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Guidance on Impact of the Fluorinated Gas Regulation for Users of Stationary Refrigeration, Air-conditioning and Heat Pump Prepared for DTI / Defra by Enviros Consulting Ltd Version 1.1 January 2007
INTRODUCTORY HELP
This "Refrigerant Charge Calculator" spreadsheet has been prepared to help estimate the amount of refrigerant in a refrigeration or air-conditioning plant. This information is required to confirm compliance with the new EU F-Gas Regulation. The spreadsheet accompanies Defra Guidance on the F-Gas Regulation. The following documents provide detailed information about the Regulation: a) Defra Guidance: EC Regulation No 842/2006 on certain fluorinated greenhouse gases available from http://www.defra.gov.uk/environment/climatechange/uk/fgas/index.htm b) Supplementary Guidance for Refrigeration, Air-conditioning and Heat Pump Users available from www.website_address The best way to establish the amount of refrigerant in the system is to use data supplied by the manufacturer: Many refrigeration systems, especially small ones, have a Name Plate showing the amount of refrigerant. Alternatively, you may have a record of the amount of refrigerant in the documentation supplied when the system was install ed or commissioned. If you cannot find information of this kind you could refer to 5 simple rules of thumb to estimate refrigerant charge. These are outlined in the Supplementary Guidance referred to above.
This spreadsheet provides a way of obtaining a reasonable estimate of the amount of refrigerant in a plant. This can only be done if you provide certain essential
This spreadsheet provides a way of obtaining a reasonable estimate of the amount of refrigerant in a plant. This can only be done if you provide certain essential information about each plant. It is recommended that you collect the data before you start completing the spreadsheet (although you can save your data part way through data entry and continue later if you prefer).
The spreadsheet has been set up to store data for up to 4 different refrigeration systems. If you need to investigate more than 4 systems you could simply save the spreadsheet with a different name and start again. There is a Clear All Data button on the Data Entry Tab that allows you to start again with an empty spreadsheet.
To navigate through this spreadsheet you can either press the grey buttons to jump to the page you want, or click on the spreadsheet tabs at the bottom of the screen e.g. "Data_entry", in order to move to a different page.
COMMENT ON ACCURACY
It should be noted that this spreadsheet only provides an approximate estimate of the amount of refrigerant in a system. To estimate the amount of refrigerant in the evaporator and condenser the calculations use representative average data for each type of heat exchanger. However, the ac tual heat exchangers used in your systems may contain a greater or smaller amount of refrigerant. Also, to keep the data entry simple we have assumed a fairly simple configuration of system. The spreadsheet is intended as a screening tool to assess the size thresholds in the F-Gas Regulation. If you need an accurate assessment of refrigerant charge this spreadsheet is not suitable you will need to have the system appraised by a suitable expert.
CALCULATION METHOD
Press the button below for details on how this spreadsheet calculatres system charge.
Rule 1: Small hermetic systems fitted with a domestic 240 Volt 13 Amp plug will be well below the 6 kg limit. This is a very important rule as it applies to millions of small systems. All domestic refrigerators and freezers fall into this category. So do many systems used in small shops (e.g. ice cream display cabinets, bottle coolers, small chilled or frozen food cabinets etc,) in pubs / restaurants (e.g. in -line drink coolers, ice makers etc.), in offices (e.g. vending machines) and in other types of building.
