ACR Journal - May 2015

VO

LU

ME

1 N

o5

acrjournal.uk

Essential Information for the Air Conditioning and Refrigeration Industry

A N NIVE

RS

ARY

A N NIV

1989-2014

MA

Y 2

01

5

ISS

N 2

05

8-

44

07

COVER_May15.indd 1 23/04/2015 09:22

Refrigeration & Air Conditioning SuppliersRefreshingly Different

www.rw-wholesale.co.uk

Simply the best... ...stocked brands!Refrigeration Air Conditioning

p02_03_acrjune15.indd 2 20/04/2015 10:33:04

Refrigeration & Air Conditioning SuppliersRefreshingly Different

www.rw-wholesale.co.uk

Simply the best... ...stocked brands!Refrigeration Air Conditioning

Branch LocationsAston - Bow - Bristol - Birmingham - Chelmsford - Dorset

Edinburgh - Exeter - High Wycombe - Hull - Kent - Nottingham

p02_03_acrjune15.indd 3 20/04/2015 10:33:13

CONTENTS04

May 2015 acrjournal.uk


AN NIVE

RS

ARY

1989-2014

EditorWill Hawkins

01778 392094 [email protected]

Publishing EditorJuliet Loiselle


Multimedia Account ManagerJames Knight


Advertising SalesTheresa Geeson


Editorial DesignAmanda Clare and Ady Braddock

Advertising DesignNatalie Reynolds

Products & Awards OrganiserShelley Bright


Production Sue Ward


SubscriptionsSingle copy 3.00;Annual UK subscription 35.00Overseas 65.00

Published by:Warners Group Publications Plc The Maltings, West Street, Bourne, Lincs, PE10 9PH

01778 391000 01778 394748 www.warnersgroup.co.uk

Copyright 2015

PRINTED BY WARNERS 01778 395111

R E G U L A R S6

News

10 IOR News Update

10 ACRIB News Update

12 Mitsubishi Column

48 Company Pro le:

Andrews Sykes

50 Women In ACR

Julie Pringle, Mitsubishi Electric

52 Out and About with Will Hawkins

VES

55 Contractors Corner

TF Solutions

The Changing of the NumbersArticles about refrigerants are the most popular on the ACR Journal website. Quite rightly too. They are at the heart of the cooling industry in helping to keep products and people at the right temperature.

Until quite recently, articles about R22 were the most read refrigerant articles on our website as the phase-out came into force in January. Readers needed information about the impact of the legislation on their customers air conditioning systems who had systems containing R22.

A few months ago, R32 was an interesting topic for the future. But, until there was the infrastructure and product range to support it, it was just a matter of interest, if our website is anything to go by.

That has now changed. Interest in R22 has waned. Readers have shifted their interest to R32. The top articles online now focus on R32.

But, how does this change of numbers translate into business? How many contractors installing R32-based systems?

I would like to hear from you if you are. Finally, we have an announcement to make about the

National ACR & Heat Pump Awards. Turn to pages14&15 or visit our website for more details:

www.acr-heat-pumps-today.co.uk/Awards/

COMPRESSOR CLARIFICATIONWe are happy to clarify that there was

a duplication of captions on Page 44

of the April edition of ACR Journal. The

smaller picture featured a former Veebloc

reciprocating compressor-based system.

40

Contents_May15.indd 4 22/04/2015 16:52

05


CONTENTS

58 Coffee Break Competition

Sponsored by Refcom

60 Products

Whats New in April

61 Recruitment

62 Classifieds

64 Chilly Chatter

Sponsored by Fujitsu

65 Spotted! Chilly Van of the Month

Sponsored by ITE (UK) Ltd

PIPEWORK40

Controlling condensation Armacell

VRF43

Call Centre MakesGreat Energy Savings

Panasonic

46Radical changes bringsuccess a step closer

Mitsubishi Electric

AIR MOVEMENT46Air Handling Units for One Born

Every Minute HospitalMansfield Pollard

F E A T U R E S

BEST PRACTICE20

Surely a better way of supporting M&E Building

Services on flat roofs?

REFRIGERATION24

Hubbard nets seafood solution with KJ Refrigeration

REFRIGERANTS26

The introduction of R32 and R1234yf/ze brings new

servicing equipmentJavac

28The importance of leak detection

A-Gas

30Refrigerant Phase Outs The

Next Round HFCs Cool Concerns

COMMERCIAL REFRIGERATION32 Delifresh Gets a Quiet Commercial

Refrigeration SolutionJ&E Hall

34 Starfrost Chiller Fires up Pizza

Production for Bakkavor

36 How to make big energy

efficiencies with a new diffuser ebm papst

About our front cover:Colset Visit their website at

www.colsec.co.uk to learn more about theCold Room specialists.

VO

LU

ME

1 N

o4

acrjournal.uk


A N NIVE

RS

ARY

A N NIV

1989-2014

MA

Y 2

01

5

ISS

N 2

05

8-

44

07

COVER_May15.indd 1 20/04/2015 09:58

20

IN THE JULY ISSUE OFTHE ACR JOURNAL:

Training l Data Centre CoolingWater Treatment l Fan Coils l CompressorsSubmissions deadlineFriday 22nd May 2015

Contents_May15.indd 5 22/04/2015 11:57

NEWS06 NEWS


Summary Table: Honeywell Solstice Refrigerants

Solstice ProductDesigned to Replace:

End-Use Application Bene ts:

Solstice zd(R-1233zd)

R-123Centrifugal chillers, high temperature heat pumps, ORC

Non-ozone-depleting GWP of 1; 99% lower than HCFC-123 and

99.9% lower than R134a Non- ammable (ASHRAE A1)

Solstice ze(R-1234ze(E)) R-134a

Chillers, heat pumps, appliances and refrigeration equipment

Non-ozone-depleting GWP of less than 1, 99.9% less than R134a ASHRAE A2L PED Group 2

Solstice N13(R-450A)

R-134a Chillers and medium-temperature refrigeration

Non-ozone-depleting GWP is 60% lower than R134a Non- ammable (ASHRAE A1)

Solstice N40(R-448A) R-404A

Low- and medium-temperature refrigeration, self-contained equipment, condensing units, transport refrigeration

Non-ozone-depleting GWP is 66% lower than R404a 5-16% lower energy consumption in

end-use applications Non- ammable (ASHRAE A1)

Four HFO Refrigerants Launched by HoneywellHoneywell announced the launch of four low GWP HFO refrigerants in April, adding to their F-Gas compliant range of products.

The HFO (hydro uoro-ole n) refrigerants will be used in supermarket, chiller and air conditioning systems, and are part of Honeywells Soltice range. The company aims to make it easier for industrial customers to move over to using alternatives to high global warming potential refrigerants.

Honeywell spokesman, Julien Soulet, who is part of the manufacturers uorine team said,Each year, the world uses more than 100 thousand tonnes of refrigerant, enough to keep food fresh in 240,000 supermarkets and to cool more than 300,000 commercial buildings.

See the summary table below to understand where Honeywells HFO refrigerants apply:

LG Electronics opened its new factory in Vietnam in April on its Haiphong Campus near Hanoi.

The 262,000 square feet building will house the factory making its air conditioning products, as well as TVs, mobile phones, washing machines and in-car entertainment systems. The products will be shipped nationally and internationally.

Over 400 people came to the opening ceremony including the countrys President and Koreas Ambassador, Dae-joo Jun.

The new factory is part of a 1 billion investment by LG and its suppliers over the next 15 years. LGs two current plants in Vietnam will move into the Haiphong Campus which gives the company room to grow.

The factorys location near to a port will make it easier to transport its products and parts in and out of the country quickly. Also, there is a well-educated workforce in the area, and government support.

Its quite appropriate to be marking this occasion on the 20th

anniversary of our entry into Vietnam, said LG Electronics CEO Bon-joon Koo. We will make every e ort to make this cooperative venture a success so that our new Haiphong Campus will play an important role in LGs global manufacturing strategy.

LG Opens New Factory in Vietnam

NEWS.indd 6 20/04/2015 09:22

EU F-gas regulation.The end for high GWP gases.The new EU f-gas regulation (517/2014) comes into force on 1.1.2015. It will quickly restrict the use of high Global Warming Potential gases such as R404A, R507 and R422D.

3 choices are available to you: Continue using your existing gas but expect to face

potential product shortages and cost increases Convert your existing equipment to run on an alternative

retrot refrigerant with lower GWP Change your refrigeration equipment to use a dierent

gas such as HFO or natural refrigerants.

BOC can help you understand the impact of phase-out on your business, develop the best plan of action and support your chosen path by providing you with the gases you need when and where you need them.

For more information please could us on 0800 02 0800 or visit www.boconline.co.uk/refrigerants

BOCThe Priestley Centre, 10 Priestley Road, The Surrey Research Park, Guildford, Surrey GU2 7XY, Y, Y United Kingdom Phone +44 800 02 0800, Fax +44 800 136 601www.boconline.co.uk/refrigerants

p07_acrmay15.indd 1 20/04/2015 10:34:14

NEWS08 NEWS


CDL Opens New ACR Training Centre in ScotlandToshiba Air Conditioning distributor, CDL, recently opened a new training centre in Glasgow recently to serve its Scottish installers. CDLs training centre is in College Milton, East Kilbride and boasts a full set of Toshiba courses to help installers learn practical and theoretical skills on installation, commissioning and problem-solving.

