CCN September 2017 by YAFFA MEDIA

Focus on water as a refrigerant SEPTEMBER 2017 Cooling Cities Forum Chillers Feature

Climate Control News

Natural Refrigerants Sustainable procurement

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Contents

Chillers Feature

Climate Control News September 2017

$20 million expansion

Seeley International relocates to a larger $20 million purpose-built facility in Wodonga, Victoria.

HVAC report

AIRAH has released the Future of HVAC report which examines the most critical issues facing industry.

World News

The Montague Company has announced plans to acquire Turbo Coil Refrigeration Systems.

Cold chain group

Launch of Australia’s first advocacy group for the cold chain.

Trade Olympics

RAC technician, Nathan McHugh, heads to Abu Dhabi for the WorldSkills competition.

This month

Focus on water as a refrigerant SEPTEMBER 2017 Cooling Cities Forum Chillers Feature

Climate Control News

Global study

Natural refrigerants

Australia is one of six countries selected for an international study into mitigating the urban heat island effect (UHI).

HyChill general manager, Mario Balen, provides an overview of the current state of the nation for natural refrigerants.

Chiller project 16

CCN profiles a multi-million dollar chiller replacement project.

Industrial refrigeration

Global standard

Improve plant efficiency through variable defrost timing and termination.

The world's first international standard for sustainable procurement.

Natural Refrigerants Sustainable procurement

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In the news

Kawasaki Heavy Industries assistant manager of engineering and development, Hayato Sakamoto, explains why a water-based refrigerant and centrifugual chiller is the best solution to global warming.

HCFC, HFC, HFO and Natural Refrigerants

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CLIMATE CONTROL NEWS SEPTEMBER 2017

Editorial

Climate Control News EDITOR Sandra Van Dijk Ph: (02) 9213 8277 sandravandijk@yaffa.com.au NATIONAL SALES MANAGER Michael Northcott Ph: 0420 403 044 michaelnorthcott@yaffa.com.au ADVERTISING PRODUCTION Michelle Carneiro Ph: (02) 9213 8219 michellecarneiro@yaffa.com.au SUBSCRIPTIONS GREATMAGAZINES.COM.AU CALL 1800 807 760 SUBSCRIPTIONS@YAFFA.COM.AU

Keepin’ it hot & spicy IF VARIETY IS THE SPICE OF LIFE, THEN THIS ISSUE OF CCN IS VERY HOT AND SPICY. Sandra Van Dijk – Editor

THE CONTENT RANGES from a special report on non-conforming products to the biannual chillers feature and our natural refrigerants feature. Our very first fans, air movement and ventilation feature begins on page 22. And, of course, there are always new products featured in every issue as well as research dealing with the latest market trends. It is hard to match 50 pages of HVACR news but for those that really like to spice it up there was our annual CCN Live event held in Sydney last month. I want to thank everyone who attended and supported the half day event. It was a great opportunity to drill down on the latest industry developments and also network with peers. Congratulations to our award winners for being such great HVACR champions. They will be profiled in the next issue of the magazine, which will also feature full coverage of the speaker presentations.

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Until then here are this year's award winners. They are: Kenneth Ball of Teco Australia Pty Ltd (HVACR Leader of the Year); Brad Wiseman of Airepair Air Conditioning Services (Contractor of the Year Award); Samit Sen of Johnson Controls (Innovator of the Year Award); Shayne Boyle of Heatcraft Australia (Female Rising Star Award); Sean Hart of Temperzone (Male Rising Star Award); Jason Glendenning of Grosvenor Engineering Group (Tradie of the Year Award); Thomas Heine of ebm-papst ANZ (Leader in Energy Savings and Sustainability Award); and Kelli McDonald of Airmaster (Woman of the Year in HVACR Award). I want to thank the award sponsors - ABB, Airefrig Australia, Daikin, Hitachi, Innotech and Toshiba. A special thanks to Refrigerant Reclaim Australia and our special guest judge for the awards program, Peter Cashel of Fujitsu General. For all the latest news headlines, visit www.climatecontrolnews.com.au. ✺

SUBSCRIPTION RATES 1 year $99.00 Overseas 1 year NZ A$110 ASIA A$125 ROW A$170 PUBLISHER Helen Davies CUSTOMER SERVICE MANAGER Martin Phillpott MARKETING MANAGER Sabarinah Elijah MARKETING EXECUTIVE Jasmine Gale PRODUCTION DIRECTOR Matthew Gunn ART DIRECTOR Ana Heraud STUDIO MANAGER Lauren Esdaile DESIGNER Bree Edgar YAFFA CUSTOM CONTENT DIRECTOR Matt Porter Ph: (02) 9213 8209 mattporter@yaffa.com.au CLIMATE CONTROL NEWS is published by Yaffa Media Pty Ltd ABN 54 002 699 354, 17-21 Bellevue Street, Surry Hills NSW 2010. Ph: (02) 9281 2333 Fax: (02) 9281 2750 ALL MAIL TO: GPO Box 606, Sydney NSW 2001

ISSN 1446-6937. Member Circulations Audit Board.

News

Perth Hospital plagued by compliance delays MORE THAN 1200 ASSEMBLY BOXES LOCATED NEAR WATER OUTLETS CONTAINING BRASS VALVES WILL HAVE TO BE REPLACED WITH STAINLESS STEEL BEFORE PERTH'S NEW CHILDREN'S HOSPITAL CAN OFFICIALLY OPEN. THE $1.2 BILLION hospital was supposed to open in 2015 but ongoing compliance issues which have led to cost blowouts have delayed the opening until 2018. WA Health Minister, Roger Cook, said it is unlikely the hospital will open this year. "It is with great disappointment, given the work that now needs to be undertaken, the hospital will not open this year, however, we are on a clear path forward to rectify this issue," he said. "I believe it will be early 2018 but obviously

we have to be sure that the chief health officer is satisfied.” Cook said rectifying the brass fittings problem was the responsibility of the builder, John Holland, adding that there should be no additional cost to the government. In a report by the State's chief health officer Tarun Weeramanthri, said the fittings were found to have corroded, leaching lead into the water system. The report recommended the fittings, contained in 1,200 mixing valve assembly

boxes, be removed and replaced. The report said the problem is "most likely widespread throughout the building" and called on John Holland, to remedy the situation. John Holland is yet to officially comment, with a spokeswoman saying it was still assessing the report. The report blamed contract management failures during the construction phase for the ongoing problems. In addition to the brass valves the hospital has been plagued by other issues including asbestos in roofing panels and damage to hundreds of decorative panels on the building's facade.

TOP: A selection of images showcasing the new $1.2 billion Children’s Hospital in Perth which will now open in 2018. RIGHT: WA Health Minister, Roger Cook.

Lamina lowers infection risk A LAMINA FLOW air conditioning system has been installed in a North Queensland private hospital to lower the risk of infection to patients.

ABOVE: Friendly Society Private Hospital in Bundaberg

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The technology is being used at the Friendly Society Private Hospital in Bundaberg which is a 143 bed surgical and medical facility with more than 400 staff. Renovations in the hospital’s operating theatre were completed last month. The theatre was fitted out with the lamina flow system which helps to provide a shroud of air surrounding the patient, minimising the risk of infection. It is also designed to maintain optimal comfort levels for surgeons and to ensure all air entering the operation theatre is HEPA filtered. The lamina flow system creates three dif-

ferent air velocities in the room, working to ensure clean air is directed from the area where the operating table is, to the perimeter of the room. This ensures maximum patient protection. It also complies with air quality accreditation class ISO5, set by the International Standardisation Organisation as a benchmark for hospitals worldwide. In addition, the hospital has upgraded the surgical lights to LED, which give off minimal heat and also cast no shadows. This upgrade comes after the relocation of all scope procedures to the dedicated endoscopy unit, which opened in March.

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News

Seeley announces $20 million expansion as part of relocation plans ABOVE: Lacrosse Apartments, Docklands.

New fire safety measures AMENDMENTS TO THE National Construction Code (NCC) in the wake of the Lacrosse cladding disaster in Melbourne, are now available for public comment. The deadline for public comment is September 10, 2017, with a draft report likely to be released in early 2018. A packages of measures for fire safety in high rise buildings was developed following the Lacrosse Apartments fire which occurred on the morning of November 25, 2014. Key aspects of the amendment include a new Verification Method that adopts the external wall testing standard, AS 5113 as well as referencing an updated sprinkler standard AS 2118. Supporting materials will accompany the amendment when it is published by the Australian Building Codes Board (ABCB). The ABCB Fire Performance of External Walls and Cladding Advisory Note will be updated to reflect the amended provisions and a new Evidence of Suitability Handbook will complement the revised evidence of suitability provisions. “Understanding that external wall cladding and/or assembly will, at a minimum, have contributed to the rapid spread of the fire at Grenfell Tower, it is important that appropriate steps are taken to minimise this potential from occurring in Australia, with a substantial body of work having already commenced following the Lacrosse apartments’ fire in Docklands Melbourne,” the ABCB said in a statement.

Action plan INDUSTRY HAS MOVED quickly to respond to the gaps and weaknesses in Australia's compliance regime by creating the Construction Product Alliance (CPA) which involves more than 40 industry bodies. It was created in response to the dangers of non-conforming products. To find out more about the CPA's 8-point action plan turn to CCN's special report on page 18.

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SEELEY INTERNATIONAL HAS ANNOUNCED EXPANSION PLANS WHICH INVOLVE RELOCATING ITS EXISTING ALBURY MANUFACTURING PLANT TO A LARGER $20 MILLION PURPOSE-BUILT FACILITY TO BE CONSTRUCTED AT NEARBY WODONGA, VICTORIA. SEELEY INTERNATIONAL FOUNDER and executive chair, Frank Seeley, said the move is partly funded by a grant from the Victorian Premier’s Job and Investment Fund, which aims to establish a state-of-the-art manufacturing hub to produce a range of innovative products to be sold in Australian and international markets. “As a long-standing employer within the Albury-Wodonga community, Seeley International is pleased that this investment accommodates our expansion needs and positions the company for significant jobs growth and success in the years ahead,” Seeley said. Seeley has forecast 64 per cent growth in new local employment opportunities over the next five years. “Our local manufacturing facility continues to play a critical role in our overall operations, and as well as continuing to fully manufacture award-winning Braemar heating products, the Climate Wizard metal range and the entire AIRA product range, we have also recently wel-

comed a dozen new engineers and other team members to the plant,” he said. “One of the biggest challenges we now face is that we have outgrown the existing factory, and with space at a premium it has fast-tracked the need for relocation plans. Establishing a new and larger facility at nearby Wodonga allows us to retain and grow local employee numbers and maintain a strong employer presence within the local community.” Acknowledging the financial contribution from the Victorian government, Seeley said it was critical that all levels of government assist manufacturers to develop new products and production facilities. “Seeley International continues to commit high annual expenditure on research and development of new manufacturing techniques, and to create innovative products that are the most energy efficient, necessitating state-of-the-art facilities to enable this to happen,” he said. “Seeley International is living proof that there is a bright future for the Australian manufacturing industry, and we have been able to compensate for the higher costs within Australia by focusing on innovation, world class technology and high levels of automation, while many others are closing doors or downsizing. “We are bucking the trend and ramping up employment growth at our Albury manufacturing plant which is expected to grow over the coming months.” As the home of Braemar gas heaters and airconditioners, Seeley said the Albury-based plant has established a vertically integrated manufacturing and assembly operation that employs more than 80 permanent people. Seeley International has been a major employer in the region for more than 20 years. While a construction site and plans are yet to be finalised, Seeley said the new Wodonga manufacturing facility will be operational in early 2019. LEFT: Seeley International founder, Frank Seeley.

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News

Nominations open for ARBS Awards 2018

Award programs support the talent that sustains Australia's HVACR and building services industry.

