Page 1
“HC in RAC Equipment:
Handle with care and competence”
SESSION V: SESSION V:
Installation & Service: Best Practices in Installing
and Servicing Systems with New Refrigerants
Bernhard Siegele
GIZ Proklima
28th/29th October 2014, Dubai
Page 2
• Deutsche Gesellschaft für Internationale Zusammenarbeit GmbH
• An international cooperation enterprise for sustainable development
with worldwide operations
• Owned by the German Government
• Established in 1975
• In more than 130 countries
• With 67 own offices.
• ~18,000 employees
Page 3
Proklima worldwide
Integrated ozone and climate protection with focus on
natural refrigerants with low-GWP and energy-efficient
applications
– ~ 19 years worldwide initiatives
– ~ 245 projects
– ~ 40 Partner countries
– ~ 8,100 ODP tons reduced
– ~ 100 Mio tons CO2eq. reduced
– > 35.000 technicians trained
Page 4 10/11/2014
RHPAC = Refrigeration, Heat Pumps, Air- Conditioning Source: adapted from Mayekawa, 2012
Potentials of Natural Refrigerants RHPAC Applications
Page 5
HC application
HCs used in domestic fridges since
1990’s
• 700+ million in operation worldwide
• > 50% of new domestic refrigerators
use HCs
• > 1.5 million HC ice cream freezers
and bottle coolers, humidifiers
• > 100,000 split AC units
HCs also now in larger chillers
Industrial applications with larger HC
charge
Page 6
Key factors of safety management
Required changes and instruments :
- Innovative technology/know how demonstrate application
- Awareness provide information
- Education build competence
- Skills practical guidance
- Behavioral aspects
- Normative action
certification/registries
regulation/standards
quality assurance
monitoring
enforce controls
Page 7
Building capacity
throughout the
value chain
Transformational Education:
Know what? Informal
Know how ! Formal
Know why ... Competent
Person
Page 8
•Industry associations
•Technical/vocational institutes and associations
•Development and funding agents
•National authorities
•Standardisation bodies
•Accreditation bodies /quality assurance
•Research institutions and others ……
Building capacity throughout organisations
Integration with national stakeholder processes is essential for
sustainability of activities
Page 9
System categories
Risk rating (Low, Medium, High)
Overall
risk level charge
size
numbe
r of
SOIs
Simi-
larity
extern
al
other
items
Domestic refrigeration L H L H L level 2
Retail refrigeration
Integral (stand-alone) L M M H L level 2
Split (condensing unit) M M H M H level 4
[Central direct
expansion] H H H M H [level 4]
Central indirect M L L L M level 2
Air conditioning
Integral
(window/portable) L L L H L level 1
Split L L L M L level 1
Close control M H M M M level 3
Rooftop unit M M M M M level 3
[Ducted direct
expansion] H H H M H [level 4]
[Multi-split] H M H M H [level 4]
Chiller H L L L M level 2
Transport
Car air conditioning L L L L L level 1
Transport a/c M M H M L level 3
Truck refrigeration M M M L M level 2
Fishing vessels M M H M M level 3
Food processing,
bespoke H M H M H level 4 0 1 2 3 4 5 6
level 4
level 3
level 2
level 1
Introduction year
Time frame needs to be adjusted
Capacity building activities
need to start as early as
possible. Suggested timescale
for the staged introduction of
HC refrigerants according to
risk level
Page 10
Main topics within RAC safety standards
Classification of refrigerants, occupancy, systems
Refrigerant charge size – limits/conditions
Safe design and testing of components and pipes
Safe design and testing of assemblies (systems)
Electrical safety, sources of ignition
Installation areas, positioning, pipework, mechanical ventilation, gas
detection\
(Preventive) Maintenance, leak detection
Instructions, manuals, data-sheets/plates
Refrigerant handling
General safety rules for alternative refrigerants
Page 11
Having a strict work-routine in
place
General topics
• Technician activities and
refrigerant handling
• Installation of equipment
• Commissioning of
installations
• Routine maintenance
• Service and repair
• Dismantling
Page 12
Temporary
Flammable Zones
Temporary Flammable Zones
Page 13
There is no one simple solution to leakage reduction. All the
following contribute to minimising leaks:
• If the system is provided with fixed tubing, modifications are not permitted
(extension or shortening) > intrinsic safety
• Design systems with minimal joints using components which are known
not to leak excessively
• Route, support and clamp pipe work correctly, avoid chafing
• Keep equipment and tubing protected against corrosion
• Maintain adequate vibration isolation (equipment and tubing)
• Ensure brazers are competent and qualified > e.g. ISO 13585-2012
• Pressure leak test systematic to the correct standard
• Charge systems with the correct amount of refrigerant
• Carry out planned preventative maintenance to minimise head pressure
and ensure systems are operating at the optimum level
• Carry out sufficient leak testing and repair leaks where necessary
• Improve service practices, including replacing caps after service,
tightening flanges correctly and replacing gaskets where necessary
Installation and Leak Reduction
Page 14
General – Leak reduction
(design/construction)
• Improve the tightness of systems (use existing refrigerant)
• Good design
• Avoid vibration, external mechanical impact, possibility of corrosion, etc
• Selection of components
• Avoiding flare connections, Schraeder valves, good parts
• Components tested under EN 16084 (Qualification of tightness of components and joints)
• Tightness testing
• Systematic testing of systems, use of helium tracer gas and high sensitivity gas detectors
Page 15
Brazers competence certification
Page 16
Service and Repair
All staff and others working in the local area must be instructed
on the nature of the work being carried out
The area around the workspace must be sectioned off
Obtain permit for hot work (if required), place warning signs
Working within confined spaces should be avoided
No flammable materials are stored in the work area
No ignition sources are present anywhere in the work area and
avoid sparks by static electricity
Suitable fire extinguishing equipment (CO2 or dry-powder type)
is available within the immediate are
The equipment should, whenever possible, be isolated from
the electricity supply
Ensure that all refrigerant handling and mechanical handling
equipment is available
All necessary personal protective equipment is available and
being used correctly
Page 17
What is Leak Detection?
