GCAP’s NH3 Operator III Competencies also know as RAGAGEP

Prerequisite: Ammonia Refrigeration Experience
Bring your P&ID’s

All of this material is covered or introduced to the student at our seminar. This selection of material will allow success in companies training structure and it follows the new IIAR Task Force Guideline using IIAR’s Ammonia Refrigeration Library and GCAP’s Supplemental Material.

Ammonia Operator III (RAGAGEP) will use the most current printed IIAR Ammonia Refrigeration Library as primary text

ANSI/IIAR 1
- Definitions and Terminology used in IIAR Standards

ANSI/IIAR 2
- “Standard for Design of Safe Closed-Circuit Ammonia Refrigeration Systems”
  - - General
    - Definitions
    - Reference Standards
    - Location of Ammonia Refrigeration Machinery
    - General System Design Requirements
    - Machinery Rooms
    - Refrigeration Equipment Located in Areas Other Than Machinery Rooms
    - Equipment
    - Compressors
    - Refrigerant Pumps
    - Condensers
    - Evaporators
    - Pressure Vessels
    - Piping and Hoses
    - Packaged Systems and Equipment
    - Overpressure Protection Devices
    - Instrumentation and Controls
    - Ammonia Detection and Alarms

ANSI/IIAR 3
- “Ammonia Refrigeration Valves”
  - - Purpose
    - Scope
    - Definitions
    - References
    - General Requirements
    - Materials of Construction
    - Pressure Envelope Requirements
    - Marking
    - Production Testing
    - Documentation
    - Sources of Reference

ANSI/IIAR 4
- Installation of Closed-Circuit Ammonia Refrigeration Systems
  - Purpose
  - Scope
  - Definitions
  - Normative References
  - General Requirements – Installation Requirements
  - General Requirements – Equipment Installation
  - Piping Installation
  - Components and Controls Installation
  - Insulation Systems

ANSI/IIAR 5
- Start-up of Closed Circuit Ammonia Refrigeration Systems
  - Purpose
  - Scope
  - Definitions
  - References
  - Ammonia Specifications
  - Pre-Charging Activities and Requirements
  - Charging
  - Start-Up Process
  - Sources of Reference
ANSI/IIAR 7
- Developing Operating Procedures for Closed-Circuit Ammonia Refrigeration Systems
  - Purpose
  - Scope
  - Definitions
  - References
  - Developing and Maintaining Operating Procedures
    - Operating Procedure Content
    - Non-Routine Tasks
    - Maintaining SOPs
  - Equipment
    - Compressors
    - Condensers
    - Evaporators
    - Pressure Vessels
    - Refrigerant Pumps
    - Purger
    - Oil Removal
  - Safety Systems
  - Tasks
ANSI/IIAR 8
- Decommissioning of Closed-Circuit Ammonia Refrigeration Systems
  - Purpose
  - Scope
  - Definitions
  - References
  - Decommissioning Requirements
  - Preparation
  - Decommissioning Activities
ANSI/IIAR 9
- Standard for Minimum System Safety Requirements for Existing Closed-Circuit Ammonia Refrigeration Systems
  - - Purpose
    - Scope
    - Definitionss
    - References
    - Equipment and System Component Documentation
    - Inspection, Testing, and Maintenance
    - System and Equipment Operation
    - Minimum System Safety Requirements Applicable to all Systems
    - Minimum System Safety Evaluation Methodology
ANSI/IIAR 2 Appendix C (Formerly known as Bulletin No. 108)
- Water Contamination in Ammonia Refrigeration Systems
  - - Preface
    - Ammonia-Water Relationship
    - Effects on Water Dilution
    - Water Contamination Sources
    - Areas of Highest Water Content
    - Detection of Water Contamination
      - Apparatus
      - Sampling Locations
      - Sampling Procedures
      - Test Procedure
    - Percent Water Determination
    - Removal of Water from System
    - Safety Precautions
      - Other Precautions
    - Percent of Water by Weight

