HVAC&R Nation February/March 2021 by AIRAH

Homage to Harrison The quest to honour Australia’s father of refrigeration

Skills

WORKSHOP

Performance tests for chillers

It’s a blast! New cold store and blast-freeze facility achieves energy-efficiency excellence

February–March 2021 / ISSUE 136

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February–March 2021 / ISSUE 136

It’s a blast! 20

HVAC&R Nation is published by the Australian Institute of Refrigeration, Air conditioning and Heating (Inc). AIRAH – National Office James Harrison Centre 3/1 Elizabeth Street, Melbourne VIC 3000, Australia. Tel: 03 8623 3000

Fax: 03 9614 8949

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Magazine team Communications Manager Matthew Dillon matt.dillon@airah.org.au Tel: 03 8623 3000 Editor Mark Vender mark.vender@airah.org.au Tel: 03 8623 3001 Contributing writers Danny Chan Sean McGowan Willow Aliento

A new cold store and blast-freezing facility in Melbourne’s west is delivering big energy savings thanks to an innovative, low-charge ammonia refrigeration system. Sean McGowan reports.

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Glenn Douglas glenn.douglas@airah.org.au Tel: 0411 839 667

John McGrath john.mcgrath@airah.org.au Tel: 0419 556 108

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HVAC&R Nation is printed on paper sourced from well manned forests and other controlled sources.

HVAC&R Nation is an official publication of the Australian Institute of Refrigeration, Air Conditioning and Heating Inc. Statements expressed in HVAC&R Nation do not necessarily reflect the policy or views of AIRAH or its members. No responsibility is accepted by AIRAH, the Editor or HVAC&R Nation’s supply partners for the accuracy of information or for errors or omissions. HVAC&R Nation is distributed without charge to all financial members of AIRAH.

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The Toolshed

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Industry news from around the world

Exclusive to this issue

Full-timers or contractors? We analyse the pros and cons

AIRAH News

Researching affordable heating and cooling with i-Hub

Industry News

The rebate for recovered refrigerant has just tripled

Around the Nation

Who’s in the news?

Smoko with …

Homage to Harrison

He invented mechanical refrigeration right here in Australia, and yet James Harrison remains virtually unknown in this country. We look at the efforts to honour a legend.

Q&A with Shivanhi Nair

Green Wedge

Refrigerated transport goes solar

Lighter Side

The shonkier side of the nation February–March 2021

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Ed’s letter

HERE’S TO HARRISON The stories in HVAC&R Nation begin in many different ways, but there is always one moment when I become convinced it’s a story worth telling. For our feature story on page 10, “Homage to Harrison”, that moment came when I got a call from a gentleman who wasn’t even in our industry, but had something to tell me about a James Harrison monument at Rocky Point, near Geelong.

was a symbol of just how neglected James Harrison is as a pioneer in this country. I knew then that we had to write something about it. At the same time, we were talking to a dedicated group of historians and locals who have tried to establish a James Harrison Museum at Rocky Point. I’ll let you read the story to find out how they fared, but I will say that they’ve organised an exhibition and a live-streamed chat as part of Geelong Design Week in March this year. I’ll be checking it out, and I encourage you to do the same.

Now before we get into this, I’m assuming you all know who James Harrison is. If you don’t, go to your fridge, open it and say: “Thanks James”. He led the development of mechanical refrigeration, and built his first ice-making machine at Rocky Point (hence the monument). And yet, he is sadly almost unknown in this country. So, on with the story … The aforementioned gentleman had texted me a photo of a cairn at Rocky Point dedicated to James Harrison. He’d found it a few years earlier, when he was walking his German Shephard near the Barwon River. At that time, he said, the whole area was overgrown with weeds and grass and he assumed his dog had gone in there to sniff out a dead animal. But on closer inspection he found the plaque. For some reason it had fallen into disrepair and been forgotten. For me it

Suffice to say, Harrison is still waiting for recognition. Over the years, people have tried to shine a light on the man and his achievements, not just as a pioneer of refrigeration, but also as a newspaper editor and a local politician. AIRAH has named a medal after him, which we present at our annual awards show. Our HQ is also known as the James Harrison Centre. But is there a way to give him more mainstream recognition?

Maybe we could find a place for him on one of our Australian dollar notes, start a campaign to put “Harrison on the hundred”. Although these days, in our almost cashless society, that mightn’t make much of a difference. My only other idea is to set up a James Harrison museum as part of a brewery bar. It would allow some historic items to be preserved and enjoyed by lots of people. And what better way to celebrate his work than by raising a glass of beer, cooled by the system that he originally invented? Cheers James – this one’s for you! ■ @AIRAHnews

Mark Vender Editor mark.vender@airah.org.au

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HVAC&R Nation

Toolshed 1

Great wall

Daikin has expanded its Super Multi NX (R32) indoor unit range to include a designer wall-mounted series. The R32 designer wall-mounted CTXJ series has a compact design with a depth of 185mm. The units are available in four models ranging from 2.5kW to 6.0kW with the option of a White Hair Line or Black Wood finish.

Inova is looking for suitable pilot programs to demonstrate the value of the system in the Australian environment, and welcomes enquiries from industry professionals.

The Condair DA desiccant dehumidifier range includes capacities from 0.6 to 182L/Hr (@20°C/60%RH) from its standard models with customised units able to meet larger drying requirement.

Dwyer handles the heat

The multi-purpose 3000MR/3000MRS Photohelic device contained in the Series AT-3000MR/MRS is designed for monitoring pressure, vacuum, and differential pressure. Solid‑state switches allow for switching in high-cycle rate applications and are designed to extend the life of the sensor. These products can be installed in varying process or HVAC applications globally because of the numerous pressure ranges and units available. Suitable for industrial applications, the Series AT-3000MR/MRS incorporates a cast aluminium enclosure with texture epoxy coating. It also features a standard windowed enclosure cover that allows users to visually verify changes in the process.

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Manufactured by Swedish technology company Enjay, the patented system purportedly features technology that enables the heat exchanger to survive in harsh kitchen environments requiring little ongoing maintenance. Lepido is available in multiple sizes with flows ranging from HVAC&R Nation

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The system can be separated into a fan unit and heat exchanger. The company says this makes installation within the roof cavity of existing homes easier. An optional Truss Transition Kit can assist when installing the indoor unit around and between existing roof trusses.

Go to: www.fujitsugeneral.com.au ■

Inova has announced the Australian release of Lepido, a system that recovers energy from restaurant and kitchen ventilation.

Fujitsu General is adding an 18kW high‑static three-phase ducted air conditioner to its Infinity range. This will provide installers with a new option for projects with limited space outdoors and in the ceiling cavity.

The new 18kW Infinity ducted air conditioner is compatible with zone control and the Fujitsu General anywAiR technology ducted controller. Zone control ensures different areas in a unit or home can be set up for optimal indoor comfort and energy management.

Go to: www.daikin.com.au ■

According to Inova, the system recovers energy from waste kitchen exhaust air, and generates both heating and cooling outputs in order to lower buildings’ energy consumption and reduce CO2 emissions.

Infinity and beyond

This 18kW option includes a narrow 480mm outdoor unit and lightweight (69kg) indoor unit. The narrow outdoor unit provides more options when finding a suitable location, while the lightweight indoor unit offers installation flexibility and is less labour-intensive.

The R32 SkyAir Compact Cassette range consists of five models from 2.5kW to 7.1kW. End-users can control the system from their mobile or tablet device via the optional Airbase WLAN module (BRP15B61). The app is available for both Apple and Android devices and supports up to 10 indoor units connected to the same network. Each unit requires an adapter.

Ceiling-mounted models enable installers to either integrate the unit in a suspended ceiling system or simply fix it overhead to avoid taking up floor space. Dehumidifying capacities range from 49 to 190L/24hr (@30°C/80%RH). Go to: www.condair.com.au ■

Daikin has launched the Compact R32 SkyAir Cassette, in line with its commitment to release more products with low‑GWP refrigerant R32.

Units can incorporate on-board touch screen PLC controllers with high-level supervisory connectivity. For process airflow greater than 500 m3/hr (DA-500), AC or EC fans are available, with the regeneration fan positioned prior to the desiccant rotor in a push configuration. The company says this avoids contact between the fan and the hot humid exhaust air, prolonging the life of the fan. The rear wall-mounted systems can be remotely located in a room adjacent to the area being dehumidified. Humid air is circulated to the dehumidifier and dry air fed back to the room via the rear wall connection.

Go to: www.dwyer-inst.com.au ■

Condair expands range

Humidity control specialist Condair has extended its dehumidifier range to include more desiccant models, wall- and ceiling-mounted systems, and units that control temperature as well as humidity.

Go to: www.daikin.com.au ■

The Dwyer Series AT-3000MR/MRS, an ATEX/IECEx approved Photohelic switch and gauge, incorporates a flame-proof aluminium enclosure that protects the device for use in hazardous areas commonly found in process or industrial applications.

