# Presentation: 588895

## R-22 Breakout

- HCFC Phaseout
- Keilly Witman, US EPA
- HCFC Replacement Refrigerants
- Nick Strickland, DuPont
- Retrofit Procedures
- Dave Demma, Sporlan
- Retailer Experiences
- Richard Royal, Wal-Mart

## HCFC Phaseout

- Montreal Protocol
- HCFC Phaseout Schedule & Milestones
- Servicing Existing Equipment after 2010
- Options during the Transition Period
- GreenChill Retrofit Guidelines

## Montreal Protocol

- Treaty to reduce production of Ozone Depleting Substances such as CFCs & HCFCs
- HCFC Phaseout Milestone 2010
- Goals are to restore ozone layer, prevent harmful effects of ultraviolet radiation overexposure
- Outstanding environmental and health benefits
- 6.3 million U.S. skin cancer deaths prevented by 2165

## HCFC Phaseout Schedule

## Milestones for HCFC Phaseout

## HCFC-22 Supply and Demand

- 0

- 10,000

- 20,000

- 30,000

- 40,000

- 50,000

- 60,000

- 70,000

- 80,000

- 90,000

- 100,000

- 2010

**HCFC-22 (MT)**

- Anticipated R-22 Supply from Recovered R-22

- Virgin R-22 Needed to Satisfy Service Demand

- Total R-22 Service Demand

- 90%  of U.S. HCFC Consumption Cap

- U.S. HCFC Consumption Cap

- 2015

- 2020

- Source: EPA's Vintaging Model (VM IO file_2007_11-12-07)

## Estimated R-22 Supply and Demand

- *Metric tons of R-22

## Servicing Existing HCFC-22 Equipment after 2010

- In 2015, HCFC-22 needs will exceed the 2015 cap by more than 10,000 metric tons
- Recovery and reuse needed to provide room under the cap and meet demand for all HCFCs
- What can you do?
- Improve service practices (recover, recycle, reclaim)
- Fix leaks
- Retrofit/Replace where economical

## Servicing Existing HCFC-22 Equipment after 2010

- You will not have to stop using HCFC-22
- You will not have to replace existing equipment
- Existing equipment using HCFC-22 can be serviced as usual
- After 2010, supplies of HCFC-22 will be more limited
- After 2020, only stockpiled or reclaimed supplies will be available to service equipment

**Notes:**
As of January 21, 2003 imports of HCFC-22, HCFC-141b, and HCFC-142b are restricted to holders of consumption allowances.  Similarly, imports of all used HCFCs are restricted to those who have obtained EPA approval prior to the shipments export from the country of origin. 

As of January 1, 2015, as part of the phaseout of all HCFCs, the sale and use of HCFC-22 and HCFC-142b will be banned except for transformation or servicing refrigeration and air-conditioning applications.  EPA will not permit newly manufactured HCFC-22, HCFC-142b, or blends containing either substance, to be used for charging new equipment 

These rules apply also to blends containing HCFC-22 or HCFC-142b.

## During the Transition Period

- Businesses have three options:
- Convert existing system to alternative refrigerant
- Buy a new system that uses an alternative refrigerant
- Continue to operate existing system
- Establish a plan to replace/repair leaking equipment
- Recover and reuse refrigerant from equipment that is discarded
- Begin to transition to alternative refrigerants
- Many businesses have started to switch
- Consider amount of time needed to convert

**Notes:**
This slide is most appropriate for businesses.

## Retrofits = most widespread strategy to prepare for HCFC-22 phaseout in existing stores
Opportunity to tighten up the system! 

- Opportunity to tighten up the system!

