Professional Documents
Culture Documents
Copyright
INSTRUCTOR
Insert Instructor Name Here
Copyright
OBJECTIVES
Discuss Industrial Process Refrigeration. Discuss the Requirements of the Refrigerant Recycling Rule. Discuss How to Determine Full Charge of A System.
Copyright
GOALS
Understand Industrial Process Refrigeration. Understand the Requirements of the Refrigerant Recycling Rule. Be Familiar With How to Determine Full Charge of A System. Understand How to Calculate Leak Rate. Understand When to Make Leak Repairs. Understand the Requirements for Retrofit and Retirement. Understand the Requirements for Oil Changes. Understand Disposal Requirements. Be Familiar With Required Reports and Recordkeeping.
Refrigerant Compliance Management 4 / 63
Copyright
BACKGROUND
Ozone depleting substances (ODS) are found in certain refrigerants manufactured before 1995. The United States and over 150 other countries signed the Montreal Protocol that pledges the phasing out of ODS by the end of 1995. EPA is authorized to assess fines of up to $27,500 per day for any violation of ODS regulations.
Copyright
LEARNERS
Supervisors
Facility Engineers
Maintenance Personnel Department Managers
Building Occupants
Process Specialists Environmental and Safety Committees
Copyright
OVERVIEW
The goal of this course is to provide supervisors with the tools needed to stay in compliance with the Clean Air Act Amendments relevant to industrial process refrigeration systems. It recommends practical, actions that can be carried out by facility management, maintenance personnel and building occupants. The course will help you to integrate good industrial process refrigeration management activities into your existing organization and identify which of your staff have the necessary skills to carry out those activities.
Refrigerant Compliance Management 7 / 63
Copyright
Copyright
Copyright
FEDERAL REGULATIONS
Pertinent Regulations: 40 CFR Part 82, Subpart F
Copyright
REQUIREMENTS
Require service practices that maximize recycling of ozone-depleting compounds (both chlorofluorocarbons [CFCs] and hydrochlorofluorocarbons [HCFCs] and their blends) during the servicing and disposal of airconditioning and refrigeration equipment Set certification requirements for recycling and recovery equipment, technicians, and reclaimers Restrict the sale of refrigerant to certified technicians Require persons servicing or disposing of airconditioning and refrigeration equipment to certify to EPA that they have acquired recycling or recovery equipment and are complying with the requirements of the rule
Refrigerant Compliance Management 11 / 63
Copyright
REQUIREMENTS
Require the repair of substantial leaks in airconditioning and refrigeration equipment with a charge of greater than 50 pounds Establish safe disposal requirements to ensure removal of refrigerants from goods that enter the waste stream with the charge intact (e.g., motor vehicle air conditioners, home refrigerators, and room air conditioners)
Copyright
APPLICABILITY
Industrial process refrigeration used in the chemical, pharmaceutical, petrochemical, and manufacturing industries This sector also includes industrial ice machines, appliances used directly in the generation of electricity, and ice rinks The refrigerant recycling rule applies to systems that contain and use a class I or class II substance as a refrigerant: Class I refrigerants are mostly chlorofluorocarbon (CFC) refrigerants or any mixture containing a CFC Class II refrigerants are hydrochloro-fluorocarbon (HCFC) refrigerants or any mixture containing an HCFC
Refrigerant Compliance Management 13 / 63
Copyright
APPLICABILITY
Applicability Triggers The leak repair requirements of this regulation are triggered when an owner or operator of an industrial process refrigeration system discovers that refrigerant is leaking at a rate that would exceed 35 percent of the total charge in a 12-month period
Copyright
APPLICABILITY
Trigger Rates For all systems that have a refrigerant charge of more than 50 pounds:
SYSTEM Commercial refrigeration Industrial process refrigeration Comfort cooling All other refrigeration
Copyright
APPLICABILITY
EXEMPTIONS OR EXCLUSIONS Leak repair provisions of this regulation do NOT affect systems normally containing 50 pounds or less of refrigerant
Copyright
PROHIBITION ON VENTING
Section 608 of the Act prohibits individuals from knowingly venting ozone-depleting compounds used as refrigerants into the atmosphere Only four types of releases are permitted under the prohibition: 1. "De minimis" quantities of refrigerant released in the course of making good faith attempts to recapture and recycle or safely dispose of refrigerant 2. Refrigerants emitted in the course of normal operation of air-conditioning and refrigeration equipment such as from mechanical purging and leaks
Refrigerant Compliance Management 17 / 63
Copyright
PROHIBITION ON VENTING
3. Releases of CFCs or HCFCs that are not used as refrigerants 4. Small releases of refrigerant that result from purging hoses or from connecting or disconnecting hoses to charge or service appliances will not be considered violations of the prohibition on venting
Copyright
RECLAMATION REQUIREMENT
EPA has also established that refrigerant recovered and/or recycled can be returned to the same system or other systems owned by the same person without restriction If refrigerant changes ownership, however, that refrigerant must be reclaimed Refrigerant used in MVACs and MVAC-like appliances is subject to the purity requirements of the MVAC regulations at 40 CFR Part 82 Subpart B EPA updates the list of reclaimers as new companies are added.