Go to: www.inovacorp.co ■

The CTXJ Series also features built-in wi-fi; Daikin Flash Streamer Technology for improved indoor air quality; Intelligent Eye human presence sensor; Grid Eye Sensor to ensure even temperature when heating; and quiet operations of 19dBA.

800–5,000L per second of exhaust air. Applications include restaurants, clubs, health and aged-care facilities, shopping centre food courts, and maritime vessels.

February–March 2021

Air defence

The AP BIO air purifier comes from Fläktgroup, a European supplier of energy-efficient indoor air technology solutions. The air purifier is available in three sizes: 500, 1,000 and 2,400m³/h. All feature the AirFend technology that is designed to filter and eliminate bacteria and viruses. AP BIO is a three-stage filtration air purifier that purportedly delivers Biocell deactivation of bacteria and viruses in a short time period.

Toolshed Tested according to the EN14476 + A2-07-2019, the unit is said to hold back 99.995 per cent of all pollutants and offer a safe solution against COVID-19 with its HEPA14 filter.

Sentinel is recommended for use in indoor environments without openable windows – where it can purportedly reduce the risk of airborne transmission by over four times.

The company says that the biologic AirFend technology can minimise the risk of transmission by deactivating virus‑contaminated aerosols, the main carriers for coronaviruses.

Go to: www. www.halton.com ■

The AP BIO is distributed in Australia by Vekavent. Go to: www.vekavent.com.au ■

Camfil’s ProSafe range of filters is designed to be compliant to safety, traceability and control demands within the food processing and life science industries.

Sentinel against virus

The filters are manufactured with materials that comply with European Food Contact Regulation (EC) No 1935:2004. According to Camfil, the ProSafe filter range is free of toxic chemicals bisphenol A, phthalates and formaldehyde and resistant to cleanroom decontamination and cleaning procedures (including hydrogen peroxide and other commonly used agents).

Halton has designed Sentinel, a mobile ultraviolet germicidal irradiation (UVGI) solution to minimise viral spread and protect personnel and guests in indoor spaces. According to the indoor air solutions company, the new mobile filtration unit complements and enhances the effectiveness of current mitigation practices – such as social distancing, respiratory masks, hand washing and updated sanitation practices. With a long history as a tool for minimising viral spread, UVGI products are popularly used in the health-care segment. “Through careful selection of UV tube glass and safety controls, the wavelength of the UV light emitted in the Halton Sentinel UVGI unit specifically targets the COVID-19 virus without producing the respiratory irritant, ozone,” says Halton.

Play it safe

The products also conform to BRCGS global standards for food safety, and are fully compliant with the ISO 846:2019 anti‑microbial growth standard and the VDI 6022 hygiene in HVAC systems standard.

ProSafe HVAC and HEPA filters are suitable for use in air conditioning and ventilation systems, as pre-filtration for cleanroom applications and within terminal housings, cleanroom ceilings or laminar airflow benches.

“Air from the room is drawn into the Sentinel filtration unit for the critical exposure dose of UV to inactivate viral, bacterial, and fungal organisms and then the treated air is filtered through MERV 13 filters for return to the room.”

The ProSafe filter range is now available from Camfil Airepure nationally. Go to: www.camfil.com ■

DO YOU HAVE A NEW PRODUCT TO GO IN THE TOOLSHED?

Email mark.vender@airah.org.au All submissions received will be considered, though publication cannot be guaranteed.

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5/02/2021 3:59:52 HVAC&R NationPM| 7

Global Update

KENYA

USA

PLANETARY GAME PLAN

ROAD TO KIGALI

The United Nations is bringing a message on the importance of the ozone layer to the gaming and animation world. Developed by the Nairobi-based UN Ozone Secretariat, Reset Earth is the name of a mobile game and animation film designed to educate adolescents about the fundamental role of the ozone layer in protecting the planet. Featuring hand-drawn graphics, the single-player mobile game challenges players to solve puzzles about environmental history and the science of protecting the planet. Set in a post-apocalyptic world circa 2084, where the ozone layer has been damaged, the film follows the mission of three time-traveling teenagers to save the planet from an unstoppable virus. To save the ozone layer, they must ensure the signing of the Montreal Protocol agreement. Both the game and film are part of the Reset Earth educational platform that launched on World Education Day (January 24). ■

US President Joe Biden has set the wheels in motion for his country to ratify the Kigali Amendment for the phasing down of HFCs. It was announced among a raft of measures aimed at addressing climate change. Biden directed his administration to prepare to send the Kigali Amendment to the Senate for its advice and consent to US ratification. It was just one of the orders signed on “Climate Day” at the White House, which together signal a radically different approach to environmental issues to the outgoing administration. “We have already waited too long to deal with this climate crisis, we can’t wait any longer,” said Biden. If the US does ratify, it may prompt China and India to follow suit. Although both countries have developed domestic phase-down plans, they are conspicuously absent from the list of ratifying countries, which now numbers more than 110. ■

CANADA

INDIA

SAVINGS FROM WASTEWATER

EYES ON THE PRIZE

A Moncton-area utility is rolling out plans to heat buildings using the sewage and wastewater it treats.

The teams competing in the Global Cooling Prize have completed the field test portion of the prize, and have now started lab testing at CEPT University.

TransAqua’s existing wastewater treatment process involves blowing warm air into the water to help break down organic material, raising its temperature to 10°C.

Following delays caused by the pandemic, field testing began last October at the Tata New Haven site in Bahadurgarh. Due to COVID-19, the units were installed and virtually commissioned via livestream to the finalists.

In an effort to cut power consumption and greenhouse emissions, the utility wants to tap into the material’s thermal energy via a heat recovery system. “We need to think outside the box and say, how can we reduce our greenhouse gas emissions even more?” says TransAqua’s general manager Kevin Rice. According to Rice, the new system is expected to reduce the facility’s net greenhouse gas emissions by approximately 22 per cent. “Instead of using our expensive air conditioning systems and expensive heat systems,” he says, “the amount of temperature that’s drawn from the wastewater would be able to reduce costs significantly.” ■ 8

HVAC&R Nation

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February–March 2021

In November 2019, eight finalists were chosen and each awarded US$200,000 to develop and ship their prototypes to India for testing. The prototypes are now undergoing a test of simulated full-year operation at the CEPT University lab. The innovation competition seeks to incentivise development of a residential cooling solution with at least five times less climate impact than existing standard room ACs. Participants include major manufacturers, start-ups and corporations, and one university. Winners will be announced at a virtual award ceremony in April 2021. ■

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Feature

HOMAGE TO HARRISON Sir Don Bradman has one, so does Saint Mary McKillop, Norman Lindsay, and Bert Hinkler. So why isn’t the story of James Harrison, the father of refrigeration, told in a museum? As Sean McGowan reports, one dedicated group is working towards this goal. After ascending to the role of editor, Harrison was sent south-west to Geelong where he established another of Fawkner’s titles, the Geelong Advertiser, in 1840. He would go on to own the Advertiser by September 1842.

Imagine the heady days of colonial life – a time when industrialisation was transforming the Australian economy and bringing the world a step closer. A Scotsman by birth and printer by trade, James Harrison found a country still 64 years shy of federation when he emigrated to Sydney in 1837.

A man of many talents and interests, Harrison played a distinguished role in public office too – first as an inaugural member of Geelong’s first town council in 1850, and then as a representative of the Geelong and Geelong West electorates in the Victorian Parliament.

The then 21-year-old, having completed a printing apprenticeship in London, responded to an advertisement by London-based company Tegg & Co. for a compositor to join its Sydney office. Thus began Harrison’s contribution to Australia’s print media. Following contributions to Tegg & Co.’s short‑lived Literary News, and a stint with the Sydney Herald, Harrison headed south to Melbourne where he found work as a compositor with the Port Phillip Patriot. The Patriot was one of many print titles established by the city’s founding father, John Pascoe Fawkner. 10

HVAC&R Nation

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But it was Harrison’s interest in science that led him to his perhaps his greatest achievement. It started when he recognised there might be other uses for sulphuric ether than just for cleaning the removable type on his printing press. Experiments with the ether and a whorl coil from a heating apparatus followed.

February–March 2021

He was onto something, and after joining forces with blacksmith John Scott, the duo established an ice works on the banks of the Barwon River at Rocky Point (more about that location later). Harrison’s ether-vapour compression refrigeration system used a compressor to force ether through a condenser where it cooled and liquefied. The liquefied gas was then circulated through refrigeration coils, and vapourised again, cooling down the surrounding machine. In 1854, the first mechanically-made ice was made, and within a year Harrison had submitted his first patent titled Refrigerating Machine. According to Dr Roy Lang’s book James Harrison – Pioneering Genius, Harrison named ether or alcohol as the refrigerants and gave special directions for the use of ammonia or other gaseous solutions.

