Good Practices in Refrigeration - UBF-ACA

190 Pages·2010·8.26 MB·English

Proklima International
Good Practices in Refrigeration

Proklima International
Good Practices in Refrigeration
Published by:
Deutsche Gesellschaft für
Technische Zusammenarbeit (GTZ) GmbH
– German Technical Cooperation –
Programme Proklima
Dag-Hammarskjöld-Weg 1-5
65760 Eschborn, Germany
Internet:
http://www.gtz.de/proklima
Name of sector project:
GTZ Proklima - a programme to save the ozone layer
Contact person at the Federal Ministry for
Economic Cooperation and Development (BMZ):
Gisela Wahlen
German Federal Ministry for Economic Cooperation
and Development (BMZ)
Environment and Sustainable Use of
Natural Resources Division
Bonn, Germany
Email: [email protected]
Editors:
Dr. Volkmar Hasse (Programme Manager)
Deutsche Gesellschaft für
Technische Zusammenarbeit (GTZ) GmbH
– German Technical Cooperation –
Programme Proklima
Dag-Hammarskjöld-Weg 1-5
65760 Eschborn, Germany
Email: [email protected]
Linda Ederberg and Rebecca Kirch
GTZ Proklima
c/o HEAT GmbH
Zum Talblick 2
61479 Glashütten, Germany
Phone: [phone]
Email: [email protected]
Email: [email protected]
Technical supervision/responsible for content:
Rolf Hühren
International Consultant
Hohe Straße 23
40213 Duesseldorf, Germany
Phone: [phone]
Fax: [phone]
Email: [email protected]
Design:
Bloomoon – Silke Rabung
Print:Eschborn, March/April 2010
PROKLIMA is a programme of the Deutsche Gesellschaft für Technische
Zusammenarbeit (GTZ) GmbH, commissioned by the German Federal
Ministry for Economic Cooperation and Development (BMZ).PROKLIMA has
been providing technical and financial support for developing countries since
1996 to implement the provisions of the Montreal Protocol on Substances
that Deplete the Ozone Layer.

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Good Practices in Refrigeration
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Preface .......................................................................1
Part I
TOOLS AND EQUIPMENT
Introduction to Part I ..................................................3
Chapter 1: Tools for Tubing (TT) .............................5
Chapter 2: Tools for Refrigerant Handling
and Containment (RHC)......................18
Chapter 3: Equipment for Recovery,Recycling,
Reclamation and Evacuation (RRRE)....32
Chapter 4: Measuring Instruments (MI).................41
Part II
SKILLS AND OPERATION
Introduction to Part II...............................................53
Chapter 5: Assembling a Refrigeration System.....55
Chapter 6: Bending,the Process..........................77
Chapter 7: Brazing,the Process...........................81
Chapter 8: Flaring,the Process............................90
Chapter 9: Domestic Refrigeration.......................95
Chapter 10: Domestic Refrigeration HC.................104
Chapter 11: Pressing,the Process..........................121
Chapter 12: Refrigerant,Recovery,Recycling
and Containment in the Field............129
Chapter 13: Retrofit.............................................148
Chapter 14: Safety...............................................164
Annex
Glossary ..................................................................170
Acronyms and Abbreviations ...................................175
Index......................................................................176
Acknowledgements
We thank the author Rolf Huehren for his thorough compilation and detailed demonstration of
how to service and maintain refrigeration systems and Daniel Colbourne for technical advice.
Furthermore,we thank the following companies for their kind provision of picture material:
Agramkow Fluid Systems A/S and RTI Technologies Inc.,Appion Inc., Peter M. Börsch KG,
Danfoss GmbH,Fluke Deutschland GmbH,GEA Kueba GmbH,Harris Calorific GmbH,IKET –
Institut für Kälte-,Klima- und Energietechnik GmbH,ITE N.V.,Ixkes Industrieverpackung e.K.,
Manchester Tank,Mastercool Europe,Moeller GmbH,Ntron Ltd.,Panimex,Parker Hannifin GmbH
& Co.KG,Perkeo-Werk GmbH & Co.KG,Refco Manufacturing Ltd.,Rotarex,Sanwa Tsusho Co.
Ltd.,Georg Schmerler GmbH & Co.KG,Testboy GmbH,Van Steenburgh Engineering Labs Inc.,
Vulkan Lokring Rohrverbindungen GmbH & Co.KG,Worthington Cylinders.
Volkmar Hasse,Linda Ederberg and Rebecca Kirch
Preface
The phase-out of HCFCs and the introduction of various alternative refrigerants confronts both
the servicing technicians and vocational trainers in the refrigeration and air-conditioning sector
with specific problems.Refrigeration technicians are not yet sufficiently prepared to deal with
the new technologies which will have to be introduced in the near future.
The manual ‘GOOD PRACTICES IN REFRIGERATION’ is the second edition of a booklet jointly
published by the PROKLIMA Programme of the ‘Deutsche Gesellschaft für Technische
Zusammenarbeit’ (GTZ) GmbH,the Brazilian ‘Servico Nacional de Aprendizagem Industrial’ (SENAI)
and the ‘Ministério do Meio Ambiente do Brazil’ (MMA) in 2004,which had been widely used as
part of the training courses on ‘Best practices in refrigeration servicing and CFC conservation’,
which were implemented by PROKLIMA as part of the national CFC phase-out plan in Brazil.
This manual has now been updated to provide professional guidance on how to service and
maintain refrigeration systems operating with new technology,e.g.ozone-friendly alternative
refrigerants to CFCs and HCFCs.It addresses essential know-how on containment of HFC refri-
gerants which have a high Global Warming Potential (GWP) and are already widely applied.It
also provides extensive information on the safe use of natural refrigerants,such as CO,Ammonia
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or Hydrocarbons,which are much more environmentally-friendly with zero or negligibleGWP.These
efficient but still relatively little used refrigerants are in fact suitable replacements for HCFCs in
all applications of refrigeration and air-conditioning equipment.
Part I of this picture book addresses important tools and equipment for tubing;refrigerant hand-
ling and containment;for recovery,recycling,reclamation and evacuation,as well as measuring
instruments.Part II focuses on the handling of servicing and maintenance of refrigeration systems,
such as brazing,flaring,recovery,retrofit and recycling.
Illustrations should help the technicians to easily remember,identify and communicate elements
of best practices in refrigeration.
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Background
Ozone depletion and Montreal Protocol
In the 1970s,scientists discovered the dangerous impact CFCs have in the earth’s atmosphere.
CFCs were used as foam blowing agents,refrigerants and solvents.It was found that they destroy
the ozone layer,so that aggressive UV-B radiation can reach directly the Earth’s surface causing
genetic damage in the cells of people,plants and animals.Therefore,in 1987,an international
treaty was concluded at Montreal,Canada (the so called Montreal Protocol on Substances that
Deplete the Ozone Layer),to prevent the ozone layer from further destruction and begin the phase-
out of the use of CFCs and other ozone-depleting substances (ODS).Until November 2009,all
states worldwide had signed the Protocol.They have worked effectively and successfully towards
a substitution of CFCs which have been banned since1January 2010.In 2007,the treaty was
adjusted to address the phase-out of HCFCs which are the last group of ODS.The refrigeration
and air-conditioning sector,especially in many Article-5 countries,uses very large quantities of
HCFCs and is therefore particularly relevant in the imminent HCFC phase-out.
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