Also in its training portfolio are courses on F-Gas regulations to help contractors understand the changes, how it impacts them and their end user customers. Delegates on courses will get their hands on working equipment including Toshibas SMMS mini-VRF.

Darrel Birkett, managing director, said: One of the biggest constraints on the growth of the air conditioning industry is the availability of skilled engineers. As a successful and growing distributor, we have a responsibility to help grow the next generation, and make sure todays sta are fully up-to-speed, on the technology, the environment and the regulations. That way everyone bene ts.

Find out more about training courses in the new training centre here: call 01355 234776 or via CDLs Sunderland headquarters on 0191 5496964.

Delegates on one of the fi rst courses New 6.5 million UK HQ for EberspcherThe German maker and supplier of heating and air conditioning systems for the automotive, construction, and marine markets opened its new, 6.5 million UK headquarters in Ringwood recently.

The 150 year old German company opened its rst UK o ce in 1977 but has now moved its three other UK o ces into the new site.

Vince Lee, Eberspcher UKs Managing Director, explained: We needed to retain the particularly unique skills of the current workforce so waited patiently for this site to be developed in Ringwood.

He continued,Now, with our new facility, we have an unprecedented opportunity to increase production, create new jobs in the area and bring the latest technologies and innovations to life.

At 5,276m2, the new site is three times bigger than its previous sites combined. The new HQ has a state-of-the-art climatic chamber, boasting a temperature range of -30C to +60C. This will help them to develop new condensers and evaporators which will come o the production line in April.

The heating, ventilation and air conditioning (HVAC) market is forecasted to increase by nearly 7% a year between now and 2019, according to a report by the Freedonia Group.

The growth rate in this period is nearly double that seen between 2009 and 2014. The rise is driven by investment in construction spending, particularly in the refurbishment and repair sectors. Furthermore, the report forecasts that demand for highly sophisticated and technical HVAC solutions will contribute to the growth.

Tax incentives to install more e cient domestic HVAC systems ended in 2014 which could mean less demand in this market. The report anticipates that more than a quarter of

HVAC equipment shipments will be imported systems by 2019.

However, the impact of refrigerant regulations (e.g. R22 phase-out) and more e cient equipment will mean that demand will be strong. Also, heat pumps which can provide both heating and cooling for commercial properties will be in demand where energy e ciency is important.

US HVAC Market Set to Reach 13.7 Billion by 2019

NEWS.indd 8 23/04/2015 16:06

09NEWS


Carrier Commercial Refrigeration has opened an academy eld training facility in Germany, its rst in a live-store environment.

The academy o cially opened 25th March at Carriers Research Development Centre in Mainz. It will serve as the central training site for Carriers service and installation technicians from across Europe, providing practical training and exercises to improve skills, while sharing best practices. Assigned technicians will be trained on speci c carbon dioxide (CO

2) refrigerant technologies, while supplemental local training initiatives will also continue.

Participating in internal training activities under best-in-class conditions enables our field technicians to gain and apply the latest knowledge on how to install and service CO

2OLtecturnkey projects

with the highest level of quality and reliability, said Bart Driessens, Service Operations Director at Carrier Commercial Refrigeration Europe.

The new facility features a training room as well as an operational cold room and freezer room. A CO

2OLtec refrigeration system is installed and connected with remote cabinets to create a fully operational CO

2supermarket where real-time situations, such as scheduled service and other necessary repairs, can be simulated.

ACR and Heat Pump Apprenticeship ApprovedThe air conditioning, refrigeration and heat pump industry received a boost this in April when the government approved a new apprenticeship standard for the sector.

The Refrigeration, Air Conditioning and Heat Pump Engineering Technician apprenticeship was developed by employers with the help of the Institute of Refrigeration and the ACRIB (Air Conditioning & Refrigeration Industry Board).

Skills Minister Nick Boles said:Apprenticeships are a real success story. Through giving leading employers in your sector the power to design and deliver high quality apprenticeships we can give young people the skills our economy vitally needs.

It is big step forward for the ACR & HP industry which struggles to attract enough young people with the right skills to help it grow.

It is critical for us as an industry that we lead the development of skills for the RACHP sector. The new RACHP Engineering Technician apprenticeship will enable our industry to support and engage with young people at an early stage in their career, said IoR President Graeme Maidment.

There is much more work to be done to bring this new standard to the market but we are con dent that with continued high levels of support from employers, it will make an immediate and lasting

contribution to the future of the industry.

The new Apprenticeship standard outlines the knowledge, skills and behaviours needed to achieve full competence in RACHP Engineering Technician job roles. The standard was developed by a group of twelve employers designated a Trailblazer by BIS (Department for Business Innovation and Skills). They will continue now to prepare an Assessment Plan, leading to a new Apprenticeship for the RACHP Engineering Technician, linked to Engineering Council national standards.

People who enrol in the three year course will learn to apply relevant scienti c principals and basics, coupled with work-based experience and training with real employers.

Beijer Ref Expands into ANZBeijer Refs expansion continues with the announcement from the air conditioning and refrigeration wholesaling business that it has bought Patton, a company with operations in New Zealand, Australia, India and Thailand.

Patton has a long history in the refrigeration industry, having started in 1923. The company now turns over around 31.3 million a year. The company is not only a wholesaler but a manufacturer too of its own brand products.

Most of Pattons business comes from New Zealand and Australia. But, its sales are growing in India where the countrys refrigeration infrastructure is developing. Its Thai manufacturing business makes and sells its products through the Middle East, South East Asian and Australia.

Beijer Ref complements Pattons current product supply with several strong international brands, which are currently missing in its product portfolio. It means that Beijer Ref, with its overall product o er, will become more competitive in these markets. In addition, we see synergies on the purchasing side as well as on the production side,

Carriers New Academy Training Facility

NEWS.indd 9 20/04/2015 09:22

IOR NEWS10May 2015

ARE Y

OU A

REFR

IGER

ATIO

N AI

R CO

NDITI

ONIN

GOR

HEA

T PUM

P EN

GINE

ERIN

G TE

CHNI

CIAN

?AR

E YOU

A RE

FRIG

ERAT

ION

AIR

COND

ITION

ING

OR H

EAT P

UMP

ENGI

NEER

ING

TECH

NICI

AN?

Refrigeration, Air Conditioning and Heat Pumps (RACHP) industry underpins everything we do. Refrigeration reaches in to vast range of elds, that we all in counter in our everyday lives for example without it the food supply would still be seasonal and limited to locally produced non-consumable items; data centres would not work, comfortable living conditions and certain medical advancements would be impossible.

RACHP account for 19% of UK electricity demand or around 10% of total greenhouse gas (GHG) emissions. Last month at an EU meeting in Paris, the EU agreed to intensify reductions in carbon emission further from 2020 to 2030. This will include a further 40% GHG reduction, through much greater use of renewable technologies and a massive increase in energy e ciency.

As a big GHG emitter and electricity user, the RACHP industry will be at the forefront Adopting di erent ways of reducing the energy use and carbon emission for RACHP such as utilising and developing e cient innovative and low carbon technologies.

Modern refrigeration is almost entirely based on a compression and expansion refrigeration cycle. Vapour compression refrigeration is a mature, reliable and relatively low cost technology. Over the years, the design of components and equipment of refrigeration systems, such as heat exchangers, compressors, fans, pumps, refrigerants and expansion valves were considerably improved due to extended research and developmental e orts. Anticipated improvements, however, are incremental since modern refrigeration is already near its fundamental limit of energy e ciency.

However, vapour compression is not the only cooling technology available. There are many many others, including technologies

An eye on

ACRIB

If you ask anyone what a Service Engineer or Technician is, there are always a lot of di erent views. But, the nal word has to go to the UK Engineering Council. The Engineering Council award professional titles such as Engineering Technician or Chartered Engineer across all elds using a speci c set of criteria against which an individuals experience, knowledge and skills is judged whatever their area of work. The Engineering Technician in the RACHP sector is awarded by the Institute of Refrigeration in association with CIBSE, through our membership of the Engineering Council.

SO WHY SHOULD YOU BOTHER? In practical terms, gaining the letters EngTech after your name will mark you out as a registered professional. It could help boost your career. It is an internationally recognised mark of your engineering skills, experience and competence and shows the commitment youre prepared to make to your career and to keeping your skills updated in the future.

The rst step towards registration is to become a Technician Member of the Institute of Refrigeration. Technician members gain access to regular practical updates and news on standards and legislation, their membership is based on holding a suitable F Gas Quali cation and having at least 3 years veri ed experience in the industry.

Once you are an IOR member you can apply for Engineering Council registration in one of two ways.

