BEST PRACTICE - 04 - Industrial Refrigeration Sections - v11 - 130118 - en
BEST PRACTICE - 04 - Industrial Refrigeration Sections - v11 - 130118 - en
BEST PRACTICE - 04 - Industrial Refrigeration Sections - v11 - 130118 - en
BEST PRACTICE
Industrial refrigeration sections
This document is the property of Carrefour and may not be copied or modified
without prior permission.
Contents
1 GENERAL ............................................................................................................... 7
1.1 BEST PRACTICE, INDUSTRIAL REFRIGERATION SECTIONS ..................... 7
1.2 DOCUMENTS TO BE APPLIED ....................................................................... 7
1.3 FOREWORD ..................................................................................................... 7
1.4 DEFINITION OF THE SERVICES TO BE PROVIDED ................................... 10
1.5 TECHNICAL DOCUMENTS ............................................................................ 10
1.5.1 TECHNICAL DOCUMENTS ..................................................................... 10
1.5.2 OVERALL POWERS AND FLOW-RATES ............................................... 11
1.6 LEGISLATIONS .............................................................................................. 11
2 CALCULATION BASES......................................................................................... 11
2.1 BASIC OUTDOOR CONDITIONS................................................................... 11
2.2 BASIC INDOOR CONDITIONS ...................................................................... 11
2.3 PERFORMANCE OBLIGATION ..................................................................... 11
2.4 THERMAL REQUIREMENTS ......................................................................... 12
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1 GENERAL
1.1 BEST PRACTICE, INDUSTRIAL REFRIGERATION SECTIONS
By working on the basis of a standard within a circle of companies involved at a national and
international level, we can develop standardization. Using this system, we obtain installations
using current techniques produced in different places and by different people, all of them
using identical working processes and techniques.
Carrefours Best Practice is an internal standard used internationally. Putting these
concepts into practice will, in the long term, lead to unified engineering with installations of
high quality. Cost reduction will be the result of rationalizing resources. The contents of best
practice documents are for information only and do not constitute a set of specifications.
The manual takes account of external temperatures of +34 C. If this value is different,
appropriate measures must be examined separately.
1.3 FOREWORD
Installations under the contract shall be carried out in accordance with the instructions and
dimensions given in this best practice document drawn up by Carrefour as both project
owner and project manager, and with the instructions common to all work packages; they
shall comply with the set of plans in the dossier.
As a general rule, the contract is assumed to include all work or rulings stipulated by the
instigators of the project and works inspectors in ensuring the compliance of the work in
accordance with the regulations in force for the work covered by the order.
All deliveries and work must correspond with statutory requirements and with the
requirements of the professional associations.
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In all cases, calculations must be based on the contents of the best practice documents
appended and must include all those elements and capacities guaranteeing a suitable
implementation and perfect operation of the installations.
If the contractor has an alternative opinion in terms of the conditions, design, capacities,
controls, or materials, or if they obtain different results, they shall state this in an ancillary
document, stating their reasons explicitly.
In the absence of written reservations or objections, it is assumed that the best practice
document bases also correspond to the opinion of the contractor (refrigeration engineer).
The contractor has an obligation to inform the project owner, at the latest at the contract
award meetings, in order to agree any possible special conditions.
In all cases, the agent shall assume entire responsibility for the installations as well as for
their faultless operation.
The tender shall include all the associated structures and services necessary for full and
perfect completion of the work. The company must supply complete installations and parts in
full working order; all work must be carried out in accordance with Best Professional Practice.
If there are several possible interpretations of this text, the contractor has an obligation to
inform the project owner of this in writing for them to clarify the situation. If they fail to do so,
the project owners interpretation shall take precedence.
If the contractor should wish to use materials or variants other than those indicated, they
must make their request in a separate written document.
The project owner reserves the right to split the contract award between several suppliers.
The contractor will not be able to claim any compensation in the event of partial or total
abandonment of certain positions during execution.
The contractor shall remove all transport and packing materials from the site at their own
expense. Unloading and fitting expenses (e.g. lifting plant) justified by the construction will be
billed to the contractor.
All prices shall be free at fitting location, with installation and adjustment, including
associated works, even if these have not been expressly mentioned in the best practice
documents or otherwise, but constitute part of the work required for faultless fitting.
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Any modifications to the order by increasing or eliminating certain work may only be carried
out with the agreement of the project owner. No claims will be accepted without written
confirmation from the project owner or by a corrective order.
All additions or modifications to the original delivery volume will take place under the same
conditions as for the principal mandate, as set down in the contractor contract.
In principle, under a cost plus basis, working time is not remunerated, other than under a
formal order from the project owner. Reports must be presented for signing within two days
of the order. No cost plus reports will be accepted if not duly signed.