Rule 2: Most split systems will be above the 3 kg limit. A split system is one with at least 2 major components located in different locations, connected by refrigerant pipework that is fitted by an installation contractor. For example, an air-conditioning system with a cooling unit inside a room and a condensing unit
Rule 2: Most split systems will be above the 3 kg limit. A split system is one with at least 2 major components located in different locations, connected by refrigerant pipework that is fitted by an installation contractor. For example, an air-conditioning system with a cooling unit inside a room and a condensing unit (consisting of various components including a compressor and a condenser) that is located remotely, usually outside the building. The components are interconnected by 2 refrigerant pipes, often made of copper. One or both of the pipes will be covered in insulation. Split systems are used for many refrigeration applications (e.g. cold stores, larger retail systems for supermarkets and large shops, industrial applications and air-conditioning in many types of building). The majority of split systems will use at least 3 kg of refrigerant. Exceptions to Rule 2: Very small split systems that are close coupled e.g. an air -conditioning system serving a small room where the indoor and outdoor units are less than 5 metres apart could be below 3 kg. If a small split system is operated via a 240 Volt 13 Amp plug (see Rule 1), then it is more likely that the system has less than 3 kg but only if the units are close coupled. Rule 3: Most air-conditioning water chillers will be above the 3 kg limit. Water chillers for air-conditioning are usually factory built units where the components are located together in a fairly compact layout. They usually provide quite a large cooling duty and will be well over the 3 kg limit. Exceptions to Rule 3: Very small water chillers, e.g. with a cooling duty below 15 kW might be below the 3 kg limit. Also, small units could be hermetically sealed, in which case the 6 kg threshold applies a hermetically sealed water chiller providing less than 30 kW cooling might be below the 6 kg limit. Rule 4: A crude approximation is that the compressor motor kW equals the kg of refrigerant. For example, a system with a 5 kW compressor motor might contain about 5 kg. This is only an approximation the actual refrigerant charge depends on many different factors. However, it can be a useful screening test e.g. a system with a 1 kW compressor motor is less likely to be above the 3 kg limit. Rule 5: Any system with a liquid storage vessel will contain more than 3 kg. Some systems are fitted with a high pressure liquid receiver which is located under the condenser. They are usually quite large vessels containing well over 3 kg. Other types of storage vessel are also used in other locations e.g. an evaporator surge drum or an intercooler for a 2-stage plant. Again these will contain well over 3 kg.
Simply enter Yes or No. If you say Yes, a new question will appear asking for the cooling duty in kW. If you say No, a new question will appear asking for the compressor power in kW. Please state the kW cooling duty of the system Enter the design cooling load of the system, in kW If cooling duty is not available, you will be prompted enter compressor motor power in kW Enter the total compressor motor power of the system, in kW. If there is more than one compressor please ensure you enter the value of all the motor powers summed together. Please note that the results from this spreadsheet will be inaccurate for 2 stage systems. Type of evaporator (choose from drop down list) You must select 1 of 3 evaporator types: (1) Finned air cooler this type of evaporator is used for the majority of air cooling applications. (2) Shell and Tube liquid cooler this type of heat exchanger is common for water chillers and other types of liquid cooler. Please note, if you select this option you will be asked an extra question about the type of shell and tube cooler. (3) Plate Liquid Cooler this is a modern type of heat exchanger sometimes used for water chilling or for cooling other liquids. Type of shell and tube cooler (choose from list) You must select 1 of 2 shell and tube cooler types: (1) DX shell & tube the refrigerant flows through the tubes of the heat exchanger and the liquid being cooled flows through the shell. (2) Flooded shell & tube the liquid being cooled flows through the tubes of the heat exchanger and the refrigerant evaporates in the shell. Type of condenser (choose from drop down list) You must select 1 of 4 condenser types: (1) Air Cooled Condenser this type of condenser is common for small and medium sized systems. Air is blown over a finned coil to reject heat from the condensing refrigerant in the tubes of the condenser. (2) Water Cooled Shell and Tube Condenser this type of condenser is common for large systems. Refrigerant condenses in the shell of the heat exchanger, being cooled by water flowing through the tubes. (3) Water Cooled Plate Condenser this is a modern type of condenser in which refrigerant condenses inside a plate heat exchanger cooled by water. (4) Evaporative Condenser this type of condenser is common for large systems. Refrigerant condenses in steel coil, being cooled by water sprayed the coil which is being cooled by a blast of air. Type of compressor (choose from drop down list) Please select which type of compressors are used in this system. Is this a hermetically sealed system A hermetically sealed system is usually a small factory built unit with a hermetically sealed compressor and all welded or brazed connections. A common example of a hermetically sealed system is a domestic refrigerator. The exact definition used in the Regulation is: a system in which all refrigerant containing parts are made tight by welding , brazing or a similar permanent connection which may include capped valves and capped service ports that allow proper repair or disposal and which have a tested leakage rate of less than 3 grams per year under a pressure of at least a quarter of the maximum allowable pressure. Liquid line dimensions: diameter (mm / inches) The liquid line is the pipe that transfers liquid refrigerant from the condenser to the expansion valve. You should measure the outside diameter of this pipe and select the value from a drop down list that shows standard sizes in both mm and inches. On small plants the liquid line usually will be between 10mm and 20mm in diameter. For larger plants the liquid line could be up to 50mm in diameter. Liquid line dimensions: length (m) You must also estimate the length of the liquid line from the condenser to the expansion valve. A good approximation will be sufficient. The length must be entered in metres. Do you have a high pressure liquid receiver? A high pressure liquid receiver is a cylindrical vessel located beneath the condenser that is partially filled with liquid refrigerant.
