HVAC&R Nation March 2018 (final) by AIRAH

True brew Coopers’ $65 million upgrade

Skills WORKSHOP

Testing for electrical faults

Beating the heat How to stay safe

when the temperature soars. March 2018 / ISSUE 109

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Beating the heat 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

www.airah.org.au/nation

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 3000

During Australia’s scorching summer the public depends on air conditioning and refrigeration equipment – and HVAC&R technicians often confront dangerously high temperatures to keep that equipment running. Sean McGowan explains the dangers of working in the heat.

Contributing writer Sean McGowan

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HVAC&R Nation regulars

Glenn Douglas glenn.douglas@airah.org.au Ph: 03 8623 3018

ISSN 1834-9522 HVAC&R Nation is printed on paper sourced from well manned forests and other controlled sources.

See what’s new in the ‘Shed

John McGrath john.mcgrath@airah.org.au Ph: 03 8623 3007

The Toolshed

Skills Workshop Testing for electrical faults

8 Global Update Industry news from around the world

Exclusive to March

Cool Tech A wood fire that charges your phone

Green Wedge Using traffic to generate electricity

Disclaimer 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. The publisher reserves the right to alter or omit any article or advertisement submitted and requires indemnity from advertisers and contributors against damages or liabilities that may arise from material published. No part of this publication may be reproduced, stored in a retrieval system or transmitted in any form or by any means electronic, mechanical, photocopying, recording or otherwise, without permission of the Publisher.

13,170

Safety Corner Arc-flash hazard assessments

24 Around the Nation Who’s in the news?

26 Insurance Advice Covering your debts

28 AIRAH News. The Refrigeration 2018 conference is here

29 Smoko with . . . Q&A with Chris Gallagher

Lighter Side The shonkier side of the nation

True brew The craft beer sector is booming in Australia, with around 400 craft brewers now operating across the country. The growth of this sector locally and worldwide has, in part, led Coopers to open a $65 million maltings facility boasting a cutting-edge refrigeration plant.

PLEASE CONSIDER THE ENVIRONMENT AND RECYCLE THIS MAGAZINE IF YOU ARE NOT GOING TO KEEP IT.

March 2018 | www.airah.org.au/nation | HVAC&R Nation | 3

Editorial

THE NEW GUY You know the rules when you start a new job: try to remember everyone’s names, make absolutely sure you turn up on time, and whatever you do, don’t bring in that leftover fish curry for lunch. But no matter how well you keep your head down and your nose clean, there’s always the threat of a workplace initiation ceremony. You know the kind of thing. A couple of doozies have been doing the rounds on social media lately, from the humorous (an apprentice being given a garbage bag and told to collect air samples) to the harrowing (another young bloke taped to the ceiling and smeared with sponge cake). So I was a little nervous when, on my third day in the office, AIRAH CEO Tony Gleeson, M.AIRAH, and Executive Manager Phil Wilkinson, F.AIRAH, suggested that a few of us (including yours truly) go up to the roof of our building, “to have a look”. Up and up we climbed, conversation flagging with each flight of stairs. By the time we emerged onto the rooftop – 11 storeys up and far above the city traffic – everything was eerily quiet. Was it the view, right across the top of Flinders Street Station and spanning from Port Melbourne in the west to the Dandenongs in the east? Or was this the moment of truth? I stood at the edge of the building and waited.

Whatever you do, don’t bring in that leftover fish curry for lunch It was all smiles . . . until they dangled him off the side of the building.

“Will you have a look at that,” said Phil.

for their new $65 million maltings facility. After reading it, I’ll never look at a Pale Ale the same way again!

I turned around to see the team gathered around the air conditioning system, hotly discussing the pros and cons of the installation.

There’s also our cover story on the risks of working in the heat, which could surprise even the more experienced HVAC technicians.

After a couple of minutes attention turned to the city around us. There was Fed Square with its thermal labyrinth, Council House 2 with its electronically actuated windows and shading, and the Pixel building over on the city fringe with its perfect Green Star score. Suddenly it hit me – once you start becoming aware of HVAC&R, you see the world in a different way.

So happy reading, and here’s to HVAC&R Nation continuing to bring you the most up-to-date news from the industry, fascinating features and a top read every month. Mark Vender (aka the new Ed) @AIRAHnews

This month we’ve got a feature on Coopers Brewery and the innovative cooling system they’ve put in place

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

Want to connect with AIRAH? There are lots of ways to stay up to date with what we’re doing.

AIRAHAU

@AIRAHNews

4 | HVAC&R Nation | www.airah.org.au/nation | March 2018

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5/2/18 5:16 pm March 2018 | www.airah.org.au/nation | HVAC&R Nation | 5

Toolshed 01

Bonza Bitzer bounty

In a special deal running this month, Appion is offering a $100 trade-in on its G5Twin recovery unit.

Compressor specialist Bitzer has introduced a complimentary one-year individual warranty extension for its IQ products, extendable up to an overall guarantee of five years. For non-IQ products, specific warranty extension packages are now available in the 2018 official price list.

“The Appion G5Twin is still the most reliable and fastest recovery unit in real world conditions,” the company says. “While other manufacturers constantly try to replicate the Appion G5Twin, none have taken the time to understand the application of a recovery machine.

All IQ products bought starting from January 1, 2018 benefit from the free one-year extra warranty, which goes beyond the legal one-year warranty. Customers can activate the free extended warranty by scanning the QR code on the product and following the prompts through the activation process.

“Its unique design with an isolated crankcase enables the machine to work in varied applications, from transferring virgin liquid refrigerant to recovering the worst burnt-out system without any deterioration to the components. The large gear-driven fans ensure maximum cooling of the machine and refrigerant to prevent undue wear and reduce bottle temperatures. In the rare event of damage to the G5Twin through poor recovery practice, the unit is completely field serviceable or can be returned to the Appion service centre in Melbourne for in-house service.

Bitzer IQ products include intelligent compressors and condensing units as well as frequency inverters and operating modules such as the CM-RC-01 pictured here. “We are confident in our abilities, and therefore know just how reliable our products with IQ technology are,” says Bitzer’s director of services and after-sales Philippe Maratuech. “We want our customers to benefit from this confidence and to strengthen their trust in our intelligent solutions, which is why we decided to grant them one extra year of warranty.”

“For the month of March 2018, Appion Australia is offering a $100 trade-in of your existing recovery machine – dead or alive – when you purchase an Appion G5Twin from any Australian wholesaler.”

The Bitzer Group is the world’s largest independent manufacturer of refrigeration compressors. It is represented across the globe through distribution companies and production facilities for reciprocating, screw and scroll compressors, pressure vessels and heat exchangers.

Go to www.appiontools.com n

Go to www.bitzer.com.au n 02

Carel doing well

The AHR Expo, the world’s biggest international exhibition of air conditioning, heating and refrigeration, was held in Chicago from January 22–24. It featured more than 2,000 exhibitors and around 65,000 industry professionals from over 165 countries worldwide. Carel was there, presenting several solutions based on wireless connectivity. One of these solutions is μChiller, a new controller designed for complete management of air/water and water/water chillers and heat pumps with on-off and/or DC compressors. Its distinctive feature is complete control of high-efficiency units through integrated management of devices such as electronic valves and brushless DC compressors. The range of models includes wireless connectivity with NFC (near-field communication) as standard, as well as Bluetooth on dedicated models, allowing interaction with mobile devices using the Applica app. This makes it easier to configure parameters and commission the unit in the field. Also on display was the MPXone (pictured), a new Carel controller for remote showcase management in supermarket applications. “MPXone is designed to guarantee all the typical functions of these applications, as well as the possibility to integrate modulating devices to cover a wide range of solutions, from entry level to high efficiency,” Carel says. “Wireless connectivity, using NFC and Bluetooth technologies, simplifies the way that users interact with the refrigeration units, which is now done via a specific app with cloud-based support. This means that contents such as parameter configurations and documentation, and user profiles and related access levels, can all be synchronised, allowing rapid commissioning.” Go to www.carel.com n 6 | HVAC&R Nation | www.airah.org.au/nation | March 2018

Recover $100 from Appion!

Testo measures up

“The Testo 440 air velocity and IAQ measuring instrument allows technicians to cut some of the clutter and do more with less by modernising the tools HVAC engineers use daily,” says the company. “At the heart of the system is the simple yet intuitive Testo 440 and Testo 440 delta P measurement tool. It’s small enough to fit in your pocket, but capable of holding up to 7,500 readings for volume flow, K factor, pilot tube flow, heating and cooling load, mould assessment and flow turbulence measurement. The instrument was designed to function in accordance to EN ISO 7730 and ASHRAE 55 regulatory standards.” Different heads can be attached to the probe handle, including a 16mm vane probe head, hot-wire probe head, high-precision 100mm vane probe head, 100mm vane probe head, and CO, CO2 and humidity probe heads (wired optional).

