^ Envlronmenta! Protection EPA 430-F-17-001
k Agency
The GreenChill Advanced Refrigeration Partnership
Keep it Cool: GreenChill s
Guide to Refrigeration
Management for Small and
Independent Grocers
*o^eNTAL PROTECtIO/v
^fr/geration
U.S. Environmental Protection Agency
Stratospheric Protection Division
January 2017
-------
This page is intentionally left blank
-------
Table of Contents
1. Introduction 1
2. Questions for Your Technician 2
Installation 2
Routine Maintenance 3
Leak Events 4
Retirement 4
3. System Design 5
System Design Options 6
Refrigerant Selection 7
Smart Design Techniques 8
4. Servicing and Maintenance 9
Preventative Practices to Avoid and Minimize Refrigerant Leaks 9
Detecting Leaks 10
Responding to Leaks 12
5. Regulatory Requirements 13
The National Recycling and Emission Reduction Program 13
The Significant New Alternatives Policy (SNAP) Program 13
Appendix A. Useful Resources 14
Regulatory Resources 14
Technical Resources 14
Industry Resources 15
Appendix B. Monthly Refrigerant Receiver Level Chart 16
Appendix C. Leak Prevention Maintenance Checklist 17
Appendix D. Supermarket Walk-Thru Checklist 18
-------
1. Introduction
Supermarkets and other types of retail food establishments around the world rely on refrigeration
technologies to keep their produce fresh, their milk cold, and their ice cream frozen. For the most
part, commercial refrigeration systems used by retail food establishments today contain thousands
of pounds of refrigerant—commonly either a hydrochlorofluorocarbon (HCFC) or
hydrofluorocarbon (HFC) refrigerant, which depletes the ozone layer and/or contributes to climate
change when released into the Earth's atmosphere.
The purpose of this document is to provide store
owners and managers who have limited technical
experience in the area of commercial refrigeration
with the background and resources to effectively
manage their store's commercial refrigeration
system. Specifically, this guide provides helpful
information on the following:
~ Questions for Your Technician - This
section identifies important questions to ask
your service technician related to system
installation, routine maintenance, leak
events, and system retirement (Section 2);
~> System Design - This section provides an
overview of the key components of a
commercial refrigeration system, describes
common system designs, discusses
considerations for refrigerant selection, and
identifies smart design techniques (Section 3);
~> Servicing and Maintenance - This section provides background on how to prevent leaks,
detect leaks, and respond to leaks throughout the lifetime of the system (Section 4);
~> Regulatory Requirements - This section identifies relevant regulations that are pertinent
to the management of commercial refrigeration systems (Section 5);
~> Useful Resources - This section provides links to useful resources that provide additional
detail on key aspects of refrigeration management (Appendix A); and
~> Checklists and Templates - These sections provide useful checklists and templates to
support leak prevention and monitoring best practices (Appendices B-D).
Key Benefits of Refrigeration
Management
Proper management of your commercial
refrigeration system will inevitably result in
fewer refrigerant emissions and consequently
have the following key benefits:
S Reduced Refrigerant Costs - Fewer
emissions will reduce the need to
purchase refrigerant to refill your system.
S Reduced Potential for Refrigeration
Failure - Proactive maintenance and
timely repairs will reduce the likelihood
for operating temperatures to be
compromised and food to perish.
S Reduced Emissions of Ozone-Depleting
Substances (ODS) and/or Greenhouse
Gases (GHGs) - Fewer emissions will
reduce the impact of your system on
ozone depletion and/or climate change.
GreenChill Guide on Refrigeration Management
Page 1
-------
2. Questions for Your Technician
EPA certified service technicians play a vital role in the success of your refrigerant management
program. Being engaged with your service technician and asking the right questions can help
ensure your refrigeration system is running smoothly, costs are contained, and regulations are
followed. Below is a list of questions that you should ask your technician during servicing trips
throughout the lifetime of your refrigeration system (i.e., installation, routine maintenance, leak
events, and retirement). The sections that follow provide additional background information on
best practices in refrigeration management.
Installation
~ How can I reduce my refrigerant charge? At the time of installation, it may be possible to reduce the
system's refrigerant charge by strategically positioning system components. For example, the condenser
should be installed as close as possible to the compressors. Alternative piping designs¦, such as suction
and liquid loop piping, can also reduce your system's refrigerant charge. Your installation contractor
should be able to advise you on potential options appropriate for your store.
~ How much refrigerant does my system need? The amount of refrigerant your system needs will
vary seasonally. However¦, that does not mean it is acceptable to unnecessarily overcharge your system.
Talk with your technician about the appropriate amount of refrigerant for your system.
~ Can you provide a record detailing the amount of refrigerant charged into the system during
installation? Knowing your system's full charge is critical to benchmarking and evaluating your
system's performance. It is also required under EPA's National Recycling and Emission Reduction
Program (See text box on Leak Records and Documentation) for select refrigerants. Askyour
installation contractor to provide a detailed record that includes the
amount added to each low- and medium-temperature rack.
