HVAC&R News August-September 2022

NEWS From chill to grill CO2 refrigeration at Illawarra Smallgoods

Skills

WORKSHOP Filter performance parameters

Mid-tier heroes Could Australia’s ‘average’ buildings be our sustainability saviours?

August–September 2022 / ISSUE 147

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August–September 2022

August–September 2022 / ISSUE 147

NEWS

Mid-tier heroes 20

HVAC&R News is published by the Australian Institute of Refrigeration, Air conditioning and Heating (Inc).

AIRAH – National Office James Harrison Centre 3/1 Elizabeth Street, Melbourne VIC 3000, Australia.

Tel: 03 8623 3000

Fax: 03 9614 8949

www.airah.org.au/hvacrnews

Magazine team Communications Manager Matthew Dillon matt.dillon@airah.org.au Tel: 03 8623 3000 Editor Mark Vender mark.vender@airah.org.au Tel: 03 8623 3001 Contributing writers Sean McGowan Louise Belfield

While Australia’s Grade A commercial buildings are leading the world for sustainability, most of our building stock lags behind, especially when it comes to heating and cooling. Louise Belfield looks at three new reports that investigate how to improve HVAC performance in the mid-tier. Clue: fridgies will play a leading role.

Advertising sales

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Glenn Douglas glenn.douglas@airah.org.au Tel: 0411 839 667

John McGrath john.mcgrath@airah.org.au Tel: 0419 556 108

ISSN 1834-9522

HVAC&R News is printed on paper sourced from well manned forests and other controlled sources.

Disclaimer HVAC&R News is an official publication of the Australian Institute of Refrigeration, Air Conditioning and Heating Inc. Statements expressed in HVAC&R News do not necessarily reflect the policy or views of AIRAH or its members.

No responsibility is accepted by AIRAH, the Editor or HVAC&R News’s supply partners for the accuracy of information or for errors or omissions.

The publisher reserves the right to alter or omit any article or advertisement submitted and requires indemnity from advertisers and contributors against damages or liabilities that may arise from material published.

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HVAC&R News regulars

Skills Workshop 15

The Toolshed

See what’s new in the ‘Shed

Filter performance parameters

Global Update

Industry news from around the world

Exclusive to this issue

Industry Insight

Quantifying the impact of invisible gases

Around the Nation Who’s in the news?

Smoko with …

Q&A with Antonis Condoleon

Cool Tech

Time to split? This axe could help.

Lighter Side

The shonkier side of the nation

No part of this publication may be reproduced, stored in a retrieval system or transmitted in any form or by any means electronic, mechanical, photocopying, recording or otherwise, without permission of the Publisher.

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From chill to grill With a proud history of more than 100 years, Illawarra Smallgoods is looking to the future.

Sean McGowan reveals how a CO2 refrigeration system is part of the long-term plan.

March 2022

PLEASE CONSIDER THE ENVIRONMENT AND RECYCLE THIS MAGAZINE IF YOU ARE NOT GOING TO KEEP IT.

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Ed’s letter

LAW OF AVERAGES

global warming occurs in the first 20 years.

For this reason, what might look like a low- or medium‑GWP refrigerant over 100 years might not look so environmentally friendly over 20 years.

A couple of years ago I attended a course on website analytics where the presenter warned us not to put too much stock in averages. They pointed out that the “average” human being has one testicle.

More recently, I’ve had cause to question averages again.

It started when a reader emailed to query the figures we used in an article for the global warming potential (GWP) of common refrigerants.

In this case, the industry standard is the 100‑year figure.

Quick recap: GWP indicates how much energy one tonne of a gas will absorb over a given period of time, relative to one tonne of carbon dioxide (CO2). This gives you a measure of how much it will contribute to global warming.

I get the need to use the same tape measure for everything, I really do. Otherwise, we end up in a house with leaning walls and crooked windows.

The numbers are defined by the Intergovernmental Panel on Climate Change (IPCC) – the United Nations body for assessing climate science. They produce new reports once every few years, and update the numbers each time to reflect the latest scientific understanding and the makeup of our atmosphere. They also provide GWP values over 100 years and 20 years.

But if I tell you that a refrigerant has a GWP of around 670, and don’t mention that it’s actually 2,700 over the next 20 years, isn’t that also a bit skewiff?

Aren’t most of our climate policies focusing on the next 20 years, rather than the next 100?

I should point out that these are entirely my own musings and do not reflect the position of AIRAH or many wise heads in the industry. Consider this my little squeak of concern. I just keep thinking

This is where it gets a little complicated, because some gases break down much faster than others.

And if a gas breaks down quickly, all its impact on

that if someone offered me a home loan with a hundred‑year term, the interest rate would probably look pretty good too. Except the grandkids would be the ones paying it off.

As it happens, our cover story this issue is about ”average” buildings. A series of new reports has explored how we can improve HVAC maintenance in Australia’s mid-tier, and the findings are fascinating.

Check them out on page 20. ■ @AIRAHnews

Mark Vender Editor mark.vender@airah.org.au

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August–September 2022

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Inspired by nature

UK, where black duct has outnumbered the traditional ivory and white colour in the past five years.

“Slimduct adds beauty to the façade as an architectural feature, with its slim light-weight profile and ease-of-use to install.

It is made of rigid PVC capping offering impact resistance.

It is fade proof and flame retardant.”

To be launched at ARBS, the new Midea GAIA split system boasts an innovative “OxygenFresh Air Exchange System”, an I-Clean self-cleaning function, and “Breezeless Technology” with HEPA filtration and smart energy-saving features.

The company says Slimduct is a labour-saving alternative to custom-fabricated line-set ducting options.

“OxygenFresh Air Exchange technology can introduce up to 60m³/hr purified fresh air from outdoors, letting staleness out and freshness in,” Midea says.

“It is easy to install and field configure to any orientation, it is easily accessed,” the firm says, “and line-set maintenance can be performed quickly and effectively.”

“I-Clean six-step self-cleaning at up to 56°C temperature deeply purifies the evaporator, providing a fresh and clean air supply.

Brown and grey profiles will be available soon.

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“The all-new air duct and windwheel design allows airflow to pass smoothly with an operating noise level as low as 19.3dB.” Midea Appliances Australia says the GAIA product is for those who demand the “real nature-like air experience”.

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“This high-performance filter is designed to be easily retrofitted into VRV FXF(S)Q-AVM and SkyAir FCA-C(A)VMA Round Flow Cassettes to enhance their air filtration capabilities, improve indoor air quality and provide building occupants with healthy, comfortable and productive indoor environments,” Daikin says.

“In Eco mode as little as 1.29kWh per night (eight hours) is consumed,” Midea Australia says.

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“The Minimum Efficiency Reporting Value (MERV) rating system measures the performance of air filters. With a rating of 8, this filter is able to more effectively reduce common indoor air pollutants such as dust, pollen, dander and lint.

“Can do” mindset from S-5!

S-5! has introduced the CanDuit clamp, designed to secure and support chases and raceways, cable trays, gas piping, condensate lines and other round-shaped objects to metal roofs. It can be used in combination with other S-5! clamps or brackets, including the GripperFix utility mounting system.

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The CanDuit can be used in both residential and commercial settings for a range of applications including condensate drainage, electrical, solar and plumbing for gas or water.

It is available in 14 sizes, with outer-pipe diameters ranging from 20mm (0.79") to 117mm (4.6").

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Go to daikin.com.au

5 Image supplied by Temp Technical Ltd (UK)

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“Slimduct Black is a new important addition to the product range. Its quality is assured under extreme Aussie conditions, especially against UV. It is perfectly matched to dark-coloured exteriors. Black is extremely popular in the HVAC&R News

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Daikin in the great outdoors

Daikin Australia has launched its new Slimline Outdoor Air Processing unit (FXMQ-AFVM).

“This new unit can be connected to both Daikin Heat Pump and Heat Recovery VRV outdoor units,” Daikin says, “thus offering a full Daikin HVAC building solution comprising comfortable cooling and heating, required ventilation and centralised controls.”

“The addition of a built-in drain pump with 700mm lift and silver ion anti-bacterial agent box prevents the growth of mould and bacteria in the drain pan,” the firm says. “Indoor air quality can be further optimised with the unit’s compatibility with MERV 8 and 14 filters.”

“The Slimduct traditional colours of ivory and white already offer unique advantages to the installer.

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Daikin says the unit’s ability to pre-condition outdoor air to a target room air temperature reduces the air conditioning load and improves air temperature and humidity control.