- GreenChill’s Retrofit Best Practice Guidelines

## GreenChill’s Retrofit Best Practice Guidelines

- Mission & Purpose/ Scope of the Guideline
- The HCFC Situation– Why Retrofit?
- Ozone Layer Protection and the Montreal Protocol
- Montreal Protocol Implementation in the United States
- HCFC-22 Supply and Demand

## GreenChill’s Retrofit Guidelines - Contents

- HFC Refrigerant Retrofits
- HFC Retrofit Options
- HFC Refrigerant only Retrofit
- Retrofitting with New Mechanicals and HFC Refrigerant
- Leak Tightness Improvements during Retrofits
- Factors to consider when assessing retrofit options
- Value/Cost Calculation
- Lab Tests on Retrofit Refrigerants vs. HCFC-22

## GreenChill’s Retrofit Guidelines - Contents

- Best Practices for Transitioning to HFC Substitute Chemicals
- Conversion Guidelines for HFC Substitute Chemicals
- Best Practice Checklist for Conversion to HFC Substitute Chemicals

## GreenChill Retrofit Guidelines - Contents

- Best Practices - HCFC-22 End of Life
- End of Life Options for Refrigerants
- Best Practices – Recovery, Reclamation
- Safety Information
- Case Studies for R-422D, R407A, and 427A Retrofits
- Conversion Checklists for Specific HFC Substitute Chemicals

## HCFC Replacement Refrigerants

- The Business Case
- HCFC-22 is going away
- HCFC-22 price volatility likely
- Plan for a smooth and orderly transition
- Concentrate on the lowest cost solution
- Refrigerant retrofits deliver value...
- By extending the life of existing corporate assets
- R22 is a valuable corporate asset
- Use R22 to servicing other stores
- Avoid heavy machine room investments
- Free up cash for the highest ROI business investments

## HCFC Replacement Refrigerants

## HCFC-22 Producer Price

## HCFC-22 Replacement Refrigerants Availability

- Future product availability is a function of
- Product Acceptance
- Producer commitment to manufacturing and selling
- Distribution network to service retail locations

## HCFC Replacement Refrigerants

## Retrofit Procedures

- Things To Consider
-  Refrigerant & Oil
-  Compressor Capacity
-  Expansion Valve Sizing
-  Distributor Nozzle Sizing
-  EPR Valve Sizing
-  Pipe Sizing/Pressure Drop
- Control Set-Points
-  Seal/Gasket Replacement

## Retrofit Procedures

**R-22**

**R-502**

**R-404A**

**R-507**

**R-434A**

**R-427A**

**R-422D**

**R-417A**

**R-407C**

**R-407A**

**choices**

**R-422B**

**R-422A**

## Retrofit Procedures

**R-22**

**R-502**

**R-404A**

**R-507**

**R-434A**

**R-427A**

**R-422D**

**R-417A**

**R-407C**

**R-407A**

**R-422B**

**R-422A**

- _THE REAL CHOICE_
-  	Weighing The Extra Expense Of Changing Components and/or Oil
- VS.
- System Efficiency and Power Consumption After The Conversion

## Retrofit Procedures

| Refrigerant | Oil | Comments |
| --- | --- | --- |
|  |  |  |
| R-417A | Mineral Oil/AlkylBenzene |            
                  May require adding 
                     5% - 10% POE to                  
                     assist with oil  return |
| R-422A | Mineral Oil/AlkylBenzene |  |
| R-422B | Mineral Oil/AlkylBenzene |  |
| R-422D | Mineral Oil/AlkylBenzene |  |
| R-434A | Mineral Oil/AlkylBenzene |  |
|  |  |  |
| R-427A | Polyol Ester (POE) | Can tolerate up to 15% MO/AB |
|  |  |  |
| R-404A | Polyol Ester (POE) | Less than 5% MO |
| R-407C | Polyol Ester (POE) | Less than 5% MO |
| R-507 | Polyol Ester (POE) | Less than 5% MO |
|  |  |  |

