HC-290 Split AC Units a Safe, Efficient and Reliable Reality in the Market

Transcription

1 HC-290 Split AC Units a Safe, Efficient and Reliable Reality in the Market 100,000 HC-290 Air Conditioners in India with Consideration of High Ambient B Siegele, D Colbourne, D Rajadhyaksha GIZ Proklima, Dag-Hammarskj Hammarskjöld-Weg1-5, Eschborn,, Germany Godrej & Boyce Mfg. Co. Ltd, Vikhroli West, Mumbai, India

2 INTRODUCTION

3 INTRODUCTION Indian industry view is there is no suitable alternative R-410A, R-407C, etc, high GWP, likely restricted in near future and poor performance at high ambient (R-410A) HFC-32 has high GWP, HAT performance worse than HCFC-22, higher efficiencies bound by patents At least two enterprises develop ACs using HC-290 AC market in India 2012 annual AC production about 10.5 m; demand 3.4 m Annual growth rate ~10% 1/5 th for window units, remainder for split ACs 95% of the market is 1TR (~3.5 kw) and 1.5TR (~5.0 kw) Climate regions range from temperate to very high ambient

4 INTRODUCTION Extensive work carried out previously to optimise efficiency and minimise refrigerant charge; see Devotta/Padalkar et al

5 TESTED R22 & R290 SPLIT ACS AT HAT R22 model R290 model

6 RESULTS; RELATIVE CAPACITY, COP, PRESSURE RATIO, DISCHARGE TEMPERATURE Relative capacity [%] 100% 80% 60% 40% 20% HC-290 HCFC-22 Relative COP [%] 100% 80% 60% 40% 20% HC-290 HCFC-22 No performance degradation vs R22 0% Ambient temperature [ C] 0% Ambient 5 temperature [ C] HC-290 HCFC HC-290 HCFC-22 4 Improved working conditions vs R22 Compression ratio [-] Discharge temp [ C] Ambient temperature [deg C] Ambient temperature [ C]

7 PRODUCT SAFETY ASSESSMENT For flammable gas safety Regulations/ directives For electrical safety For pressure safety Atex LVD PED Harmonised standards EN EN EN EN EN EN EN 378

8 PRODUCT SAFETY ASSESSMENT Requirements under Atex/EN 1127

9 PRODUCT SAFETY ASSESSMENT Quantitative risk assessment Operation: on 12% of time, IDU airflow on 26%; include operating faults Sources of ignition: In room ~4 arcs/sparks per m 2 per 24 h + continuous SOI (candle) for 1 h /24 h; non-hc outdoor unit (20 arcs per 24 h) and cigarettes; electrical faults inside ODU and IDU; technicians replace faultyprotected components with SOIs Flammable quantities: volumes, mass, times were modelled for the various leak sizes, into the rooms, IDU, ODU and outside Leakage: annual leak rate 15%; frequency from supermarkets; overall per year; 12 kw unit with additional safety measures Scenarios

10 PRODUCT SAFETY ASSESSMENT Account for a range of different leak hole sizes and associated leak frequency 1.0E+0 Leak frequency [/y] 1.0E-1 1.0E-2 1.0E-3 1.0E-4 1.0E Leak hole size [mm]

11 PRODUCT SAFETY ASSESSMENT Quantitative risk assessment Safety valve limits amount of gas that can leak into room Risk of ignition is >10,000 times lower than background risk Background fire frequency (USA) of ACs: y -1 Can break windows only; requires an instant 3.0 mm leak hole in IDU!

12 PRODUCTION LINE Appropriate equipment used for production Refrigerant storage and feeding system Evacuation lines Strength pressure test and tightness test Refrigerant charging equipment Performance and electrical test equipment Repair area A safety monitoring, alarm and ventilation system Equipment and installation also conform to Atex

13 INFRASTRUCTURE Installation/servicing by non-competent technicians major concern critical to implement (finance-based) incentive schemes Sales and supply Mandatory free installation Free warrantee (1 5 years) is void if noncertified technician interferes Disposal covered by E-waste legislation (producer take-back scheme) Sales staff and technicians check installation details (room size, charge size, pipe length, etc) All details recorded in database Technicians must competent in handling HCs Recruited through an examination, subject to ranking scheme Assessment & experience lead to higher ranking High ranking technicians have HC training those which pass are registered to handle HC ~800 qualified to handle HC countrywide Issued with appropriate tooling

14 SERVICE AND MAINTENANCE QRA extensively evaluate all related procedures for different S&M activities Preparation Opening system Remove refrigerant Break into system Strength pressure test Charge refrigerant Close system Leak tightness test

15 SERVICE AND MAINTENANCE Summary of risk measures compared against values based for negligible limits for worker (from UKG HSE) - For 450 g R290 split AC - Significantly lower than risk of injury from usual (non-flammable) refrigeration practice - Nevertheless, highlights importance for training - No notable variation within the range of charge sizes ( g)

16 FINAL REMARKS Current status of R290 ACs From the quality database, main problems identified Dents, other external damage Compressors (at commissioning) Electrical faults (fan motors, circuit boards) Cooling complaints A fault rate of <0.5% per year implies excellent level of safety and general reliability Leak rate < 0.3% is extremely low (typically 10 15% for Article 5 countries) Leakage Number of faults Zero leaks from the IDU or IDU connecting joint

17 FINAL REMARKS Refrigerant charge compared to value in AC standard* Proportion of installed units 100% 80% 60% 40% 20% 0% Majority of units installed within requirements Small proportion over value (but tests found >20% of charge remains in systems after major leak anyway) 30-40% 40-50% 50-60% 60-70% 70-80% 80-90% % % Ratio of actual charge to mmax in standard % % *Nevertheless, values not to be considered as mandatory

18 FINAL REMARKS R290 charge [g] Refrigerant charge compared to value in AC standard Max charge Equiv safety Add meas Based on new SAC designs low charge, high efficiency products, most applications achieved 250 W/m2 200 W/m2 150 W/m2 100 W/m2 Higher capacities in larger spaces resolved through additional measures Room area [m2]

19 FINAL REMARKS Comparison of TEWI and efficiency against equivalent products 15 power refrigerant TR '7-star' 3.70 TEWI [tco2-eq] 10 5 Efficiency (EER) [W/W] Model B Model A Model E Model D Model C 0 1.5TR, 5-star 1.5TR, 7-star Model A Model B Model C Model D Model E TR '5-star' Specific cooling cost [Rs/W]

20 FINAL REMARKS So far about 100,000 HC-290 split ACs introduced in India Service history, feedback, quality database and safety analysis implies high success General, use of HCs Impose new responsibilities on manufacturers for safe productionpractices Requires additions and changes to the existing production processes Products must be designed for safety, capacity and efficiency Infrastructure must be established to ensure safe environment Re-training of technicians must be concurrent with development processes Safety issues related to high ambient Flammability risk is extremely low; >10,000 times below background fire risk Risk to S&M technicians also miniscule Compared to competing products, HC-290 has lower TEWI, low-to medium cost (per kw) and higher efficiency Activities are ongoing to expand the range of products Developments include designs for greater integrated safety to further reduce the flammability risk

21 Thank you for your attention