SHOW YOUR COMPETENCEIf you have a level 3 NVQ or Apprenticeship plus suitable experience the process is straightforward. You need to provide an additional portfolio of evidence demonstrating your competence and commitment to regular on-going training and your annual SES CPD Certi cation! Help is available to mentor applicants through each step. Fees to the IOR and Engineering Council will also apply.

Industry employers are currently working on a new RACHP Engineering Technician Apprenticeship framework that will be closely aligned to the Engineering Council standards, so future entrants to the sector will be recognised nationally with the same status as other engineering professions.

For more information www.ior.org.uk

If you are working in the service, maintenance, installation, commissioningor refrigeration,air conditioning or heat pump equipment, you probably are!

IOR_ACRIB.indd 10 21/04/2015 17:24

May 2015

the future

ACRIB

that maybe familiar like absorption and adsorption refrigeration, however, there are some more obscure technologies such as Electrocalorics and thermoacoustics.

In a series of articles SIRACH will review individual heating and cooling technologies and simply describe how they work, who has been developing them. The potential bene ts of application and the challenges in bringing to market. Next month we will describe Magnetic refrigeration.

SIRACH will be exploring the topic of - Innovations in Heat Pumps and Cooling - The Integration Challenge. The event will focus on the integration challenge and latest developments and innovations in heat pumps and cooling technologies and look at the challenges that integration poses. Presentations will include an overview and technical presentation from Arctic Circle. The SIRACH event will also include a unique tour of Arctic Circles leading edge research and development facilities in the UK. Arctic Circle is well known for providing low carbon solutions to the industry through innovation in compressors, heat recovery, chillers, thermal storage and heat pumps. Delegates will be able to hear from experts on the design and manufacturing process in this unique tour. Anyone who wants to attend this event can book online.

For more information or to be included on the SIRACH mailing list please visit at www.sirach.org.ukor email [email protected]

A win-win-situationRefrigeration systems with heat pumps twice as effective

In food and beverage production to take only

one example GEA Refrigeration Technologies

makes a double contribution to sustainability.

GEA Grasso compressors and chillers with natural

refrigerants are the industrial standard even

for great temperature differences, and with top

energy efficiency. Added-on heat pump systems

from GEA use heat emitted from cooling processes

and generate up to 5 kW of heat with 1 kW of elec-

tricity. Wherever refrigeration and heat are needed

at the same time cost-effectively

and sustainably you can naturally

benefit from the GEA win-win-

solution. More than one reason to

talk to the experts at GEA.

GEA Refrigeration Technologieswww.gea.com

engineering for a better world

Ad_ACRtoday_Heatpump_102x297mm_4C_US.indd 1 18.03.15 14:48GEA.indd 1 20/04/2015 10:34:47

IOR_ACRIB.indd 11 21/04/2015 17:24

12

With an election this close, the future is already certain

So, it is election time, when we as a country choose the government we want or not!At the time of writing, if the polls are to be believed, no one party

will win an overall majority and we look likely to be led by a coalition. What that means for us as individuals remains unclear but one

thing I would predict is that things will not change drastically for us collectively as the Aircon industry.

I say this because to a large degree, the future is already mapped out, with legislation both from here and from Europe, continuing to direct the way that things are heading, regardless of the avour or colour of the next UK government.

We already have F-Gas and the Building Regulations governing the way we work and operate.

We already know that we will see the increasing impact of

1212MITSUBISHI COLUMN12 MITSUBISHI COLUMNMITSUBISHI COLUMN


energy labelling, both of buildings and of equipment, as part of the on-going drive to reduce energy use and lower carbon emissions.

We will also see an increasing pressure to reduce the use of refrigerants in occupied spaces especially in the hotel sector and we are starting to see three real options here: We can design systems to reduce refrigerant; we can add the cost of including sometimes complex leak

detection systems; or we can utilise the new systems coming on the market that

use other refrigerants such as CO2 or even water as is the case with our own HVRF system. What I do con dently predict though is that we as an industry

will have an increasingly important role to play because we are the specialists who understand the need to balance internal creature comfort with energy use and emissions.

I meet keen, fresh-faced engineers, straight out of college, and old-hands who come in for updates on things they already know like the back of their hands.

It is us collectively that are charged with making the buildings work properly once they are designed, built and occupied.

Its our job to keep the nation cool, warm and ventilated, to enable the nation to work, rest and play in comfort. As a trainer, I can also see that we are continuing to develop the people with the skills to meet these challenges regardless of whoever ends up in Number 10!

Ben Bartle-Ross, Technical Trainer

TUBE EXPANDING JUST GOT A WHOLE LOT EASIER

Part number

HY-EX-6 4687047 full kitHY-EX 4687048 handle only

IncludesHydraulic expanding tools with heads from 3/8th to 1.1/8plus a HD deburring tool.

Features 120 degree angle provides a natural wrist angle Single hand operation with release button Accepts all common HVAC/R size copper tubin g Soft rubberised grip for easy use. Angle creates ease of use above head height.

Exclusive to Available from all good wholesalers

Make life easy with the new RefcoHydraulic tube expander

T: 01642 232880E: [email protected]

Javac.indd 1 20/04/2015 10:35:19MIT.indd 12 21/04/2015 17:40

The Ultimate Win/Win from Thermofrost Cryo

London Birmingham Manchester

Buy the ultimate cassette Win the ultimate in prizes

The latest LG cassette systems are full of advanced features which makes using them a great decision in its own right.

Now - Couple that with the ability to trade your accumulatedThermofrost promotional points for a selection of fantastic LG consumer products and you have an unbeatable combination. The promotion lasts throughout 2015 and any LGcassette purchases already made this year will count towardsyour points total. So, you may already be well on the way to agreat prize.*

LG Cassettes feature:

*For full details and terms of the 2015 Thermofrost LG Cassette Promotion, please contact us

Refrigeration & Air Conditioning

Points for Prizes

Powerful BLDC Compressor for improved efficiency Smart load Control for improved comfort and efficiency Optimised Heat Exchanger Path for improved efficiency Dual Temperature and Pressure Control for improved control Improved Outdoor Grille and Fan - lower noise levels Compact Indoor Unit Size from only 204mm depth High Ceiling Mode up to 4.2m ceiling height Auto Elevation Grille Option for easier service and cleaning Independent Vane Operation for full airflow adjustment Forced Cooling Operation allows pumpdown during service work

LG Points for Prizes Ad Steve Amends 13.3.15_Layout 1 13/03/15 10:31 AM Page 1

p13_acrmay15.indd 1 20/04/2015 10:36:00

ENTRIES ARE NOW OPEN!CLOSING DATE 16th SEPTEMBER 2015

Town HallVictoria Square,

Birmingham, B3 3DQ

HERE ARE THEAWARD CATEGORIES:> ACR Commercial Project

> Domestic Air Source Project

> ACR Retail Project

> Domestic Ground Source Project

> Non Domestic Air Source Project

> Non Domestic Ground Source Project

> Air Conditioning Product

> Heat Pump Product

> Refrigeration Product

> ACR Ancillary Product

> In-Situ Monitoring

> Heat Pump Installer

> ACR Contractor

> Wholesaler/Distributor

> HVAC&R Champion

Visit: www.acr-heat-pumps-today/AwardsBOOK NOW! PLACES ARE LIMITED

NACRHPA DPS2.indd 14 22/04/2015 14:06

ENTRIES ARE NOW OPEN!CLOSING DATE 16th SEPTEMBER 2015

Celebrating innovations, projects, installations and environmental successes the awards bring together Manufacturers, End Users, Distributors, Heating Engineers,

ACR Contractors and Consultants, providing the best possible platform for rewarding excellence in the ACR and Heat Pump Industry

28th JANUARY 2016

HERE ARE THEAWARD CATEGORIES:> ACR Commercial Project

> Domestic Air Source Project

> ACR Retail Project

> Domestic Ground Source Project

> Non Domestic Air Source Project

> Non Domestic Ground Source Project

> Air Conditioning Product

> Heat Pump Product

> Refrigeration Product

> ACR Ancillary Product

> In-Situ Monitoring

> Heat Pump Installer

> ACR Contractor

> Wholesaler/Distributor

> HVAC&R Champion

Visit: www.acr-heat-pumps-today/AwardsBOOK NOW! PLACES ARE LIMITED

SPONSORED BYSUPPORTED BY

NACRHPA DPS.indd 15 23/04/2015 09:48

CHILLERS16


The deal with Korean company, World Energy, is exclusive for the UK for its absorption chillers. The chillers capture waste heat from buildings and industrial processes. The technology converts the heat in high efficiency cooling which is used in either comfort or process cooling.

Klima-Therm managing director, Robert Mallozzi said, Harnessing waste heat in place of primary energy, such as electricity or gas, can deliver dramatic cost savings for end users, not to mention the

environmental benefits. World Energy has been active in the field for many years and is absolutely at the forefront of technology. Its reputation for excellent design and reliability is well deserved.

World Energys Max Santini explained that, with their technology, customers can use heat from solar thermal, geo thermal, flue gases, waste heat from chimney, district heating, and chemical heat source fired chillers, for example.

