HVAC&R Nation April 2019 by AIRAH

Skills

WORKSHOP Flammable lower toxicity refrigerants

PLAYING WITH FIRE Getting to grips with flammable refrigerants

HEAVY DUTIES HEAVY LIFTING FACTS AND HACKS

April 2019 / ISSUE 120

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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 3022

Contributing writer

Lifting heavy kit is a regular part of the job in HVAC&R. We get expert advice on how to do it right.

Sean McGowan

Advertising sales

HVAC&R Nation regulars

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

Global Update

Exclusive to this issue

Industry news from around the world ISSN 1834-9522

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

Flammable lower toxicity refrigerants

See what’s new in the ‘Shed

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

The Toolshed

Skills Workshop

Cool Tech Cleaning naval warships with robots

Insurance advice What kinds of cover should a fridgie consider?

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.

Everything you need to know about Industry Nights

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.

26 28

Playing with fire

The HFC phase-down has seen the rapid emergence of flammable refrigerants, but is our industry ready?

Smoko with . . . Q&A with James Mason

13,159 PLEASE CONSIDER THE ENVIRONMENT AND RECYCLE THIS MAGAZINE IF YOU ARE NOT GOING TO KEEP IT.

Green Wedge Electric racing comes to the twowheeled world with MotoE

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Around the Nation Who’s in the news?

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Lighter Side The shonkier side of the nation

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Ed’s letter

FOR FRANK It was early on Wednesday morning and I was tapping out an email to Frank, our offsite designer. I’d already sent a few of this issue’s articles over for him to lay out and hadn’t heard back, which was odd – he usually responds pretty quickly.

I was just through typing “Hey mate, hope everything is OK” when my boss came into the office and called me and the rest of AIRAH’s publishing team into the boardroom. It was obvious from his face that it wasn’t good news. He proceeded to tell us that he’d just received an email from Frank’s sister. Frank had died on Sunday night of a heart attack.

It was strange also because I never met Frank face to face. He worked offsite, and not just in another part of town, but in another country. A few years ago, long before I started, he moved to Spain to look after his ageing parents, and then on to Thailand where he started a family. A few times we said we’d do a Skype call. But as the deadlines flew past, we never got around to it. The guys who’d known him longer said he’d mellowed over the past few years. That he was content. Frank had worked with AIRAH since the early 2000s, meaning he was there for the first issue of HVAC&R Nation – and every one since. Putting a mag together involves a cast of dozens and a few key actors who really have to take responsibility for bringing it to life. One of those is the designer. Their work is definitely the most visible, and probably the most critical. As a big believer in the power of writing it’s hard for me to say that, but people aren’t going to read the articles if the designer doesn’t make the magazine itself look good. And Frank made it look great.

FREE INDUSTRY MAGAZINE

AUGUST 2011 • ISSUE Nº 044

FREE INDUSTRY MAGAZINE

Up and away

Revising the Standards of HVAC&R

On shaky ground

The greatest show on Earth

The challenges of adjusting to a new normal in Christchurch

Trade night wrap-up

The Green Wedge

Training tips

Taking the High Line

CO22 refrigerant safety

Skills Workshop LIFT-OUT

Ammonia safety requirements and hazard identification

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Condensation in buildings – Part 2

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SEP TEM BER 2010 • ISSUE N º 035

Retrofitting a goliath of the sea On board Australia’s Pacific Dawn

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JUNE 2011 • ISSUE Nº 042

Japan earthquake Sending shivers through the supply chain

State of the nation

The fly guy

The man cave

Viva la vuvuzela

Send in your pics

Skills Workshop LIFT-OUT

Skills Workshop LIFTOUT

An introduction to Building Management and Control Systems – Part 2

An introduction to commercial and industrial refrigeration systems

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JULY 2010 • ISSUE N º 033

Zero emissions housing

The Australian air conditioning industry in 2010

A new fit-out for Suncoast Fresh

The iPhone revolution Apps for work – really!

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Backflow prevention

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FEATURE

nOls uPdate

moving towards a national licensing system FEATURE

When you work in a team you get used to your workmates being there. A couple of times I caught myself going to email a story to Frank. Even weirder was seeing his emails from a few days ago, or any of the pages, flyers or ads he recently laid out. He was here, then he wasn’t. Just like that.

Please consider the environment and recycle this magazine if you are not going to keep it.

The reality is closer than you think

Playing it cool on the Sunshine Coast

Training tips Stats aren’t just for footy

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arbs PreView

As you can imagine, this issue of HVAC&R Nation has been a strange one.

NOVEMBER 2011 • ISSUE Nº 047

A revolution is under way

Refrigerant prices soar

WORKSHOP

Skills Workshop

LIFT-OUT

Guidelines for gas cylinder safety – Part 2

what’s on offer at arbs 2012?

I thought about trying to find a photo of him to include with this editorial, but I’ve never actually seen one. The only visual I have of Frank is in the pages he produced – like the covers shown here.

australian manufacturing

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Again, as a believer in the power of writing, it hurts to say it, but words often fail at times like these. So I’ll simply sign off by dedicating this issue of HVAC&R Nation to Frank, and all the amazing work that he did over the years.

@AIRAHnews

APRIL 2012 / ISSUE 050 / FREE

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

Advertise in HVAC&R Nation HVAC&R Nation, has the highest distribution and readership of any HVAC&R publication in Australia. Targeted distribution Circulation 13,170 Readership 32,925 HVAC&R Nation is distributed free over the counter at more than 260 outlets Australia-wide including: Actrol, Heatcraft, Airefrig Australia, Beijer Ref, Cold Chain Group, Polyaire, Reece, Totaline, Tradeline Plumbing and TAFE colleges.

Contact: Glenn Douglas – glenn.douglas@airah.org.au or John McGrath – john.mcgrath@airah.org.au 03 8623 3000 4

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Toolshed 01 Cylinder management made easy

Heatcraft has released a new app to help customers better manage their cylinder fleet.

According to SACE, the machine is suitable for established ductless air conditioning technicians as well as those just starting out.

Gas2Go lets business owners and contractors assign and transfer cylinder holders, bar-code scan and geo-locate cylinders. They can also assign locations and add activity notes against each cylinder. And fill weights can be adjusted for an accurate measurement of refrigerant across the fleet.

“Our machine is simple to use and will deliver a highquality result for customers and service professionals alike,” says the company. Go to www.sacemachine.com ■

The app notifies users when cylinders are due for leak testing and when they are due to be returned, reducing the risk of cylinders being invoiced as lost. “Refrigerant and cylinder management is identified as a huge risk by our customers and the cost of mismanagement can be significant,” says Heatcraft parts and refrigerant marketing manager Brett Hedge, M.AIRAH.

04 A sticky solution 02

DuctTech, a supplier of PVC low-profile ducting for ventilation, has released a new duct glue. The company says the product is the result of several months’ development and enables ducts to be joined together in the same way as blue hydraulic PVC pipe in sanitary plumbing.

“Our customers want a simple yet comprehensive way to manage their cylinder activity and highlight cylinder ownership to their technicians. We’re pleased to be able to offer them this new functionality, free of charge.”

“We are always striving to improve and find new ways to make work easier, faster and cost-effective,” says DuctTech. “Labour onsite is very expensive. In our product development, saving labour cost is always our numberone aim and we believe we have achieved this aim with our newest product.

The Gas2Go app is available for the latest versions of iOS and Android, is free to download and available to all Heatcraft customers with a smart@ccess account. For more information or to open a smart@ccess account, contact Heatcraft on 13 23 50. ■

“The glue forms an instant lock (one minute). It is totally safe and does not affect the fire rating property of our product.”

02 Become a time lord Job management specialist Simpro has launched a new app to help trade businesses keep better track of their technicians’ work hours.

“The SACE cleaning equipment is a heavy duty and robust system that is built in Australia and is fully compliant with industry standard best practice.”

The company says it’s as simple as gluing the outside edge of the joint and the inside edge of the duct. Then immediately assemble and wait up to one minute for an instant, solid lock.

“We believe this will be a game changer,” says DuctTech.

The Timesheet app lets technicians in both service and project environments keep track of time and easily allocate hours worked from their mobile devices. It is tailored for staff working on large projects. Simpro’s chief technology officer Jonathan Eastgate says this is a first.

Go to www.ducttech.com.au ■

“The ability our Timesheet app gives to allocate times across a variety of work completed in a day means that businesses can better account for the time their staff are spending on each project,” Eastgate says.

As the new National Construction Code comes into force this May, some manufacturers are scrambling to ensure their products comply. Kingspan has taken a more proactive approach.

“The extended app gives all technicians who use it a new level of autonomy. Time can be recorded retrospectively – or as the job is being completed. And the ability to use the app offline gives users access to review and record activities no matter where they are.”

The company’s bestselling Kooltherm K10 FM Soffit Board will no longer be compliant to the NCC after the cut-off date. As a result, Kingspan has discontinued the product and replaced it with a new one.

Simpro says the app will significantly minimise the administrative legwork required by onsite technicians and is a major leap forward for those working in project-heavy environments.

05 Kingspan cracks the code

Go to www.simpro.com.au ■

Kingspan’s new foil-faced rigid board insulation, named Kooltherm K10 FM G2 Soffit Board, features a thicker foil lining and has already undergone the ISO 9705 test, achieving a Group 2 rating.

03 Clean machine After many years of development, Specialised Air Conditioning Cleaning Equipment (SACE) has released a new lightweight and portable air conditioning cleaning machine. The unit is fitted with a long-life 12V solid-mass battery that is said to clean between 10–12 units per day without needing to be recharged. It features fast flow and optimal pressure of 100PSI. “Users and customers will see the results to their ductless air conditioning system,” says SACE. “It will deliver a hygienic clean to their unit and fresh air for the whole family. 6

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“Kingspan Insulation has been preparing for this transition for some time,” says sales director Craig Burr. “We are confident in our ability to supply a product that will not only adhere to the new NCC standard but will also provide the same great thermal performance that our customers have come to expect from us.”

April 2019

“We have been supplying our Kooltherm K10 FM G2 Soffit Board to the New Zealand market for a few years now, and are confident in transitioning the product into Australia,” says Burr. “The product is CodeMarkcertified for NCC compliance and is ready to be introduced to the market.” Go to www.kingspan.com/au/en-au ■

Toolshed 06 Daikin’s wi-fi wonder

Daikin has released its new ducted wi-fi controller app, Daikin Airbase.

Poor maintenance access is a regular headache for HVAC&R technicians. And once you do manage to get to the equipment, there’s also the problem of seeing what you’re doing when the unit is close against a wall or in a space with insufficient lighting.

The app is available for download through the Apple App Store and Google Play and gives users easy access to the functions of Daikin’s ducted system. This includes the countdown on/off timer, operation mode theming, filter cleaning reminder, zone on/off, multiple zone control and the ability to enter zone names. “In conjunction with Daikin’s BRP15B61 wireless LAN adaptor, which now comes with a 20m cable for easier installation in an occupied space, the Airbase app allows users to operate their ducted air conditioning system from their phone or tablet, via their in-home wi-fi or remotely with an internet connection,” says Daikin. “Up to five systems can be conveniently monitored and controlled via the app anywhere, anytime.”

07 Lightbulb moment

A headlamp such as this MH7 model from Ledlenser could provide a solution. The lamp features an Xtreme LED with a maximum brightness of 600lm. You can also change the intensity of the light across different settings, and an Advanced Focus System lets you adjust the focus with one hand, to aim light where it’s needed.

