Zero ODP, Low GWP, HCFC Alternatives


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  • Zero ODP, Low GWP, HCFC Alternatives

    1. 1. Industry Roundtable on Zero ODP, Low GWP, HCFC Alternatives Dharubaaruge, Male, Maldives 8-9 May 2011
    2. 2. One of the largest privately-held diversified industrial corporations in India. In 1897 Ardeshir Godrej gave up law and turned to lock-making, to make safes and security equipment of the highest order, and then to creating toilet soap from vegetable oil. His brother Pirojsha Godrej carried Ardeshir's dream forward, leading Godrej towards becoming a vibrant, multi-business enterprise and laid the foundation for the sprawling industrial garden township (ISO 14001-certified) now called Pirojshanagar in the suburbs of Mumbai. Godrej enjoys the patronage and trust of over 470 million Indians every single day. To them, it is a symbol of enduring ideals in a changing world. With 7 major companies with interests in real estate, FMCG, industrial engineering, appliances, furniture, security and agri care – to name a few – our turnover crosses 2.6 billion US dollars. 20% of our business is done overseas Best Practices - Refrigerators Industry Select Awards
    3. 3. Committed to Environment Protection & Service to Mankind Mangroves Godrej Vikhroli Campus – an industrial garden township Integrity I Trust I To serve Respect I Environment Our Values Respect for Environment
    4. 4. Hydrocarbon Adoption Roadmap <ul><li>1958 – Godrej commences production of domestic refrigerators </li></ul><ul><li>1995 – Process of compliance to the Montreal Protocol started </li></ul><ul><li>1999 –Foaming agent changed from CFC-11 to Cyclopentane </li></ul><ul><li>2001 - Refrigerant changed from CFC-12 to HC blend (HC-290 and HC-600a) </li></ul><ul><li>2002 - 1st and only Company in India to make its Entire Refrigerator Range Green (100% CFC, HCFC & HFC free). </li></ul><ul><li>Factories moved to Satellite locations : </li></ul><ul><li>Mohali, Chandigarh : Compressors & Direct cool Refrigerator </li></ul><ul><li>Shirwal, Pune : Frost-free Refrigerator </li></ul>Godrej & Boyce Mfg Co Ltd is the only Indian company to use HCs in refrigerators
    5. 5. 1996: Pilot Foaming Plant at Vikhroli – Trials being conducted Virtual Factory Visit - Vikhroli
    6. 6. Virtual Factory Visit - Mohali Refrigerant Charging Cabinet Foaming - Injection Refrigerant Storage Tank Cyclopentane Storage Tank
    7. 7. Godrej Converts CFC to CFC-Free - Ahead of Deadline CFC-Free, Energy Labeled Products
    8. 8. Experiences with the servicing of hydrocarbon refrigerators, the best practices developed and adopted by Godrej, India D D Rajadhyaksha, S A Juvekar & A A Acharekar 9 th May 2011
    9. 9. ECOFRIG Our Collaboration Godrej Supports Service Technicians
    10. 10. Training Programs Godrej Supports Service Technicians Created a team of Trainers for imparting Training in Servicing & Retrofitting with HC refrigerants
    11. 11. Training Programs Godrej Supports Service Technicians Imparted HC refrigeration Training to over 5000 techs Across India (including metro and small remote cities)
    12. 12. Training Support Activities Recovery Unit New Charging Station Refrigerant Cans Godrej Developed Indigenous Materials Poster on HC Refrigerant
    13. 13. Appreciation by Print Media Godrej Supports Service Manuals
    14. 14. Participation in International Conferences Godrej Participates - Conferences
    15. 15. <ul><li>Shortage - qualified/trained service technicians </li></ul><ul><li>Insufficient quality technical institutes like ITIs </li></ul><ul><li>Restricted admissions in those institutes </li></ul><ul><li>Many small & private institutes w/o status </li></ul><ul><li>Tuition fees - Rs. 18K+ (Kolkata, Mumbai, Cochin etc.) </li></ul><ul><li>Limited and outdated curriculum, no industry touch </li></ul><ul><li>Inadequate infrastructure & no hands-on practice </li></ul><ul><li>Key issues not taught (Quality/Service/Productivity etc.) </li></ul><ul><li>Diminishing employee loyalty </li></ul><ul><li>Recruitment - big challenge </li></ul>The Need Godrej Vocational Training School
    16. 16. Vocational Skills in India Unfavorable compared to other countries. India Receives only 8% formal Vocational Training - least. % Source: Efficiency training Study Report by ILO Vocational Training in India – a Challenge! Godrej Vocational Training School
    17. 17. Solution Establish Vocational Training School (Mumbai, Kolkata, Delhi, Chennai & other 96 major cities) Godrej Vocational Training School Solution?
