HVAC&R Nation February 2020 by AIRAH

Skills

WORKSHOP

Evaporative condensers and water towers

The big freeze A refrigeration revolution triples output at the Australian Lamb Company

2020 VISION Industry insiders’ views of the year ahead

February 2020 / ISSUE 128

PRINT POST APPROVAL NUMBER PP 727272/60606

FREE

HVAC&R Nation

www.airah.org.au/nation

February 2020

February 2020 / ISSUE 128

2020 vision 20

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

Fax: 03 9614 8949

www.airah.org.au/nation

Magazine team Communications Manager Matthew Dillon matt.dillon@airah.org.au Tel: 03 8623 3000

Editor Mark Vender mark.vender@airah.org.au Tel: 03 8623 3022

Contributing writer Sean McGowan

Five key figures in the Australian HVAC&R industry predict the biggest challenges and opportunities for the year ahead.

Advertising sales

HVAC&R Nation regulars

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

Water-cooled condensers and cooling towers

See what’s new in the ‘Shed

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

The Toolshed

Skills Workshop

Global Update 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.

Exclusive to this issue

Cool Tech Custom chronometers, made to order

Legal Speak Choosing a solid structure for your business

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.

We speak to RMIT’s Outstanding Overall Student for 2019, Sharon Roussos

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.

No part of this publication may be reproduced, stored in a retrieval system or transmitted in any form or by any means electronic, mechanical, photocopying, recording or otherwise, without permission of the Publisher.

13,144 September 2019

Around the Nation Who’s in the news?

The publisher reserves the right to alter or omit any article or advertisement submitted and requires indemnity from advertisers and contributors against damages or liabilities that may arise from material published.

AIRAH News

Green Wedge Reusable packaging is coming to a supermarket near you

The big freeze

A cutting-edge blast freezer tunnel using natural refrigerants has revolutionised operations at the Australian Lamb Company’s Colac facility. Sean McGowan reports.

Smoko with . . . Q&A with Chris Kazantzidis

Lighter Side The shonkier side of the nation

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

February 2020

www.airah.org.au/nation

HVAC&R Nation

Ed’s letter

PAST, PRESENT, FUTURE. I always make grand new year’s resolutions. Never mind that by February they’ve mostly been broken, or even forgotten. I still do it every year, just like putting up the Christmas tree.

There’s the mundane stuff of course: exercise more, drink less. But it’s also a chance to reconnect with my goals and dreams, to lift my gaze and aim high.

Here at HVAC&R Nation we’re looking forward to another big year. I’m excited about uncovering more of the hidden stories in our industry, highlighting the amazing work people do and the opportunities HVAC&R offers. Our feature story on a cutting-edge blast tunnel freezer (page 10) is a good example. We all say that the trade needs greater recognition. I believe that starts with us recognising ourselves.

For this issue we’ve also surveyed people from the industry to get their outlook on 2020. They come from different parts of the business, and from around the country. Are they feeling optimistic going into the new year? Turn to page 20 to find out. As always we’ve had our ears to the ground, and over the past couple of months we’ve been picking up rumblings around licensing and education – two issues that the industry has been grappling with for years. We’ll be watching those spaces with interest over the coming months. It’s also an ARBS year, which means many of us will be rubbing shoulders at the Melbourne Convention and Exhibition Centre in May. In short, there’s lots to look forward to. But this year, for something of a change, I’ve also been looking back.

incorporated in Melbourne. Later that year the Institute held its first conference in Geelong – where James Harrison set up Australia’s first ice‑making plant midway through the previous century. Ahead of our centenary celebrations we’ve been reading through the AIRAH annals and interviewing people who remember what the industry used to be like. The daughter of one of our early members got in touch the other day and shared her childhood memories of going to an AIRAH national conference in Perth in the ’50s. They travelled overland from Melbourne to Perth, with stops along the way at Kalgoorlie and Mundaring to check out the pumping stations. Back then, HVAC&R equipment wasn’t manufactured overseas and imported. They had to make it themselves, and sometimes raw materials were hard to come by. Hearing these stories, you appreciate how Australia forged its identity as a can-do culture. So this year we’ll also be remembering the rich history of our industry – in Australia and abroad. If you have any blasts from the past you’d like to share, please get in touch. And have a look at our centenary website: airah100.org.au ■

@AIRAHnews

In 2020, AIRAH is turning 100. On March 29, 1920, the Victorian Institute of Refrigeration was officially

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

PROTECT YOUR TOOLS FROM THIEVES HEAVY DUTY STORE-SAFE SITE BOX WITH THEFT DETERRENT FEATURES Anti-Jimmy design - Internal hinges & locking rods Fully welded 2mm steel construction Anti-drill / hammer counter-sunk lock Registered Bi-lock key system

GET $100 OFF* USE CODE: StopTheft2020

Call Us Now 1800 888 714 Proudly part of

www.store-safe.com | info@store-safe.com T&Cs - $100 off per customer for orders placed before COB 30/04/2020 4

Half Page Advert February 2020.indd 1 | HVAC&R Nation | www.airah.org.au/nation |

February 2020

Protecting your tools of trade since 1988 9/12/2019 3:01:11 PM

We’ve got flow. Now you can, too!

Introducing IFD-LL A new Low-Loss Intumescent Fire Damper from Kilargo. Available now

Key Improvements: • • • • •

Higher Performance Design Low-Loss = Reduced Pressure Drop Reduced Noise Tested to AS1530.4 2014 Section 10 & 11 Insulation Rated up to 120min

Scan Q.R. Code for more info or visit: www.kilargo.com.au/ ourproducts/ifd-ll

Talk to us today!

1300 858 010

February 2020

E: info@kilargo.com.au

www.airah.org.au/nation

HVAC&R Nation

Toolshed 1

Haier calling

Carel says the calculation speed of the pCO5+ HS means it can respond more quickly and precisely to variations in the main unit input values in terms of temperature, pressure, and humidity.

Haier has released a new high-wall split-system air conditioner called Dawn.

The pCO5+ HS comes with two built-in serial interfaces, two expansion slots and two USB ports. The controller also features a wide range of optional cards for managing the communication protocols typically used in HVAC&R. Communication with Carel apps can also be implemented using 1tool.

The new unit has been tested in Australia to ensure it can cope across the country’s diverse climate. “From the searing heat of the desert, to the humidity of the tropics, to the chill of Tasmania, Dawn will help you create an environment you’ll love to be in,” says the company. Wi-fi connectivity is a standard feature. Dawn also offers voice control using Google Home, and can be activated remotely. Haier notes that the new system offers benefits for indoor air quality, too.

The pCO5+ HS is available with two built-in electronic expansion valve drivers and an optional Ultracap module. This is designed for integrated energy saving management. Go to www.carel.com/carel-australia ■

“Haier’s revolutionary patented self-clean technology freezes the indoor heat exchanger, trapping pollen and dust,” says the company. “It then defrosts, washing away the trapped contaminants and leaving your air conditioner to deliver clean, healthy air.”

Dwyer Instruments has recently released its series IEF Insertion Electromagnetic Flow Transmitter featuring electromagnetic technology.

Finally, Dawn is equipped with a smart movement and light sensor designed to sense motion over a large area and precisely locate any humans in the room. If no one is detected, the unit goes into sleep mode to conserve energy.

Dwyer says the transmitter accurately and reliably measures fluid velocity in addition to providing several continuous signal outputs.

Go to haier.com.au ■

“This series is specifically designed to offer superior performance paired with simple installation and use,” Dwyer says. “One unit is adjustable to fit pipe sizes from 4 to 36" – 101.6 to 914.4 mm – and offers several output options including selectable BACnet MS/TP or Modbus RTU communications protocol over 2-wire RS-485 in addition to the standard analogue, frequency and alarm outputs.

All the way with AWA

Armaturenwerk Altenburg (AWA), a European manufacturer of valves, sight glasses and fittings for refrigeration and air conditioning technology, has released a new oil‑level‑regulation system called OLC.

“High-performance accuracy is maintained through temperature, density or viscosity.”

“The AWA OLC guarantees the optimum oil level in refrigeration compressors, and is used in compound systems with reciprocating or scroll compressors,” says the company. “Its functionality is essentially based on the almost infinitely variable level measurement by means of an electronic float sensor. It can be used in systems of up to 120 bar for a variety of refrigerants and oils, and ensures permanent and instantaneous level detection. In addition to the level, the speed of change of the level is also evaluated for the first time.”

Dwyer says field-configurable, integral or remote set-up displays allow for flexibility by accommodating a variety of application configurations with one model through multiple display configurations such as pipe size and material through to calibration factor.

According to AWA, the electronic float is insensitive to foaming and swashing oil. Other features include a large sight glass for better level recognition, an LED display on the front for fast status recording, and a modular adapter system for connection to all common compressor types. And the installation dimensions have been reduced by up to 25 per cent.

Steel reinforcement channels have been added to give extra support to the box during concrete pour. And the Fyreboxes are now powder coated for extra durability.