ANSI/IIAR 6 – Standard for Inspection, Testing, and Maintenance of Closed -Circuit Ammonia Refrigeration Systems
- Responsibility for Compliance
- CMMS(s)
- ITM
- Compliance Schedule(s)
- Frequency of Inspections and Tests
  - Daily
  - Weekly
  - Monthly
  - Quarterly
  - Semi-annual
  - Annual
  - Bi-annual
  - Tri-annual
  - Five Years
  - Ten Years
- Inspection and Testing Required Documentation
- History of Deficiencies
- Record Keeping Requirements
- Refrigeration System Records
- MIEL
- SSEL
- Inspection Requirements
- Testing Requirements
- Maintenance Requirements
- ITM examples
- ITM – Screw Compressors
- ITM – Reciprocating Compressors
- ITM – Rotary Vane Compressors
- Test Safety Systems
  - Screw
  - Recip
  - Vane
- Permitted Test Methods
- Non Permitted Test Methods
- ITM – Liquid Pumps
- ITM- Condensers
- ITM – Evaporators
- ITM – Pressure Vessels
  - NDT – Pressure Vessels
  - Corrosion Pressure Vessels
  - Corrosion Allowance Pressure Vessels
    - 25%
    - 50%
    - 75%
  - Suitable for Continued Use
  - Re-Rate Pressure Vessel
  - Repair Pressure Vessel
  - Retire Pressure Vessel
  - Replace Pressure Vessel
- ITM – Piping
  - Piping Damage
  - Piping Corrosion
  - Preparing Pipe
  - Pitting in Piping
  - Insulated Piping
  - Internal Pipe Loss
  - NDT Techniques
- ITM – Hoses – Ammonia Use
- ITM – Hoses – Non Ammonia Use
- ITM – Valves
- ITM Safety Systems
  - Ventilation System
  - Lights
  - Alarms
  - Equipment E- Stops
  - Intake Luevers
  - Ammonia Detection System
  - Shunt Trip
  - All switches
  - Emergency Shutdown Switches for Machinery Room
  - Computer Controlled Processors
  - Eyewash Showers
  - High Level Cut-Outs
  - Low Level Cut-Outs
  - High Discharge Pressure Cut-Outs
  - Low Discharge Pressure Cut-Outs
  - Low Suction Pressure Cut-Outs
  - High Oil Pressure Cut-Outs
  - High Discharge Temperature Cut-Outs
  - Minimum Oil Pressure Differential Cut-Out
  - Amp Factor Protection Cut-Out
  - Gas Defrost System Steps and Timing
  - Low Oil Temp Cut-Out
  - High Oil Temp Cut-Out
  - Illumination
  - Camera System
  - Fire Suppression Systems
- ITM – Relief Valves
  - Frequencies
  - Replacement Requirements for Discharge to atmosphere
  - Service Life of a PRV
  - Replacement requirements when discharged
  - Bench Testing
  - Hydrostatics
- ITM – Purgers
- ITM – Secondary Coolants
- Safety Checklists
  - Compressors
  - Condensers
  - Evaporators
  - Pumps
  - Pipes
  - Valves
  - Vessels
  - Purgers
- Water Purity Inspections
  - Detection
  - Sampling Locations
  - Sampling Procedures
  - Removal of Water
- Pressure Shock
  - Hydraulic Shock
  - Trapped Liquid
  - Sudden Liquid Deceleration
  - Vapor-Propelled Liquid
  - Hot Gas
- Risk Based Inspections/Testing/Maintenance

ANSI/IIAR 2 Appendix Q (Formerly Known as Bulletin No. 114)
- Guidelines for Identification of Ammonia Refrigeration Piping and System Components
  - - Introduction
    - Scope
    - Definitions
      - Piping Systems
      - System Components
    - Identification System
      - Piping Markers
      - Marker Body
      - Physical State
      - Pressure Level
      - Ammonia Piping Abbreviations
      - Directional Arrows
      - Pictorial View of a Pipe Marker
      - Identifying Small or Hidden Pipe
      - Pipe Marker Dimensions and Letter Sizing
      - Component Markers
      - Component Marker Dimensions and Letter Size
      - Pictorial View of a Component Marker
      - Ammonia System Component Abbreviation
    - Marker Location
    - Visibility
    - Piping Color Scheme
      - Piping color scheme scope
      - Piping color scheme purpose
      - Ammonia piping color scheme recommendations
      - Pressure relief valve vent
      - Non-pressurized refrigeration piping and related process piping color scheme recommendations
    - Reference Chart
    - Expanding the Identification Guidelines

ANSI/IIAR 6 Appendix D (Formerly known as Bulletin No. 116)
- Avoiding Component Failure in Industrial Refrigeration Systems Caused by Abnormal Pressure or Shock
  - - Preface
    - Hydraulic Shock
    - Trapped Liquid
      - Causes
      - Preventive Measures
    - Sudden Liquid Deceleration
      - Causes
      - Preventive Measures
    - Vapor Propelled Liquid Slug and Condensation – Induced Shock
      - Causes
      - Preventive Measures
      - Liquid in Hot Gas Lines
      - Initiation of Hot Gas Defrost
      - Termination of Hot Gas Defrost
      - Light and No-Load Conditions
    - Operating System’s Emanating Sounds – Normal or Abnormal?

Brief review of PSM/RMP, Ammonia Characteristic, Safety, Basic Refrigeration Cycle
Consequences of Deviation
GCAP’s Oil Draining Video Analysis
PSI Data Collection on most Ammonia Valves DVD

Contact us for more info

Garden City Ammonia Program
2405 E. Fulton Plaza
Garden City , KS 67846
620-271-0037
620-271-0484 FAX
GCAP@AmmoniaTraining.com
www.AmmoniaTraining.com