The warranty starts to run as soon as all defects noted during acceptance have been
eliminated.
Any defects noted during the warranty period must be repaired at the contractors expense
(including indirect damage). If the latter is able to prove that they are not responsible for the
damage, they will be released from their obligations.
The project owner or their consulting engineers shall carry out new checks prior to expiry of
the warranty. Any defects shall be rectified within the times laid down in writing, and the
project owner shall be informed of the repair.
All documents necessary for execution of the work, such as assembly and connection
diagrams, installation diagrams, etc., must be submitted by the contractor. A detailed
diagram shall be produced for each installation and all devices shall be marked according to
their type; no legends or additional sheets will be accepted. The refrigeration diagram shall
be submitted to the project owner prior to the start of assembly.
Services provided by the project owner or their consulting engineers:
- checking execution outline diagrams
- technical spot checking of work
- acceptance of the installations
Acceptance conditions:
After the official commissioning, it will be necessary to establish an electronic temperature
control strip for each refrigerated object (e.g. Hamster or Escort). For meat and fruit & veg
cold rooms, the measurements will be made with the help of thermoscriptes. The
measurement points will be agreed in advance with the project owner or their engineers. The
minimum measurement duration shall be 24 hours. A check strip for the ambient temperature
and relative humidity of the air in the store shall also be presented in addition to the
temperature measurement. Each check strip shall be attached to an A4 format sheet; the
position, date, and duration of the measurement shall also be indicated on this.
At the latest 2 months after the unit has been officially brought into service, and following
establishment of the control strips, the unit will undergo acceptance with the project owner or
their consulting refrigeration engineers and the project owners maintenance department.
The contractor shall inform the consulting engineers 3 weeks before the planned date.
Acceptance includes:
- inspection of the equipment/supplies
- temperature checks
- checks of functions and powers
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Ten hours shall be set aside for acceptance of the refrigeration installations by the project
owner or their engineers. If at that time any untoward issues are observed in the installation
or in certain parts, the acceptance process will be interrupted and adjourned. Any additional
costs incurred by this delay will be deducted from the contractors invoice.
The refrigeration installer is responsible for the faultless operation of the refrigeration
installations and is liable for any damage caused to merchandise by malfunctions due to their
own fault, from commissioning up to reception.
Sales staff shall receive all necessary instructions for correct handling of the installations no
later than the acceptance date.
By signing, the contractor accepts the best practice documents, which form an integral part
of the order. The contractor likewise certifies that they have been informed of the nature and
volume of the work and deliveries, as well as about local conditions.
Within the operating documents, the exact locations of the probes must be shown on each of
the diagrams for the refrigerated units (p4, p1, etc.). Using these documents, maintenance
personnel must very quickly be able to locate the probes in the event of a breakdown.
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After on-site reconnaissance by the service provide and unless the client requests a
modification, it is specified that the contractor's bid will remain a fixed sum, regardless of any
changes to circuit routing that might prove necessary when finalizing the execution plans.
1.5.2 OVERALL POWERS AND FLOW-RATES
The powers and flow-rates figuring in the tender documents are given for information only;
this work package will be required to adapt the powers to the store configuration in
accordance with the clients requests.
1.6 LEGISLATIONS
In general, national and local regulations, standards, and laws must be respected.
Exceptions specific to each country, identified in relation to this best practice document, must
be communicated immediately to the project owner. It is requested that counter-proposals be
presented to the project owner.
The best practice document is subordinate to the laws and regulations specific to each
country.
The contractor is responsible for satisfying all the laws specific to each country, regulations
and standards in force.
Best Practice has been prepared on the basis of various standards. The separate
fundamental standards folder gives an overview of the various standards, but the list is not
definitive.
2 CALCULATION BASES
2.1 BASIC OUTDOOR CONDITIONS
Target values
Summer temperature
Chiller refrigerant
Freezer refrigerant
+34 C
Actual values
depending on
country
+ ___ C
R744 (CO2)
R744 (CO2)
The manual takes account of outdoor temperatures up to a maximum of +34 C. If this value
is exceeded, appropriate measures must be examined separately.
