Fairconditioning ARCHITECTURE Training OF Trainer Workshop

FAIRCONDITIONINGARCHITECTURETRAINING OF TRAINERWORKSHOP

Natural Refrigerant ACsDX.X

Natural Refrigerants ACs : Content Flow

Refrigerant Issues

Refrigerants Overview

Natural Refrigerants

R290 (Propane)

R290 Split ACs, Central ACs

ISSUE: HIGH GWPS

Issue: AC Refrigerant Progression

CFCs(banned)

HCFCs(being phased

out)

HFCs (stop-gap solution)

Natural Refrigerant (long term solution)

‘leapfrogging’ is possible

ISSUE: AC REFRIGERANT PROGRESSION

ISSUE: AC REFRIGERANT PROGRESSION

REFRIGERANTS OVERVIEW: TRADEOFFS

REFRIGERANTS OVERVIEW: SAFETYRefrigerant Safety / Toxicity Classification

NATURAL REFRIGERANTS: TYPESNatural Refrigerants can be divided into :

• Hydrocarbons – Propane (R290), Propylene (R1270), R600a

• Ammonia

• Carbondioxide

NATURAL REFRIGERANTS: BENEFITSRegulatory Compliance – In many countries, the use and availability of HCFCs and HFCs are controlled by legislation due to their environmentalImpact. Not subject to the Montreal Protocol, Kyoto Protocol or other related local environmental legislation.

Low environment impact – They have zero ODP and minimal GWP. In comparison, commonly used HCFCs and HFCs have a GWP varying from hundered to thousands.

High Performance- They have excellent thermodynamic properties.

Cost competitiveness- Use of natural refrigerants generally leads to lower operating costs due to less leakage, lower maintenance requirements and better energy efficiency.

Compatibility – Natural refrigerants work well with commonly used oil and fluids.

R290 (PROPANE) ANALYSIS: CRITERIATHE PRINCIPAL CRITERIA FOR REFRIGERANT GAS Different refrigerant options of ACs are compared with each other on three characteristics, that are identified below:• Environmental • Safety• Efficiency• Price

R290 (PROPANE) ANALYSIS: CRITERIA

BASIC CONCEPT:

EER (Dimensionless Number)Energy Efficiency Ratio

=Ratio of Cooling Output (kW) to Energy

Input (kW)

(is the Basis of the BEE Star Rating System)

R290 EFFICIENCYEfficiency Perspective: Natural Refrigerants Are Energy Efficient

Efficiency Related Data of R744 (Carbon Dioxide) and R717 (Ammonia) is not available

R290 EFFICIENCYVolumetric Refrigerating Capacity (kW / m3 ) = cooling achieved per unit volume of refrigerant moving through the compressor

While this is LOWER for R290 vs. say R22, the cumulative effect of kW/m3 and the higher volumetric efficiency needs to be considered to gauge overall efficiency of the refrigerant.Volumetric Efficiency:

where:m (kg/s) = mass flow rate of refrigerant VSW (m3/s) = compressor displacement rateVe (m3/kg) = specific volume of the refrigerant at compressor inlet

R290 EFFICIENCY

<kW/m3(refrigerant)

>>m3(refrigerant)/m3

(compressor disp.)

>kW per m3(compressor

disp.)

R290: SAFETYBasic Safety Concept

CNG as a fuel is flammable, but would you call a CNG Car ‘Flammable’?

LPG as a fuel is flammable, but would you call you kitchen ‘Flammable’?

R290: SAFETYFlammability Concerns Related to R290NOTE: the following concerns are already addressed in equipment construction practices and all risks associated with Hydrocarbon Refrigerant use are mitigated through compliance with all legal norms and safety regulations• It belongs to safety group A3 and is highly flammable and non toxic.[4]

• Lower Explosive Limit – 2.1 %, Upper Explosive Limit – 9.5 %. [5]

• Color Less and Odor less Gas• Flash Point is below the atmospheric temperature and exposure to

atmosphere in combination with spark/flame/hot surface may cause fire immediately

• Readily forms an explosive air-vapour mixture at ambient temperatures.• Vapour is heavier than air and may travel to remote sources of ignition

(e.g. along drainage systems, into basements etc).[6]

R290: SAFETYSAFETY CONSIDERATIONS FOR USING R290 REFRIGERANT IN ACs BY CATEGORY ‘A‘ PEOPLE

Here we are addressing safety considerations of ACs with special reference R290 refrigerant for its use in commercial/residential ACs. All general safety considerations like electrical operations, Installation site etc has to be followed as followed during HCFC/HFC ACs installation / Repair / Modification / maintenance / disposalSafety can be addressed by using 5 broad classifications:A.During Construction / ManufacturingB.During OperationC.During Maintenance / RechargingD.During DisposalE.Additional Safety Considerations