In control with Carel

“Fyrebox Cast-In … provides a single, compact, pre‑formed fire-rated opening in floors that trades can run any number of mixed services through,” the firm says. “This is especially important for the HVAC&R industry, as it is common to have a large volume of services needing to be routed through a small footprint.

Carel has released its pCO5+ HS (high-speed) programmable controller, designed to improve the efficiency of HVAC&R kit such as chillers, process chillers, and equipment in data centres. “The new pCO5+ HS guarantees improved performance both in terms of application times – start-up and cycle – and upgrade speed,” Carel says. “This improved controller performance translates into faster unit set-up. When commissioning in the field, system management is also much faster. “Native integration of the USB port further simplifies maintenance: the data logger files saved on the controller can be simply and quickly copied to a USB flash drive or PC, for detailed analysis.” |

HVAC&R Nation

www.airah.org.au/nation

Fyrebox in effect

Since the Fyrebox Cast-In earned the AIRAH Product of the Year in 2018, it has had a number of changes.

Go to www.awa-armaturenwerk.de ■

“A set-up wizard and installation tool are simple to use, allowing for quick and precise installation,” Dwyer says. “The IEF has long life-cycle and minimal maintenance requirements, with no moving parts to wear or break, and electrodes that discourage fouling.” Go to www.dwyer-inst.com.au ■

The AWA OLC also incorporates special autonomous electronics functions to protect compressors.

Go with the flow

February 2020

“By casting directly into the floor slab, Fyrebox Cast-In eliminates the need for core-drilling of holes or forming of openings, which saves HVAC&R trades time and money,” the company says. “Furthermore, common compliance issues associated with proximity of services and structural integrity factors are eliminated, protecting HVAC&R trades from costly rectification works and reputational damage.

Toolshed “Fire tested and fully approved to AS1530.4 and AS4072.1, the Fyrebox Cast-In achieves a fire rating of up to four hours and offers an opportunity for HVAC&R trades to make passive fire compliance easier, ensuring life safety.”

“The VeriShield 100 series spare no comfort, armed with lightweight cushioned headbands and memory foam ear cushions, offering denser and softer foam than previous models, for greater comfort and attenuation.”

Go to www.tfire.com.au/FYREBOXCI ■

The range includes three different models. ■

Lend me your ears

Airbitat in the habitat

Honeywell Industrial Safety (HIS) has introduced the Honeywell Howard Leight VeriShield 100 Series Passive earmuffs.

Climate Rental Solutions has released the Airbitat Evaporative Cooler.

“From indoors to outdoors working with machinery, to the tools being operated and the processes taking place – all can be sources of harmful noise, and all require effective protection for workers,” HIS says. “The range of options offered ensures comfort and protection against any noise level, for every worker.”

“The Airbitat is a revolutionary new product, which is designed to be 50 per cent more effective in delivering deeper cooling than conventional evaporative coolers by using its three-step Reevac deep-cooling technology,” Climate Rental Solutions says.

“The Airbitat operates from a standard power supply, attaches to a continuous water supply, is fully mobile on wheels, and covers an area of approximately 50–75m2.” Developed and manufactured in Singapore, the units are distributed by Climate Rental Solutions on the east coast of Australia and South Australia, and by Safety Cool in WA.

“The VeriShield range reduces the short- and long-term effects of hazardous noise on hearing, and are designed to provide optimum comfort over long periods of use,” HIS says.

“The Airbitat is self-cleaning,” Climate Rentals says. “Its web‑based smart control system means it can be operated and monitored remotely, allowing for real-time performance data and settings adjustment.”

“Key features include large dimension range, with 17 per cent more adjustability than earlier models, comfortably fitting a wide range of head sizes. Wide cup openings, with 16 per cent more opening manoeuvrability, are ideal for workers with larger ears or who wear hearing aids.

Go to www.climaterentals.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.

FOR 2020 WE HAVE ALL YOUR WINDOWS OF OPPORTUNITY COVERED • FOR ALL OF YOUR ANALOGUE & DIGITAL CONTROLS – REGULATOR HAS YOU COVERED WITH RELIABLE SOLUTIONS FOR OVER 40 YEARS • FOR VALVES / ACTUATORS & RETROFIT SOLUTIONS – WE HAVE MANY LEADING BRANDS TO MEET YOUR NEEDS • COME AND SEE US FOR ALL OF YOUR BMS CONTROLS REQUIREMENTS • PERIPHERAL DEVICES FOR HVAC SOLUTIONS • GREAT TECHNICAL SUPPORT • REFURBISHMENT AND REPLACEMENT SOLUTIONS CC-HV&R-023

The earmuffs have been designed with the construction, manufacturing, utilities, oil and gas, and medical industries in mind.

For all your HVAC product, design, installation and servicing needs: Call (02) 9804 6366 or visit www.regulatorautomation.com.au

February 2020

www.airah.org.au/nation

HVAC&R Nation

Global Update

USA

VATICAN

NEW SUCCESSOR TO R410A?

HOLY HFC PHASE-DOWN

ASHRAE has given Honeywell’s new stationary air conditioning refrigerant R466A (also known as Solstice N41) the official designation A1 – non-toxic and non-flammable. The classification could be a key factor for manufacturers deciding which refrigerant to use in their systems in the medium-term. As a result of the HFC phase-down and the transition to refrigerants with a lower GWP, many manufacturers have already switched from R410A (with a GWP of 2,088) to R32 (675). In Australia, more than half of all small air conditioners imported now contain R32. However, R32 is classified as A2L – mildly flammable – making it unsuitable for units with larger charge sizes, such as VRF units. R466A may be seen as a more favourable option, given its A1 classification and its ability to be used in a wider range of systems. Its GWP of 733 is comparable to R32. ■

PRIZE FINALISTS

GO WITH THE FLOE

The eight teams selected pitched a wide range of technologies, including smart hybrid designs of vapour-compression, evaporative cooling, and solid-state cooling technologies that use little or no refrigerants. The finalists now move into the testing phase of the competition. The winner of the Global Cooling Prize will be announced in November of 2020 and awarded more than US$1 million in prize money. ■ HVAC&R Nation

“The continued acceleration of changes affecting humanity and our planet, coupled today with a more intense pace of life and work, should constantly urge us to ask whether the goals of this progress are truly directed to the common good and to a sustainable and integral human development, or whether they cause harm to our world and to the quality of life of much of humanity, now and in the future.” ■

INDONESIA

The finalist teams are led by some of the world’s largest AC manufacturers, including Gree, Daikin, and Godrej and Boyce; start-ups and corporations, including S&S Design Startup Solution, Transaera, M2 Thermal Solutions, and Kraton Corporation; and Barocal, a new spin-out from a University of Cambridge lab.

“It is important that the Kigali Amendment quickly gain universal approval on the part of the whole family of nations, as has happened with the Vienna Convention and the Montreal Protocol,” said Pope Francis.

INDIA

The eight finalists of the Global Cooling Prize have been selected. The international innovation competition aims to promote the development of super-efficient and climate-friendly residential cooling solutions for homes.

Late last year Rome hosted the 31st Meeting of the Parties to the Montreal Protocol – the international convention for protecting the ozone layer. And Pope Francis took the opportunity to announce that the Vatican is supporting the Kigali Amendment to phase down HFCs.

www.airah.org.au/nation

February 2020

As climate change attracts more and more attention, expect to see crazier (and sometimes downright scary) attempts at fixing the problem with technology. One of the latest concepts comes from Indonesia, and it has impressed the Association of Siamese Architects enough to win second prize in their recent design competition. The idea? A submarine that makes icebergs to replenish the melting polar icecaps. At this stage the proposal is light on technical detail. The video simply says: “The temperature in the polar region is indeed enough to freeze fresh water, but is accelerated by using a giant freezing machine.” But Penn State professor Michael Mann has (ahem) poured cold water on the idea. “It’s like trying to save the sandcastle you built at the beach using a dixie cup as the tide comes in,” he says. ■

February 2020

www.airah.org.au/nation

HVAC&R Nation

Feature

THE BIG FREEZE

By running two compressors and designing for 75Hz overspeed, backup coverage is available. Source: Hoctor Refrigeration

One of Australia’s largest blast tunnel freezers has helped a Victorian lamb supplier triple its outputs, and has showcased the safe application of super low-temperature ammonia/CO2 cascade systems. Sean McGowan reports. 10

HVAC&R Nation

www.airah.org.au/nation

February 2020

Feature The Australian Lamb Company (ALC) is one of Australia’s largest lamb producers. It operates from two fully licensed facilities in Victoria – one in the Melbourne suburb of Sunshine and another in the south-west town of Colac. The company processes over three million lambs per year for supply to Australian supermarkets, butchers, restaurants and hotels. It also fulfils export demand to South-East Asia, the Middle East and the USA. The state-of-the-art Colac facility opened in 2000. Processed meat originally had to be sent to Sunshine to be frozen, until a $7 million cold storage facility was added in 2005. It wasn’t long, however, before the company’s production exceeded the capacity of the cascade ammonia/CO2 blast freezing tunnel, leading to bottlenecks and inefficiencies. Meanwhile, domestic and export demand was increasing. “The existing tunnel system handled a carton box rate of six lambs per minute,” says James Hoctor, director of Hoctor Refrigeration. “But the kill floor and boning room worked at 12.8 lambs per minute, meaning that the freezing process put a significant brake on production.” At the same time, quality standards of export markets placed further pressure on ALC to deliver products frozen at lower temperatures. While traditional markets required meat products frozen at -10°C, new growth markets were demanding -18°C freeze points and less time between slaughter and the consumer.

