1. Dutch Approach
Human beings and the RAC system
The influence on the leakage rate of RAC
equipment
Jan Reijmers info@stek
Thematic Meeting Hungary 21-10-11 1

2. Dutch Approach
Human beings and the RAC system
• Introduction
• Implementation
• Results
• Logbook and work report
• SPARK Project
• Summary
Thematic Meeting Hungary 21-10-11 2

3. Dutch Approach
Human beings and the RAC system
• Introduction
• 1991 implementation of the mandatory CFC reduction
in NL in cooperation with the Dutch RAC industry.
• Approach was „bottom-up‟ procedure
• Why?
• In NL 98% of the RAC installers are SME (≈3- 8 fte)
• We started with certification of personnel (human
beings)
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4. Dutch Approach
Human beings and the RAC system
• 1992 start of Assessment
• Most of the first persons were in the position of
“director/owner” of a Small Enterprise
• Content of Assessment:
• Soldering/Brazing
• Handling Refrigerant (work-procedures)
• Refrigerant register
• RAC knowledge
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5. Dutch Approach
Human beings and the RAC system
• The awareness of this assessment was
• these “persons” refreshed their knowledge
through a Course, or self study
• they did a practical training to be better
prepared for the Assessment
• As “director/owner” you must succeed.
• What did they learn during this preparation ?
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6. Dutch Approach
Human beings and the RAC system
• What did they learn during this preparation ?
 it is mandatory, which means we will be checked !
 we need a weight scale, for the refrigerant register
 we have to report that there is no leakage !
 there is a better way of soldering, because the soldering
was never checked by the pealing test and they never saw
the innside (what is the effect of the use of backing gas).
 nothing new about installation and commissioning of an
RAC systems
• Thematic Meeting Hungary 21-10-11 6

7. Dutch Approach
The results was
Prevention of leakage by:
1 Quality improvement
(accounting refrigerants, handlings and reporting)
2 Technical requirements: reduction of
leakage
(design, installation, maintenance)
3 Competence of personnel
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8. Dutch Approach
Results
• High awareness
• General quality improvement
• Leakage diminished rapidly (from ↑30% to 5-10%)
• Decrease of spare parts sales
• No free riders
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9. Dutch Approach
Scheme to certified Company
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10. Dutch Approach
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11. Dutch Approach
Audit List for STEK Certified Company
Auditing body data such as name, auditor
Company data such as name, address place and responsible director
Official documents of the certified Company
Officially statement of the company
Registration system for regular leak checking
Registration system for work report including checking of regular leakages by refrigeration system
A system for achieving work report of the last 3 years
Thematic Meeting Hungary 21-10-11 11

12. Dutch Approach
Audit List for STEK Certified Company
Certified Persons
List of certified persons
Signed letters of understanding of the official statement of the management of the company.
Procedure to inform all employees about the official company statement
Refrigerants register
Registration of each type of refrigerant The interval of registration is minimum one month Is the registration by
kg
Procedure to correct the loss refrigerant
Overview of purchased refrigerant by type in a interval of 3 months
Overview of returned refrigerants with or without pollution
Overview of used refrigerants of the last 3 years by type of refrigerants
Overview of used for new systems of each type of refrigerants of the last 3 years
Overview of used for service and maintenance of each type refrigerants of the last 3 years type of refrigerants
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13. Dutch Approach
Audit List for STEK Certified Company
Logbook Documents
Pressure Certificate with data and figures acc STEK guidelines
Evacuation Certificate with data and figures acc STEK guidelines
Leakage test Certificate with data and figures acc STEK guidelines
Work reports
To register the amount of used refrigerant
To register the used components and spare parts
To report the executed work
To report the executed work special place for, starting up the system, leak checking, repairing, return of
refrigerant (with or without pollution)
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14. Dutch Approach
Audit List for STEK Certified Company
Work procedures
Procedure how to recording the data and figures in the logbook of the end user
Procedure for a pressure test, evacuation test, handling refrigerant,
Procedure for leak checking
Procedure of the way the certified persons will be informed about developments, new refrigerants and new
procedures
The Equipment of the STEK certified persons
Manifold & Mobile leak detector & Temperature meter
Refrigerant weight Scale
Vacuum pump & Vacuum meter
Recovery set & Recycling cylinder
Thematic Meeting Hungary 21-10-11 14

