagrams#3and#3aareexamplesoftheflamepriorto,
andafterexposuretogasseswithchloride.
Flametestingvideolink:www.youtu.be/JDBTxSJ7H8
Diagram#3ContaminatedR134aRefrigerantGas
Diagram#3aUncontaminatedR134aRefrigerantGas
Afteratestthatispositiveforchloride,andtoavoidapossiblefalsepositiveresult,beforethenextR134a
cylindertest,youneedtothoroughlycleanandpurgethetestinggaugeandconnectorwithcompressedairor
nitrogen.Ifthelinesarenotpurged,tracesofchloridemayremaininthetestinggaugecausingfalsepositive
readingswhentestingotherwisepureR134asamples.Asageneralrule,thetestinggaugeneedstobepurged
aftereachtestandparticularlyafterapositivechloridetestresultinginagreenflame.
Followtheseproceduresforflametesting.
1. ConnectapurgedandcleanedCGEARStoanitrogenbottleandpressuretestforleaks.
2. ConnectfittingAtoR134arefrigerantbottle,thenconnectSchraderadaptorL.Thenattachquick
connectvalveC.(Ifrefrigerantbottlehasfitting,connectSchraderadaptorL,andthenconnect
tobottlewithquickconnectvalveC.)
3. EnsureballvalvesMandGareclosed.
4. Connecttheexplorationtubefromthehalidetorchtothebarbedfittingontheinsideofthehood.
5. Connectanotherpieceofexplorationtubetotheoutsidebarbedfitting.
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6. Raisethecleardoorofthehoodandlightthetorchwithanignitionsource.
7. Adjustthecenterflameconesothatthetipoftheflameisjusttouchingthecopperreactorplate.
8. Afterthetorchisoperatingproperly,closetheplexiglassfrontcover.
9. Lettheflameburnuntilthereactorplateisglowingred(usually23minutes).
10. Slowlyopenthevalveoftherefrigerantbottleandthenopenquickconnectvalve,thenopenballvalve
Gandallowpressuretoreach6080psi.(Pressuremayvarydependingonambienttemperature.)
11. Closethevalveonthebottle,alsoclosethequickdisconnectvalveandballvalveGoftheCGEARS.
YouhavenowessentiallytrappedyourgastestsampleintheCGEARS.
12. DisconnecttheCGEARSfromtheR134acylinderandtaketestgaugetotheventilatedhalideflame
testlocation.
13. ConnectSchraderadaptorLtomaleconnectorNandthentocapillarytubeassembly.Insert
SchraderadaptorLintoquickdisconnectvalveC.
14. Insertthecapillarytubeintoasmallcontainerofwater,whilepositioningtheexplorationtubefrom
thehalidetorchapproximately1inchabovethewater.
15. OpenballvalveG,thenslowlyopenvalveCuntilaslightgasflowfromthecapillarytubeisvisually
confirmedbybubblesinthewater.Closelywatchthehalidetorchflamethroughtheslotsintheflame
shieldforabrief,temporarychangeinflamecolorfrombluetogreen.
16. Ifthereisacontaminantcontainingchloride,theflamewillturngreenwithinafewsecondsandburn
greenforbetween1and5seconds.Iftheflameremainsaconstantblue,thetankbeingtestedisfree
ofchloridecontaminants.
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LABELLINGANDTRACKINGTESTRESULTS
Anauditableprocessfortestinggassamplesisessentialtodocumentwhichcylindershavebeentestedto
preventadditionalcontaminatedgasfrombeingintroducedtorefrigeratedcontainermachines.Whenanew
gascylinderisreadytobeusedforservice,ahalidetestshouldbeperformedtodetermineifthegashasbeen
contaminated.Oncethecylinderhasbeentested,thetestingtechnicianwilluseanindeliblemarkertomark
DIRECTLYONTHECYLINDER1)thedepotlocation,2)cylindernumber,3)testdate,4)testresultand5)
techniciansignature.Thisinformationisthenrecordedonalogtocreateanaudittrailthatcanbeeasily
sharedwithcontainerownersandauditorsuponrequest.Anexampleofthelogisattachedasreference.