Kilma-Therm sees a market opportunity in the UK for absorption chiller. The mandatory

Kilma-Therm in Double Distribution Deal with Gree and World Energy

Chiller and air conditioning specialist, Klima-Therm, is the new distributor for Grees centrifugal chillers and World Energys absorption chillers.

move towards using renewable energy sources to contribute to energy use in buildings is driving it. The company believes that absorption technology use will grow in the near future as organisations look to use energy from waste, combined heat and power and micro-generation plants.

The UK government is encouraging the uptake of district heating, or heat networks, to provide heat and hot water to domestic and non-domestic properties. These large scale projects often use absorption technology to provide heating and cooling.

Klima-Therms other UK distribution agreement is with Chinese company Gree, which makes 60 million air conditioning units and 5.5 million CAC units a year.

Continued on page 18

32_kilmatherm.indd 16 21/04/2015 17:34

This portable air conditioner is suitable for offices, computer rooms and light commercial

use. It is also ideal for cooling flats, conseratories or loft conversions during hot summer

months.

The heat pump model can also be used as an energy

efficient form of heating during the cold winter months.

Pump House Portable Air Conditioning - In Stock!

Meets EN14511 standard & EU commission regulation

206/2012

No pump required - self evaporating condensate

LED display and remote control (both models)

Flexible exhaust hose - 1.5m (both models)

Proven well-tested designs

Suitable for areas up to 26m

R410A Refrigerant

A

ENERGY

EFFICIENCY

R

4

1

0

A

R

e

f

r

i

g

e

r

a

n

t

ENERGY

Contact Pump House on 0115 900 5858

or e-mail [email protected]

High

Efficiency

Solutions.

careluk.com

CAREL U.K. Ltd

Unit 2 Roebuck Place, 110 Roebuck Road, Chessington, KT9 1EU

tel +44 208 391 3540 - fax +44 208 391 0457

[email protected] - www.careluk.com

ultraCella

The ultimate Cold Room Solution

Introducing the new ultraCella, the ultimate in coldroom controllers, designed for ease of use with

built in Commissioning Wizards, programmable via USB key and 1ph / 3ph compatible.

With Data logging, control of EEVs, compressers, temperature and humidification the ultraCella delivers

on all fronts. Built in a modular format and ready for DIN rail mounting it is quick and easy to install.

Programmable, Controllable, quick and easy, all great reasons to install CAREL

p17_acrmay15.indd 1 20/04/2015 10:37:19

CHILLERS18


The quality and scale of the company is beyond impressive, it is breath-taking

Klima-Therm is backing the launch of Gree centrifugal chillers with a five-year warranty, believed to be an industry first in UK chiller market. Tim Mitchell, Klima-Therms sales director, said: It demonstrates our confidence in Gree technology, and provides a compelling additional benefit for consultants and end users.

Continued from page 16

The agreement is to distribute Grees high efficiency, cost-competitive centrifugal chiller solutions used in buildings and estates that need several gigawatts of cooling capacity. Grees products include its variable speed centrifugal chiller and photovoltaic (PV) powered inverter chiller. These provide renewable electricity for powering cooling systems and can also feed power directly into the grid, respectively.

Mallozzi continued, Having visited a number of their factories and headquarters in China, the quality and scale of the company is beyond impressive, it is breath-taking. After two decades of rapid growth, one in three residential air conditioning units in the world is now manufactured by Gree, an astonishing feat. Our goal is to make them as famous in the UKs commercial sector.

WORLDS FIRST DIRECT DRIVEN PV CENTRIFUGAL CHILLERThe worlds first photovoltaic (PV) direct-driven inverter centrifugal chiller was developed by Gree in 2014. With an outstanding COP 7.10, it can deliver energy savings of up to 40 per cent compared with a standard centrifugal chiller.

First installed on Grees own facility in China, the chiller contains five core technologies: PV Direct Drive Technology, Maximum Power Point Tracking Technology, Pulse Amplitude-Width Modulation Interleaving Control Technology, Power Integrated Management Technology and Ternary Communication Technology.

After being operated for a year from Gree s 3890 square metre PV array at the companys R&D centre, it has saved more than 831,600 kWh of power, providing free electricity free and saving more than 93,000.

32_kilmatherm.indd 18 20/04/2015 09:32

p19_acrmay15.indd 1 20/04/2015 11:18:44

BEST PRACTICES20


If you have ever been up on a at roof where there are old existing building services in-situ, it should be all too clear that the traditional manner of supporting these services is often less than ideal these days. The question now is whether these traditional methods of casting concrete plinths, building brick piers or manufacturing steelwork are becoming a thing of the past?

OLD HEAVYWEIGHTSTraditional concrete plinths require shuttering works prior to concrete pouring, with additional waterproo ng layers to be added following this. With brick piers

Laurence James of Pump House in Nottingham looks at how mechanical and electrical contractors are changing their views on the best practice in supporting rooftop M&E building services by favouring independent and non-penetrative support systems now widely available across the UK.


A BETTER WAY OF SUPPORTING M&E Building Services on fl at roofs?

curing times and separate trades are also required. Alternatively, steel plinths which break through the waterproo ng membrane and insulation down to the structural roof can cause inherent risks themselves, such as potential cold bridging issues, and may a ect current Building Regulations Approved Document Part L energy reduction gures.

It goes without saying that the time-frame and di ering trades required to carry out such old traditional detailing can have an adverse e ect on the smooth running of building contracts. Potentially, there is the risk of delay should, for example, there be ingress of water through an area of extra waterproo ng detailing carried out to these plinths

LIGHTER ALTERNATIVESThe problems may be compounded in that traditional practices can cause headaches for the building owner or end user in respect of future upgrading of their at roof insulation. If replacement of the existing building services becomes necessary, in favour of smaller, more high-e cient equipment, it can lead to the new items not tting upon the original plinth locations at all!

It is of little surprise then that we are seeing greater emphasis on utilizing the non-invasive, independent and lightweight supporting products available in todays market? These proprietary products are typically manufactured from mild steel strut or box sections that are hot dip galvanized to produce frameworks which support building services.

Pump House.indd 20 22/04/2015 17:05

Engineered for tomorrow.

Hitachi Air Conditioning

To find out more call Hitachi on 01628 585 394hitachiaircon.com | hitachiheating.com

Widest range with highest ESEER on the market

TM

FSXNH

FREE FUEL OR TRAVEL VOUCHERSwhen you purchase any Set Free VRF

Boasting the markets only 2-pipe heat pump or 3-pipe heat recovery from a single unit, our Set Free VRF range is already pretty impressive. Available with the widest range (14kW to 100kW nominal cooling), the highest seasonal efficiency (up to 8.79 ESEER(2) ), and connectable to more indoor units than any other VRF, new Set Free FSXNH is naturally great news.

Japanese engineering excellence, naturally

p21_acrmay15.indd 1 20/04/2015 10:40:06

BEST PRACTICES22


The frameworks manage the imposed loading down through their polypropylene, plastic or rubber feet which are square, rectangular or round in fashion; these in-turn sit on the nished waterproo ng layer or upon the insulation boards within an inverted roof design.

Since the advent of independent support systems, introduced into the UK back in the mid-nineties, contractors, speci ers and consultants alike are realizing that these lightweight solutions negate many of the traditional elements and overall provide greater exibility, whilst reducing unnecessary risk of delays to the project program.

WHY CHANGE? One would suggest that the key to the rise of such products is their simplicity? Lightweight non-penetrating solutions that can be manually positioned at the last minute, without being set within a pre-determined location dictated early on in the project works. They provide the installer with a fully exible solution that ultimately is quick and simple to install with little, if any, training required.

As mentioned they negate the requirements for often

awkward and time consuming waterproo ng detailing, avoiding cutting through the insulation layer causing thermal de ciencies and potential interstitial condensation complications. These independent frameworks are robust enough to manage the heaviest building services such as large chillers and packaged plant rooms quite satisfactorily.

CONSIDERING THE RISKSHowever, these support solutions can come with some inherent risk themselves. What with a plethora of support systems now available to purchase through many di erent companies within the UK, the installer should not lose sight of key considerations associated with such systems.

In the very nature that these solutions are lightweight and independent, they can be susceptible to wind loadings, particularly in exposed areas such as high rise buildings or coastal environments. Therefore guidance and, if necessary, wind loading data should be sort from the manufacturer of such systems prior to delivery.

Another factor is when heavy services, such as packaged plant rooms, large chillers and air-handling units, have concentrated loads which need to be managed to ensure the roo ng insulation within the roof build up is not compromised and compressed.

Again, creditable calculations relating to foot pressures, leg

reactions and roof loadings ought to be a prerequisite, and a sound knowledge of modern-day at roof designs and insulation types should be mandatory to ensure there are no inherent damaging e ects to the roo ng build-up post the installation of framework and plant on top.

SUPPORT FOR THE SUPPORTAbove all when the consumer makes their selection on which supporting system to purchase, they should ensure they are automatically receiving the technical support, long term experience and professional advice by the product manufacturer.

