daikin's experience in the production with r32 - uae & omandubai, uae (28-29 oct, 2014)...

29/10/2014 Daikin Industries, Ltd. CSRJOB-2014001 29/10/2014 Daikin Industries, Ltd. CSRJOB-2014001

DAIKIN's Experience in the production with R32

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)

29/10/2014

DAIKIN Industries Ltd.

Tadafumi Mikoshi

29/10/2014 Daikin Industries, Ltd. CSRJOB-2014001

Disclaimer

• 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..

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3

Field US Europe International Contents

Refrigerant

Classification

ASHRAE 34

UL 2182

-NA-

(based on

ISO) ISO817 Calling in A2L

Usage

Restriction

for Safety

ASHRAE 15 EN378 ISO5149-2014 General safety

standard UL 207

UL 250

UL 471

UL 474

UL 484

UL 984

UL 1995

UL 60335-2-40

EN60335-2-40

IEC60335-2-40

Ed.5.0:2013

Product Safety

Standard

International Standards for Product design

The Main premise of factory safety

ISO & IEC followed perfectly for product design


4

Basic Technology R32 AC Manufacturing

General Manufacturing for industrial Products

AC Manufacturing of R22

R410A

R32

Challenges Methodologies

Risk assessment

& Flammability countermeasure Lower Flammability

General

Safety, Quality

Productivity

“Kaizen”

“5S Activity”

TQC TQM etc.

Occupational

Safety and Health

AC products

Safety Quality

Productivity “Clean” “DRY” “Tight”

Higher Level of

“Clean” “DRY” “Tight”

Technology analysis in the sight of Refrigerant

Lubricant Oil change

HCFC

HFC

R32 AC

Manufacturing

Technology


5

I Contamination II Chemical

Corrosion III Pressure V Flammability

R32

R410A

R22

High Pressure

=4.15MPa

HNBR (Hydrogenated Nitrile

-Butadiene Rubber)

HFC-resistant

Nylon

Synthetic Oil

Polyol

Ester

Ether

1.6 times

Pressure

Higher

Reliability

Lower flammable

A2L

Flammability

Countermeasures

Mineral Oil

Suniso Polychloroprene

(CR or Neoprene)

Middle Pressure

=2.9MPa

Non flammable

A1

Refrigerant Change

Main Changes from R22

Byproducts

when mixed

Higher level of “Clean” “Dry” “Tight” required same as R410A


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.

Details of “Clean” “Dry” & “Tight”


Assemble piping Air-tight test Vacuum

drying

Refrigerant

charging

Insulation /

Withstand

voltage test

Leakage

test

Operation

test

Fitting out to

completion

Material Processing Brazing Air-tight test Completion

Purchased parts

Assembly line

Piping/Heat exchanger line

Observe basic rules for brazing work

Carry out leakage test

Purchased parts

Care of purchased parts

Care of completed components

Carry out vacuum drying

Carry out measures

against residual oil

Carry out measures against

residual scrap from processing

ＣＴＤ

ＣＤ

Ｔ

ＣＴ

Ｄ

Ｔ

ＣＤＣＴ

Ｔ

ＣＤＣ

Ｃ

Clean Dry Air-tight

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.

Carry out leakage test Carry out leakage test

Observe basic rules for brazing work

Checking Points for “Clean” ”Dry ” & ”Tight”

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Flammability & Three conditions for Ignition

3. Existence of

Ignition Source

1. Existence of Flammable material

2. Mixture with Oxygen

at certain density

Coestablishment of following Three conditions is mandatory for ignition

Leakage

Complete “Tightness”

& Equipment Maintenance

Enough Ventilation

& no air stagnation

Electrical safety

& Isolation of ignition source

8

Air flow analysis Contactor*

*Rarely ignition of R32 with 200 V 60A


◇ 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.

Key Considerations for Safety - Gas handling

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◇ 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.

• 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.

Regardless of the type of refrigerant, the following points must be observed inside factories at all times.

Key Considerations for Safety - General

10

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 30m3/h/person.