HP liquid receiver (a cylindrical vessel): vessel diameter (mm) Enter the approximate diameter of the liquid receiver in mm. HP liquid receiver (a cylindrical vessel): length (mm) Enter the approximate length of the liquid receiver in mm.
HP liquid receiver (a cylindrical vessel): orientation (horizontal or vertical)
HP liquid receiver (a cylindrical vessel): orientation (horizontal or vertical) All liquid receivers are cylindrical in shape. Most are oriented horizontally i.e. the cylinders long axis is horizontal. Some liquid receivers are oriented vertically.
Do you know the depth of liquid in the liquid receiver? If you know the depth please state Yes and you will be prompted for a value. If you do not know the depth we will use a default value of 30%. If known, enter the approximate depth of liquid refrigerant in mm Please measure the depth of liquid from the bottom of the vessel. Enter the value in mm. Do you have a low pressure receiver or surge drum? A low pressure receiver or surge drum is a cylindrical vessel located after the expansion valve on certain types of flooded system (e.g. in large industrial plants such as cold stores or blast freezers). It is partially filled with liquid refrigerant. NB Questions listed above for the HP receiver on vessel dimensions and orientation are also repeated of the LP receiver.
CALCULATION METHODOLOGY
This spreadsheet tool splits a refrigeration system into a number of component parts and then calculates the quantity of refrigerant in each part. These parts are as follows: Liquid line. The user is prompted for actual data for the diameter and length of the liquid line. The density of the liquid refrigerant a t a default condensing temperature of 30oC is looked up in a data table. The liquid line volume is calculated from the input data and then the mass of liquid is estimated using the density value. High pressure liquid receiver. The user is prompted for actual data for the diameter and length of the liquid receiver and the orientation of the vessel (it is assumed the vessel is a cylinder, either in a horizontal or vertical configuration). The density of the liquid refrigerant a t a default condensing temperature of 30oC is looked up in a data table. The receiver vessel volume is calculated from the input data. The user has an option of enteri ng a liquid depth. This is used to calculate the volume of liquid in the vessel and then the mass of liquid is estimated using the density value. If the depth is not known we use a default depth of 30% of the height of the vessel.
Low pressure receiver. The calculations are similar to those for the high pressure receiver, except that the density is based on a user entered cool ing temperature level.