## Retrofit ProceduresTheoretical Compressor Capacities  As Compared to R-22

- Retrofit ProceduresTheoretical Compressor Capacities  **As Compared to R-22**

|  | R-22 | R-417A | R-422A | R-422D | R-404A | R-507 |
| --- | --- | --- | --- | --- | --- | --- |
| 105oF Condensing Temperature                     +20oF Evap Temperature        50o Liquid Temperature | 100% | 82.6% | 97% | 85%
 | 108% | 108% |
|  |  |  |  |  |  |  |
| 105oF Condensing Temperature                     -25oF Evap Temperature          50o Liquid Temperature | 100% | 86% | 106% | 90%
 | 117% | 117% |
|  |  |  |  |  |  |  |

## Retrofit Procedures

- Distributor Capacity Based On:
**	**
- Thermodynamic Properties of the Refrigerant
- Feeder Tube Diameter, Nozzle Diameter
- System Conditions
- Evaporator Temperature
- Liquid Refrigerant Temperature

## Retrofit Procedures

- R-22 Distributor Feeder Tubes & Nozzle Selections.
- Selected Before TEV (ΔP will affect TEV Capacity).
**REFRIGERANT DISTRIBUTOR SELECTION DATA**
**              ****Refrigerant R- 22                    Number of Circuits:   4**
**      **
**   ****Evaporator Temperature (°F): -20             Dist Tube Length (in):  30   **
**   **
**       ****Liquid Temperature (°F):  50      Evaporator Capacity (Btu/hr): 16000    **
**    ****Tube OD   Tube DP  Percent  Nozzle Orifice  Nozzle DP  Percent  Total DP **
**   **
**      ****(in)     (psi)   Loading      Number        (psi)    Loading    (psi)     **
**   ****3/16      1****3****     ****  **** 1****24****         ****       **** 1           ****   ****  2****7****       10****9****       ****   **** ****40**** **

## Retrofit Procedures

**Distributor Tube/Nozzle Capacities for Alternative Refrigerants using existing R-22 Selections **

| 18,000 Btu Evaporator                     -20oF Evap Temperature  50o Liquid Temperature | R-22
 | R-407C | R-422A | R-422D | R-404A | R-507 |
| --- | --- | --- | --- | --- | --- | --- |
| Feeder Tube ODF | 3/16” | 3/16” | 3/16” | 3/16” | 3/16” | 3/16” |
| Feeder Tube ΔP | 13 psi | 17 psi | 23 psi | 22 psi | 19 psi                                   | 20 psi |
| Feeder Tube % Loading | 124% | 152% | 200% | 197% | 170% | 171% |
| Nozzle Size | #1 | #1 | #1 | #1 | #1 | #1 |
| Nozzle ΔP | 27 psi | 34 psi | 42 psi | 37 psi | 38 psi | 39 psi |
| Nozzle % Loading | 109% | 134% | 168% | 152% | 151% | 154% |
| Total Distributor ΔP | 40 psi | 51 psi | 65 psi | 59 psi | 57 psi | 59 psi                        |
| Replace Nozzle | ------- | No | Yes   #2 | Yes   #2 | Yes   #2 | Yes   #2 |

## Retrofit Procedures

**	****	****TEV Capacity Based On:**
**	**
**Thermodynamic Properties of the Refrigerant**
**TEV Pin, Port, and Stroke Dimensions**
**System Conditions**
**Evaporator Temperature**
**Liquid Refrigerant Temperature**
**Pressure Drop Across TEV Port****	****	****	**

## Retrofit Procedures

- R-22 TEV Selection For Summer/Winter   Conditions (ΔP from Distributor Selection Used).
-  **THERMOSTATIC EXPANSION VALVE SELECTION DATA                   **
**                      **
**              ****Refrigerant R- 22               Liquid Temperature (°F):  50      **
**   ****Evaporator Temperature (°F): -20       Dist & High Side Loss (psi):  41**
**      **
**    ****Condenser Temperature (°F): 115  ****(70)    ****Evaporator Capacity (Btu/hr): 16000    **
**  ****Subcooling at TEV inlet (°F):  64   ****(18)            ****DP Across TEV (psi): 187 ****(66)**
**     **
**                  ****Suggested Thermostatic Charge: VZ or VZP40                    **
**                          ****Valve           Percentage of                         **
**                       ****Description       Rated Capacity                         **
**                         ****EGVE-2                  59** **(99)**