NOMINATIONS FOR THE ARBS INDUSTRY AWARDS 2018 OFFICIALLY OPENS ON SEPTEMBER 1, 2017. THE AWARDS RECOGNISE excellence in Australia’s HVAC, refrigeration and building services industries across a range of areas including: • ARBS Young Achiever Award 2018 • ARBS Product Excellence Award 2018 • ARBS Software/Digital Excellence Award 2018 • ARBS Project Excellence Award 2018 • ARBS Outstanding Service & Maintenance Provider Award 2018 • ARBS Industry Education/Training Award 2018 • ARBS Hall of Fame The awards attract nominees from across the industry, and are endorsed and supported by the major industry associations including the Australian Institute of Refrigeration, Air Conditioning and Heating (AIRAH). ARBS events organiser, Sue Falcke, said the awards program has continued to grow and attract more participants as the industry acknowledges the respect and continued recognition associated with receiving an ARBS Award. "The Awards are an opportunity for industry participants to showcase their skills, products

and performance across all sectors of the HVACR and building services industry,” she said. “It’s important that we identify, encourage and congratulate the talent and endeavour that sustains our industry.” A panel of industry experts will evaluate the nominations based on various criteria such as leadership, sustainability, performance and innovation. The ARBS Hall of Fame, a popular category celebrating industry leaders, by recognising their service, contribution and commitment to furthering the industry, are now open for nominations from the general industry. ARBS Industry Award winners will be honoured at a gala dinner to be held during the ARBS

Future of HVAC report THE AUSTRALIAN INSTITUTE of Refrigeration, Air Conditioning and Heating (AIRAH) has released the Future of HVAC report which examines the most critical issues facing industry over the next decade. Report findings state that building regulations must assess true performance and target net-zero energy, and that mandatory energy disclosure for existing buildings is a must. The foresighting report entitled Future of HVAC – in a Net-Zero World is based on a recent workshop attended by experts and practitioners from the HVAC, building services and associated industries. AIRAH CEO, Tony Gleeson, said attendees considered what form HVAC will take in the net-

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zero building sector of the future. “Foresight can help an industry navigate change by providing an early warning of the barriers and opportunities ahead, and it also provides evidence for government policy makers with grass roots insights,” he said. “By tasking a group of experts and practitioners to develop a credible picture of future buildings and future heating, ventilation and air conditioning (HVAC), AIRAH has been able to start the conversation on the strategies that can be used, and the changes to industry, technology and practice that will be required to make this happen.” The paper provides a snapshot of future HVAC in a net-zero world, and outlines some of the main themes from the workshop discussions, such as:

2018 exhibition, from May 8-10, 2018 at the International Convention Centre (ICC) in Sydney. Nominations close on February 5, 2018 and the Awards Gala Dinner will be held on May 9, 2018. Further details and full category and criteria requirements for entry are available on the ARBS 2018 website, www.arbs.com.au.

the changing relationship and behaviour between occupants and buildings; a shift in the approach and objectives for town planners; a move to lowenergy HVAC technologies, including step changes in controls; a regulatory focus on building performance rather than construction; extension of government regulation into operational energy use. AIRAH’s government relations manager, Phil Wilkinson, said a series of recommendations have been developed to help government and industry understand how the HVAC and property sectors can best transition to netzero-energy buildings. ✺

LEFT: AIRAH's Phil Wilkinson said the report is a snapshot of the main themes covered at the workshop.

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World News

Solution overcomes unstable grid supply THE APK GROUP IN RUSSIA HAS COMMISSIONED ITS NEWEST MEAT PROCESSING PLANT, INCREASING THE COMPANY'S CAPACITY TO PROCESS 5,000 CATTLE DAILY, ONE OF THE HIGHEST MEAT PROCESSING CAPACITIES IN THE WORLD. THE “STATE OF the art” facility operates in closed cycles that reduce residue production to a minimum, improving resource efficiency and keeps pace with modern sustainability standards. The new plant was developed by ETW Energietechnik GmbH (ETW). To ensure permanent energy supply without disruption, ETW developed a customised Combined Heat and Power (CHP) solution to deliver electricity, heat and steam, independent from the grid. The new plant includes three CHPs with 2 MWel capacity, producing a total of 6 MWel

power and 3,021 MWth power, fueled by natural gas and expanded by three steam boilers. The hybrid steam boilers run on both, exhaust heat and natural gas, producing up to 14.7 tonnes of additional process steam. To overcome the very unstable grid supply, ETW designed the energy system to operate parallel to the grid and in island mode. In case of a grid failure, the CHPs automatically switch to island mode without shutting down APK's meat production. Once the grid has stabilised, the CHPs can be resynchronised automatically due to a customised automation system developed by ETW.

RIGHT: ETW created a Combined Heat and Power (CHP) solution with a customised automation system.

A-Gas buys Dutch business BTC A-GAS HAS ACQUIRED the Dutch reclamation business BTC and will be investing several million dollars in the operation to strengthen its offering to customers across Europe. The deal was completed last month and will result ABOVE: A-Gas in A-Gas increasing its ca- managing director, pacity to handle, clean and John Ormerod. return waste gases to the market for resale. A-Gas UK and Europe managing director, John Ormerod, said BTC are specialists in the reclamation and disposal of special gases, refrigerants and fire suppressants which can often be a complex and difficult process. “It’s a very good fit for us as reclamation and disposal of gases is a key part of our business at Portbury near Bristol,” he said. “This is our first acquisition in Continental Europe and we will put in place a significant investment program to enhance the recycling and reclamation capabilities at BTC.” A-Gas is planning to add to the workforce and invest in new equipment. BTC is based at Eygelshoven near the German border which makes it ideally placed to access markets across Europe. In recent years, A-Gas has invested heavily in the reclamation and recovery side of its operation and this has been reflected by the development and installation of a new gas separator onsite in Portbury – bringing the total to three – and the launch of the A-Gas Rapid Recovery business in the UK. Ormerod said the BTC purchase highlights the company’s commitment to providing industry with the capacity and infrastructure required to support the F-Gas phasedown.

Montague Company to acquire Turbo Coil THE MONTAGUE COMPANY has announced plans to acquire California-based Turbo Coil Refrigeration Systems, an award-winning manufacturer of advanced evaporator coils. Turbo Coil Refrigeration Systems has a unique platform of patented technology centered around the Turbo Coil evaporator coil. These include glycol chef bases, glycol cold rails and glycol prep tables that can function with R290 refrigerant and the latest approved refrigerant blends. The two companies have had a strategic alliance for the past three and a half years. As a result, food service company Montague has already incorporated Turbo Coil patent-protected technology into key equipment and products. The acquisition will pave the way for Montague to fully leverage Turbo Coil’s innovative refrigeration expertise and technological prowess, according to Montague president and CEO, Tom Whalen.

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“Competition in the restaurant business is fierce. Embracing and incorporating Turbo Coil’s technology and expertise ensures we can continue to deliver cutting edge equipment,” he said. ✺ The two companies have had a strategic alliance for the past three and a half years.

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In Focus

Hydrogen trial to strengthen renewable energy supply

THE AUSTRALIAN RENEWABLE ENERGY AGENCY (ARENA) HAS ANNOUNCED A TRIAL FOR AN INNOVATIVE NEW TYPE OF ELECTROLYSER WHICH COULD SEE EXCESS RENEWABLE ENERGY STORED IN THE GAS GRID AND USED TO DECARBONISE AUSTRALIA’S GAS SUPPLY. ARENA HAS PROVIDED $5 million in funding to Wollongong-based company AquaHydrex to commercially develop its new class of electrolyser to produce cheap hydrogen for splitting water. In partnership with Australian Gas Networks (AGN), which owns the gas distribution network in South Australia, AquaHydrex will design and build an electrolyser pilot plant to trial injecting a small amount of hydrogen into the South Australian gas grid in a process known as “power-to-gas”. Power-to-gas involves converting electricity into hydrogen by splitting water, then injecting this into the gas grid, providing long-term energy storage and stabilisation of variable output solar and wind power. ARENA CEO, Ivor Frischknecht, said this demonstration is the first Australian trial to test ‘power-to-gas’ that will see hydrogen being in-

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jected into the gas network. “Hydrogen can be injected directly into the natural gas network without modification at levels of at least 10 per cent, with some experts recently suggesting levels closer to 30 per cent are viable to supplement our gas needs,” he said. Depending on the material the gas pipeline is made out of, the network can support up to 100 per cent hydrogen in due course, once appropriate regulatory transition and appliance modifications are implemented. When hydrogen burns, it produces only water vapour and no carbon dioxide. “There is huge untapped potential in power-to-gas to convert surplus renewable energy to hydrogen and use our existing gas network infrastructure for long-term, safe, reliable energy storage,” Frischknecht said. “In the future, there will be increasing amounts of surplus renewable energy when it is sunny or windy.”

AquaHydrex was developed out of research undertaken by scientists and engineers at ARC Centre of Excellence for Electromaterials (ACES) - University of Wollongong and Monash University nodes. AquaHydrex managing director, Paul Barrett, said the funding would bring the Australian developed innovation closer to producing cheap hydrogen at commercial scale. Storing renewable energy directly in the gas network was a logical first route to market for the invention. “Hydrogen is an outstanding energy carrier, and has the potential to connect the electricity and natural gas grids, significantly increasing the storage capacity available for renewable electricity and helping decarbonise the natural gas grid,” Barrett said. “This renewable hydrogen also opens up the possibility to exporting renewable energy – which Australia, with its vast renewable resources, is well positioned to exploit.” The volumetric potential of renewable energy stored in the Australian gas infrastructure could be as much as six billion household Liion batteries, according to Ben Wilson, the CEO of AGN. “This provides what is for all intents and purposes a ‘bottomless battery’ that is already in place and capable of storing and transporting vast amounts of time-shifted renewable energy,” he said. AGN is one of Australia's largest natural gas distribution companies. It owns approximately 25,000 kilometres of natural gas distribution networks and 1,100 kilometres of natural gas pipelines, serving over 1.2 million consumers in South Australia, Victoria, Queensland, New South Wales and the Northern Territory. AGN’s role in the energy chain is to transport natural gas to customers for retailers. ✺

ABOVE LEFT TO RIGHT: AGN CEO, Ben Wilson; ARENA CEO, Ivor Frischknecht.

RECOGNISING

EXCELLENCE The ARBS Industry Awards recognise achievements and excellence in individual performance, projects, products, services and education categories within the HVAC&R and building services sector.