“All probe heads also offer built-in temperature and humidity sensors, and can secure to the telescope to reach airflow ducts that are up to 1m away, or 2m with its extension. Only the probes have to be sent in for calibration, so you can attach another and move on with your work,” the company says. “The air velocity and IAQ data logger set was created with commercial office, industrial or warehouse facilities – as well as laboratory clean rooms – in mind. It’s capable of connecting through Bluetooth to its small, wireless printer for on-site data reports, as well as transferring data in a CSV file format through a USB connection to a computer or laptop.” Go to www.testoaus.com.au n

Johnson keeps on moving on

Johnson Controls has unveiled the York YZ Magnetic Bearing Centrifugal Chiller, which it says is the first chiller fully optimised for ultimate performance with a next-generation low-GWP refrigerant – R-1233zd(E). “The York YZ chiller uses an integral, variable-speed drive and advanced magnetic bearing technology that features a single moving assembly suspended in a magnetic field that does

Toolshed AC Smart Connectivity enables direct serial communication between Schneider Electric’s EcoStruxure Building Solution and intelligent room controllers with Panasonic’s packaged air conditioning (PAC) and variable-refrigerant-flow-based (VRF) HVAC heating and cooling systems.

not require lubrication,” the company says. “This technology requires 80 per cent fewer moving parts than traditional oilor refrigerant-lubricated drivelines. The result is enhanced reliability, reduced maintenance and improved efficiency. “Compared to traditional fixed-speed oil-bearing chillers, the YZ delivers up to 35 per cent annual energy savings. “The YZ operates with entering condenser water temperature as low as 4.5°C, providing enhanced performance in every operating condition and the widest operating envelope in the industry. It uses an optimised single-stage design to provide industry-leading real-world energy efficiency. The chiller can also operate with condenser temperatures below the evaporator temperatures, eliminating the need for a water-side economiser, which simplifies the system, requires less mechanical room space, and saves money on components, piping, controls and maintenance.”

“A single interface provides full control to building owners and managers – including HVAC, lighting, power, security and electrical distribution – for actionable insights that can improve occupant comfort, reduce a building’s energy consumption and increase cost savings,” Panasonic says. 05

“The AC Smart Connectivity solution has been designed for easy installation and integration, making it suitable for retrofits of buildings. It takes advantage of plug-and-play technology, which simplifies system configurations for extensive AC systems, or it can be installed as a part of a standalone system.”

Go to www.york.com/next n 06

Panasonic partnership

Panasonic has integrated its AC Smart Connectivity solution with Schneider Electric’s EcoStruxure Building Solution and Intelligent Room Controllers. The new system aims to reduce operating costs while optimising a building’s overall green credentials.

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

The system offers a range of controllers and window, wall, ceiling and CO2 sensors. It is compatible with Panasonic FSV systems, and PAC systems including high-static ducted, cassette, under-ceiling and wall-mounted. Panasonic offers a five-year labour and parts warranty. For more information contact 1300 COMFORT (1300 266 367). n

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

March 2018 | www.airah.org.au/nation | HVAC&R Nation | 7

Global Update

CHINA

RUSSIA

THE CHINA (refrigerant) SYNDROME

BITCOIN ON THE BOIL

A continued surge in refrigerant prices in China is expected to increase pressure on HFC prices worldwide. According to Chinese sources, the price of fluorspar reached a six-year high in late 2017, with increases of nearly 80 per cent. China is the source of more than half of the world’s production of fluorspar. As a result, the price of R32 rose around 120 per cent, while R125 experienced increases of over 85 per cent. This has had a particularly severe impact on the air conditioning sector, where both are used extensively.

With crypto-craziness spreading across the globe, Russian entrepreneurs Ilya Frolov and Dmitry Tolmachyov have developed a working prototype for an underfloor heating system that uses the heat generated by Bitcoin miners. Bitcoin mining involves using a computer – or hundreds of computers – to validate transactions made with the cryptocurrency, and all that computing generates a lot of heat. While there’s been talk of harvesting the heat from large data centres, Frolov and Tolmachyov wondered if they could use the principle on a smaller scale to heat a home.

The main air conditioning refrigerant R410A, which consists of a 50/50 blend of R32 and R125, saw prices rise over 100 per cent in 2017. Single-component refrigerant R134a experienced increases of around 35 per cent. n

They built a simple cabin in the Siberian town of Irkutsk and installed two bitcoin miners. The heat from these small computers warms up a liquid that’s then pumped through a sub-floor heating system. The cabin is essentially heated at a profit of AU$540 a month from processing transactions. n

FRANCE

USA

MAGNIFIQUE FUTURE HEATER Late last year the Interclima+elec trade fair celebrated its 50th birthday in Paris. Almost 400 exhibitors gathered to display their wares, including Atlantic, which ran a competition to find the heater of the future. The winner was Roman Pin, a freelance designer, who came up with a “woven” ceramic inertia heater that can be manufactured in a variety of colours and shapes. Made of enamelled porcelain, it is ideal for large atypical areas of buildings, and can be used to separate spaces without blocking out light. Pin’s creation stood out for its aesthetic appeal as well as its thermal properties. Unlike ceramic convection heaters, which can experience hot spots, the openwork mesh of Pin’s heater allows better circulation of heat. It can also be installed horizontally or vertically. n

AIR FRIDGE ONE Donald Trump's presidential jet is getting two new chiller units at a cost of US$23.6 million (Au$29.3 million). The work will be done by Boeing, which also built the heavily modified 747. While it might sound like a cushy contract, it's not your average install. Air Force One has to support onboard staff for extended trips and they do not restock food while overseas – a safety precaution – so standard commercial units are not up to the task. The new chillers will be customised to carry 2m3 and will allow 3,000 cabin meals to be stored in a total of 26 climate-controlled compartments below the passenger cabin. The value of the contract also reflects the work involved in design, manufacture, conducting environmental testing and obtaining Federal Aviation Administration certification. n

8 | HVAC&R Nation | www.airah.org.au/nation | March 2018

USA

TRIPPY DIPPY ICE-CREAM Dippin’ Dots, the USA’s leading flash-frozen beaded ice-cream brand, has formed a company to market its patented cryogenic technology and equipment. Leveraging its 30 years of experience and its intellectual property in cryogenic processes and machinery, the company will make Dippin’ Dots’ patented technology and equipment available to other cutting-edge industries using cryogenics, including food, pharmacy, agriculture, aquaculture and animal feed. The Dippin’ Dots Cryogenics process uses liquid nitrogen to flash-freeze products that require high-quality standards. The process is suitable as a first step for any products that need to be freeze dried. Industries that create probiotics, bacterial cultures and plant extractions are key examples. n

ITALY

COOL DATA? NO PROMBLEMO A new 20-hectare facility, claimed to be “the world’s first self-powered data centre,” has opened in Milan. All energy used to power the Global Cloud Data Centre is certified by the European Guarantee of Origin (GO) and produced using 100 per cent renewable resources. It also includes a large PV system and a hydroelectric unit, which together can produce up to 90MW. The air conditioning system for the data rooms employs a geoexchange system that makes use of the cold water found underground. Furthermore, ducts in the server rack design aid efficiency by targeting the undergroundcooled air onto the parts of the rack that need cooling the most. Double insulation with a defrost system is used in the data room construction. n

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Control without compromise. QUE is the most advanced integrated home air conditioning control platform yet. Coming with a sleek modern design and high-quality components, QUE’s easy to use interface brings home air conditioning controls into the 21st century. QUE is more than just a pretty face – it’s a control platform packed full of innovations and features, that can evolve with you and adapt to meet your changing needs into the future. And while QUE is one control platform, it provides many control options, allowing you to control the system from a variety of touchpoints:

Master Controller

Zone Controller

Remote Sensor

Mobile App

Smarty pants. 5.7” 1080x720 pixel, full colour touch screen and powerful dual core processor with 1GB RAM.

Life is wireless – now your controls can be too. You can now connect your zone controllers and room sensors wirelessly, allowing for a simple installation that minimises intrusions and can save time and money.

Complete control at your fingertips. QUE provides you with a level of control never before possible in home air conditioning, with features like Energy History, a Scheduling function, and an easy to use Master Timer.

Connect to comfort, wherever you are. The QUE platform comes complete with a mobile app, QUE Connect as standard.

It’s thanks to features like these that QUE delivers control without compromise.