+ = Gas Detector + Inspector Gadget = Find Leak
Page 18
Hydrocarbon refrigerants are heavier than air
Work area must be ventilated to disperse the HC,
especially important if the refrigerant is exposed below
ground level (basements, pits, trenches etc.)
Avoid direct contact with liquid refrigerant. HC-Blend
evaporation temperature is -31,5°C @ atmospheric
pressure. Refrigerant causes violation at skin, eyes and
respiratory tract.
Wear protective clothes as well as gloves, goggles
Hydrocarbon refrigerants (as well as CFCs etc.) displace air
and will cause suffocation
Potential Hazardous Situations
Page 19
Cylinder Storage
In a locked cage
At ground level
Away from air intakes to building
Remote from ignition sources
No smoking
Outside - follow local regulations for LPG, if none at least:
Page 20
Summary - Safe Work Area
Golden rules:
Ventilation
Within 2m of work area:
• No flames (e.g. brazing)
• Do not use switches
• No smoking
• No other people
Page 21
Workshop Environment
Page 22 10/11/2014
GIZ series on safe use of natural refrigerants More than 30 national training programmes under MLF since 1996
Page 23
Cool Training
• Aim: to provide comprehensive knowledge and capacity for the
operation and maintenance of new cooling technology using natural
refrigerants
• Approach: Trainings in cooperation with the Bundesfachschule Kälte-
Klima-Techik (BFS), an international institution for vocational and
advanced trainings in the area of RAC technology
• Target group: technical and training RAC experts active in developing
and emerging countries
Page 24
Cool Training Concept
• Training consists of 30 %
theory and 70 % practical work
• Main subject is the application
of natural refrigerants for
commercial refrigeration
systems
• Training includes excursions to
innovative enterprises in the
sector
• Regional replication and
upscaling
Page 25
Training curriculum
• Refrigeration systems and heat pumps – safety and environmental
requirements according to DIN EN 378 1-4
• Refrigerant circuit pipes joining and installation methods
• Brazer Examination according to DIN EN ISO 13585
• Leak finding and tightness test activities in practice
• Application of propane (R290) as refrigerant
• Application of carbon dioxide (R744) as a refrigerant
Page 26
The Pilot Training
• First training held June
16th – 27th 2014 in BFS
Center in Maintal,
Germany
• 15 RAC trainers and
experts from 12 countries:
Brazil, China, Columbia,
Costa Rica, India, Iran
Kenya, Malaysia,
Mauritius, Mexico,
Philippines, and
Seychelles
„The training was an
amazing opportunity,
especially with the use
of real equipment in the
workshops.“ Wilbert Alvardo Marin (RAC
trainer/expert from Costa Rica)
„I am bringing home what
I have learned, and will
make sure training centers
will be impacted in their focus
on natural refrigerants.“ Fernando del Castillo Uribe (RAC
trainer/expert from Columbia
Page 27
Upcoming…
• Next trainings: November 2014
and April, June & October 2015
• Organization body is open for
nominations of participants
from partner agencies
• Regional replication of training
from first batch of experts in
planning phase
Page 28
For more information, please refer to the webpages of the Green
Cooling Initiative and the Cool Training Alumni:
http://www.green-cooling-initiative.org/
https://www.green-cooling-initiative.org/rac-alumni-network/
Page 29
Challenges
• Target 30,000 - 26,000 officially certified during NPP
• 80% of workshops „informal“ or „self-employed“
• huge geographical area, remote areas with low or no
access to qualification
• culture of training on the job, formal education low
• RAC vocational training concentrated in large centres
• national standards not developed
• High leakage, low carbon intensity of electricity
Approaches
• registration and certification system
• mobile training for decentral course system
• integrating with national training agents
• preference to practical training
• integrate contents in formal education
• adapted materials (visualized manuals)
Example: Brazil best practice
Page 30 10/11/2014
Transforming to a knowledge-based economy
• Resolving complexities is a typical starting point
of environmental sound technologies
• Safety & best practice is not refrigerant-specific,
it is a general requirement when competently
managing RAC systems
• Continued education and knowledge sharing is
essential for transformation, e.g. engineers,
technicians, mechanics require to update their
knowledge and need to learn to think systems.
Lessons learned:
• HC refrigerators: just one example for global acceptance, incl.
know-how & infrastructure, RefNat example in commercial refrigeration
• Establishing qualification and controls for safe behaviour is essential
for public safety when introducing sustainable alternatives
Page 31
• Newly acquired competences develop multiple benefits:
higher energy efficiency from better practice (15 % +, EU)
less wastes and operational failure - better economy
customers understand value and pay for it
local supplies of natural refrigerants, no dependence on imports
enhances local know how and production options
longer term application of framework and know how
• High safety standards may generally improve services & performance
• Cash saved during operation could be used to pay qualified workers
Sustainable practice provides sustainable income!
Conclusions
Page 32 10/11/2014
Conclusions
• Training has to be seen in the context of ongoing transformation of global
economies; this takes time, better start as early as possible
• Despite the “burning” issues of introducing new refrigerants, a culture of
continued education and knowledge sharing in RAC sector is necessary
• In many countries formalization of education and certification to take place
• Capacity building not restricted to servicing personnel, integration with
value chain and public stakeholders essential
• Public support insufficient, initiative and cooperation from private sector
stakeholders required. Transnational technology cooperation specifically
beneficial.
Page 33
Thank you for your attention!