The new black from Inaba Denko

“Inaba Denko has launched a new range of internal and external PVC capping that ensures air conditioning refrigeration pipes are protected with an aesthetic and professional finish,” the company says.

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“Tested by the Daikin Technology and Innovation Centre, the new MERV 8 Filter is proven to effectively remove up to 70 per cent of 3.0–10μm particles and 20 per cent of 1.0–3.0μm particles.”

Daikin says the MERV 8 filter can replace an existing cassette’s prefilter, with efficiency maintained for up to six months.

Made from electro-zinc coated steel, the CanDuit clamp features two halves that clamp around the pipe or conduit with an EPDM liner pad, which protects against abrasion, and a threaded M8 stud that allows for attachment to S-5! Products.

This facilitates securement without scratching, corrosion or other damage to the roof, S-5! says.

Adjustability within each clamp enables minor size adjustment to secure most conduit and other piping.

V8 Filter power

Daikin Australia has released its MERV 8 Filter – BAF552A160.

The GAIA is offered in three operating power options: 50 per cent, 75 per cent and 100 per cent.

For more information go to www.Midea.net.au

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The company says the ability to connect fan coil units for air conditioning and outdoor air-processing units to the same refrigerant line offers enhanced design flexibility, space saving and a significant reduction in total system costs.

Go to commercial.daikin.com.au

August–September 2022

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Midea’s split and slim

Blauberg Ventilation has introduced Civic, a new range of German-designed wall-mounted ERV units.

Midea is launching its MSP and HSP Duct units at ARBS. “The new Midea MSP slim-line and the split-design HSP duct indoor unit offer reliability and high efficiency with ease of installation and energy savings,” Midea says. “With split design structure, the HSP duct indoor unit can easily be separated into a coil part and a fan part. And it can be reassembled within a ceiling for installation.

“COVID-19 and the 2019–20 bushfires raised major issues with insufficient quality ventilation in school classrooms and offices,” says the company. “Bad air quality, high humidity levels, high CO2 concentration, and low oxygen levels create a long-term unsafe study and work environment for occupants.”

“The new compact 7kW outdoor unit takes approximately 22 per cent less footprint [than average],” Midea says.

“One installer can carry it easily. This is especially useful for renovation and retrofits, saving on installation, maintenance and labour costs.

Some public health authorities have recommended 4–6 air changes per hour, and AS 1668 indicates that the required ventilation to be designed into an active HVAC system for classrooms is 12L/second/person.

Blauberg says the Civic meets these guidelines by providing filtered fresh outside air, rather than filtered recycled air, through a heat exchanger to minimise energy loss. H11 HEPA fresh air filters are included to maximise indoor air quality and safety. And according to Blauberg, with a very low noise level of 24–25 3m dB(A), the Civic units provide a pleasant indoor environment.

“With a durable R32 full DC inverter duct split using GMCC R32 twin-rotary compressors offering highly efficient heat transfer and refrigerant cooling with inner-groove high-efficiency tubes, the unit is optimised.

“Compared with fixed-speed air conditioners, full DC invertor air conditioners can reduce approximately 55 per cent power consumption in a year.”

Go to www.Midea.net.au

Blauberg gets Civic

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Manufactured in Europe, the Civic units can be fitted with Blauberg EC motors for low power consumption.

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DO YOU HAVE A NEW PRODUCT TO GO IN THE TOOLSHED?

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Email mark.vender@airah.org.au All submissions received will be considered, though publication cannot be guaranteed.

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Global Update

PERU

AUSTRIA

ANDEAN HOUSING PLAN

GASSED OUT

Peru’s Ministry of Housing, Construction and Sanitation plans to build almost 32,000 bioclimatic houses in 10 Andean areas to protect the population from extreme cold.

The plan will run from 2022–2024. During the first year the government will invest about AUD$83 million to finance construction of 7,942 “Sumaq Wasi” thermal houses.

The name means “beautiful house” in Quechua.

These Sumaq Wasi dwellings will benefit 31,770 residents, who will participate in the construction of the houses.

The dwellings are designed to capture the heat of the day and keep it in the house at night, at an average temperature of 14°C. In June, temperatures of –21°C were registered in some places. The government hopes the project will improve the quality of life of low-income families in rural Andean communities.

“With these houses we reduce respiratory diseases and deaths as a result of frost,” says the Ministry of Housing’s Claudio Hancco, “especially in children and older adults.” ■

The Austrian government plans to ban the installation of gas boilers in new buildings from next year. Also, from that date, any broken oil or coal heating systems may only be replaced by renewable heating systems.

The decision was made against the background of the Russian invasion of Ukraine and Europe’s high dependence on Russian gas.

“Every gas heater that we replace with a sustainable heating system is a step out of dependency,” says Minister of Climate Action, Environment, Energy, Mobility, Innovation and Technology Leonore Gewessler. “Every apartment that we keep warm with sustainable heating makes us freer and less vulnerable to blackmail.

That’s why from 2023 there should be an end to gas heating in new buildings.”

The 2023 gas heating ban in new buildings brings forward the deadline of 2025 originally planned in the government program.

The government is providing financial support, including 100 per cent of the cost for low-income households. ■

CHINA

EGYPT

WORDSKILLS CANCELLED

SEAWATER SOLUTION

Due to continuing pandemic prevention and control restrictions in China, the 46th WorldSkills International Competition scheduled to be held in Shanghai has been cancelled. Slated for October 12–17, 2022, the competition was originally planned for 2021 before being postponed due to the pandemic.

The United Nations Environment Programme (UNEP) has completed a feasibility study investigating the development of a seawater air conditioning system in Egypt.

Conducted in New Alamein City on the Egypt’s north coast, the study sought to find a more climate-friendly cooling solution for the ancient sun-baked country.

“It is with deep disappointment that we announce the cancellation of WorldSkills Shanghai 2022,” says WorldSkills International president Chris Humphries. “Looking ahead to the future, we have no doubt that when China hosts a WorldSkills Competition, it will be extraordinary. Alongside WorldSkills members and partners, we are working actively to develop alternative competitive arrangements to celebrate your skills in 2022.”

During summer, about half of Egypt’s electricity goes towards air conditioning.

Temperatures can hit 40°C and remain in the high 30s.

One option could be to hold the international Refrigeration and Air Conditioning competition as part of Chillventa 2022, slated for Germany in October.

Perth-based Tom Clancy was due to represent Australia in the Refrigeration and Air Conditioning category – see the April/May issue of HVAC&R News – and had been training intensively. ■ 8

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The test system in New Alamein City works by pumping seawater into a cooling station and passing it through a heat exchanger, where it absorbs heat from buildings. Cool air generated from the cold water is used to maintain comfortable temperatures in the buildings, while the warm water is sent back into the sea.

Taking two years to build, the plant will cost about AUD$170 million and a further AUD$30–36 million for the distribution network.

The 30,000 tonnes of refrigeration (TR) capacity would cut refrigerant emissions by about 99 per cent, and CO2 emissions by 40 per cent in the city. ■

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Feature

FROM CHILL TO GRILL

A highlight of the project is the specially designed CO2 rack, switchboard, pump station and 200L buffer tank – all incorporated into a shipping container.

Owned and operated by the Hutton family since 1921, Illawarra Smallgoods is an icon of the region. Now the business has turned to natural refrigerants to better cater for growing demand while future-proofing its investment. Sean McGowan reports.

Illawarra Smallgoods has overcome many challenges throughout its 100-year history.

From the Great Depression of the 1930s, to the rationing of meat during the Second World War, and the emergence of supermarkets that resulted in many traditional butcher shops closing, the business has weathered plenty of storms and emerged stronger.

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Now specialising in large‑scale manufacturing of sausages, corned silverside, hams, frankfurts and other meat products, Illawarra Smallgoods has enjoyed strong growth in recent years.

“We were facing a few issues simultaneously,” says Thomas Hutton, manager of sales and human resources at Illawarra Smallgoods – and a descendant of company founder Gordon Hutton.

So when the Wollongong-based company needed to expand its production and throughput capability to better serve its supermarket clientele, attention quickly turned to a refrigeration system in need of overhaul.

“Our existing production facility had reached capacity, our existing loadout was over capacity and highly complicated, and the refrigeration system for those areas was ageing.”

August–September 2022

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Feature The solution was the construction of a new facility that would double the existing production space by utilising the pre-existing cold storage site for production.

The modular design allowed for the entire system to be installed much faster than a conventional system.

“We would also nearly quadruple onsite cold storage – dramatically increasing production capacity and allowing us to simplify loadout operations for our storeman,” says Hutton.