The manufacturer should automatically give consideration to all aspects associated with the support system namely, the roo ng build-up beneath, the imposed roof loadings and foot pressures and wind load management. Maintenance & Service manuals for the support system should be available for inclusion within the end user/building owners Operation & Maintenance manuals.

With all factors considered and selection made these alternative solutions are clearly the way forward for future projects that require mechanical and electrical building services supported on at roofs. Speed, simplicity and robustness are key, and it is of no surprise we nd ourselves working within an industry that chooses more often than not to use such systems over outdated traditional methods. After all time is money!

laurence.james@ exisupportsystems.co.uk 07730 435 792


They provide the installer with a fully fl exible solution that ultimately is quick and simple to install

Pump House.indd 22 22/04/2015 11:35

Blygold UK Ltd, Olympic House, 63 Wallingford Road, Uxbridge, Middx., UB8 2RWT.01895 259346 F. 01895 259356 E. [email protected] W. www.Blygold.com

Blygold UK Ltd, Units 2/3 Dinting Ind. Est., Dinting Lane, Glossop, Derbs, SK13 7NUT. 01457 859111 F. 01457 850715 E. [email protected] W. www.Blygold.com

Anti-Corrosion Coatings for Fin Coil Heat Exchangers

U N I T E D K I N G D O M

Doubles the life of your coils Reduces your Energy Bills Reduces the wear & tear on your units Reduces Maintenance Costs Reduces Call Outs Reduces the need for early replacement

[email protected]

TQ8000 Control panel combined with TQ122 sensors (any gas) with visual/audible alarm.

The TQ8000 provides individual 4-20mA outputs for interfacing to programmable logic controllers, PCs and building management systems.

A compact, portable and cost effective solution to air purification and sterilization using tried and tested UV-C technology against airborne viruses and bacteria. Ideal for office use in areas up to 186 sq.m.

SafeAir 3500

Gas Monitoring SolutionsGas Monitoring Solutions

Control panel combined with sensors (any gas) with

provides individual 4-20mA outputs for interfacing

visual/audible alarm.

provides individual provides individual

TQ Environmental Limited Flanshaw Way Wakefield West Yorkshire WF2 9LP01924 380700

Untitled-28 1 18/4/12 16:56:42Untitled-1 1 03/10/2013 08:53:46

p23_acrmay15.indd 1 20/04/2015 11:52:01

COMMERCIAL REFRIGERATION24

The installation at Coombe Fisheries, Barnstaple, one of the Southwests largest sh processing and exporting businesses doubles its capacity for processing, packing, freezing and storing. Coombe Fisheries exports approximately 75% of its production and freezing and storing stock are an essential processing requirement. Produce is predominantly shell sh, focusing on scallops, whelks and a range of cephalopods destined for consumption throughout Western Europe.

Hubbard Products, the UKs leading designer and manufacturer of bespoke industrial freezing systems have completed a large-scale industrial seafood processing solution for KJ Refrigeration of Barnstaple.

The high-performance refrigeration equipment is housed in a 4 million; 21,000 square foot purpose-built extension and serves newly installed facilities. These include a holding freezer (-20C), a 157m3 blast freezer (-25C), two separate 262m3 blast freezers (-25C), a Helix Spiral Freezer, Hybrid Tunnel & Contact Freezer and a HT Finishing Freezer (all -40C).

KJ Refrigeration specialise in cooling for food processing and industrial applications. The two-year project was overseen by managing director Kevin Jones, who explains:

Our customer is one of the UKs largest processors of seafood for wholesale exporting across Europe. The need is to freeze fresh products quickly while remaining environmentally sound. And, to have total control in matching the freezing duty to uctuating volumes of product within the processing lines in an energy-e cient manner was paramount.

This was more than an installation of o -the-shelf packaged condensing units. The need for a collaborative approach with a single manufacturer with the capability to design the correct equipment and to create bespoke

software to manage the running of the equipment was the only way forward for this sophisticated requirement.

SUSTAINABILITYThe need to balance refrigeration reliability and running cost with an almost instantaneous response to cooling requirement and the maintenance of production quality are part of Hubbards approach to industrial process refrigeration and especially to the seafood sector. The company boasts a well-proven track record in sustainable refrigeration. Hubbard was the rst Carbon Trust ETL qualifying manufacturer of cellar cooling equipment in 2005 and most recently have been accredited with Triple E approval for Irish businesses.

Working with KJ Refrigeration, Hubbard created a refrigeration plant schedule consisting of: A twin installation of two Zanotti

vertical discharge external housed packaged equipment to service the holding freezer, each unit providing cooling capacity of 28.5Kw

A single Zanotti vertical discharge pack to service the 1600m3 packing area

Two twin semi-hermetic internal screw compressor packs to service the two 262m3 blast freezers with a combined duty of 230Kw

Two twin semi hermetic screw compressor packs, externally housed with economisers and



34_hubbard.indd 24 23/04/2015 09:16

25COMMERCIAL REFRIGERATION

sub coolers, including receiver, control panel and weatherproof housing to service the Spiral Freezer with a duty of 199Kw and Contact Freezer (Crust freezer) with a duty of 90Kw

Inverter compressors were speci ed to ensure cost-e ciency through energy consumption and speed of response to production requirementsKevin Jones continues: Coombe Fisheries and KJ

Refrigeration have a long-standing relationship of over 30 years, and we are pleased to still be supplying a growing company in a globally competitive market place. Coombe Fisheries is supported by the EU, to develop a sustainable business model, to act as peer leaders and to reduce their carbon footprint through energy-e ciency.

As refrigeration consumed almost 25% of the overall project

Having a reliable and trusted supplier like KJ Refrigeration who in turn have an excellent partnering relationship with Hubbard Products, an international manufacturer themselves, encourages us to believe we have achieved an industry leading processing plant. That can only be good for Coombe Fisheries, the South West and for the UK as a whole.

budget, it was a guiding principle that the chosen manufacturer could demonstrate knowledge of food-processing requirements.

CUSTOM SOFTWAREHubbards expertise was immediately a valuable addition to the project team. The writing and debugging of bespoke plant management software ensured that Coombe Fisheries were involved in the ne-tuning of the refrigeration plant and equipment. A generic software package could only deliver average performance rather than a Coombe Fisheries speci c solution.

James Spear, managing director Coombe Fisheries adds: This is a project that we started late in 2011 and completed at the end of 2014. The development will give us the added capacity to build our export and domestic markets. Taking sh from the open market, processing, freezing and delivering across Europe.



34_hubbard.indd 25 23/04/2015 09:17

REFRIGERANTS26


Scott Davies from JAVAC reports on the new equipment available on the market to support R32 and R1234yf/ze.

R32 IS FAST BECOMING A HOT TOPIC! Various AC manufacturers are now in the process of introducing split AC systems with R32 refrigerant. R32 is already heavily used in Air conditioning equipment, as it makes up 50% of R410A. Its a single component refrigerant so will not separate and it has a global warming potential (GWP) of 675. Its more energy e cient and will feature predominantly in smaller splits, 10kw and under. R32 has been classed as mildly ammable and is in the A2L classi cation.

So thats the statistics over with what everyone really wants to know is where they stand with regards to recovering and detecting R32. In the A2L category of mildly ammable means that engineers and companies will have to equip themselves with the correct tools for use on installations and service which do not have the potential to cause a spark!

The introduction of R32 will bring forward discussions within the industry regarding safe equipment to use and Javac UK is working hard to help ensure installers are ready. Providing clear information on the new refrigerant recovery, vacuum and leak detection equipment on o er will ensure companies using R32 will be con dent in their equipment. Javac UK will also o er

Engineers and companies will have to equip themselves with the correct tools

for use on installations and service

R32 and R1234yf/ze Require New Equipment

full training on the equipment and is also available to o er advice to wholesalers and end-users to help them make informed choices when selecting the correct recovery equipment and leak detectors when required.

HFOs such as R1234yf or R1234ze are also classed as mildly ammable in the A2L category.

They have very low GWP and are replacements for R134a. R1234yf is more commonly used in the automotive trade whereas R1234ze will be seen in the commercial industry. Their pressure and energy e ciency are however not suitable for replacing R410A in air conditioners and heat pumps. Javac UKs equipment will also be suitable for these refrigerants.

SUITABLE EQUIPMENT TO USERecovery of this refrigerant will have to be carried out with a unit which is completely spark proof and has a potential to spark rating of zero. Javac UK has introduced the ALTIMA-A2L spark proof recovery unit. This is also the case when it comes to detection of the refrigerant were a leak to occur.

When detecting a leak only an ATEX approved leak detector will be suitable as anything not ATEX approved will have the potential to cause a spark.

ATEX is the name commonly given to the legal requirements for controlling explosive atmospheres and the sustainability of equipment and protective systems used inthem.

Foreseeing this Javac has introduced the Gas-Mate ATEX approved leak detector.