R290: SAFETYSAFETY CONSIDERATIONS DURING OPERATION

• Smoking has to be prohibited. [6]

• The equipment should be positioned so that there is always good free ventilation around all sides of the equipment, and it will not be inhibited by any permanent or temporary blockages.• The area should be free of combustible materials. [6]

• The equipment housing should be designed to prevent or inhibit interference from others, possibly by Locks etc.• Consideration should be given to the positioning of the equipment with regards to areas

where people may congregate or gather.• Do not install system in Humid places and do not clean the system with water. [6]

• Air Conditioner must be kept away from fire, spark with energy > 20mJ /hot surfaces > 450 deg C to prevent the ignition of R290 (Auto ignition temp 540 deg C). [8]

• If anything irregular occurs like burnt parts, smell, loud noise then disconnect the system immediately and isolate the system from electric supply. [6]

R290: SAFETYSAFETY CONSIDERATIONS DURING MAINTENANCE & RE-CHARGING

• Regular maintenance and system checks have to be made. [8]

• Any technician working on a system must be properly trained and certified with the appropriate qualifications. [8]

• Before servicing the unit, the surrounding area where the work will be done must be clear of safety hazards to ensure safe working. [6]

• Nevertheless it is required to carry out a risk assessment in order to minimise the risk of ignition of R-290.• It is recommended to isolate the working environment in order to keep out any

unauthorised personnel. [6]

• It is prohibited to store any combustible goods within the working environment.• Within two (2) metres radius, ignition sources are not allowed in the working area.

[6]

• Fire extinguisher (dry powder) must be easily accessible at any time. [6]

R290: SAFETYSAFETY CONSIDERATIONS DURING MAINTENANCE & RE-CHARGING

• Do not charge the system with any refrigerant which is not R290. Do not mix any refrigerant. [6]

• Servicing by competent technicians must be done by using proper equipment.• Before Recharging the refrigerant technician must do leak testing. [8]

• Before filling ensure that there is no air or other non condensable gases like nitrogen etc left in the system. [6]

• While recharging technician has to ensured that the refrigerant charge of the of the system do not exceed the charge size limits and he must also ensure that the quantity of recharging is not less than specified as it may reduce the system performance. [6]

• After recharge examine and confirm by the use of appropriate leak test. [6]

• Retrofitting has to be done by trained technician

E N 3 7 8 :2 0 0 7 a n d

D ISISO 5 1 4 9 :

2 0 0 7

For S y s t e m s Tha t Con ta in Ch a rge S ize m o r e t h a n 1 5 0 g

Typica l ly H C ach ieve “A3 ” c lassificat ion. T h e m a x i m u m c ha rge for a n y re f r igerant d e p e n d s o n the oc c u p a n c y ca tegory a n d o n the

locat ion o f the re f r igerant -conta in ing parts .Fo r Ca tegory A t ype o f oc c upanc y - genera l o c c u p a n c y no t restr ic ted

a t all. Dwe l l i ngs a n d pub l ic p laces m a x i m u m c ha rge l imits a re as b e l o wCategory A : General Occupancy, Dwelling and Public Places

Sl/No Particulars Maximum Charge Size1 System in Human occupied 1.5 Kg If System is placed above

spaces the Ground level2 System in mechanically

ventilated enclosure130 * LFL of the Refrigerant

3 System in Open Area 5.0 Kg If System is placed abovethe Ground level

A l lowab le c ha rge quant i t ies a re ca lcu la ted b a s e d o n the f o rmu la g iv ing d u e cons idera t ions to a rea o f the r o o m a n d he igh t at w h i c h AC s a re p lacedA R m = ( M A L / 2 .5 * (LEL)^(1.25) * h ) 2

A R m = Ro o m AreaM A l = A l lowab le M a s s pe r Ci rcu i tLEL = Lo w e r Exp los ive L imi t ( Kg / m3 ) for R 2 9 0 is 0 .038 K g / m 3 h = He igh t in (m) , accord ing to pos i t ion o f the e q u i p m e n t

h = 0 .6 m for floor m o u n t e d h = 1 m for w i n d o w m o u n t e d h = 1 .8 m for wa l l m o u n t e dh = 2 .2 m for ce i l ing m o u n t e d