15. Dutch Approach
Leakage rate by HCFC's (R22)
remark 1999 beginning of fase out process
HCFC's (R22)
Tailor made Content
filled reduction
Content lifecycle 15 y emission leakage rate
kg/year -6,7% kg/year %
1990 933333 14000000 2380000 17,00%
No reliable figures during implementation
1999 254940 12000000 418424 3,49%
2000 180982 11196000 409420 3,66%
2001 88182 10445868 521701 4,99%
2002 65653 9745995 453751 4,66%
2003 45240 9093013 457286 5,03%
2004 31405 8483781 387907 4,57%
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16. Dutch Approach
Leakage rate HFC
remark on the market since 1993 ?
Tailor
made Pre-charged installations
filled growth by year 5,00% Total Life cycle Total content
new leakage
Content Heat load Average Content content multiplier until year emission rate
kg/year kW kg/kW kg/year kg/year by year kg kg/year %
1999 233269 + 619025 0,5 309512 = 542781 8 4342251 149774 3,45%
2000 434875 + 651605 0,5 325803 = 760678 9 6846098 187059 2,73%
2001 474885 + 685900 0,5 342950 = 817835 10 8178350 248680 3,04%
2002 573849 + 722000 0,5 361000 = 934849 11 10283339 323529 3,15%
2003 496242 + 760000 0,5 380000 = 876242 12 10514904 380808 3,62%
2004 481401 + 800000 0,5 400000 = 881401 13 11458213 434528 3,79%
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17. Dutch Approach
RAC Company Adminstration
New installation
Sales 100.000 euro
Personel costs 40.000 euro
Material incl refrigerant 30.000 euro
Indirect costs 10.000 euro
Total 80.000 euro
Profit 20.000 euro
Thematic Meeting Hungary 21-10-11 17

18. Dutch Approach
RAC Company Adminstration
Service & Repair
Personel costs 400 euro
Material incl refrigerant 200 euro
Indirect costs 100 euro
Total 700 euro
Invoice total 1.000 euro
Profit 300 euro
Thematic Meeting Hungary 21-10-11 18

19. Dutch Approach
RAC Company Adminstration
For New + Service & Repair orders
Book keeping system, SAP, Exact, Unit4 etc
Personnel planning system
Logistic flow of materials
Search function with the results
For example Refrigerant type/quantity
for printing or export by excel sheets
So it is available Refrigerant register.
Thematic Meeting Hungary 21-10-11 19

20. Dutch Approach
Logbook
The operator of a refrigerating system with a total refrigerant charge equal to or
greater than 3 kg, shall have a logbook which is kept in the vicinity of the
refrigerating system.
This logbook shall include the following information:
a. the date on which the copy was issued ;
b. the name, address and telephone number of the operator of the refrigerating
system who keeps the logbook at the central location;
c. the refrigerant charge and type of refrigerant used in the refrigerating system;
d. the date on which maintenance or installation activities on the refrigerating
system were carried out and the name, address and telephone number of the
company which undertook these activities;
e. an overview of the quantity of refrigerant charged into the system over a period
of two years preceding the date on which the last maintenance or installation
activities were undertaken Thematic refrigerating 21-10-11
on the Meeting Hungary system. 20

21. Dutch Approach
Logbook
First in operation
a. name of the installer;
b. date of the inspection;
c. name of the STEK technician;
d. type of refrigerating system;
e. type of refrigerant;
f. total charge of refrigerant;
g. highest and lowest temperatures and pressures;
h. blow off pressure of the installed relief devices;
i. statement about the leakproofness of the refrigerating system;
j. statement about the Strenght pressure test;
k. statement about the evacuation and charging;
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22. Dutch Approach
Logbook
Work report:
a. nature of the inspection, maintenance, repair and installation activities on the
refrigerating system;
b. faults and alarms related to the refrigerating system;
c. quantity and type of refrigerant charged into the system;
d. quantity and type of refrigerant drained from the system;
e. results of leak detection activities;
f. the name of the person who undertook the activities listed under a. through e.
above and, where applicable, the name of the company employing that person;
g. official mark issued by the person referred to under item f. with respect to the
activities undertaken by him or her.
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23. Dutch Approach
Work report
Work report
Lot of paperwork in the beginning
Work report
incl. pre printed statement documents as tightness, strength and evacuation pressures test
Electronic Work report installed on a laptop computer or handheld or smart phone
with pre installed information and statement documents such as:
a. the inspection, maintenance, repair and installation activities on the refrigerating system;
b. faults and alarms related to the refrigerating system;
c. quantity and type of refrigerant charged into the system;
d. quantity and type of refrigerant drained from the system;
e. results of leak detection activities;
f. the name of the person who undertook the activities listed;
g. official mark issued by the person;
The facility to make a print or sign on a screen for authorisation
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24. Dutch Approach
Human beings and the RAC system
Summary:
• Mandatory regulation
• Bottom-up approach to realize the awareness by SME is
important to reduce the leakage rate of RAC systems.
• Tools are available in the F gasses regulation and EN 378.
EN 13313.
• you need time to influence Human beings at least 5 year
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25. Dutch Approach
SPARK Project
EU Leonardo da Vinci project 2010 - 2012
Partners: B, UK, D, H, and NL
To develop a test for new RAC personnel
For the Job profile’s
 Craftsman Category I
 Craftsman Category II
 Installation technician under supervision Category I
 Recovory Technician Category III
 Tecnician only leaking/tightness check Category IV
 Heat pump installer circuit content below 3 kgr without breaking in
the circuit
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26. Dutch Approach
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27. Dutch Approach
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28. Dutch Approach
The Dutch approach
The sheets and other documention available on
USB Stick
Thank you for your attention
Jan Reijmers info@stek.nl
Thematic Meeting Hungary 21-10-11 28