Finally a suitable vacuum pump will also have to be used. Although the majority of the time there will

So thats the statistics over with what everyone really wants to know

to recovering and detecting R32.

ammable means that engineers

themselves with the correct tools for use on installations and service which do not have the potential to

The introduction of R32 will bring

industry regarding safe equipment to use and Javac UK is working hard to help ensure installers are ready. Providing clear information on the new refrigerant recovery, vacuum

using R32 will be con dent in their equipment. Javac UK will also o er

selecting the correct recovery equipment and leak detectors when required.

HFOs such as R1234yf or R1234ze are also classed as mildly ammable in the A2L category.

to be carried out with a unit which is completely spark proof and has a potential to spark rating of zero. Javac UK has introduced the ALTIMA-A2L spark proof recovery unit. This is also the case when it comes to detection of the refrigerant were a leak to occur.

approved leak detector will be suitable as anything not ATEX approved will have the potential to cause a spark.

given to the legal requirements for controlling explosive atmospheres and the sustainability of equipment and protective systems used inthem.

introduced the Gas-Mate ATEX approved leak detector.

will also have to be used. Although the majority of the time there will

XTR_Altima A2L

JAVAC.indd 26 17/04/2015 15:49

27


Only an ATEX approved leak detector will be suitable as anything not ATEX approved will have the potential to

cause a spark

ALTIMA A2L SPARK PROOF REFRIGERANT RECOVERY UNIT The revolutionary Javac ALTIMA A2L has the fastest recovery rate in the industry due to its 240v V-Twin compressor design and is fully spark proof.

The recovery rates are as follows, Liquid-216kg/hr, Vapour-30kg/hr and push pull at 660kg/hr.

Along with R32 and R1234yf/ze the ALTIMA A2L is also suitable for all common refrigerants including R410a. The spark proof switches and circuit breaker are UL listed and the power supply lead is a hard wired with a length of 5m.

GAS MATE ATEX APPROVED HAND HELD LEAK DETECTORThe Javac Gas-mate is the UKs only ATEX approved hand held leak detector with an accuracy of 5 PPM (methane) and is twice as sensitive as its nearest competitors. The ATEX approval means that it is designed not to have the potential to cause a spark or means to ignite

a combustible gas. Powered by two size D batteries the Gas-Mate comes from the same technology used in the ever popular Tek-Mate and D-Tek Select with incredible pinpoint accuracy. The Gas-mate will detect all hydrocarbons including R32, R1234yf/ze R600, R290 and also the leak detection product Trace-A-Gas.

BULLDOG 160 A2L SPARK PROOF VACUUM PUMP The Javac Bulldog 160 A2L is a 240v fully spark proof vacuum pump for use with all systems for evacuation which contained hydrocarbons. This is a two stage oil sealed vacuum pump featuring a solenoid isolation valve to eliminate the chance of oil suck back. The dual oil demister is designed to eliminate all oil mist and smoke entering the atmosphere. This feature is unique to the Bulldog creating a clean atmosphere on large evacuations.

Using the correct equipment will ensure complete safety when using new mildly flammable A2L category refrigerants. There are also various training facilities up and down the country which now offer full compliance training on the refrigerants and equipment.

For more information contact: 01642 232880 www.javac.co.uk

Gas Mate Leak Detector

REFRIGERANTS

be no refrigerant present when performing an evacuation there is always potential that a small amount of refrigerant molecules could be dormant in the system which, when under vacuum, will be released. Alternatively, mildly flammable refrigerant could be present in the atmosphere.

For this circumstance Javac UK have the Bulldog A2L spark proof vacuum pumpavailable.

JAVAC.indd 27 17/04/2015 15:49

REFRIGERANTS28


The F-Gas Regulations are placing an increased emphasis on leak reduction and having the right equipment to carry out this work has never been more important. The refrigerants we use are changing and in upgrading plant engineers and customers are left with two options replace the entire system or retro t it with an alternative refrigerant.

Replacement can be a time-consuming and expensive route to take. To be fair, there are instances when this may be the only alternative but a retro t is often a cost-e ective and often more e cient way of dealing with problems within a refrigeration or air conditioning system.

Recently at A-Gas we have had rst-hand experience of a successful in-house retro tting project. At our o ces in Portishead, near Bristol, an ancient 10 horsepower 28 kW Daikin VRF air conditioning system was running on R22 and needed an upgrade to comply with the ODS Regulations. If you follow social media you will know that R22 is still posing problems for many engineers and end-users even though it has been phased out.

The importance of leak detectionA-Gas Managing Director John Ormerod on why leak detection is playing a wider role in the lifecycle of refrigeration and air conditioning systems.

The system at A-Gas, with ten separate air handling units containing 16.9 kilograms of refrigerant, was used to heat and cool the rst oor o ce areas.

DECIDING TO RETROFITIn the rst instance, we considered a replacement system but this was going to cost in the region of 30,000. We looked again at the project and saw that a retro t o ered an alternate way forward.

By using the Trace-A-Gas leak detection system, a ve per cent hydrogen and 95 per cent nitrogen mixture from A-Gas, we were able to get to the heart of the problem. This enabled us to locate the leak and nd evidence of former leaks. We made the repairs, retested with Trace-A-Gas to make sure all was okay, evacuated the system and recharged it with R438A which has low Global Warming Potential (GWP) values. The system is now up and running as it should be and we have saved a lot of money into the bargain.

In this instance the use of leak detection also bought us time. Because of where we are in the F-Gas legislation it gave us the opportunity to wait until the major manufacturers bring out R32 as a refrigerant for air conditioning

28_agas.indd 28 17/04/2015 17:12

29REFRIGERANTS


The importance of leak detection

Please use photo of John Ormerod used in page 18 of April 2015 issue

a-gas_leak_detection_system (might be too low in resolution)

rather than use R410A which we will ultimately have to replace anyway so we can get to a point where we can replace it as we would like.

BETTER THAN SOAPY WATERIn recent years there have been signi cant developments in leak detection. Its hard to believe but some still think that spraying soapy water is all that is needed to detect any leak. In fact such an operation will only detect large leaks. Advanced technology is already with us and Trace-A-Gas, a valuable tool for any retro t when used with an electronic leak detector, can nd leaks smaller than 5g per year.

Improved leak detection forms part of a rethink on the lifecycle performance of systems. The lifecycle of a system should now be the key factor for customers and engineers, and the industry is being forced to look at a more holistic approach to managing refrigerant use.

LEAKAGE CUTSAs a result of this, sales of reclaimed refrigerant are on the up and besides improved leak detection there are better installation and work practices and equipment is more e cient in its use of energy. Enhanced equipment design and improved

training for contractors and skilled technicians is also contributing to this. In the UK, leakage in modern air conditioning systems has been cut drastically compared to the levels of 15 years ago and I expect this tocontinue.

ORIGINAL EQUIPMENTManufacturers (OEMs) are also raising their game by producing better components which deliver more e ciencies. The industry is now more focused than ever on leak detection and this shows that we are beginning to get our act together with a more sustainable approach to working practices.

28_agas.indd 29 17/04/2015 17:12

REFRIGERANTS30


As an industry we are well used to phasing out widely used refrigerants and nding workable alternatives. We probably did not think so at the time, but we had plenty of notice to decide which the best alternatives were in both new and existing systems and to e ciently deploy them. For example we had to stop using R22 in new systems at the end of 1999, but had up to the start of this year to service them.

And here we go again! The revised EU Fluorinated Gas regulation introduces bans and quotas on HFCs as well as changes in supply and leak test regimes. This will force industry to move away from high global warming potential (GWP) HFCs with a speed and uncertainty we have not seen in previous phase out scenarios.

Refrigerant Phase Outs The Next Round - HFCs

Year Max GWP System type

2015 150 Domestic fridges and freezers

2020 2500 Commercial fridges and freezers

2022 150 Commercial fridges and freezers

2020 2500 Most HFC stationary equipment

2022 150Central plant for commercial use (retail, food services) > 40 kW

Exception - cascade high stage, GWP > 1500

2020 150 Moveable room AC

2025 750 Single split < 3kg

BANS AND RESTRICTIONSThe service bans and restrictions on the use of some HFCs in new systems are quite clear.

From 2020 we will not be able to use HFCs with a GWP greater than 2500 to service systems over 40 tonnes CO

2 equivalent. This equates, for example, to a system charged with 10.2 kg R404A. We will be able to use recycled R404A until 2030 if we can get it.

There will soon be bans on using HFCs in many new systems, dependent on GWP, as show in the table below.

This is also quite clear, and in fact several of the systems in the table already predominantly use other refrigerants, such as domestic and commercial fridges and freezers where hydrocarbons are widely used.

THE QUOTA SYSTEMHowever, revised F Gas Regulation has introduced a quota system on

the supply of HFCs, and with it a huge degree of uncertainty. From this year there is a phase down in the amount of HFC that can be supplied, speci ed in CO

2 equivalent and compared to the average supplied in 2009 to 2012.

The average GWP column is just that its what the average GWP of HFCs sold in Europe would have to be if the quantity (weight) of HFC sold is to remain the same. So you can see that within a few years it is likely the suppliers will not be selling high GWP HFCs such as R404A (GWP = 3922) if they are to maintain sales volume. And a few years later lower GWP refrigerants such as R134a (GWP = 1430) are also less likely to be available.