Having serviced the site for five years, West Refrigeration – specialists in supermarket cold storage and food processing – were called in to advise on a new refrigeration system.

“The new facility at Illawarra Smallgoods would expand their cold storage with 448m² of new freezer space and 488m² of combined chiller, loadout and corridor space,” says David West, Affil.AIRAH, managing director at West Refrigeration.

As well as expanding capacity, Illawarra Smallgoods wanted an energy-efficient refrigeration design that included the use of non-toxic, natural refrigerants.

“From the get-go, the customer wanted to ensure the new addition to their facility would be future‑proofed,” explains West.

“They could see the benefits of CO2 as a low‑GWP (global warming potential) refrigerant, and as a low‑cost alternative to traditional HFC refrigerants.”

From the get-go, the customer wanted to ensure the new addition to their facility would be future-proofed

OUTSIDE (AND INSIDE) THE BOX In choosing a new refrigeration system, Illawarra Smallgoods had some minimum conditions.

First, the company was determined to use a refrigerant that was not being phased down. That meant the two standout options were ammonia (R717) or CO2 (R744). Second, the refrigerant of choice had to be as energy efficient as possible due to existing power limitations on the site, and the company’s will to lower overall site emissions.

“Most of the site storage is low temperature – which CO2 is highly efficient for,” says Hutton. “The rest is medium temp, where ammonia is more efficient.

“It eventuated that while both options could meet our power requirements and would tick all boxes, we made our choice of CO2 based on our experience with West Refrigeration and the systems they specialise in.”

Finally, it needed to be a simple, safe application that would not impact the local community.

Once the project team decided to adopt a transcritical CO2 system, a new plant deck was designed to maximise the internal facility’s storage area.

This consequently required a unique plant design to suit the space.

“The compressor rack and switchboard needed to be enclosed, as there was no traditional plantroom allowed for,” says Mark Ward, Affil.AIRAH, project manager for West Refrigeration.

This led West Refrigeration to call on Bitzer Australia for assistance.

Together, the two companies developed a modularised design incorporating a pre-installed transcritical CO2 rack, switchboard, pump station and 200L buffer tank contained within a 40-foot shipping container.

The entire plantroom could then be crane-lifted as one unit onto the condenser deck, with a gas cooler located beside it.

Transcritical CO2 refrigeration design in 40-foot container.

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Source: BITZER Australia.

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August–September 2022

“Our work, both locally and internationally, has demonstrated that transcritical CO2 systems can fulfil

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Feature all aspects of what the client was looking to achieve,” says Ian Suffield, Affil.AIRAH, national engineering manager at Bitzer Australia.

LESSONS FROM THE PROJECT

Additionally, Illawarra Smallgoods established early in the design phase that it preferred a warm glycol system for the low-temperature (freezer) evaporator defrost over a traditional electric defrost.

West Refrigeration’s managing director David West, Affil.AIRAH, shares the lessons he took from the installation of the transcritical CO2 refrigeration system at Illawarra Smallgoods.

“This is perfectly suited to transcritical systems,” says Suffield.

Transcritical CO2 is the answer moving forward.

With the assistance of Bitzer, Danfoss and the commitment from our commissioners, the plant has proven to be efficient, effective and reliable.

“There is an abundant amount of heat available for this process, which in turn reduces the need for large storage tanks that are typical when this is being applied to HFC and sub-critical CO2 systems.”

Warm glycol defrost is an effective alternative to electric defrost for freezer rooms.

RACK ’EM UP! The transcritical CO2 rack is made up of three low‑temperature, semi-hermetic compressors, four medium semi-hermetic compressors and three parallel semi-hermetic compressors.

It’s important to ensure all members of the service team have suitable training to understand the operation of a transcritical CO2 plant. We needed to ensure that all the necessary information is at the service technicians’ disposal, so the plant continues to operate efficiently. ■

“Our main concern was the safety of technicians working within the space. That meant considering and designing access, lighting, and ventilation – as well as fitting the equipment within the container.”

But the fully contained, modular design of the refrigeration system ended up being a huge advantage. Once the timing of the installation was locked in, the entire system could be installed within just two or three crane lifts.

“This meant the work onsite primarily consisted of running pipes, and so was completed very quickly,” Hutton says.

The gas cooler is V-shaped with humidification pads to make use of the evaporation effect.

Bitzer used 3D-design software to provide a visualisation of the equipment layout to West Refrigeration and Illawarra Smallgoods, and demonstrated that serviceability and ongoing access to vital components could be assured.

The rack is also fitted with a vertical glycol pump that circulates glycol through one side of a rack-mounted plate heat exchanger with discharge gas on the other side.

According to Hutton, the implementation of the system on a new build was challenging because of the small installation window in the builder’s schedule.

“One of the most significant challenges for use was to deliver the rack pre-fitted into the container – this was new territory for us,” says Suffield.

“Compounding this were constant delays fuelled by ongoing wet weather, which kept pushing the schedules back,” he says.

The total freezer design load is 67.556kW @ –26°C saturated suction temperature, and a combined medium temperature load of 115.300kW @ –6°C saturated suction temperature.

The V-shaped gas cooler makes use of the evaporation effect via humidification pads.

UP AND RUNNING Since the new transcritical CO2 refrigeration plant at Illawarra Smallgoods was commissioned in March 2021, it has reportedly operated extremely well.

The benefits of a lower temperature defrost are also evident in the conditions inside the freezer room.

“CO2 has proven to be extremely effective for us,” says Hutton.

“We have had some hot days, during which the system did not exhibit any signs of strain.

The issues that have come up have been simple to fix and have really just been part of the commissioning process.”

Now, 18 months into its operation, West Refrigeration continues to tune the new system for operational and energy efficiency gains.

“We would not hesitate to use CO2 for our next installation,” says Hutton. ■

PROJECT AT A GLANCE THE PERSONNEL ▲ Client: Illawarra Smallgoods ▲ Refrigeration Contractor: West Refrigeration

▲ Refrigeration Plant Design: BITZER Australia

THE EQUIPMENT ▲ ▲ ▲ ▲ ▲ ▲ ▲ ▲ 14

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Compressors: BITZER Australia Condensers: Guntner Controls: Danfoss Evaporators: Guntner Pumps: Grundfos Sensors: Danfoss Tanks: Masterflow VSDs: ABB

MODULE

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Skills summary ■ What?

Properties to consider when selecting air filters.

■ Who?

Relevant for designers of HVAC systems and maintenance technicians.

FILTER

PERFORMANCE

PARAMETERS This Skills Workshop discusses the four key properties that must be considered when designers are selecting air filters – airflow, resistance, efficiency and dust-holding capacity – as well as the concepts of size/penetration curves, particle adhesion and electrostatic effects.

The concepts of filter resistance, filter efficiency (arrestance), filter penetration and the factors that affect the dust-holding capacity of a filter are explained. A method for estimating the filter service life is also provided.

Filter performance properties

In order to compare the performance of various products, filter manufacturers have to rate the performance of their equipment in accordance with a recognised test or standard.

• For most air conditioning filters, when velocity increases, resistance increases exponentially with a power between 1.3 and 1.8.

Clean filter resistance can be easily read off performance graphs of filter resistance for different flows.

Every air filter has four key properties: • Manufacturer’s recommended airflow • Airflow resistance characteristic of the filter • Efficiency/arrestance at removing dust and contaminants from the airstream • Dust-holding capacity at particular test conditions (initial pressure versus final pressure and dust loading).

Most filter manufacturers publish initial resistance (clean filter) and final resistance values that are verified by certified test reports.

Each of these four properties must be considered when selecting or comparing air filters for a particular application.

Efficiency and arrestance

Air capacity

Efficiency and penetration

Air filters are rated by the manufacturer to handle a maximum quantity of air (L/s), or to have a maximum face velocity (m/s). This is a limit of the filter performance rating.

All other performance factors have little meaning unless referred to this airflow rate, as each filter performance property is dependent on the other three.

The required size of an air filter bank can be selected using the continuity equation and the recommended face velocity for the filter/media.

Blocked air filters drastically reduce air conditioning and ventilation system performance, so filters must be serviced at the proper time. Pressure differential sensors should be fitted to monitor filter resistance. The filters/system should be marked with the design final resistance and checked regularly.

Unattended air conditioning systems may be equipped with remote alarms to indicate that the air filter has reached its pre-determined final resistance.

