Guidelines for the safe use of hydrocarbon refrigerants - UBF-ACA

320 Pages·2010·7.75 MB·English

Proklima International
Guidelines for the safe use
of hydrocarbon refrigerants
A handbook for engineers, technicians, trainers and
policy-makers - For a climate-friendly cooling
2
Guidelines for the safe use
of hydrocarbon refrigerants
A handbook for engineers, technicians, trainers and
policy-makers - For a climate-friendly cooling
3
Imprint
Published by: Editors:
Deutsche Gesellschaft für Dr Volkmar Hasse
Technische Zusammenarbeit (GTZ) GmbH (GTZ Proklima: [email protected])
– German Technical Cooperation – Dr Daniel Colbourne
Programme Proklima Linda Ederberg
Dag-Hammarskjöld-Weg 1-5 Rolf Hühren
65760 Eschborn, Germany
Internet: http://www.gtz.de Peer reviewer:
Stephen Benton (Cool Concerns Ltd)
Name of sector project:
GTZ Proklima - a programme to save Cover picture:
the ozone layer ice cube © Katarzyna Krawiec - Fotolia.com
Federal Ministry for Economic Cooperation Design:
and Development (BMZ): Jeanette Geppert,
Gisela Wahlen www.jeanette-geppert.de
German Federal Ministry for
Economic Cooperation and Development (BMZ) Eschborn, September 2010
Environment and Sustainable Use of Natural
Resources Division
Bonn, Germany
Email: [email protected]
Lead author:
Dr Daniel Colbourne
(GTZ Proklima: [email protected])
Contributing authors:
Rolf Hühren
(GTZ Proklima: [email protected])
Bernhard Schrempf
(TÜV SÜD: [email protected])
TÜV SÜD Industrie Service GmbH
Westendstr. 199
80686 München
Deutschland / Germany

Linda Ederberg (Contact person)
(GTZ Proklima: [email protected])
Sabine Meenen
(TÜV SÜD: [email protected])
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PROKLIMA is a programme of the Deutsche Gesellschaft für Technische
Zusammenarbeit GmbH (GTZ), 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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Contents
PREFACE 18
PART 1: SAFETY INFRASTRUCTURE 22
1.1 GENERAL INTRODUCTION 22
1.1.1 Background 22
1.1.2 Using the handbook 25
1.1.3 Approach of the handbook 25
1.1.4 Considerations for policy-makers 27
1.1.5 Key stages during equipment lifetime 29
1.2 BASIC SAFETY WITH FLAMMABLE REFRIGERANTS 30
1.2.1 Introduction 30
1.2.2 Safety classification of HC refrigerants 31
1.2.3 Basic approach for working with flammable refrigerants 32
1.3 DEVELOPMENT OF SAFETY MANAGEMENT SYSTEMS 34
1.3.1 Introduction 34
1.3.2 Development of a policy 35
1.3.3 Organising personnel 35
1.3.4 Planning and setting guidelines 36
1.3.5 Measuring performance 38
1.3.6 Auditing and reviewing 38
1.4 IDENTIFICATION OF COOPERATION PARTNERS 39
1.4.1 Introduction 39
1.4.2 Industry associations 39
1.4.3 Technical institutes and associations 40
1.4.4 Development agencies 40
1.4.5 National authorities 41
1.4.6 Standardisation bodies 42
1.4.7 Accreditation bodies 44
1.5 FRAMEWORK OF REGULATIONS AND STANDARDS 44
1.5.1 Introduction 44
1.5.2 National health and safety rules 45
1.5.3 Regulations 45
1.5.4 Standards 45
1.5.5 Other publications 51
PART 2: QUALITY SYSTEMS FOR SAFETY 52
2.1 INTRODUCTION 52
2.1.1 General overview 52
2.1.2 Quality control systems 55