~ Has my system been tested for leaks in accordance with
GreenChill's Best Practices Guideline for Leak Tightness at
Installation? Your installation contractor should complete and sign the
Installation Leak Tightness Testing: Verification Form to verify that
he/she tested the remote commercial refrigeration system per
GreenChill's Guideline prior to the store's opening.
ar«nCh,llBraPracte , .
Ensuring I eak-T,nh,, ,Vu,uel"
" c 8 '"spallations,
GreenChill Guide on Refrigeration Management
Page 2
-------
Routine Maintenance
4* Has there been a drop in the refrigerant level of
the receiver? A drop in the receiver level from a
previous reading may indicate a leak in the system. Ask
your technician to compare current receiver levels with
those logged during previous inspections. GreenChill's
Receiver Refrigerant-Level Chart can help you and your
technician keep track (See Appendix B).
~ Do any of my system components need upgrades? Some existing system components may need to
be replaced with parts that are more leak-resistant (e.g., suction stepper valves¦, loop piping systems,
and remote manifolds). Such components may cost more upfront, but can save money overtime.
Did you observe any vibration? Most vibrations
occur on or near the compressor discharge lines. Areas
with excessive vibration are prone to leaks. Eventually,
the constant movement can cause a rub-through
and/or broken lines or fittings. Ask your technician
what can be done to reduce or eliminate vibrations.
Are any valve caps or seals missing? Certain valves
require caps and proper seals (e.g., o-rings) to ensure
leak tightness. Askyour technician to replace any
missing caps or seals.
Image of broken clamp caused by vibrations
Did you observe any corrosion on rack
components? Copper evaporator coils and steel rack
components may corrode over time and develop leaks.
Corroded parts should either be removed or painted
with a rust-inhibiting paint to help prevent further
corrosion. Askyour technician to use cleaning agents
that are compatible with your system's components, as
some cleaning agents can cause corrosion.
Image of a Schrader valve with no caps
Did you observe any oil seepage? Oil seepage can
indicate a leak in the system. Askyour technician to
use soap bubbles or an electronic leak detector to
identify and repair the leak.
Excessive corrosion on rack components
GreenChill Guide on Refrigeration Management
Page 3
-------
Leak Events
~ Where was the leak located? Knowing and
documenting leak locations can help identify
problem areas in your store. Recurring leaks in
the same location may indicate the need to
replace a part or component.
~ Did you inspect the entire system to make
sure all leaks were found and repaired? In
many cases the first refrigerant leak found
may not be the only leak in the system. Ask
your technician to compare the quantity of
refrigerant lost with the leak rate of the leak
found. If the leak found is too small to justify
the quantity of refrigerant lost, the technician
should assume there is another leak in the
system and resume the leak search.
~ What is the cause of the leak and how was it addressed? Knowing the cause of the leak and taking
steps to address the root of the problem can lower costs over the long run. Simply topping-offthe system
with additional refrigerant is not an acceptable way to address leaks.
~ Was there a drop in receiver levels after the repair was made? Once the repair is made, askyour
technician to check the receiver level to ensure no additional refrigerant was lost. A drop in receiver
level is an indication that there are probably more leaks in the system.
~ Was the system charged with additional refrigerant as a safety buffer? It is common practice for
service technicians to charge additional refrigerant to a system as a safety buffer. This practice should
be avoided since it will add to the potential loss in a future leak event and is an unnecessary cost.
~ Am I in compliance with all relevant leak repair regulations? Commercial refrigeration systems
must comply with applicable federal state, and local leak repair regulations. Make sure you are familiar
with current leak repair requirements and take appropriate measures to ensure compliance.
Retirement
~ What should I do with my system's refrigerant? Not only is it illegal to vent refrigerant, but it's also
harmful to the environment and human health. Per EPA regulations, all refrigerant must be recovered.
Once it is recovered, options may include recycling the refrigerant for use in your store's new system,
reclaiming the refrigerant, or destroying the refrigerant.
Leak Records and Documentation
During each leak event, it is important to document
leak repair efforts and maintain records over time.
Important items to document include:
S Date of service
S Identity and location of the appliance
S Type of service performed
S Location of repairs
S Results of verification tests
S Quantity and type of refrigerant added (if any]
EPA's National Recycling and Emission Reduction
Program have specific recordkeeping and reporting
requirements. To ensure compliance, see 40 CFR
Part 82. Subpart F.
GreenChill Guide on Refrigeration Management
Page 4
-------
~ Is your refrigerant recovery equipment certified by an EPA-approved equipment testing
organization? Persons involved in the disposal of refrigeration and air conditioning equipment must
certify to their EPA Regional Office that they have acquired (built, bought, or leased) and are properly
using refrigerant recovery equipment certified by an EPA-approved equipment testing organization.
EPA-certified refrigerant recovery equipment will ensure maximum recovery of refrigerant from your
retired system.