Feature and the process, and sought steam engineering expertise. There, he commissioned engineers Siebe & Co. to build a new version of his original machine at Rocky Point at a cost of £1,200. The first commercial Harrison-Siebe refrigeration machine was sold in 1857 to a London brewery. Further improvements and sales quickly followed and by 1861, Harrison’s refrigeration machines were in use around the world.

Harrison received medals of commendation from exhibitions in London (1863) and Melbourne (1873) where he showed his refrigeration machines. He also won a prize from the Geelong and Western District Agricultural and Horticultural Society for his “Self-acting beer preserver” in 1863.

“The purposes were the manufacture of ice from water, either pure or salt; the preservation of provisions by congelation; the cooling of buildings; and generally for the reduction of temperature wherever required. “…this 1855 machine costing over £1,000 had a capacity of 3,050kg of ice per day and was driven by a 3.5 horsepower engine.” Harrison’s concept would come to be the forerunner of our extensive HVAC&R industry. Committed to improving his machine, Harrison set out for London where he patented both his machine

Returning to Melbourne with a new 10hp (7.457kW) machine in tow, Harrison began producing slabs and blocks of ice of various weight and in 1859, founded the Victoria Ice Works in Franklin Street. A year later, he co-founded the Sydney Ice Company with another machine.

FINDING RECOGNITION Although Harrison’s invention did not bring him sustained personal financial success, his creativity and ingenuity should always be remembered. Today he is mainly recognised by those in the HVAC&R industry as the father of refrigeration. AIRAH’s head office in Melbourne – the James Harrison Centre – is named in his honour.

This plaque was unveiled at Rocky Point in 1997.

But it remains somewhat of a surprise to find that Harrison’s story is not more widely known or told – or that his name is not held among the most adored of pioneering Australians. “It says something about our society that there is so little acknowledgement of this great figure,” former Victorian Premier John Brumby once said of Harrison and his work.

So too is the highest honour AIRAH can bestow on an individual – the James Harrison Medal, one of the highlights of the Institute’s annual awards.

Every school student in the country should

Then there’s the Harrison Bridge over the Barwon River in Geelong, and a bronze marker on the river’s bank recognising the site of that historic ice works.

know his name.

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Feature An architect’s impression of the proposed James Harrison Museum at Rocky Point, Geelong.

“I thank AIRAH and its members for that support, as the industry would be poorer without the inspiration of James Harrison,” says Hobbs. Despite the committee’s best efforts, it fell well short of the funding required to build and maintain the museum. Faced with a lack of support from local and state governments, the committee eventually disbanded in 2012. At this time, Hobbs assumed the role of repository of all records. And there are many. Parts of the historic machinery the committee managed to obtain over the years – lovingly restored by the committee’s engineering members in a shed donated by Tollport at Corio Quay – have been relocated to Ceres, not far from Geelong. A model of Harrison’s refrigeration machine from around 1857 – the only non-American object to have been on display at the Smithsonian Institute in Washing DC, USA – is now under the stewardship of Museums Victoria at Scienceworks.

KEEPING THE FAITH MUSEUM-WORTHY For more than 30 years, a group of business leaders, historians and interested members of the Geelong community have campaigned long and hard for the work of James Harrison to find a dedicated home. It started in 1988 when the Geelong Rotary Club raised $5,000 to have a giant Linde ammonia compressor and flywheel installed in the city’s Steampacket Gardens.

With an appropriate site at Rocky Point identified, work commenced on architectural plans for the James Harrison Museum, incorporating an information and interpretation centre, with an estimated build cost of $1.75–$2.25 million. In 1994, local lawyer Graham Hobbs became chairman of the committee, ably supported by a team of members including Webster and among others, the late Jim Harrison – James Harrison’s grandson. Former editor of the Geelong Advertiser, Daryl McLure, joined the committee as Vice Chairman in 1996. The committee unveiled the James Harrison memorial plaque at Rocky Point with local MP the Hon. Ann Henderson MLA, a year later.

Originally used in the Jackson Freezing Works in the early 1900s, where it produced 150 tonnes of ice an hour, the compressor and flywheel worked on the same principle as Harrison’s machine. After the idea failed to gain approval, a committee of members of the Geelong Regional Commission was formed to carry the proposal of a museum forward.

The James Harrison Museum Appeal was also launched to raise funds for the multi-million dollar project. The appeal raised some $132,000 – including funding from a Federal Government grant, and pledges of financial support from the Australian HVAC&R industry including AIRAH. The in-kind work of committee members was valued at $40,000.

Soon after, James Harrison Museum Inc. was established. Led by the late Bruce Webster, a local engineer and commissioner on the Geelong Water Board, the new committee set about completing all the necessary groundwork to create the museum, including repairs and restoration of the historic machinery that would be part of the exhibit.

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Graham Hobbs and I told our story, but our committee no longer existed. Is there hope for a James Harrison museum in the future? Maybe.

Hobbs says he would be only too glad to point them in the right direction. “Each time a person opens the fridge, we should say ‘Thanks James’,” says Hobbs. ■

MORE TO THE STORY

Featuring interviews with local Harrison aficionados Graham Hobbs and Daryl McLure, it is available to stream on Foxtel’s History Channel.

HVAC&R Nation

“In recent years there has been a renewed interest in Harrison’s pioneering work in refrigeration with Sydney ABC broadcaster Richard Glover and a film production crew visiting Geelong to tell his story,” wrote McLure in the Geelong Advertiser in 2020.

Just as others benefited from Harrison’s work, perhaps a new generation of mechanical and refrigeration engineers and mechanics might one day fulfil the dream of creating a dedicated museum honouring his work.

James Harrisons’ story was told in the eight‑part documentary series, Aussie Inventions that Changed the World – a program produced by SkinnyDip Pictures and Northern Pictures in 2019.

Both Hobbs and McLure are enthusiastic to share Harrison’s story – the latter having written about the topic on numerous occasions.

Visit the Eastern Cemetery at Geelong and you can find Harrison’s final resting place. Pointedly, the headstone reads: One soweth, another reapeth.

CELEBRATING AUSSIE INVENTIONS

Almost 10 years has passed since the committee for the James Harrison Museum Inc. was disbanded, but the passion remains among those who fought long and hard for the project to succeed.

Harrison corresponded with another pioneer of science from the 19th century – Charles Darwin. February–March 2021

To read more of Harrison’s story, including his role in the race to ship frozen meat to London, visit AIRAH’s Centenary website at www.airah100.org.au/jamesharrison

Feature

GET IN ON THE CELEBRATIONS! Not everyone knows that Geelong was declared a UNESCO City of Design in 2017. This designation is underpinned by the city’s history of innovation as an industrial and wool centre.

As a keen supporter of Geelong’s UNESCO designation and the week-long event, the GRBNT annually promotes and features heritage-related events as part of the program.

It was the location for over 60 inventions (or inventors), some being world-firsts – including James Harrison’s ice-making machine – that would see the city become a leader in architectural and wool education, research and technology.

In 2021, the GRBNT has chosen to feature James Harrison’s career from printer-to-journalistto‑inventor presenting:

Now, every year, the City of Greater Geelong celebrates Geelong Design Week. This year it will be held from March 18–21 with the theme “unpredictable”. The event will demonstrate resourceful adaptation that turns challenges into opportunities, and celebrates clever and creative human environment design that turns obstacles into building blocks. Fittingly, James Harrison’s work will be celebrated thanks to the efforts of the Geelong and Region Branch of the National Trust (GRBNT).

■ An online streamed event James Harrison – Geelong inventor, editor, and entrepreneur on Friday, March 19 at 6.55pm (timed to allow Harrison’s compatriots in Scotland to participate). This session will be moderated by Associate Professor Dr. Meghan Kelly, of Deakin University’s Design department. For bookings, go to www.trybooking.com/BMYIK ■ An exhibition, James Harrison’s Momentous Achievements: Models, Medals and Memorabilia, held from March 20–28. It will show a timeline of Harrison’s amazing life, a model of one of his early machines,

an early household refrigerator and medals and tributes that he earned. For bookings, go to www.trybooking.com/BMZPQ Both events will be held at the National Trust-owned heritage property, Barwon Grange, near Rocky Point. Members of the former James Harrison Museum Inc. committee are contributing their knowledge, supported by a curator and designer. “The GRBNT sub-committee hopes, through these events, to raise James Harrison’s profile in Geelong and to advocate for a permanent place to commemorate his life and works,” says Lex Chalmers OAM, chair of the GRBNT City of Design Sub‑Committee. “As an untrained – but expert – designer, engineer and inventor, he’s the perfect subject for the Geelong UNESCO City of Design to celebrate.” Later in the year, the GRBNT hopes to place a commemorative plaque near James Harrison’s last dwelling at Point Henry. ■

WOULD YOU LIKE TO KNOW MORE? To subscribe for booking information about the full Geelong Design Week 2021 program visit www.geelongcityofdesign.com.au/geelong-design-week To learn more about the work of the GRBNT, visit www.nationaltrust.org.au/branches-vic/geelong-region-branch

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Business Tips

HIRE GROUND

Is it better to hire contractors rather than full-time staff? Service Today founder Zak Saboune looks at the pros and cons. Hiring full-time staff can help build a stable team, and help you to foster loyalty and commitment to your business. Staff will likely be more invested in the company’s goals and can be trained to a fixed set of processes.