The system makes use of a cascade condenser. Source: Hoctor Refrigeration.

IMPROVING EFFICIENCIES In 2018, ALC engaged consulting engineering firm Niras Australia to explore the expansion of the Colac facility’s cold store as part of a wider project looking at automation and improvements to the storage and handling capabilities. The project was broken down into nine different packages. Refrigeration was one of them.

“The others included construction, conveyors, automated storage solutions, IT software interfaces, robotic palletising and racking systems,” says Glenn Jacobsen, senior consultant with Niras. In June of the same year, Hoctor Refrigeration was commissioned to modify the existing freezer tunnel system with the aim of increasing capacity, minimising costs and delivering greater efficiencies. Recognising that a single tunnel system was necessary – because plate freezing would not support

The testo 300 Flue gas analyser. Smart, fast and robust. Take 3 minutes and see how it can change how you work. testo.com.au

Scan to see the 15 sec video

info@testo.com.au 1300 837 861

February 2020

www.airah.org.au/nation

HVAC&R Nation

Feature

The new tunnel can pull product temperatures down from +4°C to -12°C in just 24 hours. Source: Hoctor Refrigeration

ALC’s different carton sizes – Hoctor leveraged the existing systems to create efficiencies with minimal disruption to operations.

DID YOU KNOW

“Sustainable natural refrigerants were already part of the equation,” says Hoctor. “But they had not been demonstrated at the super low temperatures required.”

FACT #1 Australia is the largest exporter of sheepmeat in the world, and is the world’s second largest producer of lamb and mutton (behind China).

FACT #2

Hoctor Refrigeration convened two project teams to coordinate the plant and tunnel elements, and worked with consultant engineer Klaas Visser, M.AIRAH, to design and deliver plant improvements.

The off-farm meat value (domestic expenditure plus export value) of the Australian sheepmeat industry was approximately $6.6 billion in 2018–19 – up 1 per cent on the previous year.

The teams dismantled, manufactured, reinstalled and commissioned the modified, automatically loaded blast freezer tunnel, and in doing so increased capacity from 3,312 to 7,632 cartons per day.

FACT #3

TUNNEL VISION

In 2018–19, Australia produced almost 501,000 tonnes (cwt or carcase weight) of lamb, and 230,000 tonnes (cwt) of mutton, with the average Australian consuming around 7kg of lamb and 0.3kg of mutton.

The blast freezer tunnel at ALC Colac allows cartons of various sizes to be continuously stored at the same pace as product lines, while being frozen throughout the duration of the production process.

This places us among the highest sheep meat consumers in the world.

In the previous system, freezing took between 36 and 40 hours at -30°C to -35°C. The new tunnel is able to pull the product temperature down from +4°C to -12°C within just 24 hours.

FACT #4 Australia produced about 7 per cent of the world’s lamb and mutton supply in 2018.

To achieve this, the tunnel features the largest CO2 compressor package of its type in Australia at 1,200kW with 100 per cent redundancy to achieve temperatures between -45°C and -50°C.

FACT #5 Like the HVAC&R industry, Australia’s red meat industry is also a major employer, with around 172,000 people employed in on‑farm production, processing and retail – and almost 32,000 agricultural businesses involved in the sheep and lamb industry.

“This expedites product movement, requires less plant and storage inputs and has resulted in 13 to 15 per cent less energy consumption,” says Hoctor. “There is now continuous product flow across the plant, while the lower freeze temperatures meet the food safety requirements of emerging markets.”

Source: Meat & Livestock Australia

To eliminate ice formation on stock‑control sensors, an innovative dehumidification system was used. “By replacing the air in the tunnel with dehumidified air with a dew point lower than the operating temperature, ice cannot form,” he says. The evaporator has successfully reduced the need for manual defrost maintenance. Previously, this required weekly plant stoppages and energy wastage. “This has resulted in one-third of the normal required defrost, leading to longer run times and greater efficiency as less heat is added,” says Hoctor. 12

HVAC&R Nation

www.airah.org.au/nation

February 2020

ICY CHALLENGES The team had to overcome a number of challenges inherent to super low-temperature systems in CO2 plant design for the ALC Colac project. These included maintaining a steady suction pressure and the selection of plant materials suitable for the required rated pressures. “At -56.6°C, CO2 reaches triple point, where it transforms from liquid to solid (dry ice),” says Hoctor. “The refrigeration design nudges this edge closely, with agile controls and control logic in place.” Managing oil at low temperatures also proved a challenge. The original system at ALC Colac used a pumped CO2 system and four coil blocks. In the new system, Hoctor Refrigeration designed custom DX evaporators and had them manufactured to increase capacity and overcome potential oil logging issues on the modified system. According to Jacobsen, one of the largest challenges of a project like this was the interruption to existing operations. “Throughout the whole process we had key stakeholders from ALC involved in weekly project meetings to ensure all parties were aware of what the others were up to,” he says. “ALC could provide processing information and operation times, and the trades, including Hoctor Refrigeration, could work around as best as possible to ensure production did not become affected at all.” To further minimise disruptions, Hoctor Refrigeration took the innovative approach of running two compressors and designing for 75Hz overspeed as well as 100 per cent redundancy. Any safety risk associated with the potential mixing of ammonia and CO2 was mitigated by the installation of high‑alert cross-contamination sensors – the first of their kind to be used in Australia. The volume of ammonia charge within the system was also minimised as much as possible. During commissioning, sensors were checked and readjusted on multiple occasions due to the steel shrinking by 20mm when the freezer was brought down to the operating temperature. Hoctor says quality and agile project management were critical to designing, manufacturing, importing

Feature The safety risk of CO2 and ammonia mixing was mitigated by installing high-alert cross-contamination sensors, the first time used in Australia. Source: Hoctor Refrigeration

can realise higher yields, find operating efficiencies, reduce equipment and maintenance costs, and enhance environmental credentials,” he says.

It will inspire risk averse

Additionally, Hoctor says the project represents a refrigeration-led approach to business growth and economic development, and showcases the HVAC&R industry as an enabler for other industry sectors to become more sustainable, profitable and reputable.

naysayers to be confident in the safety and capacity of low‑emission ammonia and carbon dioxide models to deliver at scale Overall, Jacobsen says the modifications made to the operating facility at ALC Colac have improved many aspects of the inherent OH&S issues associated with traditional cold store facilities.

and commissioning so many different components and parts in the project’s short timeframe. “It was also a challenge to quickly source equipment with appropriate load capacity,” says Hoctor, who scoured six countries for the right equipment. Onsite spatial limitations were resolved by assembling components at a dedicated factory in Bendigo in central Victoria. These were then transported to the site, where Hoctor Refrigeration teams deftly manoeuvred around ALC operations.

“ALC has a big focus on employee safety, and working alongside all parties ensured this was a major aspect of this project,” he says.

“The innovation at ALC Colac demonstrates how financial and environmental imperatives can be mutually supportive,” he says. “And (I hope) it will inspire risk averse naysayers to be confident in the safety and capacity of low‑emission ammonia and carbon dioxide models to deliver at scale.” So when you next throw a lamb chop on the barbie, know that refrigeration has played a large part in that meat’s progress from paddock to plate. ■

FI N AL I ST

END GAME According to Hoctor, the improved 24-hour, lowtemperature blast freezer tunnel operating at ALC Colac demonstrates the capabilities of ammonia/ CO2 cascade systems running at lower temperatures to deliver higher yields.

Hoctor Refrigeration’s work on the ALC Colac project was a 2019 AIRAH Awards finalist in the Excellence in Innovation category.

“By adopting low-emission refrigerants and benefitting from a lower temperature freeze, our stakeholders

February 2020

www.airah.org.au/nation

HVAC&R Nation

Cool Tech

TICK OF APPROVAL Perhaps it’s time for your watch to get a personal touch. Once upon a time if you wanted to personalise a watch given as a present (usually for a significant birthday or milestone), your options were limited to simple engraving: Dave, thanks for your 50 years of stellar service.

These days the options for wrist instrument personalisation and modification are far more extensive. The Hong Kong-based Undone watch company allows purchasers of its watches to mix and match colours and styles for watch faces, hands and bands across a selection of different watch types, from chronographs to dive watches. Beyond this, there are opportunities to personalise the back of your watch with a photograph, message or monogram. You can also add a logo or your initials to the watch face to make it unique. The watches are available in quartz (battery), automatic, and even mechaquartz, a combination of the two. “You pick, you click,” Undone says. “We’ll make it tick.”

