DAIKIN's Experience in the production with R32

Transcription

1 The 4th Regional Symposium on Alternative Refrigerants for High-Ambient Countries; Risk Assessment of Future Refrigerants in Production, Installation, and Service Dubai, UAE (28-29 Oct, 2014) DAIKIN's Experience in the production with R32 29/10/2014 DAIKIN Industries Ltd. Tadafumi Mikoshi

2 Disclaimer 2 The contents of this presentation have been compiled based on the newest technical information available and every effort has been made to ensure that the presentation is accurate and up to date. However, the accuracy of the information shall not be guaranteed, and Daikin Industries, Ltd. and/or its affiliates shall bear no responsibilities whatsoever for any damage that may be caused as a result of using information and documents contained in this presentation. Check & follow relevant local laws and standards on your own responsibilities.. CSRJOB

3 Field US Europe International Contents Refrigerant Classification Usage Restriction for Safety International Standards for Product design The Main premise of factory safety ISO & IEC followed perfectly for product design ASHRAE 34 UL NA- (based on ISO) ISO817 ASHRAE 15 EN378 ISO UL 207 UL 250 UL 471 UL 474 UL 484 UL 984 UL 1995 UL EN IEC Ed.5.0:2013 Calling in A2L General safety standard Product Safety Standard 3

4 Basic Technology R32 AC Manufacturing 4 Challenges Lower Flammability AC products Safety Quality Productivity Technology analysis in the sight of Refrigerant HFC HCFC R32 R32 AC R410A Manufacturing Technology AC Manufacturing of R22 Methodologies Risk assessment & Flammability countermeasure Higher Level of Clean DRY Tight Lubricant Oil change Clean DRY Tight General Safety, Quality Productivity General Manufacturing for industrial Products CSRJOB Kaizen 5S Activity TQC TQM etc. Occupational Safety and Health

5 Main Changes from R22 5 Refrigerant Change I Contamination II Chemical Corrosion III Pressure V Flammability R32 R410A Synthetic Oil Polyol Ester Ether Byproducts when mixed HNBR (Hydrogenated Nitrile -Butadiene Rubber) HFC-resistant Nylon Higher Reliability High Pressure =4.15MPa 1.6 times Pressure Lower flammable A2L Flammability Countermeasures R22 Mineral Oil Suniso Polychloroprene (CR or Neoprene) Middle Pressure =2.9MPa Non flammable A1 Higher level of Clean Dry Tight required same as R410A CSRJOB

6 Details of Clean Dry & Tight 6 Clean No contamination Dry No moisture Tight No Leakage PHENOMINON CAUSES Oxidized film by brazing Entering of foreign items such as dust, particles and oil from outside. Rain drop infiltration at poor transportation quality. Moisture condensation inside the pipe. Insufficient brazing Inadequate flaring or insufficient tightening torque. Inadequate tightening of flange connection. PROBLEM Clogging of expansion valve, capillary tube, etc. Poor performance of cooling or heating. Degradation of refrigerant lubricant oil. Malfunction of compressor. Gas shortage Higher Temperature of discharge gas.

7 Checking Points for Clean Dry & Tight 7 The block diagram below is an example of AC manufacturing line, focusing on the 3 basic rules Clean Dry Tight. Confirm pressure intensity of equipment, pipe, hose, connection coupler, etc. against higher pressure of R32 refrigerant. Piping/Heat exchanger line Carry out measures against residual scrap from processing C Carry out leakage test T Material Processing Brazing Air-tight test Completion Purchased parts C D Carry out measures against residual oil C Observe basic rules for brazing work C T Care of completed components C D Assembly line Carry out vacuum drying D Assemble piping Air-tight test Vacuum drying Refrigerant charging Insulation / Withstand voltage test Operation test Leakage test Fitting out to completion Observe basic rules for brazing work Carry out leakage test T Carry out leakage test T C T Purchased parts Care of purchased parts C Clean D Dry T Air-tight C D CSRJOB