Each ducted system requires a BRP15B61 adaptor and must be connected on the same wi-fi network. Go to www.daikin.com.au ■

Ledlenser says that the battery is easy and quick to charge with a magnetic USB charging cable. It’s also possible to use conventional disposable batteries. Additionally, it’s equipped with a red-light LED and has an energy-saving mode if you’re expecting a long session. At max power, the battery is claimed to last for seven hours. The lamp can also be removed and used as a handheld light, and it’s protected to IP54. The MH7 costs $164.95. Go to ledlenser.com.au ■

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.

April 2019

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HVAC&R Nation

Global Update

CHINA

USA

PROMOTING THE PRIZE

CANINE COMFORT

The Rocky Mountain Institute (RMI) has been travelling all over the world to promote the Global Cooling Prize. The Prize offers US$3 million to inventors who can design a room air conditioner with five times less climate impact than standard units on the market today. As well as visiting Australia last month, RMI Senior Fellow Iain Campbell attended a launch in Beijing with the China Association of Refrigeration. Members of both organisations and various Chinese government departments spoke at the event and called on industry players to get involved in the competition. The event was attended by over 60 delegates from major manufacturers, research institutes, universities and international organisations. They gathered to discuss the prize application process, criteria, testing protocols, and support for the competition. ■

This is in addition to the Cabin Overheat Protection feature – designed to protect children and pets sitting in a parked Tesla – which turns the vents and air conditioning on if the cabin temperature exceeds 40°C. The change came about after a customer tweeted Tesla CEO Elon Musk asking for the feature. ■

NEW ZEALAND

A COOL PIECE OF HISTORY

TRAINING SHAKE-UP

The compressed-ammonia chiller is of great historical importance for the science of refrigeration. It also confirms the long relationship between refrigeration and beer. The machine was designed for the Dreher Brewery in the hot and humid city of Trieste (then part of the Austro-Hungarian Empire). It first ran using methyl ether as the refrigerant, but a second design switched to ammonia. Linde’s ice machine revolutionised the brewing of summer beers such as lager, which had previously relied on ice harvested from lakes and ponds. The machine will be one of the major exhibits at the new Regensburg Museum, due to open in June. ■

Simply tap a fan icon at the bottom of the touchscreen when the car is parked, change climate setting to “dog”, and adjust the temperature limits. If your battery reaches less than 20 per cent charge, you receive a notification on your mobile app.

GERMANY

The Cooling Post reports that the first ammonia refrigeration machine designed by German pioneer Carl von Linde in 1876 is to be put on permanent display in Germany.

Tesla has rolled out a “Dog Mode” on its cars. The feature lets you set a cabin temperature to keep your dog comfortable and displays a message to let passers-by know that everything is under control.

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The New Zealand government has proposed an overhaul of the country’s vocational training system. According to the NZ Herald, a new Institute of Skills and Technology will take over program design and administration for New Zealand’s 16 separate polytechnics. It will also take over enrolling and managing apprentices and industry trainees from what are now 11 industry training organisations (ITOs). The ITOs will be replaced by new “industry skills bodies” which will be led by employers. “We currently have a vocational education system that is in many cases struggling,” said Prime Minister Jacinda Ardern. “We know we need more tradies and yet they’re just not coming through fast enough. At a time when we are facing critical skills shortages, our polytechnics and institutes of technology are in many cases going broke.” ■

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HVAC&R Nation

Cover Feature

HEAVY DUTIES Lifting heavy objects is one of the most common causes of work‑related injuries for those in construction, including fridgies. Sean McGowan gets the experts’ advice. Many of us have felt it: a pain or twinge while lifting something heavy. Manual handling is a routine part of the job for fridgies, but it can easily lead to serious injury.

A 25kW ducted unit in a

In New South Wales, 9 per cent of workers compensation claims in the construction industry are related to body stressing. SafeWork NSW considers heavy lifting in the workplace to be any manual task that involves repetitive or sustained force, high or sudden force, repetitive movement, sustained or awkward posture and exposure to vibration.

display home or medium office weighs around 153kg

And those in the HVAC&R industry perform these tasks on an all-too-regular basis. “Tasks that involve manually moving, lifting, carrying and handling of any heating, ventilation, air conditioning and refrigeration [equipment] may be considered as a hazardous manual task,” says SafeWork NSW director of health and return to work, James Kelly. 10

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With some common items of HVAC&R kit weighing over 200kg, how do you go about moving them? And if you’re a sole trader working one-out onsite, what’s the best way of removing heavy items from your vehicle and into position? This is a challenge that faced HVAC&R technician Mark Willoughby of Amark Refrigeration & Air Conditioning. “I predominantly work by myself,” says Willoughby. “I have several trollies that I make the most of.

April 2019

But when it comes to lifting units onto and off my work truck it does become quite dangerous.”

Recently, he had to lift a heavy condenser for a ducted air conditioning system onto his ute by himself. “During the lift, I knew it was quite dangerous, but I needed to move it from the customer’s residence. Once I eventually got it onto the back of the ute, I thought to myself that there must be a better way.” In search of a solution, Willoughby reached out to his fellow fridges at the Australian Refrigeration Mechanics Association (ARMA) for ideas.

WHAT THE FRIDGIES SAY Willoughby found that he wasn’t alone. Many others face the challenge of lifting heavy gear and equipment. While some joked that it was the role of an apprentice (more on that later), others had useful suggestions ranging from mechanical intervention to seeking more hands. And as you’d expect from our innovative industry, there were a few heavy lifting hacks offered too. One fridgie recommended putting the heavy end of the object the on lip of the tray, finding the pivot point and then sliding it.

Cover Feature

During the lift, I knew it was quite dangerous, but I needed to move it from the customer’s residence Another suggested the use of an eight-foot timber sleeper with an angle iron on one end. This hooks under the tray so it won’t slip, and the sleeper acts as a ramp to slide the item down to ground level. The most popular solution appeared to be installing a manual hand lifter. “The feedback I received was great,” says Willoughby. “Everyone had their own way of doing things and they are all willing to pass this information on.”

WHAT THE TAFE SAYS According to Jack Johansen, a refrigeration teacher in the East Coast Region of TAFE Queensland, his students regularly lift heavy condensers. “A recent survey at TAFE NSW showed that 72 per cent of TAFE students worked for employers who primarily did air conditioning installations, which means regularly lifting condenser units on and off work vehicles,” Johansen says. While small businesses commonly use trolleys to wheel condensers around work sites, he says most apprentices and tradespeople admit to lifting heavy condensers by themselves without mechanical aid. “A 25kW ducted unit in a display home or medium office weighs around 153kg,” says Johansen. “I have personally witnessed a local company lifting one of these from a trailer – just one tradesman and an apprentice.”

GOING UP

Another popular option is a manual tailgate lifter. Source: Healy Group.

MANAGING THE RISK This includes:

Alarmingly, research has shown that lifting technique training is not effective in minimising the risk of injury to manual tasks.

• Identifying hazardous manual tasks • If necessary, assessing the risks of MSDs associated with hazardous manual tasks

“This is mainly because the risk factors causing the problem are not changed, and if workers attempt to apply safe-lifting techniques, they may still risk a serious injury,” says SafeWork NSW’s James Kelly.

• Implementing suitable risk-control measures • Reviewing the effectiveness of control measures

He says a person conducting a business or undertaking (PCBU) should take a proactive and holistic approach in reducing risk by consulting with workers and applying the risk management approach.

“When determining control measures, the PCBU must have regard to all relevant matters that may contribute to an MSD as per Clause 60(2) of the Work Health and Safety (WHS) Regulation 2017,” says Kelly.

An overview of the risk management process for manual tasks is provided in the NSW Hazardous Manual Tasks (HMTs) Code of Practice.

“Also, the duty holder must consider the hierarchy of control as stated in Clause 36 of the WHS Regulation 2017.

Here are some commonly handled HVAC&R equipment and items – and their approximate weights.

HVAC&R KIT • 560mm fan assembly – 15kg • Semi-hermetic compressor – 210kg • Cabinet evaporator – 8kg • Coolroom evaporator – 170kg • Scroll compressor – 60kg • 2.5kW split system – 40kg • 7.1kW split system – 65kg • 25kW ducted system – 155kg

TOOLS OF THE TRADE • Refrigerant reclaim unit – 15kg • Nitrogen D-size cylinder – 15kg • Nitrogen E-size cylinder – 30kg • 3/4” Annealed Copper roll R410 – 10kg • Pair Coil 3/8”–5/8” – 14kg Source: Actrol and TAFE Queensland Manual handling is also the biggest cause of injuries in Victorian workplaces, according to WorkSafe Victoria. April 2019

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HVAC&R Nation

Cover Feature by 50 per cent by 2022 in high risk sectors, including the construction industry. To support this, it has developed an MSD strategy with relevant stakeholders. It has also worked with them to develop the Building and Construction Work Health and Safety Sector Plan to 2022.

The construction industry was in the top three for serious musculoskeletal

“This plan outlines the importance of reducing MSDs by engaging industry leaders to identify realistic and workable solutions that can be implemented to protect workers from hazardous manual task risks,” says Kelly, “including muscular stress while lifting, carrying or putting down objects.”

disorder (MSD) claims for the period 2014–2017 Recognising the risks of heavy lifting, TAFE Queensland includes the topic in their courses.

Additionally, Safework NSW is running free workshops for all industries, including the construction industry, under which HVAC&R falls.

“The TAFE is required by standards to teach the appropriate methods for lifting and teach a general workplace health and safety (WHS) competency at the beginning of an apprenticeship,” says Johansen.

The Participative Ergonomics for Manual Tasks (PEforM) workshops are a simple manual task risk management program based on an internationally recommended approach for reducing MSDs. They are organised around the country by state and territory WH&S authorities. For a full list, go to www.safeworkaustralia.gov.au

“In this competency, we make students aware of mechanical aids such as duct lifters and cranes.” While cranes are often used in multi-storey commercial buildings, a mobile crane can be an inexpensive and suitable solution to lift items of around 150kg onto smaller buildings.

SafeWork’s Work Health and Safety Roadmap for NSW 2022 and the 2017–2022 Musculoskeletal Disorder (MSD) Strategy are available on the SafeWork NSW website at www.safework.nsw.gov.au

“Local businesses I know use hire companies to rent duct lifters for small lifts to get onto singlestorey roofs,” says Johansen.

WHAT SAFEWORK NSW SAYS According to the latest data from SafeWork NSW and the State Insurance Regulatory Authority (SIRA), the construction industry was in the top three for serious musculoskeletal disorder (MSD) claims for the period 2014–2017.

Some items are obviously heavy. Kit such as condenser or evaporator units often weigh 150kg or more. But many other common items should also be (manually) handled with care. According to Actrol, a 10kg refrigerant cylinder can weigh around 21kg when full, while a 20kg cylinder can weigh 15kg when empty and as much as 37kg when full (depending on the type of gas and the fill ratio). Nitrogen cylinders should also be lifted, carried and put down carefully, with D-size cylinders weighing around 15kg and E-size cylinders 29kg.

Of those claims, the largest number were related to handling, lifting, carrying or putting down objects.

Even a roll of 3/4” 19mm annealed refrigeration copper suitable for R410 systems weighs 10kg.

In the two-year period of 2016/17 and 2017/18, SIRA received over 5,500 workers compensation claims applications from the construction industry resulting from exposure to body stressing. Of these, 39 per cent of the injuries and diseases were caused by muscular stress while lifting, carrying or putting down objects.

With a growing business on the Sunshine Coast, Willoughby says his experience has already led to changes in the way he approaches the lifting and movement of heavy equipment.