HVAC&R Nation

www.airah.org.au/nation

February 2020

The end result will be your very own custom timepiece – which Undone thinks hits a reasonable price point between accessibility and personalisation. We’ll let you be the judge of that. www.undone.com ■

MODULE

125 128

PROUDLY SPONSORED BY

AIRAH

WATER-COOLED CONTROLS CONDENSERS AND FUNDAMENTALS COOLING TOWERS

■ What?

Controls are an increasingly important consideration in new building design and existing building renovation. They are directly system, linked to The condenser is a most important unit in a refrigeration building performance and energy management, commissioning and as it is into this that all of the heat-laden vapour pumped by the retro-commissioning, operation and maintenance and broader links compressor is forced under high pressure. It must be of greater to building sustainability, building health and safety, and ultimately capacity than the evaporator because the condenser must dissipate building satisfaction and productivity. the mechanical energy from the compressor as well as the heat absorbed in theand evaporator. The operation control of environmental systems in buildings is a

■ Who?

critical activity in terms of operating costs, environmental footprint, Condensers are classified according to the type of cooling medium occupant comfort, and indoor environment quality. The operation of used – and are of three general types: air-cooled, water-cooled and many building systems is sub-optimal and the performance of these evaporative. This skillswith workshop looks at evaporative condensers. systems can improve better control strategies. Efficient buildings

Skills summary A description An overview of ofbuilding the different controls types and the terms commonly of water-cooled condensers used and when discussing them. cooling towers.

need efficient controls. This Skills Workshop also looks at cooling towers. All water‑cooled refrigeration and air‑conditioning systems must the water This Skills Workshop provides a broad overview ofrecirculate control system fundamentals and explains of theby common terms used when using cooling towers to coolsome the water evaporation. discussing control systems.

Relevant for mechanical Maintenance service providers, contractors, controls vendors consultants, OEMsand andintegrators, installers designers and operating within contractors, refrigeration, air construction and project conditioning processmanagers, cooling facility managers, and heating applications. building owners and developers, tenants and occupants.

Evaporative (Type 3) condensers Evaporative condensers utilise both air and water to achieve heat rejection. The refrigerant flows into a condenser located in an enclosure; water is sprayed over the condenser to promote cooling of the refrigerant and air flows over the condenser to promote evaporation of the water and removal of heat energy. The water cycle is all in the condenser cabinet in this system. Longer refrigerant runs are usually needed to carry refrigerant to the evaporative condensers.

solenoid stop valve sight glass

At distances greater than these, problems of liquid condensing in the discharge line and flowing back to the compressor and of liquid refrigerant in the heads dictate the choice of separate water-cooled condenser and cooling water. The cooling capacity is affected by the relative humidity of the air (water will not evaporate readily at high humidity) and by high water and condensing temperatures.

Usually the evaporative condenser is mounted out of doors; however, it is possible to locate an evaporative condenser indoors by providing air ducts linking the condenser to the outside.

strainer

Evaporative coolers are often used in preference to cooling towers where the distance from the compressor to the preferred location of the condenser does not exceed 10–30 metres in a horizontal direction, or six metres vertically from the compressor.

evaporator capillary tube equaliser tube

liquid shut-off valve thermostatic expansion valve

evaporative condenser

remote bulb blower section suction line

liquid line hot gas line suction valve discharge valve

purge valve

sprays

condenser shut-off valve liquid valve

Fig 2 Typical custom-built evaporative condenser

emergency shut-off valve

Some systems pump the water to a tray located above the condenser and the water drips over the coils as air is forced through the coils. A fan operates to blow air over the condenser at all times when the condensing unit is operating. The water normally circulates continually, although, as with cooling towers, the fan may be slowed or turned off if water temperature falls too low.

condensing coil

rubber hose

compressor unit

vibration insulators

pump liquid receiver

pressure relief valve

fusible plug liquid sight glass

This type is most economical with the water – and makes a most effective condenser. As the condenser heat evaporates the water, the water absorbs heat at the rate of the

Fig 1 Evaporative condenser installation (Reproduced from Trane Reciprocating Refrigeration Manual. Courtesy of Trane, Ingersoll Rand.)

February 2020

www.airah.org.au/nation

HVAC&R Nation

HVAC&R Skills Workshop latent heat of vaporisation, which is approximately 2250 kJ/kg. Added to this is the sensible heat change. Allowing for “bleed-off” of water to reduce the salt content, and for natural evaporation, such a plant would use only about three to four litres of water per kilowatt of refrigeration.

Cooling towers Strictly speaking, cooling towers are not part of the refrigeration system, but are used to cool the heat-laden condenser water so that it can be re-used. Cooling towers can use either natural convection or forced convection to promote airflow over the water droplets and improve evaporation of the water and therefore removal of heat energy in the process so the remaining cooled water can be recycled for reuse. However, the evaporation of water, plus the absorption of airborne pollutants by the water in the cooling tower, can cause costly corrosion problems. It is important, therefore, that the cooling water is monitored and chemically treated to reduce scaling and corrosion. “Bleed” – In addition to water treatment, some of the water must be constantly “bled” to waste, to prevent concentration of solids as the water evaporates off. This is costly, as some of the treatment chemical is also lost and requires replacing. The amount of “bleed” varies according to the level of solids in the water (water quality) and the rise in water temperature. Water flow rates through condenser tubes should be of the order of 0.2 litres/second per 3.5 kW of refrigeration, while flow velocities should be low enough to prevent erosion of the tubes at the end shields or “U” bends by solids in the water.

Fig 3 Baltimore Aircoil counter‑flow forced-draught cooling tower (Reproduced with the permission of Baltimore Aircoil [Aust] Pty Ltd.)

Because of fresh water shortages, the running of water to waste is limited by law in many places, and most water-cooled plants use a cooling tower to lower the water temperature again for recirculation through the condenser. These towers are erected on roofs of buildings or in other locations where air can circulate freely through them. Some buildings may use the one cooling tower to reject heat from many refrigeration and air conditioning systems located around the building but small cooling towers of a few kilowatts of refrigeration capacity are also available.

Cooling towers are divided into two broad classes: • natural-draught or wind towers – where the circulation of air through the tower depends upon natural wind movement • forced- or induced-draught towers through which air is forced or drawn by fans. However, most large cooling towers are in fact a combination of both, having fans – controlled by temperature sensors in the water – which run only when the water temperature exceeds a certain set limit, usually about 25°C, or using fan motor speed control to vary fan speed to suit the load. When the fans are not necessary, these (usually) roof-mounted towers rely upon natural breezes to evaporate the water sprayed from the top of the tower.

Fig 4 Diagrammatic representation of the cooling tower shown in Figure 3 (Reproduced with the permission of Baltimore Aircoil [Aust] Pty Ltd.)

The water which evaporates is replaced by “make-up” water from the mains, entering through a float control to the basin. If the fan is thermostatically controlled and the tower is in a windy location, the fan will turn off if the water temperature falls below about 25°C. motor

fan support fan

fan stack

sprinkler pipe

casing

fill

louvre

fill support water basin tower support stand

Fig 5 Hyperbolic cooling tower

Figure 6 shows two important points which must be considered when using towers Firstly, there is always an accumulation of solids which remain in the water after some has evaporated and, to prevent the concentration of solids creating corrosion or scaling problems, a percentage of the return water (depending on the characteristics of the mains supply and the evaporation rate) must be “bled-off” to waste. Secondly, because in cold weather the problem of over-condensing can be a serious one, an automatic “bypass” valve will recirculate water through the condenser whenever the condenser water temperature falls below 21°C for air conditioning loads.

Large towers suitable for plants exceeding 1750kW of refrigeration (for example, for office towers) use cooling towers with end or overhead fan or fans and generally plastic “fill” down which the water slowly cascades, against the incoming air. Figures 3 and 4 show a typical example, while Figure 5 shows an all-plastic variety of forced-draught cooling tower. Regardless of the type of cooling tower, water circulation differs little from that shown in Figure 4. In operation there is a reservoir of water in a tank or basin at the bottom of the tower. From this basin, water is pumped through the water-cooled condenser; then, having picked up the heat of condensation, the water is forced to the top of the tower and out through spray nozzles or similar distribution devices over the cooling tower “fill”, over which it trickles down to the basin against the cooling airflow. Water which enters the tower at 32°C to 38°C will be cooled mainly by the evaporation of about five per cent of its volume, with each kilogram of water 16

HVAC&R Nation

www.airah.org.au/nation

February 2020

that evaporates absorbing latent heat of 2250 kilojoules. In Perth, Western Australia, where on 35°C days the wet bulb temperature averages 24°C, water will cool to approximately 24°C by the time it reaches the basin and can be immediately recirculated. However, in more humid climates, the evaporation rate is lower, and towers must be much larger as the temperature drop would be much less. Dry climates provide the most effective cooling due to the low wet bulb temperature, but dry areas usually lack sufficient water for water‑cooled condensing.

