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GuidetoGoodCommercial
RefrigerationPractice

Part8
RefrigerantsandRetrofitting

BritishRefrigerationAssociation

InstituteofRefrigeration

Issue1December2008

GuidetoGoodCommercialRefrigerationPracticePart8
RefrigerantsandRetrofitting

Licensed copy from CIS: DUBLIN, DUBLIN INSTITUTE OF TECHNOLOGY, 10/10/2014, Uncontrolled Copy.

CONTENTS

8.1.0

8.2.0

8.3.0

8.4.0

8.5.0

8.6.0

INTRODUCTION
REGUALTORYCONSIDERATIONS
8.2.1 GENERAL
8.2.2 OZONEDEPLETION
8.2.3 GLOBALWARMING

REFRIGERANTTYPES
8.3.1 GENERAL
8.3.2 HALOCARBONS
8.3.3 CFCsANDHCFCs
8.3.4 HFCs
8.3.5 HYDROCARBONS
8.3.6 AMMONIA,R717
8.3.7 CARBONDIOXIDE,R744

REFRIGERANTSELECTION
8.4.1 ENERGYEFFICIENCY
8.4.2 NEWINSTALLATIONS
8.4.3 CONVERSIONOFEXISTING(ODSCONTAINING)SYSTEMS
8.4.4 COMPRESSORLUBRICATINGOILCONSIDERATIONS

REFRIGERANTSCOMMERCIALLYAVAILABLE

LEAKDETECTION

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8.1

INTRODUCTION
Refrigerant is one of the key components in a refrigeration system and should be
selectedwithgreatcarebecauseitschoicecanimpact,substantially,onthesystem
design,andancillarymechanicalcomponents.Therefrigerantshouldbeselectedto
ensure that the system will be cost effective (throughout the lifetime operation of
the system and should not have any detrimental environmental effects) consistent
withuseandlocalregulatoryrequirements.

8.2 REGULATORYCONSIDERATIONS

8.2.1 GENERAL

Refrigerants are volatile chemical substances they exist in the liquid phase when
containedunderpressure,butmostrefrigerantswillbeinthevapourphaseunder
atmospheric temperatures and pressures. If the refrigerant is released due to an
accidentalruptureofthesystemorasaleak,refrigerantvaporisesrapidlyandwill
quickly diffuse into the local atmosphere before eventually dispersing. Local
concentrations in air can exist for long periods before dispersing (by means of
convection, natural air movement, mechanical ventilation, or other mechanisms).
Refrigerant/airmixtureshavesignificantsafetyconsequencesforhumans,including
thepotentialforasphyxia,toxiceffects(frominhalationofrefrigerantvapours)and,
inthecaseofflammablerefrigerants,fireorexplosion.Chemicallyinertrefrigerants
existintheatmosphereformanyyearswithpotentialadverseconsequencesforthe
globalenvironment.

Use of refrigerants is controlled through safety regulations by regulatory bodies.

Regulations are based on the safety classification of refrigerants, which govern
applicationsandlocationsofuse.Theregulationsusesafetystandardsastheirbasis.
EN378:2008assignssafetyclassificationsandPracticalLimitconcentrationsforeach
refrigerant. These classifications and Practical Limits govern the maximum system
chargesizeforspecifiedOccupancycategories.

In general the morestrict the safety class of the refrigerant (by toxicity or
flammability class, or both) the smaller the system charge allowed by the
regulations, especially where the public may be affected in the case of abnormal
operation. Systems are designed where highly toxic or flammable refrigerants are
usedwithacceptablehazardrisk,howeversuchdesignsarecomplexwithadditional
costs.
8.2.2 OZONEDEPLETION

Environmental regulations have a significant impact on the refrigeration industry.

The introduction of the Montreal Protocol bans the use of Ozone Depleting
Substances(ODSs).