NOMINATIONS NOW OPEN www.arbs.com.au

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Winners will be announced at the ARBS Industr y Awards Gala Dinner to be held on 9th May, 2018 in Sydney

In Focus

Australia's first cold chain advocacy group AUSTRALIA'S FIRST ADVOCACY GROUP TO IMPROVE COMPLIANCE AND STANDARDS IN THE HANDLING OF FOOD AT ALL LEVELS OF THE COLD CHAIN HAS BEEN ESTABLISHED AT A GROUND-BREAKING MEETING IN QUEENSLAND LAST MONTH. THE INAUGURAL SESSION of the Australian Food Cold Chain Council (AFCCC) brought together a cross section of executives in manufacturing, food transport, refrigeration and cold chain services. Against a mounting background of community pressure about the costs and environmental damage of food wastage, the AFCCC is seeking to find a solution, encourage innovation, compliance, waste reduction and safety across the Australian food cold chain. Interim chair Mark Mitchell, a leading cold chain service provider with a cold chain research and validation facility, SuperCool Australia Pacific Pty Ltd, said the new council is not about promoting an industry – but changing it for the better. “One of our priorities will be to apply

whatever pressure is needed in industry and government to make sure the existing Australian standards for cold chain food handling are properly followed,” Mitchell said. “There's lots of rhetoric in government programs, associations and among food handlers and suppliers about commitments to food waste reduction and cold chain compliance, but little, if nothing, is being done at any level about improving the cold chain, and ensuring that standards are followed. “Australia's track record in efficient cold food handling, from farm to plate, is far from perfect.” The interim directors of AFCCC are: Stephen Elford ANZ general manager, Carrier Transicold; Mark Mitchell managing director, SuperCool Australia Pacific Pty Ltd; Peter Lawrence ANZ

L to R: Mark Padwick, Kyle Hawker, Kelly Geddes, Kevin Manfield, Jon Mitchell, Mark Mitchell, Adam Wade, Stephen Elford, Brett Fraser, Peter Lawrence, Greg Picker, Stuart Kirkwood.

technical director, Thermo King; Kyle Hawker transport manager, Simplot Australia; Adam Wade national transport leader, Lion; Kevin ManfieldgGeneral manager products & markets, MaxiTRANS Australia Pty Ltd; Plus a nominated person representing the transport industry TBA. Food waste is a massive problem for Australia. On average, Australians waste 860 kg of food per person annually. It's not just the food, but this means that all inputs into food production like the water, soil and energy are also wasted. An estimated five per cent of Australia's greenhouse gas emissions come from food wastage. Mitchell said Australian industry is well placed to tackle this issue. He said performance across the cold food chain can be improved with better equipment and handling processes as well as with improved monitoring and assessment to identify weaknesses. In investigating the food cold chain in Europe, Deloitte estimated that for every unit of energy and dollar invested in expanding the food cold chain the return to investors was 10-fold. “As an industry, as a society, we simply cannot afford to waste such an opportunity,” Mitchell said. The AFCCC believes Australian industry has the tools, technologies and workforce capable of reducing food waste via the cold chain. It is in that spirit that leading companies have signed up as inaugural members of the AFCCC. The new advocacy group's first priorities will be contributing to both the development of the National Food Waste Strategy and becoming part of the CRC. ✺ Those interested in joining the AFCCC or learning more about it, can email AustralianColdChain@ gmail.com.

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Industry responds to the dangers of non-conforming products THE GRENFELL TOWER FIRE AND LACROSSE CLADDING DISASTER HAVE EXPOSED THE SERIOUS PROBLEM OF NON-CONFORMING PRODUCTS (NCP) IN THE AUSTRALIAN MARKET. CCN TALKS TO AUSTRALIAN INDUSTRY GROUP CEO, INNES WILLOX, ABOUT FINDING A SOLUTION. EMPLOYER BODY, THE Ai Group, blames NCPs on a lack of independent verification and visible regulatory authority. Ai Group CEO, Innes Willox, said Australia's regulatory system has not kept pace with the emergence of complex global supply chains. “As a result, unscrupulous operators have taken advantage of weaknesses in the conformance framework by supplying these products into our markets,” he said. “To date, we have only seen the tip of the iceberg.” The AI Group undertook a survey of members to find out how extensive the problem is and if there is a solution. “We found that 92 per cent of 222 respondent companies reported non-conforming product in their market,” Willox said. “We found gaps and weaknesses in the building and construction conformance that included inadequacies with surveillance, audit checks, testing, first party certification and enforcement.” Recognising the need to work with all sections of industry, the Ai Group formed the Construction Product Alliance (CPA) involving over 40 industry bodies. The CPA has developed an eight-point action plan to tackle NCP and submitted it to the

ABOVE: The Construction Product Alliance (CPA) involves over 40 industry bodies.

Building Ministers' Forum for consideration. Ai Group believes that the following are priorities to address the problem: Regulators should be increasing surveillance and audit activities of product. High risk building products should have a higher level of evidence of compliance (third party certification) in the National Construction Code. The feasibility of establishing a confidential reporting system to facilitate the reporting of NCP should be assessed. Responsibility for product conformance should be established at point-of-sale. ✺

WHITE PAPER PROVIDES GUIDANCE A new white paper from local building products company, Cemintel, examines how the use of these products have emerged as one of the fastest growing problems facing industry. There have been a number of incidents in recent years which have highlighted the potentially devastating consequences of using non-conforming and non-compliant products in a project. The paper looks at some of the most notorious events in recent years to be associated with the use of these products. The events include the Lacrosse Apartments building fire, where non-compliant external cladding was found to have fuelled the fire which caused over $40 million worth of damage. It also delves into the recent asbestos crisis, where a large number of products imported from China, including roofing and metal skirting, have been found to contain traces of asbestos, already exposing hundreds of workers to the deadly substance with fears the incidence will be far-reaching. While the wheels are certainly in motion for tighter regulation across the industry to provide better protection against the use of non-compliant and non-conforming building products, there is no quick fix. This paper helps industry professionals understand the risks involved with specifying non-conforming and non-compliant products, and what steps can be taken to help avoid potential disaster.

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WorldSkills 2017

RAC technician prepares for global competition at trade Olympics A YOUNG REFRIGERATION AND AIR CONDITIONING TECHNICIAN FROM JIMBOOMBA IN SOUTH EAST QUEENSLAND, NATHAN MCHUGH, HAS BEEN SELECTED BY WORLDSKILLS AUSTRALIA TO COMPETE IN ABU DHABI THIS OCTOBER. HE JOINS AN elite team of young Australian trades people who will compete against their international counterparts at the 44th WorldSkills International competition. The team, known as the Skillaroos, was chosen after a four-day Global Skills Challenge. The challenge saw over 100 participants from 16 countries test their skills in 21 trades. McHugh competed against refrigeration competitors from Russia, China, Hong Kong, Malaysia and Brazil, and at the end of the four-day competition he was judged the winner by the team of international judges. He is 21 years old and was a student at TAFE Qld SkillsTech and is employed by DTM Air Services. He has been training towards possible selection to Abu Dhabi since May last year when he won the Gold Medal at Australia’s Refrigeration and Air Conditioning National WorldSkills competition held as part of the 2016 ARBS Exhibition in Melbourne. As part of his reward for winning the national competition, in October 2016 he attended the TOP LEFT: RAC technician, Nathan McHugh, has been selected to compete at the 44th WorldSkills International competition. LEFT: Nathan McHugh secures Gold at the national competition held at last year's ARBS event.

Chillventa International HVACR Exhibition in Nuremberg, Germany thanks to sponsorship from LuVe Contardo Pacific. Not only did he see and learn about the latest developments and technologies, but he also observed the German refrigeration mechanics compete in their national WorldSkills competition which was held during the exhibition. He has worked closely with his mentor and WorldSkills Australia’s International Judge, Carl Balke, and his fellow teachers at TAFE Qld SkillsTech in Brisbane and well as WorldSkills Australia’s previous international judges, Chris MacDonald from City Holdings and Noel Munkman from the Australian Refrigeration Council. More than 3,000 competitors, experts and officials from 77 countries will take part in WorldSkills from October 14 to 19. Australia, currently ranked 12th in the world, is aiming to finish in the top 10 in 2017. WorldSkills Australia CEO, Brett Judd, congratulated McHugh on his selection saying it had been based on an arduous training regime. “I applaud his determination and congratulate him on his selection as a Skillaroo,” Judd said. “These young people are excelling in their fields and being rewarded with international experience and opportunities. Their trades are really taking them places.” McHugh has received strong support from the local industry including sponsors Refrigerant Reclaim Australia, ARBS Exhibition, Heatcraft, LuVe Contardo Pacific, Danfoss and Rothenberger with support from TAFE Qld SkillsTech, RACCA, City Holdings and ARC. ✺ Details at https://www.worldskills.org.au.

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Strategies to deal with urban heat,

microclimates

AUSTRALIA’S FIRST OFFICIAL GUIDE DESIGNED TO KEEP CITY DWELLERS COOLER DURING HOT WEATHER BY HELPING TOWN PLANNERS, REGULATORY AGENCIES, ARCHITECTS AND DEVELOPERS MITIGATE URBAN HEAT ISLANDS AND MICROCLIMATES CITIES CREATE, WAS LAUNCHED LAST MONTH AT THE CRC FOR LOW CARBON LIVING'S (CRCLCL) COOLING CITIES NATIONAL FORUM. UNSW’S DR PAUL Osmond and CRLCL project leader, who led the team that compiled the Guide to Urban Cooling Strategies, said it covered different climate zones that define cities across Australia. “The range of urban landscapes that the Guide covers include dense inner cities, middle ring and outer suburbs with a focus on design intervention, including streetscapes, plazas, squares and malls,” he said. “The importance of design to embrace vegetation cover, particularly tree canopy, the use of shade to minimise heat, and the orientation of these elements are also key to cooling. Interventions may be active, such as misting systems and awnings, or passive, like street trees, green roofs, water bodies, cool roofs and facades. “All these elements have an effect on urban temperatures. For example, radiant temperatures in urban parks with sufficient irrigation can be

2-4°C cooler compared with adjacent unvegetated or built-up areas, while air temperature reduction may be up to 2°C according to a park’s extent and the proportion of trees. This is is known as the park cool island effect,” Osmond said. “The Guide also highlights the fact that street trees contribute to radiant and air temperature reduction by evapotranspiration and shading over buildings and street surfaces. A streetscape with heavy tree canopy can enjoy up to 15°C cooler surfaces and 1.5°C cooler air temperature compared with a street with no tree canopy and shade,” he said. Three dimensions to contexualise the effectiveness of urban cooling strategies are used in the Guide: urban form, climate type and the nature of intervention. This matrix provides the Guide’s framework in terms of process (methods) and product (the design outcomes). Dr Osmond explained that urban climates are ultimately created from a balance between the heat of the sun and heat lost from walls, roofs and ground by heat exchange via air movement between ground, buildings and atmosphere, and by heat generation within the city itself, for example from motor transport. “Global climate change and the urban heat island phenomenon – where cities absorb and release more heat than the surrounding countryside – carry growing potential to make urban life at particular times and places an exercise in low grade TOP & ABOVE: Darker coloured, solar exposed surfaces misery. Studies across the world’s have higher surface temperatures. Shaded surfaces and major cities show that a systematic vegetation have lower surface temperatures. higher average temperature of 2°C to 12°C exists in highly-urbanised areRIGHT: CRCLCL CEO, Professor Deo Prasad.

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ABOVE: The Guide to Urban Cooling Strategies.

as compared with their rural surroundings,” Dr Osmond said. CRCLCL CEO, Professor Deo Prasad, said the Guide was also a major milestone in the CRCLCL’s work as it brings together data from a three-year Urban Microclimates project it has funded. “This publication is unique, as it not only draws on our painstaking three year research along with global research, it cross-references to our Microclimate and Urban Heat Island Decision Support Tool project and benefits from relevant research at the CRC for Water Sensitive Cities,” he said. “I believe the Guide to Urban Cooling Strategies should be read by all those involved in creating built environments so they can plan and design for the future, to ensure generations to come will be living in cities that minimise the effects of climate change, particularly when extreme heat is an outcome.” ✺

Fans, Air Movement and Ventilation

UHI: A global perspective AUSTRALIA IS ONE of six countries selected to be part of an international study to be undertaken by Yale University into mitigating the urban heat island effect (UHI). The study, which has been awarded a grant from NASA, will look at two global trends: climate change and rapid urbanisation. The grant, which is worth $40,250 annually, can be renewed for up to three years. UHI is a phenomenon in which urban areas are significantly warmer than the surrounding countryside, inducing local climate effects that compound the global effects of greenhouse gas emissions. In many places this combination is expected to exacerbate public health risks and drive up energy consumption in what becomes a dangerous feedback loop. One of the more promising strategies to mitigate these impacts is the expansion of urban green spaces, such as city parks, which through the natural process of transpiration help to cool local temperatures — as much as 1.3 to 1.6ºC according to previous studies. There’s a catch, however. Nourishing these green spaces requires precious water resources that many growing cities simply can’t spare. The Yale study will examine this delicate relationship between cooling and water consumption in some of the world’s drier cities including Phoenix in North America, Lima in South America, Cairo in Africa, Madrid in Europe, New Delhi in Asia and Adelaide in Australia.

Led by Kangning Huang, a doctoral student at the Yale School of Forestry and Environmental Studies (F&ES), the study will evaluate the potential outcomes of irrigating green spaces in six cities. “There is a tradeoff in mitigating the urban heat island effect and conserving water,” Huang said. “Do you want to use that water to reduce those impacts or save it for other purposes?”