KEY SAFETY CRITERIA – AC CIRCUIT CHARGE LEVELR 290: SAFETY

R290: SAFETYKEY SAFETY CRITERIA – COMPLIANCE BY GODREJ EON ACB. TECHNICAL FEATURES & SPECIFICATIONS FOR SAFETY• Additional protection sleeves are provided on the wire – to disable the chances of accidental

combustion• Limitation of installation pipe length up to 6m only – to ensure refrigeration charge does not

exceed mass required to mitigate the chances of accidental combustion• GMCC PH310G2C – 4KTH compressor• Internal OLP (Overload Protection) for compressor and burst – proof capacitor

C. CONSIDERATION OF INTERNATIONAL STANDARDS FOR SAFETY:• European standard (EN 378), limitation is 360-365 gm for a 1.5T SAC – HCACs are within this limit

D. TECHNICAL EXPERT SUPPORT:• Service capabilities across India • Installation and post installation support for the products

E. PROVED ENERGY SAVINGS:• HCAC achieve Energy Savings primarily because of lower working pressure than R22.• Godrej can share PH for specific customers as the need arises – unable to share the PH at present

due to design confidentiality

R290: SAFETYSUMMARY for Architects

1. Ensure distance between Indoor and Outdoor Units is less than 20 ft.

2. Do not recommend for areas where naked flames or other sources of ignition are expected to be present.

3. For 2.2 m IDU installation height, ensure room area is atleast 113 sq. ft. per 1 TON AC or 170 sq. ft. per 1.5 TON AC.

R290: Use Cases

R290: Use Cases

R290: Use Cases

R290: Use Cases

R 290 SPLIT ACS

HC-AC vs. Conventional Split/Window ACs

1,298

1,917

2,473

1,197

1,796

2,403

951

1,426

1,901

951

1,426

1,901

Window - 1 ton Window - 1.5 ton Window - 2 ton Split - 1 ton Split - 1.5 ton Split - 2 ton

A. EFFICIENCY IMPROVEMENT

Power Consumption Comparison- Coventional vs. Hydrocarbon ACs - (wa6s -

W)

Conventional ACs HC ACs

2.71 2.75 2.84 2.94 2.94 2.93

3.70 3.70 3.70 3.70 3.70 3.70

Window - 1 ton Window - 1.5 ton Window - 2 ton Split - 1 ton Split - 1.5 ton Split - 2 ton

A. EFFICIENCY IMPROVEMENTHC-AC vs. Conventional Split/Windows Acs

Energy Efficiency Ratio Comparison- Coventional vs. Hydrocarbon ACs - (EER - kW cooling/kW power) Conventional ACs HC ACs

R 290 CENTRAL AC SYSTEMS

R290 CENTRAL AC SYSTEM

R290 Chiller installed at Church House, Westminster Abbey

• Church House in Westminster Abbey, built to commemorate Queen Victoria’s golden jubilee

• 600kW air-cooled water chiller R290 refrigerant – supplied by Earthcare for comfort air conditioning

• Achieves minimized environmental impact through a combination of natural refrigerants and optimal energy efficiencySource: 1. Natural Gas, CIBSE Journal, June 12 ; 2. Case Study, Church House, Westminster

Abbey – Nicholas Cox, Earthcare

R290 CENTRAL AC SYSTEMSavings Achieved

GHG EMISSIONS OF AC SYSTEMS

LIFE CYCLE GHG EMISSIONS OF COOLING TECHNOLOGIES

LIFE CYCLE GHG EMISSIONS OF COOLING TECHNOLOGIES

Scope 1 Emissions

(Ref. Fugitive

Emissions)

Scope 2 Emission

s( Electricit

y Emissions

)

Scope 3 Emission

s( AT&C Loss

Emissions)

Total Life Cycle GHG Emissions

CASE A• Library Building• 84 TR Direct-Expansion Chiller System• EER of System = 2.93• R22 Refrigerant• 3,000 hours/year use• Energy Cost = 13.25 INR/kWh• Energy Penalty (above contract demand) = INR 300 / kVA / month• Capital Cost = INR 16.20 Lakh• Building Dimensions:–Length: 131 feet–Width: 82 feet–Height: 10 feet 6 inch per floor–5 Floors

CASE B• Library Building• 84 TR Output Direct-Indirect EAC + DX Hybrid System• 53 TR Compressor Output (i.e. 37% downsizing) @ 2.93 EER• R290 Refrigerant• 3,000 hours/year use• Energy Cost = 13.25 INR/kWh• Energy Penalty (above contract demand) = INR 300 / kVA / month• Capital Cost = INR 54.00 Lakh• Building Dimensions:–Length: 131 feet–Width: 82 feet–Height: 10 feet 6 inch per floor–5 Floors