8 Flammability & Three conditions for Ignition 8 Coestablishment of following Three conditions is mandatory for ignition 1. Existence of Flammable material Leakage Air flow analysis Complete Tightness & Equipment Maintenance Contactor* Enough Ventilation & no air stagnation 2. Mixture with Oxygen at certain density Electrical safety & Isolation of ignition source *Rarely ignition of R32 with 200 V 60A 3. Existence of Ignition Source

9 Key Considerations for Safety - Gas handling 9 When storing cylinders Valves must be closed tightly Cylinders must be stored in a cool (below 40 ) space, in a dry space to prevent corrosion and in well ventilated space. Cylinders must be kept away from direct sunlight or fire. Measures must be taken to protect the valve against external impacts or damage. When handling cylinders Use of cylinders under high temperature or near strong sparks* and flames is forbidden. *High power around 20KW or more. The cylinders must be handled with care, avoiding external impacts. When attaching or detaching cylinders to or from the equipment, sufficient care must be taken to avoid leakage. When handling the refrigerant The space of refrigerant handling must be in low temperature and sparks and flames free. Workers must be equipped with appropriate protective equipment to avoid contact with eyes or skin, or inhaling. The refrigerant must not be released into the air. The area for the production equipment must have a structure with ventilation to prevent refrigerant stagnation. CSRJOB

10 Key Considerations for Safety - General 10 Regardless of the type of refrigerant, the following points must be observed inside factories at all times. Provide and keep safe and healthy work environment To prevent gas stagnation inside the factory, provide openings to create a well-ventilated environment. To Carry out local exhaust ventilation and total ventilation inside the factory. Example) Industrial Safety and Health Act of Japan Keep enough openings area, equivalent to 1/20 of the factory floor area, or Install ventilation equipment with a capacity of over 30m 3 /h/person. To keep temperature, humidity, luminance, noise and chemical atmosphere in the factory at certain level regulated by the authority. Carry out 5S Activity (Seiri: Sort / Seiton: Set in Order / Seiso: Shine / Seiketsu: Sanitize / Shitsuke: Sustain) Clearly separate necessary parts from unnecessary parts, and dispose unnecessary parts. Keep all parts in their specified locations, and make sure they are accessible at all times. Keep the working area and equipment clean at all times, maintaining a clean workplace. Clean, sort and tidy up parts and working area. Make a habit of keeping rules and carrying out work in the correct order. CSRJOB

11 Heinrich s Law 11 1 Serious injury or death 29 Major Injury 300 Near Misses Unsafe Acts & Conditions

12 R32 Flammability Countermeasures 12 Risk Assessment Kaizen & 5S Complete implementation R32 of conventional Flammability regulation & standers cover R32 Flammability Countermeasures Countermeasures General Occupational Safety and Health Complete Implement of Clean Dry Tight No special investment is required Local Regulation

13 13 Reality of R32 AC manufacturing Line Detailed Examples of equipment installation

14 AC factory and various equipment 14 Tightness test Control Panel Refrigerant charge Refrigerant Leakage Test Final Operation Test Gas detector Gas detector Press Machine Parts cleaning High pressure gas Refrigerant Supply Vacuum pump

15 Blocking pipe end 15 Prevent contamination and moisture from entering into the refrigerant piping parts during storage or transportation of parts. Compressor suction and discharge pipes should be capped. End of piping should be capped N 2 (Nitrogen) should be sealed inside the compressor (positive pressure) Check the measurement to prevent from entering moisture and contamination, such as above. Refrigerant pipes should be stored inside vinyl bags CSRJOB

16 Air blow cleaning of the pipes 16 Blow low pressure air to remove oil in pipes. Remove any contamination and moisture from the low pressure air using a drier, etc. <Compressor for low pressure air> <Drier> (moisture removal) After the moisture is removed, use the low pressure air for blowing (contamination removal) <Heat exchanger> Toshiba Industrial Products and Systems Corp. oducts/industrial.htm Not displayable SMC Corp. paration/ Daikin s example <Contamination removal using low pressure air blowing> Contamination removal Low pressure air blowing Heat exchanger tubes (pipes) Contamination Remove any contamination and moisture remaining inside the piping. CSRJOB

17 Chemical Corrosion Proof on Hose and Coupler 17 Product connection hose Change the inside surface material of the hose to HFC-resistant nylon. Product connection coupler Change rubber seal specifications. (CR HNBR) Coupler for equipment connection Change rubber seal specifications. (CR HNBR) Please contact manufacturers of your equipment regarding chemical attack on the parts of equipment (i.e. hose or coupler).