‘bleed off’line

cooling tower ‘make-up’ water

hot gas in ‘bypass’

condenser liquid out

pump

Fig 6 Recirculating water system

HVAC&R Skills Workshop Water treatment

Over-condensing

The inside of a cooling tower or condenser may become coated with, and attacked by, foreign materials both from the air (e.g., smog, chemical fumes etc.) and the water. These may be removed by water-softening or metal‑cleaning materials, fungicides and anti-corrosive materials. Unfortunately, the treatment of one source of contamination often requires the addition of another chemical to offset the by‑products of the first treatment, and so on, so that treatment is a very costly business with seemingly no single treatment satisfying the needs of any two plants.

Over-condensing in winter months can be a serious problem, particularly with remote air-cooled condensers, and water- or evaporative-cooled units, as liquid can accumulate in the condenser, starving the rest of the system. Also, overcapacity of the compressor under the low head pressures can cause inefficient operation of the refrigerant control and short cycling for the compressor.

Regular draining, or even excessive “bleed-off” is not the answer, as algae and scale can form in pipes and on surfaces with relatively fresh water. Again, a combination of water treatment and excessive bleeding is costly in materials, as the water treatment chemicals are lost in bleeding. Despite all treatments, corrosion can occur if water is acid or alkaline. It can also be caused by electrolysis that occurs between various metals (for example, copper and steel) used in construction; this has been known to eat through 12-millimetre steel condensing plates in six months. Regular cleaning and inspection for rust and deterioration is necessary on all water towers and condensers and adds considerably to large plant operating costs. The development of all‑fibreglass and plastic towers and components is an attempt to reduce this expense.

Water regulating valves The water flow rate through a water‑cooled condenser is often automatically controlled by a water regulating valve (see Figure 3). The valve is installed on the water line at the inlet of the condenser and is actuated by the compressor discharge, as in Figure 3.28. When the compressor is in operation, the valve acts to modulate the flow of water through the condenser in response to changes in the condensing pressure. An increase in the condensing pressure tends to collapse the bellows further and open the valve wider against the tension of the range spring, thereby increasing the water flow rate through the condenser. Likewise, as the condensing pressure decreases, the valve moves towards the closed position so that the flow rate through the condenser is reduced accordingly. Although the regulating valve tends to maintain the condensing pressure within reasonable limits, the condensing pressure will usually be considerably higher during periods of peak loading than those of light loading. When the compressor “cycles on” again, the water valve remains closed until the pressure in the condenser builds up to the valve‑opening pressure, at which time the valve opens and permits water to flow through the condenser. The opening pressure of the valve is approximately 50kPa above the shut-off pressure. The water valve is set for the desired shut-off pressure by adjusting the tension of the range spring. The minimum operating pressure for the valve – that is, the shut-off pressure – must be high enough so it will not remain open and permit water to flow through the condenser when the compressor is on the “off” cycle. Since the saturation temperature of the refrigerant in the condenser can never be lower than the ambient temperature at the condenser, the shut-off point of the water should be set at a saturation pressure corresponding to the maximum ambient temperature in summertime at the condenser location. The shut-off pressure of the valve must also be high enough so the minimum condensing temperature in wintertime is sufficiently high to provide a pressure differential across the refrigerant control large enough to ensure its proper operation.

Fig 7 Water regulating valve (Reproduced with permission of Danfoss [Australia] Pty Ltd.)

Electrically operated solenoids may also be used, connected to open when the motor starts and close when the motor stops. However, this system does not give precise control of head pressure, as does the pressure-operated valve.

PROUDLY SPONSORED BY

AIRAH

On air-cooled units, special bypass valves are available which bypass discharge gas directly into the liquid receiver in cold weather. In the case of multiple-fan condensers, the bypass valves “off cycle” one or more fans as the temperature falls. Another way of controlling head pressure is to use speed controllers on condenser fan motors. With simple water-cooled units, valves operated by head pressure are used to control water flow. With cooling towers and evaporative condensers, the water temperature should not fall below 20°C. Control can be maintained by: • cycling the air-circulating fans off as the water temperature falls to 25°C, or • bypassing some, or all, of the water directly back into the condenser or water reservoir without evaporation in the airflow.

Common faults and testing High head pressures on water-cooled plants are generally due to one or more of the following: • air or non-condensable gas in the condenser • restricted water flow due to pump inefficiency, air in the lines, valve or strainer restriction, or scale accumulation in supply or condenser tubes • high relative humidity of atmospheric air onto the cooling tower, resulting in high water supply temperature. Quick tests can be made, using thermometers only, to isolate these problems: • The water temperature from the cooling tower and into the condenser should not exceed 30°C. • The water out of the condenser should approximately be – but not exceed – 6K above the water-in temperature (eg water in at 30°C with water out at 36°C or water in at 27°C with water out at 33°C). • The refrigerant condensing temperature should be approximately 5K above the water-out temperature (e.g., water outlet temperature = 35°C; correct condensing temperature, R22 refrigerant = 40°C; headpressure, R22 refrigerant = 1430kPa gauge). Note: Condensing temperatures for water‑cooled units may be as much as 20K below similar air‑cooled units. This results in at least 20 per cent increase in cooling capacity. ■

discharge

water regulating valve warm water out

suction condenser

cold water in from mains

liquid to control

Fig 8 Waste water system

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

Next month: Corrosion and asset protection February 2020

www.airah.org.au/nation

HVAC&R Nation

www.airah.org.au/nation

February 2020

Legal Speak

LAYING FIRM FOUNDATIONS

COMPANY A company is an independent legal entity able to do business in its own right. You will run the business as a director and/or shareholder. The advantages of a company are that your liability for the debts of the business is limited to the money you have invested in the business, unless you agree to personally guarantee the debts. A company can also own property in its own name There is, however, a large initial establishment fee. The establishment rules are complex, and the regulations are strict.

How do you choose the best structure for your business? HVAC&R Nation legal expert Frank Gambera shares some tips. Your choice of business structure depends on a number of factors. These include how profits are to be shared with other people; who is legally liable for the actions and debts of the business; and the tax implementations on earnings from the business. We look at the most relevant structures below.

SOLE TRADER The sole trader structure involves an individual trading on their own. This is the easiest method of starting a business and the simplest form of business structure. The advantages of being a sole trader include low commencement/registration fees and independent control over business decisions. All profits and capital also belong to you.

TRUST

But there are disadvantages too. Your capital is limited by your personal assets, and you will be personally responsible for all debts and liabilities.

PARTNERSHIP A partnership exists when two or more people go into business together and plan to make a profit. A partnership is not a separate legal entity like a company, so all assets of the partnership are owned by the partners jointly. On the positive side, a partnership is inexpensive to start and establish. And shared control reduces your individual burdens. On the other hand, partnerships bring the potential for disputes over profit sharing, administration and development. You will also be personally responsible for business debts and liabilities incurred by your partners.

Frank Gambera is a director for McMahon Fearnley Lawyers Pty Ltd. Contact him on 03 9670 0966 or through www.mcmahonfearnley.com.au

Corporate trusts have become extremely popular in the industry. According to ATO data, in the 2014 financial year there were 802,000 tax returns lodged for trusts with a total income of $345 billion compared with 763,000 tax returns lodged for companies and 344,000 tax returns for partnerships. A trust is a business structure where a trustee holds property or income for the benefit of others called “beneficiaries”. With a corporate trustee, the company is a trustee who owns the assets of the business and manages the trust. The members of the trust are directors of the company. A trust deed is usually prepared by a lawyer who formalises the powers of the trust. There is a limited liability for trusts, because the business is a separate legal entity. They also make it easier to separate trust assets and personal assets. And business income can be split among beneficiaries to assist in minimising tax. The disadvantages are that it is expensive to establish a business under a trust structure. And it does not offer protection from personal liability When deciding which structure will be best for your business circumstances, you should seek professional advice to avoid selecting the wrong structure and incurring unnecessary costs. ■

February 2020

www.airah.org.au/nation

HVAC&R Nation

Cover Feature

Damien Walsh

Stefan Jensen

Sarah Simmonds

Brett Hedge

Sue Falcke

2020 VISION The new decade we’ve just entered will present both opportunities and challenges to the HVAC&R industry. Sean McGowan explores the year ahead with Damien Walsh, group brand manager at Temperzone; Stefan Jensen, F.AIRAH, managing director at Scantec Refrigeration; Sarah Simmonds of Simmonds Heating & Cooling; Brett Hedge, M.AIRAH, sales and marketing manager at Kirby; and Sue Falcke, events organiser for ARBS Exhibitions.

HVAC&R Nation

www.airah.org.au/nation

February 2020

Cover Feature How would you describe 2019 for your business? Walsh: It was an exciting year for Temperzone with the introduction of many new products from both Temperzone and Hitachi. There has been strong market growth in various product segments, particularly around residential channels in NSW and Queensland, and newer commercial products, despite a challenging economy. Jensen: Following three very busy years leading up to New Year 2018/19, the start of 2019 was characterised by a slow-down in business. The timing of this slow‑down appeared to coincide with the publication of various polls predicting an ALP win at the May 2019 federal election. The federal election result did not cause an immediate improvement in business, but towards the end of third quarter 2019, signs of improvements did emerge. Simmonds: We’ve taken some big hits from some players in the building industry that we have been working hard to recover from. In saying that, it has also been an exciting year, with us focusing a lot on our commercial division and taking on our own commercial estimator and project manager. We saw some results of all the hard work and effort put in by not only ourselves as owners but the whole team at Simmonds when we won the 2019 CCN Contractor of the Year award. Hedge: It was a year of much change, largely concentrated around the rebranding of the company and a reset on focus areas to help reinforce this change back to Kirby in our wholesale stores.