CASE AStep 1: Derive power consumption for 84 TR system cooling output• 84 TR = 84 TR x 3.517 kW / TR = 295.4 kW cooling• EER = 2.93 = 295.4 kW output / X kW input• X = 295.4 kW / 2.93 = 100.8 kW input (electrical)

Step 2: Determine annual energy consumption for calculated system kW• 100.8 kW x 3,000 hours/year = 302,486 kWh/year

Step 3: Calculate annual GHG emissions for energy consumption• Scope 2 Emissions (Indirect Electricity Emissions) = 302,486 kWh/year x0.96 kg CO2e/kWh (Avg. India Grid Electricity Emission Factor) = 290.4 MT CO2e/year• Scope 3 Emissions (AT&C Loss Emissions) = 302,486 kWh/year x 0.29 kg CO2e/kWh (Avg. India Grid AT&C Losses Emission Factor) = 87.7 MT CO2e/ year

Step 4: Determine Non-Energy (Fugitive) Emissions from Refrigerant Use Life-Cycle

Step 1: Methodology for determining total emissions from refrigerant leakage from refrigerators and air conditionersGuidelines:REFRIGERATION AND AIR CONDITIONING, Volume 3: Industrial Processes and Product Use, Chapter 7: Emissions of Fluorinated Substitutes for Ozone Depleting Substances, 2006 IPCC Guidelines for National Greenhouse Gas Inventories

Etotal ,t = Econtainers,t + ECharge,t + Elifetime,t + Eend −of −life,t

EMISSIONS FROM MANAGEMENT OF CONTAINERSEcontainers, t = RMt • c / 100 Where:Econtainers, t = emissions from all HFC containers in year t, kgRMt = HFC market for new equipment and servicing of all refrigeration application in year t, kg c = emission factor of HFC container management of the current refrigerant market, percent

CASE A

EMISSIONS WHEN CHARGING NEW EQUIPMENTEcharge, t = Mt • k / 100 Where:Echarge, t = emissions during system manufacture/assembly in year t, kgMt = amount of HFC charged into new equipment in year t (per sub-application), kgk = emission factor of assembly losses of the HFC charged into new equipment (per sub-application), percentEMISSIONS DURING EQUIPMENT LIFETIMEElifetime, t = Bt • x / 100 Where:Elifetime, t = amount of HFC emitted during system operation in year t, kgBt = amount of HFC banked in existing systems in year t (per sub-application), kgx = annual emission rate (i.e., emission factor) of HFC of each sub-application bank during operation, accounting for average annual leakage and average annual emissions during servicing, percentEMISSIONS AT SYSTEM END-OF-LIFEEend-of-life, t = Mt-d • P/100 • (1-nrec,d/100) Where:Eend-of-life, t = amount of HFC emitted at system disposal in year t, kgMt-d = amount of HFC initially charged into new systems installed in year (t-d), kgp = residual charge of HFC in equipment being disposed of expressed in percentage of full charge, percentηrec,d = recovery efficiency at disposal, which is the ratio of recovered HFC referred to the HFC contained in the system, percent

CASE A

CASE AIPCC/TEAP. 2006. IPCC/TEAP Special Report: Safeguarding the Ozone Layer and the Global Climate System. Intergovernmental Panel on Climate Change

SCENARIO

DISTRIBUTIONPHASE HFC- USE PHASE END-OF-LIFE PHASE

FROM HANDLINGCONTAINERS

OPERATIONALLEAKAGES

LEAKAGESFROM INITIALCHARGING

REMAININGCHARGEFORSERVICING

LEAKAGESFROMSERVICINGRECHARGE

REMAININGCHARGE ATEND-OF-LIFE

RECOVERYEFF.

[% OF MARKET]

[% OF INITIALCHARGE / YEAR]

[% OF INITIALCHARGE]

[% OFINITIALCHARGE]

[% OFSERVICINGRECHARGE]

[% OFINITIALCHARGE]

[% OFREMAININGCHARGE]

BUSINESS-AS-USUAL SCENARIO 10% 10% 1% 60% 2% 80% 0

INTERMEDIATE LEAKAGE SCENARIO

10% 5% 1% 65% 2% 85% 0

BEST-PRACTICES SCENARIO 2% 1% 0.20% NA 0.40% 90% 80%

CASE A

System Type Refrigerant Type GHG EF Units

Ductable AC Conventional)

Avg. High GWP Refrigerant Mix 149.76 kg CO2e/kW cooling/year

Ductable AC (Conventional) HFC-32 16.32 kg CO2e/kW cooling/year

Ductable AC (Conventional) R-290 0.08 kg CO2e/kW cooling/year

Calculated Refrigerant (Fugitive) Life-Cycle Emission Factors for Developing Countries (India) with Minimal Leakage Mitigation Efforts