March 2018 | www.airah.org.au/nation | HVAC&R Nation | 9

Feature

Coopers Brewery in Regency Park, SA, with the new maltings plant in the foreground. (Photo source: Ahrens Group)

TRUE BREW

It’s this growth that has contributed to Coopers deciding to return to the maltings business after a 16-year hiatus. It has done so in a big way too, with the construction of a $65 million purpose-built facility at its Regency Park site in Adelaide. Once again Coopers will have full control over one of the key ingredients in its beer: malt.

The craft be er sector is b ooming, wit now operati h around 40 ng across th 0 craft brew e country. T ers has, in part, h is g ro w th locally an led Coopers d worldwide to open a $6 5 million ma in Adelaide. lt ings facility Sean McGo wan reports . Yes, I’ll admit it. I’m a devotee of craft beer. No, I don’t have a hipster beard, nor do I wear chinos rolled up to my ankles. I don’t own a bicycle either. But I do enjoy craft beer. And a quick glance in my fridge proves it. Surrounding a six-pack of something safe to keep the old man happy are colourful cans reminiscent of 1970s soft drink containers and bottles of pale ale brewed in towns I can’t find on a map. Of course, my conversion from the conservative took some doing. I mean, Jedi Juice and Krush don’t really sound like beers do they? But despite my initial

misgivings I was ultimately swayed by their artisan appeal. I’m appreciative of the art of brewing, of the subtle flavour variations achieved from simple ingredients like malted barley, and the fact that someone, somewhere has had a go. And I’m not alone. While overall beer sales in Australia have reportedly hit a 65-year low, craft beers are bucking the trend. Sector revenue is reported to soon nudge $500 million a year, based on annualised growth of almost 10 per cent.

10 | HVAC&R Nation | www.airah.org.au/nation | March 2018

A statue of Thomas Cooper, founder of Coopers Brewery. (Photo source: Coopers)

Feature

While overall beer sales in Australia have reportedly hit a 65-year low, craft beers are bucking the trend

STATE-OF-THE-ART DRAUGHT The project represents the single biggest investment in the company’s 155-year history, and is considered the most technically advanced maltings in the world. Built by South Australian firm Ahrens Group and spanning some 13,000m², the facility houses the world’s best equipment sourced from Germany. It is set to produce about 54,000 tonnes of malt a year. Coopers will use about 17,000 tonnes in the production of its own beer products, with the balance sold to domestic and export customers, including the many independent brewers of craft beer looking for reliable malt supplies. “South Australian farmers are recognised as producing some of the best malting barley in the world,” says Coopers managing director Dr Tim Cooper. “We will be looking to establish strong relationships with them into the future.”

THE MALTINGS PROCESS Malt is a key ingredient in the production of beer, along with hops, yeast and water. As well as affecting the flavour, sweetness and aroma of the brewed beer, malt also affects its colour – the darker the malt, the darker the beer. At Coopers, malt is produced in a multi-stage process that germinates and processes barley, enabling specific sugars and enzymes to be accessed.

Stage 1: From the farm Barley is received at the plant from farmers and checked, graded, cleaned and stored in grain silos on site.

Stage 2: Steeping At Coopers, 180 tonnes of barley (in three 60-tonne batches) are steeped – a process of immersion in water and aeration, which elevates the moisture levels in the grain from 10 per cent to 40 per cent to stimulate germination.

CRITICAL LIQUIDS

Stage 3: Germination After steeping, the barley is moved to one of four germination vessels, where it is left to germinate over the course of four days under strictly controlled conditions. The grain is continually turned to avoid “felting” as roots appear. It is during this period that the internal structure of the grain is transformed by biological processes to allow the carbohydrate in the grain to become available to hydrolysis during the brewing process.

Stage 4: Kilning The germinated grain is kiln-dried to reduce water content to less than 5 per cent and stop germination. The roots are removed (deculmed) and the malted barley is cleaned and tested. This process is where the flavours and aromas of the malted barley emerge.

Stage 5: Storage The malted barley is then stored for future use by the brewery or sold to domestic and export brewers. Source: Coopers Brewery and Cold Logic

Dr Cooper and his team in the establishment of the $40 million Regency Park brewery in 2001.

Dr Cooper says particular care and attention was given to the aesthetics of the new maltings building.

The water used in production is sourced from saline aquifers located deep beneath the brewery and desalinated on site. Power is mostly drawn from Coopers’ on-site co-generation plant, which also provides recovered heat for the kiln.

The facility also features a number of innovations, including enclosed conveyors, advanced process control and monitoring.

Critical to the maltings process is a large refrigeration plant, designed and installed by Adelaide-based industrial refrigeration specialist, Cold Logic.

“In terms of water usage, process control and automation,” Cooper says, “this is the most advanced maltings in the world.”

Cold Logic’s relationship with Coopers began with the maintenance of the company’s old Leabrook brewery more than 30 years ago. This led to Cold Logic assisting

“Our strong focus on expert service has ensured the reliability and longevity of their refrigeration plant to provide some of the best-brewed beers in Australia,” says Cold Logic’s Dr Michael Riese. Accordingly, Cold Logic was the obvious choice to set up the refrigeration plant serving the new maltings facility. The plant is particularly important in three stages of Coopers’ processes. “Firstly, the refrigeration plant is sized to supply chilled water to the actual beer brewing process at a rate of 100,000 litres every two hours,” Dr Riese says. “Secondly, the plant chills 360,000L of RO (reverse osmosis) water from 30°C to 15°C each day to be used in the steeping process. And lastly, the chilled water is used to condition air during the germination and steeping process, which forms the main load of the plant throughout the day.” For this third process alone, Cold Logic expects to see a throughput of 2.5ML of chilled water on an average 25°C day at Regency Park. With chilled water used around the clock as part of the maltings process, the key challenge for Cold Logic was to design a system that could cope with peak loads during hot weather to ensure 100 per cent production rates. Conversely, the system also needed to cater to reduced heat loads on cold days, or when there is reduced throughput in the system. To cater for this, Dr Riese says the overall plant is designed to accommodate a flow rate of 130L/s of 6°C chilled water. However, he says instantaneous flow rates observed on the maltings plant during commissioning have ranged from 20L/s to 95L/s on medium to hot days.

Maltings refrigeration plant room showing the three custom-built compressor packages. (Photo source: Cold Logic)

“To cope with varying instantaneous chilled water requirements, it was important to avoid short cycling while at the same time stage the compressors and evaporative condensers in such a way as to avoid rapid changes in motor speeds,” says Dr Riese.

March 2018 | www.airah.org.au/nation | HVAC&R Nation | 11

Feature coils at 3m in length). This reduces the number of valves and amount of pipework required – ultimately reducing the capital cost and areas of possible wear or failure. “For a plant of this size that operates around the year, energy conservation and efficiency was a major component of the design and the control system,” says Dr Riese. To improve energy efficiency of the three evaporative condensers, they are operated in parallel at the minimum appropriate fan speed. Two gravity-fed gasketed plate heat exchangers are used for the heat transfer and the surge drum fed for a ceiling-hung liquid receiver. A floating discharge pressure control system has been implemented to maximise the energy efficiency of the overall system. “Using a variable-discharge pressure-control system maximises the performance and realises additional efficiency gains on colder days throughout the year,” says Dr Riese. “By implementing the correct control system, we achieve steady flows and loading on the plant without large spikes in power drawn.”

Low-pressure ammonia surge vessel in the maltings refrigeration plant room. (Photo source: Cold Logic)

LESSONS FROM THE DESIGNER Dr Michael Riese from Cold Logic reveals some of the key lessons from the project. 1. A full understanding of the customer’s requirements and intended operation of the entire process and facility is essential to design a refrigeration plant that is the most appropriate for any given circumstance.

Two gasketted plate heat exchangers used in parallel for chilling water in the primary circuit. (Photo source: Cold Logic)

CLOSED LOOP The closed-loop water system features separate hot and cold tanks, each with a capacity of 175,000 litres. By using separate tanks, Dr Riese says the loading on the refrigeration system can be optimised and controlled to reduce potential power spikes that may result from rapidly ramping the system up or down. “One of the main objectives of the system is to supply chilled water to the brewing process,” he says. “So a reservoir is effectively created between the two tanks, ensuring the brewery will have sufficient chilled water available at all times.” The system is designed around a separate primary loop, which maintains the fill level and temperature of the cold tank, with the process side controlled by the brewery system. “Our cooling system receives a cooling call, which then activates the secondary pumps and controls

on delivery pressure,” says Dr Riese. “A number of fully stainless-steel pumps are sized to accommodate different parts of the system. And depending on criticality of their function, are either deployed in a duty-only or duty and standby configuration.” The chilled water system is controlled on tank levels and the plate heat exchanger leaving temperature. Pump speeds are controlled on the delivery pressure to minimise the energy required. Three ammonia compressors, with a total concurrent operating capacity of 3600kWr at design conditions, have been installed on site. Two units act in a lead-lag arrangement and the third compressor on stand-by. These are matched by three evaporative condensers installed on the rooftop some 24m above the plant room. Each condenser is 6m long and 3m wide, and features two axial fans connected to individual VSDs (variable-speed drives) for speed control. In an Australian first, these units use two condensing coils at approximately 6m in length (rather than four

12 | HVAC&R Nation | www.airah.org.au/nation | March 2018

The original design specifications are only the beginning, and significant discussions with the client are essential to realising the best value – both considering capital expenditure and ongoing operating costs.