These figures prompted SafeWork NSW to commit to reducing serious musculoskeletal injuries and illnesses

“It has definitely made me realise that I require help to perform some tasks and I can’t do it all on my own,” he says. ■

Table 1: Body stressing claims in the construction industry, 2016/17 and 2017/18 Number of claims 2016/17

Number of claims 2017/18

Total

1,084

1,082

2,166

39.0

Muscular Stress While Handling Objects other than Lifting, Carrying or Putting down

944

1,157

2,101

37.9

Muscular Stress with No Objects Being Handled

466

488

954

17.2

Repetitive Movement, Low Muscle Loading

151

175

326

5.9

Mechanism of incident Muscular Stress While Lifting, Carrying or Putting Down Objects

Total

2,645

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5,547

100.0

Clause 60(1) states that a person conducting a business or undertaking (PCBU) must manage risks to health and safety relating to a musculoskeletal disorder (MSD) associated with a hazardous manual task (HMT), in accordance with Part 3.1. Clause 60(2) states that in determining the control measures to implement under subclause (1), the PCBU must have regard to all relevant matters that may contribute to an MSD, including: • Postures, movements, forces and vibration relating to the HMT • The duration and frequency of the HMT • Workplace environment conditions that may affect the HMT or the worker performing it • The design of the work area • The layout of the workplace • The systems of work used • The nature, size, weight or number of persons, animals or things involved in carrying out the HMT. The NSW HMT Code of Practice (2016) also provides practical guidance to a PCBU on how to manage the risks of MSDs arising from HMTs in the workplace. It applies to all types of work and all workplaces where manual tasks are carried out. This code also includes various references to provisions of the WHS act and regulations that set out the legal requirements.

Do you have a heavy lifting “hack” to share with the HVAC&R community? Email mark.vender@airah.org.au

Source: State Insurance Regulation Authority (SIRA) |

2,902

WHAT THE LAW SAYS Laws relating to the management of risks to health and safety in New South Wales workplaces are covered within the Work Health and Safety (WHS) Regulation 2017.

HEAVIER THAN IT LOOKS

“But for small 20kg to 30kg condensers, we generally teach that two workers using appropriate lift techniques can manage it, as long as it is not lifted above chest height.”

A mobile folding crane like this can lift up to 1,000kg.

April 2019

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Mobile App

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April 2019

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Cool Tech

AUTOMATON FOR THE PEOPLE AMAR is a compact, flat box on four discreet wheels, about the size of a dinner tray.

A ship-shape robot may be the solution for completing a thankless, dangerous task. Remember those futurists from back in the day who predicted that by the year 2000 robots would be doing most of life’s unpleasant tasks? A bit like the paperless office, this never quite eventuated. Let’s face it, there are still plenty of irksome jobs to do, and they usually require some poor sap to do them. And we are still waiting patiently for the robot revolution. Maybe, though, the first tentative steps have been taken. A robot that cleans and paints navy ships while in dry dock was the winning idea in UNSW Sydney’s recent Maker Games. The Games challenge budding engineers, inventors, entrepreneurs and designers to solve real-world problems set by industry partners. Event winners Team Arash responded to the challenge set by a mentor from defence industry group BAE Systems to revolutionise the process of cleaning and painting naval warships. After months of brainstorming, tinkering with models, and seeking advice from mentors, Team Arash emerged with AMAR (Autonomous Magnetic Attraction Robot).

“The robot is designed using magnets to attach to the side of a steel vessel, with hose nozzles that could clean or paint the ship using high-pressure water or paint,” says team member Evan Pignatelli.

As well as eliminating

During its pitch to the judges, the team put AMAR through its paces in a simulation of the robot working on a ship’s exterior. AMAR moved autonomously back and forth along a makeshift ship’s hull that was set up on stage at an acute angle.

could potentially reduce

Conventional cleaning and painting of a naval ship is extremely expensive, dangerous and laborious. It involves a vessel being lifted into dry dock, with many maintenance workers working in often dangerous and precarious conditions, costing $250,000 a day.

safety issues, its use the maintenance bill by millions of dollars per ship. Los Angeles. There they will network with leading engineering and design organisations over the course of a week. ■

AMAR requires one person per device to oversee its operation. As well as eliminating safety issues, its use could potentially reduce the maintenance bill by millions of dollars per ship. The four winning members of Team Arash will be flown to California’s Silicon Beach, the tech hub of the western beach suburbs of

Demonstration of the AMAR prototype.

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April 2019

HVAC&R

MODULE

120

FLAMMABLE

Skills Workshop LOWER TOXICITY PROUDLY SPONSORED BY

AIRAH

REFRIGERANTS

Skills summary ■

Properties of flammable refrigerants as listed in the Institute of Refrigeration’s 2018 Safety Code of Practice.

This Skills Workshop is taken from the Institute of Refrigeration’s 2018 Safety Code of Practice. The object of this code is to define minimum requirements for safety in the design, construction and installation, commissioning, inspection and maintenance of vapour compression refrigerating systems utilising flammable, lower toxicity refrigerants. These are classified as Group A2L, A2 or A3 refrigerants.

■ Who?

This section of the code deals with the properties of these refrigerants.

What?

Relevant for every person with responsibility through ownership, consultancy, design, construction, installation, commissioning, decommissioning, operation, maintenance, inspection, repair, modification or testing of a compression refrigeration system.

Relevant properties of refrigerants Physical properties Table 1 on page 17 shows some of the important physical properties for the most common flammable lower toxicity refrigerants. The normal boiling point indicates the type of application for which the refrigerant should be used. The Practical Limit (PL) of the refrigerant indicates the allowable refrigerant charge related to the smallest human occupied space as defined in BS EN 378-1:2016. Reference is made to the Lower Flammability Limit

1000

The code of practice is intended to apply within the United Kingdom. However, the information is of general use in Australia as well. Where appropriate, relevant Australian standards have been noted next to the British standards. (LFL) and the Upper Flammability Limit (UFL) in air and the Auto-Ignition Temperature (AIT). The occupational exposure limit (OEL) indicates the concentration of refrigerant in the atmosphere that is allowable for continuous exposure during an eight-hour working day. The PL for A2L, A2 and A3 refrigerants is based on approximately 20% of the LFL. Refrigerant detection devices should be set to warn of concentrations of A2L, A2 or A3 refrigerants which approach the PL and the OEL. The Figure below shows the pressure temperature relationship of a selection of different refrigerants including Propane which is an A3 Flammable Lower Toxicity Refrigerant covered by this Code.

Figure 1. Pressure temperature relationship of selected refrigerants

Pressure (bar(A))

10 Atmospheric Pressure CO2 R-32 Ammonia Propane R-134a

0.1 0.01 0.001 -120 -100 -80

April 2019

-60

-40

-12 0 20 40 Temperature (°C)

100

Moisture is sparingly soluble in most refrigerants at ambient temperature. The solubility decreases as the temperature reduces and excess water can lead to the formation of ice or hydrate at the expansion device, which could impair or stop the operation of the system. Moisture also increases the possibility of chemical reactions between the refrigerant, the oil and the system components and in many refrigeration applications acids may form which could damage the windings of hermetic or semi-hermetic compressors. Due to the chemical make-up of hydrocarbons, this is unlikely to occur with A3 refrigerants, but still applies to A2L and A2 refrigerants. Adsorbent desiccants (molecular sieves) which preferentially adsorb water in the presence of many refrigerants are generally applicable to most A2L, A2 and A3 refrigerants provided the appropriate grades of adsorbent desiccant are selected.

100

Moisture solubility

120

Conventional desiccants, such as activated alumina, will adsorb moisture in the presence of most A2L, A2 and A3 refrigerants. However such desiccants do not retain moisture at higher temperatures as well as the molecular sieve materials. Moisture removed during operation of the refrigerating system may therefore be returned to the system when it is switched off and warms up. It is strongly recommended that drier cores (or beads etc) specifically designated for the refrigerant are used.

Lubricants

140

In general, blends containing A2L or A2 refrigerants are not soluble in mineral or alkyl-benzene oils. Special synthetic lubricants are recommended. The most common type of synthetic lubricant for use with A2L or A2 refrigerants is the polyolester |

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HVAC&R Nation

HVAC&R Skills Workshop Chemical properties and potential hazards

oil (POE) (although the automotive industry commonly uses polyalkylene glycol (PAG) oils for automotive air conditioning). It is a disadvantage of these lubricants that they have a much greater affinity for water than traditional mineral oils to the extent that they will absorb moisture from the atmosphere. They therefore have to be kept from contact with the atmosphere as much as possible. PAG oils have the additional disadvantage that they are intolerant of trace quantities of chlorine.

A risk assessment shall be carried out by a competent person prior to commencing any work. The following items should be considered – note this list is not exhaustive and a site specific risk assessment should be carried out.

Reactivity A2L, A2 or A3 refrigerants do not react with steel, copper, aluminium and brass in acceptably dry refrigerating systems. Alloys containing more than 2% magnesium will react with fluorine and chlorine atoms in A2L and A2 blends and so should only be used with pure A3 refrigerants. In the presence of moisture, zinc and galvanised steel are particularly susceptible to corrosive attack.

In general, pure A3 refrigerants can be used with a wider range of lubricants, particularly mineral and alkyl-benzene oils. However, solubility tends to be increased with A3 refrigerants so it may be necessary to select a lubricant with a higher viscosity grade. Polyalphaolefin (PAO) and polyalkylene glycol (PAG) are also acceptable for use where approved by the compressor manufacturer. POE oils are also acceptable but do exhibit an even higher solubility with A3 refrigerants. It is a disadvantage of these lubricants that they have a greater affinity for water than ordinary mineral oils and therefore have to be kept from contact with the atmosphere as much as possible.

Thermal decomposition A3 refrigerants are subject to thermal decomposition at temperatures of the order of 450°C, and A2L and A2 refrigerants at temperatures in excess of 250°C. In the presence of oil and other contaminants they are subject to reaction and decomposition at lower temperatures, particularly if impurities such as moisture are present in the system. Temperatures in refrigerating systems should be limited to about 135°C. Many A2L, A2 or A3 refrigerants have low indices of compression, which tend to produce low compressor discharge temperatures, although some can have higher discharge temperatures e.g., R32.

Care should be taken that the correct lubricant is selected for the application, for the compressor and for the refrigerant used. Seek advice from the compressor manufacturer if there is any doubt.

Materials compatibility It is important to consider the compatibility of the refrigerant and the compressor oils with system materials such as plastics, elastomers, metals, etc.

Since A3 refrigerants lack chlorine and fluorine atoms there is no possibility of acid formation in the presence of moisture and therefore salt formation and subsequent blockage in appliances is unlikely. Thermal decomposition of A3 refrigerants external to the system does not produce harmful decomposition products, whilst decomposition of fluorinated refrigerants can produce toxic substances such as hydrofluoric acid which is harmful to human health at atmospheric concentrations above 2 ppm v/v.

Virtually all common elastomer and plastic materials used as ‘O’ rings, valve seats, seals and gaskets are compatible with A2L, A2 or A3 refrigerants. Materials that are not compatible and should not be used in HC systems include EPDM, natural rubbers and silicone rubbers. It should be noted that chloroprene (neoprene) products are specifically incompatible with unsaturated A2L, A2 or A3 refrigerants (i.e. R1270, R1150, etc).

Care shall be taken to exclude refrigerants where any brazing, welding or other hot work is to be undertaken. Systems shall not be installed in the same enclosure as flame producing equipment.

Whilst testing has been conducted on a number of selected materials with refrigerant and oil combinations it should be noted that there are numerous different grades available in the market and for this reason compatibility should be checked with the manufacturer or supplier of the component.