~ Can you show me the certification label on your refrigerant recovery equipment? Asking to see
the certification label on the recovery equipment will help ensure compliance with EPA's regulations
and the maximum amount of refrigerant is recovered from your system. The label should say, "This
equipment has been certified byAHRI/UL to meet EPA's minimum requirements for recycling and/or
recovery equipment intended for use with [appropriate category of appliance—e.g., HCFC appliances
containing less than 200 pounds of refrigerant, all high-pressure appliances, etc.]."
3. System Design
In a supermarket, refrigeration systems cool
display cases and walk-in coolers that house
food products and other perishable goods.
Each system is designed to accommodate the
refrigeration needs of the specific retailer as
well as the confines of the building. While
most systems are custom designed, they all
consist of the same key components,
including compressors, condensers,
receivers, display cases, expansion valves,
evaporators, and piping. Figure 1 below
presents an overview of the key components
of a commercial refrigeration system and
their common location within a
supermarket.
The Source and Cause of Refrigerant Leaks
Leaks can occur in a variety of locations throughout a
supermarket, including the compressor racks, display
cases, walk-in evaporators, condensers, piping, and
remote headers. Leaks are generally caused by the
inevitable wear and tear on a refrigeration system as
well as poor design and improper installation,
servicing, and/or maintenance practices. Specifically,
common causes of leaks include:
• Poor brazing techniques
• Improperly tightened fittings
• Valve caps and seals missing
• Material incompatible with oil or refrigerant
• Vibration
• Thermal expansion and contraction
• Corrosion
• Metal-to-metal contact of tubing
• Improper support of tubing
GreenChill Guide on Refrigeration Management
Page 5
-------
Figure 1: Supermarket System Overview
3 Rooftop
Condenser - Typically located
outside, the condenser transfers the
heat from the high-pressure vapor
refrigerant to the surrounding air or a
water supply, causing the refrigerant
to convert back into a liquid.
Machine Room
Compressors - Often located in a machine room at
the back of a store, compressors pump the low
pressure vapor refrigerant from the evaporators
and compress it to a high pressure and temperature.
5 Piping
Piping is used to transfer
the refrigerant from the
machine room to the cases
located throughout the
store. Piping also connects
the compressor rack to the
condenser via the discharge
and condensate line.
i Sales Floor
Display Cases - Located throughout the sales area, display cases
are used to store refrigerated and frozen products.
Expansion Valve - The expansion valve, located inside the display
cases, controls the flow of the refrigerant to the evaporator.
Evaporators - Located inside the display cases, evaporators are
used to remove heat from the conditioned space within the display
cases. Inside an evaporator, liquid refrigerant boils, or evaporates,
absorbing heat as it changes to a vapor.
achine Room
Receiver - The refrigerant
charge required of a
system varies seasonally.
To accommodate this
variation, additional liquid
refrigerant charge is stored
in a vessel, known as the
receiver, located
downstream of the
condenser.
System Design Options
Although the core components of a retail food refrigeration system remain consistent across all
systems, the specific design of a system can vary significantly. Historically, centralized direct
expansion (DX) systems have been the most commonly used system design in commercial
applications. However, due to a growing effort to reduce refrigerant charge sizes and leak rates as
well as to transition to alternative refrigerants, many retailers are choosing to adopt advanced
design options. The most commonly used system designs are generally defined below.
GreenChill Guide on Refrigeration Management
Page 6
-------
~> Centralized DX Systems: A centralized DX system is comprised of several compressors that
are mounted together and located in a centralized, single machine room. The compressors
share suction and discharge refrigeration lines that run throughout the retail space, feeding
refrigerant to the cases and coolers.
~ Distributed DX Systems: Similar to a centralized DX system, a distributed DX system is
comprised of several compressors that feed refrigerant directly to the cases and coolers
located throughout a supermarket. However, instead of having a central compressor system
in one machine room, a distributed system uses an array of compressor racks that are
strategically located near the refrigerated cases.
~> Secondary Loop Systems: A secondary loop system also is comprised of a centrally located
compressor rack; yet, rather than circulating the primary refrigerant throughout the retail
space, the compressors are connected to a chiller system that is used to cool a secondary fluid.
This secondary fluid is then circulated through the store to cases and coolers.
~> Cascade Systems: A cascade system consists of two independent refrigeration systems that
share a common cascade heat exchanger. The high temperature system typically uses an HFC
refrigerant, ammonia, or propane in a DX or secondary loop design, while the low temperature
system uses a carbon dioxide compressor to raise CO2 gas from low-temperature conditions
up to an intermediate temperature; the high temperature system is then used to condense the
gas before circulating it through the store to cool low temperature cases and freezers.
~> CO2 Transcritical Systems: A CO2 transcritical system is similar in design to a centralized DX
system but uses CO2 as the primary refrigerant and operates at a high pressure to
accommodate the low critical temperature of CO2.