18 Air-tight Test by High Pressure Compressor 18 Equipment specifications (pressure) R22 (HCFC) equipment specifications 1 2 Equipment operation pressure (MPa) 2.9 Equipment design pressure (MPa) 3.5 R32 (HFC) equipment specifications Equipment operation pressure (MPa) 4.15 High pressure compressor for air-tight test Equipment design pressure (MPa) 5.0 Daikin's example Kajitech Corp. Not displayable Daikin s recommendation for special specification: oil-free type 1 Equipment operation pressure indicates the product design pressure. 2 Equipment design pressure indicates the equipment s design pressure.

19 Refrigerant Charging Equipment / Medium Speed Type Medium pressure type and exclusive use for R32 Equipment specifications (pressure) R22 (HCFC) equipment specifications Equipment operation pressure (MPa) 2.0 Equipment design pressure (MPa) R32 (HFC) equipment specifications Equipment operation pressure (MPa) 3.0 Equipment design pressure (MPa) 3.53 Refrigerant charging instrument (Mass flow type) Daikin's example To-ou Kogyo Co,. Ltd. Not displayable

20 Refrigerant Charging Equipment / High-speed Type 20 High pressure type and exclusive use for R32 Equipment specifications (pressure) R22 (HCFC) equipment specifications Equipment operation pressure (MPa) 2.92 Equipment design pressure (MPa) 4.0 Daikin's example R32 (HFC) equipment specifications Equipment operation pressure (MPa) 3.92 Equipment design pressure (MPa) 5.0 Refrigerant charging equipment (Measuring cylinder type) CSRJOB To-ou Kogyo Co,. Ltd. Not displayable Daikin s recommendation for special specification: double piston cylinder *Double piston cylinder: refrigerant charging equipment which has separated refrigerant piston and hydraulic piston

21 Operation Testing Equipment 21 Higher pressure type and exclusive use for R32 R22 (HCFC) equipment specifications <Operation testing instrument (refrigerant piping system)> Equipment specifications (pressure) Equipment operation pressure (MPa) 2.92 Equipment design pressure (MPa) 3.5 R32 (HFC) equipment specifications <Operation testing instrument (refrigerant piping system )> Equipment operation pressure (MPa) 4.15 Equipment design pressure (MPa) 5.0 Piping system must be separated to ensure R32 does not mix with other refrigerants. (Use specialized refrigerant piping system.) CSRJOB

22 Refrigerant Leakage Test Detectors for HFC (R32) 22 Since R32 (HFC) does not contain Cl (Chlorine), halogen-type* refrigerant leakage test detectors (Chlorine detector) can not be used for R32 units. *Halogen-type is not enough accurate to detect R32. R22 R32 refrigerant leakage detectors (examples of use) Daikin's example Halogen type Semiconductor type Infrared type Infrared type D4302 Suzuki Giken Co,. Ltd. 500, ,000 JPY/unit AIMEX-008XR PRO AEMSS Inc. 800,000 JPY/unit Not displayable HLD5000 INFICON Co,. Ltd. 1,000,000 JPY/unit

23 Conclusion 23 AC manufacturing is integrated technology. Clean, Dry & Tight are basic and mandatory requirements for AC manufacturing, especially for HFC(R410A,R32) AC R32 flammability countermeasure can be covered by complete implementation of conventional standards and regulation. No special investment required. No golden rule for Safety. Ceaseless effort and maintenance required. Top management involvement and leadership absolutely required for safety management. Check & follow relevant local laws and standards on your own responsibilities.

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