Currently,gascylindersdonothaveuniqueserialnumbersthatcanbeusedforidentification.Therefore,
repairfacilitiesneedtocreateauniquenumberforeachcylinderthatistested.AtConGlobalIndustries,the
cylindernumberwilladheretothefollowingformat.Itstartswithathreealphacoderepresentingthedepot
companyname;followedbyathreealphacoderepresentingthetestinglocation;andendswithasequential
threenumbercode.UsingCGISEA001asanexample,CGI=ConGlobalIndustries;SEA=Seattle,Washington;
and001=sequentialnumber.Ifacylinderisnotlabelledwithall5piecesoftestinginformationlistedabove,it
shouldnotbeused.
Afteratankisempty,thevalveshouldbeknockedoff.Besurethetankisemptyandproperlyevacuated
beforeknockingoffvalve!Thetankcanthenbescrapped.Crushingthetankmayberequiredbysome
recyclers.Checkwithyourlocalscrapmetalrecyclerfortheirspecificrequirement.Afterdestruction,notethe
destructiondateontheGasBottleTestingLogSheetunderthecommentssection.
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REFRIGERATEDCONTAINERGASCYLINDERHALIDETESTINGLOG
FLAME
TEST
DATE
DEPOT
LOCATION
CYLINDER
NUMBER
PASS/
FAIL
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
TESTERNAME
COMMENTS
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5.0 NEWSAFETYREQUIREMENTSFORSERVICINGR134AREFRIGERATED
CONTAINERS
Theinvestigation(s)ofthecontainersthathaveexplodedindicatethatoneofthepossibleconditionscausing
theexplosionsistheintroductionofafreshR134arefrigerantchargeintoacontaminatedsystem.Inan
efforttokeepourservicetechnicianssafe,withimmediateeffect,anyrefrigeratedcontainerusingR134a
refrigerantthatrequirestheconnectionofamanifoldgaugesetforanyreason,including::
AR134arefrigerantgascharge,
TheevacuationofR134arefrigerantgasforanyreason(i.e.systemrepair),OR
Simplepressurecheck.
willfirstberequiredtoundergoaRefrigerationgashealthandsafetycheck.Thisprocesswillentailthata
smallsampleofrefrigerantgasbeextractedbymethodscarefullydevelopedbyConGlobal,andfieldscreened
/testedbyeitherHalideflametestorbyRRAChloridetesttube.Thecostforthisfieldscreeningisminimal
andisavailabletoConGlobalclientsuponrequest.
(AvideooftheHalideflametestcanbeviewedathttp://youtu.be/JDBTxSJ7H8)
Theresultsforallrefrigerantsamplestestedwillbecommunicatedtotheclientsandwillberecordedwiththe
ConGlobalservicehistoryfortheunit.Iftherefrigerantgassamplepassesthefieldscreentest,thenour
servicetechnicianswillaffixaR134arefrigeranttestdecaltotheunit(seebelowformoredetails)andproceed
withthenormalserviceroutine.
However,anyR134arefrigerantgasfailingthefieldscreentestwillbesubjecttoaGasChromatography
MassSpectrometry(GCMS)openscanlabtestbeforeanyfurthermachineryrepairsarecarriedout.Thecost
toourclientforthisadditionalrequiredsafetytestwillnotbeincurreduntilapprovalbytheclientisreceived.
ThedetailedresultsoftheGCMSopenscanwillbeprovidedelectronicallytothecontainerclient/ownerfor
theirrecordsandwillalsobekeptintheunitservicefilesatConGlobal.
Note:GCMStestresultsindicatinganydetectablelevelsofR40(methylchloride),TrimethylAluminum(TMA),
Tetramethylsilane(TMS)oranyotherpyrophoricgasorsubstancewillresultintheunitbeingclassifiedas
potentiallydangerousandallserviceworkwillSTOPuntilconsultationwiththeownerregardingneutralization
measuresaretakenandtheaffectedcontainercanbesafelyreturnedtoserviceordestroyed.
ConsistentwithARI700refrigerantstandards,anyGCMSresultsindicating>.5%(1/2of1%)ofothernon
dangerouscontamination,i.e.R142b,R12,R22,etc.,willresultintheunitbeing1)completelyevacuated,
purged,orcleanedwithdrynitrogen,2)oilremovedandreplaced,3)anewfilterdrierinstalled,and4)the
systemrechargedwithnewR134arefrigerant.Afterrechargingtheunitandrunningitfor30minutes,another
refrigerantgasscreentest(HalideorRRATubetest)willbeperformedtoconfirmtheeffectivenessofthe
process.