Refrigerant Selection
In addition to understanding the various system design options available, it is important to
understand the different refrigerant types that can be used in your system. Commercial
refrigerants generally fall into one of four categories, as summarized below in Table 1. With
chlorine-containing refrigerants (i.e., CFCs, HCFCs) no longer permitted for use in new systems due
to the United States' commitments under the Montreal Protocol (see Section 5), most retailers today
use HFC refrigerants. In light of anticipated and recent regulations that will prohibit the use of
certain HFCs in supermarket applications (see Section 5), many retailers are adopting lower-global
warming potential (GWP) HFC blends and/or system designs that can accommodate non-
fluorinated refrigerants. While these regulations do not prescribe refrigerant selection or require
stores to retrofit existing systems, careful examination of the available refrigerant options is
recommended in order to make an informed decision on which refrigerant is best for your system.
GreenChill Guide on Refrigeration Management
Page 7
-------
Table 1: Summary of Refrigerant Options for Retail Food Applications
Category
Examples
ODS"
GWP
Status of Use
Chlorine-Containing
Refrigerants
CFC-12, R-502,
HCFC-22
Yes
Yes
• CFC-12, R-502, and HCFC-22 no longer
permitted for use in new systems.b
HFC Blends
R-404A, R-507A,
R-407A, R-407F
No
Yes
• Predominately used today in both new
and existing systems.
• R-404A, R-507A and other select
blends will no longer be permitted for
use in new systems as of January 1,
2017.c
HFO/HFC Blendsd
R-448A, R-449A
No
Yes
• Recently approved for use.
• Other refrigerants under development
Non-Fluorinated
Refrigerants
R-290 (propane),
R-717 (ammonia),
R-744 (C02)
No
No
• Used as a primary refrigerant in
limited applications.
• Used as a secondary fluid in
combination with HFC blends.
aODS = ozone-depleting substance
b July 30,1992; 57 FR 33754; December 10,1993; 58 FR 65018
cJuly 20, 2015; 80 FR 42870
dHFOs (hydrofluoroolefins] are unsaturated HFCs (i.e., chemicals that contain a carbon-carbon double bond].
Smart Design Techniques
Regardless of the system and refrigerant type, the design techniques listed below should be
considered to help reduce the environmental impact of your system. As highlighted in Section 2,
make sure to talk with your system provider and installation technician to discuss other design
techniques to ensure you maximize the efficiency and effectiveness of your system.
•/ Install the condenser as close as possible to the compressors to minimize the system's
refrigerant charge.
•/ To reduce your system's refrigerant charge, use split condenser piping along with automated
switching techniques to enable the condenser to operate on only one of the two circuits
during cold weather months. Apply industry accepted techniques and controls to permit
pump out of stranded refrigerant from the inactive condenser circuit.
S Compressor racks should be positioned as close as possible to the display cases and walk-ins
within the store. They should also be positioned in such a way so that they are easily
accessible by maintenance and service personnel.
GreenChill Guide on Refrigeration Management
Page 8
-------
"/ Oversized receivers can lead to overcharged systems. To minimize the charge, carefully
select the vessel size to appropriately accommodate your system. Additionally, if possible,
use a vertical receiver, which requires less charge than a horizontal receiver.
¦/ Alternative piping designs, such as suction and liquid loop piping can be used to reduce the
linear feet of piping required by your system as well as the number of fittings. This in turn
reduces both the charge size and leak potential of the system.
•S A variety of practices can be used to reduce the energy consumption of display cases,
including the use of LED lights, electronically commutated motors (ECMs), and no-heat glass
doors. Reducing the energy consumption of cases reduces the required refrigerant load,
which in turn reduces the amount of refrigerant charge required of the system.
4. Servicing and Maintenance
Once your refrigeration system has been designed and installed, regular servicing and maintenance
is required to keep your system operating effectively. While some refrigerant leaks are inevitable,
preventative practices, leak monitoring, and clearly defined reaction plans can help to reduce leak
occurrences and minimize the impact of your system on the environment, as discussed in the
sections below. See Appendix C for a checklist of recommended maintenance measures.
Preventative Practices to Avoid and Minimize Refrigerant Leaks
•S Clean Equipment: A clean and uncluttered mechanical room provides a safe and accessible
environment for service technicians. Dirty
refrigeration compressor racks, condensers,
remote headers, and walk-in evaporator coils
make it difficult for technicians to spot leaks.
Compressor racks and their components should
be free of oil and dirt. In addition, corrosion on
steel components should be removed and
components painted with a rust-inhibiting paint
to help prevent future corrosion. Equipment
should be thoroughly cleaned once a year, or
more frequently in response to the accumulation
of oil and dirt.
•S No Overcharging: The amount of refrigerant required of your system varies throughout the
year, with more refrigerant required during the winter to permit flooding of the condenser
to maintain a minimum operating system head pressure. While some excess refrigerant is
needed to accommodate these seasonal variations, the refrigerant charge should not exceed
the required amount in order to minimize the potential for refrigerant emissions.