“THERE IS A TRADEOFF IN MITIGATING THE URBAN HEAT ISLAND EFFECT AND CONSERVING WATER." - KANGNING HUANG, YALE UNIVERSITY.

There are many factors that enhance the urban heat island effect in cities, including the often staggering number of human-created heat sources, the tall and densely configured buildings that can affect heat radiation and air movement, and a preponderance of impermeable surfaces — of buildings, parking lots, roads — made of materials with higher heat capacity. While the impacts of these attributes will only grow as urban populations increase, other factors can be managed through the addition of green roofs and the irrigation of green spaces. When it comes to irrigating green spaces, Huang

said it will only be worthwhile if the benefits outweigh the costs — namely, if municipal water resources are used sustainably. This will become increasingly challenging. Already more than 150 million people in urban settings worldwide live under water stress. According to a 2011 study that number is expected to reach one billion by mid-century. Figuring out the tradeoff, Huang said, requires an understanding of the relationship between cooling and water consumption. “For some reason,” he said, “there remains a limited understanding of how much water is required to achieve the level of cooling you would want in a city.” For the study, he will use regional climate models to simulate the urban heat island effect in six arid or semi-arid cities located on six different continents. Then, using data from a variety of satellitebased technologies, Huang will alter the soil-water moisture levels on a daily basis to mimic the irrigation process. He will also run a separate model, based on another satellite-based product, the MODIS-based land surface temperature, to verify the accuracy of the modeling. Ultimately, he plans to simulate irrigation uses that push regional water supplies up to the point of “water stress” levels, which is the maximum amount of water a city can afford to use in irrigating urban green spaces. The study will yield maps of urban surface structures and irrigation water usage, as well as the water-UHI relationship. ✺

Cities selected for the study are Phoenix, Lima, Cairo, Madrid, New Delhi and Adelaide.

CLIMATE CONTROL NEWS SEPTEMBER 2017

Fans, Air Movement and Ventilation

IN AN INCREASINGLY DATA RELIANT WORLD, DATA CENTRES ARE BECOMING MORE PREVALENT IN OFFICE BUILDINGS AROUND THE GLOBE.

Project delivers payback in less than two years DATA CENTRE FACILITIES typically house business-critical systems and as a result, their physical environment is hugely important and are rigorously controlled. Europe’s leading manufacturer of fans and motors, ebm-papst, collaborated with Vertiv and CBRE to review energy efficiency at three of UBS’s London-based data centres. ebm-papst undertook an initial site survey to review the types of units being used and the potential solutions that were needed. They provided an estimation of the payback period for any new kit based on potential energy savings. The existing units in place used chilled water coolers and utilised fans with AC technology. In order to improve efficiency, ebm-papst

CLIMATECONTROLNEWS.COM.AU

recommended upgrading the equipment with EC fan technology. Based on the survey results a trial was then agreed on a single 10UC and 14UC CRAC unit to establish actual performance and energy savings. Data was logged before the upgrade and again once the trial units were converted from AC to EC. UBS then went ahead with the conversion of all units, installing 191 fans in total within 76 CRAC units. Three different unit models were installed: 39x14UC units, 21x10UC units and 16xCCD900CW. The main element of the upgrade project was the replacement of all fans with ebm-papst’s EC technology direct drive centrifugal fans including the installation of EC fans within a floor void that required modification. Project restrictions were extensive, given that the work was being conducted in a live data envi-

ronment, the upgrade teams were only allowed one unit switched off at any one time due to redundancy. Despite this, the upgrade was delivered on time, within budget and without disruption. The energy savings are obviously accompanied by corresponding reductions in CO² emissions, and typical payback periods of less than two years are normally achieved. With ebm-papst GreenTech EC fans, the impeller, motor and electronics form a compact unit that is far superior to conventional AC solutions. The UBS project is an excellent example of how upgrading from AC to EC technology can impact on energy savings, carbon and CO² reduction. On average UBS has seen a 48 per cent energy saving across all units and a payback period of under two years. Other project paybacks include a CO² reduction of 5229 tonnes. In addition to the above savings, a new control strategy software was put in place, which controls the EC fans on supply air temperature. This saw a further reduction of 14 per cent in energy usage. UBS’s data centres are now also benefitting from reduced noise levels, increased cooling capacity and extended fan and unit life. ✺

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Fans, Air Movement & Ventilation

Controlling airflow and leakage in data centres BUILDING SERVICES RESEARCH AND INFORMATION ASSOCIATION (BSRIA) SENIOR RESEARCH ENGINEER, CALUM MACLEAN, EXPLAINS THE IMPORTANCE OF AIRTIGHTNESS IN THE DATA CENTRE. AIRTIGHTNESS IS SOMETIMES a forgotten hero of energy efficiency and because of the high energy demands in data centres, any savings will be magnified significantly. Any air movement outside of the designed air paths (leakage) will affect the distribution of the cooled air and may also introduce contaminated air into the data centre. The air paths are different for the different applications, from CRAC-cooled, raised-floor data centres to individual water-cooled racks with internal fans passing air through a water/glycol cooled coil. Airtightness is vital in maintaining the energy efficiency of any building. Airtightness can be applied in a wide range of

CLIMATECONTROLNEWS.COM.AU

situations in data centres and data centre equipment, including whole building, floor voids, contained aisles, container, standalone racks and even some individual components (CRAC units etc). Whole building airtightness is important so that refrigerated or conditioned air inside cannot escape but also so that untreated outside air cannot get in. The effect of wind on buildings can be dramatic in a building with poor airtightness and lead to significant airflow path changes internally and possible cooling inconsistencies. Floor void leakage can have a significant impact on the distribution of cold air. Floor tiles should be sealed prior to and during installation and the air paths identified during design

and minimised during construction. Cold air from the void can leak into the cold aisles, or other chilled areas prior to the servers, which may be useful in terms of cooling, but cooling will be inefficiently distributed. On the other hand, if the cold air leaks into the hot aisles or return air paths, this will lead to cooling losses and inefficiency. When contained aisle construction is utilised, the airtightness of the containing structure is paramount in delivering the chilled air onto the racks removing the hot air in cold/hot containment, respectively. The elephant in the room is can you eliminate air leakage entirely? The simple answer is not easily or cost effectively. However, significant savings can be made by planning the airtightness from the start and committing to following the design throughout the build. Airtightness methodology can be applied to a full range of building types, ensembles and equipment (e.g. floor void or contained cold aisles). The basic principle is to pressurise (or depressurise) a building and measure the air flow required to achieve that pressure differential. The amount of air introduced is effectively the air leakage at the test pressure. The ATTMA TSL2 standard for testing buildings and structures is the generally accepted methodology for airtightness quantification. Airtightness tests can be applied to data centre components, such as floor void or contained cold aisles, with slight modifications from the ATTMA TSL2 standard. For example, BSRIA has recently published Floor Plenum Airtightness â&#x20AC;&#x201C; Guidance and Testing Methodology (BG65/2016) or DW/144 Sheet Metal Ductwork (BESA, 2016). The design and build phases of any new data centre, or even the upgrade of an existing one presents the ideal opportunity for investigating and minimising the air leakage paths from any data centre type. Low air leakage levels in different data centre applications can minimise the amount of active cooling being lost to the surrounding spaces or into a hot aisle, reducing the amount of cooling required and associated costs. Improving airtightness will also reduce the ingress of untreated, potentially contaminated air (e.g. dust particles) which could cause system failures. Lower air leakage levels will further improve the air distribution in the data centre, providing the right temperature and relative humidity conditions, therefore, reducing the risk of degradation of the equipment. Reducing the risk of equipment degradation and maximising the cooling capacity by good air distribution will ultimately improve both uptime and cost efficiency. â&#x153;ş This is an edited version of an article first published in Data Centre Management magazine.

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The full Aeroflex range is available from Airefrig Australia.

Insulation tested to Australian standards vides protection and maintains pipe integrity. Aeroflex is one of the largest suppliers of pipe insulation on the Australian market with a fire AIREFRIG AUSTRALIA IS THE rating of 0003. This fire rating offers builders and EXCLUSIVE AUSTRALIAN consultants peace of mind when selecting insuDISTRIBUTOR FOR THE lation for projects as it is backed by a written, inAEROFLEX RANGE OF CLOSED dependent test report. CELL PIPE INSULATION. Tested to the Australian standard AS1530.3 – 1999. (see table below) Aeroflex insulation is available in wall thickAEROFLEX INSULATION IS made of Ethylnesses from 9mm to 63mm to meet R Values reene Propylene Diene Monomer (EPDM) which quired by BCA2011. All lengths are flexible and is a high quality, lightweight elastomeric maeasy to fit, facilitating a speedier pre-assembly terial providing long lasting pipe insulation. line or pipe can be easily split to apply to existEPDM is moisture and vapour resistant and ing lines and joints sealed with Aeroflex adhehas a high UV rating and weather resistance sive. The Aeroflex adhesive chemically bonds without the need for further coating applicathe insulation and creates a strong, permanent tions. EPDM does not react with copper or vapour seal. stainless steel piping unlike other pipe insulaThe Aeroflex pipe insulation is also available tion featuring a PVC composition which has a in the high temperature (HT) range. Providing a known reaction to copper pipe, causing detemaximum service temperature of 150°C and inrioration of the pipe over time. Aeroflex prodependently certified to BCA 2011, the HT range is suitable for solar, heating FIRE RATING and sanitary applications. Wall thicknesses all meet R Values per AS/ Measurement Rating Range NZ3500.4:2003. Ignitability Index 0 (0 - 20) The full Aeroflex range of accessories are also available to complement Spread of Flame 0 (0 – 10) this insulation, including adhesives, tapes, FX blocks and aerostands. To Heat Evolved Index 0 (0 – 10) find out more about the Aeroflex prodSmoke Developed Index 3 (0 – 10) uct, contact your local Airefrig Australia branch on 1800 671 500. ✺ (To be read in conjunction with the Building Code of Australia)

CLIMATECONTROLNEWS.COM.AU

Multi-spiral technology used in new range FAN MANUFACTURER NICOTRA Gebhardt added a fundamentally new type of fan to its range that focuses consistently on energy conservation and compact design. Behind this is the newly developed MultiEvo technology that has resulted in a range of directly driven hybrid centrifugal fans with multiple integrated guide vanes. Development manager, Dr. Johannes Anschütz, said the RQM MultiEvo by far exceeds every traditional free-running fan in terms of energy efficiency thanks to the optimised interplay of components comprising a hollow section impeller with real turbulence profile, permanent magnet motor and integrated electronics. Traditional housing fans have always been advantageous in respect of static pressure increase and energy efficiency. Speed-controlled, free-running fans are suited for compact design. “While most providers in the industry rely solely on optimising individual components in the further development of their free-running fans, and thereby increasingly come up against physical limits, Nicotra Gebhardt looks at things holistically,” Anschütz said. “We examined the entire flow profile in detail and included it in the concept.” The multi-spiral technology – known as MultiEvo - combines the easy handling of free-running centrifugal fans with the effectiveness of traditional housing fans. Depending on the size, the RQM reaches eight to 15 per cent higher energy efficiency than the best, traditional freerunning fans on the market, the company said. In many cases, the increase makes it possible to reach the optimal duty point of a system with a lower motor power rating. Besides more cost-effective operation, this results in additional savings in the initial investment, the company said. Impeller sizes are 355 to 710mm, each reaching a maximum pressure increase of approximately 2,000 Pa. More impeller sizes and motor outputs of up to 22kW will be available this year. ✺

ABOVE: MultiEvo technology is all about energy efficiency and compact design.

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Natural Refrigerants

HYCHILL GENERAL MANAGER, MARIO BALEN, PROVIDES AN OVERVIEW OF THE CURRENT STATE OF THE NATION FOR NATURAL REFRIGERANTS IN AUSTRALIA.