The efficiency or arrestance of an air filter may be defined as the proportion of dust retained (or arrested) by the filter, expressed as a percentage of the total dust carried by the airstream to the filter, see Figure 1. Conversely, penetration is the proportion of dust that passes through the air filter.

In gravimetric tests the efficiency measurement is called synthetic dust weight arrestance (often simply referred to as arrestance) to distinguish it from efficiency measured using sub-micron tests.

Air resistance

The efficiency of a filter generally increases as the filter loads with particulate.

If the filter is loaded beyond the manufacturer’s recommended final resistance, the efficiency will usually decline rapidly due to agglomerated particles being dislodged from the fibres.

Filter resistance affects fan selection, size of plant and ongoing energy consumption.

Efficiency %

Fan capacities are generally selected based on anticipated final filter resistance (prior to change-out). As a result, there may be (unacceptably) high airflow rates when filters are clean unless there is an automatic variable fan speed control available to compensate, i.e., a higher fan speed to compensate for the increased filter resistance to provide the same airflow rate.

= 100%

Resistance varies according to the degree of air turbulence in the media.

The resistance/flow relationship varies with filter type generally as follows: • For some fabric and most metal filters, resistance increases as the square of the velocity • For laminar airflow through HEPA filters, the resistance is nearly proportional to velocity

+ Penetration %

Figure 1: Air filter efficiency and penetration.

The stated efficiency of a filter is meaningless unless other related factors are also quoted, including: • Standard dust or size of particles being filtered (filter test standards typically use synthetic particles to enable reproducibility and fair comparison) August–September 2022

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HVAC&R Skills Workshop • Filter identification (characteristics such as dimensions, configuration, model, media type) • Type of test method used • Airflow rate (L/s) or velocity (m/s).

When assessing or comparing data for different filters, care must be taken to ensure comparisons of test data are valid, i.e., tests should be at the specified face velocity and data should be compared for the same final resistance.

Different test dusts, different results

Dust-holding capacity

The fact that all of the key performance parameters of air filters are inter-related is most obvious when considering the dust-holding capacity of an air filter.

Dust-holding capacity is the total mass of dust held by an air filter at a particular final resistance. This is very dependent on the airflow rate applied.

Filter tests fall into two types: 1. Tests of flat media samples only 2. Tests of complete filter units, i.e., media fitted into frames to give an extended surface.

The performance of the filter with one test dust is not a reliable predictor of performance with another test dust or with the local ambient dust.

Different filters can only be reasonably compared under similar test conditions.

The dust-holding capacity of flat panel media samples is most usefully expressed in grams per square metre of free area (g/m²).

Predictions for other panel sizes are then simplified.

Relationship between classifications

The dust-holding capacity of complete filter units is better expressed as grams held for that particular configuration, or grams held divided by test airflow rate.

A notional relationship between the various filter classification systems of AS 1324.1, ISO 16890, EN 779 and ASHRAE 52.2 is shown in Table 1.

The ASHRAE legacy 52.1 standard ratings are also shown for reference.

Because the test methods are similar but not identical, the relationships mapped in Table 1 are approximate not exact and are provided for comparison only. For this reason inter-test standard comparisons are not a sound practice on which to base a design. Specific filter/test results are required.

Note: At the time of publication it was not clear which test standard would become dominant in Australia, ISO 16890 or ASHRAE 52.2.

In particular ISO 16890 defines filtration efficiency for three different sizes of particles (PM10, PM2.5 and PM1) whereas other classification systems are based on a specified particulate size. Table 1 outlines notional or approximate ISO 16890 ePMx ratings, and highlights where the various classification systems align and where they do not. For example, it is theoretically possible that an EN 779 G4-rated filter could be rated as an F5 filter if tested to AS 1324.2, because the test processes and test particle sizes differ. Based on the classifications of EN 779:2012 and ASHRAE 52.2 the reliability of sub-micron filter efficiency requires at least a minimum F7 or MERV11 classification. A manufacturer or supplier needs to have test reports (for the specific test standard) to substantiate any performance claims.

Because ISO 12103-1 A2 Fine Test Dust has a closer size spectrum to office dusts than other test dusts, this holding capacity best indicates the anticipated time between filter replacements in offices and other buildings with similar dust characteristics. This is most valid when the test airflow rate and filter final resistance are the same as in the intended application.

Factors affecting dust-holding capacity include: Media area – dust-holding capacity of a filter is approximately proportional to the area of media exposed to the airstream.

Media construction – graduated density media increases dust-holding capacity since large particles will collect in the first stages of the media profile while finer particles will collect in the denser stages. This type of media is common in air conditioning filters.

Media air velocity – reducing media air velocity will increase dust-holding capacity for the same final resistance. Increased surface area reduces velocity through the filter media.

Media compression – media will be ineffective for dust holding where it is compressed. For example, media compression at folds around wires in V form filters reduces dust holding at the folds. This is particularly the case with 50mm V-form panel filters where a substantial proportion of the media is affected by folds.

Table 1: Notional relationship between the filter classification systems Note: These technical comparisons are not always or entirely valid and any filter must be type-tested in accordance with the appropriate test standard before any particular performance can be claimed.

AS 1324* Rating

ISO 16890 Rating

ASHRAE 52.1 Rating

(approximation)

EN 779 Rating

ASHRAE 52.2 MERV Rating*

Arrestance

Efficiency

G1

ISO Coarse> 50%

G1

MERV 1 – 4

60 – 80%

< 20%

G2

ISO Coarse> 65%

G2

MERV 1 – 4

60 – 80%

< 20%

G3

ISO Coarse> 80%

G3

MERV 5

80 – 90%

< 20%

G4

MERV 6

90 – 95%

20 – 30%

ISO Coarse> 90%

G4

ISO ePM10 > 50%

F5

ISO ePM10 > 50% ISO ePM10 > 60%

F6

ISO ePM2.5 > 50% to 65%

G4

MERV 6 – 7

95%

25 – 30%

G4/M5

MERV 7 – 8

95 – 98%

30 – 40%

M5

MERV 8 – 9

98%

40 – 50%

M5

MERV 9 – 10

99%

50 – 60%

M6

MERV 10 – 11

99%

60 – 70%

M6

MERV 12 – 13

99%

70 – 80%

F7

MERV 13 – 14

99%

80 – 90%

F8

MERV 14 – 15

99%

90 – 95%

F9

MERV 16

99%

> 95%

ISO ePM10 > 85% F7

ISO ePM2.5 > 65% to 80% ISO ePM1 > 50% to 65% ISO ePM10 > 90%

F8

ISO ePM2.5 > 80% ISO ePM1 > 65% to 80% ISO ePM10 > 95%

F9

ISO ePM2.5 > 95% ISO ePM1 > 80%

* MERV A rating (i.e., on the discharged filter to be consistent with the other methods)

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August–September 2022

HVAC&R Skills Workshop Pinhole defects

Careless construction or handling of high-efficiency filters, especially where thin sheets of media are used, may result in small tears or pinholes.

The effects of pinhole leaks are accentuated at low face velocities. Testing at normal face velocities does not always show a significant increase in penetration by sub-micron particles in the presence of these pinhole leaks.

A2 V2

Penetration through high-efficiency filters decreases with decreasing air velocity; however, this characteristic is altered in the presence of pinhole leaks.

At very low velocities the proportion of flow through a hole increases relative to the rest of the filter, and penetration rises steeply. This effect is explained if the hole is considered as an orifice where airflow rate is proportional to the square root of the pressure drop, while flow through the main body of the filter is directly proportional to pressure drop.

This increase in penetration is most serious in the biological field where near absolute filtration is necessary, and low air velocities are used to favour low penetration. Clumps of bacteria, or particles with bacteria attached, could easily pass through pinholes. Scan testing of the filter pack will detect pinhole leaks and should be used for all critical applications.

A1 V1 Figure 2: Duct transition to filter bank.

For incompressible, steady flow:

A1 . V1 = A2 . V2 = Q/1,000 Where:

Filter service life

One of the most important economic considerations for an air filter in general ventilation and air conditioning is its service life. Filter service life can be estimated from Equation 1:

k × G × 109 L= (C × Q × E × 3,600) Where:

L k

Equation 1

Life in hours A factor that relates the actual dust held in the field to the dust held under test for the same final resistance and airflow

G

Dust held (g) by the filter when tested with the representative test dust to the application’s final resistance and at the application airflow

C

Concentration of dust in the airflow, as annual geometric mean (µg/m³)

Q E

Airflow rate (L/s) Efficiency rating as a decimal, not percentage (Not HEPA/ULPA efficiency) – average efficiency is used for the service life estimation.