Clean machine room at a Farm Fresh store
GreenChill Guide on Refrigeration Management
Page 9
-------
¦S Component Upgrades: System components should be replaced with parts that are more
leak-resistant or have a reduced number of potential leak sources. For example, discharge-
piloted evaporator pressure regulating (EPR) valves may be replaced with suction stepper
valves, which eliminate the high-side control line, provide better temperature control, and
are generally more reliable. Suction and liquid manifolds may be replaced with loop piping
systems or remote manifolds to reduce the number of fittings subject to rack vibration.
Other Recommended Actions to Reduce Leak Potential
• Replace flared connection components with brazed connection components.
• Replace valves with bolted connections with hermetic one-piece valves with no mechanical joints.
• Replace valves with control lines with valves that don't require control lines.
• Ensure the proper cap is in place on all valve stems designed to be capped, as well as access Schrader
valves. The caps should also have the proper seal or o-ring in place to ensure leak tightness.
• Replace fragile cap tube-type control lines with steel lines or armored flexible lines.
• Tighten bolts on flanges used to connect valves and filter-drier covers to the proper torque and use a
new gasket in reassembly.
• Use an approved thread sealant to prevent leakage from threads or from corrosion around threads.
• Protect tubing by creating a space separation or using a cushioning material.
• Ensure equipment located in vulnerable environments has epoxy or phenolic coatings on fin-tube
surfaces, refrigerant piping or other components that are subject to corrosion. Vulnerable equipment
may include service deli cases that are in contact with vinegar-containing products and rooftop
condensers that are located near the coastline or a chemical plant.
• Ensure chemical compatibility of cleaning agent with components and materials.
• Eliminate liquid hammer by mounting a sealed vertical tee ahead of the solenoid valve.
Detecting Leaks
S Regular Leak Inspections: Leak inspections should be routinely performed to proactively
check for refrigerant leaks. To perform a leak inspection a certified service technician
should check receiver levels, compare refrigerant levels to data from the previous visit, and
walk through the store with portable leak detection device, making sure the device is
appropriate for the type of refrigerant used in the refrigeration system. Checks should be
done at least once every three months (as required by CFR 40, Part 82, Subpart F), but
preferably every one to two months, depending on the size and type of the system. See
Appendix D for a supermarket walk-thru checklist and Appendix B for an example monthly
refrigerant receiver level chart.
GreenChill Guide on Refrigeration Management
Page 10
-------
S Leak Detection Systems: In
addition to performing regular leak
inspections, you may also use an
automated leak detection system.
Leak detection systems are either
direct or indirect. A direct detection
system directly measures the
refrigerant in an air sample taken
near a refrigeration system or one of
its components. An indirect system
measures changes in receiver
refrigerant levels, the weight of the
condenser/receiver assembly, or
system temperature. Leak detection
systems vary in both sophistication
and cost; the decision to install one
may depend on the size and type of
refrigeration system in use.
S Alarm Systems: If a leak detection
system is used, the monitoring system needs to be tied to an alarm system that proactively
notifies store management of potential leaks. Levels of redundancy or checks in the alarm
system procedure should also be in place to ensure that the alarm does not go unnoticed. For
instance, an alert could be linked to horns or a strobe system in the store, the manager's
office, or a third party service. Also, it is important to make sure that the alarm threshold is
set as low as possible to maximize the capability of the technology.
S Locating a Leak: Once a leak is detected—
whether through continuous monitoring or
through a regular leak inspection—a handheld
leak detector will be needed to further locate
the source of the leak. It is important that the
right portable leak detector is used to
accurately locate your system's leak. Similar to
the leak monitoring systems, there are a variety
of technologies available for portable leak
detectors. Make sure the leak detector used in
your store is sophisticated enough to detect all
leaks and is appropriate for the type of
refrigerant used in your system.
Leak Detection Sensors
What sensors should I use?
There are two main types of leak detection sensors:
semiconductor detectors and infrared (IR] analyzers.
Semiconductor sensors are a cost-effective way of
detecting larger leaks (i.e., >50 ppm], While IR systems
are more expensive, they are able to detect significantly
smaller leaks (i.e., 1-10 ppm).
Where do I monitor for leaks?
Since you cannot monitor for leaks everywhere, sensors
should be placed strategically throughout your store in
high probability areas, including the compressor room,
walk-in coolers/freezers, and aisles with refrigerated
cases. In your compressor room, install one sensor at
each end of each compressor rack. In your walk-ins, place
the sensors underneath the evaporators, making sure the
sensors are placed away from the door to avoid frost
build-up. In the aisles, sensors may be placed inside or
outside cases, in kick rails, at each end of the aisle, or
behind and in between two aisle cases.
Example Leak Detector (Source: GreenChill
webinar on Achieving Leak Reduction Goals
through Effective Refrigerant Management, 2016]
GreenChill Guide on Refrigeration Management
Page 11
-------
Responding to Leaks
Preparing for Leaks
Repairing a Leak
Leak Repair
Verification
All supermarkets should have
policy in place for responding
to refrigerant leaks. The policy
should establish a maximum
response time that is as short
as reasonably possible (e.g.,
two to four hours). The policy
should also ensure that service
technicians follow all relevant
federal, state, and local codes
and regulations.