State of the

Nation

HOSE WHO, FIVE years ago, regarded the HVACR industry as being in an utter state of confusion and uncertainty must be scratching their heads in total disbelief. The situation today is more complex and less certain. Consider this: another generation of synthetic refrigerants are on the skids. With the previous generation such as R22 still living out its final days in many systems, HFCs (from R134a to R404 and others) are now in a phasedown mode too. R32 systems have barely hit the market, yet the talk is already adrift that it is only a transitional and temporary solution. The newest stuff we are seeing now, such as the widely trumpeted HFOs, have largely unknown performance characteristics, uncertain pricing structures and their application and retrofitting abilities are still untested.

“SELECTING THE RIGHT REFRIGERANT IS STUFF THAT NIGHTMARES ARE MADE OF. THERE ARE LITERALLY HUNDREDS OF VARIETIES ON THE MARKET.” - HYCHILL GENERAL MANAGER, MARIO BALEN.

Selecting the “right” refrigerants is stuff that nightmares are made of – there are literally hundreds of varieties on the market! The government is doing its own usual best to muddle the issue even more. With no clear phasedown policy, uncertain dates and rubberelastic announcements, it provides little guidance and help to the industry. Flammability and toxicity of both refrigerants and lubricants are now factors we need to learn to live with. Not only do we have hydrocarbon refrigerants and ammonia, now many of the new HFOs are flammable or even extremely toxic under certain conditions as well. Yes, of course, we are being told that their flammability is somehow different than the rest but flammable they are! When transported, stored and handled HFOs (and R32 too) are classed as 2.1 (Flammable) under the Dangerous Goods Act, yet somehow, as if by magic, once they are decanted into an air con or a chiller, they are re-born as A2L (Mildly Flammable

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Natural Refrigerants

LEFT: triangle

category under the ASHRAE classification). If you happen to come from the synthetic refrigerants communit, such wizardry makes perfect (commercial) sense. If you belong to the ‘naturals’ camp – it sounds hilarious – like being half-pregnant.

OPPOSITE PAGE: HyChill general manager, Mario Balen.

TRAINING Then we come to training and education. Not a single Australian educational institution is presently capable of producing a HVACR graduate engineer. Moreover, the industry is utterly unable to agree on the minimum trade training standards and qualifications. Various industry organisations are at odds over whether Certificate II qualification should restrict its holder to perform only the installation of split systems or allow them to conduct maintenance as well. When it comes to refrigeration, there is no qualification mandate at all. Although the Australian Skills Quality Authority (ASQA) has mandated that hydrocarbons should be covered within the core HVACR curriculum, many training organisations have not complied and risk losing their RTO status. The current licensing regime is operated by the Australian Refrigeration Council (ARC) under the auspices of the Federal Department of the Environment and the Montreal Protocol. Its basic intent is to control sales and application of synthetic refrigerants which are listed under the Protocol. Yet, it has been consistently overreaching its role trying to present itself as a “qualificationbased” licensing scheme, to the almost universal annoyance of technicians, installers, designers and mechanics. Recently, the ARC launched a voluntary licensing scheme for natural refrigerants despite having no real expertise in this area.

The solution to so many problems the industry is facing has been staring us all in the face since the very beginning, and that is, natural refrigerants. A mmonia, hydrocarbons and CO2 offer superior efficiency, vast application suitability, ready availability and excellent cost performance – between them they cover just about every possible HVACR application now and in the future. Once adopted and engineered in the system, they guarantee a stable and predictable future without twists and turns every 10 years. No obsolescence and phaseouts, no environmental

Engas M10 Suitable for replacement of all R600a refrigerators and freezers.

Engas M40

Hydrocarbon Refrigerants Technical support and application engineering advice available for the safe use and correct application of all Engas products.

Pure hydrocarbon refrigerant replacement R290 and R22.

degradation or sudden (albeit entirely predictable) “surprises” about ozone depletion, global warming impact or thermal decomposition resulting in toxic by-products. No dependence on whims of manufacturers with restricted, patentprotected complex chemical compounds that cost a fortune. A significant part of the industry has already changed or is in the process of doing it - domestic and light commercial refrigeration, medium size commercial and industrial refrigeration and air conditioning are all cases in point. Isn’t it time to accept that the future is natural? ✺

Engas M20 Special purpose hydrocarbon refrigerant specifically designed to replace R32.

Engas M50 Suitable replacement for R22, R502, R404a, R407c and R507c.

Engas M30 Designed as a direct replacement for R12 and R134a.

Engas M60 Special purpose hydrocarbon refrigerant specifically designed to replace 410a.

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www.engas.com.au CLIMATE CONTROL NEWS SEPTEMBER 2017

Natural Refrigerants

Proof of superior performance

The energy efficiency benefits for hydrocarbon refrigerants are substantial.

ENGAS AUSTRALASIA IS a Perth based supplier of Hydrocarbon refrigerants. Engas hydrocarbon refrigerant products can be applied to a wide range of temperature control applications. However, the performance and success of these refrigerants is not well understood or appreciated in the Australian market. But they are in demand in China, Indonesia, Malaysia and the Philippines. The team at Engas have been researching, developing and testing alternative formulations of hydrocarbon based refrigerants for over 15 years. These products have been shown to deliver superior performance in all regards, particularly energy efficiency and cost effectiveness. Engas Refrigerants have been applied safely in retrofit conversions for many years and there is now enormous potential for retrofitting equipment designed for synthetic refrigerants as the global HFC phasedown comes into effect.

PERFORMANCE Hydrocarbon refrigerants have been used by hundreds of clients across the range of applications shown (see breakout box). There are a number of central considerations required to appreciate the value of all Engas products: 1. Hydrocarbon refrigerants deliver superior energy efficiency because their thermal transfer capability is by definition superior to synthetic refrigerants. 2. Engas has optimised the performance of hydrocarbon refrigerants by blending various hydrocarbon elements to deliver specific and targeted performance objectives. There is only one other company in the world that has adopted and delivered this strategy. 3. Engas products are guaranteed to be available in the long term because global and domestic regulations will not restrict their availability, while high GWP synthetic refrigerants are being phased out. High volume synthetic refrig-

Don’t melt. Replace your old APAC unit with Specialized air conditioning.

Right now, roof top units everywhere are reaching their “use by” dates. But you can replace them quickly and easily with an exceptionally efficient solution from Specialized Engineering. In fact, Specialized systems are a perfect replacement for APAC units as they use exactly the same footprint, duct work, mains power and controls, so there are no expensive modification costs. Find out more at specializedengineering.com.au

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Hyperflex™ High Efficiency Air Cooled Packaged Units on R410A 012 to 095kW

Natural Refrigerants

“HYDROCARBON REFRIGERANTS DELIVER SUPERIOR ENERGY EFFICIENCY.”

erants will be increasingly expensive as their quotas are reduced. This includes R32. 4. A key consideration in the use of all Engas products is their safe use. The synthetic refrigerants industry has made extreme efforts to characterise hydrocarbon refrigerants as unsafe. They have done so based on a series of false assessments. Engas provides inhouse training on the safe use and correct application of all Engas Hydrocarbon Refrigerants. 5. Engas Australasia has recently completed many successful conversion and commissioning projects in Asia, such as: Bosch Siemens Home Appliances Co, where Engas converted a 1049 kilowatt f luid chiller

(used for industrial process cooling) from R407C to Engas M50. The energy efficiency saving was 28 per cent. The environmental saving was estimated at 7,671,328.40 KGs of CO2 equivalent saved from the atmosphere over the next 20 years. Duvel International Trading (China) Limited where we commissioned a new Coolroom measuring 2,633 square metres and 8.1 metres high to operate on Engas M50. The Coolroom refrigeration system has a nominal cooling capacity of 1280 kilowatts. The energy efficiency saving was 28 per cent. The calculated environmental benefit is estimated at 6,860,792.48 KGs of CO2 equivalent saved from the atmosphere over the next 20 years. These projects demonstrate that subject to compliance with certain safety principles, the application of hydrocarbon refrigerants can be completed as safely as any other type of refrigerant. The energy efficiency benefits are substantial and the environmental advantages should not be ignored. ✺

HOW IT WORKS Following is a brief outline of Engas refrigerants and the chemicals refrigerants they are designed to replace. • M10 - suitable for replacement of all R600a refrigerators and freezers. • M20 - special purpose hydrocarbon refrigerant specifically designed to replace R32. • M30 - designed as a direct replacement for R12 and R134a. • M40 - pure hydrocarbon refrigerant replacement R290 and R22. • M50 - suitable replacement for R22, R502, R404a, R407c and R507c. • M60 - special purpose hydrocarbon refrigerant specifically designed to replace 410a.

For details visit www.engas.com.au .

Hydrocarbon Refrigerants Superior performance in all conditions.

hychill.com.au/distributors

CLIMATE CONTROL NEWS SEPTEMBER 2017

Natural Refrigerants

TRENDS DRIVING THE HVAC MARKET The creation of the CO2 compressor for use in Daimler's air conditioning systems was created in record time, according to Sanden. A joint Japan-Germany development team was created in 2014 to develop the compressor in response to the German car manufacturer's safety concerns about the use of the mildly flammable R1234yf. Daimler has been taking delivery of the CO2 compressors from Sanden’s Yattajima plant since May. Daimler had previously refused to use R1234yf – the only refrigerant that was commercially available that complied with the European MAC directive to use a refrigerant with a GWP below 150. While eventually relenting, the German car manufacturer promised to offer production passenger cars equipped with CO2 air conditioning systems in its S- and E-Class cars in Europe from this year, before rolling out CO2 across the range. Meanwhile, TMR Research released research last month which claims growing demand for modern automatic temperature control in cars for maintaining air quality in and out of the cabin is a key factor driving the evolution of the HVAC market. The substantial demand for integrated cabin comfort through the rising use of sophisticated radiation and light sensors for enhanced safety and comfort of the passengers and driver is a prominent trend in 2017, the report said. Moreover, the use of advanced refrigerants by automakers is a key factor expected to accentuate the market in the coming years. Regionally, Asia Pacific is projected to develop as the most lucrative market for automotive HVAC. A substantial production of vehicles in nations such as Japan, China and India has offered abundant opportunities for vendors and automotive manufacturers.

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Sanden joins Daimler in Sindelfingen success story

EXECUTIVE DIRECTOR OF COMMUNICATIONS AND EDITORIAL AT THE AUTOMOTIVE, AIR CONDITIONING, ELECTRICAL AND COOLING TECHNICIANS OF AUSTRALASIA (VASA), HAITHAM RAZAGUI, GETS A FIRST HAND LOOK AT THE WORLD'S FIRST CO2 AIR CONDITIONING SYSTEM. JUST AS YOU were getting your head around the latest automotive air-conditioning refrigerant, R1234yf, another one crops up on the scene. Last September, I was at an auto-AC conference in Frankfurt, where a prototype Mercedes-Benz S-Class using carbon dioxide as air-con refrigerant was being demonstrated. The refrigerant name for CO2 is R744. It behaves very differently to the synthetic gases we’re used to, operates at seriously high pressure and can form dry ice if you’re not careful. Beneath the gleaming black S-Class bonnet, among what looked like desert sand – evidence of hot-weather testing – I spotted a Sanden R744 compressor and some Valeo heat exchangers plumbed around the V6 turbo-diesel engine. Now Sanden has officially announced it is supplying Mercedes-Benz parent company Daimler with “the world’s first CO2 compressor for mass-produced passenger cars”.

The global media launch for the facelifted Benz f lagship took place in Switzerland in July, with six-cylinder engines moving from V6 layout to inline format. So I take it the prototype in Frankfurt was a proof-of-concept machine and that testing of the straight-six engines with CO2 air-con components came later. Indeed, the announcement from Sanden suggests the development timeline for this technology was compressed. “It has been quite a challenging project also for Daimler to get the R744 AC system launched in such a short period,” said Daimler AG project leader for R744, Dr Ralf Theurer. He added that the reason for selecting Japanese component manufacturer Sanden as development partner for Daimler’s CO2 airconditioning systems was “their extensive experience with this refrigerant and pioneering spirit towards new technologies”.