This Protocol was enacted in Europe as Regulation 2037/2000, (See Part 3) which
banned the use of CFC refrigerants ( R11, R12, R502 and others) both for new

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RefrigerantsandRetrofitting
systems and for servicing existing systems and HCFC refrigerants (of which R22 is
thebestknown)foruseinnewsystems.Newlyproduced(socalledvirgin)HCFC
refrigerants can be used for servicing existing refrigeration and airconditioning
systems only until the end of 2009. Recovered HCFC refrigerantscanbeuseduntil
theendof2014.

8.2.3 GLOBALWARMING.

Manyfluorinatedrefrigerantsaregreenhousegases(GHGs)whichwhenreleasedto
theatmospherecontributetoclimatechange(commonlyknownasglobalwarming).
AlthoughpotentGHGsintermsoftheirindividualGWPs,HFCrefrigerantswhich
arereplacingtheOzonedepletingCFCandHCFCrefrigerantsarecurrentlyreleased
in small quantities in comparison with other GHGs (CO2, Methane, Nitrous Oxide,
etc.)thattheiroveralleffectonclimateissmall.Itisimportant,howevertoensure
thattheemissionsofHFCsarenotallowedtogrowinanuncontrolledmanner.To
thisendtheEUhasintroducedtheFGasRegulation(SeePart3)aimedatcontrolling
emissions of nonODS Fluorinated fluids, (HFCs and PFCs). The use of these
substancesisnotpermittedinmanynonrefrigerationapplications.Theyareallowed
in refrigeration and air conditioning systems subject to controls ensuring minimal
emissions.

8.3 REFRIGERANTTYPES

8.3.1 GENERAL.

Vapour compression cycle refrigerants are those which change their physical state
from liquid to vapour and back again, during the refrigeration cycle. The phase
change is used to collect heat from the evaporator and transfer heat to the
condenser.Refrigerantswhichchangetheirphaseattherequiredtemperatureonly
existasvapoursatnormalambientpressuresandtemperatures,andhencetheiruse
in a closed circuit system in which the refrigerant is contained during its working
lifetime. Refrigerants must be inert (unreactive) to the component parts of the
system.Thereareseveralgroupsofchemicals,whichmeettheserequirements.

Themainclassesofrefrigerantfluidsare:

HalogenatedFluids,ieHCFCsandHFCs

Hydrocarbons

Ammonia

Carbondioxide

8.3.2 HALOCARBONS

These synthetic chemicals have been used for domestic, commercial and many
industrial refrigeration and air conditioning systems since their introduction in the
early 1930s, due to their chemical inertness and low hazard to humans. The
halocarbon family of refrigerants are often used as mixtures of two or more

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RefrigerantsandRetrofitting
individual refrigerants to produce a blend with appropriate physical properties
(principallyboilingpoint)fordifferentrefrigerationapplications.Toaididentification
of these substances an R Number classification system has been universally
adoptedbytherefrigerationindustry.AllrefrigerantshavebeenassignedauniqueR
Number.(TheserefrigerantsaresubjecttospecificregulationsintheUKSeeclause
8.2.2)

8.3.3 CFCSsANDHCFCs

Asubsetofthehalocarbonfamilyisthechlorinecontaininghalocarbons(CFCand
HCFC refrigerants ), and bromine containing halocarbons (Halons), which are
responsible for Stratospheric Ozone Depletion and are being phasedout under
regulationsinaccordancewiththeMontrealProtocol(see8.2.2).

8.3.4 HFCs

Nonchlorine (or bromine) containing halocarbons, the HFCs (and PFCs), are
replacing CFCs and HCFCs in many applications. The HFC/PFC family has far fewer
members than the overall halocarbon family and relatively few of these chemicals
havetherequisiteproperties(physicalandsafety)toqualifythemforrefrigeration
use. Commercial refrigerants with the required properties have been developed
usingmixtures/blends(2,3,orsometimes4constituents)ofHFCs.Mixtures/blends
areassignedRNumbers,intheR400andR500series.