Inhalation A2L, A2 and A3 refrigerants have a low order of toxicity but the inhalation of high concentrations can be dangerous. Practical limit values for refrigerants in groups A2L, A2 and A3 are quoted in Table 1. Care shall be taken to select a suitable leak detector, which shall not be a potential source of ignition. Exposure to high concentrations may lead to one of more of three physiological effects:

Selection of refrigerant Refrigerants should be selected so that they contribute to good system efficiency. The effect of temperature glide and composition shift on system performance should be considered when blended refrigerants are used.

a. If the concentration of refrigerant vapour is very high, the atmosphere will become deficient in oxygen and unconsciousness or death may result due to asphyxia.

Refrigerant purity Refrigerant grade product should be used for all refrigerating, air conditioning or heat pump applications. Commercial grade hydrocarbons contain significant quantities of sulphur, water, and other impurities and could contribute to oil degradation, shorten compressor life and invalidate warranties. The composition of commercial LPG is variable so the thermodynamic properties of the fluid may vary significantly from cylinder to cylinder. Also, unlike commercial LPG, Hydrocarbon refrigerants are not odourised. A2L and A2 refrigerants are also not odourised. 16

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b. Refrigerants at high concentrations can have a transient narcotic effect on the central nervous system (CNS effects). Returning the exposed person to fresh air will reverse the symptoms. c. Cardiac sensitisation can result from inhalation of high concentrations of refrigerant vapour. If subsequently a cardiac stimulant is used or is present, cardiac arrhythmia can occur which can prove suddenly fatal. |

April 2019

Excursions to concentrations above the Occupational Exposure Limit values quoted in Table 1 are permitted as defined by the short-term exposure limit (STEL) where listed by the HSE or other short-term limits as advised by refrigerant manufacturers after risk assessment. The vapour of most refrigerants is colourless, odourless and denser than air. If inadvertently released to atmosphere it will initially collect at low level, particularly in pits, trenches and basements. Suitable temporary forced ventilation which does not provide a source of ignition shall be provided to disperse the vapour rapidly. Care shall be exercised on entering a pit, trench or basement where there is a possibility of a high concentration of refrigerant vapour. Fatal accidents involving refrigerants can occur either as a result of asphyxiation or ignition.

Direct contact Where liquid refrigerants having boiling points below zero Celsius at atmospheric pressure come into contact with the skin or eyes, evaporation may cause freezing of the skin or eye fluids and freeze burns may occur. Clothing saturated with liquid refrigerant may freeze to the skin. Higher boiling point refrigerants have solvent actions that can cause defatting and cracking of the skin. Goggles, suitable temperature rated gloves and other suitable clothing shall be worn whenever there is a risk of exposure to refrigerant liquid.

Potential sources of refrigerant leakage The refrigerating system contains refrigerant in both liquid and vapour states. It is possible under abnormal conditions for liquid refrigerant to enter the compressor, for example by way of faulty valves or by overcharge of refrigerant to the system. A compressor is designed to compress refrigerant gas and not to pump liquid; if excess liquid does enter a compressor, damage can occur, with possible release of refrigerant. Liquid refrigerant is liable to damage all types of compressors. Worn, poorly aligned and out of balance machinery can cause excessive vibration and premature failure of piping and components, again with possible release of refrigerant. Liquid refrigerant has a high coefficient of thermal expansion. Care should be taken to ensure that liquid refrigerant is not trapped in pipelines or fittings between shut off devices. A rise in ambient temperature may be sufficient to expand trapped liquid, generate excess pressure and rupture components, resulting in release of refrigerant.

Hot works Brazing, welding and all sources of flame in contact with a refrigerating system constitute a hazard. The probability exists of a flammable refrigerant/oil/air mixture being present within parts being modified. Precautions must be taken before brazing, welding or any operation involving a source of flame in contact with a refrigerating system. A risk assessment is required under WHS/ OH&S, AS/NZS 60079, and AS 2865 may also apply.

HVAC&R Skills Workshop Working in confined spaces

Corrosion

The precautions to be taken before persons are permitted to enter a vessel or similar confined space where there is a risk of them being overcome by dangerous fumes are set out in AS 2865. These precautions should be followed in order to comply with the general requirements of the Australian WHS/OH&S legislation. AS 2865 Confined Spaces, contains advice on the procedures and safeguards, which are essential to such work. Attention is drawn to the dangers of entering or working on vessels which have formed part of a refrigeration system; even after air samples from the vessel appear clean, oil/refrigerant mixtures remaining in the vessel can release hazardous quantities of refrigerant when disturbed.

Corrosion can occur on the external surfaces of the steel piping and vessels used for refrigerating systems, reducing the strength of the containment and eventually resulting in leaks. Corrosion of unprotected steelwork can be rapid in wet or damp conditions; such conditions often occur on the low‑pressure side of the system when metal temperatures are below the dew point of the ambient atmosphere. Insulation where the vapour seal is defective or incomplete will not prevent condensation and may enhance corrosion; corrosion usually occurs relatively slowly on lines permanently below 0°C but has been found to be particularly rapid on pipes such as hot gas defrost lines where dampness and heat are present together.

Internal metal surfaces of refrigerating systems characteristically have a protective oil coating, by virtue of the compressor lubricating oil becoming entrained within the refrigerant flow. It is therefore rare to find internal corrosion in operating systems. Systems out of operation for long periods can, however, corrode, particularly if they are open to atmosphere. In systems deliberately designed to be oil free, internal corrosion may occur. Where heat-transferring liquids such as calcium chloride or sodium chloride solutions are present they may form an additional source of corrosion. Chemical treatments of such solutions are prescribed by the suppliers of chemicals and should be adhered to rigorously.

Table 1. Refrigerant information Practical Limit (kg/m3)

Toxicity (OEL) (ppm v/v)

Lower Flammability Limits (LFL) kg/m3

% v/v

GWP

ODP

Refrigerant Number

Formula and Common Name

NBP (°C)

AIT (°C)

Reduced gravity (m/s2)

A2L

R-1234yf

CF3CF=CH2

-29.4

405

29.7

0.058

500

0.289

6.2

A2L

R-1234ze(E)

CF3CH=CHF

-19.0

368

29.7

0.061

800

0.303

6.5

A2L

R-32

CH2F2 (methylene fluoride)

-52

648

8.0

0.061

8500

0.307

14.4

675

A2L

R-447B

R32/R125/R1234ze(E)

-50.1 to -46.0

n/a

0.062

970

0.312

12.1

740

A2L

R-452B

R32/R125/R1234yf

-51.0 to -50.3

n/a

0.062

870

0.310

11.9

684

A2L

R-454A

R32/R1234yf

-48.4 to -41.6

n/a

0.056

690

0.278

8.0

238

A2L

R-454B

R32/R1234yf

-50.9 to -50.0

n/a

0.039

850

0.303

11.7

466

A2L

R-454C

R32/R1234yf

-46.0 to -37.8

n/a

0.059

620

0.293

7.7

148

A2L

R-455A

R744/R32/R1234yf

-51.6 to -39.1

n/a

0.086

650

0.431

11.8

148

R-141b

CH3CCl2F

32.0

532

—

0.053

1300

n/a

9.0

725

0.11

R-142b

CH3CClF2

-10.0

750

25.2

0.065

10000

0.329

8.0

2310

0.065

R-143a

CH3CF3

-47.0

750

19.2

0.056

53000

0.282

8.2

4470

R-152a

CH3CHF2

-25.0

455

13.1

0.027

14000

0.13

4.8

124

R-413A

R-218/134a/600a

-29.4 to -27.4

n/a

26.2

0.08

2100

0.375

8.8

2053

R-50

CH4 (methane)

-161.0

645

[-4.4]

0.006

1000

0.032

4.9

R-170

C2H6 (ethane)

-89

515

0.5

0.008

1000

0.038

3.0

R-1150

CH2=CH2 (ethylene)

-104

425

[-0.3]

0.006

1000

0.036

2.7

R-290

C3H8 (propane)

-42

470

5.4

0.008

1000

0.038

2.1

R-1270

C3H6 (propylene)

-48

455

4.7

0.008

1000

0.046

2.5

R-600

C4H10 (butane)

10.5

0.0089

600

0.038

1.5

R-600a

CH(CH3)3 (isobutane)

-12

10.4

0.011

1000

0.043

1.8

R-601

C5H12 (pentane)

—

0.008

600

0.035

1.4

R-601a

CHCH2(CH3)3 (isopentane)

—

0.008

600

0.038

1.4

R-E170

(CH3)2O (dimethyl ether)

-25

6.1

0.013

1000

0.064

3.4

Safety Group

Note 1: OEL are based on OES values detailed in EH40 published by the HSE, where they are available; otherwise they are based on short term exposure limits (STEL) as advised by refrigerant suppliers. Note 2: For practical limits, see AS/NZS 5149. Note 3: Reduced gravity in parentheses implies lighter than air, “-“ means liquid at atmospheric pressure. Note 4: For GWP values, see the Australian ozone protection and synthetic greenhouse gas management Act (or IPCC 4th Assessment Report). Note 5: See AS/NZS 5149 for a fuller list of refrigerants Note 6: ND = Not determined Note 7: N/A = figures not currently available

PROUDLY SPONSORED BY

AIRAH

This month’s Skills Workshop has been taken from the Institute of Refrigeration’s 2018 Safety Code of Practice. This code is available for purchase from www.ior.org.uk

Next month: HVAC hygiene April 2019

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GUIDE

AIRAH TIN G OF AN D HEA TIT UTE NIN GAIRAH AN INS GUIDE STR ALI CO ND ITIO A guide to THE AU N, AIR Model WHS Law in Austra ERATIO lia for the REF RIG

HVAC&R industr y A guide to

GUIDE

AIRAH

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HVAC&R safety – an essential guide

WHS and OH&S regulations have a big impact on the HVAC&R industry and its stakeholders. With this in mind, AIRAH has published the Guide to Model WHS Law in Australia for the HVAC&R Industry. The guide sheds light on the ins and outs of regulations. And it helps provide an understanding about specific WHS issues and challenges that our industry members encounter in their work, in addition to the general duties assumed by employers and supervisors. Indeed, the guide outlines very clearly where individual responsibilities in the industry reside. AIRAH’s aim in publishing the guide is to raise awareness of legal responsibilities so that those onsite can safely install, maintain and operate HVAC&R equipment.

Buy a copy now at www.airah.org.au/store

HVAC&R Nation

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April 2019

Insurance Advice

RISKY BUSINESS

ACCIDENTS WILL HAPPEN

Trades work involves special types of risk and exposure. Sarah Gardiner-Smith from AB Phillips runs us through the types of insurance that fridgies should consider. There are three key areas tradespeople need to consider when it comes to business insurance. They are: • Tools of trade insurance – covers either replacement or indemnity value if stolen from a locked vehicle or worksite • Public liability insurance – covers third-party bodily injury and property damage as a result of the insured’s negligence

A public liability policy covers your business for thirdparty bodily injury and property damage arising from you or your staff’s negligence. If your client’s property was to be damaged as a result of your negligence or if a third party was injured on the worksite arising from your negligence, this policy would provide cover.

ANYONE SEEN MY GAUGE? What happens if your tools or equipment are stolen from the site, the office, the factory carpark, or the driveway of your personal property?

• Personal accident/income protection insurance – up to 75 per cent of your income paid in the event you are unable to work due to injury or sickness.

Unless you have a “tools of trade” insurance policy you won’t be covered. A tools of trade policy will provide you with cover if your portable tools are stolen from a vehicle or locked worksite and can be extended to anywhere within Australia.