When repairing a leak, adding
more refrigerant to the system
(i.e., topping off the system) is
not a viable solution to
addressing a leak. Even once
the leak is repaired, technicians
should also check for other
leaks in the system: especially
when there is a discrepancy
between the quantity of lost
refrigerant charge and size of
the identified leak.
Technicians should check the
system to verify it is leak-free
after making the repair. The
verification should include a
check of the repaired area as
well as the receiver level to
ensure that no additional
refrigerant was lost. A drop in
receiver level is an indication
that there could be more
leaks in the system.
Example Policy Language on Responding to Refrigerant Leaks
Service hours
Service shall be provided on a seven day a week, twenty-four hour a day basis. Response time shall be less
than two hours if possible but not exceeding four hours for emergency calls. Emergencies shall be considered
those requests that could cause product loss, refrigerant loss or loss of sales. Non-emergency calls such as
prep room areas and HVAC may be handled on a non-overtime basis provided response time does not exceed
twenty-four hours. The twenty-four hour response time shall be waived the week preceding the following
holidays: Christmas, New Years, Easter, Memorial Day, Independence Day, Labor Day, and Thanksgiving.
Codes, laws, regulations and policies
The Contractor and his employees shall conform to all federal, state, and local codes, laws, and regulations
including OSHA and the EPA regulations governing refrigerants. The Contractor and his employees shall also
obey any store policies while working in the store. No Company employee is authorized to direct a Contractor
or any of his employees to disregard any relevant code, law, or regulation in the performance of this contract.
GreenChill Guide on Refrigeration Management
Page 12
-------
5. Regulatory Requirements
As a signatory of the Montreal Protocol on Substances
that Deplete the Ozone Layer, the U.S. government is
responsible for phasing out the production and
consumption of ozone-depleting substances (ODS) in
the United States. In response to the Montreal
Protocol, Congress amended the Clean Air Act (CAA)
in 1990, adding provisions to protect the
stratospheric ozone layer. The CAA amendments
require that the Environmental Protection Agency
(EPA) develop and carry out regulations for the
responsible management and phaseout of ODS in the
United States, consistent with the Montreal Protocol
obligations. In addition to adhering with the core
obligations of the protocol, Title VI of the CAA
encompasses other requirements for stratospheric
ozone protection, as highlighted below.
The National Recycling and Emission Reduction Program
Under Section 608 of the CAA, also known as the National Recycling and Emission Reduction
Program, EPA has established regulations that prohibit the knowing release of refrigerant during
the maintenance, service, repair, or disposal of air-conditioning and refrigeration equipment. The
purpose of the program is to prohibit any person from intentionally venting ODS refrigerants (e.g.,
CFCs and HCFCs) and their substitutes, such as HFCs, into the environment; reduce the use and
emissions of these refrigerants; maximize the recapture and recycling of refrigerants; and ensure
safe disposal of refrigerants. To this end, owners and managers of commercial refrigeration
equipment must comply with the leak repair, reporting, and recordkeeping requirements set forth
by Section 608 of the CAA, as codified in CFR 40. Part 82. Subpart F.
The Significant New Alternatives Policy (SNAP) Program
Under Section 612 of the CAA, EPA has established a process for the review of ODS substitutes
under the Significant New Alternatives Policy (SNAP) program. Under SNAP, substitutes for ODS
that are used in various industrial, commercial, and military sectors—including refrigeration and
air conditioning—are evaluated to ensure they offer lower overall risks to human health and the
environment. In reviewing the proposed alternatives, consideration is given to the climate impacts
of the substitutes as part of the review of environmental impacts. The list of acceptable substitutes
for use in retail food refrigeration applications can be found on EPA's website.
What is the Montreal Protocol?
The Montreal Protocol on Substances that
Deplete the Ozone Layer is an international
agreement that requires nations that are Parties
to the Protocol to reduce and eventually
eliminate their production and consumption of
ODS. The protocol, which entered into force on
January 1,1989, was established in response to
growing concerns about the harmful effects of
chlorofluorocarbons (CFCs) and other halogen-
containing industrial chemicals on the ozone
layer. In addition to being the world's first and
only international treaty to achieve universal
ratification by all 197 countries in the United
Nations, the protocol is credited with avoiding
millions of skin cancer-related deaths, cataract
cases, and a range of other damaging impacts on
plants, marine ecosystems, and materials.