Blends are susceptible (to a greater or lesser extent) to a phenomenon called

compositionshift.Compositionshiftisaconsequenceofadifferenceincomposition
between the liquid and equilibrium vapour phases of the individual refrigerants
making up the blend. If, for example the vapour phase leaks, or is preferentially
removed, the remaining blend composition will be different from that of the
standard blend composition originally charged into the system. If a significant
quantityofvapourisremovedthecompositionoftheresidualliquid(andtherefore
itscharacteristicsasarefrigerant)canalsochange.

The composition of some blends (notably R407C) results in the blend not
evaporating/condensing at a fixed temperature and evaporates/ condenses over a
range and this is known as Temperature Glide In practice, for commercial
refrigerantblendstemperatureglideisnotanissuetheevaporatororcondenser
behavesasifitstemperatureisatthemeantemperature.

While HFC refrigerants used in commercial applications have attractive safety and
physicalpropertiestheyareGreenHouseGases(GHG)andareincludedinClimate
Changeregulatorymeasures(see8.2.3above).

8.3.5 HYDROCARBONS.

HydrocarbonrefrigerantshavezeroODPandverylowGWPandasaresultoftheir
environmentalpropertiestheyhavebeenintroducedasrefrigerantsinsmallsystems

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where the refrigerant charge is low. These refrigerants are highly flammable,
formingexplosivemixturesinair,andtheiruseisregulatedbysafetystandards(EN
378,EN60335240andothers)andlocalsafetyregulations.
Licensed copy from CIS: DUBLIN, DUBLIN INSTITUTE OF TECHNOLOGY, 10/10/2014, Uncontrolled Copy.

Hydrocarbon refrigerants in properly designed systems are good refrigerants,

howevertheirapplicationrangeislimitedbecauseoftheirsafetycharacteristics.
Butane (R600), iButane (R600a), Propane (R290) and Propene (R1270) are the
mostcommonlyusedrefrigerants

8.3.6 AMMONIA,R717

Ammonia(R717)isoneoftheoriginalchemicalsubstancesusedasarefrigerantfor
mechanicalrefrigerationsystems.IthaszeroODPandzeroGWP,butithasahigh
level of toxicity. Ammonia is used in large industrial refrigeration systems such as
cold stores. Safety regulations often prohibit the use of ammonia in refrigeration
systemsinresidentialareas.
Ammonia is also used (in very small quantities) in absorption refrigerators often
seeninhotelroomminibars.

8.3.7 CARBONDIOXIDE,R744

CO2hasazeroODPandaGWP=1.Interestincarbondioxideisreawakeningdueto
its environmental properties and its attractive thermal transport properties (good
heattransferproperties).CO2 doeshave,however,somechallengingpropertiesasa
refrigerant, such as at high condensing pressures (>100 bar) It has a relatively low
critical temperature (31C). This means that for most systems the highpressure
vapour cannot be condensed and this type of system is described as transcritical,
Veryhighgaspressures(>100bar)intranscriticaloperationaregeneratedandthe
gasiscooledinagascooler.CO2 alsohasarelativelyhightriplepointpressure,5.3
bar,belowwhichaliquidphasedoesnotexist.

ConsiderabledevelopmentworkhasbeencarriedoutinrecentyearsonCO2systems
foruseincommercialapplications.

8.4 REFRIGERANTSELECTION

8.4.1 ENERGYEFFICIENCY

Refrigeration and air conditioning systems, collectively, are responsible for a

substantial proportion of global energy consumption. With the increasing focus on
ClimateChange,theenergyefficiencyofrefrigerationandACsystemsarebecoming
evermoreimportant.

Efficiency of refrigeration systems is governed by the laws of physics and by

practicality. Practicality embraces cost and legislative requirements, refrigerant
safety characteristics and maintenance considerations. Efficiency is primarily
dependent on good design, selection of appropriate system, good maintenance.

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Practicality often leads to a choice of HFC refrigerants. For some applications,

ammonia,hydrocarbonsorcarbondioxidewouldbethepreferredchoice,butthese
refrigerants are not suitable for all applications. Good design and maintenance is
vitaltominimizeemissionsofgreenhousegases.