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2.2 FEED-IN ELEMENTS (INPUTS) 57
2.3 TESTING 58
2.4 INSPECTIONS 60
2.4.1 Introduction 60
2.4.2 Use of third-parties for inspections 61
2.4.3 Function of an inspection body 61
2.4.4 Practical aspects of inspections 62
2.5 MONITORING 63
2.6 FEEDBACK AND PREVENTATIVE/CORRECTIVE ACTION 64
2.7 ACCREDITATION AND CERTIFICATION 65
PART 3: TRAINING 67
3.1 INTRODUCTION TO TRAINING 67
3.1.1 Significance of training 67
3.1.2 Recognising the importance of training 67
3.1.3 Approach for training and certification 69
3.1.4 Training for field service technicians 70
3.2 TRAINING FACILITIES 71
3.2.1 Introduction 71
3.2.2 Ideal set-up of training workshop site 71
3.2.3 Tools and equipment 72
3.2.4 Implications of location situation 74
3.3 MANAGEMENT SYSTEM 75
3.3.1 Introduction 75
3.3.2 Input requirements 77
3.3.3 Assessment 78
3.3.4 Guidelines for certification of persons 78
3.3.5 Technician and company registration (licensing) 81
3.3.6 Inspection of operations and monitoring 82
3.4 CONTENT FOR STANDARD REFRIGERATION TRAINING 82
3.4.1 Introduction 82
3.4.2 Categorisation of ARC topics and ARC competence description 83
3.4.3 Additional syllabus for HC refrigerants 83
3.4.4 Example of assessment criteria 83
3.5 TRAINING FOR DESIGN AND DEVELOPMENT 83
3.5.1 Introduction 83
3.5.2 Technical core training 84
3.5.3 Product core training 84
3.5.4 Fundamental training 84
3.5.5 Peripheral training 84
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3.6 TRAINING FOR PRODUCTION 84
3.6.1 Procedures for working within production area 84
3.6.2 Awareness-raising of manufacturing personnel 85
3.6.3 Personnel to be trained 85
3.6.4 Identification of areas 85
3.6.5 Changes to work situation 85
3.6.6 Procedures review 86
3.6.7 Staff training for distribution 86
PART 4: PRODUCTION AND MANUFACTURING FACILITIES 88
4.1 INTRODUCTION 88
4.2 REFRIGERANT SUPPLY 89
4.2.1 Refrigerant storage 89
4.2.2 Refrigerant pumping and control supply 91
4.2.3 Refrigerant supply distribution pipework 91
4.3 APPLIANCE PRODUCTION 91
4.3.1 Refrigerant charging areas 91
4.3.2 Appliance repair and refrigerant recovery area 92
4.3.3 Other work areas 92
4.4 FACTORY SAFETY SET-UP 93
4.4.1 Introduction 93
4.4.2 Gas detection 93
4.4.3 Ventilation system 93
4.4.4 Warning alarms 94
4.4.5 Control system 94
4.4.6 Marking and signs 94
4.4.7 Instructions and procedures 95
4.5 CONSIDERATIONS FOR WORKSHOP/REPAIR AREAS 95
4.5.1 Introduction 95
4.5.2 Area layout 95
4.5.3 Workshop safety system 96
4.5.4 Working practices 97
4.5.5 Equipment for workshop area 97
4.6 CARRIAGE OF SYSTEMS 98
4.6.1 Introduction 98
4.6.2 Transport by road 98
4.6.3 Transport by sea 98
4.6.4 Transport by air 99
4.7 STORAGE OF SYSTEMS 99
4.7.1 Introduction 99
4.7.2 Risk assessment 100
4.7.3 Major accident prevention policy 101
4.7.4 Set-up of warehouses 101
4.7.5 General procedures 102
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4.7.6 Shipping-in/-out procedures 103
4.7.7 Record keeping procedures 103
4.7.8 Damaged equipment procedures 103
PART 5: EQUIPMENT DESIGN AND DEVELOPMENT 105
5.1 INTRODUCTION TO SAFE DESIGN FOR HC REFRIGERANTS 105