GreenChill Guide on Refrigeration Management
Page 13
-------
Appendix A. Useful Resources
Regulatory Resources
• The Montreal Protocol on Substances that Deplete the Ozone Layer
ozone.unep.org/en/treaties-decisions/montreal-protocol-substances-deplete-ozone-layer
• Clean Air Act, Title VI
www.epa.gov/clean-air-act-overview/title-vi-stratospheric-ozone-protection
• CFR 40, Part 82
www.ecfr.gov/cgi-bin/text-idx?tpl=/ecfrbrowse/Title40/40cfr82 main 02.tpl
• EPA's Ozone Layer Protection Regulatory Programs
www.epa.gov/ozone-layer-protection/ozone-protection-under-title-vi-clean-air-act
• EPA's Stationary Refrigerant and Air Conditioning Page
www.epa.gov/section608
• EPA' Significant New Alternatives Policy (SNAP) Program
www.epa.gov/snap
• California Air Resources Board Refrigerant Management Program
www.arb.ca.gov/cc/rmp/rmp.htm
Technical Resources
• Opportunities for Green Design: Commercial Refrigeration Technologies
www.epa.gov/greenchill/commercial-refrigeration-technologies
• GreenChill Best Practices Guideline Ensuring Leak-Tight Installations of Commercial
Refrigeration Equipment
www.epa.gov/greenchill/greenchill-best-practices-guideline-ensuring-leak-tight-
installations-commercial
• GreenChill Best Practices Guideline: Commercial Refrigeration Leak Prevention & Repairs
www.epa.gov/greenchill/greenchill-best-practices-guideline-commercial-refrigeration-leak-
prevention-repairs
GreenChill Guide on Refrigeration Management
Page 14
-------
• Report of the Refrigeration, Air Conditioning, and Heat Pumps Technical Operations
Committee (RTOC)
http://www.ozone.unep.org/Assessment Panels/TEAP/Reports/RTOC/RTOC-Assessment-
report-2010.pdf
• Best Practice Guide: Code of Conduct for Carbon Reduction in Retail Refrigeration Sector
www.ior.org.uk/app/images/pdf/Best%20practice%20guide%2022nd%20Tune%202011.p
df
• UNEP Manual for Refrigeration Servicing Technicians
www.unep.org/pdf/7443-e-Ref manual servicing technicians.pdf
• Construction and Demolition: How to Properly Dispose of Refrigeration and Air-
Conditioning Equipment
www.epa.gov/sites/production/files/documents/ConstrAndDemo EquipDisposal.pdf
Industry Resources
• GreenChill Partnership
https: //www.epa.gov/greenchill
• Food Marketing Institute
www.fmi.org/
• The Institute of Refrigeration
www.ior.org.uk/
• REAL Zero
www.realskillseurope.eu/
GreenChill Guide on Refrigeration Management
Page 15
-------
Appendix B. Monthly Refrigerant Receiver Level Chart
Store # Rack #
Mill",.
'Ml".,
sir,,
3-*
r ""0M I.
t wi'1"
= >(l"„
Cj
~ 4lr\.
.ill"..
ID
t .1[ih ^ I .i! \j"i Nt.f'. I is 11 l
-------
Appendix C. Leak Prevention Maintenance Checklist
This checklist identifies several maintenance measures that can help prevent refrigerant leaks in commercial
refrigeration systems.
~ Identify and log the refrigerant level of the receiver of each rack. A drop in the receiver level
from a previous reading may indicate a leak in the system.
~ Visually check the compressor racks, piping, and valves in the mechanical room for any oil
seepage. If oil seepage is observed, use soap bubbles or an electronic leak detector to identify
any refrigerant leak and pinpoint the exact location.
~ Check the control line temperature of all high-pressure switches at a point that is about 12
inches from the compressor connection. If the temperature is above the mechanical room
ambient temperature, it may indicate a leak in the control line, fitting, or control bellows.
~ Check the pressure relief valves of each system for refrigerant release. Each relief valve should
have a balloon, blow-off cap, or other telltale way to signal that a relief valve has discharged.
~ Visually check all air-cooled condensers for oil seepage underneath the unit and on finned coil
surfaces.
~ Check condenser fan blades for cracking or tearing of the metal, especially at the point where the
fan blade is riveted to the hub.
~ Check for imbalance in the condenser fan blades and wear in the motor mounts/bolts. Excess
vibration in the blades can result in motor mount failure. This can cause the spinning motor to
drop and tear the tube sheet, resulting in a high-pressure leak.
~ Visually check piping and fittings to ensure that there is no pipe chafing and no excessive stress
on piping or fittings from thermal or mechanical pipe movement during operation.
~ Work with equipment suppliers to verify that equipment is leak-tight when it leaves the factory,
and provide feedback to suppliers if leaks are found in factory-built equipment or subsystems.
~ If permanent leak detectors are installed, ensure their proper function.
~ Using an electronic leak detector at its most sensitive setting:
o Slowly move the probe over all mechanical room components.
o Walk through the sales area of the store and the entire length of the discharge air stream
of each refrigerated case,
o Check each walk-in cooler, freezer, and refrigerated prep area in the store,
o Check subsurface refrigeration access pits, starting with riser pits,
o Check accessible overhead refrigeration lines by following the path of the lines.
GreenChill Guide on Refrigeration Management
Page 17
-------
Appendix D. Supermarket Walk-Thru Checklist
This checklist should be used to routinely check your store for refrigerant leaks. To complete the leak inspection,
you will need a hand-held electronic leak detector capable of measuring refrigerant leaks ofV2 oz per year. The
leak detector should be checked and calibrated at least once a year and preferably more often. Remember¦, the
only way to solve refrigerant leaks is to repair them; topping-offyour system is not a viable solution!