## Retrofit Procedures

- TEV Capacities For Alternative
- Refrigerants Using R-22 Selections

| 18,000 Btu Evaporator                     -20oF Evap Temperature           50o Liquid Temperature | R-22 | R-407A | R-422A | R-422D | R-404A | R-507 |
| --- | --- | --- | --- | --- | --- | --- |
| TEV Selection (using R-22 Distributor Tubes/Nozzle) | EGVE  2 | EGVE  2 | EGSE 1-1/2 | EGVE    2 | EGSE 1-1/2 | EGPE  1-1/2 |
| Thermostatic Element Change Required ? | ______ | No |  Yes
SZ/SZP | No | Yes | Yes   SZ/SZP |
| Nominal TEV Capacity After Element Replacement | ______ | 2     Ton | 1-1/2 Ton | 2           Ton | 1-1/2    Ton | 1-1/2   Ton |
| % Rated Capacity at 115oF Condensing  | 59% | 58% | 74% | 84% | 65% | 66% |
| % Rated Capacity at 70oF Condensing  | 99% | 97% | 131% | 149% | 113% | 115% |
| Valve Replacement Required? | ______ | No | Yes
EGSE-2 | Yes 
EGVE-3 | Possible EGSE-2 | Possible EGSE-2 |

## Retrofit Procedures

| 
Refrigerant | Liquid Temperature Entering TEV (oF) |  |  |  |  |  |  |  |  |  |  |  |
| --- | --- | --- | --- | --- | --- | --- | --- | --- | --- | --- | --- | --- |
|  | 0o | 10o | 20o | 30o | 40o | 50o | 60o | 70o | 80o | 90o | 100o | 110o |
|  | Correction Factor, CF Liquid Temperature |  |  |  |  |  |  |  |  |  |  |  |
| R-22 | 1.56 | 1.51 | 1.45 | 1.40 | 1.34 | 1.29 | 1.23 | 1.17 | 1.12 | 1.06 | 1.00 | 0.94 |
| R-407A | 1.75 | 1.68 | 1.61 | 1.53 | 1.46 | 1.39 | 1.31 | 1.24 | 1.16 | 1.08 | 1.00 | 0.92 |
| R-404A | 2.04 | 1.94 | 1.84 | 1.74 | 1.64 | 1.54 | 1.43 | 1.33 | 1.22 | 1.11 | 1.00 | 0.89 |
| R-507 | 1.99 | 1.89 | 1.79 | 1.69 | 1.59 | 1.50 | 1.40 | 1.30 | 1.20 | 1.10 | 1.00 | 0.89 |

- An Alternative To Replacing TEVs
- Lower Liquid Temperatures Yield Increased TEV Capacity:

## Retrofit Procedures

- EPR Capacity Based On:
- Evaporator Temperature
- Suction Vapor Temperature
- ΔP Across Valve Port (Difference between EPR Set-Point and Common Suction Pressure – *for the circuit with the lowest design temperature this should be kept to a minimum).*

## Retrofit Procedures

- 		R-22 EPR Selection:
-  **EVAPORATOR PRESSURE REGULATOR SELECTION DATA **
**   **
**Refrigerant R- 22               Liquid Temperature (°F):  50  **
**    **
**      ****Common Suction Temp (°F): -2****1.5****           Suction Vapor Temp (°F):  50  **
**    **
**        ****EPR Valve Setting (°F): -20      Evaporator Capacity (Btu/hr): 18000    **
**Pressure Drop Available Across Valve (psi): 0.86  **
**	**
**	****	****	****Valve****	****            Valve ****	****  Req’d Pressure****	****Percentage of****               **
**	****	****	****Description        Type               Drop (psi)             Rated Capacity**
**              **
**	****	****	****(S)ORIT-12          Piloted          0.82 psi                      98%                       **
** ****	****	****	****0/100                   Externally**