The impact of the phase down may be greater than shown if, as expected, the requirement for refrigeration and air conditioning increases within Europe.

So the e ect of the quota system

Here we go again.

by Jane Garthorpe from Cool Concerns

30_cool concerns.indd 30 17/04/2015 15:37

31REFRIGERANTS


THE CONCEPT OF CO2 EQUIVALENTThe revised F Gas regulation uses CO2 equivalent to determine bans and leak test regimes. The CO2 equivalent of a system is simply the GWP of the refrigerant multiplied by the weight (mass) of refrigerant in the system. Consequently the revised regulation has a greater impact on high GWP refrigerants.

Year Phase down % Average GWP

2015 100% 2300

2016 - 17 93% 2139

2018 20 63% 1449

2021 23 45% 1035

2024 - 26 31% 713

2027 - 30 24% 552

2030 21% 483

will be to phase out high and medium GWP refrigerants, but it will be market driven and not simple to predict in terms of timescale and availability. In the UK we will be a ected by HFC demand in the rest of Europe, making the situation even less predictable.

PHASE OUT AND ALTERNATIVESThe impact of the quota system and the bans / restrictions means we are now urgently planning to replace R404A in both new and existing systems. Unlike previous phase outs we dont know the exact timescale but we do have an increasing range of replacements available.

Some of the replacements, such as the R407 series (GWP approximately 2000), are actually better refrigerants, but their life is probably limited to a few years by the quota system. The longer term replacements are probably HFO blends, of which there is a proliferation as the chemical companies brew their own blends.

OTHER CHANGESThe other revisions to the regulation seem minor in comparison with the e ect of the quota, bans and restrictions, but should help reduce emissions. The supply of HFCs is now

restricted to companies which are registered. This means they have to employ certi cated engineers and have appropriate equipment;

Non hermetic systems which are pre charged with HFC (e.g. split AC) can only be installed by a registered company;

The leak test regime is now based on the CO

2 equivalent of the HFC charge in a system. The e ect of this is more frequent leak testing of high GWP refrigerants (such as R404A), and less frequent testing for low GWP systems.

IN CONCLUSIONThe aim of the revised F Gas regulation is to reduce emissions of HFCs by 80% by 2030 compared to 2005 levels. It will certainly accelerate our move to alternative refrigerants (R744, HCs, HFOs). But uncertainty in the availability of high GWP HFCs within a very short timescale is going to challenge the RAC industry.

For more information:Cool Concerns Ltd

+44 (0)1684 290333 www.coolconcerns.co.uk

30_cool concerns.indd 31 17/04/2015 15:37

COMMERCIAL REFRIGERATION32

Five J & E Hall Fusion Commercial Condensing Units have been installed in Bradford at Delifresh, a specialist supplier of fresh produce and delicatessen products to the catering industry. The company works with hotels and restaurants throughout the north of England and is passionate about the quality of its products.

The Delifresh unit in Bradford

LONG-STANDING INSTALLER RELATIONSThe installer of the new cooling equipment for the project was GRS Refrigeration of Leeds, who enjoy a long-standing business relationship with J & E Hall. This was recognised by Delifresh, when it commissioned GRS to install the equipment at its new two-acre facility in Essex Street, just a mile from Bradford city centre. The distributor was FSW.

GRS Refrigeration, which will soon be celebrating 30 years in the cooling industry, is a business employing eight people, which carries out extensive work in the restaurant and catering industry. The new Delifresh premises, constructed from highly insulated panels, needed a complete install of equipment to cool vefood-handling areas.

COOL, CREATIVE THINKINGWith a total of more than 8500 cubic metres of cooled spaces, each having its own temperature requirements, the job presented some interesting challenges requiring equally creative engineering solutions.

Contracts Manager for GRS Refrigeration Andrew Pinder takes up the story:

Over the years we have found that there is usually a product from the extensive J & E Hall range that is right for the job. This is great for smaller companies such as ours because it

Delifresh Gets a QuietCOMMERCIAL REFRIGERATION SOLUTION


Price isnt everything, of course.The equipment has to work and quite

simply we dont get any problems with J&E Hall thanks to the build quality

JE Hall.indd 32 20/04/2015 09:35

COMMERCIAL REFRIGERATION 33


allows the installation of top spec equipment at a price that is acceptable to the customer.

The total project cost for the new site was in the region of 3 million but with reasonably modest cooling technology costs of around 150,000 we were able to compete on a level playing eld with the industrys big names.

Price isnt everything, of course. The equipment has to work and quite simply we dont get any problems with J & E Hall thanks to the build quality. Of course, with each installation being di erent to the last, there can always be questions on how to achieve a particular goal but there is little if anything that cannot be overcome with the great level of support they provide.

THE HARDWARE SOLUTIONThe project for Delifresh called for a number of units to be installed to achieve the correct temperature requirements for cooled areas of di ering sizes. Installed indoors were two 8.25 horsepower JEH2-

The J & E Hall condensing units

0825-L-3 Fusion units for the 10.4m x 6.3m -20C freezer. Two ten horsepower JEH2-1000-M-3 Fusion units were installed outdoors for the 30.7m x 12.8m pre-pack area together with a single three horsepower JEHS-0300-M-3 Fusion unit for the 6.78m x 5m chilled store.

J & E Hall o ers an extensive range of medium and low temperature reciprocating and scroll-housed commercial condensing units using R404a. Medium temperature scroll condensing units qualify for Enhanced Capital Allowance. This Government scheme allows tax relief for businesses investing in energy e cient projects.

The acoustically-lined Fusion range houses a reciprocating compressor which is tted with a compressor jacket to further reduce noise. MrPinder explained:

Although the area around the site in Bradford is not particularly residential, and there is a major road running alongside, we were conscious not to add signi cantly to the noise levels.

The J & E Hall Fusion units we installed have inbuilt sound insulation for the cabinet and the compressors, so are particularly quiet, with the loudest of them being no more than 42 Db(A), even at full load.

Another bonus of selecting this particular equipment for use in a busy location such as Bradford is the blue anti-corrosion coating seen on the condenser ns. It comes as standard on the Fusion units and gives increased resistance to any corrosive elements that may be present in the urban or industrial atmosphere. In the long term this will obviously extend the working life of the equipment but in normal use it also helps to improve condensere ciency.

The installation completed at the Delifresh site in Bradford demonstrates how, with the backing of high quality, reasonably priced equipment and support, a small company such as GRS Refrigeration can compete on equal terms with much largerorganisations.

JE Hall.indd 33 20/04/2015 09:35

COMMERCIAL REFRIGERTION34


Starfrost.indd 34 20/04/2015 14:52

3535COMMERCIAL REFRIGERTION


Market leading food manufacturer Bakkavor has invested in a custom designed chilling system for pizza production from British equipment specialist Starfrost.

UK-based Starfrost supplies bespoke freezing and chilling systems for the worldwide food processing industry. The rm works alongside food manufacturers to develop the best IQF (Individual Quick Freeze) solution, ensuring maximum throughput, high e ciency and low energy costs.

Starfrost Chiller Fires up the Pizza

Bakkavor manufactures chilled own label food products and fresh prepared food for major supermarkets and foodservice operators in the UK. The company has recently invested in new equipment and facilities, principally its pizza operations and salad businesses, to meet changing customer demands.

CHILLING SPIRALStarfrost has supplied a bespoke spiral chilling system for pizza bases at Bakkavors processing facility in Harrow, Middlesex. The fully automated in-line chiller features Starfrosts innovative Frost Removal System (FRS) for extended run times between defrosts.

Starfrosts engineering team custom designed, built, installed and commissioned a Helix Spiral Chiller with a processing capacity of 6,400 pizza bases per hour (1,900 kg/hr). The Helix Spiral features a 32inch wide stainless steel conveyor belt around a single rotating stainless steel drum, with 32.5 spiraling tiers.

The bespoke Helix Spiral Chiller is designed to process 12-inch pizza bases, at a rate of over 100 per minute. The freshly baked

product enters the in-line chiller at a temperature of +95 degrees Celsius. Each individual pizza base is then chilled down to +3 degrees Celsius.

Starfrost Sales Director Robert Long says:

The innovative design of our Frost Removal System was key to securing the Bakkavor contract. The system enables Bakkavor to achieve signi cantly extended running times by maintaining evaporator e ciency, without the need to install complex and expensive sequentially defrosting evaporators.

He adds: Our Helix Spiral Chiller is custom

designed for maximum performance and reliability. The addition of our optional Frost Removal System reduces refrigeration costs and ensures increased productivity and pro t for the operator.

Starfrosts Helix Spiral is suitable for freezing and chilling food that requires medium to long retention times, such as ready meals, poultry, pizza, potato products, sh, desserts, bakery products and ice-cream. The system is available in site built and compact assembled format, with single drum, double drum and twin

belt designs. Available with a range of belt sizes and tier heights, it can process from 500kg/hr, to capacities over 6,000kg/hr.

