Preparing for the F-gas regulation

F-gases (HFCs) do a wonderful job inside chillers, but they are very unkind to the environment if they escape. ADRIAN TREVELYAN explains the forthcoming regulation to contain F-gases — and how they are an opportunity rather than a threat.In six months’ time, on 4 July 2007, the F-gas regulation becomes law in Britain. However, many in the industry are still unclear if and how it will affect them. The main aims of the F-gas regulation are to reduce environmental damage from the leakage of F-gases used as refrigerants into the atmosphere and lifetime costs or air-conditioning systems. For many people, compliance should simply be a matter of changing the paperwork, as the F-gas regulation formalises what should already be good practice — keeping F-gases contained. Global-warming potential HFCs, which include R134a, R407C and R410A, are F-gases (fluorinated gases) and as such fall within the Kyoto Protocol because of their high global-warming potential (GWP)*. The F-gas regulation sets out to reduce emissions into the atmosphere by minimising leakage. Once contained, HFCs are the most energy-efficient refrigerant available. They are used throughout the stationary air-conditioning and refrigeration (ACR) industry in providing accurate and fail-safe cooling solutions to maintain critical services. As yet, there are no proven, safe and environmentally superior alternatives. The F-gas regulation can affect anyone who operates uses or installs ACR equipment that is charged with 3 kg or more of HFC refrigerant (or 6 kg if hermetically sealed). Those responsible must ensure: • ACR equipment is always leak-tight;
• anyone who handles refrigerant is fully certified;
• regular leak inspections are carried out on each item of plant;
• leaks are repaired as soon as possible after detection;
• a follow-up inspection is carried out one month after repairs;
• detailed records track refrigerant from design to disposal;
• F-gases are recovered during servicing and at end of plant life;
• new equipment is labelled with name and quantity of gas. Checking for leaks is normally carried out in two ways — direct, using electronic leak detectors and indirect, by monitoring operating conditions. The actual methods and requirements have yet to be specified, but the frequency of leak testing is clearly defined according to refrigerant charge (Fig. 1). Extra guidance is set out in a document available from DEFRA.† The brunt of responsibility is placed on the ‘operator’ of the equipment — who is defined as the person exercising actual power over the equipment and is likely to be the owner, even if there is a comprehensive maintenance contract in place. Clarification is needed at the outset, as it is the operator who will be responsible in the event of a breach of the regulation. It is in the operator’s interests to use competent, specialist contractors, installers and maintenance providers. All personnel handling refrigerant will need to be certified by 4 July 2007. It is expected that Britain will choose to use C&G 2078 or the CITB refrigerant-handling qualifications as the certification schemes. Every Airedale engineer handling refrigerant is, as a matter of course, properly qualified with the necessary skill card and training. Energy efficiency By formalising leak detection, the F-gas regulation also addresses energy efficiency. By far the biggest factor in the overall environmental impact of air conditioning over its lifetime is energy efficiency. A leaking system is less efficient and therefore uses more power to do less cooling. A 10% loss of gas increases energy consumption by up to 20% (Fig. 2).
Fig. 2: A beneficial side effect of the F-gas regulation is to prevent loss of chiller efficiency through undetected loss of refrigerant.
Considering the case of a conventional 150 kW chiller with electricity costing 5.5 p/kWh and estimated annual energy running costs of £18 467, even a 10% loss of gas and resultant 15% drop in EER would push running costs up by £3259. Compare this figure with the typical cost of a maintenance contract at £1800 for a whole year. Manufacturers are honing their products for maximum efficiency — which means containment from design, through manufacture to installation, commissioning, service and maintenance. Design features prevent leaks and manufacturing processes have changed considerably to encompass stringent testing of system integrity. In addition, sophisticated controls software is being developed for remote, intelligent leak detection. Specifiers already recognise their responsibility to design cooling to reduce the impact of the legislation on the operator and to specify equipment from a responsible manufacturer. We would like to see maintenance form part of the specification, levelling the playing field between those that previously included maintenance of the equipment and those that did not. Levels of penalties and the form of policing have yet to be decide, but it is in the interests of the industry to ensure containment works. The threat of an HFC ban when the EC review takes place in 2010 is ever present if the industry fails to deliver. Containment also buys time for the industry while it looks for safe, environmentally-friendly alternatives which can better the energy efficiency of HFCs. Adrian Trevelyan is service and maintenance manager with Airedale. * R134a has a global warming potential (GWP) of 1300 (i.e. 1300 times greater than carbon dioxide).
R407C is a blend of R134a, R125 (GWP 3400) and R32 (GWP 650). R410A is a blend of R32 and R125. † The DEFRA guidance document can be downloaded from: www.dti.gov.uk/innovation/sustainability/fgases/ page28889.html Details on all aspects of the F-gas regulation can be downloaded from: www.defra.gov.uk/environment/climatechange/ uk/fgas/index.htm You can view Airedale’s guidance document on www.airedaleservice.com



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