Safety Considerations for Adopting zero-ODP and low-GWP Refrigerants

Ozone2 Climate Technology Road Show and Industry Roundtable Beijing, China
Jay Kohler April 12, 2012

Safety Considerations for Adopting zero-ODP and low-GWP Refrigerants

Presentation will focus on the safe application of refrigerants to HVAC&R equipment I will also address environmental considerations My presentation will provide an update on some relevant ASHRAE safety Standards. This presentation has a US emphasis, but also touches on safety standards and applications in other regions.

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Considerations for Refrigerant Selection

Characteristics that Manufacturers Consider in the Selection of Refrigerants:

Performance- Efficiency and Capacity No Ozone Depleting Potential (ODP) Lowest Global Warming Potential (GWP) Practical Affordable for end-users Available Can be safely applied Focus of this presentation

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Environmental Considerations

Brief discussion of Global Warming considerations. GWP is important, but it is not the only consideration. In many cases, it is not even the most important consideration.

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How Can We Relate Performance to Low GWP?:

Indirect Effects

Safety Considerations Total Equivalent Warming Impact (TEWI)

Direct Effects

Cost Considerations

How Low is Low GWP?

Different types of equipment have different refrigerant requirements based on:

n
n Maintenance practices

GWP GWP >30 GWP > 100 GWP > 300

Classification Ultra-low-GWP Very low-GWP Low-GWP Moderate-GWP High-GWP Very High GWP Ultra-High GWP

n Application n Charge size n Leak rate

GWP > 1000 GWP > 3000 GWP > 10,000 GWP > 10,000

n Equipment life n Recovery / End of Life

n 95% of global HFC use is currently between 700 and 4000 GWP

(TEAP 2010)
Low and High GWP are relative terms, applications need to be treated differently

n TEAP proposed to classify GWPs by considering Use Patterns

Safety Considerations: Flammability and Toxicity of Refrigerants

ASHRAE Standard 15-2010

ASHRAE Standard 34-2010

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Designation and Safety Classification of Refrigerants ASHRAE Standard 34-2010 Toxicity Chronic Exposure measures Class A No known toxicity at < 400 ppm Class B Evidence of toxicity at < 400 ppm Based on PEL or OEL measures Acute Toxicity Reflected in the RCL (Refrigerant Concentration Limit), which looks at both flammability and toxicity measures

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Designation and Safety Classification of Refrigerants ASHRAE Standard 34-2010

Historical classification has included 6 safety groups, with three flammability groups

refrigerant safety groups higher flammability lower flammability no flame propagation

A3 A2 A1
lower toxicity

B3 B2 B1
higher toxicity

Designation and Safety Classification of Refrigerants ASHRAE Standard 34-2010

Flammability Classification Class 1 - No Flame Propagation Class 2 - LFL > 0.10 kg/m^3 and heat of combustion < 19 MJ/kg Class 3 - LFL 0.10 kg/m^3 or heat of combustion 19 MJ/kg

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Designation and Safety Classification of Refrigerants ASHRAE Standard 34-2010

Recently added was an optional flammability classification of 2L

refrigerant safety groups higher flammability lower flammability difficult to ignite and sustain no flame propagation

A3 A2 A2L A1
lower toxicity

B3 B2 B2L B1
higher toxicity new 2L

Designation and Safety Classification of Refrigerants ASHRAE Standard 34-2010

New 2L flammability classification Similar to class 2, except for an additional requirement. Refrigerant must have a maximum burning velocity of 10 cm/s (3.9 in./s) when tested at 23.0C (73.4F) and 101.3 kPa (14.7 psia). Combustion tests have shown burning velocity to be a significant parameter. As compared with refrigerants with a higher burning velocity, 2L refrigerants are:
More difficult to ignite Have a less stable flame Are less likely to cause a rapid pressure buildup (i.e. explosive event)

The 10 cm/s criterion is not reflective of a sudden change in combustion behavior, but rather is a convenient condition for differentiating combustion behavior of lower and higher burning velocity refrigerants

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Designation and Safety Classification of Refrigerants ASHRAE Standard 34-2010

Why the interest in 2L refrigerants? Need for low GWP refrigerants with short atmospheric lifetime Such refrigerants are less stable than other refrigerants. Need a balance of stability in refrigeration systems, short atmospheric lifetime, and flammability characteristics.

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Safety Standard for Refrigeration Systems ASHRAE Standard 15-2010

ASHRAE Standard 15-2010 provides requirements for the safe design, construction , installation, and operation of refrigeration systems. It is applied to buildings (stationary applications). Requirements based on three classifications: 1.Occupancy (Section 4) 2.Refrigeration System (Section 5) 3.Refrigerant (Section 6 & Standard 34)

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Safety Standard for Refrigeration Systems ASHRAE Standard 15-2010

ASHRAE Standard 15-2010 has limitations on the application of flammable and toxicity class B refrigerants. Section 7.5.2 Applications for Human Comfort. Group A2, A3, B1, B2, and B3 refrigerants shall not be used in high probability systems for human comfort (with some exceptions).