Example – estimation of filter service life A filter has a 95% efficiency rating and a dust-holding capacity of 1,100 grams when tested at a final resistance of 125Pa at 1000L/s. The dust concentration in the air is 45µg/m³ and we assume a good quality filter with a k factor of 1.0.

G C I E L

= 1,100g = 45µg/m³ = 1,000L/s = 0.95 = 1.0 x 1,100 x 109 / (45 x 1,000 x 0.95 x 3,600) = 7,148 hours

For 10 hours per day, 5 days per week, 50 weeks per year = 2,500 hours of operation per year.

Estimated filter service life is 2.8 years for an average supply air dust challenge of 45 µg/m³.

Sizing filter banks on air capacity

Air filters are rated by the manufacturer to handle a maximum quantity of air (L/s) or have a maximum face velocity (m/s). Other performance factors are determined at this flow rate.

The required size of air filter bank and housing can be determined from the required system airflow and the recommended face velocity for the filter type and application.

A1 Area of duct at section 1 (m²) V1 Velocity of air at section 1 (m/s) A2 Area of duct at section 2 (m²) V2 Velocity of air at section 2 (m/s) Q Airflow rate (L/s).

Equation 2 states that for a fixed airflow Q, the product of area (A) and velocity (V) will remain the same. As “area” increases “velocity” reduces, as “velocity” increases “area” reduces.

Where Q is known and V2 is the recommended face velocity for the filter type and application (or lower), the required face area of the filter media bank (A2) can be determined.

Where V1 is the recommended air velocity in the duct, the cross‑sectional area of the duct A1 can be determined. This calculation will provide the general dimensions of the filter bank (face area and transition from duct size).

Example 1: Calculate face area Given flat panel air filters with openings of 500 x 500mm and a recommended face velocity of 1.5m/s, determine how many panels are required to handle 3,000L/s.

From Equation 2, for each panel

Q = A x V × 1,000 = 0.25 x 1.5 × 1,000 = 375L/s (maximum airflow, one panel)

3,000 / 375 = 8

Therefore 8 panels will be required to handle 3,000L/s.

Example 2: Calculate velocity Given a flat media surface area of 1.2m² and total air quantity of 2,000L/s, determine the velocity of airthrough the panel.

From Equation 2

V = Q / (A × 1,000) = 2,000 / (1.2 × 1,000) = 1.67m/s Filter manufacturers normally select the velocity of air across the media to achieve optimum performance relative to the fibre diameter, packing density, thickness of medium and anticipated dust load.

The recommended maximum air quantity for any filter or system should not be exceeded unless performance is verified by tests. ■ AND DITIONING N, AIR CON IGER ATIO E OF REFR INSTITUT TRALIAN THE AUS

HEATING

This skills workshop is taken from DA15 – Air Filters and Cleaning Devices.

For more information go to airah.org.au/da_manuals

DA15 D ERS AN AIR FILT DEVICES NG CLEANI

Continuity of flow In a duct with varying cross-sectional area the velocity changes along the duct as shown in Figure 2, i.e., in direct proportion to the change in area.

The continuity Equation 2 can be used to determine the dimensions of a duct‑to- filter bank transition, sized to target a required maximum air velocity at the face of the filter bank.

(Equation 2)

DESIGN

TION MAN APPLICA

UAL

Next month: Refrigeration piping – Suction lines August–September 2022

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August–September 2022

Industry Insight

WHAT’S IN A NUMBER?

Do we really appreciate the impact of the refrigerants we use?

TAFE NSW teacher Glenn Marsh gives us some perspective.

R404A – 3,943; R410A – 1,924; R32 – 677.

These are the global warming potential figures for three common refrigerants. We may or may not know these figures, or a version of them, but what do they actually mean?

Substitution

Are there any measures that can alleviate this situation?

Yes. And they follow OHS general risk assessment and control processes.

We need to switch refrigerants to options that have less environmental impact. Some of the alternatives have been around for some time – R744 (carbon dioxide) and R717 (ammonia) for example – and some are quickly becoming more viable, such as hydrocarbons. These will be the pillars that support our industry, and we need to get on board with them sooner rather than later. If we are not ready for the wave of change, it will crash on top of us.

THREE STEPS Training

DRIVING IT HOME Think of it this way. According to cars-data.com, a Toyota Hilux 2020 gives off 174g CO2/km.

This means this model would give off 1kg of CO2 for every 5.75km it is driven.

R404A has a GWP of 3,943. Multiply this by 5.75km and you would effectively have to drive the Hilux 22,661km for the same environmental impact. A 20g purge to the atmosphere is the same as 453km in the Hilux.

Considering how many purges might be done by technicians each year, and the number of technicians undertaking this practice, the numbers become very concerning.

We need high-quality, engaging, and up‑to‑date delivery of courses that are industry recognised, not only nationally but internationally.

With this, Australia could become an international leader in clean cooling and heating due to its movement in renewable energy and its sunshine!

This then takes us full circle back to training, and making sure that our technicians are ready to work with the incoming refrigerants and technology. ■

Elimination

Glenn Marsh teaches air conditioning and refrigeration at the TAFE NEW Newcastle Campus, Infrastructure, Energy and Construction.

The HFC phase-down is happening, and Australia has targets that are ahead of the Kigali Amendment timetable. These HFCs have a limited lifespan for use, so why not start making changes now?

This then moves on to …

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August–September 2022

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A U G U S T

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Cover Feature

MID-TIER HEROES A trio of new studies reveal how Australia’s HVAC&R industry – and our much‑neglected mid-tier buildings – can help us achieve our net zero aspirations. Louise Belfield reports.

TOWARDS ZEROENERGY BUILDINGS

According to the Australian Sustainable Built Environment Council (ASBEC), buildings in Australia make up about 19 per cent of total energy consumption and about 23 per cent of greenhouse gas emissions. And according to the Green Building Council of Australia (GBCA), commercial buildings account for 10 per cent of overall energy consumption, with commercial office buildings making up about 2.5 per cent.

The initiative, the Trajectory for Low Energy Buildings and its Addendum (the Trajectory) came out of the National Energy Productivity Plan. It was designed by a stakeholder reference group of 600 members representing energy consumers, the energy-efficiency sector, the building and property sector, the appliance and technology sector, the energy supply sector, gas suppliers, environmental organisations, energy consultants, universities, the Australian government, and state and territory governments.

Knowing the impact of the commercial building sector – and also that most of the energy we use in these buildings is used for cooling and heating – the next step is clearly to look at how we can improve the performance of our HVAC&R systems.

The Trajectory outlines policies to deliver costeffective energy-efficiency improvements to homes and businesses with a view to lowering energy bills, contributing to energy security and affordability, reducing carbon emissions, improving people’s comfort and health, reducing wastage for the wider economy, and reducing pressure on the electricity grid.

In March 2021, a study funded by the Department of Industry, Science, Energy and Resources (DISER) and undertaken by the University of Wollongong (UOW) provided results of the largest national survey of facilities managers, HVAC contractors and associated design and systems specialists ever conducted. The question they wanted to answer was how the management and maintenance of HVAC in commercial office buildings impacts on their energy performance.

These homes and business, however, make up only a fraction of our building stock.

The study focused on those directly responsible for this work in mid-tier commercial office buildings.

The resulting report, Better Ways to Work: HVAC Management, Repair & Maintenance in the Mid-Tier Commercial Office Sector (see HVAC&R Nation July 2021), was in response to a key initiative agreed to by all Commonwealth, state and territory energy ministers in 2019 to achieve zero energy and carbon-ready commercial and residential buildings in Australia by 2030.

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WHAT IS THE MID-TIER? Mid-tier office buildings are generally defined as non‑premium constructions. This is a sector that has been under-represented in energy upgrade activities to date, with little in the way of systematic data collection, says Daly.

“These buildings are often found in suburban and regional locations and have enormous potential for becoming more energy efficient. The Better Ways to Work project was commissioned to really get at some of the complexities of why we’re struggling to improve energy efficiency in this area.

“On paper, HVAC maintenance and upgrades have a very strong business case, but we also know that there are a lot of other factors impacting on lifting building energy efficiency – things such as work cultures and practices, owners not understanding the value of maintenance, regulatory complexity, as well as business models and established market ‘norms’ of lowest-cost contracting,” says Daly.

Any policies designed to improve the situation need to take all of this into account, he adds.

“The real challenge in reducing energy consumption is with about 85 per cent of our buildings – those older, smaller, and poorer quality buildings that make up most of Australia’s office building stock – the ‘mid-tier’,” says Dr Dan Daly, project co-lead for the UOW study.