Natural Refrigerants

According to Sanden it accelerated the development for Daimler by drawing on its experience in R744 applications including freezers, refrigerators and vending machines, then incorporated technologies from all these products to create a high-performance automotive compressor. “Therefore the strategic partnership with Sanden has been very important and we are pleased about this successful launch,” Dr Theurer said. Sanden Automotive Components took the development of this R744 compressor incredibly serious, establishing a project team that reported directly to the company president, in close collaboration with their German counterparts at Daimler. Company president, Tsuguo Ito, said he intends to expand this technology and use the knowledge gained throughout the development to grow in a sustainable manner in the world market. The R744 compressor has a 31cc capacity, a fifth of the R134a unit it replaces, but Sanden claims its cooling performance and function

07868 NRC.indd 1

exceeds conventional compressors. Its packaging and weight is also said to match that of the old R134a compressor and it is able to withstand five times the operating pressure. Sanden also says the new R744

“THIS REFRIGERANT BEHAVES VERY DIFFERENTLY TO THE SYNTHETIC GASES WE KNOW.”

ABOVE: The Mercedes-Benz S-Class features the world’s first CO2 air conditioning system.

pump included internal design features designed to reduce noise, with new control technology that improves its stability and safety. Facelifted S-Class limousines are now literally driving themselves off the end of the Sindelfingen production line just outside Stuttgart, travelling 1.5 kilometres to a holding yard without anyone behind the wheel.

They are obviously pretty capable of avoiding accidents, but if you see one in your panel shop, don’t be surprised to find a pretty alienlooking AC system to recommission. I’m travelling back to Frankfurt this month (September) for the international motor show, and will bring back updates about which R744 cars are coming to Australia, and when, from the people in suits at each German car manufacturer. Watch this space. ✺

CLIMATE CONTROL NEWS SEPTEMBER 2017

11/08/17 9:58 AM

Chillers Feature

KAWASAKI HEAVY INDUSTRIES ASSISTANT MANAGER OF ENGINEERING AND DEVELOPMENT, HAYATO SAKAMOTO, EXPLAINS WHY A WATER-BASED REFRIGERANT AND CENTRIFUGUAL CHILLER IS THE BEST SOLUTION TO GLOBAL WARMING.

The future is

water-based refrigerant

IRSTLY, THIS IS a refrigerant that doesn't heat the planet, deplete the ozone layer, or present any risk to combustion and toxicity. There is a general perception that water is a substance of zero ozone depleting potential (ODP), zero global warming potential (GWP), non-combustibility and non-toxicity. As a refrigerant, water is the ultimate refrigerant because of these characteristics. However, when it comes to a whole chiller system, there are some challenging obstacles. When applying water as a refrigerant for chillers, inside pressure of the chiller needs to be reduced less than 1/100 atmosphere pressure in order to vapourise the water in the evaporator. Therefore, using water as a refrigerant multiplies the volumetric flow rate 100-fold due to the low pressure and this necessitates the use of a large compressor, which inevitably makes the chiller larger in general. In addition to this, the required pressure ratio between the evaporator and condenser is around seven

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while that of HFCs is two to three. Compressors under the conditions of the low pressure and high pressure ratio tend to be low efficient. Therefore, the state-of-theart technology is imperative to maintain the power consumption at the same level as HFCs or lower level. Overcoming these obstacles is a necessary process to expand use of water refrigerant chillers. Kawasaki Heavy Industries was able to develop a water-refrigerant centrifugal chiller, which achieved a cooling capacity, a footprint and energy efficiency on par with existing HFC chillers. A Kawasaki water-refrigerant centrifugal chiller features a capacity of 100 USRt (352kW), COP of 5.1(power consumption: 69kW) and Integrated Part Load Value (IPLV) of 8.5 (Figure 1 and Table 1). This is the same level of performance as HFC chillers and, of course, water-refrigerant chillers emit no HFCs. Assuming a service life of 15 years, it will reduce 740 CO2 equivalent tonnes as a direct emission (HFC emission).

Using water as a refrigerant has the added benefit of significant savings in maintenance costs. Unlike HFC chillers which require a periodic inspection of refrigerant leakage, a water-refrigerant centrifugal chiller doesn’t need to be inspected periodically. Moreover, the compressor is driven by a high speed motor instead of a speed increasing gear, that is, direct drive and oil free compressor. In fact, a test unit has been in operation for air conditioning at Kawasaki’s Kobe Works since 2013, and so far it has been running smoothly without specific periodic maintenance. As of July 2017, the total operation time is 5,100 hours. The intended application of Kawasaki waterrefrigerant centrifugal chiller is air conditioning, which requires the chilled water at 7ºC. While a Kawasaki water-refrigerant centrifugal chiller has COP of 5.1, as a characteristic of a water refrigerant, there is an advantage of COP at higher temperature compared to HFC chillers. Figure 2 shows the performance curve of Kawasaki water-refrigerant centrifu-

Chillers Feature

TABLE 1: SPECIFICATION OF KAWASAKI WATER-REFRIGERANT CENTRIFUGAL CHILLER Cooling capacity

100USRt (352kW)

Power consumption

69kW

Refrigerant

R718(water)

Chilled Water

Inlet

12degC

temperature

Outlet*

7degC

Cooling Water

Inlet

30degC

temperature

Outlet

35degC

Motor drive

Inverter

Power supply

3Ф, 400/440V (50/60Hz)

Size

2.5m x 2.5m x 2.6m

Weight

8.0 ton

Intended application*

Air conditioning

*Kawasaki water-refrigerant centrifugal chiller can supply the chilled water at higher temperature up to 20degC, and be applied to other applications such as process cooling etc..

CLIMATE CONTROL NEWS SEPTEMBER 2017

Chillers Feature

"USING WATER AS A REFRIGERANT HAS THE ADDED BENEFIT OF SIGNIFICANT SAVINGS IN MAINTENANCE COSTS.” - HAYATO SAKAMOTO.

gal chiller. This indicates that Kawasaki water-refrigerant centrifugal chiller performs higher COP at higher chilled water temperature, and water refrigerant has its strength for those applications such as air conditioning of a data centre, air conditioning combined with desiccant* and process cooling which requires the chilled water at 15ºC to 20ºC. *A desiccant air conditioning system is one which separates processes of the latent heat load and the sensible heat load. The conventional air conditioning systems need the chilled water at low temperature to manage both air temperature and its humidity. However, a desiccant air conditioning system dehumidifies the air with desiccants and controls the air temperature with the chilled water at a higher temperature.

CO2 REDUCTION Tests have also been undertaken to assess total Greenhouse gas (GHG) emission, which includes HFC emission and CO2 emission derived from power consumption. Kawasaki conducted calculations to predict GHG emissions considering conditions of ambient temperature and dew point temperature based on the weather history of 2016 and the estimated power consumption with the relationship between ambient temperature and cooling load. Table 2 and Figure 3 show these calculation conditions. As a base-

Fig. 3 : Calculation conditions ( relationship between Ambient temperature and Cooling load)

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TABLE 2 : CALCULATION CONDITIONS Weather history

Jan 1st 2016 – Dec 31st 2016

Locations

AU : Sydney, Melbourne, Brisbane, Perth, NZ : Christchurch

Referenced temperature data

Maximum ambient temperature and maximum dew point temperature in each month

Assumption

• Cooling water temperature is dew point temperature + 5degC • Chiller is operated when the ambient temperature is more than 25 degC • Average HFC leakage rate : 15%/year1 • (HFC134a, Filled amount 230kg) • Chiller operation days : 20 days/month • Life time : 15 years • CO2 emission factor : 0.852 kg-CO2/kWh2

line for the comparison, the performance of a HFC centrifugal chiller in the same capacity category is referenced. Figure 4 shows that Kawasaki water-refrigerant centrifugal chiller has its advantage of total CO2 emission despite its disadvantage of power consumption. This is the grace of water refrigerant which doesn’t emit HFCs. A Kawasaki water-refrigerant centrifugal chiller has strengths in areas of cooler climate, and in Christchurch as shown in Figure 4 the total CO2 emission would be reduced by 26 per cent. Currently Kawasaki water-refrigerant centrifugal chiller is only available for 100USRt capacity. We will add product series of various capacities to our portfolio.

ADOPTION HURDLES Water refrigerant is a promising substitute, however, there are hurdles to its widespread adoption. As described above, water refrigerant needs a large compressor. This is the same situation for our water-refrigerant

Fig.4 : Estimated total CO2 emission in AU and NZ

chillers although they are as compact as existing HFC centrifugal chillers. Weight is heavier than other chillers, and accordingly it is relatively expensive to produce. Reducing product cost is a manufacturer’s responsibility, but standards and regulations restricting HFC's usage are imperative to facilitate widespread dissemination of water refrigerant. Especially, for the applications which need the chilled water at 7-20ºC, there is a possibility that HFCs can be phased down by maintaining the power consumption at the present level or lower level. In order to accelerate the water-refrigerant technology for those applications, standards and regulations which encourage adoption of a water refrigerant is necessary and expected. ✺ References [1] Expert Group, “Refrigerant emissions in Australia – Sources, causes and remedies”, 2010 [2] International Energy Agency, “Energy Policies of IEA Countries, Australia, 2012 Review”, 2012

Chillers Feature

Multi-million dollar project at iconic Brisbane office tower AIRMASTER HAS COMPLETED A MULTI-MILLION DOLLAR CHILLER REPLACEMENT PROJECT AT ONE OF BRISBANE'S LEADING OFFICE TOWERS – WATERFRONT PLACE ON THE BRISBANE RIVER.

ABOVE: Work on the chiller replacement project at Waterfront Place began last year.

STANDING 162M TALL, the 40 storeys of office space afford spectacular views over the Brisbane River, Storey Bridge and Moreton Bay. To maintain its stature as one of Brisbane’s premium office towers, a mechanical services upgrade was one of the first items of refurbishment when Dexus Property Group and Dexus Wholesale Property Fund took ownership of the building in mid-2015. Airmaster was successful in winning the tender for a multi-million dollar chiller replacement program last year and began work on the project immediately. The project consisted primarily of replacing the buildings’ existing and aging chiller sets. These were made up of four 1800kW York centrifugal water-cooled chillers serving Waterfront Place, and one 470kWr air-cooled chiller serving the Eagle Street Pier restaurant, retail and entertainment complex. Unfortunately the Waterfront Place building’s configuration and plantroom design meant that these chillers could not be removed by crane. Instead, each had to be physically dismantled and removed from the plantroom via the goods lift. Likewise as the replacement chillers could not be craned into position, Airmaster made its chiller selection based on the ability to construct the new chillers on site. “The new chillers needed to be dismantled and

brought up (to the plantroom) via the goods lift,” according to Airmaster’s Queensland state manager, Wayne van Aken. “As a result, we selected Geoclima chillers that feature a split vessel design and Turbocor compressors for this project.” A total of seven 1100kW Geoclima air-cooled chillers replaced the existing chiller set serving Waterfront Place. The chiller upgrade also included the replacement and installation of 14 chilled water pumps, and 14 condenser water pumps featuring variable speed drives (VSDs). A large fluid cooler serving the building’s secondary condenser water loop was also refurbished as part of the chiller replacement program. The existing air-cooled chiller serving the Eagle Street Pier complex was replaced by two 850kW Climaveneta ERACS magnetic bearing (Turbocor) water-cooled chillers. Commonly used in Europe, ERACS chillers offer a number of efficiency advantages including the ability to produce free heating or cooling. Additionally, the plant’s existing four chilled water pumps and four condenser water pumps were also replaced with energy efficient pumps featuring VSDs. Airmaster was also successful in having the award-winning PlantPRO system included in the chiller replacement project. Its integration required building management system modification works. ✺

A new standard in packaged units THE NEW APS series sets a new standard in packaged refrigeration condensing units. Acpac is Actrol's exclusive packaged refrigeration condensing unit range. This successful new range, manufactured specifically for Actrol by Tecumseh, includes models with hermetic, scroll, and semi-hermetic compressors. Acpac is a fully optioned series which is kept in stock, allowing it to be used for both new projects and breakdown replacement projects. The APS semi hermetic range has now been extended with the inclusion of more Tecumseh Semi Hermetic compressors for both medium and low temperature applications.

