Environment
Keeping cool about 2010 PDF Print E-mail
Written by Barry Lyons, Business Development Manager, BOC Refrigerants, 2008   

Major changes to air conditioning and refrigeration systems are due to take effect in 18 months' time but many organisations remain unaware of the impact they are likely to have. Barry Lyons of BOC outlines the implications for facilities managers.

  • What alternatives are available to cope with the complete phase-out of refrigerant R22?
  • What points need to be covered in an air conditioning inspection report?

R22 is the most widely used refrigerant in Europe. Yet from 1 January 2010, there will not be a single kilogram of new material for sale - anywhere.

For a period of up to five years (less if certain European politicians have their way), there may be a certain amount of recycled R22 refrigerant available to top up or replace losses in existing systems.

But no one knows how much will be available or how much it will cost. After 2015, though, R22 cannot be legally bought or sold.

Refrigerant materials


R22 is a hydrochlorofluorocarbon (HCFC) that affects the ozone in the atmosphere.

While less damaging than chlorofluorocarbons (CFCs), which were the first to be phased out completely under the Montreal Protocol of the late 1980s, HCFCs still have an impact. Hence the ban, which takes effect from 2010.

These substances, and their synthetic replacements, are also powerful greenhouse gases. R22, for example, has a global warming potential 1,700 times that of CO2.

So, the EU has instigated further measures to minimise leakage of the hydrofluorocarbons (HFCs) that are now replacing HCFCs.

These are contained in the F-Gas Regulations (the 'F' stands for 'fluorinated') that became effective last year.

Given the number of air conditioning and refrigeration applications that depend on R22, it is perhaps surprising that there has been so little publicity about the changes.

Perhaps this is due to a feeling that, with the use of recycled material still permitted from 2010, there is no great rush to take action. I believe that such an attitude is risky and makes no business sense.

Risk assessment


First, there is no guarantee that there will be sufficient quantities of recycled R22 to meet all the requirements in the coming few years.

In fact, no one knows how much - or how little - will be available. And since neither the supply levels nor the demand are known, it is impossible to estimate price.

Doing nothing in the hope that there will not be a problem is not a recipe for business success. Now is the time, then, to look at replacements and prepare for the eventual complete phase-out of this material.

After all, five years is a short time in a building's maintenance and refurbishment cycle.

If doing nothing is not an option, then building owners and managers need to know that their building services providers have an appropriate plan in place to cope with the changes.

The two main choices are to plan a replacement of the equipment itself, or to find an alternative 'drop in' refrigerant that does the same job.

Total replacement is one option. New systems can be installed using natural refrigerants, such as ammonia, carbon dioxide and hydrocarbons.

These are chemicals that occur in nature's biochemical processes. They do not deplete the ozone layer and make negligible (or zero in the case of R717 ammonia) contributions to global warming.

Their high efficiencies mean they make a much lower, indirect contribution to global warming than many synthetic refrigerants.

While this may be the long-term solution, as an immediate response it can be very expensive, especially if it is not integrated into the planned maintenance/refurbishment cycle.

Selecting an alternative


There is another possibility though. While there has been, in our view, too little publicity about the phase-out, product manufacturers have been aware of the impending changes since the regulations were first introduced.

A number of alternative refrigerants have been developed for different air conditioning and refrigeration applications, based on HFC technologies.

While few are as versatile as R22, there will be at least one suitable alternative refrigerant for virtually every individual application.

And the use of these alternatives can save organisations a great deal of money. One commercial coldstore facility on Merseyside was faced with replacing all its units unless an alternative could be found.

However, an HFC replacement for the R-22 material was recommended - ISCEON(r) MO79 (R422A) at a cost of just 10 per cent of the cost of total equipment replacement. With over 30 units on their Merseyside site, the coldstore facility saved hundreds of thousands of pounds of potential capital investment.

In addition, there was no disruption as the R22 could be replaced with the alternative over a period of time with no downtime.

With the deadline for phase-out fast approaching, it is advisable for facilities managers to ensure that their HVAC systems suppliers have prepared for this event and have adequate plans to meet any contingency.

It should be noted that, although the legislation at present allows recycled R22 (however much of it there is) to be used up to 2015, there is some risk that EU institutions may shorten the deadlines and ban its use in all air conditioning and refrigeration applications from 2012.

Air conditioning inspections


Another piece of European legislation due to take effect in the UK in the coming months is the last piece of the Energy Performance of Buildings Directive (EPBD).

After enhanced Building Regulations and the introduction of Energy Performance Certificates, regular inspections of air conditioning systems must now be carried out for all systems with an output of more than 12kW.

The inspections must be carried out by an approved energy assessor. For systems with an output of more than 250kW (and all systems on a single site are aggregated to give the final output) the inspection must be completed by 4 January 2009.

For smaller systems, the inspections must be completed before 4 January 2011. A first inspection of air conditioning installed after 31 December 2008 is due within five years.

The written report must include:
  • An assessment of air conditioning efficiency;
  • A judgement on the size of the unit(s) in relation to the building's needs;
  • Suggestions for improvements, replacement or alternatives;
  • Identification data.

The efficiency of the system can be significantly affected by impurities in the refrigeration circuits, a problem that increases over time.

Prolonged contamination (whether by moisture or oil or acidic by-products) can also increase the risk of breakdown.

Operating efficiency


BOC carries out thousands of tests a year on air conditioning and refrigeration systems.

It has found that a third (33 per cent) were operating with contaminated refrigerants, which affected the efficiency - and therefore the energy consumption - as well as causing excessive wear.

Some 36 per cent of refrigerant blends were out of specification and required complete recovery and recharge.

And 50 per cent of the systems examined needed immediate attention in order to tackle high moisture levels.

Moisture combines with oil and refrigerant to form acids that attack metal parts and motor windings.

Water removes copper ions from tubing and deposits them on hot surfaces, where a build-up can cause bearing surfaces to seize and compressor failure.

Over time, water and oil form sludge that blocks oil flow passages, filters, polished surfaces and restricts metering devices.

Unfortunately refrigerants such as R22 and R134a have an affinity for water around 10 times greater than the old CFCs, making regular refrigerant testing more important than ever.

Left untreated, moisture build-up can lead to serious problems like a compressor burnout. High levels of moisture in the refrigerant are often caused by allowing air into the system during maintenance or through leaks.

Each 1 per cent of oil contamination in a refrigerant reduces its capacity by about 2 per cent, so systems have to work for longer periods to obtain the required temperatures, resulting in higher energy costs and increased stresses on the plant.

The good news is that analysis is not complex, can be easily carried out and regular testing and remedial works would dramatically prolong the lifetime and reduce the running costs of literally thousands of highly expensive systems.

Gas and oil analysis is a relatively quick service. Results can be available within three days and most importantly can help identify and possibly eliminate more serious problems.

Clearly contamination and the ensuing inefficiency are issues that need to be addressed. Operators of air conditioning systems are to some extent unaware of the need for regular maintenance and remedial action.

The message is that regular analysis of system fluids - as part of a regular maintenance programme - is key to efficient, safe and cost-effective running.

Barry Lyons is Business Development Manager, BOC Refrigerants. BOC, a member of The Linde Group, is a supplier of industrial gases. Please visit www.gas2010.com
 
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