2. Expert designers, engineers and trade staff are essential to the success of the project. Specialists in ammonia refrigeration are scarce in Australia, and having the best people on board makes projects easier, more successful, more commercially viable and reduces errors. 3. A good relationship with the head contractor is essential to the overall success of the project. The refrigeration project at Coopers was only $3.5 million out of an overall $65 million project budget. The head contractor is generally chosen from the construction trade and as such, often has very little knowledge of the ins and outs of industrial refrigeration contracting. In this case, there have been excellent relations with Ahrens Group, which allowed us to accelerate and prioritise individual parts of the install as needed, without any major delays for any of the parties involved. 4. Communication to the client, the head contractor and employees is key. By ensuring that everyone is up to date and abreast of any potential issues, there are no surprises – making the project a success for everyone involved.

Feature also been important. To this end, pumps that are not readily available off the shelf in Australia are deployed in a duty/stand-by configuration to ensure the facility can continue to run following a pump failure.

SWEET SMELL OF SUCCESS

Three evaporative condensers, first of their specific type for BAC in Australia. (Photo source: Ahrens Group)

REDUNDANCY With the Coopers malting facility operating 24/7, all year round, redundancy was an important aspect of the chilled water plant design. It resulted in one permanent stand-by compressor being used to provide 50 per cent redundancy.

THE EQUIPMENT Compressors: Mycom

The new facility was officially opened on November 30, 2017 by His Excellency, the Honourable Hieu Van Le AC, Governor of South Australia. Since the opening, commissioning on the process side has continued, and the loading on the refrigeration plant gradually increased under the watchful eye of Cold Logic. “Our engineers have monitored and tuned the system on an ongoing basis,” says Dr Riese. “This is done via remote computer access for the most part, but has required the occasional visit on site to adjust physical valves and other control items.” With thanks to Tom Bullock, project manager for Coopers Brewery. n

Controls: Siemens Cooling coils: Cabero Evaporative condensers: BAC Hot and cold tanks: A&G Engineering Plate heat exchangers: Alfa Laval Pumps: Grundfos Sensors: Endress+Hauser, OneTemp VSDs: Danfoss

THE PERSONNEL Client: Coopers

“Although we are using all three evaporative condensers in a parallel mode, the system is designed to be able to run on two condensers at full capacity,” says Dr Riese. “The expansion valves are split in two, again to allow for servicing and in an emergency, with the plant able to operate on one valve for part of the time.” Given that a number of the fully stainless-steel pumps used at the facility were made to order in Europe, with a lead time of up to 26 weeks, redundancy here has

PROJECT AT A GLANCE

Controls: Cold Logic/Tristar Electrical Head contractor: Ahrens Group Mechanical services design: Cold Logic Mechanical services contractor: Cold Logic Tours of the site are available – go to coopers.com.au for details. (Photo source: Coopers)

Processing equipment: Bühler

March 2018 | www.airah.org.au/nation | HVAC&R Nation | 13

Cool Tech

FLAMIN’ GREAT IDEA! You can get off the grid but still stay plugged in with this wood-burning, electricity-generating camp stove.

With the BioLite CampStove2 you can top up your Galaxy while you lie back and admire the galaxy, or recharge your Kindle with a handful of kindling, or . . . you get the idea.

Picture the scene: you’re sitting around a fire and toasting marshmallows or enjoying a cold beverage (or both). After a three-day camping trip the only worry you’ve got is finding the way home tomorrow when your phone is all but flat and your natural sense of direction is, let’s just say, not perfect. Never fear, with the BioLite CampStove, you can plug in and get enough of a charge to see you through. While the stove’s ability to recharge phones and other devices has grabbed people’s attention, its other big advantage is a clean and efficient burn. This was the goal when BioLite co-founders and avid campers Jonathan Cedar and Alec Drummond began looking for an alternative to gas canisters. As they tinkered with wood-burning prototypes, they came across thermoelectric generators, and realised this was the key. It allowed them to generate enough electricity to power a small fan that could blow air back into the burn chamber, thereby improving combustion and reducing smoke. As a bonus, surplus energy from the generator could be used to recharge devices. The CampStove was born. At the same time they discovered that an efficient wood-burning stove wouldn’t just be handy for campers. Around half the Earth’s population still cooks using wood fires, producing significant amounts of CO2 and other toxic gases, which incredibly lead to four million premature deaths a year.

A variant of their product designed for home cooking is being sold in developing countries and helping tackle these problems. Updated in 2017, the CampStove now boasts greater charging ability (up to 3W) and a built-in 2600mAh battery. Weighing in at just under a kilo, it is heavier than other stoves, requires fairly constant feeding, and even when the fire is cranking, it takes a long time to charge your phone. It’s also on the pricey side at around $250. But you don’t have to carry fuel for it, you won’t get smoked out, and it’s contributing to a good cause. n

Refrigeration innovation Refrigeration 2018 March 26–27 • Sydney AIRAH’s Refrigeration 2018 Conference will be held March 26–27 in Sydney. The conference will include sessions reviewing the latest developments regarding legislation, technologies, and a multitude of industry-specific case studies. The conference trade display will give participants the opportunity during the breaks and cocktail functions to interact with leading industry suppliers on the latest refrigeration technology offerings. If you work in refrigeration, you cannot afford to miss the Refrigeration 2018 Conference. Major Sponsor:

Supporting Sponsors:

For more information, go to www.airah.org.au/conferences 14 | HVAC&R Nation | www.airah.org.au/nation | March 2018

HVAC&R

MODULE

109

Skills Workshop PROUDLY SPONSORED BY

AIRAH

Skills summary n What? A guide to testing for electrical faults in refrigeration systems and troubleshooting common problems.

n Who?

PULLOUT

HVAC&R apprentices, teachers, lecturers, contractors, installers, mechanics/technicians and maintainers.

PREVENTATIVE TESTING It is not generally known that a megohmmeter (or megger) can be used to indicate moisture inside sealed units, and so warn the service technician of potential seizure of the compressor or burn‑out of the motor. Because moisture is a ready conductor of electricity, while refrigerants and oils are dielectric (low conductors), a megger test between winding terminals and frame that shows a resistance of less than 1 megohm generally indicates the presence of moisture or the by‑products of chemical action – mainly carbon. An oil and refrigerant change, dehydration or the fitting of driers (preferably all three) will remove the immediate source of contamination and prevent rapid and complete breakdown of the system.

TESTING FOR ELECTRICAL FAULTS IN REFRIGERATION SYSTEMS The first consideration when working on electrical equipment should be for the safety of yourself and other users. The major risk is of leakage to earth through the insulation, which is compounded if the earth lead is broken, or just damaged or corroded. As well as being dangerous, electrical faults can stop or reduce the efficiency of refrigerating systems. Using a range of standard testing instruments and following the procedures described below, it is possible to run practical tests and diagnose the problem. Most manufacturers specify test procedures in their service manuals, and may also include a diagnosis guide and test charts, together with complete instructions as to the appropriate replacement or repair technique to be used. This Skills Workshop covers the main service faults, dealing with refrigeration system faults as well as electrical faults where the one may be indistinguishable from the other, or is a direct cause of the other.

(b) Test thermostat or LP control for open circuit. If low‑pressure control is open‑circuited, check for refrigerant pressure – do not short circuit unless system pressure is normal. (c) Check for power to relay and motor overload; then check relay or overload for open circuit. Study relay circuit to ensure understanding of circuit. Do not short circuit overloads – look for reason for failure. (d) Test compressor winding resistances against manufacturer’s specification using ohmmeter (see Table 1 for examples), looking for open circuit, short to earth or shunted winding. Use megger to test for short to earth if main fuse is blown. (e) Test capacitors for fault if motor tries to start but stalls (if capacitors are fitted).

(f) If no electrical fault can be found and compressor tries to start, compressor may be seized. Three‑phase units: (a) Check supply on all three phases right through the circuit, using circuit diagram to assist. (b) If unit has high‑pressure or oil failure cut‑out switches, check these also for open circuit, then find the reason for failure. (c) Check contactor for open circuit; if overload circuit is open, find the reason. If coil is open‑circuited, check that correct voltage is applied across coil (connection between one phase and neutral for 240V coil, and between two phases for 415V coil).