5.1.1 Integrated safety 105
5.1.2 Other safety considerations 108
5.2 AVOIDANCE OF LEAKAGE 109
5.2.1 Introduction 109
5.2.2 General system design 110
5.2.3 Considerations for piping 111
5.2.4 Considerations for major system components 112
5.2.5 Considerations for valves 112
5.2.6 Leak detection 112
5.3 REFRIGERANT CHARGE SIZE LIMITS 114
5.3.1 Introduction 114
5.3.2 Occupancy categories 115
5.3.3 Category A occupancies (general occupancy) 116
5.3.4 Category B occupancies (supervised occupancy) 117
5.3.5 Category C occupancies (authorised occupancy) 117
5.3.6 Calculation of allowable charge sizes 118
5.3.7 Equipment airflow 119
5.4 CHARGE SIZE REDUCTION 123
5.4.1 Introduction 123
5.4.2 General approach 123
5.4.3 Consideration of individual components 124
5.5 SOURCES OF IGNITION AND METHODS OF AVOIDING IGNITION 128
5.5.1 Introduction 128
5.5.2 Hot surfaces 128
5.5.3 Electrical sources of ignition 129
5.5.4 Fan assemblies 129
5.5.5 Further considerations 131
5.5.6 Leak simulation tests for potential sources of ignition 132
5.6 DESIGN OF SYSTEM INSTALLATION 138
5.6.1 Introduction 138
5.6.2 General requirements for installation of systems inside 138
5.6.3 General requirements for installations outside 138
5.6.4 Machinery rooms 140
5.6.5 Ventilated enclosures 143
5.6.6 Installation of pipework 146
5.6.7 Indirect or secondary systems 147
5.6.8 Use of pressure safety devices 148
5.6.9 Fixed refrigerant detection 152
5.6.10 Integration of system safety concepts 153
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5.7 MARKING AND INSTRUCTIONS 157
5.7.1 Introduction 157
5.7.2 Marking and signage 157
5.7.3 Manuals and other instructions 160
5.8 RISK ANALYSIS 163
5.8.1 Introduction 163
5.8.2 General risk assessment techniques 163
5.8.3 Specific methodology 169
5.8.4 Flammability characteristics 177
5.8.5 Refrigerant leakage 177
5.8.6 Dispersion of refrigerant releases 180
5.8.7 Consequences of ignition 185
PART 6: WORKING ON SYSTEMS AND EQUIPMENT 189
6.1 TECHNICIAN ACTIVITIES AND REFRIGERANT HANDLING 189
6.1.1 Introduction 189
6.1.2 Risk assessment 190
6.1.3 General precautions for working 192
6.1.4 Accessing a refrigerant circuit 195
6.1.5 Refrigerant recovery 195
6.1.6 Refrigerant venting 197
6.1.7 Repair of leaks 198
6.1.8 Leak checking (for tightness testing) 299
6.1.9 Strength (pressure) testing 200
6.1.10 System evacuation 200
6.1.11 Charging 200
6.1.12 Repairs to electrical components 201
6.1.13 Routine system checks 202
6.1.14 Gas detection 203
6.1.15 Cylinder handling 203
6.2 INSTALLATION OF EQUIPMENT 205
6.2.1 Introduction 205
6.2.2 Preparation 205
6.2.3 Conformity to safety guidelines 205
6.2.4 Site work 208
6.2.5 Testing 208
6.2.6 Marking and documentation 208
6.3 COMMISIONING OF SYSTEMS AND INSTALLATIONS 209
6.3.1 Introduction 209
6.3.2 Commissioning requirements 209
6.3.3 Preliminary design aspects 210
6.3.4 Specification 211
6.3.5 Pre-commissioning 212
6.3.6 Refrigerant handling 214
6.3.7 Setting to work and adjustments 214
6.3.8 Start-up, shut-down and running-in 215
6.3.9 Handover and documentation 215
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