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Best Practices in the
Indian Servicing
Sector
Markus Wypior, GTZ-Proklima



MAC and Environment: India policy workshop on...
Project History




                  07.06.2010   Page
                               Seite 2
HIDECOR (2001-2004)
Human and Institutional Development in Ecological Refrigeration
  2001: HIDECOR project launched as an...
NCCoPP (2004-2010)
         National CFC Consumption Phase-out Plan


 2004: NCCoPP project launched based on the Agreemen...
HIDECOR/NCCoPP Target Group



Main target group: Micro, small and low income
service enterprises from the informal sector...
HIDECOR/NCCoPP Access Routes




                          07.06.2010   Page
                                       Seite 6
NCCoPP Steering Structure

                                                     MoEF / Ozone
                             ...
Training Activities under NCCoPP



 Standard training for servicing of domestic
and small commercial appliances

Mobile A...
Key Achievements HIDECOR/NCCoPP


20,000+ technicians
trained
(60 % outside
metros)

1,000+ equipments
supplied




      ...
Improvement of Service Practices




                               07.06.2010   Page
                                    ...
Options to reduce consumption of CFCs
               and other refrigerants in MAC servicing


Adoption of Good Service Pr...
Estimated CFC consumption
                         in MAC servicing in 2005/06


             Estimated Annual CFC Consump...
Strategy for Training
                         MAC Service Enterprises




 Development of Training                       ...
Training Material




                    07.06.2010
                      07.06.2010   Page
                             ...
Training Material




Can be downloaded free of charge from www.nccopp.info
                                          07.0...
Guidelines for proper MAC servicing




                               07.06.2010
                                 07.06.2...
Guidelines for HFC-134a retrofit




                               07.06.2010
                                 07.06.2010...
Guidelines for HC blend retrofit




                               07.06.2010
                                 07.06.2010...
Guidelines for HC blend retrofit




                               07.06.2010
                                 07.06.2010...
Guidelines for HC blend retrofit




                               07.06.2010
                                 07.06.2010...
MAC training programmes


               Achievements NCCOPP: MAC training

    Activity           AWP 2004-05 AWP 2005-06...
Equipment support under HIDECOR/NCCoPP




                               07.06.2010
                                 07.0...
Changing scenario
          during implementation

At time of project inception > 2 Mio CFC
MAC systems in the market
Acce...
Lessons learnt from HC retrofitting


    Technically feasible, but more complicated than use of
    CFC-12 (proper traini...
Training Partners




Training infrastructure can still be used by industry!
                                             ...
Thank you!
Contact: markus.wypior@gtz.de
                                07.06.2010
                                  07.0...
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Best Practices in the Indian Servicing Sector

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Best Practices in the Indian Servicing Sector by Markus Wypior

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Best Practices in the Indian Servicing Sector