8.4.2 NEWINSTALLATIONS

Choiceofrefrigerantwillbedeterminedbytheapplication,systemlocation,safety
and cost effectiveness of system design. System design is typically evaluated on a
life cycle cost basis as to both the environmental cost in terms of total carbon
equivalentemissions,andtotalmonetarycostofownership(investment,operating,
maintenanceanddecommissioningattheendofitsusefullife).

Thereareregulatoryconstraintsontheuseofrefrigerants,notablythebansonthe
use of ODS refrigerants, and local planning regulations which restrict the use of
refrigerantssuchasammoniaandhydrocarbonsincertainlocationsorapplications.
Often, where there are public safety risks, the use of HFC refrigerants is the only
practicalsolution.

8.4.3 CONVERSIONOFEXISTINGODSREFRIGERANTSYSTEMS

Environmental regulations, have resulted in the banning of ODS refrigerants (CFC

and HCFC) refrigerants), and have affected many millions of refrigerating and air
conditioningsystemswhichusethesesubstances.Theserefrigerantswillbenotbe
availabletoservicesystemsaftertheendof2009,thereforetherefrigerantwillneed
tobechangedtoenablethesesystemstooperateonanongoingbasis.

It is not feasible to replace a CFC or HCFC refrigerant with a hydrocarbon (due to

fundamentalelectricalsafetydesignconsiderationstopreventexplosions),ammonia
(material compatibility because ammonia corrodes copper,andtoxicity),orcarbon
dioxide(highpressure/refrigerantperformancecharacteristics).

The nonavailability of CFC and HCFC refrigerants will require that systems using
theserefrigerantsbereplacedortherefrigerantchangedforaHFCrefrigerantwith
similarpressureandperformancecharacteristics.Series400refrigerantshavebeen
developed, and are commercially available, as replacements for CFC and HCFC
refrigerantsinexistingsystems(seetablein8.5).Achangeofrefrigerantmayrequire
anoilchange.(seebelow)

8.4.4 COMPRESSORLUBRICATINGOILCONSIDERATIONS

Refrigeration compressors have a long operational life with minimal servicing over
the lifetime of the refrigeration system. An important contributor to compressor
reliability is the lubricating oil used. The interaction between the oil and the
refrigerantisimportant.

During system operation small amounts of the oil are carried with the compressor

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discharge vapours from the compressor within the refrigerant vapour. It is
importantthatthisoilreturnstothecompressorforadequatelubricationofmoving
parts. To assure consistent and adequate oil return the oil has to have a good
solubility/miscibility relationship with the refrigerant. CFC and HCFC refrigerant
systems have traditionally used hydrocarbonbased compressor lubricating oils
(mineraloilsoralkylbenzenebasedoils,ormixtures.).

WhenHFCrefrigerantsweredeveloped(toreplacetheregulatedCFCsandHCFCs)in
the 1990s it was realised that these fluids did not have the required
solubility/miscibilitywithhydrocarbonbasedoils,andfamiliesofsynthetic(PAGand
POE) lubricants were rapidly developed that are miscible. All new HFC system
compressorsusethesenewlubricants.

Systems using hydrocarbon compressor lubricating oils, present a problem when

they have to be converted to HFC refrigerants. When using HFC refrigerants
lubricatingoilintheoldsystemhastobetotallyreplacedwithoneofthenewoils
(usually POE). A relatively low residual level of Hydrocarbon oil (usually not more
than 5%) in the POE can be tolerated. To achieve these low levels the old
hydrocarbonoilhastobeflushedfromtheentirerefrigerationsystem.

Recently a group of hydrocarbon oiltolerant, zero ODP, HFC based refrigerant

mixtures/blendshasbeencommercialised.Thesefluidsdonotrequirethattheold
hydrocarbonbasedoilsberemovedfromthesystem,withobviousbenefitsinterms
oftheeaseofconversiontozeroODPrefrigerants.