Many HVAC business owners prefer to hire contractors rather than full-time employees. They figure it’s cheaper, simpler, less risky, and that contractors will ultimately save them both time and money. However, I can share from personal experience that it seldom works out like that in the long run. It is true that hiring contractors can mean fewer outgoings, greater flexibility and less management issues. The big risk with this approach is a lack of quality control.

Full-time staff will then stick to those sets of

Unlike most in the tradie business, I prefer to hire full-time employees so that I can better manage my staff and ensure that they will deliver quality service to my customers.

processes and ensure that quality measures are met and that KPIs are hit.

BATTING FOR YOUR TEAM It’s highly likely that contractors will be less loyal since they work with multiple businesses and may not prioritise your company’s objectives. You’ll also have less authority over them. Even if you set guidelines on expectations and deliverables, contractors tend to be more autonomous and work to their own set of rules. 14

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As a result, you can keep everything in house, making it easier to manage workloads, guide your staff and keep your IP secure. Of course, once you’ve hired full-time staff, you’ll need to be prepared to invest in them, which undoubtedly costs time and money. In my business, training my staff is key to ensure that our high quality standards are met and upheld. It’s an upfront cost, but the outcome ensures that customers are satisfied and that repeat business is secured.

WORTH THE RISK Another consideration you have to factor in when hiring full-time employees is that you may end up hiring someone who is the wrong fit, which can come at a large cost to your business. To get around this issue, ensure all new employees are rigorously screened and skill tested to ensure quality service, and are provided with ongoing training, development and support. If you factor in these costs, in the long run you stand to benefit from greater employee loyalty, along with a higher standard of workmanship and quality of work. All of this will ensure repeat business and a serious boost to your bottom line. What could be better than that? ■

This article was prepared by Zak Saboune, founder of Service Today, a leading professional home services company with over 180 employees in Sydney, Melbourne and Adelaide. For more information go to: www.servicetoday.com.au

February–March 2021

MODULE

136

PROUDLY SPONSORED BY

AIRAH Industry Nights

Skills summary ■ What? An overview of chillers and ways of testing them to ensure that performance matches the specifications.

■ Who? Relevant for anyone involved in the commissioning or bringing up to operational status of HVAC&R systems that incorporate chillers.

PERFORMANCE TESTS FOR CHILLERS The final step in the process of installing a refrigeration or air‑conditioning plant is the commissioning of it. This last step is vital for the successful operation of the plant. No matter how well designed or installed, a plant will not be at its best unless it has been properly brought into operation. Poor commissioning may lead to inadequate temperature control, inefficient energy use and customer complaints. Commissioning involves the testing, balancing and adjustment of all of the plant’s components. All new plant requires commissioning at some level. This Skills Workshop introduces and outlines the procedures that can be adopted for the successful commissioning of chillers.

Before commissioning a chiller, a series of equipment checks should be carried out to ensure that all systems are in fact ready. The start‑up and check‑out of centrifugal and absorption machines is usually under the supervision of the manufacturer and in accordance with the manufacturer’s instructions. For reciprocating chillers and compressors, the following steps should be taken: 1. Purge air from evaporator water side 2. Check flow switch and freeze‑protection thermostat operations 3. Check that equipment start‑up and control adjustments have been made 4. Check expansion valve operation and superheat by recording suction pressure and temperature readings 5. Check high‑pressure and low‑pressure cut‑out and oil safety cut‑out settings and operation 6. Check proper operation of crankcase heaters 7. On open compressors, check drives, shaft, seal leakage and coupling alignment 8. Verify proper refrigerant charge by inspection of sight glass and condenser liquid level indicators

Introduction Put simply, a chiller is a device that cools a fluid by removing heat from it, either through a vapour‑compression or absorption refrigeration cycle. The key components are the compressor, condenser, evaporator and expansion device. Most typically, the fluid used in chillers is water, which can sometimes be treated with anti-freeze in low temperature applications. Once chilled, this water is then used to cool and dehumidify air in a range of applications, from office buildings and shopping centres, to laboratories and manufacturing facilities. The chiller takes the heat from the water at the evaporator, and in doing so lowers its temperature before rejecting it via the condenser. This method of moving the heat from the chiller’s evaporator to its condenser is refrigeration, which can be electric driven using compressors, or achieved via absorption, which is achieved through a heat source such as steam, hot water or another indirect source.

9. Confirm that unloaders have been set to maintain specified suction temperature 10. Inspect vibration isolation system 11. Inspect alignment and restraint of any flexible connections. A major part of the “commissioning”, or bringing up to operational status, is the performance tests – designed to prove that performance matches the specifications. There are three ways to test a chiller: • Approved factory tests on the packaged unit • On‑site tests using the building load • On‑site tests using an external heat exchanger for load. Factory tests, carried out on a test rig as in Figure 1, have the major advantage that the chiller can be tested, and proved, independently of any other components (pump, cooling tower, coils etc.) which may affect its performance. If faults occur in the total installation, the chiller can be eliminated from tests. February–March 2021

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HVAC&R Nation

HVAC&R Skills Workshop water manometer mercury thermometers

orifice flow meter

orifice plate

mercury manometer

turbo chiller

mixing tank baffle adjustment

pressure gauge FT head

magnetic flow meter and recorder mixing valve mixing tank cooling tower Figure 1 – Factory test rig for testing chillers

building load isolated during test other chillers isolated during test

auxiliary cooling on chiller T

dall tube

cooling tower

T T

T T chiller

T dall tube T T

plate heat exchanger Figure 2 – Pipework arrangement using plate heat exchanger for performance testing 16

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February–March 2021

HVAC&R Skills Workshop Onsite tests using the building load are very difficult except in the hottest weather because the building cannot be sufficiently loaded for most of the year. Also, it may be difficult to distinguish between chiller faults and other system faults. A heat exchanger added to the basic installation, as in Figure 2, can be used to transfer condenser heat back into the chilled water circuit at a predetermined rate while using the tower to discharge the excess heat. Figure 1 shows the test points for thermometers and flow meters which are necessary for any performance test on a chiller, whether new or in service. Readings of flow rates and temperature changes can give accurate performance ratings. Example: A chiller on test shows the following test results: Evaporator water flow ‘Water in’ temperature ‘Water out’ temperature

= 45.5L/s = 13.3°C = 5.6°C

Condenser water flow ‘Water out’ temperature ‘Water in’ temperature

= 79.5L/s = 35.0°C = 29.5°C

Electrical volts = 415V amps = 920A power factor = 0.89 From the above figures, calculate: 1. The total cooling 2. The heat discharged through the condenser (kW) 3. The actual input power into the chiller (kW) 4. The specific power performance W/kW.

1. Cooling in the evaporator Using the basic equation

Qh = m × SH × TD and because 1 litre of water weighs 1 kg: mass specific heat temperature difference . . . Qh

= 45.5kg/sec = 4.187kJ/kg K = 13.3 – 5.6 = 7.7K = 45.5 × 4.187 × 7.7 = 1,467kJ/sec = 1,467kW

Areas to target in retrocommissioning Further to the above information, the following points are common issues that arise and are worth considering for inclusion in a retrocommissioning program. The list is not meant to be definitive, simply a guide to common areas for chillers that deserve to be investigated. • Check electronic TX valves are fitted (on older plant), consult chiller manufacturer as necessary

Similarly:

2. Heat discharged in the condenser mass specific heat temperature difference . . . Qh

• Vessel water flows and pressure drops are correct

= 79.5kg/sec = 4.187kJ/kg K = 35.0 – 29.5 = 5.5K = 79.5 × 4.187 × 5.5 = 1,830kJ/sec = 1,830kW

• Check that chiller set points are correct (evaporator and condenser) • Unloading and staging of chillers is optimised • Check correct pump operation • Check source of minimum cooling call • Check chiller capacity • Review preventative maintenance chiller logs and reports. ■

3. Input power into the chiller Using the equation

kW = V × A × PF

THE AUST RALI

EDITION

and assuming the power factor of 0.89: 415 × 920 × 0.89 calculated kW power = = 340kW 1,000

= 0.232kW/kW cooling = 232W/kW cooling

NCE 1920

SI C

340 = 1,467

input power = cooling effect

O YOU HT T BY UG O

GIVIN

4. specific performance, watts/kilowatt

ION RIGER AT G NIN IAN REF AUSTR AL AIR-CONDITIO RESOURCE NATIONAL AND

THE I ND

This month’s skills workshop has been taken from Australian Refrigeration and Air‑conditioning, Volume 2, authored by Graham Boyle, F.AIRAH, and from AIRAH’s design application manual DA27 – Building Commissioning.