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GCMStestresultsindicating99.5%R134aorbetter,withnodetectableamountsofR40,TMS,TMAorother
pyrophoricgassesorsubstances,willbedeemedsafeandroutineservicewillproceed.AsmallGASTEST
Placard,liketheonepicturedbelow,willbeappliedtoallcontainermachinerywhen:
Fieldscreentest=PASSOR
CGMStest=99.5%+R134a(withnodetectablelevelsofpyrophoricgas,orofR40,TMS,
TMA
ADDITIONALSAFEGUARDSIMPLEMENTEDATCONGLOBALINDUSTRIES
ConGlobalIndustries,Inc.hasalsodevelopedspecificpractices,policies,anddisciplinesdesignedtoprevent
theproliferationandspreadofcounterfeitorcontaminatedR134arefrigerantwhileservicingcontainersatall
ofourservicelocations.Thesepracticesinclude:
FlametestingandcreatingapapertrailforallnewandexistingstocksofR134arefrigerant,confirming
itspurityandthatitisfreeofchlorideatlevels>300ppm(thelevelofsensitivityforaflametest).
Aseriesofhygieneprotocolrequiringthenitrogencleansingandflameretestconfirmationof
servicegaugesandreusablerecoverybottles,whenpriorrefrigerantgaspurityiseitherunknownor
positivelyconfirmedbyflametestorRRAtesttocontainchloride.
Thedestructionanditsdocumentationofdestructionofalldisposable,nonrefillableR134abottles.
Thisisintendedtoensurethatthebottlesarenotretrievedandusedinthecounterfeitmarket.
Nomixingofrefrigerantfromoneunittoanother.Anyrefrigerantevacuatedandrecoveredfroma
container,afterflametesting,canonlybereturnedtothesamecontainerthatitwaswithdrawnfrom
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andwillnotbemixedwithrefrigerantfromanyotherunit.Ifforsomereasontherefrigerant
withdrawnfromaunitisnotreplacedinthesameunit,therefrigerantwillberecycled,reclaimedor
incineratedratherthanusedinanotherunit.ThispolicyisintendedtoincludeALLcontainersinEVERY
circumstanceincludingsaleandscraprefrigeratedcontainers,whereitiscommoninsomerepair
facilitiestoevacuatetherefrigerantwiththespecificintentofresale.
TheestablishmentandimplementationofarecordkeepingsystemforallR134arefrigerantsusedto
servicearefrigeratedcontainerthatcanbetracedbacktothebottleoforigin.Whencombinedwith
thenewbottletestingprotocoldescribedearlier,unitspecificservicerecordscaneasilybetracedback
toaflametested/purityprovenR134arefrigerantsource.
ThetrainingofeveryConGlobalrefrigerationservicetechnicianandpartsreceivingpersonnelastothe
characteristicsthatmightindicatearefrigerantcylindermaybeacounterfeitedproduct.
AsaconditionofemploymentatConGlobaloraffiliatedcompanies,everyservicetechnician,their
supervisors,andfacilityGeneralManagerswillacknowledgereceiptofthesepolicies;acknowledge
theircompleteunderstandingandtheintentionsofthesepolicies;andpledgetofollowtheprotocol
andrefrigeranthandlingprocedures.Additionally,thishandbookshouldbeincludedinthe
refrigerationpersonnelnewhirechecklist.
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6.0 CONGLOBALGASEXTRACTIONANDANALYSISRECOVERYSYSTEM
(CGEARS)
SAMPLINGMETHODS
ConGlobalsrefrigerationgassampling,testmethodology,andproceduresaredescribedinthisdocument.
1. Samplemethodtosafelyextractgasandtofieldcheckrefrigerationmachineryforchlorine
contamination.
2. TakingasamplefromarefrigerationmachineforlaboratoryanalysisMAIsampletube.
IMPORTANTPRECAUTIONS
Itisadvisableforalltechnicianstoconsiderthatarefrigerationmachinesystemmightbecontaminatedbefore
turningthepoweronandbeforeanyattemptismadetotakeagassample.
Currently,thesimplestandmostreliabletestfordetectingthepresenceofchloridecontaminationisthe
HalideFlameTest.Itshouldnotbeusedwithoutfollowingdetailedinstructionsandtakingsuitable
precautions.TheHalideFlameTestissensitivetoapproximately300ppmforchloride(0.03%)anditis
thereforelikelytodetectifasystemhasbeencontaminatedwithachloroalkanesuchasR40orHCFCssuch
asR22,R12orR142b.