Consequently, the Addendum to the Trajectory for Low Energy Buildings – Existing Buildings, the second stage of the national plan, provides a suite of initiatives to do this.

“The Better Ways to Work project has provided a significant new empirical data source on maintenance practices for this sector, as well as detailed commentary on the policy implications of the new data, to assist the federal government in tailoring policies to improve the performance of HVAC in the mid-tier.”

These initiatives include developing information, training and energy rating tools for households and businesses to enable greater understanding of energy‑efficiency options and applications, developing and expanding target building policies, and identifying and developing supporting measures.

August–September 2022

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Cover Feature

BETTER WAYS TO WORK

BETTER WAYS TO WORK

BETTER WAYS TO WORK

IDENTIFYING COMMON ISSUES IN MID-TIER HVAC MAINTENANCE: COMMERCIAL OFFICES, AGED CARE, HOTELS AND SHOPPING CENTRES

MAPPING DECISION-MAKING AND OPPORTUNITIES FOR IMPROVING ENERGY EFFICIENCY ACROSS THE MID-TIER HVAC MAINTENANCE LIFECYCLE

UNDERSTANDING THE BARRIERS TO SKILLS DEVELOPMENT FOR ENERGY EFFICIENCY IN COMMERCIAL BUILDING HVAC

AUGUST 2021

DECEMBER 2021

JANUARY 2022

IDENTIFYING COMMON ISSUES IN MID-TIER HVAC MAINTENANCE: COMMERCIAL OFFICES, AGED CARE, HOTELS AND SHOPPING CENTRES

BETTER WAYS TO WORK

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MAPPING DECISION-MAKING AND OPPORTUNITIES FOR IMPROVING ENERGY EFFICIENCY ACROSS THE MID-TIER HVAC MAINTENANCE LIFECYCLE

1

HOW THE STUDY WAS CONDUCTED

BETTER WAYS TO WORK

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This was followed by a series of “deeper dives”, culminating in three final reports (shown above).

“We used industry interviews and targeted surveys to better understand the maintenance workflow and highlight where to target information programs, incentive schemes or regulation for maximum effect,” says Daly.

The UOW team brought together engineers and social scientists to design a project that could delve into the complex issues, Daly says.

“The resulting Better Ways to Work study looked at issues right across the maintenance and upgrade procurement cycle, as well as workforce and contractual concerns.”

“We also considered the extent to which the issues identified in the mid-tier sector were present in other types of buildings, namely hotels, shopping centres and aged-care facilities.

Finally, we looked at workforce issues that came out of the survey, and how government and industry could better support this workforce, which is going to be vital as Australia’s climate continues to change.”

The first step, in 2020, was a large survey that went out to HVAC contractors and facilities managers.

More than 1,000 respondents provided solid data about what they see in buildings, and the barriers they face in achieving good maintenance, repair and retrofit work.

UNDERSTANDING THE BARRIERS TO SKILLS DEVELOPMENT FOR ENERGY EFFICIENCY IN COMMERCIAL BUILDING HVAC

1

BETTER WAYS TO WORK

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1

THE THREE FINAL REPORTS Ultimately, the team identified three areas for further investigation: •

Common HVAC maintenance issues across different mid-tier sectors: commercial office buildings, aged care, hotels and shopping centres

•

Decision-making and opportunities for improving energy efficiency across the mid-tier HVAC maintenance lifecycle

•

Barriers to skills development for energy efficiency in commercial buildings.

“In designing the initial survey for the Better Ways to Work study we were very aware that HVAC technicians

BARRIERS TO BETTER MAINTENANCE This report looked at decision-making across the HVAC maintenance life-cycle, and the issues that impact the quality of HVAC maintenance.

The team prioritised 15 key issues, according to their impact on the quality of HVAC maintenance, how frequently the issues are encountered, and a significance ranking. These ranged from how job performance is judged (the evaluating maintenance performance phase) to perverse influences on design decisions (the design and installation phase).

1. Job performance is judged on a different timeframe (short) to the impacts of maintenance decisions (long), leading to short-term fixes

5. FMs’ job performance is judged on budgets, not life-cycle performance, with potentially adverse impacts on the HVAC system

2. Upfront cost implications of repair or upgrade prioritised over life-cycle cost and system

6. Budgets are often pre-determined before HVAC professional input, which rules out the best solutions

3. Preventative maintenance contracts lack detail regarding expected standards, resulting in conflicting interpretations between contractor and client

7. Split incentives for maintenance decisions, with tenants paying the cost of maintenance, but owners paying the cost of upgrades 8. Lack of consequences for malpractice

4. The preventative maintenance market is highly competitive and cost driven, so it is delivered as a lowest cost service

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9. Lack of sufficient oversight of HVAC installation and maintenance quality

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10. FMs are unable to provide appropriate maintenance oversight either due to lack of time, or skills and experience 11. Perverse incentives impacting maintenance decisions about whether to patch, repair or upgrade 12. Lack of time provided to understand HVAC systems in new buildings or new contracts 13. Lack of detailed project briefs or specifications, particularly in smaller buildings 14. Conflicting priorities between fixing performance or “fixing” complaints 15. Perverse influences on design decisions.

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Cover Feature The Better Ways to Work report was the first of the series, released in 2021. It provides the high-level findings from the initial survey, and important context for the deeper dives.

and FMs are busy, and would have limited time to respond to our questions,” says Dr Matthew Daly, the researcher leading the maintenance workflow stream.

“So, we kept the survey short and sharp, and were delighted by the very high response rate relative to previous mid-tier projects. This provided national context around the people, buildings and systems in this sector, and the relative importance of some of the key issues from previous work. We then designed a number of follow-up projects to dig into the detail of the responses that we received.

The Identifying common issues in mid-tier HVAC maintenance report addresses the extent to which mid-tier issues are unique to the sector, or common across many types of commercial buildings.

“Most HVAC technicians work across multiple sectors,” says Carr, “so they were in a great position to compare and contrast.”

“Many of the participants kindly agreed to be contacted regarding their responses, and we had a fantastic opportunity to go back to survey respondents and talk to them in more detail about the maintenance procurement process. It also gave us an invaluable cohort of engaged respondents to test out our conclusions and recommendations in focus groups and targeted surveys.”

The Mapping decision-making and opportunities for improving energy efficiency across the mid-tier HVAC maintenance lifecycle report presents the findings of follow-up interviews, focus groups and surveys with HVAC technicians and FMs. These helped the team better understand maintenance workflows, and importantly, to identify the most critical issues and most promising policy solutions.

Dr Elyse Stanes, the researcher leading the skills and training stream, says they also took some of the findings and issues identified in the initial surveys and sought out other stakeholders to get new perspectives.

Finally, Understanding the barriers to skills development for energy efficiency in commercial building HVAC addresses fundamental questions about the HVAC&R workforce. It looks at the skills, knowledge and professional networks required to meet the federal government’s Trajectory for Low Energy Buildings. It also explores how to strengthen training and professional development pathways for those working on commercial buildings.

“Given the success of the initial survey, DISER were keen to understand the extent to which the findings might apply to other hard-to-engage sectors,” she says.

“Issues around skills and training were also highlighted from our survey, so we took a deeper dive into the skills, training and licensing of HVAC technicians around the country.

NEXT STEPS

“The HVAC workforce is crucial in improving energy efficiency in buildings, and also in electrification of many systems. There is a major societal transition already underway that will have HVAC technicians right at the frontline, and it is important that the training system is ready to equip the workforce with the skills needed.”

With little existing work available in the academic or policy space dealing with the mid-tier, the UOW team is working to place the results in the context of global experiences of the energy transition, and to continue to build the case that maintenance is vital to decarbonisation, says Dr Dan Daly.

COMMON THEMES AND ISSUES

“We’ll be presenting the findings in many forums over the coming year, including ARBS 2022 and AIRAH’s the Future of HVAC Conference, and will be very interested in industry feedback.

Dr Chantel Carr, project co-lead for Better Ways to Work, says all four reports are designed to stand alone; however, they do share common themes and issues, and together they give a comprehensive picture of the issues facing policymakers looking to target energy efficiency in the mid-tier.

“We’ll also be actively working to ensure the important issues raised through Better Ways to Work continue to be considered by the incoming federal government.” ■

BEYOND COMMERCIAL OFFICES Hotels: The hotels sector is diverse in terms of size, building type and ownership profile. Because motels and small hotels typically use domestic air conditioning systems, discussion focused on larger hotels. These appear to operate in a relatively similar manner to the office sector, using similar HVAC equipment and building stock. Typical HVAC configurations include a central chilled water plant with fan coil units serving individual rooms, although there were many examples of the use of packaged units or split systems, even in large hotels.