AN INST ITUTE OF REFRIGER

ATION,

AIR CON DITIONING

DA27 BUILDING

APPLIC

COMMISSI

ATIO N

ONING

MA NUA

VOLUME

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AND HEAT ING

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February–March 2021

AIRAH News

COME TOGETHER

Their role is to support the HVAC&R industry with knowledge dissemination, skills-development and capacity-building. Each of the initiatives has a clearly defined scope and agenda. The i-Hub Data Clearing House was developed to support Australian innovation in the area of smart controls and the digitalisation of buildings.

Can leading businesses and institutions across the HVAC&R spectrum join forces to create new climate and energy solutions? The Innovation Hub for Affordable Heating and Cooling is banking on it. Air conditioning and refrigeration accounts for almost a quarter of all electricity generated in Australia. It is responsible for about 12 per cent of Australia’s CO2 emissions, and makes up about half of peak electricity demand across different parts of the electricity network. In view of this, the Innovation Hub for Affordable Heating and Cooling (i-Hub) was created to bring about a step change in our industry. The idea is to create a common platform on which leading businesses and institutions can discuss and adopt an integrated approach to developing more affordable heating and cooling solutions.

GETTING CONNECTED The initiative is led by AIRAH in conjunction with the CSIRO, Queensland University of Technology, the University of Melbourne and the University of Wollongong and supported by the Australian Renewable Energy Agency (ARENA). The i-Hub brings together leading universities, researchers, consultants, building owners and equipment manufacturers to create a connected R&D community in Australia. The aim is to support the HVAC&R industry with knowledge dissemination, skills-development and capacity-building. In line with the National Energy Productivity Plan, i-Hub is geared towards facilitating the

HVAC&R industry’s transition to a low-emissions future, stimulating jobs growth, and showcasing HVAC&R innovation in buildings. “The i-Hub project brings a uniquely concerted effort from the HVAC&R and property industries to use the design and operation of air conditioning services as a tool for supporting onsite and local grid renewables,” says AIRAH CEO Tony Gleeson, M.AIRAH. “Through the deferral of HVAC&R loads – during renewable energy supply shortages – and the use of HVAC&R loads as a ‘productive source of demand’ during periods of excess supply, this project will increase the value of onsite renewable energy production and increase the fraction of building energy that can be economically provided by onsite renewable energy.”

INNOVATION PLATFORMS The i-Hub project is made up of three interlinked initiatives. They are the Smart Building Data Clearing House, Living laboratories – Green Proving Grounds, and Integrated Design Studios.

The Living Laboratories aim to provide real-world validation of technologies that integrate onsite renewable energy and HVAC loads to improve the value of renewable energy in front of major building portfolio owners. With a view to facilitate integrated design in the industry, the i-Hub Integrated Design Studio aims to explore its development between architects, engineers, and clients in a project environment.

TECHNOLOGICAL BET At a time when rising electricity costs are putting enormous pressure on Australian consumers and businesses – a problem made worse by COVID-19 – initiatives like the i-Hub are betting on technology to reverse the trend. The i-Hub reflects the strong desire to support Australian innovation in delivering better energy efficiency and minimising peak demand. The project also aims to deliver innovative solutions that have renewable energy and building efficiency at their core. Stark as the current energy and climate challenges are, new market opportunities abound for smart energy and energy-efficient products and services. The i-Hub is working to assist the HVAC&R industry’s transition towards a low‑emissions future. In so doing, it is strengthening Australia’s position to lead the global market for smart and zero-energy buildings. ■

For more information about i-Hub and to subscribe to the i-Hub newsletter go to www.ihub.org.au

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Cover Feature

IT’S A BLAST Through the adoption of an innovative, centralised low-charge NH3 solution, significant energy savings are being realised by a major Victorian logistics operator at its new cold store facility in Melbourne’s west.

Located in Truganina in Melbourne’s outer west, this new refrigerated warehouse facility is the result of a decision by the operator to consolidate three existing facilities into one. It presented an opportunity for the third-party logistics (3PL) operator to move away from traditional air‑cooled HFC and CFC systems, and consider a future‑proof, energy-efficient alternative for its new facility. Having not operated a facility refrigerated by ammonia, the operator was introduced to the concept of a centralised low-charge NH3 (ammonia) refrigeration system by Scantec Refrigeration Technologies. As part of its due diligence process, the operator sought to inspect a similar facility in Brisbane 20

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featuring blast freezers served by the same type of refrigeration plant.

incorporates “cold lake” air distribution and automatic ambient air defrost.

After this inspection, and considering the estimated energy cost savings of about $40,000 per month, reductions in maintenance costs and a five‑year payback period, a decision to proceed was made in mid-2019.

The system services a freezer store, a dual-duty chiller/freezer and an ante room. The latter serves as a space that minimises infiltration into the freezer room(s) and enables marshalling of products during receipt and despatch.

The new Truganina refrigerated warehouse facility has been designed to incorporate a blast freezing facility within the refrigerated storage space. It includes rack blast freezing for carton-packaged meat. When not in use, the rack can be used for pallet storage also.

The refrigeration plant employs insulated coolers where the coils and fans are contained within insulated air handling units (AHUs).

Stefan Jensen F.AIRAH, is the managing director of Scantec Refrigeration Technologies. He says the centralised, low-charge NH3 refrigeration system

February–March 2021

These insulated coolers are mounted in the ceiling space above the ante room, with access for all maintenance and repairs to the air coolers (evaporators) taking place outside the refrigerated spaces.

Cover Feature

LESSONS FROM THE REFRIGERATION DESIGN ENGINEER According to Scantec Refrigeration Technologies managing director Stefan Jensen, F.AIRAH, there are many challenges associated with the selection of refrigeration systems in the refrigerated warehouse sector.

therefore have no tool(s) and/or standards with which a qualitative assessment of refrigeration systems can be performed prior to installation. This usually leads to the lowest capital cost option(s) being accepted. This was prevented in this case.”

He offers a few lessons that can be learned from the Truganina project.

ENERGY EFFICIENCY VITAL

BEST PRACTICE “There is a total lack of best-practice energy performance benchmarking for refrigerated warehouses in Australia,” he says. “Building occupants, contractors, developers, landlords, consultants, and construction companies

SUMS STACK UP “Based on the recorded energy performance of this new facility, there is evidence emerging that the difference in energy costs between this and a typical low-efficiency neighbouring facility will pay for a complete replacement plant every four to five years,” says Jensen.

“It is in the commercial interest of the facility owner/ landlord to ensure that a refrigeration plant with the highest level of energy efficiency is installed even though that entity may not be responsible for energy consumption costs,” says Jensen.

“What this means is that for building occupants who lack capital, but have a past track record of being able to fund excessive energy costs, a finance option for an energy-efficient replacement plant concept that has a track record may be within reach.”

“This is the case because an energy-efficient refrigeration plant adds value and assists in tenant retention.”

COLD LAKE

AMBIENT AIR DEFROST

The “cold lake” air-distribution concept employed by Scantec Refrigeration Technologies at Truganina relies on the differences in density between relatively cool and relatively warmer air.

Defrost is carried out by means of automatic motorised shutters. During defrost the cooling coil is isolated from the refrigerated warehouse on the air side, while ambient air is circulated through the cooling coil, causing it to defrost. This minimises heat ingress into the freezer during defrost.

“In any refrigerated warehouse, it is the circulating airstream that cools the space,” says Jensen. “The airstream does this by warming up slightly as it circulates throughout the facility. As the air warms, the density reduces, and the air seeks to rise towards the ceiling of the facility without requiring any mechanical assistance to do so.” From there, the air returns to the evaporator (air cooler) return, is refrigerated again and returned to the room. This is in contrast to the conventional air-distribution method, which injects relatively cold air at high level into the refrigerated space, forcing the airstream to more or less do the opposite of what it naturally seeks to do when used as the cooling agent cooling the warehouse.

The use of dry expansion refrigerant feed and the employment of evaporator materials with high thermal conductivities create a faster defrost cycle. The reason for this? Air coolers contain significantly less refrigerant at the commencement of the defrost, and warm up faster. In the event of a refrigerant leak, the air cooler is forced into defrost mode. This prevents leaked refrigerant from entering the refrigerated space. Any ammonia exposure risk in the freezer(s) is further mitigated by the inherently lower operating refrigerant inventory in the air coolers of low-charge NH3 refrigerated systems. The operating evaporator refrigerant inventory is typically 30–50 times lower than conventional liquid overfeed ammonia plant. The overall plant inventory is typically four to five times lower. At Truganina, the total refrigerant inventory is about 475kg. This is below the threshold that classifies the site as a Dangerous Goods Storage facility.