Tradespeople often operate under a sole trader structure, which carries a certain level of exposure when it comes to protecting your assets if any issues were to arise with a customer. It’s important to consult a risk adviser to discuss your business structure and ensure your assets are protected.

This policy requires that any vehicle used to carry the goods or worksite used to store the goods be securely locked when unattended. It can be extended to cover electronic items such as laptops, tablets and mobile phones and can also be upgraded to settle claims on replacement value rather than indemnity value.

What happens if your tools or equipment are stolen?

Note that your public liability policy will not extend to include cover for claims arising from your subcontractors’ negligence. Whenever engaging subcontractors it is important that you request a copy of their public liability insurance.

INSURING INCOME If you are unable to work for an extended period due to injury or sickness, you can’t rely solely on your workers compensation policy. You need to have an income protection policy in place so that you can continue to pay your bills and support your family’s lifestyle. Income protection pays up to 75 per cent of your income if you are unable to work due to sickness or injury and is a vital part of a sound risk management plan. ■

The information in this article was provided by AB Phillips. AB Phillips has a dedicated Construction and Trades Insurance department and offers insurance programs tailored specifically to the HVAC&R industry. Call 1300 242 136 or email sarahg@abphillips.com.au April 2019

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HVAC&R Nation

Feature

PLAYING WITH FIRE As the HFC phase-down kicks in, the RAC industry needs training on the safe use and handling of the flammable refrigerants that are filling the void. Sean McGowan reports. conditioning market is expected to take around five years – similar to the timeframe for industry to switch from R22 to R410A.

If you’re still wondering what the HFC phase-down is all about, just have a look around. Almost 70 countries, including Australia, are now reducing the use of hydrofluorocarbons (HFCs). New, lower-GWP (global warming potential) refrigerants are emerging in their place. And many of these are flammable.

Meanwhile, the move to flammable A3 hydrocarbon refrigerants by the domestic refrigeration sector is almost complete. Around a million refrigerators with an average charge of 55g are imported and sold each year.

R32, for example, which falls into the new A2L safety classification of having mild toxicity and flammability, is becoming particularly commonplace in small, limited-charge products like domestic highwall split systems. Over 450 models containing R32 have been registered on Australia’s GEMS website.

The small commercial refrigeration sector is not far behind.

According to the Cold Hard Facts 3 report – a comprehensive inventory of the Australian HVAC&R sector – the transition to R32 has been rapid. In 2016 it could be found in more than 40 per cent (by quantity) of pre-charged equipment imported into Australia with charges between 800g and 2.6kg.

HVAC&R Nation

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containing R32 have been registered on Australia’s

The 2017 and 2018 numbers are still being analysed, but the penetration is expected to be above 70 per cent. The complete transition in the small air 20

Over 450 models

GEMS website. April 2019

THE CATCH UP

Faced with such statistics, it is concerning that so many practitioners in the RAC industry are unprepared for flammable refrigerants. How did it come to this? As detailed in previous issues of HVAC&R Nation, the trade-off between low GWP and flammability has always existed around refrigerants due to the physical characteristics of the chemicals used. To achieve a lower GWP, the refrigerant’s chemical compounds are typically less stable and therefore more flammable. Conversely, to achieve more stability and reduce flammability in the refrigerant, the GWP increases. And since the phase-out of HCFCs, the industry has become accustomed to using blends that contain “mildly flammable” refrigerants. For example, R410A – commonly found in packaged and split systems – is a blend of R32 and the fire suppressant R125. Another refrigerant blend, R407C, contains 23 per cent R32. The increased use of mildly flammable refrigerants like R32 is now forcing a paradigm shift in industry practices and expectations. Yet for reasons both historical and otherwise, many industry practitioners remain cautious, leading to a slower than expected transition at the coalface.

Feature

High-profile accidents involving flammable refrigerants have cast a pall over their use “There are only small pockets of awareness that I can see,” says Heatcraft’s manager of product development, David Upward. “Some previous market activities adversely affected perceptions of flammable refrigerants and contributed to caution amongst many practitioners in the industry.”

WHEN IT GOES WRONG High-profile accidents involving flammable refrigerants have cast a pall over their use. Many in the industry remain extremely cautious about their suitability in RAC systems. Two men, Barry Purtell and David Lobb, died after gases from a refrigeration compressor ignited in the cellar of the Rochester Hotel north of Bendigo in June 2014. A coronial investigation completed last year heard that the men, neither of whom were qualified refrigeration mechanics, were helping the publican of the hotel remove the refrigeration compressor from the building’s basement. The compressor was known to be leaking refrigerant for several years and had been topped up with car hydrocarbon air conditioning refrigerant eight months before the accident by Purtell, a motor mechanic. At the time of the accident, the compressor contained a mixture of flammable and nonflammable refrigerants. In attempting to remove the

SUITABLE SPACES According to the Flammable Refrigerant Safety Guide, the allowable charge of a flammable refrigerant in a system represents the maximum amount that could discharge into an occupied space due to leak. It is determined by the practical limit (in kg/m³) multiplied by the net room volume (in m³). The practical limit is 20 per cent of the lower explosive limit (LEL) of the flammable refrigerant concerned and assumes uniform dispersion. Therefore, where a room is not well ventilated or where collection of heavier-than-air gases could occur, flammable refrigerants should not be used. This includes the installation of a split-system air conditioner charged with a flammable refrigerant such as R32 in small enclosed spaces such as lift motor rooms, storage cupboards and the like.

Flammable refrigerants make it even more vital that plant rooms have proper ventilation and safety signage.

compressor from the hotel’s basement, the copper refrigerant pipework was cut with a hacksaw and the refrigerant mix leaked into the cellar. An explosion subsequently occurred when Purtell or Lobb used a cigarette lighter. Coroner Paresa Spanos noted that the explosion could have been averted through correct maintenance, correct use and labelling of refrigerants, and correct dismantling and removal processes. She also pointed out that neither Lobb nor Purtell should have been doing the work.

Wilkinson also noted that the Coroner’s report detailed that while one of the men died as a result of the hydrocarbon mixture exploding, the other man died later with evidence of acidosis. Acute respiratory acidosis occurs when an abrupt failure of ventilation occurs in the body. The lungs are unable to remove enough carbon dioxide (CO2), and the increasing concentration of CO2 causes the pH of blood and other bodily fluids to decrease. “This leads me to think that it was caused by the formation of hydrogen fluoride from the decomposition of R134a present in the condenser,” says Wilkinson. “It is something we, as an industry, have heard about as a safety impact.”

“Their deaths highlight the dangers of unqualified people doing work that requires qualifications or, at least, a solid understanding of the substances and risks involved.”

SAFETY GUIDE

The coroner went on to say that the refrigeration industry faces challenges with the move to low‑GWP refrigerants. “None the least because the low-GWP refrigerants are flammable and the vast majority of refrigeration mechanics/technicians were not trained in the use of such refrigerants.” But the coroner declined to make recommendations for changes to industry practices, as neither of the men were qualified refrigeration mechanics. AIRAH executive manager for government relations and technical services, Phil Wilkinson F.AIRAH, was called in by the investigation to provide an industry perspective.

Recognising the emerging trend towards flammable and mildly flammable and toxic refrigerants, AIRAH published the Flammable Refrigerant Safety Guide. It first appeared in hardcopy form in 2013. Developed by a Flammable Refrigerants Taskforce made up of key industry stakeholders and leaders in the field, the guide recognised that if misused or applied incorrectly, flammable refrigerants pose a risk to industry practitioners and the public. “It was driven by the industry and the concerns at the coalface about the safe use of flammable refrigerants, and the new skills that were needed,” says Wilkinson. “It was also recognised that the regulator space was extremely complex, and the industry needed a guide to make this visible.”

He says the accident shows why all RAC systems should be treated with caution and care, and that all refrigerant leaks should be properly fixed.

The guide covers safe design, manufacture, supply, installation, conversion, commissioning, operation, maintenance, decommissioning, dismantling and disposal of refrigeration and air conditioning equipment using a flammable refrigerant.

“The main insight I took away from the coroner’s reports was that it is too easy for unlicensed people to access hydrocarbon refrigerant and fiddle with refrigeration systems,” he says. “The impact can be catastrophic for the untrained.” Additionally, Wilkinson says the report highlighted the need for proper ventilation in plant rooms and visible safety signage.

In 2018 the guide was updated to reflect changes to Australian Standards (AS/NZS 1677 being superseded by AS/NZS ISO 817 and AS/NZS 5149 series) as well as changes to regulations impacting the application of flammable refrigerants.

April 2019

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HVAC&R Nation

Feature AIRAH also developed a free online version of the

UPPING THE LIMITS

Last year, the International Electrotechnical Commission (IEC) voted to increase the charge limits of flammable A3 hydrocarbon refrigerants, such as propane, in commercial refrigeration equipment. Should the change be enacted as a global standard, it promises to have a significant impact on small to medium commercial refrigeration – particularly larger refrigeration display cases and walk-in coldrooms. If approved in the European Union, however, any change would still need to be considered by the standards committee for AS/NZS 5149 before charge limits could change in Australia. Watch this space! Since the launch of the online guide, AIRAH has seen registrations from New Zealand, France, Norway, the UK and the USA.

guide in partnership with the Department of the Environment and Energy. This resource was officially launched in January. “We had previously partnered with the Australian government to deliver free training to the trade and distribute copies of the guide, but we could only reach a finite number of people this way,” says Wilkinson.

There are only small pockets

“The face-to-face delivery model had its limits, so rather than them coming to us, this free online resource takes the training to the technicians in the field.” The new online format allows people to access the resource whenever they have time; material is broken down into “smoko-sized” chunks of around 20 minutes. “Users can complete a module, leave it and then pick it back up again at a time of their choosing,” says Wilkinson.

Free to access, it includes eight module videos as well as audio content and a “test your knowledge” feature to benchmark your understanding.

The Flammable Refrigerants Safety Guide – Online Resource is free to access at www. pointsbuild.com.au/airah/flammablerefrigerants-safety-guide-online-resource

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“It is extremely important for technicians to remain current with industry standards,” says Raines. “Most students feel far more comfortable and competent in handling these types of refrigerants after completing the above courses.” The training package for Refrigeration and Air Conditioning is under review and will include a new unit on flammable refrigerants. This will help ensure that newcomers to the trade get the skills they need. It’s a positive sign. But lots of work is still needed to make sure that the industry keeps up with the changing nature of refrigerants. ■

Properties of R32 versus R410a. R32

R410a

Boiling/Bubble Point

52°C

51.5°C

“Up until now there were no training competencies endorsed for mildly flammable refrigerants like R32, creating a growing risk for apprentices and technicians who are more and more likely to work with them.”

Critical Point

78.1°C

70.5°C

Saturation Pressure at 5°C

848 kPa

839 kPa

“Our industry hangs its hat on its skill and professionalism, and this new unit of competency will provide increased safety for technicians in a growing refrigerant market.”

Saturation Pressure at 40°C

2382 kPa

2338 kPa

Global Warming Potential

675

2090

Flammability Rating

A2L Low Flammability

A1 Non Flammable

The addition of this course alongside training products that already exist for the A1 (non-flammable) and A3 (highly flammable) category refrigerants means all training organisations now have access to a full suite of products.

Simply register online to access the resource, which is available for desktop, mobile and tablet devices.

Box Hill Institute is currently running or developing courses on the safe use of A2/A2L refrigerants, hydrocarbon refrigerants and CO2.

PROPERTIES

According to Kevin O’Shea, president of the Refrigeration and Air Conditioning Contractors Association (RACCA), it’s a big win for technician safety.

