Principles and Practices of Mechanical Integrity for Industrial 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

• 11/5/2025  08:00am - 05:00pm
• 11/6/2025  08:00am - 05:00pm
• 11/7/2025  08:00am - 02:30pm

All times listed are Central Time Zone.

This in-person course will have an online course site from which you will access the course materials, course evaluation, and participation certificate. Details on how to access the online course site will be sent with registration confirmation.

• Program Director

  Douglas Reindl

• James Kovarik

  Vice President, NDE Technology

  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.

• Douglas Reindl

  Professor

  Douglas Reindl, PhD, PE is a professor at the Department of Mechanical Engineering and a Program Director at the Office of Interdisciplinary Professional Programs at the University of Wisconsin-Madison. He has extensive experience in mechanical systems – including industrial ammonia refrigeration systems. As the founding director of the Industrial Refrigeration Consortium, he works extensively to improve the safety, efficiency, reliability, and productivity of ammonia refrigeration infrastructure. Dr. Reindl received his BS in mechanical engineering technology from the Milwaukee School of Engineering, MS in mechanical engineering from UW–Madison, and PhD in mechanical engineering from UW–Madison. He is a registered professional engineer in the State of Wisconsin.

If you are planning to attend an Interdisciplinary Professional Programs course, payment is required at the time of registration. Below are the payment options:

Pay by Credit Card

Enroll online and pay by credit card.

• Search for the course on the website and then click on the Enroll Now button from the course webpage.
• Enter all necessary course attendee information and payment information on the course enrollment page.
• You will receive an email to confirm successful enrollment and payment.

Enroll over the phone and pay by credit card.

• Call CERC Registrations at 608-262-2451.
• Provide the registrations representative with:
  • the course name, dates, and/or course number.
  • the necessary course attendee information and payment information.
• You will receive either a mailed document or an email to confirm successful enrollment payment.

Pay by Check

Mail in a completed registration form and check payable to UW Madison.

• Fill out a registration form (found either in the back of the course brochure you received in the mail or here).
• Prepare a check, made payable to UW Madison.
• Mail the registration form and check to: CERC Registrations 21 N Park St, Ste 7101 Madison, WI 53715
• You will receive either a mailed document or an email to confirm successful enrollment and payment.

Pay by Purchase Order

• Request Purchase Order information from interpro@union.wisc.edu
  • If a fee quote is needed, contact custserv@interpro.wisc.edu first
• You will receive an invoice from UW–Madison Business Services for payment, usually within 3–5 business days

Military

If using SF-182 form, please call our registration number at 608-262-2451 or email interpro@union.wisc.edu for details and instructions.

Event Cancellation

We reserve the right to cancel a course due to insufficient enrollment or unforeseen events. If we cancel a course, participants will be notified via email or phone and will be given the option for a full refund or to transfer their registration and any fees paid to another course. We are not responsible for non-refundable plane tickets, hotel reservations, and other travel related expenses. For enrollee Course Cancellation, refer to notes on course page.

If you cannot attend, please notify us no later than one week before your course begins, and we will refund your fee. Cancellations received after this date and no-shows are subject to a $150 administrative fee. You may enroll a substitute at any time before the course starts.

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.