## Retrofit Procedures

- An Undersized EPR Requires A Lower Suction Pressure
- To Maintain Fixture Design Temperature

| 18,000 Btu Evaporator                     -20oF Evap Temperature
-21.5oF Common Suction      50oF Liquid Temperature
50oF Return Vapor Temperature | R-22 | R-407A | R-422A | R-422D | R-404A | R-507 |
| --- | --- | --- | --- | --- | --- | --- |
| EPR Valve | (S)ORIT-12 | (S)ORIT-12 | (S)ORIT-12 | (S)ORIT-12 | (S)ORIT-12 | (S)ORIT-12 |
| Required Pressure Drop | .82 psi | 1.0 psi | 1.3 psi | 1.4 psi | 1.0 psi | 1.0 psi |
| Available Pressure Drop | .86 psi | ,82 psi | 1.0 psi | .83 psi | 1.0 psi | 1.1 psi |
| % of Rated Capacity | 98% | 108% | 113% | 130% | 100% | 100% |
| Use Existing Valve 
Lower Suction Pressure | 
--------- | Yes | Yes | Yes | 
--------- | 
--------- |
| Replace Valve | --------- | Yes | Yes | Yes | --------- | --------- |
| New Selection | --------- | (S)ORIT-15 | (S)ORIT-15 | (S)ORIT-15 | --------- | --------- |

## Retrofit Procedures

- Setting Changes:

| 18,000 Btu Evaporator                                -20oF Evap Temperature                          50o Liquid Temperature | R-22 | R-407A | R-422A | R-422D | R-404A | R-507 |
| --- | --- | --- | --- | --- | --- | --- |
| EPR Setting: -20oF | 10.2 psi | 8.5 psi | 14.5 psi | 8.1 psi | 16 psi | 17.6 psi |
| Subcooler EPR Setting: 40oF | 68.5 psi | 69.4 psi | 83.5 psi | 66.4 psi | 85.4 psi | 89.2 psi |
| Condenser Holdback Valve: Pressure Equivalent to 70oF | 121.4 psi | 148.8 psi | 152 psi | 132.5 psi | 149.3 psi | 153 psi |
| Receiver Bypass Valve: 20 psi Less Than Condenser Holdback Valve | 101.4 psi | 128.8 psi | 132 psi | 112.5 psi | 129.3 psi | 133 psi |
| Common Suction Header         Target Pressure (-21.5oF) | 9.4 psi | 7.6 psi | 13.6 psi | 7.3 psi | 16.5 psi | 15 psi |
| Condenser Fan Cycling Pressure Controls, Alarm Set-Points,   | Check With Equipment Manufacturer For Recommendations |  |  |  |  |  |
|  Safety Relief Valves | Check With Equipment Manufacturer For Recommendations |  |  |  |  |  |

## Retrofit ProceduresSeals and Gaskets

- Retrofit ProceduresSeals and Gaskets

- Refrigerants and Lubricants:
- 	How Do They Affect Elastomers?
- Test Results Show:
**	**A certain amount of swell, and loss of physical properties when exposed to refrigerants/oil.