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8.5

REFRIGERANTSCOMMERCIALLYAVAILABLE
Commercial Refrigerant Fuids (most commonly used)
Refrigerant

ODS

Boiling Point
(C)

Replacement for

Comment

R12
R502

YES
YES

-29.0
-45.4

R22
R401A
R402A
R403B
R408A
R409A

YES
YES
YES
YES
YES
YES

-40.8
-33.4
-49.2
-49.9
-44.6
-34.7

R12
R502
R502
R502
R12

R404A
R507A
R407A
R407C
R410A

NO
NO
NO
NO
NO

-46.5
-46.7
-45.0
-43.8
-51.6

R402, R403, R408

R402, R403, R408
R402, R403, R408
R22
OEM only

Requires POE
Requires POE
Requires POE
Requires POE
Requires POE

R413A
R417A
R422A
R422D
R424A
R426A
R428A

NO
NO
NO
NO
NO
NO
NO

-29.4
-39.1
-46.5
-43.2
-39.7
-28.4
-48.4

R401, R409
R22
R502, R402, R403, R408
R22,
R22
R401, R409
R502, R402, R403, R408

Mineral oil tolerant

Mineral oil tolerant
Mineral oil tolerant
Mineral oil tolerant
Mineral oil tolerant
Mineral oil tolerant
Mineral oil tolerant

R600
R600a
R290
R1270

n-butane
i-butane
propane
propene

NO
NO
NO
NO

-0.5
-11.7
-42.1
-47.6

OEM
OEM
OEM
OEM

Flammable
Flammable
Flammable
Flammable

R717

Ammonia

NO

-33.3

OEM only

Toxicity concerns

R744

CO 2

NO

-56.6

OEM only

Triple Point at 5.2 bar(a)

Critical Temperature 31C

Fluorocarbons
CFCs
Banned
Banned

HCFCs
Regulated
Regulated
Regulated
Regulated
Regulated
Regulated

HFCs
OEM

oil
oil
oil
oil
oil

Service

Non Fluorocarbon
only
only
only
only

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8.6 LEAKDETECTION

Loss of refrigerant from a system has a direct impact on global warming, and causes
inefficient and unreliable operation. In compliance with Fgas Regulation (EN 842/2006)
operatorsofHFCrefrigerationsystemsmustpreventleakage,ensureleakchecksarecarried
out,repairanyleaksassoonaspossibleandarrangeproperrefrigerantrecovery.Seealso
Part 5 of this Guide. The legal requirements are covered within the FGas Regulations EN
842/2006,andtheBRACodeofPracticeforRefrigerantLeakTightness,whichalsoincludes
asectioncoveringrefrigerantdetectionsystemcertification.

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ThisGuideispublishedinthefollowingParts:

Part1Introduction
Part2SystemDesignandComponentSelection
Part3SafetyRegulations,StandardsandDirectives
Part4SystemInstallation
Part5SystemCommissioning
Part6SystemMaintenanceandService
Part7SystemandComponentDecommissioningandWasteDisposal
Part8RefrigerantsandRetrofitting
Part9AssessmentofSkillsRelatedCompetenceandTraining

TheBRAandIORdisclaimallliabilitytoanypersonforanythingorfortheconsequencesof
anythingdoneoromittedtobedonewhollyorpartlyinrelianceuponthewholeoranypart
ofthecontentsofthisGuidancedocument.

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PublishedBy:

BritishRefrigerationAssociation
2WalthamCourt,MilleyLane,HareHatch,Reading,Berkshire,RG109THUnitedKingdom
TelNo:+44(0)1189403416FaxNo:+44(0)1189406258
email:info@feta.co.uk

InstituteofRefrigeration
KelvinHouse,76MillLane,Carshalton,SurreySM52JR,TelNo:+44(0)2086477033Fax
No:+44(0)2087730165

email:ior@ior.org.uk

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