“If the facility has been serviced by a conventional liquid overfeed refrigeration plant, the ammonia inventory would have been 2,000 to 2,500kg,” Jensen says. The operating refrigerant inventory in all air coolers combined is about 25kg – up to 40 times lower than conventional liquid-overfeed systems. “The significantly lower refrigerant inventories in the air coolers and in the plant as a whole, contribute to an installation that is safer than conventional plant with liquid overfeed,” Jensen says.

ENERGY SAVINGS Well known for its work in the design of NH3 refrigeration systems across a variety of sectors from Far North Queensland to Western Australia, Scantec Refrigeration Technologies has collected sufficient data to accurately compare the energy efficiency that this type of plant offers against other plant concepts. “The superior energy efficiency is the key feature that delivers above-average returns on investment,” Jensen says. This is evidenced by the green dots in the graph below, that represent a number of centralised low-charge NH3 plants. In some cases, energy

Specific Energy Consumtion — Volume [m3] vs Energy use [kWh/m3-yr]

120

ASHREA Guide for Sustainable Refrigerated Facilities

The above visualisation depicts typical temperature distribution for the freezer store inside elevation.

Firstly, a certain length-over-height ratio range needs to be satisfied to avoid the use of auxiliary fans. Secondly, there needs to be space below the racking for the refrigerated air to distribute evenly throughout the facility. “Because air distribution relies more on air density differences as opposed to mechanical work,” Jensen says, “fan power is reduced and ducting within the refrigerated facility is eliminated.” In addition, structural loads are positioned close to walls, and refrigerant pipelines in the ceiling cavity above the freezer(s) are eliminated, as are all condensation risks.

100

Scantec Refrigeration Technologies – DX Ammonia Scantec Refrigeration Technologies – Two Stage Liquid Recirculated 5

Energy use [kWh/m3-yr]

“There are certain dimensional criteria that the warehouse needs to satisfy to achieve the most optimal outcome,” says Jensen.

Lismore (DX Ammonia with screw compressors)

Power (Scantec Refrigeration Technologies – DX Ammonia)

SRT 9

CO2 ) Melbourne (Transcritical CO2) 60

4 6

S 8 SRT

1 TTamworth

SRT 7 10

9 SSRT 6

S 5 SRT

3 Banks meadow w Townsville e 20 Gillman man n

S 4 SRT

Perth M Melbourne (DX Ammonia) Yatala Y

S 3 SRT SRT 2

TTrade Street

S 1 SRT

ICCL Malaysia (estimated)

50,000

100,000

150,000

200,000

250,000

300,000

350,000

400,000

Volume [m3] February–March 2021

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HVAC&R Nation

Cover Feature Additionally, the interface between the insulated cooler discharge and the freezer wall required acute attention to detail, both in design and installation. This helped avoid condensation issues, air leaks and expansion/ contraction damage.

consumption levels are several times lower than the conventional systems also featured in the graph. According to Jensen, it is also evident that there is a greater level of predictability associated with the specific energy consumption (SEC) of centralised low‑charge NH3 plant.

Fortunately, with the bulk of the refrigeration work at Truganina already completed prior to the COVID-19 pandemic, the impact of Melbourne’s city-wide lockdown on the project was moderate.

“The SEC values on the vertical axis are recorded in kWh/m3/year,” Jensen says, “where the volume in m3 refers to refrigerated volume.” Other benefits of this installation type include the use of all stainless steel pipelines and stainless steel condenser, the elimination of ammonia pumps, and avoiding most of the liquefied refrigerant management problems associated with extensive periods of low loads and/or automatic re-start after power failures.

WINDOW OF OPPORTUNITY One of the major challenges associated with the Truganina installation was the relatively narrow window of opportunity for insulated cooler installation. This relied on accurate installation programming to eliminate any installation delays.

COMMISSIONED AND OPERATING Commissioning of the centralised low-charge NH3 refrigeration system commenced in late September 2020. Despite some minor issues in association with the commissioning of the control of the automatic defrost flaps on the insulated coolers, the end-user was able to move their first pallets into the new facility in late November 2020. To date, the system’s energy consumption is in line with expectations. ■

LOCATION, LOCATION In designing the centralised low-charge NH3 refrigeration system at Truganina, Scantec Refrigeration Technologies elected to locate all air coolers (evaporators) outside the refrigerated space. As well as simplifying maintenance, this design is able to utilise the ceiling space often available above ante rooms, which have lower ceiling heights than freezer rooms. The location of the air coolers outside the refrigerated space also reduces noise levels, improves operator safety, simplified the refrigerant pipework design and installation, eliminated any protrusions or obstructions within the refrigerated warehouse and improved refrigerant leak management.

Centralised low‑charge NH3 engine room holding less than 500kg of ammonia.

Defrost and emergency ammonia venting are carried out by means of automatic motorised shutters.

PROJECT AT A GLANCE

COMPARING AMMONIA The below chart provides a comparison between a typical centralised low-charge NH3 refrigeration plant and a range of other refrigeration plant concepts. The small green star represents a Brisbane refrigerated storage facility serviced by a low-charge NH3 plant, commissioned in 2020. The remaining dots represent facilities owned and operated by one US‑based entity specialising in refrigerated storage.

Two stage NH3

Plot area

100

Energy use [kWh/m3-yr]

THE EQUIPMENT

Two stage NH3

Two stage NH3 Subcritical CO2/NH3

Two stage NH3

60 Single stage NH3 Two stage NH3

Single stage NH3

Two stage NH3 Subcritical CO2/NH3

Subcritical CO2/NH3

Two stage NH3

Subcritical CO2/NH3 Subcritical CO2/NH3

Two stage NH3 NH3 DX

NH3 DX

Two stage NH3

Subcritical CO2/NH3 Single stage NH3

Subcritical CO2/NH3

NH3 DX

Subcritical CO2/NH3

Transcritical CO2 0

50,000

100,000

150,000

200,000

250,000

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Subcritical CO2/NH3

Subcritical CO2/NH3 300,000

Volume [m3]

Subcritical CO2/NH3

Two stage NH3 Two stage NH3

Subcritical CO2/NH3 0

▲ Controls: Allen Bradley ▲ Head contractor: CIP Constructions ▲ Refrigeration design engineer and

Lucas Refrigeration

120

company

▲ Refrigeration maintenance contractor:

Two stage NH3

▲ Client: Unnamed major logistics

contractor: Scantec Refrigeration Technologies

Specific Energy Consumtion — Volume [m3] vs Energy use [kWh/m3-yr]

140

THE PERSONNEL

February–March 2021

350,000

400,000

450,000

▲ Air coolers: Thermofin ▲ Compressors: SABROE/Johnson Controls ▲ Condensers: Patkol Heataway ▲ Controls: Allen Bradley ▲ Cooling coils: Thermofin ▲ Evaporators: Thermofin ▲ Pipework: Scantec ▲ Sensors: HB Products, Danfoss and ECE Fast

▲ Valves: Danfoss ▲ VSDs: Danfoss (Source: Scantec Refrigeration Technologies)

February–March 2021

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HVAC&R Nation

Industry News

HIT THE GAS! Fridgies are racing to take advantage of Refrigerant Reclaim Australia’s new rebate rates for recovered refrigerant this year. We talk to managing director Kylie Farrelley about the new Gas Seeker Initiative. “Last year was such a challenging year, so now is a really good time to give back to the industry. And we thought if we’re going to do it, let’s go hard – we’ll triple the rebate. It’s all about shaking things up a bit, to see how effective our program can really be.”

QUICK QUIZ. Did you know that it’s a legal requirement to recover, return and safely dispose of ozone depleting and synthetic greenhouse gas refrigerants, and that by doing this you are helping protect the environment?

The initiative has just started, so there are no numbers yet on how much extra refrigerant is being handed in, but Farrelley says there have been some positive early signs. Call volumes are up, with contractors wanting to know how the scheme works, and wholesalers have also been requesting more empty cylinders.

Even better, did you know that you can get money back by taking your recovered refrigerant to your local wholesaler? And, finally, did you know the amount of money you get for refrigerant has been tripled this year? That’s right, Refrigerant Reclaim Australia (RRA) is increasing the rebate for recovered refrigerant rebate to $10 per/kg as part of its Gas Seeker Initiative.

RIGHT PLACE, RIGHT TIME RRA is a not-for-profit organisation created to work nationally with industry to share the responsibility for, and costs of, recovering, reclaiming and destroying surplus and unwanted refrigerants. Since 1993, it has recovered more than 7,000 tonnes of refrigerant. More than 6,700 tonnes (91 per cent) of the refrigerant has also been safely destroyed.