Hard copies of the Flammable Refrigerants Safety Guide – as well as the Online Overview – can be downloaded for free as PDF documents from the AIRAH website at www.airah.org.au

In a further indication that the industry is catching up with the use of mildly flammable refrigerants by equipment manufacturers, training for A2/A2L mildly flammable refrigerants was officially endorsed by the Victorian Registration and Qualification Authority in late 2018. The unit of competency – VU22583 Class A2/A2L Flammable Refrigerants – can now be utilised in all states and territories across Australia.

GET THE GUIDE

“We need to ensure that, as the use of alternative refrigerants picks up, our industry is properly equipped to work safely, efficiently and professionally with any refrigerant they encounter. And that’s where the Flammable Refrigerants Safety Guide has a crucial role to play.”

TAFE TRAINING NOW UNDER WAY

AIRAH has partnered with leading provider of online education and training courses, Pointsbuild, to deliver the online resource.

“Many HVAC&R professionals are accustomed to working with the non-flammable refrigerants that were widely used in the past,” says AIRAH CEO Tony Gleeson, M.AIRAH.

of awareness that I can see

According to Len Raines, senior coordinator of refrigeration at Box Hill Institute’s Faculty of Trades, Technology and Transport, the courses offered are open to all qualified technicians seeking to further their knowledge on specific areas.

April 2019

Source: Australian Refrigeration Council

AIRAH Industry Nights

TRADES • INNOVATIONS • ENGINEERING AIRAH Industry Nights are a great opportunity to broaden your networks and see the HVAC&R industry’s latest innovations. Whether you’re looking for the latest technology to improve your business, or extending your networks, there will be plenty on offer. May 15

MELBOURNE, Vic

Caulfield Racecourse

May 23

BRISBANE, Qld

Royal International Convention Centre

May 30

TAMWORTH, NSW

Wests Tamworth

June 13

PERTH, WA

HBF Stadium

June 26

DARWIN, NT

Sky City Casino

July 03

WESTERN SYDNEY, NSW

Rosehill Gardens

July 25

CENTRAL SYDNEY, NSW

Luna Park

August 21

CENTRAL COAST, NSW

The Entrance Leagues

August 27

CAIRNS, Qld

Pullman Casino

August 29

TOWNSVILLE, Qld

The Ville Resort Casino

September 4

SHEPPARTON, Vic

Parklake Hotel

September 25

CANBERRA, ACT

Exhibition Park

October 10

ROCKHAMPTON, Qld

Leagues Club

October 17

ADELAIDE, SA

Adelaide Entertainment Centre

October 31

GOLD COAST, Qld

Southport Sharks

Free entry – Doors open at 4pm

www.airah.org.au/industrynights April 2019

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HVAC&R Nation

AIRAH News

YOU AND ME: INDUSTRY If you’re looking for AIRAH’s Trade Nights on the calendar, look again. They’re now called Industry Nights and they’re coming to a location near you. Ever since AIRAH began way back in 1920 it has been organising events. In that first year, conferences were held in Geelong and Melbourne, and no doubt gave our industry pioneers a chance to connect and understand more about their fledgling industry. Over the years, people, companies and technologies came and went. The need for a meeting point for people in the business has remained. And AIRAH provided that space. In the early noughties the Institute started a Products Night in NSW, and the idea soon spread around the nation. Later, these were renamed Trade Nights. And this year, they’ve become Industry Nights. Catherine Martin is AIRAH’s member services officer for Victoria, South Australia and Tasmania and is responsible for organising division events in those states. She says that the name was changed to more accurately reflect the types of people who were attending.

WHAT’S NEW? The first Industry Night of 2019 was held in Hobart on February 21. “We had about 70 people come through the door, and 32 exhibitors, so it was really good,” Martin says. It’s not just the name that’s changed. This year sees a couple of important developments to the traditional format. For the first time, the Hobart Industry Night included a short information seminar. Brett Hedge, M.AIRAH, is the co-chair of AIRAH’s Refrigeration STG and marketing manager at Heatcraft, and he delivered a 15-minute presentation on the HFC phase-down. Look out for similar sessions at other Industry Nights. Then, at the Geelong Industry Night in March, the AIRAH app was introduced.

“We found that we were getting not just trades, but also lots of consultants – a more diverse crowd,” she says. “At the metro ones you get more the contractors, whereas the regional ones you get a lot more tradespeople. The new name better describes the whole HVAC&R industry.”

“It lets people and exhibitors see who is there, and they can exchange numbers by connecting through the app,” Martin explains. “It’s a great networking tool that will be very beneficial.” Over time, these events have also evolved in another important way: size. And there’s none bigger than the Perth Industry Night.

BEST OF THE WEST Last year the Perth event boasted 310 attendees and over 90 exhibitors. This year it will also run in conjunction with a symposium with various guest speakers. Daniel Belotti, M.AIRAH, is the director of DB Mechanical Consulting and a regular at the Perth night. “Our industry is larger than we think,” he says. “Even after 20 years I often find myself discovering a new supplier, product or technology that I never knew existed. This is in spite of attending regular training and information sessions, reading the journals and being involved with different projects and suppliers,” he adds.

2019

INDUSTRY NIGHT CALENDAR

May 15

MELBOURNE, Vic Caulfield Racecourse

May 23

BRISBANE, Qld Royal International Convention Centre

May 30

TAMWORTH, NSW Wests Tamworth

June 13

PERTH, WA HBF Stadium

June 26

DARWIN, NT Sky City Casino

July 3

WESTERN SYDNEY, NSW Rosehill Gardens

July 25

CENTRAL SYDNEY, NSW Luna Park

August 21

CENTRAL COAST, NSW The Entrance Leagues

August 27

CAIRNS, Qld Pullman Casino

August 29

TOWNSVILLE, Qld The Ville Resort Casino

September 4 SHEPPARTON, Vic Parklake Hotel September 25 CANBERRA, ACT Exhibition Park

In 2018, the Perth event moved to HBF Stadium to accommodate the growing crowd. 24

HVAC&R Nation

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April 2019

October 10

ROCKHAMPTON, Qld Leagues Club

October 17

ADELAIDE, SA Adelaide Entertainment Centre

October 31

GOLD COAST, Qld Southport Sharks

AIRAH News “AIRAH Industry Nights are a way of compressing 12 months’ worth of industry changes and improvements into two or three hours while walking past the various stands. If you’re time poor it can really help to get you up to speed on new developments. “I often come home with my ‘show bag’ and then spend the next few days reviewing the material and researching products, services and technology or filing the material for future reference.”

HVAC&R GOODIES The exhibitors have obviously cottoned on to the fact that attendees like the showbags and other freebies. “Whether you’ve got a jar of lollies, which is a drawcard, or a product that people haven’t seen before, there’s always a way to pull people in. I’ve seen everything from sunscreen to polo tops,” AIRAH’s Martin says. The Hobart Industry Night in February was a huge success, with around 70 people and 32 exhibitors.

Another drawcard is the chance to catch up with others in the industry – new and old – over a drink and a snack. And Martin says that’s the highlight of the Industry Nights.

AIRAH Industry Nights are a way of compressing 12 months’ worth of industry changes and improvements into two or three hours

“Having a stand that is inviting, well organised and has great colours, with people who look professional and engaged, that’s also going to draw people over. I’ve seen some fantastic stands that really put in a great deal of effort.”

“At the end of the night people often say they made some really good connections and found projects to collaborate on. Even at the smaller Industry Nights, it’s not necessarily the quantity but the quality of people that show up. The networking is probably the best part.”

GRIPPERFIX

Connecting at Industry Nights is even easier now, thanks to the AIRAH App.

■

™

Roof-mounted utilities, such as split system condensing units, duct supports, communication equipment and service walkways can support a building envelope or compromise it. The S-5! GRIPPERFIX system, with S-5! clamps and brackets are The Right Way™ to mount to any metal roof using our lifetime “double-seal” performance – or no roof penetration at all. GRIPPERFIX is quick and simple to install, preserves warranties and lasts as long as the roof itself. Don’t leave it to chance: Fix it, so it never needs “fixing.” S-5! affordable mounting products ensure roof integrity preserved from corrosion, leaks, rust, or algae. Done once – the right way – It’s a ripper!

April 2019

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HVAC&R Nation

Around the Nation 1

1 FUTURE:AIR ROADSHOW

says Reliable Controls’ regional sales manager Jason Duncan, Affil.AIRAH, pictured (right) with Superior Logic’s Nic Rowcroft (left).

Gerard Cudmore and account manager Adam Jones will manage the branch and service the Sutherland and South West Sydney regions.

A “transformation” is on the way for chillers and large air conditioning systems.

“Their focus on sustainable and ethical business practices are also aligned with Reliable Controls’ values. We are excited about the new partnership with Superior Logic and the Tasmanian industry.” ■

The new store is open from 7am–5pm on weekdays, and 8am–12noon on Saturdays. Heatcraft is now open in 56 locations across Australia.

3 STANDARDS CEO MOVES ON

5 GOVERNMENT CLIMATE PLAN

That’s the message from the Air Conditioning and Refrigeration Equipment Manufacturing Association (AREMA) and the Air Conditioning Mechanical Contractors Association (AMCA), who together have organised a seminar series to help the Australian HVAC&R industry come to grips with these changes. Named Future:Air, the seminars will run in Brisbane, Sydney and Melbourne in May.

Standards Australia’s CEO, Dr Bronwyn Evans, is leaving the organisation. She has been the CEO of Standards Australia since October 2013.

Future:Air will feature international guests Stephen Yurek, president and CEO of the Air-Conditioning, Heating and Refrigeration Institute (AHRI) in the US, and Andrea Voigt, director general of the European Partnership for Energy and the Environment (EPEE). Local industry expert and AREMA executive director Greg Picker will provide the Australian perspective.

Dr Evans thanked the board for its support through her tenure. She recounted the value of the work being done by Standards Australia, both nationally and internationally, and its impact on the quality of Australian life.

“The speakers will deliver vital information to an industry that must prepare now for the arrival of systems and equipment designed for both new technologies and a new generation of refrigerants that comply with a phase-down of high global warming potential HFCs,” say the organisers. The sessions run from 7.30–9.30am and include a full plated breakfast. Tickets are $99 per delegate. Go to futureair.ac

■

2 A RELIABLE AND SUPERIOR TEAM At the recent AIRAH Hobart Industry Night, Reliable Controls announced the appointment of Superior Logic as its new building automation specialist dealer in Tasmania. Superior Logic is a family-owned Tasmanian business delivering building automation systems to the HVAC and energy optimisation sectors. “Their commitment to offering high-quality engineering and innovative solutions impressed us,” 26

HVAC&R Nation

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“I am proud of what we have achieved in so many aspects of our work,” she said. “Standards Australia is in a great position with so much opportunity, goodwill and ambitions for the next phase of growth. I look forward to seeing Standards Australia move from strength to strength.” Dr Evans will be continuing with a number of roles including as a director of the Australia Japan Foundation and as a director of the Digital Health Cooperative Research Centre. She has also resigned as the ISO vice president of finance and IEC Australian National Committee Secretary.

Go to www.heatcraft.com.au

■

The Australian government has set out its climate change approach in the lead-up to the federal election, likely to be held next month. The Climate Solutions Package (CSP) is a $3.5 billion policy that promises to help meet Australia’s 2030 Paris Treaty commitments of reducing 2005 emissions by 26–28 per cent – although critics have pointed out that this may rely on some creative accounting. For the HVAC&R sector, there are some points of interest. The largest chunk of funding goes to the Climate Solutions Fund (CSF), currently known as the Emissions Reduction Fund (ERF). The government has pledged an additional $2 million to continue funding the projects supported by the ERF, including support to small businesses to upgrade air conditioning and refrigeration systems. There is also a pledge to improve energy efficiency by expanding the energy rating label to include “heating appliances, such as gas heaters, electric heaters and reverse-cycle air conditioners”.