Registration NOW OPEN

We continue to see start‑ups and new product offerings coming into the market Falcke: ARBS 2020 went on sale in June 2019, with demand so strong that by mid-July we had to request an extension of space with the Melbourne Convention and Exhibition Centre (MCEM). This has never happened this early before. By the end of 2019 we were tracking at just on 90 per cent sold, with the extension making ARBS 2020 the biggest exhibition ever held in Melbourne! We are delighted with the support from the industry and are looking forward to what will be a bumper show next year.

varying confidence through the country this year. We have definitely witnessed changes in behaviour throughout the market, evident by product choice and capital expenditure. Jensen: There are signs that the predictions of rising energy costs and rising costs of hydrofluorocarbon (HFC) refrigerants are slowly starting to influence buying decisions for new plant. It is also apparent that the same predictions are starting to have an impact on what refrigeration plant users do about making their existing systems more energy-efficient. Simmonds: We are hoping to be involved in a lot more commercial work, and steering away from builder work, which was a big focus in the past few years. Walsh: 2020 is expected to be another competitive year. There will be continued focus from larger companies to seek more sustainable lower-GWP products for R22 replacement, with a focus on high efficiency. We have budgeted for continued growth in 2020, along with innovative product introductions across various segments.

What business conditions do you expect to face in 2020? Falcke: When I talk to exhibitors there is still cautious optimism. We continue to see start-ups and new product offerings coming into the market. Going by the increased amount of space booked by some of the major multinational exhibitors, there would appear to be growing confidence in their ability to expand their market share in the commercial/industrial space. Hedge: We are expecting improved confidence in 2020 – noting that there has definitely been

It seems like business confidence might be improving then? Jensen: Confidence depends on whom you talk to. Clearly those entities able to provide future‑proof solutions are less concerned about the future than those entities and individuals whose future business prospects depend solely on HFC refrigerants and equipment utilising these working fluids.

SOURCE PRODUCTS SHARE SOLUTIONS CONNECT @ARBS

Visit Australia’s only international HVAC+R & building services trade exhibition, with the largest range of suppliers, products and solutions, all under one roof. Featuring the highly regarded Speaker Series, the new IBTech Insight Series and the celebrated ARBS Industry Awards, ARBS 2020 should not be missed. REGISTER ONLINE NOW

MCEC // MELBOURNE 19-21 MAY 2020

February 2020

www.airah.org.au/nation

HVAC&R Nation

Cover Feature The federal government cannot rely entirely on interest rate cuts by the Reserve Bank to deliver necessary economic stimulus. The energy conservation potential generally within HVAC&R applications is enormous. With current technologies, it is possible to halve the energy consumption of the sector. The federal government has a significant role to play with respect to incentivising this change. A very good start would be massive training initiatives at all levels of the industry from trade levels to engineering. Simmonds: In our opinion, it is improving. The feedback we get from various contractors/customers, as well as the general public is that the demand for more energy‑efficient systems and programs naturally assists our trade, and the demand for upgrades reflects this. Walsh: General market confidence remains flat, with many areas such as new homes, apartments and infrastructure down. Over the past few months some areas of the HVAC industry have seen an increase; however, the market looks to remain tough for a while yet. Falcke: I would have to say that our own experience is showing an improved business confidence simply due to the increase in demand of space sales for ARBS 2020. The improvement is evidenced since previous sales in 2017 for the ARBS 2018 exhibition in Sydney. Hedge: From what we have seen in 2019, there was some improvement in the latter part of the year and we are hopeful that this will continue in 2020. What will be the greatest challenges to businesses, like yours, operating in the HVAC&R industry in 2020? Hedge: There is increasing demand for technical support across our customers, and service level expectations are increasing. A connected world means that people expect better information in real time.

Vocational training in natural refrigerants and in flammable synthetic refrigerants is hopelessly inadequate We are also seeing some attention on the changing refrigerant landscape, and that is an area that continues to demand special attention with our customers. Jensen: The continued proliferation of flammable refrigerants and lack of application expertise at almost every level from trade to engineering. Tertiary training in industrial refrigeration engineering is not offered in Australia. Vocational training in natural refrigerants and in flammable synthetic refrigerants is hopelessly inadequate and this will jeopardise the timely technology transition that must occur within the entire Australian HVAC&R sector to ensure compliance with the Kigali Amendment to the Montreal Protocol. Another challenge will be the continuous bypassing of the HFC import quota via pre-charged equipment, which is providing the industry with a false sense of complacency. This has the capacity to drive very steep HFC price escalations when this pre-charged equipment requires HFC replenishments in the coming few years. Walsh: As a true manufacturer in Australia, ensuring we continue to develop innovative products that offer value is an area of key focus. Some of the challenges of local manufacturing include raw material and shipping costs, along with competing against regions with lower labour costs. Other key challenges include issues such as the HFC phase‑down, GEMS (Greenhouse and Energy Minimum Standards) Act and the industry skill gap.

The continued drive for energy efficiency and reduced emissions are also important. More efficient products combined with green buildings, and higher levels of insulation. Smarter controls will play a big part in the future of the industry. Simmonds: The building industry and also the effects of global warming. Falcke: We can expect an increased level of competition among the major players all vying for market share. That combined with a new and exciting range of product offerings delivering energy efficiency and new smart technologies will push the sustainability focus up another level.

Sarah Simmonds says the team at Simmonds Heating & Cooling will be looking at more commercial work in 2020.

HVAC&R Nation

www.airah.org.au/nation

February 2020

Cover Feature for end-users, but also for financiers. It is a pre-requisite, however, that the provider of the plant has a track record and can predict annualised energy efficiency with a high degree of statistical certainty. Hedge: Digital and smart technologies are having an increasing impact every year. We have seen high levels of engagement with the technological developments that we have delivered in the Kirby Smartaccess customer portal in the past year. Falcke: We are unveiling our new tech precinct, IBTech@ARBS, next May, which is dedicated to the latest smart, connected and sustainable building and property technology. The emergence of Internet of Things (IoT) into the HVAC&R industry will signal a new era in the way we configure our living, working and leisure spaces, with connected controls and data analytics creating the ability to more readily adapt a building’s services to the needs and comfort of occupants. The ARBS exhibition – slated for May 19–21 in Melbourne – is always a good barometer of the mood in the industry.

Do you have any predictions for big changes, or emerging technologies that could disrupt the industry in 2020? Jensen: Our general prediction for 2020 is that there will be an increasing element of plant replacements. The drivers for these replacements will be reductions in

energy consumption, improvements in plant reliability and minimisation of maintenance costs. Some interest is also starting to emerge in new ownership models where refrigeration plant users no longer own plant outright but pay for the conversion of electrical energy to cooling. For very high energy efficiency solutions, these types of ownership models are attractive both

Walsh: Technology is a big one, with intelligent buildings, controls and connectivity coming to the fore. Open communications along with the ability to integrate systems onsite – providing bespoke solutions’ continued drive for energy efficiency and reduced emissions – is a major focus, with high-efficiency lower GWP products having a role to play. Simmonds: We as a trade need to be constantly aware of the positive effects we can have on energy efficiency. Government laws that could be placed upon the HVAC industry in relation to gas emissions etc., could have a huge impact. ■

Why stand around recovering refrigerant for days on end, when you can call in the experts to recover liquid and vapour in a fraction of the time?

HVACR FEb 2020 HP.indd 1

February 2020

www.airah.org.au/nation

HVAC&R Nation

10/12/2019 9:44:48 AM

AIRAH News

FROM COUNSELLING TO COOLING Sharon Roussos left social work to pursue an apprenticeship in refrigeration – and is loving her new career. Late last year the RMIT School of Vocational Engineering, Health and Sciences held its annual trade awards. In the refrigeration category, awards were handed out for each year, and one special gong went to the outstanding overall student. That was Sharon Roussos, a third-year apprentice doing her apprenticeship with Veolia. As a mature age student who used to be a social worker, and as a woman, Roussos isn’t your stereotypical fridgie. While the snags were cooking on the rooftop barbie and the sun was shining, we took the opportunity to talk with Roussos about her new life in HVAC&R.

What made you decide to become a fridgie? I was a social worker. I always wanted to do a trade, but I was of the generation where women weren’t encouraged into those non-traditional roles. I saw the job advertised and asked a sparkie I was working with at the time, ‘What is this trade, refrigeration?’ And he said, ‘You have to know everything, it’s kind of like four trades in one. You’ll learn so much.’ He encouraged me. And it’s blown me away, because what I’ve learnt and what the layperson doesn’t know about HVAC&R is quite incredible.