To assess the similarities and differences between commercial buildings and other sectors, this study conducted: • A review of relevant literature for aged care, hotels and shopping centres • Interviews with sector experts and professionals • Focus groups with HVAC and facilities management professionals in these sectors.

Aged-care facilities: Based on the finding from interviews, there are many differences between aged-care facilities and mid-tier commercial office buildings. The interviews in all cases focused on residential aged care facilities, and although village‑type facilities are common, these sites typically use residential air conditioning systems and are substantively different to the commercial sector.

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Shopping centres: Interviews with sector stakeholders suggest that many of the issues identified in the mid-tier office sector will likely also exist in the shopping centres space, albeit only in certain shopping centres. The sector appears similar to the office sector, in that there is a large diversity of building stock, system quality, and ownership types. ■

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BUILDING THE SKILLS This study identified seven key skills development issues as barriers to delivering on energy transitions in the built environment: 1. Attraction, retention and attrition of HVAC contractors 2. The professionalisation of facilities managers 3. Inflexible VET training regimes for HVAC contractors 4. Limited capacity for responding to new technologies for HVAC contractors and facilities managers 5. Misalignment of routine tasks with skill levels of HVAC contractors 6. Lack of recognition for soft skills for HVAC contractors and facilities managers 7. Complex regulatory environment across states for HVAC contractors.

The report also provided a framework for improving skills development: 1. Shaping a workforce on the frontline of energy transitions in the built environment via: • Working with industry to develop a workforce attraction strategy • Government and industry support for workforce retention.

2. Enhancing capacity for skills and training to meet the Trajectory for Low Energy Buildings by: • Supporting upskilling to keep pace with new technologies and information • Broadening the remit of energy‑efficiency training to include soft skills.

3. Supporting the development of skills and training through a multi-scalar, cross-sectoral approach by: • Recognising diverse ways of acquiring skills and knowledge to deliver a future‑focused workforce • Developing a training eco-system approach to skills development for energy efficiency. ■

To read the main Better Ways to Work report and three other reports, go to betterwaystowork.com.au

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Around the Nation 2

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Training held in South Australia with CA Group at Airefrig Wingfield branch.

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INDUSTRY INSIGHT AT ARBS

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The training sessions took place at supermarkets supported by City FM in Victoria and South Australia, making use of a transportable, containerised CO2 transcritical refrigeration system, as well as the refrigeration systems at the supermarkets.

ARBS 2022 has announced an extensive line-up of seminars and presentations to be held during the exhibition at the Melbourne Convention and Exhibition Centre from August 16–18.

The sessions focused on familiarising participants with the components of the systems, and reviewing procedures for charging, pumping down, changing coalescent filters, adding oil, fault-finding, and changing a drier or compressor.

The program incorporates the ARBS Seminar Program, a content-rich program for the entire HVAC&R and building services industry; the IBTech Insight Series, dedicated to intelligent building technologies; and the ARBS Exhibitor Presentation Theatre, a space for exhibitors to present their latest equipment.

For more information, go to www.cagroupservices.com.au

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MAKING SENSE OF THE DOLLARS

AIRAH has launched the second edition of its Salary Survey to help the industry benchmark wages and forecast trends in employment. The survey will run until the end of August and is for all workers in the HVAC&R sector.

Responses will be made anonymous, collated, and shared later in the year.

Costs will be advised with the release of the final program.

For more information and to register, go to www.arbs.com.au ■

The first edition of AIRAH’s HVAC&R Salary Survey was conducted in 2019 and saw almost 500 people respond. The information provided an excellent view of the industry, and given the past two years with COVID-19 and other major upheavals, it will be interesting to see how the figures compare.

UPSKILLING WITH CO2

Industry has been skilling up on CO2 refrigeration systems through two new training programs.

The Salary Survey is 21 questions long and should take approximately 15 minutes to complete.

Beijer Ref and Superior Training Centre have joined forces to offer a nationally accredited CO2 course on state-of-the-art equipment in a custom-built facility.

Participants have the option to go in the draw to win one of three $100 gift cards.

Go to airah.org.au/salarysurvey

Those who successfully complete the two-day course receive a statement of attainment for UEENEEJ184A – Apply safety awareness and legal requirements for carbon dioxide refrigerant and UEENEEJ185A – Repair and service carbon dioxide refrigeration systems.

The accreditation is authorised by Superior Training Centre and recorded against the technician’s unique student identifier.

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PANASONIC PRESENTS …

A range of Panasonic’s indoor air quality solutions will be on display, including the nanoe X technology designed to actively clean the air and surfaces within a room.

According to the company, nanoe X uses OH radicals encapsulated in water to inhibit micro-organisms – including bacteria and

CO2 transcritical training has also been carried out by CA Group with City Facilities Management (City FM) refrigeration mechanics at retail sites around the country (pictured). |

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Panasonic will showcase its latest air conditioning and ventilation solutions at ARBS 2022.

Enrolment enquiries should be directed to bracademy@beijerrefsupport.com.au

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viruses – as well as inhibiting mould, allergens and pollen, and reducing odours. The active air purification technology is featured across most of Panasonic’s product range, from wall split and ducted systems to commercial systems, and can be operated when cooling or heating is not switched on, to minimise energy consumption.

Panasonic will be offering daily prizes at ARBS 2022, with visitors having the chance to win one of two Floor Standing nanoe X Air Purifiers.

Further details will be available at the Panasonic stand (735) during the exhibition.

Go to www.panasonic.com/au/#Air-Conditioning

Sessions include “Cold Hard Facts 2022 – Key developments and emerging trends in the RAC industry in Australia”; “Quantifying the benefits of HVAC Maintenance”; “Government update on the regulation of refrigerants”; “COVID-19 and ventilation 101”; “Better Ways to Work: Improving HVAC performance through maintenance”; and “What’s happening to refrigeration and air conditioning trade training?” – as well as many more.

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CPD NOW COMPULSORY

After a successful pilot program, Energy Safe Victoria (ESV) has officially announced the continuing professional development (CPD) requirements for electrical licence holders.

Most licence holders – including electricians and restricted electrical licence (REL) holders – must now complete a day of CPD training before their licence can be renewed. CPD can be completed at any time in the two years before a licence renewal falls due. ESV notes that working without the appropriate licence is strictly illegal, and can result in significant penalties.

CPD will be required for all licence renewals from July 1, 2023.

Class 1 REL holders will need to do eight hours, and Class 2 REL holders six hours, in a professional classroom environment at a convenient training provider. This training will need to be completed every five years.

The training will consist of 60 per cent hands-on practical work, and 40 per cent theory. An online learning management system has been developed to ensure attendees are well prepared.

Although there is no exam at the end of the training, trainers may indicate to participants any areas where they think skills knowledge could usefully be increased.

More information – including where the training can be completed – is available on the ESV website: esv.vic.gov.au/licensing-coes/licence-trainingassessments/cpd/ ■

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FREE FLAMMABLE RESOURCES

The Australian Refrigeration Council (ARC) has released a set of free A2/A2L refrigerant training resources for registered training organisations (RTOs).

The resources, developed in partnership with Refrigerants Australia and selected TAFE colleges, build on the unit of competency for A2/A2L refrigerants that the ARC created in 2018. They have been designed to assist RTO teachers in successfully teaching students about A2/A2L refrigerants, in particular R32.

R32 is mildly flammable and presents significant changes to the service tools, working practices, component standards and workplace safety considerations needed during the installation, repair, service and refrigerant recovery process.

“These training materials cover the safe handling of the gas that is rapidly becoming the most commonly used gas in split systems and is beginning to make an appearance in larger AC applications,” says ARC CEO Glenn Evans.

“The resources and assessment materials are Australian Qualifications Framework (AQF) accredited to provide confidence for both training providers and students alike.”

Go to www.arcltd.org.au/media/1132/ a2-a2l-resource.pdf ■

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A COOL CAREER

Visitors to the Lesmurdie Senior High School Career Expo in Perth were treated to a view of life in the HVAC&R sector.

The event is an opportunity for the student and parent community to find out about post-school career options. South Metropolitan TAFE was one of more than 20 exhibitors, and Darryl De Seran, Affil.AIRAH, and Joe Gosatti, M.AIRAH – both members of AIRAH’s WA division committee – were also in attendance.