Of course, the reason for the original contamination must also be found, and corrective measures taken if necessary.

GENERAL SERVICE DIAGNOSIS The following applies to commercial and domestic refrigeration.

1. Compressor will not run Single‑phase units: (a) Check main supply for correct voltage; if no power, check fuses, switch and power plug for open circuit. Check refrigeration wiring for visible signs of break.

(Reproduced with permission of Kyoritsu Electrical Instruments Works Ltd.) Figure 1: Insulation continuity tester megger. March 2018 | www.airah.org.au/nation | HVAC&R Nation | 15

HVAC&R Skills Workshop 2. Compressor starts and stops quickly (short cycles) (a) Check supply voltage for low or fluctuating voltage. (b) Test motor control. If thermostat is the cause, replace before compressor and windings are damaged. If pressure control is the reason, check system pressures, and correct system fault, or adjust control differential to approved setting. (c) Check amps and watts against name plate rating if compressor is cycling on overload. Look for reason for overload. (d) Test motor windings, capacitor and relay for fault using ohmmeter, megger and capacitor testers. (e) If unit is fitted with high‑pressure cut‑out or automatically resetting oil failure switch, check system pressures.

3. Compressor runs, but little or no refrigeration (automatic defrost models – where electrical fault indicated)

To assist in determining correct resistance, Table 1 has been compiled from service manuals for models with power ratings from 1.1kW to 3.75kW. If the particular winding you require is not included, and information is not available, some estimate may be made from the figures quoted for the equivalent power.

Example:

Table 1 gives a useful checklist which can be applied to sealed as well as open motors.

common terminal = B

To confirm your diagnosis, it will be necessary to carry out full testing procedures as previously listed, with reference to the specified current and power consumption or winding resistances.

start terminal = A

HOW TO IDENTIFY START, RUN AND COMMON TERMINALS Sealed unit windings are brought to three external terminals, one of which is common to both start and run windings, while the other two terminals connect to the individual windings.

(a) Test defrost timer circuit to ensure that timer is not stuck on defrost.

To identify terminals, an ohmmeter is essential and the procedure is as follows (refer to Figure 2).

(b) Test electric defrost heaters for short circuit to earth. Use megger.

1. Connect the ohmmeter across two of the terminals (eg A and B) and write down the resistance.

(c) Check defrost solenoid (if hot gas defrost) – if pipes in and out are hot, then solenoid valve is leaking. Check coil for power and short.

2. Connect the ohmmeter across terminals A and C and then across B and C and write down these resistances.

(d) If cooling depends on evaporator fan, check fan operation.

3. Note which two terminals show the highest resistance – the other terminal is common.

If fault is not electrical, recheck refrigeration cycle for faults such as worn compressor, leaking compressor valves, shortage of gas or overcharge etc.

4. If terminal B is common, compare the resistance between B and A with that between B and C, the lower reading indicating the run winding terminal and the higher reading indicating the start terminal.

4. Evaporator(s) blocked with ice (a) Check defrost timer operation and wiring circuit.

(a) 15 Ω

(b) Check door switch if it controls fan operation.

3Ω

(c) Check defrost solenoid for open circuit or loose wire. (d) Test setting on thermostat or low‑pressure control. Reset correctly to manufacturer’s specification. If off‑cycle defrost is required with pressure controller, leave the compressor off until ice melts off and then set pressure control to cut in at the pressure ice melts.

C 18 Ω

(a) Testing three terminals A, B and C to d etermine start, run and common terminals.

(e) If ice has accumulated in the drain pan, test drain pan heater for open circuit.

Highest reading between A and C i ndicates that terminal B is common.

(f) Check fan operation for intermittent electrical fault, tight bearings.

(b)

SEALED MOTOR WINDING RESISTANCES

start

Two problems arise when sealed‑unit motors are to be tested for fault. They are: (a) Identification of start, run and common terminals (b) Determining the correct resistance for each winding.

Resistance A – C = 18 ohms Resistance B – C = 3 ohms then, highest resistance is A to C, so: run terminal = C Note: That the highest reading must be the sum of run winding resistance plus start winding resistance because the two windings are being measured in series. Figure 2 again shows the relationship of windings to terminals.

SUMMARY OF HERMETIC COMPRESSOR TROUBLESHOOTING Handy tips to prevent wrong diagnosis 1. Thoroughly test sealed units before condemning and replacing. Remember that there are many other possible reasons for breakdown. 2. PSC motors may stall due to liquid flood‑back reducing lubrication, or overload. Test by fitting a relay and start capacitor before removing. 3. A good multimeter is essential for sealed unit testing, particularly when shunted windings are suspected. 4. A megger is the only satisfactory instrument for testing for short to earth or ground. 5. Do not test compressors when they are hot. Internal overloads in motors may remain open‑circuited for up to three hours before resetting. To be sure, disconnect power and leave motor to cool down. 6. If sealed units will not start, test the mains voltage. Supply faults can result in voltages too low to provide necessary starting torque. Also, beware high voltages, which will cause high current and burn‑out. 7. If compressors will not start yet test electrically correct, test the system pressures – suction and head.

Handy tips to prevent repeated compressor failure 1. If a system is contaminated due to moisture or acid from previous failures, only complete and thorough cleaning and dehydration will prevent repeat failure. 2. If a compressor is found to be faulty, find the reason. Because the fault may re‑occur and lead to another breakdown, test for:

run

(b) Result of test indicating internal connections of start and run winding. Start winding has higher resistance than run winding.

16 | HVAC&R Nation | www.airah.org.au/nation | March 2018

Resistance A – B = 15 ohms

Figure 2.

(a) Defective relay, capacitors, motor protector, heater thermostat, reversing valve or check valve; leaking refrigerant control; blocked valve or filter; or wiring errors. (b) Operating conditions exceeding design limits, such as excessive load (high ambient, high suction temperature).

HVAC&R Skills Workshop Resistance in ohms at stated temperatures Model

Winding

15°C

25°C

35°C

Start

5.8

6.2

6.6

Run

1.5

1.6

1.7

• Low voltage or high voltage – check name plate rating against supply.

Refrigeration motors fail for a number of reasons, some of which are:

1.1

Single‑phase

1.1

3‑phase – Model A

Across two terminals

11.8

12.6

13.4

• Phase unbalance for three‑phase – unbalance should not exceed two per cent at any time.

1.1

3‑phase – Model B

Across two terminals

7.7

8.2

8.8

• Breakdown of unit’s electrical winding insulation. On sealed units, a major reason is system contamination.

1.3

Single‑phase – Model C

Start

6.0

7.0

Run

2.0

1.3

Single‑phase – Model D

Start

5.0

6.0

7.0

Run

1.75

2.0

Across two terminals

5.4

5.8

6.15

Start

3.9

4.2

4.45

Run

1.4

1.5

1.6

1.3

3‑phase

1.5

Single‑phase

1.5

3‑phase

Across two terminals

6.8

7.2

7.7

2.25

3‑phase

Across two terminals

3.0

3.2

3.4

3.0

3‑phase

Across two terminals

3.2

3.4

3.6

3.75

3‑phase

Across two terminals

2.7

2.8

2.9

Note: Different resistances for similar power result from the different design characteristics of particular models – which require specific relays, start and/or run capacitors for correct operation. Table 1: Resistance in ohms at stated temperatures.

The understanding of component operation, the ability to use test meters and the skill of interpreting circuit diagrams are all vital to the service technician when fault finding on refrigeration and air conditioning systems. However, there is a fourth important ability that enables the others to function efficiently: that is, the use of logical thought. When you start on any job, take the time to analyse the data that you already have at hand (e.g., visual and audible information). Find the logical starting point for your testing procedure, and work from that point step by step. When you find and repair a fault, make sure that you have also repaired the cause of the fault and not just the symptom. Also, make sure that the fault you have repaired is the only fault or potential fault in the system. n

MORE INFORMATION EDITION

HT UG O

TO YOU

NCE 1920

N RATIO FRIGE NING LIAN RE ITIO URCE L RESO AUSTRAD AIR-COND NATIONA AN

D THE IN

VOLUME

Open or serviceable electrical motors suffer from the same electrical problems as the motors of sealed units, but there are additional mechanical problems to do with lubrication, bearing wear and the mechanical switch gear used instead of the electrical relay to open‑circuit the start winding.

AIRAH

CONCLUSION

PROUDLY SPONSORED BY

OPEN‑TYPE MOTOR SERVICE

• Insufficient lubrication or bearing tightness. For sealed units, correct system oil levels must be maintained without dilution by liquid refrigerants or contamination.

