the influence on leakage rate of rac equipment

Dutch Approach

Thematic Meeting Hungary 21-10-11 1

Human beings and the RAC system

The influence on the leakage rate of RAC

equipment

Jan Reijmers info@stek

Dutch Approach


• Introduction

• Implementation

• Results

• Logbook and work report

• SPARK Project

• Summary


Dutch Approach


• Introduction• 1991 implementation of the mandatory CFC reduction

in NL in cooperation with the Dutch RAC industry.

• Approach was „bottom-up‟ procedure

• Why?

• In NL 98% of the RAC installers are SME (≈3- 8 fte)

• We started with certification of personnel (human

beings)


Dutch Approach


• 1992 start of Assessment

• Most of the first persons were in the position of

“director/owner” of a Small Enterprise

• Content of Assessment:

• Soldering/Brazing

• Handling Refrigerant (work-procedures)

• Refrigerant register

• RAC knowledge


Dutch Approach


• The awareness of this assessment was

• these “persons” refreshed their knowledge

through a Course, or self study

• they did a practical training to be better

prepared for the Assessment

• As “director/owner” you must succeed.

• What did they learn during this preparation ?


Dutch Approach


• What did they learn during this preparation ?

it is mandatory, which means we will be checked !

we need a weight scale, for the refrigerant register

we have to report that there is no leakage !

there is a better way of soldering, because the soldering

was never checked by the pealing test and they never saw

the innside (what is the effect of the use of backing gas).

nothing new about installation and commissioning of an

RAC systems

•


Dutch Approach


The results was

Prevention of leakage by:

1 Quality improvement

(accounting refrigerants, handlings and reporting)

2 Technical requirements: reduction of leakage (design, installation, maintenance)

3 Competence of personnel

Dutch Approach


Results

• High awareness

• General quality improvement

• Leakage diminished rapidly (from ↑30% to 5-10%)

• Decrease of spare parts sales

• No free riders

Dutch Approach


Scheme to certified Company

Dutch Approach


Dutch Approach


Audit List for STEK Certified Company

Auditing body data such as name, auditor

Company data such as name, address place and responsible director

Official documents of the certified Company

Officially statement of the companyRegistration system for regular leak checking

Registration system for work report including checking of regular leakages by refrigeration system

A system for achieving work report of the last 3 years

Dutch Approach


Certified PersonsList of certified persons

Signed letters of understanding of the official statement of the management of the company.

Procedure to inform all employees about the official company statement

Refrigerants registerRegistration of each type of refrigerant The interval of registration is minimum one month Is the registration by

kg

Procedure to correct the loss refrigerant

Overview of purchased refrigerant by type in a interval of 3 months

Overview of returned refrigerants with or without pollution

Overview of used refrigerants of the last 3 years by type of refrigerants

Overview of used for new systems of each type of refrigerants of the last 3 years

Overview of used for service and maintenance of each type refrigerants of the last 3 years type of refrigerants


Dutch Approach


Logbook Documents

Pressure Certificate with data and figures acc STEK guidelines

Evacuation Certificate with data and figures acc STEK guidelines

Leakage test Certificate with data and figures acc STEK guidelines

Work reportsTo register the amount of used refrigerant

To register the used components and spare parts

To report the executed work

To report the executed work special place for, starting up the system, leak checking, repairing, return of

refrigerant (with or without pollution)


Dutch Approach


Work procedures

Procedure how to recording the data and figures in the logbook of the end user

Procedure for a pressure test, evacuation test, handling refrigerant,

Procedure for leak checking

Procedure of the way the certified persons will be informed about developments, new refrigerants and new

procedures

The Equipment of the STEK certified personsManifold & Mobile leak detector & Temperature meter

Refrigerant weight Scale

Vacuum pump & Vacuum meter

Recovery set & Recycling cylinder


Dutch Approach


Leakage rate by HCFC's (R22) remark 1999 beginning of fase out process

HCFC's (R22)

Tailor made Content

filled reduction

Content lifecycle 15 y emission leakage rate

kg/year -6,7% kg/year %

1990 933333 14000000 2380000 17,00%

No reliable figures during implementation

1999 254940 12000000 418424 3,49%

2000 180982 11196000 409420 3,66%

2001 88182 10445868 521701 4,99%

2002 65653 9745995 453751 4,66%

2003 45240 9093013 457286 5,03%

2004 31405 8483781 387907 4,57%

Dutch Approach


Leakage rate HFCremark on the market since 1993 ?