The event was open to the local community, with about 500 people in attendance, including Year 10, 11 and 12 students.

“It was a big, successful day,” says De Seran.

“We handed out flyers and Joe came with his box of goodies that helped students gain some insights into how vast the industry is, the skills

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and the type of work done. I also had a lot of my specialised tools on display.”

Second, gasfitters must complete an online record of servicing work, using the new VBA online portal, and provide a copy of the record to the customer, both within five days of completing the work.

As noted in the June/July issue of HVAC&R News, one of the main challenges for our industry is attracting enough talent – starting with high-school students. ■

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Maintenance technicians will need to gather additional data to carry out the service and produce the required documentation.

Where hand‑held devices are used in the field, assistance may be required from back-of-house staff to issue the client with a copy.

HONOURS FOR COMPRESSOR KING

Industry stakeholders have warned that the changes will require extra time – potentially up to 15 minutes more per appliance. This will apply to programmed maintenance and casual and quoted work where a unit needs to be tested on completion.

Ron Conry, L.AIRAH, has been awarded the Member of the Order of Australia for significant service to the HVAC&R industry.

A refrigeration technician by trade, Conry started in the industry in the 1960s. He worked for around 25 years with traditional HVAC&R equipment, before setting out to create a better compressor.

More record-keeping will also be required, and Type A boiler technicians will now need a calibrated CO meter.

Drawing inspiration from a turbo charger he had seen in 1984, Conry decided the new compressor, dubbed the Turbocor compressor, would be a small micro turbine machine. Although the technology did not at that time exist, he foresaw that advances in electronics and other industries would make it possible.

In 1994, Conry formed a team to work on the design.

Go to vba.vic.gov.au/plumbing/as4575

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According to MATES in Construction, Australia’s construction industry is losing one worker per week to suicide. Construction workers are six times more likely to die from suicide than a workplace accident.

By partnering with MATES, simPRO aims to emphasise the importance of mental health and suicide prevention in the construction industry while helping to reduce the stigma associated with seeking help.

By working with MATES in Construction, the company says its goal is to reduce the number of lives lost to suicide each year in the construction industry.

The product has since achieved global recognition with more than 100,000 Turbocor compressors in operation worldwide.

In 2009, Conry received the James Harrison Medal, the highest honour of AIRAH. He was also included in AIRAH’s 100 Faces. ■

“The mental health of the trade industry is a cause that simPRO is fully behind,” says simPRO CEO Sean Diljore.

NEW RULES FOR GAS SERVICING

As well as undertaking awareness training internally, simPRO will be supporting MATES in Construction at industry events and participating during Fly the Flag day in September – a day set aside to celebrate what the construction industry is doing to create awareness of the importance of their workers’ mental health.

As a result of amendments to the Gas Safety Regulation 2022 in Victoria, those servicing gas appliances must now meet new requirements.

First, AS 4575 has been mandated as the prescribed standard for servicing work on Type A gas appliances that are part of a standard gas installation.

August–September 2022

TEAMING UP FOR MENTAL HEALTH

simPRO and MATES in Construction are joining forces to improve suicide awareness, prevention and support programs serving the construction industry in Australia and New Zealand.

The development process took about seven years, during which time Conry drew on his own extensive experience in the field of chiller and compressor rebuilding and maintenance. He also developed other technologies to overcome design challenges.

Finally, the team produced the oil-free, magnetic bearing Turbocor compressor.

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For more details of Fly the Flag day, go to flytheflag.mates.org.au ■ |

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Smoko with . . .

Dream car: Chopped 200 Series LandCruiser with custom canopy.

Name: Antonis Condoleon on & Air Conditioning Company: Shelair Refrigerati Occupation: Refrigeration

estimator

ut working in HVAC&R? What’s the best thing abo and freezers.

Working inside coolrooms d in the industry?

How long have you worke 19 years. g that has changed What is the biggest thin you started? A lot more ce about the industry sin n when I first started. cowboys in the trade now tha efficient equipment.

Also, the shift towards more you on a worksite, If someone wanted to find son who … per they should look for the sure king ma is Has clean boots and y. bus ays alw the apprentices are s it’s Favourite tool: These day re. asu me e tap r lase the ever received: Best on-the-job advice you ething, stop.

Once you have tightened som Don’t strip the thread.

Dream holiday: Greek islands.

Favourite smoko snack: Home-cooked lasagna.

What did you listen to on the way to work today?

Liverpool Blood Red Podcast.

Sporting hero: Mark Schwarzer.

When I’m not working I’m …

Either camping or tinkering with something at home.

Cool Tech

AXE TO THE MAX

When it’s time to give something – a log, usually – the chop, the Fiskars Splitting Axe is a solid bet.

Designed for splitting large logs into smaller chunks of wood, the Fiskars Splitting Axe is a versatile and useful tool.

“There is a perfect balance between the head and the shaft, which provides a safe, comfortable and efficient swing,” says Fiskars, the Scandinavian toolmaker better known in Australia for its loppers and secateurs.

“The FiberComp shaft was designed to be ultra-light and durable, making it virtually unbreakable. It also helps to minimise fatigue, so you can save your energy for other important tasks.”

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Boasting a longer-than-regular shaft, this Fiskars model is designed to offer more power for those heavier splitting tasks. For added safety, the end of the handle is hooked to prevent slippage.

“Been struggling to split up tonnes of wood with old axes,” another review adds. “This is an absolute dream to use. Cuts wood like butter, and easy to dislodge when it becomes wedged in.

Lightweight and easy to wield.”

“This axe has a perfectly weighted and shaped head, and an extra-long handle to ensure maximum splitting power,” says one online reviewer. “Great axe.”

The Fiskars Splitting Axe XXL X27 is available from several retailers, including Bunnings and Mitre 10, for about $139. ■

(Like firing up the barbeque or topping up the drinks, maybe?)

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The Lighter Side This month’s Lighter Side brought to you by:

HVAC&R Search The search tool for specialists

BOOKINGS OPENING SOON FOR 2023!

hvacrsearch.com.au

VOTE FOR THE WINNER! Choose your favourite entry at www.hvacrnews.com.au/the-lighter-side And check out last issue’s winner: Short sighted from Ray in Sydney.

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For details go to 4

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WINDOW UNIT?

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COOLROOM NIGHTMARE

Sahil got a service call to a coolroom that wasn’t working and found this.

“Customer said it had been working fine for the last 10 years,” says Sahil. “I ran out and drove away!”

OUT WITH THE OLD

Gary came across this instal in Melbourne, where an old three-phase unit was replaced by a new wall‑hung, picking up single-phase power from the old condenser.

“Also note the pipework dropping down to the indoor unit through the middle of the box gutter on a large commercial deck roof,” says Gary. “Not ideal!”

Graham says: You wonder why anyone would Graham says: Best thing to do! They probably do this – either inadequate budget or a rip-off. wouldn’t pay. I wonder what the outdoor unit looked like.

Long-time Lighter Side fan Charlie reckons he might have a winner.

“No isolator, no duct,” he says. “The pipes and wires run through the window and the unit is balanced on bricks.

The unit has since been disconnected, thankfully.”

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Graham says: Just goes to show how resilient HVAC&R systems are. The question is: does it work efficiently and safely? That is the difference between someone who takes pride in their work and a cowboy.

Or maybe done for a mate with no budget?

FRUSTRATED BUILDER?

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GREAT AUSSIE INVENTIONS

Simon found this over‑engineered set-up on a roof in Melbourne.

“I don’t think it’s going anywhere!” he says.

You’ve heard of the Hills Hoist, how about a Fridgie Foldout?

Thanks to Phil who snapped this on a weekend away at York Peninsula, SA.

Graham says: Maybe concerned about increased cyclone activity due to climate change?

Or possibly a mate who is a scaffolder?

Graham says: Heat pump clothes driers are top-ofthe-range appliances! This one provides cooling at the same time as drying clothes – highly efficient.

Additional comments and observations provided by Graham Boyle, F.AIRAH, portfolio manager, heavy automotive and refrigeration at South Metropolitan TAFE. Please note that the comments are provided on the basis of the photos only and should be read with this in mind – not all issues or solutions are apparent from a 2D image.

HAVE YOU COME ACROSS SOMETHING SCARY, UGLY OR JUST PLAIN FUNNY? If your entry is deemed the winner, a 700ml bottle of Jim Beam will be on its way to your door. Please include a postal address with your entry. Entrants must be 18 or over. Send your hi-res (>500KB) photos to Editor, Mark Vender at mark.vender@airah.org.au 30

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