~ Receiver Levels: Identify and log the refrigerant level of the receiver of each refrigeration
system using the GreenChill Monthly Refrigerant Receiver Level Chart (see Appendix B). Be sure
the refrigeration systems are not in heat reclaim, gas defrost, split condenser, or winter flooding
mode, or any other condition that could affect receiver level. Compare the current refrigerant
level with levels logged during previous checks. A drop in the receiver level from a previous
reading may indicate a leak in the system. **REMEMBER** A significant drop in refrigerant level
must be the result of a significant leak. Do not stop at the first leak found, especially if it is a
seeping connection or valve stem leak. Continue searching until a significant leak is found.
~ Oil Seepage: Visually check the compressor racks, piping, and valves in the mechanical room for
any oil seepage. If oil seepage is identified, use soap bubbles or an electronic leak detector to
identify any refrigerant leak and pinpoint the exact location.
~ Mechanical Room: Using an electronic leak detector at its most sensitive setting, slowly move
the probe over all components in the mechanical room. Temporarily turn off the mechanical
room ventilation to reduce air movement. If the detector indicates a leak within the space, slowly
reduce the sensitivity and progressively move to the leak location until found.
~ High-Pressure Control Lines: Check the control line temperature of all high-pressure switches
about 12 inches from the compressor connection. If the temperature is above the mechanical
room ambient temperature, it may indicate a small leak in the control line, fitting or control
bellows.
~ Pressure Relief Valves: Check the pressure relief valves of each system for refrigerant release.
Each relief valve should have a balloon, blow-off cap, or other telltale way to signal that a relief
valve has discharged. Under normal conditions, a relief valve should never discharge. If it has,
the cause must be found and corrected and the relief valve replaced as they are only designed for
one release and may seep refrigerant if left in place.
~ Air-Cooled Condensers: Visually check all air-cooled condensers for oil seepage underneath
unit on finned coil surfaces. Check return bends and manifold assemblies for oil seepage. If a
view of return bends is blocked by a cover, either remove the cover to inspect or use an
electronic leak detector to probe the area under the cover. If the condenser is suspected of
leaking, the refrigeration system should be turned off temporarily along with the condenser fans
so the leak may be pinpointed using soap bubbles or an electronic leak detector.
GreenChill Guide on Refrigeration Management
Page 18
-------
~ Condenser Fan Blades and Motor Mounts: Check condition of condenser fan blades for
cracking or tearing of the metal, especially at the point on the assembly where the fan blade is
riveted to the hub. If cracking or tearing is present, disconnect the motor and replace the blade
as soon as possible. Check motor mounts of each fan motor assembly for signs of deterioration
and replace or repair immediately.
~ Sales Area: Walk through the sales area of the store with an electronic leak detector at its most
sensitive setting. Probe the entire length of the discharge air stream of each refrigerated case. If
a leak is detected, unload the case and check the evaporator coil, all valves, connections, and
interconnecting piping until the leak is pinpointed.
~ Refrigerated Walk-Ins & Prep Rooms: Check each walk-in cooler, freezer, and refrigerated
prep area in the store with an electronic leak detector at its most sensitive setting. If the leak
detector indicates a leak, slowly reduce the sensitivity and progressively move to the leak
location until found.
~ Underground Refrigerant Piping: Check sub-surface refrigeration access pits starting with the
riser pits with an electronic leak detector at its most sensitive setting. If refrigerant is detected,
reduce sensitivity to determine whether the leak is in that pit. If the leak is not in that pit, move
to the next pit in the underground piping network. A drop in the leak detector reading may
indicate that the leak is in the piping between the two pits. If it increases, continue checking each
pit in the piping network until the leak is pinpointed in a pit connection or it is determined that
the leak is in the interconnecting piping between two pits. If the leak is found to be in the
interconnecting piping and the piping is not accessible, turn off each system that has lines
passing through the pipe duct, one by one. This will increase the pressure in the suction lines
and should trigger an increased leak rate reading on the electronic leak detector when the
offending system is turned off. If this does not provide positive results, the next step is to pump
down each system one by one. This will decrease the pressure in the liquid lines and should
result in a decreased leak rate reading on the electronic leak detector when the offending system
is pumped down. If the above steps do not yield positive results and there is a high degree of
confidence that one of the systems in the pipe duct is leaking, it will be necessary to isolate each
individual line and pressure test each to 300 psig using dry nitrogen for 24 hours. Once the
leaking line is found, it will be necessary to replace the line or reroute the line overhead.
~ Overhead Refrigerant Piping: Check accessible overhead refrigeration lines by following the
path of the lines using an electronic leak detector set at its most sensitive setting. If the lines are
insulated, it may be necessary to probe under the insulation to pinpoint the leak. Be sure to
properly reseal the insulation to preserve its integrity.
GreenChill Guide on Refrigeration Management
Page 19
------- |