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Eight models have been available since last summer, in refrigeration capacities from 4.6kW to 33.6kW at medium temperature and 0.99kW and 8.3kW at low temperature. The APS range is fully fitted, wired, and protected, making it easy to apply to many cooling and freezing applications such as supermarkets, fast foods outlets, restaurants, food processors, butchers, f lorists, and many other applications. We now have four new models arriving to extend the series significantly. These four models range in capacity from 39.5kW to 64.2kW at medium temperature and 9.5kW to 16.5kW at low temperature.

With this new range, Acpac APS now covers nearly every refrigeration application, making it the new standard in packaged refrigeration condensing units. The new range is available at Actrol. Visit www.actrol.com.au. ✺

Cooling with natural refrigerant GEA Blu chillers The super-compact generation of ammonia chillers: GEA BluAstrum, GEA BluGenium, GEA BluAir. Sixteen models, all perfectly matched for maximum performance, long-term reliability and low operating costs. Engineered to meet todayâ&#x20AC;&#x2122;s industry needs, from food & beverage and production processing, to office buildings and cold storage warehouses. As a natural refrigerant, ammonia is energy efficient and environment friendly. Go GEA Blu for easy to install, ready-to-use refrigeration and air conditioning solutions. Phone: 03 8877 9966 | Email: sales.au@gea.com

Chiller Feature

Marenum powered cooling at sea

Systems are being replaced before phaseout THE GLOBAL HVAC CHILLERS MARKET WILL GROW AT A CAGR OF CLOSE TO THREE PER CENT DURING THE PERIOD 2017-2021, ACCORDING TO THE LATEST RESEARCH REPORT FROM TECHNAVIO.

THE RESEARCH FIRM lists screw chillers, scroll chillers and centrifugal chillers as the three major product segments, of which the screw chillers segment accounted for more than 35 per cent of the market share in 2016. Technavio’s lead analyst, Anju Ajaykumar, said there are three key market drivers contributing to the growth of the chillers market including growing demand for district cooling, replacement of old chillers and developing infrastructure in emerging countries. He said emerging countries in the Middle East

and Asia are experiencing increased demand for district cooling. “District cooling is replacing the traditional air cooling methods because of increased advantages such as energy-saving, low environmental damage and reduced maintenance needs. It uses up to 50 per cent less energy as compared to traditional cooling methods, which means big savings on electricity costs,” Ajaykumar said. “An increase in the district cooling market will fuel the HVAC chillers market,” he said. The need to reduce operating costs, increase energy efficiency and to take advantage of favourable government incentives has spurred the need to replace existing HVAC equipment right across the globe. Technavio expects regulations pertaining to the use of refrigerants and energy efficiency to increase investments in the replacement of old HVAC chillers. “The phase-out of R-22 units will be completed by 2020, encouraging HVAC system owners to replace their existing units before the phaseout,” he said. ✺

PRODUCING REFRIGERATION RELIABLY on sea vessels isn’t easy but it is a challenge Engie Refrigeration has overcome with its Marenum chiller. Until now, Marenum has been in use only on navy frigates but a civilian version has been released and is being adopted by cruise liners at Saga Cruise. The two ocean liners that will be equipped with the chillers are currently under construction and are scheduled to run the Baltic Sea from 2019. Each of the 236-metre vessels will see four Marenum chillers installed. This produces a total cooling power per ship of 12MW. Engie Refrigeration managing director, Jochen Hornung, said marine operation requires refrigeration to function under tough conditions at sea, chillers need to operate in extremes, weathering exposure to both seawater and heavy swell. “Besides their reliability and energy efficiency, Marenum chillers stand out through their compact design, low noise and vibration emissions, seawater resistant condenser and low maintenance requirements,” he said. The system technology is reduced to the main components necessary for refrigeration – compressor, condenser, metering section and evaporator, including the corresponding measurement and control technology. “This saves space for the customer, a major concern considering that space is often at a premium in a ship’s engine room. Redundant design with up to 12 condensers per chiller increases reliability,” Hornung said. Another major benefit offered by the chillers is free cooling. ✺

Risk strategy put to the test WESTMEAD HOSPITAL SERVES one of the largest growing population areas in NSW, so it is little surprise that they came to Active Air Rentals to install a chiller risk management strategy in anticipation of the extreme heat predicted for Sydney’s summer.

CLIMATECONTROLNEWS.COM.AU

The solution provided an emergency back up to the remaining chillers. Using the two pre-existing valves, Active Air Rentals installed 300mm stainless pipework through the wall to the exterior of the building. From there, five connections were run to five chillers with a combined capacity of 3,500 kW, each partnered with a generator. To enable seamless integration, and sequencing on and off of the chillers and generators, the solution was interfaced with Westmead Hospital’s building management system (BMS). David Dobson, WSLHD senior project manager capital works, Program Management Office (PMO) praised Active Air Rentals for a great job in testing conditions. ✺

ABOVE: Marenum chillers operate in extreme conditions at sea. TOP: Artists impression of a new Saga ship.

Cooling

Chillers

Heating

Power

Distribution

Industrial Refrigeration

When coil temperature reaches 10°C, the defrost is complete and can be terminated.

Improve efficiency

by removing excess heat

THIS ARTICLE EXPLAINS HOW TO IMPROVE PLANT EFFICIENCY THROUGH VARIABLE DEFROST TIMING AND TERMINATION.

OST FACILITIES HAVE cool rooms or freezer rooms that use fan coil evaporator units. Over time, ice forms on these coils and in their condensate trays due to airborne moisture. The rate at which ice is formed on a coil depends on several factors such as room temperature, cooling load, ambient conditions and number of door openings. As the ice layer on the coils increases, the coil’s heat exchanging capacity decreases. Hence, there is a need to defrost coils. Conventional defrosting methods use either hot gas, electricity, air or water. Many ammonia plants use hot gas defrost as there is suffi-

CLIMATECONTROLNEWS.COM.AU

cient heat available from the refrigeration plant and it is cheaper than electricity. The process of defrosting introduces heat into the refrigerated space, increasing the plant’s workload and energy consumption. The defrosting process also consumes energy. If defrosting methods are not optimised, refrigeration plant efficiency suffers. Variable defrost timing and termination refers to managing the interval between defrosts, the duration of the defrosting process and termination of defrosts. By convention, the frequency and duration of defrosts are fixed, regardless of room temperature and work load between defrosts. If there are too many defrosts or they last too long, heat will be needlessly added to the room. Hence optimised defrost management reduces overall refrigeration plant energy consumption. The variable defrost timing and termination proposed involves monitoring the time over which the coil has been operating at full capacity. The interval between defrosts will be shorter if the coil has been running continuously at full capacity and longer if it has been running at lower capacity.

The capacity of the coil can be found by assessing the amount of cooling supplied to it over a period. In the case of a flooded ammonia evaporator coil, the capacity is the time for which the liquid solenoid valve is open. Here are some of the benefits: • Managed defrosting intervals prevents wasteful defrosting during low-load periods. • Optimised defrost duration and termination of defrost prevents excess heat entering the

HOW IT WORKS Evaporator defrost timing and termination are optimised to prevent excess heat entering the refrigeration area. It reduces plant energy consumption and defrost energy consumption stabilising refrigeration plant operations. Typical plant energy savings can be up to three per cent. Implementation involves installing temperature sensing equipment and cool room load tracking devices, and programming the control system.

Industrial Refrigeration

cool room, easing the load on the refrigeration system and preventing energy waste. • Quick termination of defrost by electric defrosting units also saves unnecessary power consumption by the electric heaters. • Reduced need for defrosting during lowload situations means the refrigeration plant will be stable for longer periods of time. Similarly, with an ammonia evaporator coil, fewer defrosts means fewer suction pressure fluctuations, leading to more stable operations. Achievable annual savings depend on: • the number, type and size of fan coil units in the room • the room temperature • the cooling load profile • the type of defrost: hot gas, electric, air or water • the number of defrosts and the defrost interval currently employed • the defrost relief point: low temperature, intercooler or economiser vessel. Defrost relief piping to intercooler or economiser Implementation You need to know the:

• make and model of fan coil units in each of the rooms • defrost technique applied • coil arrangement within plant and circuit design • room temperature. To facilitate a sound defrost management strategy you will need: • A temperature sensing device attached to the face of the evaporator coil. When coil temperature • reaches 10°C, the defrost is complete and can be terminated. • A means of tracking the room cooling load, such as a monitoring solenoid or control valve. • A high-level PLC (or remote control man-

agement system unit) which controls the defrost system. This project is mainly achieved by implementing control algorithms. The only equipment required is a coil temperature thermostat or sensor to terminate the defrost cycle. The estimated cost of equipment and initial definition of the control algorithm is approximately $1500 per evaporator, if the site has a control system to which the thermostat can be connected. Optimisation costs would be additional based on the level of optimisation required. For a site with 10 evaporators, each of 50 kilowatt capacity, typical capital costs and payback could be:

TABLE ENERGY SAVINGS AND PAYBACK Energy savings (kWh/year)

Energy cost savings ($/year)

Project cost

Payback (years)

100,000

15,000

($)15,000

1.0

THIS INFORMATION WAS SOURCED FROM “I AM YOUR INDUSTRIAL REFRIGERATION GUIDE” WHICH WAS PREPARED ON BEHALF OF THE NSW OFFICE OF ENVIRONMENT AND HERITAGE BY THERMAL ENGINEERING CONSULTANCY, MINUS 40.

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Food manufacturers, distributors and retailers who own refrigeration systems: Do you have to rely on external contractors to keep your refrigeration systems running? Metis Monitoring can help you regain control! This easy to install real time monitoring system allows you to be in the know 24/7. Plus, its predictive diagnostic capabilities will tell you when a fault will occur and what action is needed. And, best of all, Metis Monitoring is compatible with any refrigeration system, at one very affordable monthly fee. With a Metis Monitoring system you won’t be left in the dark Full visibility of systems via remote 24/7 Monitoring. Predictive diagnostic and learning-based data gathering. n Reduce your exposure to unnecessary maintenance costs. n Retrofit any site for full monitoring of vital indicators. n Save money on product loss and gas leakage. n n

n T: +61 2 8850 3252 n WWW.METISMONITORING.COM.AU CLIMATE CONTROL NEWS SEPTEMBER 2017

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New products

Flow switch for chemical injection WAT E R/ WA S T E WAT E R TREATMENT AND other industries that utilise chemical injection or additive monitoring in their product processing and operations will find the FLT93 flow switch series a reliable solution for verifying chemicals or additives. The advanced FLT93 Flow Switch from Fluid Components International is suitable for flow detection of liquids or gases and is available in several wetted materials for compatibility with virtually any fluid. It is a dual-function instrument capable of monitoring and alarming on both flow and temperature in a single device. Dual 6A relay outputs are standard and are assignable to flow or temperature. The FLT93 flow switches can be specified in either insertion or inline styles for installation in pipe/tube diameters from 0.25 inch and larger. For monitoring chemical and other additive injection flow in small line sizes, the model FLT93L is an ultra-sensitive, inline-type flow switch that can detect liquid flow rates as low as 0.015 cc/sec and gas flow rates down to 0.6 cc/sec. Models FLT93S and FLT93F are insertion types and are the solution for liquids and gases in larger diameter pipe sizes, respectively. And, for sanitary processes, the Model FLT93C provides 20Ra electro-polished 316L stainless steel wetted parts and tri-clamp sanitary flanges.