The Helix Spiral Freezer/Chiller is designed with low maintenance, ease of hygiene and operational e ciency in mind. Its unique vertical or horizontal air circulation system ensures quick and even chilling or freezing without excessive air speeds that can damage delicate products, while still achieving long running times between defrosts.

Starfrosts Helix Spiral is a complete custom built solution, with system design and components selected to o er maximum performance and exibility. Starfrosts standard all-stainless steel equipment design includes framework, fully welded oor, evaporator and enclosure panels for ultimate hygiene. The Helix Spiral features a user-friendly touch screen HMI PLC control panel and optional CIP (Clean in Place) automated sanitising system.

Starfrost equipment is custom designed and built at its UK manufacturing facility near Lowestoft, Su olk.

www.starfrost.com

Starfrost.indd 35 20/04/2015 14:52

COMMERCIAL REFRIGERATION36May 2015

Will Hawkins, editor of the ACR Journal, caught up with James Cooper, product manager at ebm papst, to learn more about the background to its new AxiTop Di user.

The rst award you won in January was for the AxiTop Di user. To use the judges words, they said it is a clever product and it makes a marked di erence. They were impressed.

Essentially, a di user is not anything new. We are attempting to improve the e ciency of already e cient EC products, to take e ciency another notch up. Looking at the aerodynamics, one of the areas we wanted to focus on was the air leaving the impeller. What you nd is that as the air leaves the impeller there are losses

ENERGY EFFICIENCIES WITH A NEW DIFFUSER

The fans manufacturer, ebm papst, won two awards at the National ACR Awards in January 2015, namely the Refrigeration Product of the Year and the Company Environmental Champion.

inherent in the design as the air comes away.

It is not just air ow. There is noise too. The di user converts some of the unused, or the useless dynamic power, into static, usable energy. Therefore, it regains some of the lost energy that you get from your electricity supply to the actual air power that is doing the work.

The di user does that by slowing down the velocity of the air leaving. We can do other things like straightening the air slightly, which improves the throw. Overall system improvements can mean that you could improve an application perhaps because they were getting a bit of recirculation. By throwing the air further you can get that improvement.

As a straight improvement on the impeller, we are seeing up to 27%

improvement in energy saving for the same performance and the

same duty.However, actually we

can improve an impellers capability by a further 9% running at full speed purely by adding the AxiTop on, and so converting some of that energy.

LESS NOISE, MORE PERFORMANCE

There is another factor, which is the noise. With an

impeller, like an axial fan in

a condenser or a chiller, there is a guard over the top. You need that there for protection. But, inherent in that design is the creation of some noise as the air is leaving the impeller, because it is quite close to impeller on the arm.

An added bene t of the AxiTop is that by moving the guard further away within the structure, the AxiTop allows you to improve the noise conditions as well. You get a signi cant noise reduction, up to 7.2 dBa.

You can improve the way the air leaves the impeller to improve the ow. And, we can also reduce the noise. But, of course, by turning the fan speed down you get extra performance, which is also part of that noise reduction. It is partially the guard and partially the reduction in speed.

We have seen from trials and retro ts signi cant improvements on overall performance of a condenser or a piece of kit that is on a roof. That can range from anything from 15% to 51% depending upon the application and the speed of the fan because some of these installations are only doing part-load.

You wouldnt expect to get full energy saving. But, we have seen 51% improvements in some cases purely because the installation was a bad installation. That has helped to stop or improve recirculation.

Have you been surprised by the applications where the AxiTop is being used? Or, is it where you predicted?Pretty much going where we

HOW EBM PAPST HELPS TO MAKE

BIG


36_ebm.indd 36 17/04/2015 15:30

Iconic: Improve sales with the new face of frozen food display

Shoppers spend on average only 20 seconds in the frozen food aisles. We want to change that.

Iconics unique semi-vertical freezer improves space efficiency and increases product display area to maximise sales and revolutionise the supermarket freezer section.

Iconic from Viessmann is the rst semi-vertical freezer, designed to transform the freezer section into a exible, accessible space for retailers with an appealing marketplace feel for shoppers. With a focus on aesthetics and ergonomics, 50% more display volume has been created in same footprint as a traditional freezer island. A pilot scheme of Viessmann Iconic in a supermarket increased frozen food sales revenue 10% and pro t by 18%.

Viessmann Refrigeration Systems Limited FreePhone 0800-634 6555 www.viessmann-refrigeration.com/en

p37_acrmay15.indd 1 20/04/2015 11:21:00

COMMERCIAL REFRIGERATION38May 2015

expected. Typically, it is being used on the larger axial fans; we are looking at the 800 and 910 diameters. They are typically used on condensers, coolers and chillers, the refrigeration-type applications.

Thats where they are being used, but there is no reason why they cant be used on any other type of industrial application where this a requirement to improve e ciency. As long as it is on an impeller that is used in the way that the AxiTop needs to be used.

Sometimes products can take a while to be understood by customers and then be purchased. Are your customers quickly adopting it? They are. As you say, initially people want to see it in action, see what it can do, take samples and go through processes. But, I would say that most of the OEMs we supply to now have tested and are purchasing AxiTop for their equipment.

At ChillVenta at the end of last year, it was clear to see that a lot of

the manufacturers, not just the UK manufacturers, were using AxiTop and were using it maybe as an option, but it was there on their portfolio as this extra capability. And, they were selling it alongside the energy efficiency EC technology.

So, yes, it has been adopted and people are using it and seeing the bene ts of it in varying degrees. And even on retro t upgrades installations it has been seen as a positive. There have big roll outs on various sites where they are adding this onto an existing EC impeller. It is already a fairly new piece of kit but then they are looking to adopt even further bene ts and savings.

Have you had to use any di erent type of materials to make it? Or, does it purely come down to materials you have been using for a while, but using a di erent way to design it?Its the same materials we use on some of our impeller designs. We are always looking for new way of doing things, including moulding and shaping. It allows us to get the design and the shape more intricate than maybe metal one.

Our R&D team spends a lot of time designing new products on computers and can iron out many of the wrinkles in a product before making it. We also have our test labs where we can combine air ow and noise testing in one chamber. We listen to the tones and frequencies while it is being tested.

ADDITIVE MANUFACTURING3D printing is a big thing with a lot of manufacturers now. We do a lot of prototyping on 3D printers. It is a quicker way to try an idea and try things out. We have 3D printing capabilities for all our works, plastics and designs.

It costs more to produce but you can quickly come up with something and test it. Even though it may be more fragile than

a nished tooled product, it still allows you to test it and prove the aerodynamics and acoustics before you really start putting the money into proper tooling.

With the e ciencies you can gain, I imagine you can get some pretty good paybacks with the AxiTop di user?You can. From the e ciency point of view, you can help them do the necessary calculations with onsite measurements, depending on the installation. If you are looking at the total system saving, it is not necessarily the energy saved on the fan. That might be quite a small part of the overall system.

Think of chiller, for instance. If you have a free cooling coil on a chiller, which some of our OEMs have, and you can produce another 9% more air ow than you did previously for the same size of impeller, the same size of equipment, then it means that the system can run better. You can free cool a bit longer, be activated a degree or so earlier, in which case the compressors are not needed as much.

KNOCK-ON BENEFITSTherefore, the saving you get on those would be far outweigh the energy di erence on the fan. Although it is a signi cant saving on the fan, switching the compressor o is even better.

The knock-on system e ect of the AxiTop Di user is important. Although we can talk about the capabilities of what we can save on the fan, sometimes it is the system saving that is the bigger pull.

We might be talking a few kilowatts of savings with the fan. But, if you are switching compressors o , you might be saving huge amounts of energy. Even if they are just switched o for an extra month per year. Or a few a year. It is signi cant over the course of a year on running a big chiller plant or several chillers.

AxiTop Di user with FlowGrid


36_ebm.indd 38 22/04/2015 17:14

p39_acrmay15.indd 1 20/04/2015 10:44:06

Controlling condensation control with high performance insulation

Here, Michaela Strkmann, Armacell Technical Department Manager EMEA (Europe, Middle East & Africa), discusses how a better understanding of condensation and advances in insulation performance are leading to improved speci cations.

The single greatest issue with refrigeration and air-conditioning pipe and ductwork is that surface condensation often occurs. This condensation not only accelerates the rate of pipe corrosion but can severely impact on the health of building occupants because it results

When insulation is correctly specified it can prevent condensation forming on refrigeration pipe work systems.

in mould growth. Insulation used on refrigeration and air-conditioning pipe and ductwork must therefore prevent condensation if it is to extend the working life of pipework. Aside from this, the role of the insulation is to maximise energy e ciency of the system.

Correct installation is important, too. If air, which always contains moisture in a gaseous state, can get to the coolant pipe, then condensation will still form. So, to avoid issues with condensation it is important that the right type of insulation is speci ed and that it is installed without air gaps.

HOT AND COLDWhilst hot installations (heating and hot-water pipes) are predominantly insulated to save energy, cold systems (such as the chilled-water pipes of air-conditioning systems or the suction lines of

ACR Journal - May 2015

Documents

Transcript of ACR Journal - May 2015