“It’s something we’ve been considering for some time,” says Farrelley. “The levy hadn’t changed for many years, and we want to see if there was more gas out there we could be getting. |

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As well as helping the environment, collecting the gases provides important data about the mix of refrigerants in use in Australia. And Farrelley says that in recent years there has been a marked increase in the flammability mix of refrigerants returned for destruction. “We’ve been analysing these products for a very long time, and certainly what we’re seeing is a growth in flammable components,” says Farrelley. “I expect the way the industry handles recovered refrigerant will need to change, because we’re starting to reach that tipping point where mixtures of recovered refrigerant could be flammable really soon.”

It’s an impressive record, but RRA is looking for ways to go even further, and managing director Kylie Farrelley says it was case of perfect timing for this new initiative.

A BURNING ISSUE

There are a number of possible reasons for this. One is that some refrigerants like R410A are not flammable by themselves, but can become flammable when mixed with other products, such as R32. It could also be because different components of some refrigerants may leak at different rates – known as preferential leakage.

February–March 2021

RRA managing director Kylie Farrelley

Farrelley says more data and more analysis is required to know exactly what is behind this increase, but RRA is already preparing for the change. It is upgrading its two refrigerant destruction facilities, and will also ensure that wholesalers can provide both non-flammable and a flammable recovery cylinders. Farrelley expects the use of refrigerant analysers will be key in ensuring a safe transition to flammable refrigerants.

GET IN QUICK! “We’re encouraging everyone to make the most of the Gas Seeker Initiative while you can, as it will only be available for a limited time,” says Farrelley. The new rebates kicked in on January 1 and finish on June 30, so don’t miss out! If you’ve been holding on to old recovered refrigerant, now is the time to cash in. And next time you’re decommissioning a unit, remember that you can help protect the environment and make some money at the same time! ■ For more information about the Gas Seeker Initiative, go to refrigerantreclaim.com.au or ask your local wholesaler.

February–March 2021

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Around the Nation 1

In terms of licensing for HVAC&R technicians who use flammable refrigerants, the report notes various issues.

4 TECH EXPO

1 COMPLETE ACQUISITION

Although the Australian Refrigeration Council (ARC) does provide a voluntary accreditation program for tradespeople working with flammable refrigerants and is running a safety campaign on R32 (an A2L or mildly flammable refrigerant), some flammable refrigerants fall outside the ARCtick licensing scheme. The report notes that this scheme could be adapted to regulate the risks associated with flammable refrigerants, if there was appropriate legislation to support it.

Global refrigeration wholesaler Beijer Ref has announced its acquisition of Complete Air Supply (CAS). CAS is a manufacturer and distributor of air conditioning supplies, including ducting and associated fittings. With 40 employees on staff, the company has an established sales distribution network with three branches in Queensland.

Although not the focus of this work, the report notes that the licensing for HVAC&R technicians in Australia is “particularly disjointed”, with only New South Wales, Queensland and Victoria having specific air conditioning licence or registration classes, and extra licenses required for incidental work.

Beijer Ref is represented in Australia through Beijer Ref Australia, Kirby and ACD Trade. According to Beijer Ref, the acquisition strengthens the group’s overall presence in the APAC region and sales, which amounts to an estimated $460m. “Australia is an important market for us, and it is pleasing that we found an opportunity to grow further,” says CEO of Beijer Ref, Per Bertland. “CAS is a well-managed and fast-growing company that will add value to our group in the form of a broader product range within air conditioning.

Go to: www.refrigerantsaustralia.org ■

3 CHILL CONVERSATIONS

“This acquisition greatly enhances our position in the residential ducted market and more broadly into the commercial segment of our industry. CAS’s products, experience and expertise will complement our air conditioning product offering as well as adding to our existing customer base.”

AIRAH’s Refrigeration Conference 2021 is taking place in Melbourne from May 17–18. This year’s event will feature two full days of talks and discussions. Participants will hear from local and international industry experts in sessions reviewing the latest developments in legislation and technology, as well as specific case studies.

Go to: www.beijerref.com.au ■

2 MIND THE GAPS

Discussions include natural refrigerants and energy efficiency, transitioning to low-GWP refrigerants, and case studies reviewing a variety of technologies.

A new report commissioned by Refrigerants Australia has mapped out the laws that govern the use of flammable refrigerants in this country. It also highlights key themes and gaps within the regulatory landscape.

The conference will also feature panel sessions on technician issues in the field, heat pump applications, and global warming. Delegates will have the opportunity to attend a workshop on energy-efficiency saving measures for the industrial refrigeration industry too.

The report, written by Bronwyn Weir and Krista Weymouth, reveals a complicated patchwork of regulations. There is no one set of laws that focus on flammable refrigerants as a subject matter. Instead, there are more than 100 different instruments spanning a range of topics that regulate their use. These include WHS/OHS, electrical safety, dangerous goods, licensing, Australian consumer law, and building regulation and building product safety. 26

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In addition, a trade display will provide attendees with the opportunity to interact with leading industry suppliers and explore the latest refrigeration technology offerings. The conference program will be released shortly. For more information, go to: www.airah.org.au/ Refrigeration-Conference ■ February–March 2021

The Institute of Instrumentation, Control and Automation (IICA) will be hosting the IICA Technology Expo in Bathurst, NSW on Wednesday, March 3, 2021. The free-to-attend event presents an opportunity for participants to meet with national and international companies showcasing their latest products or services related to instrumentation, process controls, telemetry, automation, hardware and software. The event is aimed at electricians, engineers, maintenance managers, production planners, operational staff and management, instrument technicians, health and safety officers, and apprentices. The invitation is also extended to students from various industries including agriculture, food and beverage, mining, water, chemical, gas plants and so on. IICA Technology Expos are run Australia-wide in capital cities and regional areas providing a “one‑stop shop” to access equipment suppliers in an informal environment. The expos feature about 40–60 companies showcasing their products related to the instrumentation, control and automation industry. Go to: www.bookings.iica.org.au/bookings ■

5 HAVE YOUR SAY ON NEW TRAINING MATERIALS The technical advisory committees of the electrotechnology industry reference committee are seeking feedback on the draft training package materials for two projects: variable refrigerant flow AC systems, and emergency lighting and alarm systems/fire and smoke control systems. In the first project, a new unit of competency on variable refrigerant flow (VRF) air conditioning has been developed to address the required generic skills and knowledge for technicians to install, commission, service and maintain these systems.

Around the Nation 5

In the second project, a new unit of competency has been developed to address the needs of air conditioning technicians to inspect, test and repair fire and smoke control features of mechanical services systems. The existing unit, "UEEEL0048 install and maintain emergency lighting systems", has been renamed and updated to cover the needs of electricians to “inspect, test and maintain” emergency lighting systems. Detailed mapping information, tracking changes to the existing training package, is also available to view. Feedback will be accepted until close of business Monday, March 8. Go to: www.australianindustrystandards.org.au ■

6 GET A CLUE ABOUT R32! The Australian Refrigeration Council (ARC) and the Department of Agriculture, Water and the Environment have created free “tech-packs” on R32 refrigerant for licensed technicians and authorised businesses. The packs contain information on refrigerant characteristics and properties, equipment requirements, safety, relationship to R410A, and more. They also include refrigerant safety stickers to help technicians identify the refrigerant and its basic characteristics before working on a system. Finally, there is a link to online resources, including a video. The tech packs will be mailed to all stationary refrigerant trading authorisation holders Australia‑wide. The initiative is an important step towards raising awareness among technicians about R32 and flammable refrigerants in general. R32 is now the refrigerant of choice for many AC manufacturers, especially in small split systems where it has displaced R410A. According to the ARC, in 2019, R32 systems (small, pre-charged) made up 71 per cent of the market, an increase from 52 per cent in 2018 and up from effectively zero in 2013. R32 is also increasingly used in larger applications, including split ducted systems and chillers. Go to: www.arctick.org ■

7 FEMALE FRIDGIES GET FLYING START

the Virtual Industry Showcase, and held two exhibitor showcases and networking events online.

Two Indigenous Australian women are filling a growing need for more women in HVAC&R thanks to an industry-sponsored training program at TAFE NSW.

AIRAH chief executive Tony Gleeson, M.AIRAH, says Industry Nights are a great way to educate yourself, re-connect and network with leading brands and professionals in the HVAC&R field.

The “Career Start in Air-conditioning and Refrigeration” program allows students to develop their skills and knowledge in the trade by completing an entry‑level qualification.

“They are essential for all professionals and are the key to keeping ahead of the game in 2021,” he says.

Upon successful completion of the program, industry sponsor, the Air Conditioning, Refrigeration Building Services Foundation, provided the students with $600 Actrol and Airefrig tool vouchers to kickstart their careers. Proud Nyawagi woman Shivanhi Nair – who is featured in this issue’s “Smoko With” on page 28 – completed a Certificate II in Engineering, and says the program has given her valuable practical skills and helped her secure employment.

The events are free to attend and offer attendees the opportunity for networking and to see the HVAC&R industry’s latest innovations. For more information on these events, download the AIRAH Event App or go to www.airah.org.au/ industrynights ■

9 WRONGFUL CHARGE

“The course provided me with a range of skills such as how systems work, the use of hand and power tools, and how other trades are involved in air conditioning and refrigeration,” Nair says.