Tailor made Pre-charged installations

filled growth by year 5,00% Total Life cycle Total content

Content Heat load Average Contentnew

content multiplier until year emission

leakage rate

kg/year kW kg/kW kg/year kg/year by year kg kg/year %

1999 233269 + 619025 0,5 309512 = 542781 8 4342251 149774 3,45%

2000 434875 + 651605 0,5 325803 = 760678 9 6846098 187059 2,73%

2001 474885 + 685900 0,5 342950 = 817835 10 8178350 248680 3,04%

2002 573849 + 722000 0,5 361000 = 934849 11 10283339 323529 3,15%

2003 496242 + 760000 0,5 380000 = 876242 12 10514904 380808 3,62%

2004 481401 + 800000 0,5 400000 = 881401 13 11458213 434528 3,79%

Dutch Approach


RAC Company Adminstration

New installation

Sales 100.000 euro

Personel costs 40.000 euro

Material incl refrigerant 30.000 euro

Indirect costs 10.000 euro

Total 80.000 euro

Profit 20.000 euro

Dutch Approach



Service & Repair

Personel costs 400 euro

Material incl refrigerant 200 euro

Indirect costs 100 euro

Total 700 euro

Invoice total 1.000 euro

Profit 300 euro

Dutch Approach



For New + Service & Repair orders

Book keeping system, SAP, Exact, Unit4 etc

Personnel planning system

Logistic flow of materials

Search function with the results

For example Refrigerant type/quantity

for printing or export by excel sheets

So it is available Refrigerant register.

Dutch Approach


The operator of a refrigerating system with a total refrigerant charge equal to or

greater than 3 kg, shall have a logbook which is kept in the vicinity of the

refrigerating system.

This logbook shall include the following information:

a. the date on which the copy was issued ;

b. the name, address and telephone number of the operator of the refrigerating

system who keeps the logbook at the central location;

c. the refrigerant charge and type of refrigerant used in the refrigerating system;

d. the date on which maintenance or installation activities on the refrigerating

system were carried out and the name, address and telephone number of the

company which undertook these activities;

e. an overview of the quantity of refrigerant charged into the system over a period

of two years preceding the date on which the last maintenance or installation

activities were undertaken on the refrigerating system.

Logbook

Dutch Approach


First in operation

a. name of the installer;

b. date of the inspection;

c. name of the STEK technician;

d. type of refrigerating system;

e. type of refrigerant;

f. total charge of refrigerant;

g. highest and lowest temperatures and pressures;

h. blow off pressure of the installed relief devices;

i. statement about the leakproofness of the refrigerating system;

j. statement about the Strenght pressure test;

k. statement about the evacuation and charging;

Logbook

Dutch Approach


Work report:

a. nature of the inspection, maintenance, repair and installation activities on the

refrigerating system;

b. faults and alarms related to the refrigerating system;

c. quantity and type of refrigerant charged into the system;

d. quantity and type of refrigerant drained from the system;

e. results of leak detection activities;

f. the name of the person who undertook the activities listed under a. through e.

above and, where applicable, the name of the company employing that person;

g. official mark issued by the person referred to under item f. with respect to the

activities undertaken by him or her.

Logbook

Dutch Approach


Work report

Lot of paperwork in the beginning

Work report incl. pre printed statement documents as tightness, strength and evacuation pressures test

Electronic Work report installed on a laptop computer or handheld or smart phone

with pre installed information and statement documents such as: a. the inspection, maintenance, repair and installation activities on the refrigerating system;

b. faults and alarms related to the refrigerating system;

c. quantity and type of refrigerant charged into the system;

d. quantity and type of refrigerant drained from the system;

e. results of leak detection activities;

f. the name of the person who undertook the activities listed;

g. official mark issued by the person;

The facility to make a print or sign on a screen for authorisation

Work report

Dutch Approach



Summary:

• Mandatory regulation

• Bottom-up approach to realize the awareness by SME is

important to reduce the leakage rate of RAC systems.

• Tools are available in the F gasses regulation and EN 378.

EN 13313.

• you need time to influence Human beings at least 5 year

Dutch Approach


EU Leonardo da Vinci project 2010 - 2012

Partners: B, UK, D, H, and NL

To develop a test for new RAC personnel

For the Job profile’s Craftsman Category I

Craftsman Category II

Installation technician under supervision Category I

Recovory Technician Category III

Tecnician only leaking/tightness check Category IV

Heat pump installer circuit content below 3 kgr without breaking in

the circuit

SPARK Project

Dutch Approach


Dutch Approach


The Dutch approach

The sheets and other documention available on

USB Stick

Thank you for your attention

Jan Reijmers [email protected]

the influence on leakage rate of rac equipment

Business