United States
Environmental Protection
Agency
National Risk Management
Research Laboratory
Cincinnati, OH 45268
Research and Development
EPA/600/SR-97/039
June 1997
&EPA Project Summary
Options for Reducing Refrigerant
Emissions from Supermarket
Systems
Eugene F. Troy
The report was prepared to assist
personnel responsible for the design,
construction, and maintenance of re-
tail food refrigeration equipment in
implementing practices and technolo-
gies to reduce refrigerant emissions.
The report characterizes the design of
typical supermarket refrigeration sys-
tems and focuses on why these types
of systems have high rates of refriger-
ant emissions. Three case studies are
provided of companies that have suc-
cessfully implemented emission-reduc-
ing practices and technologies. The re-
port discusses a variety of technical
and procedural options that can be ap-
plied to existing systems and in new
construction.
This Project Summary was developed
by the National Risk Management Re-
search Laboratory's Air Pollution Pre-
vention Control Division, Research Tri-
angle Park, NC, to announce key find-
ings of the research project that is fully
documented in a separate report of the
same title (see Project Report ordering
information at back).
Overview
In 1993, the U.S. Environmental Pro-
tection Agency issued regulations as re-
quired by Section 608 of the Clean Air Act
Amendments of 1990. These regulations,
entitled "The National Recycling and Emis-
sion Reduction Program", require persons
working on refrigeration and air-condition-
ing systems containing chlorofluorocarbons
(CFCs) to maximize the recapturing and
recycling of CFCs during the maintenance,
service, and disposal of these systems.
The provisions of the rule that most af-
fected the supermarket industry were:
- mandatory recovery of refrigerant dur-
ing equipment service,
-certification of technicians, and
- requirements for leak repair of sys-
tems with refrigerant charges of 50 Ib
(22.7 kg) or more.
Responding to the regulations, many
refrigeration engineers, construction me-
chanics, and maintenance personnel have
become more aware of the impact of their
equipment specifications and operating
procedures on refrigerant emissions. More
and more supermarkets are now investing
resources to control refrigerant leaks from
their refrigeration systems. In this report,
three supermarkets—Hannaford Brothers,
Shaw's Supermarkets, and Jitney-Jungle
Stores of America—have participated in
case studies to document various proce-
dures and techniques which have suc-
cessfully reduced the emissions in their
stores.
Hannaford Brothers' program stresses
involvement and accountability by all de-
partments involved in refrigeration systems
including store design, construction, and
maintenance. Hannaford has implemented
a design strategy which engineers out the
emissions. New stores are constructed with
loop piping, no hot-gas defrost, stronger
solder joints, and rigorous pressure test-
ing. In addition, Hannaford has worked
with equipment manufacturers to develop
lower-emission equipment components.
Improved maintenance practices have
been implemented including weekly in-
spection of systems for leaks using bat-
tery-powered leak detectors. Fixed-cost
service and preventive-maintenance con-
tracts are used instead of service-only con-
tracts. As a result of its comprehensive
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refrigerant management program,
Hannaford Brothers has reduced its total
refrigerant consumption by 80% in 8 years.
Shaw's Supermarkets identified im-
provements which could be made in all of
its departments, including engineering,
construction, and maintenance. As part of
its leak reduction efforts, Shaw's began
using a computer program which tracks
refrigerant usage and monitors service
events to better troubleshoot refrigeration
systems. Stationary leak detectors have
been installed in many stores as an op-
tion of the energy management system.
Shaw's also began to design systems
which reduced charge size in order to
minimize the impact of catastrophic leaks.
These features include remote headers,
heat reclaim pump-out, split condensers,
and condenser bypass. Since the com-
pany felt that capillary tubes were signifi-
cant leakers, Shaw's investigated alterna-
tive technologies and materials. Improved
maintenance is also an important element
of the company's leak reduction strategy.
As a results of its efforts, Shaw's Super-
market chain has seen a 44% reduction in
refrigerant consumption since 1988, and
the computer tracking program indicates
a 29% reduction in annual refrigerant leak-
age over the last two years.
Jitney-Jungle Stores of America devel-
oped a program to conserve refrigerant
by assessing practices in engineering, ser-
vice, and maintenance. Engineering
changes include the use of vertical, in
place of horizontal, receivers and sweat-
type (brazed) valves in place of flare-type
thermostatic expansion valves. This valve
replacement alone has resulted in notice-
able reductions in refrigerant emissions.
Isolation and access valves have also been
installed on frequently serviced compo-
nents. Since systems which operate at
high temperatures and pressures were
identified as those with the most mainte-
nance problems related to leaks, Jitney-
Jungle improved mechanical room condi-
tions to reduce operating temperatures and
pressures, including the use of electronic
controllers and monitors to track these
parameters at key points. A refrigerant
tracking system has been implemented,
and leak detection and repair practices
have been improved to augment the ex-
isting preventive maintenance program.
Jitney-Jungle has also instituted practices
to reduce emissions during the conver-
sion of systems from CFCs to alternative
refrigerants.
Beyond the practices instituted by the
three supermarket chains in the case stud-
ies, a variety of additional activities can
be implemented with estimated emission
reductions ranging from 3% to 25% of the
system charge per year.
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E. Troy is with ICF, Inc., Washington, DC 20006
Cynthis L. Gage is the EPA Project Officer (see below).
The complete report, entitled "Options for Reducing Refrigerant Emissions from
Supermarket Systems," (Order No. PB97-167100; Cost: $21.50, subject to
change) will be available only from:
National Technical Information Service
5285 Port Royal Road
Springfield, VA 22161
Telephone: 703-487-4650
The EPA Project Officer can be contacted at:
Air Pollution Prevention Control Division
National Risk Management Research Laboratory
U. S. Environmental Protection Agency
Research Triangle Park, NC 27711
United States
Environmental Protection Agency
National Risk Management Research Laboratory (G-72)
Cincinnati, OH 45268
Official Business
Penalty for Private Use $300
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EPA
PERMIT No. G-35
EPA/600/SR-97/039
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