## Retrofit ProceduresSeals and Gaskets

- Retrofit ProceduresSeals and Gaskets

**	****	****Neoprene W...when exposed to:**
**	****	**_**New Installation**_
**	****	**
**	****	****R-22****/Mineral Oil results in a 4.1% swell.**
**	****	****R-404A****/POE Oil results in a 3% swell.**
**	****	**
**	****	**_**Refrigerant Conversion**_**	****	**
**	**
**	****	****R-22****/Mineral Oil retrofit to ****R-404A****/POE Oil:**
**	****	**
**	****	*****Elastomer Swell is reduced to 2.6%***** **
**	****	**
**	****	**

## Retrofit ProceduresSeals and Gaskets

- Retrofit ProceduresSeals and Gaskets

**Components which require may have elastomer **
**gaskets/seals...if so, replacement is required.**
**Solenoid valves**
**3-way reversing valves**
**Schraeder valve cores and caps.**
**Evaporator Pressure Regulators (EPRs).**
**Some older style ball valves may need replacement.**

## Retrofit Procedures

- Contaminants:
- A thorough system evacuation is essential.
- Replace oil filter.
- Replace suction line filters.
- Replace liquid line filter-driers.
- Oil breakdown deposited on the interior walls of system piping will be brought back into circulation if POE oil is used. Close monitoring of the oil will reveal whether additional action is required.

## Retailer Experiences

- Conversion data
- Conversion engineering process
- Capacity, Oil, Valves, others
- Refrigerant choice
- Follow up on maintenance, MO to POE
- Lifecycle cost, total cost of ownership
- Leak potential variability post conversion

## Conversion Data

- 561 Stores converted
- 302 are R-404A
- 253 are R-422D
- 4 are R-422A
- 1 is R-407A
- 1 is R-427A

## Conversion Engineering

- What is important to know and consider?
- Capacity, Line Sizing, Oil, Valves
- Refrigerant choice
- Controls set points
- Follow up on maintenance, oil changes
- Leak potential after the conversion
- Lifecycle cost, total cost of ownership

## Refrigerant Choice

- High Performance
- Thermophysical properties
- System mass flow requirements
- System Capacity
- Control Set points
- Low Refrigerant Inventory
- Oil and Valves
- Follow up on maintenance, MO to POE
- Lifecycle cost, total cost of ownership
- Leak potential variability post conversion
- Different refrigerants...think outside the box

## Max return gas temperature

**Note: Discharge-line temperature within 6 inches of the compressor outlet will be from 25°R to 75°R cooler than cylinder & piston temps depending on the compressor design and the refrigerant mass flow.**

## Total Cost of Ownership - TCO

- Equipment Costs
- Installed Costs
- Operational Costs (energy)
- Maintenance Costs
- Environmental Stewardship
- TCO has to be simple and cost effective

## Presenter Contact Information

- Keilly Witman, US EPA
- _[Witman.keilly@epa.gov](mailto:Witman.keilly@epa.gov)__ _
- Nick Strickland, DuPont
- _[Nick.strickland@usa.dupont.com](mailto:Nick.strickland@usa.dupont.com)__ _
- Dave Demma, Sporlan
- _[dgdemma@parker.com](mailto:dgdemma@parker.com)__ _
- Richard Royal, Wal-Mart
- _[Richard.royal@wal-mart.com](mailto:Richard.royal@wal-mart.com)__ _

## Contact Info – Phaseout and Regulatory

**US EPA - Keilly Witman **
- _[witman.keilly@epa.gov](mailto:witman.keilly@epa.gov)_**, 202-343-9742**
**Phaseout:  Ross Brennan**
- _[brennan.ross@epa.gov](mailto:brennan.ross@epa.gov)_**, 202-343-9226**
**For Sec. 608: Julius Banks,**
- _[banks.julius@epa.gov](mailto:banks.julius@epa.gov)_**, 202-343-9870**
**GreenChill Advanced Refrigeration Partnership**
- _[www.epa.gov/greenchill](http://www.epa.gov/greenchill)_
**Additional Info:**
- _[http://www.epa.gov/ozone/title6/phaseout/classtwo.html](http://www.epa.gov/ozone/title6/phaseout/classtwo.html)_
- _[http://www.epa.gov/ozone/title6/allowance.html](http://www.epa.gov/ozone/title6/allowance.html)_