5. Prevent short‑cycling of compressor on and off by ensuring correct airflow and correct location and setting of thermostat or pressure control, with correct refrigerant

7. Ensure cleanliness of the highest order during installation and service. Keep dirt and copper filings out of the pipework and equipment, use oil from sealed containers, purge through with dry nitrogen when welding, evacuate with high‑vacuum pump drawing on both sides of the system through large lines, replace old oil and fit appropriate filter-driers.

• Faults in relays, capacitors or wiring connections.

GIVIN

4. Particularly on air conditioners, return air filters must be fitted and maintained. Blocked filters result in low suction pressures and flood‑back of refrigerant to the compressor. Without filters, the evaporator coils will block up with similar results. Check centrifugal fans for build‑up of dirt inside blades.

6. Ensure fuses are correctly sized for the load. Over‑fusing greatly increases the damage resulting from electric faults, and is the major cause of fires resulting from electrical breakdown.

• Faulty winding. Factory errors or damage are rare but possible, particularly with rewinds.

3. Correctly charge the system according to the manufacturer’s specification. Capillary systems must have the exact charge as set down by the manufacturer. If the exact charge cannot be weighed into the system, or measured from a dial‑a‑charge cylinder at the correct temperature, the system should be charged to approximately 3K subcooling at the condenser at design operating conditions.

charge and supply. Motor life is greatly affected by the number of starts. Large motors may be permitted only three starts per hour.

• Compressor overload or tightness – refrigeration system faults.

(c) Poor maintenance resulting in blocked air‑cooled condenser or faulty fan, scaled water‑cooled condenser, faulty water pump, incorrect direction of rotation of evaporator or condenser fans, blocked air filters or cooling of motor- compressor.

• Insufficient ventilation or cooling suction vapour. Many sealed motors will burn out if operated on a vacuum. With some refrigerants, cool suction vapour at normal pressures is essential to prevent overheating.

PULLOUT

MOTOR FAILURE AND PROBLEMS

This month’s Skills Workshop has been taken from Australian Refrigeration and Air-Conditioning Volume 1, by Graham Boyle, F.AIRAH.

Next month: Refrigeration and safety environmental standard AS/NZS 5149 March 2018 | www.airah.org.au/nation | HVAC&R Nation | 17

AIRAH exclusive partner offers

AIRAH has gone the extra mile to build partnerships with companies offering special benefits for members and supporters. The benefits are designed to support you in your professional and personal life. The exclusive offers now include everything from insurance, footwear, workwear and hotel accommodation to cars and trucks.

www.airah.org.au/offers Supporting partners

18 | HVAC&R Nation | www.airah.org.au/nation | March 2018

Green Wedge

ELECTRIC AVENUE Researchers in the UK are developing roads that will harness the power of passing traffic to generate electricity. It’s the same concept as used in push-button gas barbeque ignitors and electric cigarette lighters, where a piezoelectric crystal is struck by a small hammer, releasing a charge. “This research is about helping to produce the next generation of smart road surfaces,” says Professor Mohamed Saafi, who is leading the project. “We will be developing new materials to take advantage of the piezoelectric effect, where passing vehicles cause stress on the road surface, producing voltage. The materials will need to withstand high strengths, and provide a good balance between cost and the energy they produce.

Engineers from Lancaster University are working on smart materials that when embedded in road surfaces could harvest and convert vehicle vibration into electrical energy. The materials are piezoceramics, which produce an electric charge in response to mechanical stress.

And the WATT nightclub in Rotterdam spruiked a “sustainable dance floor” that powered its own LED lights with the clubbers’ movements. But the plan for a piezoelectric road takes the concept even further. The project team hopes it will optimise energy recovery of around one to two megawatts per kilometre under “normal” traffic volumes of around 2,000 to 3,000 cars an hour. That’s enough to power between 2,000 and 4,000 street lamps. On top of the environmental benefits, the system would also deliver savings for taxpayers. It costs around 15p (Au25c) a kilowatt hour to power a street lamp. Therefore 2,000 to 4,000 lights can cost between £1,800 (Au$3,052) and £3,600 (Au$6,105) per day. Researchers estimate that installing and operating this new road energy harvesting technology would cost around 20 per cent of that amount. Once the technology has been developed, it will undergo field trials in the UK and other EU countries. n

“The system we develop will then convert this mechanical energy into electric energy to power things such as street lamps, traffic lights and electric car charging points.” The idea of using this power on a larger scale is not new. A project undertaken by East Japan Railway Company installed piezoelectric mats in Tokyo Station to harness the energy of passengers walking through ticket turnstiles.

The foremost resource EDITION 05 EDITION 05

N REFRIGER ATIO AUSTRALIAN DITIONING AND AIR- CON AL RESOURCE

AUSTRALIAN REFR AND AIR- CON IGER ATION DITIONING

NATION

NATIONAL RESOUR

GHT TO YO OU U B BR

E 19 20

NC SI

THE

I NDUS

G C

GIVIN

E 1920

T TO YOU BY

A GI V I NG B

H UG RO

TH E I NDU

VOLUME

Australian Refrigeration and Air-conditioning Volumes 1 and 2 AIRAH is delighted to bring one of Australia’s foremost resources for training in the refrigeration and air conditioning industry to the education sector: Australian Refrigeration and Air-conditioning, Volumes 1 and 2, authored by Graham Boyle, F.AIRAH. The completely revised fifth editions have brought a new dimension to this highly regarded resource, with a new full-colour format, hundreds of updated and upgraded images and improved text, which make for easier reading and understanding. For more information, go to www.airah.org.au/ARAC

March 2018 | www.airah.org.au/nation | HVAC&R Nation | 19

Cover Feature

BEATING THE HEAT

During Austr alia’s scorchin g summer th on air condit e public dep ioning and re ends frigeration e technicians quipment – often confro and HVAC nt dangerou to keep that sly high tem equipment peratures running. Se a n M the dangers cGowan ex plains of working in the heat. You might consider yourself too tough to admit it, but the conditions experienced on a hot summer’s day while servicing equipment on a building rooftop can be brutal.

to serious heat-related illnesses such as heat stress and heat stroke, both of which can be fatal.

Yet for almost half of the year in southern states, and perhaps longer in Queensland, the Northern Territory and Western Australia, these are common workplace conditions confronting HVAC technicians.

Safe Work Australia says working on roofs can also expose workers to very high levels of ultraviolet radiation through direct sunlight and via reflective surfaces such as concrete, metal and glass in roofing materials. So even if exposure to the sun doesn’t burn you, reflection from the materials exposed to the sun can.

Working in these situations can cause all kinds of health problems, from discomfort and heat rash to headache, nausea and dehydration, right through

Although some people might just tell you to put another spoonful of cement in your cuppa and harden up, working in the heat is more dangerous than you think.

It doesn’t take long before a rooftop reaches 70°C or more.

20 | HVAC&R Nation | www.airah.org.au/nation | March 2018

It doesn’t take long before a rooftop reaches 70°C or more

HOW HOT IS TOO HOT? According to Brisbane-based air quality and meteorological experts Katestone, there are no regulations in Australia that set a limit on temperature in the work environment. Instead, it is the employer’s responsibility to identify hazards and put control measures in place to reduce the risk. And Katestone points out that temperature is not the only important factor contributing to the risk of heat stress. “What you are wearing, what you are doing, your health, hydration and acclimatisation status need to be considered as well as temperature, radiation, humidity and wind speed,” says the firm’s website. “Heat stroke can occur at surprisingly low temperatures, provided the evaporative power of the air is sufficiently reduced.”

Cover Feature MANAGING THE RISKS According to Safe Work Australia, the following steps should be taken, so far as reasonably practicable, to ensure that workers and other people are not exposed to harm from working in the heat.

Identify the hazard

Take into consideration the air temperature, air flow, humidity, radiant heat sources, work requirements and the workplace itself.

Apparent temperature

Work/rest cycle

Hydration

27–31°C

50 mins work : 10 rest

250ml every 20 mins

32–39°C

40 mins work : 10 rest

250ml every 20 mins

40°C–49°C

30 mins work : 10 rest

250ml every 15 mins

50°C–53°C

20 mins work : 10 rest

250ml every 10 mins

≥54°C

10 mins work : 40 rest Critical/emergency work only

250ml every 10 mins

Assess the risk

“One hot summer in Adelaide during heatwave conditions I worked on the roof of a service station,” says Smith. “It was so hot that the R22 cylinder blew its safety valve and tried to leave on its own. I worked all day up there until sundown, to get the system going, and when I got home that night I weighed myself and found I’d lost 5kg.”

Conduct a risk assessment and consider the impact of the hazard and how likely the hazard is to cause harm. Take into consideration the worker, the work and the working environment.

Control the risk

Smith says technicians working in such conditions need to keep hydrated and use electrolytes, and make sure they eat well.

