HC in RAC Equipment: Handle with care and competence

Transcription

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 28 th /29 th October 2014, Dubai Page 1

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 2

3 Proklima worldwide ~ 19 years worldwide initiatives ~ 245 projects ~ 40 Partner countries ~ 8,100 ODP tons reduced ~ 100 Mio tons CO 2 eq. reduced > technicians trained Integrated ozone and climate protection with focus on natural refrigerants with low-gwp and energy-efficient applications Page 3

4 Potentials of Natural Refrigerants RHPAC Applications RHPAC = Refrigeration, Heat Pumps, Air- Conditioning Source: adapted from Mayekawa, /11/2014 Page 4

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 5

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 6

7 Building capacity throughout the value chain Transformational Education: Know what? Informal Know how! Formal Know why... Competent Person Page 7

8 Building capacity throughout organisations Industry associations Technical/vocational institutes and associations Development and funding agents National authorities Standardisation bodies Accreditation bodies /quality assurance Research institutions and others Integration with national stakeholder processes is essential for sustainability of activities Page 8

9 Time frame needs to be adjusted System categories charge size Risk rating (Low, Medium, High) numbe Similarity al extern r of SOIs other items Overall risk level 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 H H H M H [level 4] expansion] Central indirect M L L L M level 2 Air conditioning Integral L L L H L level 1 (window/portable) 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 H H H M H [level 4] expansion] [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 Capacity building activities need to start as early as possible. Suggested timescale for the staged introduction of HC refrigerants according to risk level level 1 level 2 level 3 level 4 H M H M H level Introduction year Page 9

10 General safety rules for alternative refrigerants 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 Page 10

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 11

12 Temporary Flammable Zones Temporary Flammable Zones Page 12

13 Installation and Leak Reduction 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 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 Page 13

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 (Qualification of tightness of components and joints) Tightness testing Systematic testing of systems, use of helium tracer gas and high sensitivity gas detectors Page 14

15 Brazers competence certification Page 15

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 16

17 What is Leak Detection? + = Gas Detector + Inspector Gadget = Find Leak Page 17

18 Potential Hazardous Situations 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 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 Page 18

19 Cylinder Storage Outside - follow local regulations for LPG, if none at least: In a locked cage At ground level Away from air intakes to building Remote from ignition sources No smoking Page 19

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 20

21 Workshop Environment Page 21

22 GIZ series on safe use of natural refrigerants More than 30 national training programmes under MLF since /11/2014 Page 22

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 23

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 24

25 Training curriculum Refrigeration systems and heat pumps safety and environmental requirements according to DIN EN Refrigerant circuit pipes joining and installation methods Brazer Examination according to DIN EN ISO Leak finding and tightness test activities in practice Application of propane (R290) as refrigerant Application of carbon dioxide (R744) as a refrigerant Page 25

26 The Pilot Training First training held June 16 th 27 th 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 26

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 27

28 For more information, please refer to the webpages of the Green Cooling Initiative and the Cool Training Alumni: Page 28

29 Example: Brazil best practice 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) Page 29

30 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 10/11/2014 Page 30

31 Conclusions 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! Page 31

32 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. 10/11/2014 Page 32

33 Thank you for your attention! Page 33