It’s been a big move! What are some of the major differences? I feel so much happier when I can work with my hands and there’s a tangible outcome at the end. There’s something you fixed – that chiller or that compressor or whatever it might be. I enjoyed social work, but you didn’t go home at the end of the day feeling like you’d fixed anything. And you do a lot of sitting down, so just being able to move around and be physical and get dirty and not care, I love it, it’s very liberating! I don’t have to worry about what I’m wearing every day. I get a uniform and I just go and just focus on the work and it’s great.

Do you see it as significant for a woman to win this award? Definitely. I don’t see many women in the trade itself, so it can feel a little isolating. I don’t like to generalise around gender, but there’s definitely differences in communication styles, and it’s been a big learning curve for me working with all men, to come from traditionally working with mostly women. I hope more women get into the trade. There are strengths that women can bring to the industry, especially their communication and organisation skills, that maybe the industry hasn’t recognised as being as important as being able to pick up a tool. But they’re important to being a good tradie and a good fridgie.

Is there anything that might have got you into the trade earlier? More exposure, so having female tradies coming into school and saying “Hey, I do this job, I earn this much, it’s amazing, this is my experience.” Just being able to see someone who’s done it would have really encouraged me. Outside of school, more publicity around women in trades in general would help, so young girls can see that it’s a viable option for them. There’s just so much they can get from doing a trade. It’s challenging though. They need the support along the way. The apprenticeship providers and the workplaces, everyone needs to be aware of those challenges and make sure that they walk alongside the female apprentices. Especially young women. I’m very fortunate in that I’m a mature-age apprentice. You’re a bit older and wiser and things sort of wash off your back a bit more. If I was younger it would have been more challenging.

What does the future hold for you? I’m very political and very passionate about the environment. I’m really interested in sustainable energy and how we can use waste and biomass and stuff for heating and cooling. There’s lots of opportunities that are coming up now because of climate change. But I’m also just looking forward to being on the tools and getting dirty and being a bit more independent and putting the learning into place. ■

REFRIGERATION AWARD RECIPIENTS ◆ Outstanding 1st Year Student

Hayden Davis

◆ Outstanding 2nd Year Student

Kane O’Toole

◆ Outstanding 3rd Year Student Tanner Higgins ◆ Outstanding Overall Student Sharon Roussos

HVAC&R Nation

www.airah.org.au/nation

February 2020

www.airah.org.au/nation

HVAC&R Nation

Around the Nation 1

Peter Wesener, Shawnee Zinga, Pedro Kunzel, Jessica Lane, Gregory Wetherall, Jeremy Jouen, Troy Connors, Jarrad Mappas (L-R)

1 PENALTY FOR DISPOSABLE CYLINDERS

Female fridgies were well represented. Of the nine awards, three were won by women.

A Victorian auto mechanic has been fined after it was discovered he possessed 26 illegal disposable cylinders of the synthetic greenhouse gas R134a.

Stage 2 block: Pedro Kunzel

Stage 1 block: Shawnee Zinga Stage 1 flexi: Kyle Sikacek Stage 2 flexi: Rhiannon Barr Stage 3 block: Troy Connors

According to the Department of the Environment and Energy, inspectors executed a search warrant on the mechanic’s business in April last year. During the search, they identified and seized approximately $2,500 of R134a. This was forfeited to the Commonwealth for destruction.

Stage 3 flexi: Jeremy Jouen Split system installer: Bart Pini Capstone: Gregory Wetherall Refrigeration Achievement Award: Jessica Lane ■

The mechanic was issued with two infringement notices for possessing refrigerant without a permit and storing refrigerant in disposable cylinders. These are offences under the Ozone Protection and Synthetic Greenhouse Gas Management Regulations 1995. Disposable cylinders containing scheduled substances such as R134a are banned in Australia.

3 BRAND-NEW HQ Kirby and Beijer Ref Australia have committed to a 10-year lease on a new $48 million purpose-built industrial property at Altitude, Bankstown Airport, NSW. Bankstown Airport is a prime location for the business, due to its close proximity to the M5 and M7 motorways and local amenities.

“The cylinders were originally designed to be used for servicing and commissioning of refrigeration and air conditioning equipment,” says the Department. “However, they cannot be refilled, which means a residual ‘heel’ of gas can remain in the containers. This remaining gas can enter the atmosphere once disposal of the cylinder occurs.”

The new 22,000m² manufacturing and distribution centre, on Tower Rd, Bankstown Airport, will be situated on a 40,000m² site. It will include 1,400m² of office space for both businesses’ Australian headquarters.

The mechanic has paid the infringement notices and has now obtained the appropriate permits to possess scheduled substances for use in refrigeration equipment. ■

“This new facility will help us to deliver our business strategies and objectives in Australia, acting as our main manufacturing facility, distribution centre and corporate headquarters,” says Paul Campbell, Director of Operations at Kirby.

2 RIDGY-DIDGE FRIDGIES

The new development is intended to enhance the service offer to customers and allow for greater operational efficiencies by consolidating the workplace into a single building with sustainable practices.

Late last year TAFE Queensland Skillstech held its annual student awards night at the Bracken Ridge campus. The awards were well supported by industry, including AIRAH, which donated a set of ARAC manuals for one of the winners and goodie bags for everyone who received an award. The awards recognise not only academic achievement, but also how students cooperate and get involved. As refrigeration and air conditioning teacher Neal Kidman, M.AIRAH, says, a big part of the criteria is, “Would you employ this person in your business?” 26

HVAC&R Nation

www.airah.org.au/nation

Key features of the new distribution centre include a 5 star Green Star design, which will incorporate a 250kW solar panel installation and a 50,000L rainwater harvesting system. The new facility is expected to be operational by November 2020. Go to www.kirbyhvacr.com.au ■

February 2020

4 CAPITAL COMPETITION Ryan Hanns has won the regional WorldSkills competition for ACT’s Refrigeration and Air Conditioning apprentices. “It is incredibly humbling to win this award and compete against the very best in the state,” says Hanns. “I love my apprenticeship and take great pride in it. To be recognised at a state level is a significant achievement. I’m looking forward to competing on the national stage in 2020.” Adrian Anderson from Grosvenor Engineering Group was one of the judges, and says the contestants displayed exception talent. “It was clear that they had a strong sense of their work which enabled them to visualise tasks, structure and thoughts with the working knowledge they have gained from their apprenticeship,” he says. “The apprentices of today hold the future wellbeing of our industry for tomorrow.” According to Lesa Cockburn, teacher at the Canberra Institute of Technology, the competition is useful for both students and future employers. It gives competitors the opportunity to showcase their skills, while employers can witness first-hand the skill level of future tradespeople. Winners of the WorldSkills regional competitions will compete at the national competition at ARBS in May 2020. Go to www.worldskills.org.au ■

5 ADVICE ON AUTO AIRCON Ground-breaking Australian research has led to a free guide to help automotive technicians work safely with flammable refrigerants. Refrigerant Reclaim Australia (RRA), automotive thermal and electrical trade association VASA and GHD Engineering worked together to study the management of health and safety risks associated with the use of flammable gases, including refrigerants, in an automotive workshop environment. This has become an issue not only because of the emergence of A2L (mild flammability) refrigerants,

Around the Nation 6

Adam Nobbs

Jason Lucas

but also because automotive systems are often incorrectly “topped up” with A3 (high flammability) refrigerants. Annual testing carried out by RRA has found that around 5 per cent of cars in Australia are contaminated with hydrocarbon. The guide covers legal matters related to refrigerant classifications, dangerous goods, work health and safety, hazardous areas and working with flammable refrigerants, including what to do if a system contains a flammable A3 or A2L refrigerant. The guide also contains information on handling mixtures of non-flammable and flammable refrigerants, as well as a workshop safety checklist and risk assessment worksheet. Go to www.vasa.org.au ■

6 OOMIAK EXPANSION An Australian industrial refrigeration company is expanding into the Asian market. Adelaide-based Oomiak, which specialises in the design and installation of industrial refrigeration, has opened a Malaysian office in Kuala Lumpur in response to growing demand from South East Asia. “We’ve experienced a significant increase in demand from the Asian market for high quality industrial refrigeration systems, so opening an office in the region is a logical step forward,” says CEO Cate McGuire, Affil.AIRAH. “The Asian market has a rapidly growing appetite for fresh fruit and vegetables, and with that comes the need to adequately cool and store produce to ensure it maintains maximum freshness for customers.

7 NEW ENERGY LABELS Last year the government ran information training sessions on the new energy labels that will soon start appearing on air conditioners. It has now placed a suite of information related to the content of the information sessions on the Energy Rating website.

by decades of operation and maintenance and we want to ensure that this is cost effective as possible. We believe our partnership with Ernest West & Beynon will be the right step in that direction and we look forward to working with our partners and BAE Systems Australian on this project.” Go to www.coldlogic.com.au ■

The new requirements for air conditioners take effect from April 1, 2020. The information is aimed at helping technicians and other people in the industry better understand the new Zoned Energy Rating Label as it becomes more visible in the Australian market over the coming years. It may also be a useful guide to assist customers in purchasing a more efficient air conditioner for their climate.