  1. 1. Best Practices in the Indian Servicing Sector Markus Wypior, GTZ-Proklima MAC and Environment: India policy workshop on the status of MAC replacement technologies New Delhi, India, 7-8 June 2010 07.06.2010 Seite 1
  2. 2. Project History 07.06.2010 Page Seite 2
  3. 3. HIDECOR (2001-2004) Human and Institutional Development in Ecological Refrigeration 2001: HIDECOR project launched as an Indo-Swiss collaboration Goal: Providing training on good servicing practices and hydrocarbon based retrofit to service technicians in the Refrigeration and Air-Conditioning (RAC) sector Geographic focus: Initial states: Tamil Nadu, Karnataka, Andhra Pradesh, Maharashtra, Gujarat, Delhi and West Bengal States added later: Punjab, Haryana, U.P., Rajasthan and Kerala (in anticipation of NCCoPP) 07.06.2010 Page Seite 3
  4. 4. NCCoPP (2004-2010) National CFC Consumption Phase-out Plan 2004: NCCoPP project launched based on the Agreement between India and the Executive Committee of the Multilateral Fund Goal: Providing training on good servicing practices and to service technicians in the Refrigeration and Air- Conditioning (RAC) sector Geographic focus: All over India Funding: 6.3 million USD 07.06.2010 Page Seite 4
  5. 5. HIDECOR/NCCoPP Target Group Main target group: Micro, small and low income service enterprises from the informal sector Aim: Up-gradation of skills enabling RAC technicians to continue in business Not more than two technicians from one service enterprise were considered for training to reach larger segment Industry partners could train their own service technicians along with the main target group 07.06.2010 Page Seite 5
  6. 6. HIDECOR/NCCoPP Access Routes 07.06.2010 Page Seite 6
  7. 7. NCCoPP Steering Structure MoEF / Ozone Cell Management Core Group GTZ PMU GTZ INFRAS UNDP UNEP co-financing ITAC Foam Sector RMO's/ Industry Training Technical Consultants Refrigeration Training Cells (manufacturing) 15 ORG/REC/RSET ESS Workshops / incl. transport dealers meet local facilitator ESS Refrigeration Equipment Facilitator & Principal Distributor ITI Eqpt. Facilitator Awareness National Partner National Partner Awareness Customs & Policy 07.06.2010 Page Seite 7
  8. 8. Training Activities under NCCoPP Standard training for servicing of domestic and small commercial appliances Mobile Air-Conditioning (MAC) Selected Commercial Systems / Open Type Compressors (OTC) in food processing and preservation Selected Institutional Users (Railways, Defence) 07.06.2010 Page Seite 8
  9. 9. Key Achievements HIDECOR/NCCoPP 20,000+ technicians trained (60 % outside metros) 1,000+ equipments supplied 07.06.2010 Page Seite 9
  10. 10. Improvement of Service Practices 07.06.2010 Page Seite 10
  11. 11. Options to reduce consumption of CFCs and other refrigerants in MAC servicing Adoption of Good Service Practices Recover, Recycle and Reuse of Refrigerants Proper evacuation to eliminate flushing/purging by the refrigerants Proper charging of refrigerant Retrofitting Retrofitting with HFC-134a Retrofitting with HC Blend 07.06.2010 Page Seite 11
  12. 12. Estimated CFC consumption in MAC servicing in 2005/06 Estimated Annual CFC Consumption in Servicing of MAC Year 2000 2001 2002 2003 2004 2005 2006 2007 2008 2009 2010 Production 0.24 0.26 0.23 0 0 0 0 0 0 0 0 (Million) Population 1.49 1.71 1.9 1.83 1.76 1.68 1.58 1.49 1.39 1.3 1.26 (Million) Servicing 491 562 623 601 352 337 317 297 278 261 251 (with recovery) (MT) Servicing 637 729 808 779 465 445 418 392 367 344 332 (without recovery) (MT) The production of MAC completely changed to HFC-134a from 2003! 07.06.2010 Page Seite 12
  13. 13. Strategy for Training MAC Service Enterprises Development of Training Conduct Action Creation of Manual for MAC Learning Workshops Training Facilities and Other Training Material Training Management Unit MAC Training Training by Organizers Automobile/MAC Industry MAC Training Cell MAC Service Enterprises 07.06.2010 Page Seite 13
  14. 14. Training Material 07.06.2010 07.06.2010 Page Seite 14
  15. 15. Training Material Can be downloaded free of charge from www.nccopp.info 07.06.2010 07.06.2010 Page Seite 15
  16. 16. Guidelines for proper MAC servicing 07.06.2010 07.06.2010 Page Seite 16
  17. 17. Guidelines for HFC-134a retrofit 07.06.2010 07.06.2010 Page Seite 17
  18. 18. Guidelines for HC blend retrofit 07.06.2010 07.06.2010 Page Seite 18
  19. 19. Guidelines for HC blend retrofit 07.06.2010 07.06.2010 Page Seite 19
  20. 20. Guidelines for HC blend retrofit 07.06.2010 07.06.2010 Page Seite 20
  21. 21. MAC training programmes Achievements NCCOPP: MAC training Activity AWP 2004-05 AWP 2005-06 AWP 2006-07 AWP 2007-08 Target as per AWP 44 80 180 352 Achieved 29 199 238 275 Cumulative 29 228 466 741 Total no. of training programmes 2004 - 2008: 33 07.06.2010 07.06.2010 Page Seite 21
  22. 22. Equipment support under HIDECOR/NCCoPP 07.06.2010 07.06.2010 Page Seite 22
  23. 23. Changing scenario during implementation At time of project inception > 2 Mio CFC MAC systems in the market Accelerated CFC phase-out in India: complete stop of supply 1st August 2008 Price of CFC increased thereafter (from Rs 300 to Rs 1,000+ per kg) Price of HFC-134a decreased significantly in 2007-08 (to approx Rs 300 per kg) CFC MAC systems were replaced with HFC- 134a systems on routine basis by official servicing workshops 07.06.2010 07.06.2010 Page Seite 23
  24. 24. Lessons learnt from HC retrofitting Technically feasible, but more complicated than use of CFC-12 (proper training required, need of weighing scale and vacuum pump) Supply of HC refrigerant critical bottleneck Incorrect practices resulted in poor performance of MAC systems after retrofit (no use of weighing scale, no proper vacuum etc.), however this was blamed on HC refrigerant in general HC-290 should be preferred to HC blend (as blend does not allow topping up of refrigerant) Hence service technicians did not really take up HC blend retrofitting 07.06.2010 Page Seite 24
  25. 25. Training Partners Training infrastructure can still be used by industry! 25 07.06.2010 Page Seite 25
  26. 26. Thank you! Contact: markus.wypior@gtz.de 07.06.2010 07.06.2010 Page Seite 26

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