Refrigerant Compliance Management 19 / 63
Copyright
EQUIPMENT CERTIFICATION
EPA has established a certification program for recovery and recycling equipment EPA has approved both the Air-Conditioning and Refrigeration Institute (ARI) and Underwriters Laboratories (UL) to certify recycling and recovery equipment Certified equipment can be identified by a label reading: "This equipment has been certified by ARI/UL to meet EPA's minimum requirements for recycling and/ or recovery equipment intended for use with [appropriate category of appliance--e.g., small appliances, HCFC appliances containing less than 200 pounds of refrigerant, all high-pressure appliances, etc.]"
Copyright
TECHNICIAN CERTIFICATION
EPA has established a technician certification program for persons ("technicians") who perform maintenance, service, repair, or disposal that could be reasonably expected to release refrigerants into the atmosphere The definition of "technician" specifically includes certain activities as follows: attaching and detaching hoses and gauges to and from the appliance to measure pressure within the appliance; adding refrigerant to or removing refrigerant from the appliance any other activity that violates the integrity of the MVAC-like appliances, and small appliances.
Refrigerant Compliance Management 21 / 63
Copyright
TECHNICIAN CERTIFICATION
Apprentices are exempt from certification requirements provided the apprentice is closely and continually supervised by a certified technician The Agency has developed four types of certification: 1. For servicing small appliances (Type I). 2. For servicing or disposing of high- or very highpressure appliances, except small appliances and MVACs (Type II). 3. For servicing or disposing of low-pressure appliances (Type III) 4. For servicing all types of equipment (Universal). Technicians are required to pass an EPA-approved test given by an EPA-approved certifying organization
Refrigerant Compliance Management 22 / 63
Copyright
Copyright
CERTIFICATION
Certification by Owners of Recycling and Recovery Equipment EPA requires that persons servicing or disposing of air-conditioning and refrigeration equipment certify to the appropriate EPA Regional Office that they have acquired recovery or recycling equipment and that they are complying with the applicable requirements of this rule This certification must be signed by the owner of the equipment or another responsible officer and sent to the appropriate EPA Regional Office
Copyright
RECLAIMER CERTIFICATION
Reclaimers are required to return refrigerant to the purity level specified in ARI Standard 700-1993 Reclaimers must release no more than 1.5 percent of the refrigerant during the reclamation process and must dispose of wastes properly Reclaimers must certify to the Section 608 Recycling Program Manager at EPA headquarters that they are complying with these requirements and that the information given is true and correct EPA encourages reclaimers to participate in a voluntary third-party reclaimer certification program operated by the Air-Conditioning and Refrigeration Institute (ARI) EPA maintains a list of approved reclaimers
Refrigerant Compliance Management 25 / 63
Copyright
FULL CHARGE
The full charge is the amount of refrigerant necessary for an industrial process refrigeration system to operate at normal operating characteristics and conditions There are two reasons why you need to know how much refrigerant is in the full charge for a system: 1. The leak repair requirements of this law do not apply to any system whose full charge is 50 pounds or less of refrigerant in any independent refrigerant circuit 2. To calculate the leak rate for a system, you need to know the full charge
Refrigerant Compliance Management 26 / 63
Copyright
FULL CHARGE
To determine the full charge, you must use one of the following five methods: 1. Measure the refrigerant 2. Calculate the weight of the refrigerant charge in the system 3. Use the manufacturer's information 4. Establish range 5. Use a combination of 1-4
Copyright
LEAK RATE
Each time you add refrigerant to a system normally containing 50 pounds or more of refrigerant, you should promptly calculate the leak rate. If the leak rate is higher than the trigger rate, you are required to do one of the following: a. Repair leaks; b. Retrofit the system; or c. Retire the system from service.