9 NEW FACES AT MITSUBISHI ELECTRIC

The website contains slides from last year’s information sessions, a fact sheet on how to read the new energy rating label, a booklet on the new labels, a video explaining the labels, a recording of last year’s presentation, and frequently asked questions.

Adam Nobbs has been appointed to HVAC Sales Manager for NSW Central. He brings with him over 19 years’ experience in the air conditioning industry. In the new role, Nobbs will share his knowledge with his Sydney-based team of 12 while he focuses on growing sales across the Sydney metropolitan and Central West regions.

All of the information is available at energyrating.gov.au/ACInfoSessions

Following a fourth consecutive record-breaking financial year, Mitsubishi Electric Australia has announced two new appointments.

“Thanks to our team and the great foundations that they’ve already established, we have a great customer base in the region,” says Nobbs. “I look forward to continuing to build on their great work with our premium products.”

If you would like hard copies of the fact sheet or booklet or have further questions, email energyrating@environment.gov.au ■

8 FRIGORIFIC FRIGATES Australian refrigeration specialist Cold Logic has signed an exclusive memorandum of understanding with UK naval refrigeration supplier Ernest West & Beynon.

Also joining the team is Jason Lucas, who has been appointed to the position of HVAC Sales Manager for the northern region of NSW. Lucas will be based in Newcastle, with his team covering the region from the Hawkesbury Bridge to Evans Head and inland to Moree.

Ernest West & Beynon is currently supplying the provision cooling systems for BAE Systems UK Type 26 class, which is the baseline design for Australia’s Hunter class.

“My short-term goal is to focus on supporting our existing customer base,” he says. “We now have an additional staff member to assist in completing quotations in a timely manner and supporting our customers’ needs.

“We see enormous growth in the region over the next decade, so this is a really exciting move for us that is testament to the high-quality benchmarks we’ve put in place.”

Cold Logic is delivering state-of-the-art upgrades to cooling equipment for the Royal Australian Navy’s Collins Class submarines as part of the federal government’s ongoing sustainment and capability upgrade programs, carried out by prime contractor ASC.

“The northern region is currently experiencing a rapid growth phase for Mitsubishi Electric Australia and we will be continuing to offer support to our customers to keep the momentum through the summer and beyond.”

Oomiak is also currently working on two major projects in Brisbane: a $10 million refrigerant replacement project for Arnott’s Biscuits, and a $1.4 million cold store project for Linfox. ■

“We understand that the supply and install of the new systems on the Hunter class frigates are only the first step,” says Dr Michael Riese, M.AIRAH, head of Cold Logic Defence Division, “but this will then be followed

“Our leading-edge industrial refrigeration equipment and fresh produce ripening systems, as well as the expert advice we give to clients, has been extremely well received in Asia.

Both positions will report to Zane Barron, Mitsubishi Electric Australia general manager of national sales, Living Environment Group. Go to www.mitsubishielectric.com.au ■

February 2020

www.airah.org.au/nation

HVAC&R Nation

Green Wedge

PACKAGE DEAL Woolworths is looking to stop waste at the source – with returnable packaging. Every year, the Break Free From Plastic movement organises clean-up days around the world, including Australia. They then do an audit to find out which companies produce the most bottles, chip packets and other rubbish found in our gutters, parks and waterways.

Last year, the clear “winner” was Coca Cola. A total of 11,732 branded Coca Cola plastics were recorded in 37 countries across four continents – more than the next three top global polluters combined. But encouragingly, at least some of the top 10 polluters are doing something about it, by joining a new reusable packaging system from TerraCycle called Loop. And Woolworths has announced it will be bringing the system to Australia. Beginning in mid-2021, shoppers will be able to order leading brands online and have them delivered in reusable containers.

HVAC&R Nation

www.airah.org.au/nation

February 2020

Products include washing detergent, shampoo, juice and ice-cream, from brands such as Nestle, Pepsico, Unilever and Proctor & Gamble. When you finish with the product, the packaging is collected. Or you can drop it back to a store, where it will be cleaned, refilled and reused. The system has already been launched New York and Paris, and TerraCycle says it is working well. “The number of orders are growing, as are the number of consumers participating in the platform. Loop continues to launch new products with major brand partners as more and more companies jump on board.” In France, the most popular items are beverages such as Evian and Tropicana. In the US, customers are going for household staples such as wipes and dishwasher detergent tabs, personal care items like shampoo, and ice-cream. Although customers have to pay a deposit for the reusable packaging, TerraCycle says this hasn’t been a deterrent. “While people want Loop products to cost the same as their disposable alternatives, they are not price sensitive to the deposit,” says TerraCycle. “Examples that are selling well include Clorox wipes ($10 deposit) and Haagen-Dazs ice-cream ($5 deposit).” As well as Australia, Loop will soon expand to the UK, Canada, Germany and Japan. You can register your interest in the initial Loop trial at www.woolworths.com.au/shop/discover/ sustainability/loop. ■

Smoko with . . .

Name: Chris Kazantzidis on Pty Ltd

Company: Chris’ Refrigerati

Dream car: Tesla Model S.

Occupation: Fridgie

see Dream holiday: Norway to ts. Ligh rn rthe the No

ut working in HVAC&R? What’s the best thing abo ries, places and people The wide and varied indust I get to meet. d in the industry? How long have you worke 38 years. Favourite Tool: iPhone. ever received: Best on-the-job-advice you a premium for your work, “Don’t be afraid to charge ” as long as you are thorough. o HVAC&R Industry, what d If you didn’t work in the e Probably somewher you think you’d be doing? ry. in the aviation indust nt has been with your What’s the happiest a clie er loads us up after jobs work? The fact that a custom indicates they’re happy with fruit/fish/meat, I guess with our work and service.

Favourite smoko snack: Spanakopita and a strong hot flat white. What did you listen to on the way to work today? “Right Back” by Khalid. Sporting hero: Dennis Bergkamp, former Dutch international footballer. Incredibly skilful, deadly in front of goal. When I’m not working I’m… Working out, gardening and socialising with friends and family.

QUALITY AIR FILTERS COMPREHENSIVE RANGE STOCKED AND SUPPORTED NATIONALLY

PANEL FILTERS

Particle & VOC/Odour Filters Wide Range In Stock Australia Wide

BAG FILTERS

ph:1300 886 353 www.airepure.com.au

High Efficiency Quality Media Australia Wide

COMPACT FILTERS High Efficiency Quality Construction Australia Wide

aire pure australia February 2020

www.airah.org.au/nation

HVAC&R Nation

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

Ahead of the pack APAC Commercial HVAC AC

Visit apacair.com.au for more information

1 WINNER

3 ROOFTOP RECKONING

Matt sent us a pic of this “quality” split system install. “Note the pair coil loop and the supply,” he says. “Not to mention it’s still on the pallet.” ■

1 BRICKIE INSTALL?

“Not sure what the plan was here,” says Luke, who spotted this unit on a trip to Newcastle to visit family. Clearly, it was to get that cement render looking as neat as possible. Mission accomplished! ■

SUSTAINABLE PLUMBING? 2

Dale from Melbourne went out to Coburg to check a unit leak and found this. Great use of those pipework offcuts. ■

4 BARREL OF FUN

Peter from Kangaroo Flat read our HVAC hygiene special last year and was inspired to send in this barrel fan he came across. ■

5 EXISTENTIALISM AND EXHAUSTS

“What came first, the chicken or the egg?” asks Vaughan from Melbourne. “Or in this case, the greasy fast food exhaust vent or the condenser unit. Glad we don’t service that!” ■

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

HVAC&R Nation

www.airah.org.au/nation

February 2020

Ahead of the pack

APAC Commercial HVAC

• Tailored flexibility for all commercial & industrial projects • Energy efficient operation • Low installation cost • Low noise As populations increase and become more urbanised, the demand for trusted, innovative HVAC cooling and heating solutions are greater than ever. Engineered and built in Australia, the industry-leading apac units are ready for new developments and are perfectly suited to replace existing apac units nearing the end of their life cycle. The new apac ranges are manufactured to superior standards, using the highest quality materials and components. Fully MEPS compliant and Quality ISO 9001 certified, apac is truly ahead of the pack.

Visit apacair.com.au for more information

February 2020

www.airah.org.au/nation

HVAC&R Nation

AVAILABLE NOW!

THE ALL NEW

ALIRA PREMIUM COMFORT LEVELS WITHOUT COMPROMISING ON STYLE

R32 refrigerant for lower environmental impact

Up to 9% improved heating energy performance*

20-71 Class**

MODELS

CAPACITY RANGE

9 2.0kW 9.4kW - TO -

Optional wifi adaptor to control your indoor unit with an easy to use app

Â®

*Compared to FTXM71QVMA (ACOP) **Features and appearance varies for 85-95 Class Models NATIONAL ASTHMA COUNCIL AUSTRALIA

Visit daikin.com.au

HVAC&R Nation February 2020

Articles inside

Green Wedge

Lighter Side

Smoko with

Legal Speak

The big freeze

Around the Nation

AIRAH News

Cool Tech

Skills Workshop

Global Update

The Toolshed