New features added to Yellow Jacket range YELLOW JACKET HAS released two new products that are available from Sky Refrigeration and leading wholesalers. The new Yellow Jacket digital adjustable torque wrench replaces the older style torque wrenches that had multiple heads and no feedback on pressure being exerted. They are the size of a 10-inch shifter to fit tight installations and features a digital readABOVE: New products from Yellow Jacket out, LED lights and audible signals to indicate including a gauge and the desired torque is approaching and has been hose set for transcritical reached as well as having notched mouth to systems and an adjustable digital wrench. better support brass flare nuts. In addition, they feature nine programmable pre-set points and will hold in memory the last 50 torques reached for auditing. The second product, the Yellow Jacket transcritical CO2 manifold, gauge and hose set is specifically engineered for the service, vacuum and charging of 120bar transcritical systems. Made from high strength forged aluminium with the famous Yellow Jacket double o-ring piston, they have been further enhanced with new fine pitch threads to allow for finer adjustment. In addition, the vacuum/charging ports are enlarged with 3/8 connections and appropriate 72-inch hoses fitted.

Carel invests in food and beverage industry FOR THE FIRST time ever, Carel will be exhibiting a comprehensive offering of its own at Drinktec in Germany from September 11 to 15, 2017. Although Carel has been providing high efficiency systems to the food and beverage industry for over 40 years, the company has usually exhibited technology integrated into the beverage coolers displayed by its clients. This year Carel will have its own stand and its own cooling solutions on display, according to Alessandro Greggio, Carel’s head of marketing for retail and refrigeration. “This year we have decided to take part in this important event independently, presenting a comprehensive offering of technologically-advanced products and solutions designed specifically to meet the management and control requirements of refrigerated merchandisers, thus providing added value for beverage companies,” he said. “The challenges that beverage companies face fit perfectly with the core elements of our mission: efficiency, energy saving, performance and connectivity. “In recent years, these trends have intensified considerably and Carel has exploited this opportunity by deciding to invest in technologies that ensure these results are achieved.” Meanwhile, Carel has just completed the acquisition of its distributor in Poland, Alfaco Polska. Carel Group’s investment is aimed at consolidating the growth it has recorded in recent years in the Polish, Ukrainian and Baltic markets, where double-digit growth in the refrigeration and air conditioning markets is expected over the next few years. Carel is seeking to establish a direct presence in all major international markets.

ABOVE & LEFT: Carel's Heez cooler to go on display at Drinktec in Munich later this month.

For more information contact Sky Refrigeration on 03 9735 2313. CLIMATE CONTROL NEWS SEPTEMBER 2017

New products

Digital support for frequency inverters BITZER HAS PUBLISHED a video explaining how to design, configure and commission its Varipack frequency inverters. The video shows Bitzer staff designing a Varipack frequency inverter for the requirements of a refrigeration system with Bitzer compressors. Users also require the Bitzer software, the Best software and a Best interface converter or an Ethernet cable. The two software tools are available free of charge on the Bitzer website. Once the Varipack has been installed and wired as recommended, it can be commissioned and configured. In combination with a reciprocating compressor, the intelligent Varipack frequency inverters belong to the compressor specialist’s IQ product range and offer an intuitive commissioning process that doesn’t require any specific knowledge about frequency inverters. Its advantage is that it adjusts to suit the system’s current cooling demand, reducing both energy consumption and running costs. The precise coordination of compressor and frequency inverter saves additional energy and thus increases compressor efficiency in full and part-load. The external Varipack frequency inverters are also designed for modern motor concepts, including the permanent-magnet motors of the Bitzer Ecoline reciprocating compressors and other motors modified specifically for frequency inverters.

An image taken from the You Tube video Bitzer has created.

The Varipack series is suitable for refrigeration systems, air conditioning systems and heat pumps, and can be integrated into both systems with single compressors and compound systems. The Bitzer software enables application-specific selection of the frequency inverter, while the Best software promotes easy operation and monitoring. The video explaining how to use the inverters is available here: https://www. youtube.com/watch?v=PerxFWmvfeLink to the Bitzer software: https://www.bitzer.de/websoftware/ Link to the Best software here: https://www.bitzer.de/gb/en/service/software/software/versions-best.jsp

Monitors manage rising utility costs

Building managers are relying on energy monitors to reduce costs.

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SMART ENERGY MONITORS are being rolled out by building managers to reduce high utility costs. The Buddy Ohm was developed by South Australian company Buddy Platform to help users moderate water and electricity use. Using sensors, the device is able to deliver realtime information to the cloud, enabling building managers to make the necessary changes to reduce costs as efficiently as possible. Last year, Buddy Platform established its Australian headquarters in Adelaide, its first office outside the United States. The company’s CEO, David McLauchlan, said he was approached by almost every Australian state but chose Adelaide because of the lifestyle, and the high standard of engineering talent on offer. The company has also partnered with mobile operator Digicel for its Buddy Ohm product to be marketed, sold, distributed and installed across Digicel’s 26 markets in the Caribbean and Central America. McLauchlan said the new deal was a big opportunity for the Ohm to expand across the world. “Tourism is the largest driver of economic growth for Jamaica and the Caribbean region but

many tourism operators are faced with extremely high bills for water and electricity,” he said. “The partnership with Digicel will also have a positive impact on our Adelaide-based operations and we look forward to growing our engineering and management team to support our business growth.” Hotels require a lot of energy to create unique tourist experiences so monitoring and optimising usage of electricity and water is important. According to the World Bank, electricity prices in the Caribbean are three to four times higher than the United States and, in small tourism dependent islands like Barbados, air conditioning alone accounts for 48 per cent of hotel electricity consumption. The Ohm monitors environmental conditions around hotels and are powered by batteries that last a year, enabling it to be used in areas where power is scarce. The system uses pulse sensors to track the flow of steam, water and gas to provide a complete view of usage. Digicel CEO in the Caribbean and Central America, Vanessa Slowey, said to test the product’s capabilities, Ohm was installed in their own headquarters in Jamaica.

New products

Award winning formula wins contractor support RECTORSEAL HAS WON a Silver product design award for its AC Leak Freeze PRO with Magic Frost refrigerant leak sealant in the 14th annual Dealer Design Awards (DDA). The AC Leak Freeze PRO with Magic Frost was judged by an independent panel of HVAC contractors and competed with 80 other product design entries. AC Leak Freeze PRO was introduced last January and is a quick, easy and safe applicator for applying RectorSeal’s renowned AC Leak Freeze refrigerant leak sealant into commercial and residential air conditioning and refrigeration systems. Unlike some disposable refrigerant leak sealant applicators, AC Leak Freeze Pro doesn’t require any intensive R-410A system pump down and safely withstands all typical refrigerant pressures. The Magic Frost portion of the patent-pending AC Leak Freeze formula is a lubricant additive that extends compressor lifecycles. Approved as an OEM product by many tool and compressor manufacturers, AC Leak Freeze Pro with Magic Frost is the HVACR industry’s safest formula for a service technician and the refrigeration system, the company said. “Its proven compatibility flows with the system refrigerant/oil to permanently seal small leaks and prevent them in the future,” the company said in a statement. “The AC Leak Freeze PRO with Magic Frost formula is not moisture activated, has a safer flashpoint rating than the competition, and doesn’t use or create polymers that can potentially clog compressors, recovery/ evacuation units, Schrader valves, capillary tubes, TXV valves, micro channels or manifold gauges.” Visit their site for more information, www.rectorseal.com.

LEFT: RectorSeal secures an award for its AC Leak Freeze PRO product.

Oxygen analyser for gas purity MICHELL INSTRUMENTS IS now offering to customers in the semi-conductor and gas manufacturing industries a class-leading trace oxygen analyser for ensuring the quality of ultrahigh purity gases. Analytical Industries’ PI2-UHP Oxygen Analyser from Michell Instruments is both cost-effective and reliable. With a low detection limit of 0-50 PPB low range with LDL <0.1 PPB for checking purity of ultra-high purity inert gases in the semi-conductor industries, it is designed to measure trace-level oxygen contamination in high-purity gases. The PicoIon electrochemical sensor is maintenance free and routine calibrations are quick and simple thanks to the built-in auto-calibration and sample handling system. There is no need to add electrolyte. The analyser has an integral temperature control heated enclosure and stainless steel all welded sample system. Fully automated auto-zero and auto-cal, integral data logger are all features of the analyser. To ensure the zero gas is completely free of O2, an oxygen scrubber is included as part of the integrated sampling system. To protect the sensor, a sample bypass is provided to isolate the sensor from high oxygen levels during start-up, sample line switching and maintenance. ABOVE: An oxygen scrubber is included in the sampling system.

CLIMATE CONTROL NEWS SEPTEMBER 2017

Temperature Gauge

Sustainable procurement standard

WHAT DOES THE NEW STANDARD PROVIDE?

HOLDING REDLICH PARTNER, SCOTT ALDEN, PROVIDES AN INTRODUCTION TO THE WORLD'S FIRST INTERNATIONAL STANDARD FOR SUSTAINABLE PROCUREMENT ISO 20400.

THE STANDARD AIMS to help businesses meet their sustainability responsibilities by providing guidance on the effective implementation of sustainable purchasing practices and policies. Under the ISO, sustainable procurement is defined as “procurement that has the most positive environmental, social and economic impacts possible across the entire life cycle and that strives to minimise adverse impacts”. ISO 20400 also lists a range of principles to be upheld if an organisation is to embrace sustainable procurement, including accountability, transparency, ethical behaviour, respect for human rights and a focus on innovation and improvement. In integrating these principles organisations must balance the following issues: 1. The triple bottom line – development that meets the needs of the present without compromising the ability of future generations to meet their own needs (Brundtland report, 1978); and 2. Social responsibility – responsibility of an organisation for its impact on society and the environment through transparent and ethical behaviour that: • contributes to sustainable development, including the health and welfare of society; • considers the interests of stakeholders impacted by procurement practices;

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• is compliant with the rule of law and international norms; and • is integrated at all levels.

“THE ISO IS DIVIDED INTO FOUR CLAUSES FOR DIFFERENT LEVELS OF MANAGEMENT.”

THE INTERPLAY BETWEEN SUSTAINABLE PROCUREMENT AND SOCIAL RESPONSIBILITY Sustainable procurement is a central tenet of social responsibility and it is envisaged that ISO 20400 will complement ISO 26000:2010, Guidance on social responsibility. This is because ISO 20400 directs organisations to minimise their environmental footprint, review their impact on human rights and act to positively contribute to society and the economy. To this end, important practices explored in ISO 26000 such as due diligence, analysing the sphere of inf luence, setting priorities and avoiding complicity are all practices encouraged in ISO 20400.

The ISO is divided into four clauses which provide guidance applicable for different levels of management. Integration between these diverse industry players is critical to the ISO’s ability to achieve its sustainability objectives. Clause 4 Understanding the Fundamentals is a generalist clause which discusses what sustainable procurement involves and its strategic goals. It also outlines fundamental practices such as due diligence, risk management and priority setting. Clause 5 Integrating Sustainability into the Organisation’s Procurement Policy and Strategy provides guidance to top-tier management on bridging the gap between sustainable procurement strategy and organisational policy. This clause clarifies the importance of mandating sustainability objectives within the organisation at all levels and, in particular, stresses the importance of accountability and sustainable supply chains. Clause 6 Organising the Procurement Function towards Sustainability is most applicable for people engaged in procurement management and outlines the techniques to be employed to enable successful implementation, namely enabling people, engaging stakeholders, setting priorities and measuring performance. Clause 7 Integrating Sustainability into the Procurement Process is directed towards individuals managing sourcing activities and contracts. It provides practical guidance regarding implementing sustainable procurement at each stage of the process including planning, supplier selection and contract management and review. ✺ ABOUT THE AUTHOR Holding Redlich partner, Scott Alden, advises clients in relation to commercial contracts, procurement and probity. He has specific expertise in government and commercial law, infrastructure projects, general contractual and legislative advice and the tendering process and commercial contracts of all kinds and sizes and for all industries.

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