The driver of a mining truck in Queensland has suffered serious burns in an explosion believed to be caused by an air conditioning system incorrectly charged with hydrocarbon refrigerant.

“I am now planning to continue my journey by enrolling in the Certificate III in Air conditioning and Refrigeration while working for my new employer Precise Air Group.”

According to the Queensland Mines Inspectorate, the explosion occurred in the truck cabin while the vehicle was being driven in an underground mine. It caused serious burns to the driver’s face, hands and chest. Fortunately, the worker’s eyes were protected from the blast by safety glasses.

Proud Turrubul/Bundjalung woman Lena Gill completed a Certificate II in Electrotechnology, and encourages other females to consider entering a trade. “I’ve always been a hands-on learner, so a career in trades is perfect for me,” says Gill. “If other women out there are passionate about an industry, don’t let anything hold you back.” Go to: www.tafensw.edu.au ■

8 COMING TO A CITY NEAR YOU! AIRAH has announced it will be holding 19 Industry Nights across Australia in 2021. Due to COVID-19 restrictions, AIRAH was only able to hold two face-to-face Industry Nights in 2020. AIRAH also transitioned the traditional Industry Nights into

The force of the blast dislodged some of the windows of the cabin and these were blown clear of the truck. It also deformed the metal filter access panel for the air conditioning system (shown above). Although the investigation is still ongoing, the findings so far indicate that the air conditioning system was charged with a refrigerant containing propane and isobutane (hydrocarbon) instead of R134a – as per the original equipment manufacturer’s (OEM) requirements. The system was not certified for the use of the hydrocarbon refrigerant. Additionally, the personnel servicing and charging the air conditioning system did not hold Queensland Gas Work Licences for working with hydrocarbon refrigerant. ■

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Smoko with . . .

Name: Shivanhi Nair Company: Precise Air Group trainee Occupation: Construction You never stop learning. ut working in HVAC&R? What’s the best thing abo months, 8 days. in the industry? 1 year, 9 How long have you been Favourite tool: Gauges. feel. received: Listen, look and Best on-the-job advice you HVAC&R industry, If you didn’t work in the uld be doing? Photography. what do you think you wo SRT. Dream car: Grand Cherokee ng on with the entire family and goi Dream holiday: Re-uniting Leone). rra Sie in wn eto ) and Africa (Fre a memorable trip to Fiji (Ba Kettle Chilli Chips. Favourite smoko snack: the way to work today? What did you listen to on lent” by Youngn Lipz. “Si “Mood” by 24KGoldn and nous Australian to win an. She was the first Indige Sporting hero: Cathy Freem ried the Aboriginal flag. car lap ics, and on her victory mp Oly the at d gol ual ivid ind … When I’m not working, I’m up with family and friends. g chin cat and g, urin ent Adv

There’s a whole other world of HVAC&R to discover in Ecolibrium magazine.

Get a taste of AIRAH’s official journal at www.airah.org.au/ecolibrium To advertise in ECOLIBRIUM contact — Glenn Douglas 0411 839 667 or John McGrath 0419 556 108

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February–March 2021

Green Wedge

HOT TECH FOR COLD TRANSPORT Rhyner Logistik has solar energy to power its new electric refrigeration truck. The backbone for transporting perishable goods, cold trucks dramatically reduce food waste. But they also guzzle a quarter more fuel than non-refrigerated trucks, and use potent greenhouse gases like HFCs for cooling. Surely, there’s a more sustainable option.

IN IT FOR THE LONG HAUL Swiss haulier Rhyner Logistik believes there is. The company recently added an all-electric Renault truck to its 100-strong delivery fleet. Even better, it features retrofitted solar panels to cool its refrigeration unit. These convert otherwise wasted heat into electricity to supplement the required cooling energy. The Renault D Wide Z.E. truck joins other vehicles in supplying the Denner supermarkets in Zurich and its suburbs. Denner is Switzerland’s third largest supermarket chain. Bringing Rhyner Logistik a step closer to its carbon neutrality goal, the fully electric truck with zero tailpipe

emissions marks a new direction in the company’s efforts to harness solar energy on the move. Rhyner Logistik has also acquired a rapid charging station, to charge the truck while loading.

ELECTRIC PERFORMANCE

Range D Wide Z.E. works well in an urban environment that requires frequent braking. Energy recovery alone is estimated to yield savings of 20 to 30 per cent, which translate into additional mileage.

THE ROAD AHEAD

Renault launched the all-electric Range D Wide Z.E. in the UK last year. The 6x2 rigid vehicle derives its power from two electric motors, delivering a maximum of 370kW, continuous power of 260kW, and maximum torque of 850Nm. According to Renault Trucks, it offers a range of up to 150km depending on the application and body specification. Fitted with a 22kW onboard AC charger, the all‑electric vehicle is compatible with DC fast charging up to 150kW, 200KWh batteries – which comprise four packs of high energy density nickel manganese cobalt lithium-ion cells. The regenerative braking feature of the

Convinced that electric mobility is the most effective way to achieve carbon neutrality, Rhyner Logistik will be assessing the operational results of the Renault EV ahead of future plans to electrify – or solar-power – the rest of the fleet. Other truck makers are beginning to explore the use of solar panels for powering their vehicles’ auxiliary systems. Applications include running air conditioning, heating or TVs for drivers who sleep overnight in the cabs. But we’re still a long way from moving a truck with solar energy – the roof simply isn’t big enough to fit enough panels. ■

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The Lighter Side This month’s Lighter Side brought to you by:

1 WINNER 2 3 FAULT FINDER Keith stumbled across this “lovely piece of work” while walking across a shopping centre roof in Adelaide. Graham says: The wiring draped across a metal roof between the two units probably should be protected by conduit. The broken pressure control cover on the left unit is held together with tape. The suction and liquid lines from both units use the same roof penetration and the pipe insulation is breaking down due to UV radiation. I have a suspicion that the cover on the compressor terminal box on the left unit isn’t fitted correctly, although it’s a bit hard to see. The suction line on the left unit isn’t insulated or the insulation has fallen off. I would suggest that the wiring across the roof is plain illegal and that this was piggy-backed off an existing installation by someone with enough knowledge to be dangerous!

1 WHITE CHRISTMAS John replaced this ducted unit over the festive period. “The customer said it hasn’t been cooling for a few weeks but they just turned down the temperature and let it run,” says John. “Apparently just knowing it’s on even if it’s not doing anything helps you feel cool! The suction on the outdoor was a ball of ice and the pipes were covered in ice the entire length. They also had some Christmas decorations so it seemed appropriate.” Graham says: From the looks of things, the unit has possibly been operating without a filter, and maybe even with the return air disconnected.

2 SET AND FORGET Jamie was working in Lalor Park NSW when he got a service call for an AC not working. “When I saw this I could not believe my eyes,” says Jamie. “I’ve attached two photos to show you it was still in service. Scary!”

4 FOR THOSE ABOUT TO ROCK … “Someone was too lazy to grab their spanners and adjust this evap’s v-belt,” says Callan, who found this rock just wedged under the motor. Graham says: I think he is correct about the rock!

5 BAREFOOT INSTALL Nick spotted this situation in Launceston. “A worker 5m up a ladder attempting to remove an old aircon unit by hand – with limited assistance from another guy inside the building,” Nick says. “It’s so hot in Launceston over summer (it was 22°C) he wasn’t wearing shoes.” Graham says: A WH&S nightmare. Not only no PPE but using a ladder to work off. To do this safely and properly would probably cost more than the unit he is removing, but no reason to risk life and limb.

Additional comments and observations provided by Graham Boyle, F.AIRAH, portfolio manager, heavy automotive and refrigeration at South Metropolitan TAFE. Please note that the comments are provided on the basis of the photos only and should be read with this in mind – not all issues or solutions are apparent from a 2D image.

HAVE YOU COME ACROSS SOMETHING SCARY, UGLY OR JUST PLAIN FUNNY? If your entry is deemed the monthly winner, a 700ml bottle of Jim Beam will be on its way to your door. Please include a postal address with your entry. Entrants must be 18 or over. Send your hi-res (>500KB) photos to Editor, Mark Vender at mark.vender@airah.org.au

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R32 SKYAIR COMPACT CASSETTE

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EXPANDED CAPACITY RANGE Now includes 7.1kW model in the same form compact factor

ENERGY EFFICIENT Improved energy performance of up to 31% compared to previous R410A model (EER)

WIFI CONNECTIVITY Change the set temperature, fan speed and even program 24 hour On/Off times using the Daikin Airbase app^

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HVAC&R Nation February/March 2021

Articles inside

Lighter Side

Smoko with

Industry News

Business tips

AIRAH News

Green Wedge

Global Update

Homage to Harrison

The Toolshed