ItshouldberememberedthatthetestisforchlorideandnotatestfortheverydangerousgasTMS
(Trimethylsilene)orTMA(Trimethylaluminium),whichifpresent,wouldbealiquidinthecrankcase.The
meltingpointofTMAis15oC.ItisremotelypossiblethatevenwhereaHalideFlameTesthasnotdetectedthe
presenceofchlorideinagassampletakenfromarefrigerationmachine,theremaystillbecontamination
residuesinthecompressorthatcouldbehazardous.Techniciansshouldremainvigilantandcautiouswhen
workingontherefrigerationsystem.
WhenrefrigerationsystemsarecontaminatedwithR40,harmfulchemicalsmayhavealsoformedinthe
system.Insomecases,thesechemicalsmayburnspontaneouslyinaironcontactwithwater.Techniciansare
advisedtowearprotectiveclothing,gloves,eyeprotection,keepingskincoveredasmuchaspossibleandto
avoidanycontaminatedchemicalcomingintocontactwiththeskinorbeinginhaled.
Todate,therehavebeenfourinstanceswherecompressorshaveexplodedwhilebeingworkedon.Itis
suspectedthatthismighthavebeenaresultofR134arefrigerantbeingintroducedintothecompressorduring
chargingorwhenthemachinepowerwasturnedonallowingrefrigeranttoreturntothecompressor.Other
suspectedconditionsthatmanyexpertssuspectmayleadtoexplosionsaretheintroductionofair,oxygenor
moistureintoacontaminatedsystem.Inaddition,unusuallyhighcompressortemperaturesand/orpressures
whilerunningshouldalsobeofseriousconcern,andmaycauseorcontributetoapotentialexplosion.
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Thereisapossibilitythatacontaminatedrefrigerationsystemcouldhaveanegativepressurerelativetothe
atmospherewhenitisnotrunning.Thiscanhappeniftherefrigerationsystemwascontaminatedwithalarge
amountofmethylchloride(R40).TheR40mighthavebeenconsumedbyachemicalreactionwithaluminium
componentsinthecompressor,thusreducingthepercentageofR40andthelatentpressureinthesystem.
Conversely,theextremehightemperaturesandpressuresthatacompressorcanreachwhilerunning,if
contaminatedwithcertainnon134arefrigerants,(whichhasbeensimulatedinlaboratoryconditions)isof
particularconcernandmayalsoberelatedtothepotentialexplosionofarefrigerationcompressor.
CGEARSMETHODTOCHECKREFRIGERATIONMACHINERYFORCHLORIDECONTAMINATION
Thistechniqueisintendedtoenableservicetechnicianstoquicklyandsafelycheckarefrigerationmachineina
typicalrepairdepotenvironmentforchloridecontaminationtodetermineifitissafetoworkontheunit.
Ifaunitiscontaminated,itispossiblethatthegasintherefrigerationsystemmayviolentlyreact,smoke,
combustorevenexplodewiththeintroductionofair,water,freshR134a,oranelectricalspark.
Itisveryimportanttoensurethatnoair,moisture,orwatercanenterintothesystemwhileextracting
gas.Similarlyitisimportantnottoallowanysystemrefrigeranttoleakintotheatmospherewhile
extractinggasforsampling&testingpurposes.
Allconnectionsmustbecompletelydry.
Priortotheextractionprocess,confirmtheunitisunpluggedbeforeproceeding.
Onsomesystemsthatarecontaminated,thesightglassmaybeadarkgreyorbrowncolorandnoteasytosee
into.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/flushtheC
GEARSdevicetocleananypreviouscontaminantsfromthedevice.
Note:itisveryimportanttoavoidanypossiblecrosscontaminationfromtheprevioustest,which
shouldbeconfirmedbyaHalideflametest,usingaknownsourceofpureR134a.
2. Pressuretest,withnitrogen,theCGEARSsystem(includingMAIsampletube)to6070psiandcheck
forleaks,thenreducetheregulatorpressureandsetat20psi.
3. PurgenitrogenfromCGEARSandconnectthedevicetoanewsupplyofR134a,knowntobefreeof
chloridecontamination,andtakearefrigerantsample.
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4. HalideflametestthissampleofknowncleanR134atoinsurethereisnochloridepresentintheC
GEARSdevice.
5. CheckthePHPapertoconfirmneutralPHlevelof4to8onthecolorscale.
6. EvacuateCGEARSintoavacuumof2930in/HG.Aftershuttingvacuumpumpoff,andclosingthe
quickconnectvalve,confirmvacuumismaintainedfor30seconds,confirmingnoleaksintheCGEARS
device.