Evaporator. The user selects which type of evaporator is used. For each type of evaporator we use a refrigerant coefficient expressed in kg of refrigerant per kW of heat exchanger duty. High and low values of each coefficient have been estimated - these represent the typical design variations that exist for each heat exchanger type. The values used are as follows (low / high values):
kW of heat exchanger duty. High and low values of each coefficient have been estimated - these represent the typical design variations that exist for each heat exchanger type. The values used are as follows (low / high values): Finned Air cooler 0.2 to 0.35 kg/kW DX shell and tube 0.15 to 0.25 kg/kW Flooded shell and tube 0.4 to 0.7 kg/kW Plate liquid cooler 0.3 to 0.5 kg/kW The user is able to enter either a cooling duty or, alternatively, the compressor power. If the cooling duty is entered this is used directly in the calculation. If the compressor power is entered then we estimate the COP of the system based upon the user entered cooling temperature. A Carnot COP based on a condensing temperature of 35oC and evaporating temperature 10oC lower than the cooling temperature is calculated and then a Carnot Ratio of 60% is applied. Condenser. The user selects which type of condenser is used. For each type of condenser we use a refrigerant coefficient expressed in kg of refrigerant per kW of heat exchanger duty. High and low values of each coefficient have been estimated - these represent the typical design variations that exist for each heat exchanger type. The values used are as follows (low / high values): Air cooled 0.1 to 0.17 kg/kW Water cooled shell and tube 0.15 to 0.25 kg/kW Water cooled plate 0.15 to 0.25 kg/kW Evaporative 0.2 to 0.35 kg/kW The condenser duty is the evaporator duty plus the compressor power (calculated using the estimated COP as described above). Compressor. The user selects which type of compressor is used. For each type of compressor we use a refrigerant coefficient expressed in kg of refrigerant per kW of compressor power. The values used are as follows: Scroll 0.02 kg/kW Reciprocating 0.05 kg/kW Screw 0.075 kg/kW Centrifugal 0.01 kg/kW The compressor power is the user entered value or is calculated using the estimated COP as described above.
REFRIGERANT CHARGE CALCULATOR RESULTS Note - a high and a low refrigerant estimate is calculated for each system Table 1: Charge Calculations
Amount of refrigerant in system (kg) Refrigerant split (kg) TOTAL (kg) System charge high & low HCFC estimate HFC charge charge Other #VALUE! #VALUE! #VALUE! #VALUE! #VALUE! #VALUE! #VALUE! #VALUE! #VALUE! #VALUE! #VALUE! #VALUE! #VALUE! #VALUE! #VALUE! #VALUE! #VALUE! #VALUE! #VALUE! #VALUE! #VALUE! #VALUE! #VALUE! #VALUE! #VALUE! #VALUE! #VALUE! #VALUE! #VALUE! #VALUE! #VALUE! #VALUE!
Hermetic
System number System 1 high estimate System 1 low estimate System 2 high estimate System 2 low estimate System 3 high estimate System 3 low estimate System 4 high estimate System 4 low estimate
System Name 0 0 0 0 0 0 0 0
Liquid line #N/A #N/A #N/A #N/A #N/A #N/A #N/A #N/A
Hermetically sealed? Hermetically sealed? Hermetically sealed? Hermetically sealed? Hermetically sealed? Hermetically sealed? Hermetically sealed? Hermetically sealed?
Note - status is given seperately for the high and low estimate for each system
#VALUE!
Select refrigerant
#N/A
#VALUE!
#VALUE!
Select refrigerant
#N/A
#VALUE!
#VALUE!
Select refrigerant
#N/A
#VALUE!
#VALUE!
Select refrigerant
#N/A
#VALUE!
#VALUE!
Select refrigerant
#N/A
#VALUE!
#VALUE!
Select refrigerant
#N/A
#VALUE!
#VALUE!
Select refrigerant
#N/A
#VALUE!
#VALUE!
REFRIGERANT CHARGE CALCULATOR EU F-Gas Regulation - Summary Guidance for Refrigeration Systems
The Guidance below is a brief summary of key aspects of the F-Gas Regulation. For more detailed advice refer to: a) Defra Guidance: EC Regulation No 842/2006 on certain fluorinated greenhouse gases available from http://www.defra.gov.uk/environment/climatechange/uk/fgas/index.htm b) Supplementary Guidance for Refrigeration, Air-conditioning and Heat Pump Users available from www.dti.gov.uk/files/file37001.pdf
REFRIGERANT CHARGE CALCULATOR EU Ozone Regulation - Summary Guidance for Refrigeration Systems
The Guidance below is a brief summary of key aspects of the Ozone Regulation. For more detailed advice refer to: a) Guidance on new EC Regulation No 2037/2000 on substances that deplete the ozone layer available from http://www.dti.gov.uk/innovation/sustainability/ods/page29091.html b) Refrigeration and air conditioning: CFC and HCFC phase out - advice on alternatives and guidelines - also available from the same DTI website