    18. 18. Vacuum Process Godrej Vocational Training School Godrej Vocational Training School is registered with DGET, MoL, Delhi
    19. 19. Good Servicing Practices HC based Refrigerators Godrej Promotes Work Instructions
    20. 20. <ul><li>Shift Refrigerator to a Well Ventilated </li></ul><ul><li>No Smoking Safe Area (Carefully) </li></ul><ul><li>Reconfirm & Record Defect. </li></ul><ul><li>Evaluate Refrigerator </li></ul><ul><li>Run the Refrigerator (When Possible) </li></ul><ul><li>Recover (CFC,HFC) / Vent </li></ul><ul><li>(HC) Refrigerant </li></ul>Work Instructions – Refrigerator System Repairs <ul><li>Wear Personal Protectives – goggles, apron, gloves & shoes </li></ul>
    21. 21. <ul><li>Evacuate the Sealed System </li></ul><ul><li>@ < 21” Of Hg / 0.7bar </li></ul><ul><li>Break Vacuum With Dry </li></ul><ul><li>Nitrogen Gas @ 5 Psig / 0.35bar </li></ul>Vacuum (for HC only) Work Instructions – Refrigerator System Repairs
    22. 22. <ul><li>De-braze System Joints </li></ul><ul><li>Replace Components (As Required) </li></ul><ul><li>Then in Case of Retrofitting with HCs, use retrofit kit or ensure all Electrical Components to be Adequately Sealed. </li></ul><ul><li>Polish & Flush System using Dry </li></ul><ul><li>Nitrogen @ 65 Psig / 4.5 Bar </li></ul>Work Instructions – Refrigerator System Repairs
    23. 23. <ul><li>Attach Process Tubes along-with Male Couplers & Braze All Joints </li></ul><ul><li>Choke & Leak Test upto 150psig / 10 bar </li></ul><ul><li>Check leak with leak detector or liquid soap </li></ul>Work Instructions – Refrigerator System Repairs
    24. 24. <ul><li>Evacuate System @ 200 Microns from both ends using 2-stage rotary vacuum pump, manifold & Vacuum gauge </li></ul><ul><li>Release Nitrogen From System </li></ul>Vacuum 200 Microns Dry Nitrogen Work Instructions – Refrigerator System Repairs
    25. 25. <ul><li>Charge Liquid Refrigerant </li></ul><ul><li>of Specified Quantity </li></ul>Refrigerant As Specified Work Instructions – Refrigerator System Repairs <ul><li>Select HC cans with female valves may be kept inverted using tripod while charging </li></ul>
    26. 26. <ul><li>Run The Refrigerator & Confirm Proper Functioning </li></ul><ul><li>Observe Operating Pressures </li></ul>HFC 134a HFC 134a CFC 12 CFC 12 HC blend HC 600a 0.3 to 0.4 bar 9.7 to 10.3 bar * Indicative Pressures Shown @ 32ºC Ambient < 0.3 bar 10.3 to 11 bar 0.14 to 0.3 bar 7.6 to 8.3 bar 200 to 250 mmHg. 4.8 to 5.5 bar HC 600a HC blend Work Instructions – Refrigerator System Repairs
    27. 27. <ul><li>Shift Refrigerator to its Original Location </li></ul><ul><li>and restart it. </li></ul><ul><li>Inform Customer - What’s Done and </li></ul><ul><li>Post Service Care </li></ul><ul><li>Seal, Final Test & Record </li></ul>FLAMMABLE GAS A T V REFRIGERANT TYPE …….. QUANTITY -------- g Work Instructions – Refrigerator System Repairs
    28. 28. Retrofitting of CFC Appliances Using HC Blend Refrigerant Retrofit Project with GTZ & INFRAS Godrej Promotes Retrofitting Trained over 250 technicians exclusively on Retrofitting CFC refrigerators
    29. 29. How Does Godrej Retrofit Kit Look? Modified Container PTC type Relay Overload Protector Sealed Thermostat With knob Moulded Lamp Holder Sealed Light Switch HC Label Retrofit Kit for Old CFC Refrigerators
    30. 30. Monitoring of Retrofitted Refrigerators Report Format - to be filled-in individually for each Refrigerator 1 Customer's full name (starting with surname) and address with pin code.   2 Customers contact number Ph # _______________  Mobile #  __________          3 Refrigerator serial number   4 Make & Model of the refrigerator.   5 Age of the Refrigerator     ( date of original sale / how old is the refrigerator)   6 Date of Retrofitting.   7 Warranty period for HC retrofitting* only. From  __________  to _________. 8 HC Label on refrigerator ( provided with kit) Affixed / Not affixed  9 Quantity of original CFC refrigerant ____ g 10 Quantity of HC blend refrigerant charged. ____ g 11 Stabilized Current and Voltage (after 1 hour) ----------- amps -------------- volts 12 Temperature achieved in refrigerator at the end of 1 hour at the point of contact of thermostat sensor ____ºC 13 Customer’s willingness to pay higher repairs charges due to retrofitting? How much? Yes / No. If yes, Rs ________
    31. 31. <ul><li>Charge Liquid Refrigerant </li></ul><ul><li>of Specified Quantity </li></ul>Refrigerant Qty As Calculated Work Instructions – Refrigerator System Repairs <ul><li>Select HC cans may be kept inverted while charging </li></ul>Once retrofit kit is fitted, process the system like HC servicing. Charge by Weight R12 100% HC 40% R 134a 95 %
    32. 32. <ul><li>With the gained knowledge, skills, confidence and experience </li></ul><ul><li>of servicing HC refrigerant based refrigerators in Indian service </li></ul><ul><li>Sector, in 2009, Godrej bagged order from UNDP for : </li></ul><ul><li>supplying RAC Tools & eqpts, HC blend refrigerant and </li></ul><ul><li>imparting training to 32 Trainers and 106 technicians </li></ul><ul><li>recommended by Dept. of Environment, Bangladesh. </li></ul>Godrej Assists Neighbors
    33. 33. <ul><li>Lead the national team for revising ITI curriculum of Refrigeration & Air-Conditioning trade course in India. </li></ul><ul><li>Chairmanship of Institute Management Committee at ITI, Ambernath, Kapurthala, Kalamassery etc. in India. </li></ul><ul><li>Trained over 125 instructors, 1200 students on CFC-free refrigeration & FF technology </li></ul>Godrej - A Responsible Corporate
    35. 35. Thank you for Your patient listening ! D D Rajadhyaksha, S A Juvekar & A A Acharekar 9 th May 2011