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Safety Standard for Refrigeration Systems ASHRAE Standard 15-2010

ASHRAE Standard 15-2010 has additional limitations on the application of flammable refrigerants including, but not limited to: 1.Restrictions for specific occupancies (Section 7.2) 2.Charge quantity limitations (Section 7.5.1) 3.Special machinery room requirements (Sections 7.4.2, 8.11, and 8.12) 4.Class 3 limitations (Section 7.5.3) 5.Relief valve discharge requirements (9.7.8) 6.Leak test requirements (9.14, 10.1)

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Safety Standard for Refrigeration Systems ASHRAE Standard 15-2010

ASHRAE Standard 15-2010 does not presently have requirements for class 2L refrigerants. The cognizant committee is evaluating such requirements. An Advisory Public Review was published in July 2011. Comments were received and will be taken into consideration for the next Public Review document. The committee is working towards a version of the standard that incorporates 2L refrigerants and can be referenced by US building codes.

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Safety Standard for Refrigeration Systems ASHRAE Standard 15-2010

ASHRAE Standard 15-2010 considerations for use of 2L refrigerants include: Existing Standard 15 structure and classification system, including use of RCL methodology to limit charge quantities in occupied areas Existing requirements for ammonia (R-744), which is now a 2L refrigerant and has a history of application in accordance with the standard Results of analysis and testing of 2L refrigerants. Those results show the difficulty in igniting and sustaining combustion, particularly in an environment with moving air. Need for an ignition source of sufficient energy and temperature Maximum quantity limitations, which are less restrictive than those for class 2 refrigerants

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Other Relevant Standards

ISO 817 - Refrigerants Designation and Safety Classification

n Requirements are similar to those of ASHRAE 34. Undergoing FDIS approval. Includes 2L classification, similar to ASHRAE 34.

UL-1995 - Heating and Cooling Equipment

n A working group is evaluating changes to incorporate 2L refrigerants

ISO 5149 - Refrigerating systems and heat pumps Safety environmental requirements
n A WG has been working for several years to update this standard. A FDIS version exists that includes 2L refrigerants

EN-378 - Refrigerating systems and heat pumps - Safety and environmental requirements
n Work is ongoing

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Safety Considerations: When can Flammable Refrigerants Be Used?

Flammable refrigerants will be applied as allowed by safety codes.

Experience in the industrial refrigeration sector as well as early adoption in northern European commercial AC &R sectors provides experience for the future.

Safe use in developing countries will require a significant amount of training and education throughout the supply and value chain. Infrastructure will need to be created to ensure safety codes and procedures are followed. Until this happens, HFCs and non-flammable HFO blends will need to remain available.

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Examples of Successful Commercial Applications for Flammable Refrigerants

London Heathrow T5 is cooled by ammonia chillers. Oslo, Gardamoen, and Copenhagen International Airports are cooled with NH3 District heating systems are being installed in Norway with ammonia heat pumps Aarhus University Hospital, Skejby in Denmark is cooled and heated by HC chillers and heat pumps. Hotel Scandinavia and the connected Aarhus Congress Centre in Aarhus installed NH3 chillers in 1996. McDonalds in Denmark has installed cascade system using HC and CO2 in their restaurants.
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When do Natural Refrigerants Make Sense?

Ammonia

CO2

HC Air-Cooled Chillers

Natural Refrigerants remain excellent solutions in some very specific applications: n Ammonia for refrigeration n C02 cascaded systems for supermarket refrigerators/freezers n Propane and isobutane in domestic refrigerators and appliances n Hydrocarbons in small packaged air-cooled equipment Energy efficiency of resulting systems must remain at HFC levels or better. System cost and application cost can be a barrier to adoption.
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When do HFOs and HFCs Refrigerants Make Sense?

Because of the requirements of safety, efficiency, and cost, synthetic refrigerants must remain an option in many regions and applications: n HFCs and Blends of HFOs and HFCs can provide highly efficient nonflammable solutions for developing regions. n Large commercial air-conditioning systems with significant charge amounts n Large refrigeration applications in densely populated areas Equipment Size and application will dictate types used: Most economical solution when higher GWPs can be tolerated

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The Influence of Affordability on Adoption: What Role will Installed Cost Play? In order to produce a competitive product manufactures must consider the following cost related to refrigerants:
Cost of refrigerant itself

Cost of an increases in heat exchange surface, compressor modifications, structural changes needed to meet or exceed capacity or efficiency requirements

The cost of any safety features or controls to ensure safe operation of the machine

The installed cost of any safety features or alarms that ensure safe application to the built environment

Maintenance and service cost over the life of the equipment

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How does the availability of refrigerant options affect short term decision making? Synthetic Refrigerants are used in many other applications than just stationary HVAC&R equipment. Often the justification for refrigerant manufacturers to bring a product to market depends on quantities well beyond our demand level.

While the various refrigerant companies have been actively researching new alternatives, very few, if any are available now in production quantities.

Industries such as mobile AC and the production insulating foams will dictate the timing and composition of synthetic refrigerants that enter the marketplace in the future.

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Summary

Manufactures must consider many factors when selecting future refrigerants. Global Warming concerns must consider broad measures such as TEWI. Safety codes presently address toxicity and flammability issues. New refrigerant flammability class of 2L exists in ASHRAE Standard 34. Safety codes are under revision to address 2L requirements. Those requirements will be less stringent than those for existing class 2 refrigerants. As we move toward natural refrigerants and flammable synthetic options, training, education, and safety codes will be essential for universal adoption. Synthetic refrigerants serve an important role where efficiency and safety are a primary concern.

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Questions?

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