11

Heinrich’s Law

Unsafe Acts & Conditions

300 Near Misses

29 Major Injury

1 Serious injury or death


R32

Flammability

Countermeasures

General Occupational

Safety and Health

Complete Implement of

“Clean” “Dry” “Tight”

Risk Assessment

“Kaizen” & “5S”

R32 Flammability Countermeasures

Local Regulation

12

No special investment is required

Complete implementation

of conventional regulation & standers

cover R32 Flammability Countermeasures


Reality of R32 AC manufacturing Line

【Detailed Examples of equipment installation】

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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

AC factory and various equipment


Prevent contamination and moisture from entering into the refrigerant piping parts

during storage or transportation of parts.

End of piping should be capped

Refrigerant pipes should be stored

inside vinyl bags

Check the measurement to prevent from entering

moisture and contamination, such as above.

Compressor suction and

discharge pipes should be

capped.

Ｎ２ (Nitrogen) should be sealed

inside the compressor (positive

pressure)

Blocking pipe end

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<Compressor for low pressure air> <Drier> (moisture removal)

Remove any contamination and moisture remaining inside the piping.

Blow low pressure air to remove oil in pipes.

Remove any contamination and moisture from the low pressure air using a drier, etc.

After the moisture is removed, use the low

pressure air for blowing (contamination

removal)

<Heat exchanger>

http://www.nishishiba.co.jp/nsdk/english/pr

oducts/industrial.htm

Toshiba Industrial Products and

Systems Corp. →http://www.smcworld.com/products/en/airpre

paration/

SMC Corp.

<Contamination removal using low pressure air blowing>

Contamination

Low pressure air blowing

Contamination removal

Heat exchanger tubes (pipes)

Air blow cleaning of the pipes

Not displayable

Daikin’s example

16


Please contact manufacturers of your equipment regarding

chemical attack on the parts of equipment (i.e. hose or coupler).

Product connection coupler

Change rubber seal

specifications.

(CR → HNBR)

Product connection hose

Change the inside surface material of the

hose to HFC-resistant nylon.

Coupler for equipment

connection

Change rubber seal

specifications.

(CR → HNBR)

Chemical Corrosion Proof on Hose and Coupler

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Equipment operation pressure (MPa) 2.9

Equipment design pressure (MPa) 3.5



◇ Equipment specifications (pressure)

R22 (HCFC) equipment specifications

R32 (HFC) equipment specifications

High pressure compressor for air-tight test

http://www.kajitech.com/en/products/pro-gas/hd2b-400gh-ol.html Kajitech Corp.

Daikin’s recommendation for special specification:

oil-free type

※1

※2

※1 Equipment operation pressure indicates the

product design pressure.

※2 Equipment design pressure indicates the

equipment’s design pressure.

Air-tight Test by High Pressure Compressor

Not displayable

Daikin's example

18


Refrigerant charging instrument

(Mass flow type)

To-ou Kogyo Co,. Ltd.

http://www.to-ou.co.jp/ref-charge2_e.html








Refrigerant Charging Equipment / Medium Speed Type

Not displayable

Daikin's example

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Medium pressure type and exclusive use for R32



Refrigerant charging equipment (Measuring cylinder type)

To-ou Kogyo Co,. Ltd.

Daikin’s recommendation for special specification: double

piston cylinder

http://www.to-ou.co.jp/ref-charge1_e.html







*Double piston cylinder: refrigerant charging equipment which has separated

refrigerant piston and hydraulic piston

Daikin's example

Refrigerant Charging Equipment / High-speed Type

Not displayable

20

High pressure type and exclusive use for R32


<Operation testing instrument (refrigerant piping system)>

Piping system must be separated to ensure R32 does not

mix with other refrigerants.

(Use specialized refrigerant piping system.)


R32 (HFC) equipment specifications <Operation testing instrument (refrigerant piping system )>






Operation Testing Equipment

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Higher pressure type and exclusive use for R32


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.

◇ R32 refrigerant leakage detectors (examples of use)

D4302

Suzuki Giken Co,. Ltd.

500,000-600,000 JPY/unit http://www.sg21.co.jp/pro2_13.html

AIMEX-008XR PRO

AEMSS Inc.

800,000 JPY/unit http://www.aimscorp.jp/en/index-e.html

Semiconductor type Infrared type Infrared type

Daikin's example

Refrigerant Leakage Test Detectors for HFC (R32)

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HLD5000

INFICON Co,. Ltd.

1,000,000 JPY/unit http://www.inficon.jp/leak/index.php

Not displayable

Halogen type

◇ R22


Conclusion

• 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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daikin's experience in the production with r32 - uae & omandubai, uae (28-29 oct, 2014)...

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