Refrigerated Cylinder Testing Procedures Presented by: Mike Baldwin Chairman of Depot Division President and CEO of ConGlobal Industries 28 March 2012 1
Halide Flame Testing of New/Recycled Refrigerated Gas from Cylinders Purpose to be used as an added safeguard to the refrigerant supply chain with the aim of eliminating refrigerant gasses that contain chlorinated products from being used to service refrigerated containers. Halide Flame Test Effectiveness chlorine detection at >300 ppm (1). Halide Testing is quick, low cost, and effective in detecting chlorine in refrigerant stock. Note (1): The Halide Flame test method has been recommended by Maersk, StarCool, Cambridge Refrigeration Technology (CRT) and others. 2
Concerns & Risks of Halide Flame Testing Environmental Concerns American EPA and Air Quality Boards European F Gas Regulations Workplace Safety Concerns poisonous gas resulting from the burning of refrigerant containing chlorine and can pose serious worker safety concerns. 3
Vent Hood Technical Description Made from 20 gauge galvanized steel, with two 8 x 17 filters, a.43 amp exhaust motor, 115 VAC Provides 270 cfm of air flow Exhaust is in the rear of the unit, through a 4 rigid duct Dimensions are 18.5 H x 22 W x 20 D 4
Hose and Valve Components A. Acme (auto) adaptor to ¼ flare fitting B. ¼ flare coupler C. Ball valve D. T fitting ¼ flare E. ¼ flare adaptor to ¼ pipe thread (female) F. Low pressure refrigerant gauge (R134a) G. Low loss line with ball valve, ¼ flare fittings H. Female ¼ flare adaptor to ¼ tubing I. ¼ copper tubing J. ¼ adaptor from tubing to capillary tube K. Capillary tube (0.054 inner diameter) 5
Air Quality Safety Test An Air Quality Safety Test was conducted by a certified and independent industrial hygienist to ensure level of phosgene gas is not dangerous to the testing technician and other personnel The test also included examination of the vent hood assembly and test procedures The air sampling/test was done at multiple location points before and after the halide test to compare air results The hygiene test samples were submitted to a laboratory accredited by the American Industrial Hygiene Association using proper chain ofcustody procedures Six burns of R22 gas cylinders were performed during a 4 hour period Each burn lasted about 10 seconds except one burn lasted 1 minute 6
Air Monitoring Results for Phosgene Air Monitoring Results for Phosgene Sample Location Time Results (ppm) Cal OSHA PEL (ppm) Comment Background location 1006 0 0.1 ppm Operator breathing zone Operator breathing zone 1052 0 0.1 ppm 1103 0 0.1 ppm Collected while refrigerant test was performed with contaminated refrigerant (R22). Collected while refrigerant test was performed with contaminated refrigerant (R22). Inside the exhaust duct 1445 0 0.1 ppm 1 minute continuous test, collected while running a modified test with contaminated refrigerant (R22). 7
Air Sampling Results for Phosgene Air Sampling Results for Phosgene Sample Number Sample Location Results (ppm) Cal OSHA PEL (ppm) Comment 1 Hood Exhaust Duct < 0.0021 0.1 ppm 2 Front of Hood < 0.0021 0.1 ppm 3 Background < 0.0021 0.1 ppm 4 Analyst Breathing Zone < 0.0021 0.1 ppm 5 Blank < 2 micrograms NA Collected while refrigerant test was performed with known contaminated refrigerant (R22). Collected while refrigerant test was performed with known contaminated refrigerant (R22). Collected while refrigerant test was performed with known contaminated refrigerant (R22). 8
Worker Safety Air Quality Conclusions Results show the airborne concentrations of phosgene do not exceed the Cal OSHA permissible exposure limit (PEL) of 0.1 part per million The concentration levels were 1/100 th of PEL level, making it nearly undetectable Halide testing can be done safely! 9
Conducting a Halide Test Light torch and heat copper reactor plate for 2 3 minutes flame should be blue 10
Conducting Halide Test (cont) Capture the gas to be tested in a gauge set or device similar to the one pictured earlier Slowly release minute quantities of gas into a small container of water until a few bubbles result. Pass the Halide exploration hose over the water surface and test gas will be drawn into the flame by venturni effect. If flame turns green chlorinated products are present in the sample gas at 300 ppm or above and bottle should not be used for service. Note: Purge lines with compressed air or nitrogen between tests particularly after positive chlorine test is found. 11
Flame Color Change Contaminated R134a Refrigerant Uncontaminated R134a Refrigerant A video demonstration of a halide flame test can be viewed at http://youtu.be/jdbtx-sj7h8 12
Labeling and Tracking Results Create an auditable process to document results of cylinders tested When a cylinder is tested, it is labeled with the following information Depot location, cylinder number, testing date, test results, and technician signature Currently, cylinders do not have unique serial numbers. Depots need to create one. Example format: CGISEA001 CGI = Depot Name (ConGlobal Industries) SEA = Testing location (Seattle, WA) 001 = Sequential number 13
Example of Testing Log REFRIGERATED CONTAINER GAS CYLINDER HALIDE TESTING LOG DEPOT ConGlobal Industries ConGlobal Industries ConGlobal Industries ConGlobal Industries ConGlobal Industries LOCATION CYLINDER NUMBER HALIDE FLAME TEST DATE PASS/FAIL TESTER NAME COMMENTS Seattle, WA CGISEA001 1/18/2012 Pass John Smith Seattle, WA Seattle, WA Seattle, WA Seattle, WA CGISEA002 CGISEA003 CGISEA004 CGISEA005 14
Global Reefer Sampling Initiative Presented by: Tony Maxwell Technical Director Pinnacle Corporation, New Zealand 28 March 2012 15
Purpose of the Initiative To build a comprehensive data library of reefer units to analyze the magnitude of contamination of reefer units globally (Vietnam and non Vietnam transited units) 16
17 Participants
Extraction/Test Methods Halide Flame Test 18
Extraction/Test Methods Halide Flame Test 19
Extraction/Test Methods RRA Detection Tubes 20
Test Sample Period December 15, 2011 March 27, 2012 Sample size 270 Location 7 cities in three regions (New Zealand, Europe, and United States Container Owners 12 Shipping Lines/Lessors If a unit failed the field test, a GCMS test was performed 21
Test Results Flame Test Units Not Serviced Vietnam % of Units Not Serviced in Vietnam Units Serviced in Vietnam % of Units Serviced in Vietnam Failed * 19 12% 19 16% Passed 134 88% 98 84% Grand Total 153 117 Positive chloride contamination * no TMA found in GCMS test yet * 1 TMS contamination identified in GCMS test 22
Conclusion Contamination is likely beyond Vietnam borders Approximately 50% of the contamination is not R40 Common contamination found were R142b, R22,and R12 Cross contamination appears to be common 23
24 Thank You!