CASE AStep 4: Determine Non-Energy (Fugitive) Emissions from Refrigerant Use Life-Cycle• Scope 1 Emissions (Refrigerant Leakage) = 149.76 kg CO2e/kW cooling/ year x 295.4 kW cooling = 44.2 MT CO2e/year

Step 5: Determine Annual Operating (Energy) Cost• Energy Use Cost = 302,486 kWh/year x 13.25 INR/kWh = 40.08 INR Lakh/ year• Energy Penalty Cost:–Electrical Load = 100.8 kW–Power Factor = 0.9–Apparent Power = 100.8/0.9 = 112 kVA–Penalty Cost = 300 INR/kVA/month x 112 kVA x 12 months/year = 4.03 INR Lakh/year

CASE AAnnual Emissions and Cost Summary

Parameter Value Units

Scope 1 Emissions 44.2 MT CO2e/year

Scope 2 Emissions 290.4 MT CO2e/year

Scope 3 Emissions 87.7 MT CO2e/year

TOTAL GHG Emissions 422.3 MT CO2e/year

Capital Cost 16.20 INR Lakh/Year

Annual Operating Cost 44.11 INR Lakh/Year

CASE BStep 1: Derive power consumption for 84 TR system cooling output• 84 TR = 84 TR x 3.517 kW / TR = 295.4 kW cooling• EER = 2.93 = 53 TR compressor output x 3.517 kW/TR / X kW input• X = 186.4 kW compressor output / 2.93 = 63.6 kW input (electrical)• Effective EER is therefore = 295.4 / 63.6 = 4.64

Step 2: Determine annual energy consumption for calculated system kW• 63.6 kW x 3,000 hours/year = 190,854 kWh/year

Step 3: Calculate annual GHG emissions for energy consumption• Scope 2 Emissions (Indirect Electricity Emissions) = 190,854 kWh/year x

0.96 kg CO2e/kWh (Avg. India Grid Electricity Emission Factor) = 183.2 MT CO2e/year• Scope 3 Emissions (AT&C Loss Emissions) = 190,854 kWh/year x 0.29 kg

CO2e/kWh (Avg. India Grid AT&C Losses Emission Factor) = 55.3 MT CO2e/ year

CASE BStep 4: Determine Non-Energy (Fugitive) Emissions from Refrigerant Use Life-Cycle• Scope 1 Emissions (Refrigerant Leakage) = 0.08 kg CO2e/kW cooling/year x186.4 kW cooling = 0.015 MT CO2e/year

Step 5: Determine Annual Operating (Energy) Cost• Energy Use Cost = 190,854 kWh/year x 13.25 INR/kWh = 25.29 INR Lakh/ year• Energy Penalty Cost:–Electrical Load = 63.6 kW–Power Factor = 0.9–Apparent Power = 63.6/0.9 = 70.7 kVA–Penalty Cost = 300 INR/kVA/month x 70.7 kVA x 12 months/year = 2.54 INR Lakh/year

CASE BAnnual Emissions and Cost Summary

Parameter Value Units

Scope 1 Emissions 0.015 MT CO2e/year

Scope 2 Emissions 183.2 MT CO2e/year

Scope 3 Emissions 55.3 MT CO2e/year

TOTAL GHG Emissions 238.5 MT CO2e/year

Capital Cost 54.00 INR Lakh/Year

Annual Operating Cost 27.83 INR Lakh/Year

CASE A vs BRelative Annual Emissions and Cost Summary

Parameter Value Value Savings UnitsCASE A CASE B CASE B vs. A

Scope 1 Emissions 44.2 0.015 - 44.185 MT CO2e/yearScope 2 Emissions 290.4 183.2 - 107.2 MT CO2e/yearScope 3 Emissions 87.7 55.3 - 32.4 MT CO2e/yearTOTAL GHG Emissions 422.3 238.5 - 183.8 MT CO2e/yearCapital Cost 16.20 54.00 + 37.8 INR Lakh/YearAnnual Operating Cost 44.11 27.83 - 16.28 INR Lakh/YearLife Cycle Cost (15 yrs.) 677.85 471.45 - 206.4 INR LakhLife Cycle GHG Emiss. (15 yrs.) 6334.5 3577.5 -2,757 MT CO2e

Marginal Abatement Cost = Life Cycle Cost / Life Cycle GHG Mitigation -7,486.4 INR/MT CO2e

Contact:

Vivek GilaniManaging Director, cBalance Solutions

Hub Programme Director, Fairconditioning (India)

[email protected]

Philippe DeRougemontCo-Founder, noe21

Programme Director, Fairconditioning (Switzerland)

[email protected]