Copyright
LEAK RATE
Four Steps to Calculating a Leak Rate 1. #lbs refrigerant added #lbs refrigerant in normal full charge
Copyright
LEAK RATE
Calculating a Leak Rate continued 3. Take the number you determined in step 1 and divide it by the number you determined in step 2. 4. Multiply the number you determined in step 3 by 100 (to calculate a percentage).
Copyright
LEAK RATE
Timing After refrigerant is added, you should calculate the leak rate as soon as you can If the system is leaking above the trigger rate, the law imposes strict deadlines for repairing the leaks or retrofitting or retiring the system For example, if you wait three days to determine the leak rate, there will be three less days available to solve the problem
Copyright
LEAK RATE
Purged Refrigerant In calculating the leak rate, you may exclude purged refrigerant that is destroyed A destruction efficiency of at least 98 percent is required There are monitoring, recordkeeping, and reporting requirements
Copyright
LEAK RATE
Recordkeeping/Reporting Keep records that show: 1. The date and type of service; 2. How much refrigerant was added; and 3. The date when the refrigerant was added It may be required and is always advisable to keep records of the full charge and leak rate
Copyright
LEAK REPAIR
If a system is leaking above the trigger rate, leak repairs are required within 30 days of discovery Repairs must bring the annual leak rate below the trigger rate Leak repairs are not required if you retrofit or retire the system
Copyright
LEAK REPAIR
Industrial Process Shutdown When an industrial process shutdown is needed to repair leaks from industrial process refrigeration systems, a 120-day repair period (rather than a 30-day period) is allowed.
Copyright
LEAK REPAIR
Unavailable Repair Parts or Other Regulations That Require Additional Time Additional time beyond the 30- or 120-day time periods is allowed to conduct leak repairs if the necessary repair parts are unavailable or if other applicable federal, state, or local regulations make a repair within 30 or 120 days impossible EPA must be notified if repairs cannot be completed within 30 or 120 days of discovery Only the additional time needed to receive delivery of the necessary parts or comply with the pertinent regulations will be permitted
Copyright
LEAK REPAIR
Repair Verification: There is a requirement to verify the success of leak repairs for industrial process refrigeration systems Two tests, called initial and followup verification tests are required for each repair site A successful test verifies that a leak has been repaired
Copyright
LEAK REPAIR
What are these tests for? The primary purpose of the initial verification test is to verify that a leak or leaks have been repaired before refrigerant is added back to the system Even when the system is not evacuated to complete repairs, initial and follow-up verification tests are required The primary purpose of the follow-up verification test is to re-verify that repairs continue to hold after the system is returned to its normal operating Characteristics or conditions
Copyright
LEAK REPAIR
Initial Verification Test An initial verification test must be conducted following any leak repairs A refrigeration system may not be brought back on line (if it has been taken off line), unless a) an initial verification test indicates that repairs have been successfully completed or b) a decision to retrofit or retire is made. The initial verification test must be conducted before the replacement of the full charge of refrigerant In systems that have not been evacuated, the initial verification test must be conducted as soon as practicable after the repair work is completed
Refrigerant Compliance Management 39 / 63
Copyright
LEAK REPAIR
Follow-up Verification Test A follow-up verification test must be conducted: Within 30 days after the initial verification test, where normal operating characteristics or conditions have been maintained; or Within 30 days of bringing the system back on line, if taken off line, and where the system is operating at normal operating characteristics or conditions. In certain cases the results of a follow-up verification test may be less reliable if the test is conducted at normal operating characteristics or conditions
Copyright
LEAK REPAIR
Initial and Follow-up Verification Test Methods Initial and follow-up verification tests may use any method that meets sound professional judgment Examples include: A soap bubble test; or Electronic leak detectors; or Ultrasonic leak detectors; or A pressure test; or A vacuum test; or A fluorescent dye and black light test; or An infrared test or near infrared; or Halon refrigerant gas detection methods