TAKINGSAMPLESFROMREFRIGERATIONMACHINE
SAMPLEPORTS
GassamplescanbetakenfromeithertheHighPressure(HP)orLowPressure(LP)sideofanidleunitthatis
disconnectedfromapowersource.Therecommendedaccessportisgenerallydescribedasaserviceport
locatedasfarfromthecompressoraspossiblebothitsphysicallocationinproximitytothecompressorand
thefarthestpipingdistancefromthecompressor.Thisrecommendationisintendedtoallowservice
technicianstobeasfarfromthecompressoraspossible(physicaldistance)whileaffordingtheleastlikely
chanceofencounteringTrimethylAluminium(TMA),whichmayhaveformedinthecompressorandmigrated
tootherpartsoftherefrigerationsystem.InthecaseofaCarrierNTmachinetherecommendedaccessportis
theKingValve.
SAMPLINGPROCESS
Afterproperlycleaning,pressuretesting,andleakcheckingbyvacuum,thegassamplingprocesscan
begin.
TheCGEARSdeviceshouldbeina2930in/HGvacuum.
Choosetherefrigerationunitsamplingportbasedonthecriteriaabove(samplingports).
1. Ensureaccessportiscleananddry.
2. Withthequickconnectandservicevalvesclosed(backseated)attachthequickconnectvalveof
theCGEARStotheserviceport.
NOTE:IMPORTANTINFORMATIONRELATEDTOSCHRADERVALVES
AportionofintermodalrefrigerationunitsareequippedwithRefrigerationAccessValves,
commonlyreferredtoasSchraderValves,whichisonemanufacturerofthesetypesofvalves(see
photobelow).Thesevalvescanbefoundonthedischargeservicevalve,suctionservicevalve,and
atvariouspointsintherefrigerantplumbinglines.
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TheRefrigerationAccessValveisaflareconnectorfitting.Whenconnectingordisconnectingaline
fromaSchraderValveoranyotherbrandofRefrigerationAccessValve,adischargeofrefrigerant
isnormallyreleased.
SeeSchraderValveVideo:http://youtu.be/81DrmrzdQmM
IftheR134arefrigerantthatisdischargedhadpreviouslybeencontaminatedwithchloride
contaminants,thereisapossibilitythatotherdangerousgassesmayhaveformedandthata
pyrophoricreaction(spontaneousignition)orexplosioncouldoccurifgasisreleasedintothe
atmosphere.
Assuch,anytimeaSchraderValve,orsimilarRefrigerationAccessValveisbeingconnectedor
disconnected,thetechnicianmustfirstuseaquickconnectadapter,toavoidthelossofrefrigerant
intotheatmosphere(seephotobelow).ThequickconnectcouplercommonlyusedatCGIandour
affiliatedcompanies,canbepurchasedfromThermoKing.
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3. Keepingtheservicevalveclosed,openthequickconnectvalvetoensurethatanypossibleair
remainingintheconnectionareabepulledintotheCGEARSdevicevacuumandconfirmingthe
connectionisairtight.TheCGEARSshouldmaintaina28+HGvacuum.
4. Reclosequickconnectvalve.
5. Inadditiontothequickconnectvalve,ensurethetwoothervalvesontheCGEARSdeviceandthe
sampletubeareclosed.
6. Openservicevalve.
7. Openthequickconnectvalve.ThiswillallowgasatsystempressuretoflowintotheCGEARS.
Note:Ifavacuumismaintainedafteropeningthequickconnectvalve,closeallvalves(CGEARS
andserviceport)andcontactHQforconsultation.ThisconditionmayindicatetheRefrigeration
systemisinavacuum,aconditionlikelyindicatingthepresenceofdangerousgasses.DONOTrun
theunitorattempttoreusetheCGEARSdevice.
8. OpentheCGEARSstage2valveandtheMAIsampletubevalve.Ifsetcorrectly,theregulatorwill
let20psiofgasflowintothesampletube.
9. RecloseMAIsampletubevalvetrappingagassampleintheMAIsampletube.
10. Closetheservicevalve.
11. Closethequickconnectvalve.
12. DisconnecttheCGEARSandmoveawayfromtheunit.
13. WatchthePHpaperintheMAIsampletubefor30secondsforanyacidicreaction.Ifnoreaction
occurs,proceedwiththeflametest(Note:TheCGEARSgaugeshouldnowread20PSI).
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PHPaperChart.