Eliminate risks associated with working in the heat. This may include cancelling certain work tasks, rescheduling tasks to cooler parts of the day, or waiting for hot conditions to pass. If the risk cannot be eliminated, it must be minimised.

“Wear sunscreen, long sleeves, a hat and proper, high-quality sunglasses,” she says. “And take breaks in the shade.”

Review the control measures

She recommends keeping your tools covered with a towel, so they don’t become too hot to work with.

Review the control measures to ensure they are working as planned and that they do not introduce new uncontrolled risks. For example, removing personal protective equipment (PPE) to cool a worker down may introduce new hazards such as exposure to chemicals or solar ultraviolet radiation. Although employers have a responsibility to protect their workers, as a worker you also have a responsibility to look after yourself. This includes knowing your limits and state of health, keeping hydrated, taking frequent breaks, dressing appropriately (slip, slop, slap) and looking after fellow workers, including apprentices. A good rule of thumb may also be to use the guide (above right), for work and rest cycles, sent to us by a long-time HVAC&R Nation reader.

“And protect your electrical meters!” Jenny Smith, Affil.AIRAH

A CAUTIONARY TALE As owner of About Airconditioning in Darwin, Jenny Smith, Affil.AIRAH, knows a thing or two about working in the heat. She notes that soaring temperatures aren’t the only danger – glare from rooftops can be very dangerous and cause both shortand long-term eye damage. She warns that equipment can also be damaged in such conditions.

WE DON’T NEED ANOTHER HERO Although summer is officially over in February, you can bet there will be more sweltering days before winter arrives. And as the above information shows, the risks associated with working in the heat can be extreme. The traditional approach might be to “tough it out”, but it’s not about being tough, it’s about being smart. Just as you look after your tools, you need to look after your body – it’s the most valuable tool you’ve got. n

Common heat-related illnesses

Heat rash

Skin can become irritated and cause discomfort when working in heat.

WHAT TO DO IF SOMEONE DEVELOPS A HEAT-RELATED ILLNESS

Heat cramps

Muscles can cramp as a result of heavy sweating without replacing salt and electrolytes.

Heat-related illness is a progressive condition and if left untreated it can be fatal.

Fainting

Can occur when you stand or rise from a sitting or squatting position.

Dehydration

Increased sweating can lead to dehydration if you are not drinking enough water.

Heat exhaustion

Occurs when the body is working too hard to stay cool.

If you think you or someone else has severe heat exhaustion, or heat stroke, you should call an ambulance immediately and perform first aid until the ambulance arrives.

Heat stroke

Occurs when the body can no longer cool itself. This can be fatal.

Burns

Can occur if you come into contract with hot surfaces or tools.

Slips

You sweat more in hot conditions, which can increase the risk of slips (i.e. you might slip when using sharp tools if your hands are damp).

Reduced concentration

When working in heat it is more difficult to concentrate and you might become confused. You may be more likely to make mistakes.

Increased chemical uptake into the body

Heat can cause the body to absorb chemicals differently and can increase the side effects of some medications.

Safe Work Australia offers a free guide to managing the risks of working in heat. In it, a number of the common effects of working in heat are explained. These include:

Source: www.safeworkaustralia.gov.au

For the early stages of heat-related illness, first aid can often be effective, but you should always seek medical assistance if in doubt, or if the person’s symptoms are severe. Source: www.safeworkaustralia.gov.au

For more information about heat stress management in the workplace, check out the Katestone website and articles on the subject at www.katestone.com.au

March 2018 | www.airah.org.au/nation | HVAC&R Nation | 21

Safety Corner

ARC-FLASH HAZARD ASSESSMENT The standard for electrical safety in the workplace developed by the National Fire Protection Association is NFPA 70E. It states that for incident energy equal to or less than 1.2cal/cm2 the minimum personal protective equipment (PPE) required is a long-sleeved shirt and long pants or coveralls, a face shield, safety glasses, hearing protection and heavy-duty gloves. The NFPA has developed specific approach boundaries designed to protect employees while working on or near energised equipment. These boundaries are: • Flash protection boundary (outer boundary) – The flash boundary is the farthest established boundary from the energy source. If an arc flash occurred, this boundary is where an employee would be exposed to a curable second-degree burn (1.2cal/cm2). The issue here is the heat generated from a flash that results in burns. • Limited approach – An approach limit at a distance from an exposed live part where a shock hazard exists. • Restricted approach – An approach limit at a distance from an exposed live part where there is an increased risk of shock.

Few faults are as devastating for people and equipment as an arc flash. By carrying out an assessment you can put procedures in place to minimise the risks. An arc flash, also known as a flashover, is a massive surge of light and heat produced when an insulation medium breaks down and ionisation of the air leads to a conductive path forming. Arc-flash hazards are extremely dangerous and can be caused by the following: • Accidental touching of dropped tools or loose parts discharging a spark • Using equipment with inadequate short-circuit ratings • Insulation failure • Over-voltages • Corrosion, dust, condensation or contamination • Improper work procedures • Lack of maintenance. An arc flash can be fatal, and in most cases causes serious injury to personnel. Workers exposed to the flash can find it very difficult, or even impossible, to regain their past quality of life. Typical results from exposure to an arc flash include:

A bolted three-phase, phase-to-phase or phase-toground fault creates high current that flows through the network and is contained within the equipment. Fault studies are used to select equipment that can withstand and interrupt the short-circuit currents. Arcing faults occur when the current passes through the vapour between two conducting materials. The arcing fault current is smaller than a traditional bolted fault current because the vapour acts as an impedance between the conducting materials. An arc-flash hazard assessment includes guidance on minimising the risk to personnel to levels as low as reasonably practicable (ALARP), and minimising the damage to electrical equipment and associated system downtime following an incident. It also demonstrates compliance with local codes and safety regulations. Three factors contribute to the severity of an arc-flash injury: • Magnitude of incident energy • Proximity of the worker to the hazard

• Burns (unless fire-rated clothing is worn it can burn into the skin)

• Duration of exposure for the worker.

• Fire to the plant room and building

An arc-flash hazard assessment estimates the incident energy exposure from potential arc sources. Incident energy is the amount of thermal energy impressed on a surface at a certain distance from the source, generated during an electrical arc event. Incident energy is typically expressed in calories per square centimetre (cal/cm2).

• Hot flying molten objects • Sound blast (noise can reach 140dB – as loud as a gun) • Intense heat (upwards of 20,000°C). To understand the purpose of an arc-flash hazard assessment it is important to understand the differences between a bolted fault and an arcing fault.

Incident energy of 1.2cal/cm2, is enough to cause second degree burns.

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• Prohibited approach (inner boundary) – A distance from an exposed part that is considered the same as making contact with the live part. When an arc flash hazard exists NFPA 70E states: • An arc-flash hazard assessment shall be done to protect personnel from the possibility of being injured by an arc flash. The assessment shall determine the flash protection boundary and the PPE that people within that boundary must use. • Appropriate safety-related work practices shall be determined before any person approaches exposed live parts within the limited approach boundary by using both shock risk assessment and flash risk assessment. • If live parts are not placed in an electrically safe work condition, work to be performed shall be considered energised electrical work and shall be performed by written permit only. The standard goes on to state that if working on energised equipment is unavoidable, the employer shall develop and enforce safety-related work practices to prevent electric shock or other injuries resulting from either direct or indirect electrical contacts. The specific safety-related work practices shall be consistent with the nature and extent of the associated electrical hazards. These safety related work practices could include: • Energised electrical work permit • Personal protective equipment • Insulated tools • Written safety program • Job briefing. n

This edition of Safety Corner was supplied by NDY.

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March 2018 | www.airah.org.au/nation | HVAC&R Nation | 23

Around the Nation 1

LICENCE TO CHILL

Important changes have been made to the refrigeration and air conditioning (RAC) permit scheme. First, the duration of Refrigerant Handling Licences (RHLs) and refrigerant trading authorisations (RTAs) has been extended to three years. From January 1 until December 31, 2018, you can choose to take up the new option of a three-year RHL or RTA, or stick with the existing durations. From January 1, 2019, the default duration will be three years for all RTAs and RHLs, except for trainee RHLs, which will still be valid for just one year. If applicants have genuine concerns or a legitimate reason to request a different period, there will still be scope for exceptions. However, Glenn Evans, CEO of the Australian Refrigeration Council – the body responsible for issuing the licences – reports that so far industry has been taking up the new three-year option “with gusto” and that businesses have welcomed the option of longer periods between re-applications. The re-application process has also been streamlined, and applicants will have the option of “renewing” rather than re-applying. Again, businesses should save time as a result. For more information on the changes go to www.arctick.org n

HANDS-ON FLANGE TRAINING

CTS has released a range of Australian-designed and manufactured flanged pipeline solutions incorporating Ballorex precision balancing valves for water-based heating and cooling systems and the range of Flamco expansion tanks. And as part of the launch, CTS is supporting the products with a purpose-built training facility at its headquarters in Bayswater, Melbourne. The training room is over 200m2 and features a functional hydronic system consisting of differential pressure valves, pressure independent valves, isolating valves and valve accessories. Cutaway models show the internal function and components as well as a practical installation of the CTS in-line flanged pipe products.

