The influence on leakage rate of RAC equipment

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The influence on leakage rate of RAC equipment

  1. 1. Dutch ApproachHuman beings and the RAC system The influence on the leakage rate of RAC equipment Jan Reijmers info@stek Thematic Meeting Hungary 21-10-11 1
  2. 2. Dutch ApproachHuman beings and the RAC system • Introduction • Implementation • Results • Logbook and work report • SPARK Project • Summary Thematic Meeting Hungary 21-10-11 2
  3. 3. Dutch ApproachHuman beings and the RAC system • 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) Thematic Meeting Hungary 21-10-11 3
  4. 4. Dutch ApproachHuman beings and the RAC system • 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 Thematic Meeting Hungary 21-10-11 4
  5. 5. Dutch ApproachHuman beings and the RAC system • 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 ? Thematic Meeting Hungary 21-10-11 5
  6. 6. Dutch ApproachHuman beings and the RAC system • 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 • Thematic Meeting Hungary 21-10-11 6
  7. 7. Dutch ApproachThe 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 Thematic Meeting Hungary 21-10-11 7
  8. 8. Dutch ApproachResults • High awareness • General quality improvement • Leakage diminished rapidly (from ↑30% to 5-10%) • Decrease of spare parts sales • No free riders Thematic Meeting Hungary 21-10-11 8
  9. 9. Dutch Approach Scheme to certified Company Thematic Meeting Hungary 21-10-11 9
  10. 10. Dutch Approach Thematic Meeting Hungary 21-10-11 10
  11. 11. Dutch ApproachAudit 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 company Registration 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 Thematic Meeting Hungary 21-10-11 11
  12. 12. Dutch ApproachAudit List for STEK Certified Company Certified Persons List 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 register Registration 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 Thematic Meeting Hungary 21-10-11 12
  13. 13. Dutch ApproachAudit List for STEK Certified Company 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 reports To 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) Thematic Meeting Hungary 21-10-11 13
  14. 14. Dutch ApproachAudit List for STEK Certified Company 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 persons Manifold & Mobile leak detector & Temperature meter Refrigerant weight Scale Vacuum pump & Vacuum meter Recovery set & Recycling cylinder Thematic Meeting Hungary 21-10-11 14
  15. 15. Dutch ApproachLeakage rate by HCFCs (R22)remark 1999 beginning of fase out process HCFCs (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% Thematic Meeting Hungary 21-10-11 15
  16. 16. Dutch ApproachLeakage rate HFCremark on the market since 1993 ? Tailor made Pre-charged installations filled growth by year 5,00% Total Life cycle Total content new leakage Content Heat load Average Content content multiplier until year emission 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% Thematic Meeting Hungary 21-10-11 16
  17. 17. 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 Thematic Meeting Hungary 21-10-11 17
  18. 18. Dutch Approach RAC Company Adminstration 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 Thematic Meeting Hungary 21-10-11 18
  19. 19. Dutch Approach RAC Company Adminstration 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. Thematic Meeting Hungary 21-10-11 19
  20. 20. Dutch ApproachLogbook 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 Thematic refrigerating 21-10-11 on the Meeting Hungary system. 20
  21. 21. Dutch ApproachLogbook 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; Thematic Meeting Hungary 21-10-11 21
  22. 22. Dutch ApproachLogbook 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. Thematic Meeting Hungary 21-10-11 22
  23. 23. Dutch ApproachWork report 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 Thematic Meeting Hungary 21-10-11 23
  24. 24. Dutch ApproachHuman beings and the RAC system 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 Thematic Meeting Hungary 21-10-11 24
  25. 25. Dutch Approach SPARK Project 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 Thematic Meeting Hungary 21-10-11 25
  26. 26. Dutch Approach Thematic Meeting Hungary 21-10-11 26
  27. 27. Dutch Approach Thematic Meeting Hungary 21-10-11 27
  28. 28. Dutch Approach The Dutch approach The sheets and other documention available on USB Stick Thank you for your attention Jan Reijmers info@stek.nl Thematic Meeting Hungary 21-10-11 28

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