Note:ThisisasampleofthePHpaperchart.RefertophysicalPHpaperforcolorcomparisonwithgassample.
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FLAMETESTINGOFEXTRACTEDSAMPLES
WithasampleofgassafelyextractedandtrappedintheCGEARSdeviceandtheMAIsampletube,aflame
testforchloridecontaminationcannowbeperformed.
1. ConfirmthatnoreactiontothePHpaperintheMAIsampletubehasoccurred.IfthePHpaperhas
reactedDONOTflametestthegassample.ContactHQforconsultationanddonotopenorreuse
theCGEARS.
2. ConfirmthattheMAIsampletubevalveisclosed.
3. AttachcapillarytubewithquickconnecttotheCGEARSquickconnectvalve.
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4. InaConGlobalHalideFlameteststationwithanegativeventilationfan,conductaHalideFlametestas
outlinedinConGlobalIndustriesflametest/bottletestsection.
Flametestingvideolink:www.youtu.be/JDBTxSJ7H8
Note:IftheCGEARSgaugereadsgreaterthan20PSI,slowlybleedatinysampleuntil20PSIis
achieved.ReopentheMAIsampletubevalveandreclosetoensure20PSIisintheMAIsampletube.
This20PSIreadingisaveryimportantQCmeasureforMcCampbellAnalyticalLab.
FLAMETESTRESULTS
Iftheflametestindicatesnochloridecontaminationover300PPM(BlueFlame)thentheCGEARSandthe
MAIsampletubecanbevacuumpurgedandreusedimmediatelyfortestinganotherunit(nonitrogenpurge
isnecessary,thoughrecommended).
Iftheflametestindicateschloridecontaminationat300PPMorgreater(GreenFlame),thenthesampleinthe
MAIsampletubeshouldbetaggedwiththecontainernumberandsenttoMcCampbellAnalyticalLaboratory
(MAI)forGCMSanalysis.Sampletubesshouldhavebrasscapinstalledassecondaryleakpreventionanda
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chainofcustodydocumentshouldaccompanyeachsample(multiplesamplescanbeincludedonasingleCOC
form.)Sampletubesshouldbeplacedinasealableplasticbag(asaddedleaksurety)andbesafelypackaged
andsentviaovernight(FedEXorDHL)toMcCampbellAnalyticalinPittsburg,Ca.
Note:McCampbellAnalyticalwillclean,verifyintegrity,andreturnsampletubestoCGIforreuse,aftereach
gasanalysis.
CLEANINGTHECGEARS
Afteranyfailedflametest(GreenFlame)itiscriticalthattheCGEARSbethoroughlycleanedanditschloride
freeconditionbeconfirmedpriortoreusing.Thisprocesswillgenerallytakelongerandbemoredifficultthan
imagined.Experienceindicatesthatthecleaningdifficultywilldependonthetypeandamountofchloride
contamination.Minorcontaminationcangenerallybecleanedwithtwominutesofnitrogenpurgingathigh
pressureandthreeminutesofvacuumcleaning,repeatingeachsteptwice.Moreseverecontaminationwill
takemoreeffort.
AftercleaningtheCGEARS,flametestaknowncleansampleofR134atoensurethedeviceischloridefree
andreadyforreusewithnopossibilityofafalsepositiveresult.
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7.0 EMPLOYEEACKNOWLEDGMENT
Ihavereadandfullyunderstandtheinformation,policiesandprocedures,andinstructionsoutlinedinthe
RefrigerationTechnicianHandbook.
Ifullyunderstandallthespecificissuesrelatedtoreceiving,handling,startup,bottletesting,gashandling,and
gasextractionmethodologiesreferencedinthehandbook.
IagreethatifIhaveanyquestionregardingthesepolicies,procedures,andinstructions,Iwillimmediatelyask
myimmediatesupervisorforadviceorinstruction.
Ifullyunderstandtheimportanceoffollowingallpoliciesandprocedurerelatedtorefrigerationservicework
andagreestonotcircumventanypolicy,procedureorinstructionfoundinthehandbook.
IacknowledgeIhavebeenfullyinstructedandtrainedinthenewproceduresoutlinedinthehandbook,and
furtheracknowledgeIunderstandthosepoliciesandprocedures.
______________________________________________________________________________
EmployeesName(Print)EmployeesSignature
_______________________________________________________________________________
LocationTodaysDate
_______________________________________________________________________________
SupervisorsNameSupervisorsSignature
________________________________________________________________________________
GeneralManagersNameGeneralManagersSignature
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