Deputy CEO Adrian O’Connell will act as CEO until the appointment of a new chief executive. ■

Finally, there will be an information program to inform owners of refrigeration and air conditioning equipment of the benefits of regular maintenance.

4 HEATCRAFT HEADS TO THE SHIRE

AIRAH has responded to the announcement of the CSP with cautious optimism.

Heatcraft has relocated its Kogarah store in Sydney to 33 Cawarra Road, Caringbah. The new premises has a bigger warehouse and showroom, and more parking for customers. April 2019

“Hopefully we will see the upgrade and replacement of old inefficient equipment with high-efficiency equipment,” says CEO Tony Gleeson, M.AIRAH. “However, it’s critical it is installed, commissioned and maintained properly to ensure energy is not wasted.” ■

Around the Nation 6

6 HAPPY ANNIVERSARY Mitsubishi Heavy Industries Air-Conditioners Australia (MHIAA) is celebrating its 20th anniversary in Australia. What initially started off as dedicated air conditioners sales division in 1999 under the banner of Mitsubishi Heavy Industries Australia (MHIAU), has today expanded around the country and into New Zealand. The company grew and eventually developed as Mitsubishi Heavy Industries Air-Conditioners Australia (MHIAA) in 2009. “Taking Australia’s comfort into our hands is no small feat,” says MHIAA managing director Yuji Ito. “Over the past 20 years we have witnessed and have been instrumental in creating change through engineering and design. From silent operation, to long reach airflow, energy conservation and durability right through to digital advancements with wi-fi connectivity, MHI products continue to focus on innovative solutions for the HVAC market.” To celebrate its 20 years Down Under, MHIAA ran a summer campaign that donated $20 to the Australian Red Cross Natural Disaster Relief Fund for every registered air conditioner unit purchased by consumers. Ito says the cause was chosen with the hardships of summer in mind. “While most of us enjoy a comfortable home environment throughout the year, many Australians face the reality of natural disasters each day, particularly during our harsh summer.” Go to www.mhiaa.com.au

■

7 LATEST INDUSTRY NUMBERS An updated version of Cold Hard Facts 3 – the most comprehensive inventory available of the Australian HVAC&R sector – will be released later this year. It will include 2017 and 2018 data and will identify key developments and emerging trends in the Australian HVAC&R industry.

Although the work is still under way, AIRAH understands that some key trends are already emerging. In split systems, the fast transition to R32 refrigerant continues. For pre-charged equipment imported with a charge of more than 800g and less than 2,600g, penetration is expected to be above 70 per cent (up from over 40 per cent in 2016). The complete transition of small AC is expected to take around five years from start to greater than 95 per cent penetration – similar to the timeframe for industry to transition from R22 to R410A. Hydrocarbons are becoming more common in small commercial refrigeration – one- and two-door refrigeration display cases and storage cabinets are rapidly transitioning, driven by European designs. Charges are less than 150g and annual sales are in the tens of thousands. At this stage the HFO blends that are being imported are not A2L (mildly flammable) refrigerant. They are A1 (non-flammable) such as R448A, 449A, 452A, 450A and 513A. Look out for the full report midway through the year. ■

“It is also 100 per cent recyclable at end of life.” The register covers a wide range of BEP-accredited PVC construction products including flooring, resilient wall coverings, pipes and fittings, conduit/fittings, fencing, cable and permanent formwork. “In addition to being recognised in Green Star’s Responsible Building Materials credit, Best Practice PVC is a valuable aid for specifiers and anyone procuring PVC products,” says the Council’s chief executive Sophi MacMillan. “The online register makes it simple to identify those items made to the highest sustainable standards.” Go to vinyl.org.au/in-greenstar/best-practice-pvcproduct-register ■

9 COOLING WITH GAS Refrigeration specialist Cold Logic, with the help of Yanmar Energy Australia and Eschenfelder KKU, has fired up what it says is the first gas-driven refrigeration (GDR) system in Australia. The project is situated at a beverage manufacturer at McLaren Vale, South Australia. It features a refrigeration system for glycol down to a temperature of -6˚C.

8 ECODUCT SCORES BEST PRACTICE

Cold Logic’s Dr Michael Riese, M.AIRAH, says that GDR down to -6˚C is a new development that has only been released in Europe in the last few years. The system has been available in Australia since ARBS 2018, but this is the first actual project that is going online.

In response to growth in the use of low-profile PVC ductwork, the Vinyl Council of Australia has added the product as a new category to its Best Environmental Practice (BEP) PVC Product Register. And the first product to score the BEP trade mark is the EcoDuct 300 Series.

GDR could fill a gap in the Australian market for locations that have limited electrical power.

The mark is awarded to independently assessed, Best Practice PVC-compliant products that meet stringent life-cycle criteria, developed by the Green Building Council of Australia. “Incorporating up to 50 per cent recycled PVC, the newly accredited EcoDuct is a low-impact, fireretardant duct system that is specifically designed for high-rise apartment applications where limited ceiling spaces are common,” says the Vinyl Council of Australia.

“The current example is exactly that,” says Riese. “The client would have required a costly power upgrade if they had gone full electrical. The room temperature is 2˚C, so an evaporative solution wasn’t possible either. “GDR is also more energy-efficient than electrical systems when considering the whole energy cycle. And more and more consultants and engineers are realising the benefits.” ■

April 2019

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HVAC&R Nation

Green Wedge

SILENT KNIGHTS

The bikes are quiet enough that riders can hear their

No howling V4 petrol engines, but plenty of anticipation as MotoE begins its inaugural season. This year motorcycle racing aficionados will bear witness to something never seen in the history of the sport: a world championship featuring only electric bikes.

sliders scraping against the track when they get their knees down

speed of 270km/h versus 355km/h, and a porky 225kg rather than a lean, mean 160kg. But like all electric bikes, the acceleration is impressive. The Ego Corsa goes from zero to 100kmh in three seconds.

MotoE is the FIM-sanctioned series that will be held at select MotoGP rounds in 2019. Six races will take place, all in Europe, including a double‑header weekend in Misano, Italy.

And she believes that although the series is starting small and simple, it won’t stay that way for long. “There will be a time when MotoGP will be all electric, there’s no doubt in my mind that will happen,” she says. “At the moment it’s toe in the water stuff.” ■

Also impressive is the calibre of racers. They include veterans like Valentino Rossi’s former rival Sete Gibernau, MotoGP refugees like Bradley Smith, young up-and-comers like flying Finn Niki Tuuli, Aussie hope Josh Hook, and even a female rider – former Moto3 runner Maria Herrera.

The race itself will be very much an electric entre to the petrol-powered main course of the traditional classes. It will run for around 10 laps, or just 15 minutes.

AN ELECTRIC FUTURE

THE BUZZ IS BUILDING

But will the lack of noise ruin the usually deafening spectacle of motorcycle racing? Although the bikes are far from noiseless, they are quiet enough that riders can hear their sliders scraping against the track when they get their knees down.

Although the calendar may be small, the grid is encouragingly full, with a dozen teams and 18 riders. Organising body Dorna took the prudent step of “requiring” all satellite MotoGP teams to participate, as well as some from Moto2 and Moto3.

Kellie Buckley, deputy editor of Australian Motorcycle News, says it won’t matter. “If Marquez stuffs it up the inside of Rossi on an electric bike or a petrol engine it’s still exciting.”

All will be using the same bike: the Energica Ego Corsa. Next to the MotoGP monsters, it looks very much a standard roadbike – 160hp compared to 250hp, top

HVAC Hygiene HVA C

TIN G TE OF AND HEA N INS TITU DIT ION ING TRA LIA CON THE AUS TIO N, AIR ERA REFRIG

INES PRACT ICE GUIDEL AIR A H BEST

H VAC H YGIENE

SYSTEM HYGIENE ACCEPTABLE TABLE 2.3 MINIMUM or Component HVAC System (See 1.6)

Classification. HVAC system (See 1.5)

exhausts Air intakes and

a/c

AHU – moisture Supply system producing equipment exhausts Air intakes and or Supply air system, or Return air system, Outside air system Exhaust air system Non-ducted

refrigerated a/c

Clean

Light Clean Clean Clean Light Pre filtration – – Clean Post Filtration Clean No Filtration – Moderate Clean

Clean

Evaporative coolers

mould or system due to ation of a HVAC activity that is Note: Decontamin n is a specialised State and Territory microbial contaminatio of this Guideline. s for the outside the scope have specific requirement n governments may contaminatio control of microbial reporting and

tion eve

H VAC H YGIENE

ygiene HVAC H

source of moisture presence and In particular the in the system should mould growth supporting any prevented. be identified and World is covered in the more generally Air Mould in buildings (WHO) Guidelines for Indoor ation Health Organis and Mould. Quality, Dampness

be sent to a analysis need to assessment, and Samples for fungal for testing and mycological laboratory growth site. Details of sample a fungal be analysis should identification as assessment and removal, transport, testing laboratory. the coordinated with be helpful to identification may Fungal species from the indoor there is a shift in determine whether This is needed concentration. . Clear to the outdoor risk assessment proper a owner and order to perform between the building in order communication should be established following level the HVAC cleaner acceptable fungal to determine an of the HVAC system. cleaning and remediation ated and cleaned 3. has been decontamin verified, see Section Once the system level should be the system hygiene

www.airah.org.au

1.9. HV AC restor ation

1.10. Be st pra damage hygiene ctice 2.5.7. Water and components subjected to surfaces to determine salvage All HVAC system manage In should be evaluated water damage restoration activity. ment d for success of any should be investigate1.10.1. Prin ability and likely internal insulation

AIR AH

ciples

BES T

PRACTIC

E GUI DEL

1.10.2. Record s

or lining materials HVAC insulation When internal traces of the deteriorated and within the system are found to be product found should be insulation or lining deteriorated surfaces of the system ts components, the affected componen restored and the system inspected and the entire should be cleaned cleaned as required. ts and for contaminan

AIR AH

damage

g or renovation 2.5.9. Buildin contamination t category

contaminan subject to this level of Any HVAC system to determine the hygiene ts found to have should be evaluated system or componen debris greater the system. Any dust and particulate be cleaned. 2.3 should accumulated general d, specified in Table ion encountere than the levels the type of contaminat Depending on

www.aira h.org

GUIDELINES BES T

PRACTIC

E GUI DEL

INE S H VAC

1.11. HV AC sta and reg ndards ulations

2.2. Ac cess for inspe ction

system listed in hygiene Table 2.1, inspec tor determ provide ine the HVAC with the minim if cleaning is requir four hygie ed when ne levels to in Table um acceptable assess 2.3. hygiene standards ed against as listed

