Principles and Practices of Mechanical Integrity for Industrial Refrigeration Systems

This course provides an in-depth understanding of mechanical integrity best practices, with an emphasis on refrigerant piping and pressure vessels. Attendees will explore failure mechanisms such as corrosion and stress cracking, gain hands-on insights into inspection planning and non-destructive examination (NDE) technologies, and learn how to implement recommended practices aligned with regulatory standards. With real-world examples and expert instruction, participants will leave equipped to optimize the performance and safety of ammonia refrigeration systems in their facilities.

• PSM coordinators and plant engineering staff responsible for ensuring compliance and system integrity.
• Refrigeration system operators and contractors performing mechanical integrity inspections and repairs.
• Professionals seeking to understand the fundamentals of mechanical integrity for industrial refrigeration systems.

This course is part of the Process Safety Management Professional Certificate. Increase your knowledge and effectiveness at managing PSM/RMP programs for your ammonia refrigerated facility, while earning a recognized credential. Course can be taken individually as well.

Attendees participating in this course will be able to earn a digital badge as evidence of the knowledge they obtained during the course. Digital badges are micro-credentials that can be earned by successfully passing a final quiz administered online after completing the course. Click here for information on digital badges.

Attend this course and receive the IRC’s Principles and Practices of Mechanical Integrity Guidebook for Industrial Refrigeration Systems. This comprehensive resource is a must-have for anyone working in the industrial refrigeration industry. Whether you are involved in designing, constructing, operating, or maintaining closed-circuit industrial ammonia refrigeration systems, this guidebook will help you manage the mechanical integrity of industrial ammonia refrigeration systems.

Day 1

Welcome and Introduction – Douglas T. Reindl, PhD, PE, Professor, UW–Madison

Mechanical Integrity for Refrigeration Systems – Douglas T. Reindl

• Regulatory requirements: 1910.119 (j)
• Current MI practices in refrigeration
• Common gaps in mechanical integrity programs

Refrigeration System Failure Mechanics – Douglas T. Reindl

• Corrosion, uniform and pitting
• Corrosion under insulation (CUI), causes, and cures
• Stress corrosion cracking (SCC), mechanisms, and prevention measures

Refrigeration Systems Review – Douglas T. Reindl

• Vapor compression cycle and components
• Single and multi-stage systems
• Areas of refrigeration systems with higher mechanical integrity risks

Planning a Mechanical Integrity Inspection – James Kovarik, Vice President, NDE Technology, Lixi, Inc., Huntley, IL

• Establishing a clear inspection scope
• Resource requirements for conducting inspection(s)
• "Go / no-go" criteria
• Qualifying an inspection contractor
• Interpreting results
• P&IDs - requisite elements, use for guiding inspections

Introduction to Refrigeration Systems Failure Mechanics – Douglas T. Reindl

• External corrosion on uninsulated and insulated piping and vessels
• Erosion
• Stress corrosion cracking
• Weld defects
• Physical protection

Day 2

Principles and practices for managing the MI of piping and vessels – Douglas T. Reindl

• Guiding principles
• Preparing an inspection plan
• Qualifications of inspectors
• Visual (VT) inspection process
• VT for piping and pressure vessels
• Classifying corrosion
• Assessing fitness for continued operation
• Required follow-up and deficiency management

Introduction to NDE Technology – James Kovarik

• Visual
• Liquid penetrant
• Magnetic particle testing
• Ultrasonic
• Radiographic
• Eddy current
• GUL

Principles and practices for managing the MI of heat exchangers – Douglas T. Reindl

• Modalities of failure
• Recommended inspections and tests
• Examples

Insulation Systems for Piping and Vessels – Douglas T. Reindl

• Key elements that comprise an insulation system
• Practices for proper pipe and vessel coating
• Insulation types and selection
• Vapor retarders
• Jackets
• Ongoing maintenance

Day 3

Introducing the IRC's Mechanical Integrity Guidebook – Douglas T. Reindl

• Guidebook objectives and guiding principles
• Guidebook organization
• Overview of contents
• Strategies for implementing recommendations and refining your MI program

 Principles and practices for managing the MI of machinery room safety systems – Douglas T. Reindl

• Scope
• Modalities of failure
• Recommendations for inspections and tests
• Examples

Principles and practices for managing the MI of other components – Douglas T. Reindl

• Scope
• Modalities of failure
• Recommendations for inspections and tests
• Examples

Douglas Reindl

Douglas Reindl, PhD, PE is a professor in the Department of Mechanical Engineering and a Program Director at the Office of Interdisciplinary Professional Programs at the University of Wisconsin–Madison. He brings extensive expertise in mechanical systems, with a particular focus on industrial ammonia refrigeration. As the founding director of the Industrial Refrigeration Consortium, Dr. Reindl is dedicated to advancing the safety, efficiency, and reliability of refrigeration infrastructure. He holds a BS in Mechanical Engineering Technology from the Milwaukee School of Engineering, and both MS and PhD degrees in Mechanical Engineering from UW–Madison. A registered professional engineer in Wisconsin, Dr. Reindl is widely recognized for his leadership in refrigeration education and applied research.

Marc Claas

Marc Claas is an Associate Researcher with the Industrial Refrigeration Consortium, specializing in industrial refrigeration since 2009. He focuses on system maintenance, safe operation, troubleshooting, and regulatory compliance, with a growing interest in emerging cooling technologies. Marc has led online operator training programs and brings extensive field experience in Process Safety Management (PSM), including audits and Process Hazard Analyses (PHAs). He also investigates energy efficiency and operational improvements in refrigeration systems. Marc holds a B.S. in Mechanical Engineering from UW-Platteville and an M.S. in Mechanical Engineering with a focus on Thermal Sciences from UW-Madison. He is an active member of the International Institute of Ammonia Refrigeration.

James Kovarik

James Kovarik is Vice President of NDE Technology at Lixi, Inc. Kovarik has an extensive background in both the development and utilization of non-destructive evaluation technologies in chemical plants, petrochemical facilities, and industrial refrigeration operations.