Training is conducted by Frank Smith Mech Eng. who brings substantial knowledge and experience in HVAC&R system design and commissioning of balanced hydronic systems. CTS CEO Gary Stanley states that providing training was key to taking on the Ballorex distributorship.

LEGIONNAIRES’ TEST A MUST

Monthly testing for Legionella and heterotrophic colony count (HCC) is now compulsory for all cooling tower systems in New South Wales.

“First, the products needed to be best in class and offer contractors something unique or superior to what is currently available in the market. Second, to support Australian sales and distribution we decided on-theground training and back-up was required with a fully operational facility and technical expertise to demonstrate capability. Senior staff have 30-plus years’ experience in valve supply and manufacture, instrumentation and refurbishment. The Meibes group, which makes the Ballorex valves, also provides us with full backing as one of the largest manufacturers in the world.”

On top of this, any test results that exceeds 1,000 CFU/mL Legionella or 5,000,000 CFU/mL HCC must be reported within 24 hours to local government.

Go to www.ctsflange.com.au n

“This is a good start to the improvement of cooling tower regulation in NSW,” says Hydrochem CEO Nick Duncan, M.AIRAH.

POLISHING GEMS

The federal government is undertaking the first review of the Greenhouse and Energy Minimum Standards Act 2012 (GEMS Act). The act allows the Commonwealth to set uniform national energy efficiency standards for appliances and equipment, and requires the use of energy rating labels on those products. GEMS has been a force for improving energy efficiency, contributing to reduced energy consumption, energy costs and greenhouse gas emissions. “To date, standards under the GEMS Act have saved the average household between $140 and $220 on their electricity bill each year,” says Federal Minister for the Environment and Energy Josh Frydenberg. “From 2015 to 2020, the GEMS Act is estimated to reduce Australia’s emissions by at least 27 megatonnes. That’s the same as taking over eight million cars off the road for a year.” The review will include consultation with a range of stakeholders, including industry and consumer groups as well as state, territory and New Zealand governments. It will start immediately and deliver a final report during 2018. For more information go to www.energy.gov.au n

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The changes were made based on the recommendations of the expert panel and Legionella steering committee established by NSW Health in July 2016. The panel was formed after two Legionnaires’ disease outbreaks in Sydney’s CBD in March and May 2016 that resulted in 13 confirmed infections, including one death.

“Until now, cooling tower owners in NSW were not required to test for Legionella or HCC – which has made the maintenance regime in NSW quite different to other jurisdictions. We expect to see the introduction of further regulations requiring annual risk-management plans and audits. With an increased focus on risk management, and an education process to all stakeholders, we should not see a repeat of the outbreaks that occurred in 2016.” It is estimated that there are 6,000–7,000 cooling tower systems in NSW. For more information go to www.hydrochem.com.au n

NEW FACE AT PACIFIC HVAC

Pacific HVAC Engineering has appointed Thida Kao as regional sales manager. Having earned a Bachelor of Chemical Engineering from Swinburne University, Kao started her new role in January. She brings with her 10 years’ experience in the ventilation industry and seven years’ experience in the chilled water industry. “We are thrilled to welcome Thida to the Pacific HVAC Engineering team,” says managing director Sudevan Nallathamby.

Around the Nation 5

“Her experience within both the ventilation and chilled water industries will be beneficial to our customers as they look to work with Thida across product portfolios.” Pacific HVAC Engineering is a manufacturer and distributor of specialised HVAC equipment in Australia, offering a range of ventilation products for many different air-movement applications, including mining, manufacturing, construction, agriculture as well as retail end users. The company builds its products in Melbourne, Sydney and Auckland. For more information go to www.pacifichvac.com n

BUSTED!

A New South Wales-based importer has been fined $12,600 by the Department of Environment and Energy for importing vehicles with air conditioning units containing a refrigerant gas – believed to be R134A – without an appropriate licence. The importer also incurred significant warehousing costs and business delays because of its failure to obtain an appropriate licence before importation. The company had previously held a licence to import regulated substances, however, it had lapsed several years ago. The import and manufacture of products containing these ozone-depleting substances is prohibited in Australia, unless a licence or exemption is held. Importers and customs brokers should check import requirements of ozone depleting substances or synthetic greenhouse gases, including when they are contained in equipment, before importing or exporting goods. Adequate time should be allowed to apply for a licence or exemption if one is required, which may take up to 60 days. The Australian government is committed to protecting the environment and the ozone layer. Australia is a signatory to the Montreal Protocol on Substances that Deplete the Ozone Layer, as well as the United Nations Framework Convention on Climate Change. In cooperation with the Australian Border Force, the Department has monitoring and inspection arrangements in place to ensure compliance with the Ozone Protection and Synthetic Greenhouse Gas Management Act 1989, and to undertake enforcement activities where appropriate.

The maximum penalty for each offence of importation is $2,100,000. For more information about the Act and licence requirements for importers and customs brokers, go to www.environment.gov.au/protection/ozone n

ARBS COUNTDOWN

Applicants must be in the third year of a Certificate III in Air Conditioning and Refrigeration apprenticeship at the time of being awarded the scholarship. The program was created by leading industry associations the Air Conditioning and Mechanical Contractors Association (AMCA) and the Air Conditioning and Refrigeration Equipment Manufacturers Association of Australia (AREMA). It’s supported by the ARBS Education and Research Foundation.

ARBS 2018, the premier HVAC, refrigeration and building services exhibition in the southern hemisphere is just around the corner. The exhibition returns to Sydney this year, from May 8–10, at the brand new International Convention Centre. It’s a great chance to connect and network with leaders, peers, colleagues and suppliers while discovering the latest products, systems and service evolutions in the industry.

The scholarship covers tuition, travel, meals, accommodation and training resources for both the students and their accompanying teachers. It embodies eight key units of competency from the Master Refrigeration program developed by RCCC, and runs over two separate weeks: July 2–6 and October 1–5.

The Speaker Series program will provide information and knowledge about emerging technologies, methodologies, standards and best practice.

For more information and the nomination form go to www.amca.com.au n

The awards program once again is attracting strong interest. These recognise excellence in the Australian industry across a range of areas including Young Achiever, Product Excellence, Project Excellence, Industry Education and Training, Outstanding Service & Maintenance Provider, and the new category for 2018, Software/Digital Excellence. There’s also the Hall of Fame – one of the biggest honours for those who have provided distinguished service to the industry. “We have no doubt ARBS 2018 will continue its growth trend with anticipation of a strong flow of visitors from around Australia and overseas,” says ARBS chairman Ian Hopkins (above). “I am personally looking forward to what I am sure will be a bumper exhibition and a wonderful supporting program. I look forward to seeing you in Sydney in May.” Go to www.arbs.com.au n

ATTENTION TOP TRAINEES!

Nominations for 2018 Industry Educational Trade Scholarships are now open – but only until 5pm on March 9, so you’ll need to get in fast if you are interested. Now in its third year, the scholarship gives TAFE students the chance to train at one of the industry’s premier institutions – the Refrigeration and Climate Control Centre of Excellence (RCCC) in Melbourne.

The recipients of the 2018 Industry Educational Trade Scholarship will be announced on March 23.

INFLATABLE ENTERTAINMENT

Ventilation may generally go unnoticed in everyday life, but over the December/January school holidays it was the star of the show in Melbourne’s Federation Square, where the Architects of Air set up their Arboria inflatable sculpture. Over 50 metres long and over 30 metres wide, the “luminarium” is a giant air-fil led tent made up of various chambers. Visitors remove their shoes at the entrance, then pass through an airlock. Once inside they are free to explore the installation, or just sit back and enjoy the radiance of the daylight passing through the coloured parts of the sculpture. When the luminarium visits more temperate climes it can be inflated by eight fans set up around the perimeter of the structure, each delivering up to 1400m3/hour at around 2.7 millibar pressure. But for the visit to Melbourne during our sweltering Aussie summer, seven 20kW units replaced the fans, delivering cooled air via the luminarium’s 40cm diameter air inlets evenly spread around the perimeter. When at maximum capacity the luminarium can host from 160 to 200 visitors per hour. The event in Melbourne had a daily attendance of around 1,600 visitors per day. For more information go to www.architects-of-air.com n

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