Hygiene

Level

1. Clean 2. Light

3. Mode rate

4. Heavy

.au www.aira h.org

.au

H YGI ENE

System and asseinspection ssment

2.1. Hy giene levels de The descri fined ptions

oration or 2.5.5. Deteri es non-porous surfac

s oration of porou 2.5.6. Deteri linings surfaces and

INE S

Best practi building ce HVAC hygie ne mana and system operation gement requires and maint documentati system on includ good enanc drawings system showing e manuals, accur ing up to date commission access points ate as ing data. and origin installed The buildi al conductedng owner should with record HVAC Hygiene maintain record Inspection s of s of any system cleani Repor ts any hygiene along verificat ng or remedial inspections. works and Maintaining ion carried o profile of any ut as a these a buildi HVAC hygien ng or system records buildsresult of such e mana up a hygie gement. over time that assists in ne In addit ion, any repor ts assessments relating or any energ to indo also be or a retained y with these management ir qualit y repor ts records. should

growth. Best practi particular any logging or fungal through ce HVAC hygie evidence of water salvageable the ne manageme implementa manageme ts or ducts deemed nt can be tion of nt practi Any system componencleaned and free from microbial a few relativ achiev ces. • Filter ely simpl ed logged insulation should be thoroughly maintenanc affected or water e against e – Filters growth. Any water replaced. dust be be regula and particulatesare the prima The prima products should ry defen ry design . System on within the accord rly inspected 1668.2 which standa filters shouldce and ance due to condensati of the deals with rds for HVAC and AIRAH with the requir maintained, outdoor Any water damage be assessed and the cause systems at least ventila to air, ements DA19 on are AS in system and AS/NZ location of intake tion requir system also needs of AS/NZ mitigated. HVAC&R assessment S 3666.1 identified and S 3666.2 s and discha ements (minim maint on condensati which deals be specification should includ enance. The um tofilter rges, exhau AS/NZS with micro initial structure) need is optim e a review s to determ 1668.1 detail (pipes, building al bial controst rates) g any HVAC of the control ine if filter Any water leaks type, filter for the HVAC l. prior to undertakin associated s requiremen applic system repaired and asbestos ation ts for fire , includ with mech identified likely contarating, system system due to work. ing the and smoke airflow The prima anical ventila ation of a HVAC is outside the cleaning or restoration of install minant profile and pressu filter Note: Decontamin n is a specialised activity that tion system ation maintenancry standard for re, the contaminatio information and maint and the gener s. e is AS/NZ HVAC system al qualit enance. control on the scope of this Guideline. s S 3666.2 y filters Comprehen of . Its prima operation and smoke provided selection and sp. in buildimicrobiological materials are found heat or is to in AIRAH application sive • Manag contaminan ry focus is ng water asbestos containing be shut down, likely components subjectedintegrity focuses and DA15. the system emen of and ts should If potentially friable HVAC air their on All such air handl general is critica to determine andt of moisture system, the system all fire HVAC hygie ing system as Legionella be removed by l for within a HVAC In particular should be evaluated minimising – moisture material should s but it The stand conta ne. restoration activity. mounted heaters insulation manageme mination also the poten ard coveri the asbestos containing success of any duct and alternative and any smoke contro system electric nt n o tial all i t a removalists ng l u and s n i for e the accordance h t s or comp in spills, leaks funga maint licensed asbestos smoke dampers l features . This includes onents for fitness for purpose inspec or wettin l 1851. if it is lled in its place of HVAC enance of the of AS ted should as soon AS/NZS electric heaters should be assessed maintenance protocols products insta fire systems as is practi be dried outg of HVAC • Inspec duct mounted 1668.1 and is AS 1851. and 2 are called , AS1668.2 with the survey cable. and tion board surrounding withstand and assess to and asbestos. unable be period ment – referenced up in the Buildi AS/NZS 3666 verified to contain ically ts or surfaces deemed with are beyond All HVAC part 1 and restoration the recom inspec ted Any componen out in territories standards and ng Code of Austra systems and l cleaning and part should be carried surfaces mend should are mand lia as prima removal work proper mechanica be replaced. All• porous of Practice ations of assessed in accord may be of Australia. Apart Clean, restor atory National Code Note: All asbestos ry individ this Guide be evaluated NOHSC:2002 – ance from buildi in all states e and verify salvage and should smoke damage should safety legisla ual state all other applicable or comp cleaning accordance with line. and or ng specifi s. of Asbestos and hygiene theonent subjected to fire following and requirement that should tion and regula c occupationalegislation there cleaning e replsachave level for the Safe Removal ed odour retention government regulations l health tions relatin should band restor been identified – once system for friability and assessed as friableimme operation be complied state and local ation s as diately to the eas g to HVAC and with and maint ion has including work should contaminated, to impart odours process. Any ar enance. as they are releva hygiene materials likely of the restor materials and contaminat The select ed system verifying the be under taken should be or resurfaced. Any nt to both replaced. Once all asbestos system be • cleanl HVAC should ion . Good and applic the entire iness verified. by AS 1324 housekeepin supply air stream been removed level should be ation of due to heat a comm g – HVAC damage e system hygiene filtration and minimum gener on sense as asbestos-fre cleaned and the t surface exhibiting condition of application al filters are gener approach hygiene also acceptable Any componen ts should be labelled register updated. HEPA filters ventilation system ating activit residual to an cover requir requir restored to be The componen ed es respo ements are classifi s given to any ies within limiting conta materials/asbestos be nding exposure should for the on should of ed in AS are specified in to any and the hazardous surfaces Even It is not unusual a building and minant internal 4260. AS 1668.2 everyd or replaced. Considerati on the intended promptly highly contaminat . be such that may remaindisinferesidueay tasks can Guideline that smoke residue ion cting) the smoke as cleani event. types of , food prepa affected mandatoryconflict with the recommendations copyin n of the the system. Certainto eventualand deterioratio ration andng (vacuuming, of this also be lead unacceptabg may can be Commonwestandards or requirements docum corrosive and 12 ent printin e le contat oinadve Some smoke residues r smokrtently alth, State with the requir of any of these g component surface.faces affected by smoke, hea minants into introducing or Territo ements components are to al sur the HVAC of any ry regula of non-porous toxic. Any met or odours to competent persons tion. system. When the surface be evaluated by or effective. contributing particulates residue should affect the quality will be achievable deteriorated and or otherwise adversely restoration should determine if restoration the air stream, suppression through the system, of all downstream water from fire 2.5.7. ts affected by of the air moving cleaning Any componen accordance with and inspection/ be assessed in be performed activities should out as required. components carried

If contaminat If HVAC system be taken and analysed.the samples should ion is confirmed suspected then asbestos contaminat ated by competent the presence of be decontamin entire system should persons.

smoke 2.5.8. Fire and

Light

like may have theatres and the ing/processing rooms, operating such as clean bodies, manufactur use applications other governing determined by certain HVAC special be noted that of HVAC hygiene Note: It should s for higher levels specific requirement and the like. and operators System owners activities, regulations within HVAC systems. are familiar with the regulatory that they component should ensure in which they operate. the jurisdiction ion in or on a system requirements of through visual If fungal contaminat

not readily identifiable be taken for should is suspected, but surface samples taking procedures for assessment, then are Recommended ion assessment laboratory analysis. for fungal contaminat surface samples D. detailed in Appendix by t has been confirmed, be , to If a system or componen or analytical assessment system or visual observation ed then the affected mould contaminat should be decontaminated. ts system componen remediation of a mould affected or if a thorough Decontamination only be undertaken undertaken and system should been the system has samples. assessment of based on limited not an assessment

BEST TICE H YGIAC ENE PR ES IDELIN

GUsua Unu contam l ina

2.5.4. Asbestos dust or fibres is ion by asbestos

Clean

Moderate

Exhaust air system Non-ducted refrigerated Evaporative coolers

Special Use Systems

level Minimum hygiene (See Table 2.1)

Moderate Pre Filtration – – Light Post Filtration Light No Filtration –

or Supply air system, or Return air system, Outside air system

General Use Systems

STANDARDS

Clean

AHU – moisture producing Supply system equipment

INES PRACT ICE GUIDEL AIR A H BEST

1.8.4.

HVAC system any unusu s and comp onents should any renov al contamination event such be inspec ted events are ation/building after as a fire activit assessed in accord ies. Unusual contaor flood or ance with mination 2.5 of this Guideline. Where HVAC adequately systems or component cleaned s canno they should be repair t be ed or replac ed.

BEST PRACTICE

TABLE

Description

2.1 DEFI NITIO

Access is requir ed in order of all comp to inspec onents internal t the intern and a repres surfac 1.6.12. AS/NZ es of the HVAC entative portio al surfaces n of the system S 3666 provision of access parts 1 and 2 boths as defined in for maint enance. require adequ ate Inspections and

N OF HYG

IENE LEVE

No visible LS dust, debris or other contam O n l y sli ination. ghtly vi sible lay to no variati er of fin ons in densit e g en er al dust Component y. consiste surface nt over remains the com visible benea ponent Visible levels sur face th the fine of gener with lit t layer of le al dust Component dust. with varyin surface g densit is still visible y and limite High levels in some d areas areas benea of visible of accum other contam dust, debris th the fine ulated ination fine debris dust but that cover , fibres or any Component . in isolate the comp d sectio surface onent. ns may is barely not be. if not at all visible beneath the contam ination. Reference image

s for the

four define

d hygien

e levels

are provid

ed in Appen

dix F.

www.airah.org.au

AIRAH’s HVAC Hygiene Best Practice Guidelines are available to purchase in hard copy. Establishes the criteria for evaluating the internal cleanliness of HVAC system components Clearly determines when cleaning is required, according to the building use Describes the components of HVAC systems to be evaluated Describes the types of contamination likely to be encountered and includes for post fire and flood damage assessments Specifies minimum inspection frequencies for various HVAC systems and components for scheduled maintenance programs

Purchase online at www.airah.org.au/store 28

HVAC&R Nation

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April 2019

Smoko with . . .

Name: James Mason Air Conditioning

refrigeration and Occupation: Second-year air conditioning apprentice

industry do you work in? What part of the HVAC&R h a little bit of refrigeration. Mainly air conditioning, wit industry? ut working in the HVAC&R What’s the best thing abo ple cool. You learn how to keep peo d-a-half years d in the industry? Two-an How long have you worke er.

Favourite tool? Impact driv

do you think HVAC&R industry, what If you didn’t work in the s. car as a mechanic – I love you’d be doing? Working tion on HVAC&R Nation? What’s your favourite sec Side first. Always skip to The Lighter Benz 280SL. Dream car? 1975 Mercedes Dream date? Mila Kunis

key.

Drink of choice? Wild Tur

en to? What song did you last list . ters Figh Foo by “Learn To Fly” ? Favourite quote or saying it! fix ’t don ke, bro ’t ain If it Favourite smoko snack? e Coles servo coffee and a slic ad. of banana bre ney Sporting hero? Wayne Roo captain). ted Uni ter hes anc r M me (for … When I’m not working I’m g. tyin par or Working on my ute

James, working on a brand-new coolroom 250km from Alice Springs.

und Australia in my ute.

Dream holiday? Travel aro

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April 2019

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HVAC&R Nation

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

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Peter in Melbourne was called in to check out this system. “Bit sad really,” he says. “It’s the kitchen in a retirement village and they wondered why it smelt like overcooked cabbage. Since rectified.”

DON’T LEAVE ME HANGIN’

The next install in our ongoing tie-down series is from Mark in Queensland. “Called out to inspect why system keeps getting gas leaks at the flares on the outdoor unit,” he says. “Can’t imagine why!”

HORROR IN THE CEILING

Jason came across this, erm, creative drain set-up for some cassette units in south-east Melbourne.

DRIP CHARGER

“Well-constructed roof for the aircon,” observes Reece from Victoria, “but no drain off the unit right above the switchboard!”

AN INSTALL THAT REALLY SUCKS

Shane got a call from a customer in Albury who complained that their gas heating bill was too high. “The installer couldn’t be bothered running a return air so he ran the system on 100 per cent fresh air,” says Shane. “He didn’t even bother fitting a filter to keep leaves, dust or animals out.”

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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April 2019

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April 2019

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HVAC&R Nation

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167.6kW 7,800L/S OUTDOOR AIR SERIES CAPACITY RANGE

AIRFLOW RANGE

- TO -

25.7kW 566L/S

202.6kW 4,550L/S