Refrigerant Compliance Management 41 / 63
Copyright
LEAK REPAIR
Unsuccessful Tests If you have an unsuccessful follow-up verification test, you must notify EPA and develop a retrofit or retirement plan within 30 days of the failed test If it is going to take you more than one year you must also submit the plan If the follow-up verification test indicates that the repairs to the system have not been successfully completed, the owner or operator is required retrofit or retire the system There are some options where the owner or operator is relieved of the obligation to retrofit or retire the system
Refrigerant Compliance Management 42 / 63
Copyright
LEAK REPAIR
Activity Technician Required? Evacuating the refrigerant Yes Adding refrigerant Yes Changing the oil Yes Adding oil Yes Replacing a gauge Yes Changing or calibrating a DP cell Yes Changing a pressure-relief valve Yes Drawing a sample of refrigerant or oil Yes
Copyright
LEAK REPAIR
Activity Helping dismantle a system for disposal
Any of the tasks listed so far, performed under the direct supervision of a certified technician Maintenance that would not reasonably release refrigerant Fixing leaks by tightening nuts or bolts, if no specific reason to think the activity may go wrong and increase the rate of release Any work on the system after the refrigerant has been evacuated
Technician Required?
Yes Yes No
No
No
Copyright
Copyright
continued
Refrigerant Compliance Management 46 / 63
Copyright
Copyright
Copyright
SYSTEM MOTHBALLING
System mothballing is the intentional shutdown of a refrigeration system for an extended period of time, where the refrigerant has been evacuated from the system to at least atmospheric pressure When a refrigeration system is in a mothballed condition, refrigerant leaks that existed when the system was operating have effectively been stopped because the system has been evacuated The time-related requirements resume on the day the system is brought back on line and is no longer considered mothballed Leak repairs following mothballing on industrial process refrigeration systems are still subject to initial and follow-up verification tests
Refrigerant Compliance Management 49 / 63
Copyright
SYSTEM MOTHBALLING
Applicability When a system is mothballed, the time suspensions are available for all types of systems, including commercial, industrial process, and any other systems containing more than 50 pounds of refrigerant Time suspensions under system mothballing apply to all time-related requirements for repairing leaks or replacing, retrofitting, or retiring a system, including time extensions that may be allowed in specific circumstances for industrial process refrigeration systems
Copyright
SYSTEM MOTHBALLING
System mothballing requires the refrigerant to be removed from the system to at least atmospheric pressure If the owner or operator intends to make repairs to the system that require opening the system, the refrigerant must be removed to the required evacuation levels for that refrigerant before the system is opened
Copyright
SYSTEM MOTHBALLING
Example of System Mothballing If the system operated for five days after discovery of the exceedance of the leak rate and then was shut down and mothballed for two months, when the system returned to operating, the owner would still have 25 days to either repair the leaks or develop a 12-month retrofit or retirement plan
Copyright
OIL CHANGES
EPAs refrigerant recycling amendments also address procedures to minimize emissions of refrigerant during oil changes The oil in a refrigeration system may contain large amounts of refrigerant EPA requires a reduction in pressure prior to an oil change so that the bulk of the refrigerant is recovered The maximum pressure allowed is 5 psig
Copyright
OIL CHANGES
There are two acceptable procedures to assure recovery of refrigerant: 1. Evacuate the refrigeration system, or isolated portion, to a pressure no higher than 5 psig and then remove the oil; or 2. Drain the oil into a system receiver to be evacuated to a pressure no higher than 5 psig
These procedures minimize the loss of refrigerant from: a) the oil, and b) the interior of the refrigeration system as the oil comes out
Refrigerant Compliance Management 54 / 63
Copyright
Copyright
Copyright
Copyright
Copyright
Copyright
Copyright
Copyright
Copyright
Copyright