Target values
Actual values
depending on country
Summer temperature
+25 C/60%HR
+ ___ C / HR __ % (NC)
Winter temperature
+25 C/60%HR
+ ___ C / HR __ % (NC)
Cold rooms: see refrigeration report sheets
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Stored
product
temperature
Air relative
humidity
Temperature
of products
when added
Specific heat
capacity of
products
Daily addition
rate
Guide power
per m
PRE-PACKED
MEAT
1/+1 C
RH 80%
7 C
3.349 kJ/kg*K
50 kg/m
0.20 kW/m
PRE-PACKED
POULTRY
1/+1 C
RH 80%
7 C
3.349 kJ/kg*K
50 kg/m
0.20 kW/m
CARCASSES
1/+1 C
RH 90%
3 C
3.141 kJ/kg*K
100 kg/m
0.20 kW/m
PRE-PACKED
DELI MEATS
+1/+3 C
RH 80%
7 C
3.349 kJ/kg*K
60 kg/m
0.20 kW/m
PREPARED
DISHES
+1/+3 C
RH 85%
3 C
3.141 kJ/kg*K
75 kg/m
0.20 kW/m
TROLLEYS
PREPARED
DISHES
1/+1 C
RH 80%
3 C
3.559 kJ/kg*K
75 kg/m
0.20 kW/m
0/+2 C
RH 80%
7 C
2.931 kJ/kg*K
50 kg/m
0.20 kW/m
FISH ON ICE
1/+1 C
RH 90%
4 C
3.349 kJ/kg*K
75 kg/m2
0.20 kW/m
FRUITS &
VEGETABLES
+6/+8 C
RH 90%
16 C
3.768 kJ/kg*K
100 kg/m
0.25 kW/m
PACKAGED
DAIRY/EGGS
+3/+5 C
RH 80%
4 C
2.722 kJ/kg*K
100 kg/m
0.20 kW/m
CHEESE
+3/+5 C
RH 85%
6 C
2.931 kJ/kg*K
70 kg/m
0.20 kW/m
FISH
1/+1 C
RH 75%
2 C
3.768 kJ/kg*K
100 kg/m
0.20 kW/m
FOOD WASTE
+3/+5 C
RH 75%
10 C
3.349 kJ/kg*K
80 kg/m
0.20 kW/m
FROZEN
PRODUCTS
25 C
RH 90%
18 C
1.759 kJ/kg*K
90 kg/m
0.22 kW/m
ICE-CREAMS
25 C
RH 90%
-18 C
1.885 kJ/kg*K
90 kg/m
0.22 kW/m
Given the frequency of deliveries, the refrigeration power shall be calculated with a loading
factor of 25% of the total volume of the cold room.
The values must be verified according to the country and specifically for each project
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Laboratory type
CUTTING
CUTTING / PACKING
PACKING / CUTTING /
MARKING
Air
temperature
+8/+10 C
+8/+10 C
+8/+10 C
Air relative
humidity
RH 70%
RH 70%
RH 70%
Installed power
Occupation
0.06 kW/m
0.12 kW/m
0.30 kW/m
0.1 person/m
0.125 person/m
0.167 person/m
OPERATING TIMES:
Dairy cold rooms 12 hr
Fruit & veg cold rooms 14 hr
Meat cold rooms 14 hr
Fish cold room 14 hr
Miscellaneous cold rooms 14 hr
Freezer rooms 16 hr
Insulation assumptions shall correspond to existing thermally-insulating barriers for existing
cold rooms, and 6 W/m (walls, ceiling, floor) for new cold rooms.
The air renewal assumptions are specific to the volumes of the cold rooms.
2.4.1.2 THERMAL REQUIREMENTS
Where there are no consulting engineers, calculation of the thermal requirements for cold
rooms, laboratories, and other areas is the responsibility of the refrigeration work package.
The total installed power, resulting from the thermal, furnishing, cold room and laboratory
requirements, shall be used to determine the type of refrigeration unit.
Chiller installation:
Freezer installation:
+ 5%
reserve
reserve
100% Refrigeration power in
positive refrigeration units
Equivalent refrigeration
power in negative
refrigeration units
reserve
+ 5%
reserve
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The refrigeration power and operating rate (evaporation temperature) are provided by the
unit manufacturer.
The contractor is responsible for the power calculations.
The powers declared shall comply with the EN23953-2:2005 +A1:2012 standard or be in
accordance with local legislation.
Reminder: cold rooms and refrigerated sales fixtures are intended to keep products for sale
at the correct temperature.
2.4.2.2 AMBIENT SURROUNDINGS CLASS
The store is heated in winter and cooled in summer, but not in spring or autumn, or airconditioned for part or all of the year in hot regions.
The power of the refrigerated sales fixtures shall be calculated in Class 3.
Dry temperature +25 C
Relative humidity 60%
Depending on country references
2.4.2.3 THERMAL REQUIREMENT
Where there are no consulting engineers, calculation of the thermal requirement for
refrigerated display cabinets and other elements is the responsibility of the refrigeration work
package.
Nevertheless, the refrigeration work package service provider must check all the powers.
The total installed power, resulting from the thermal, furnishing, cold room and laboratory
requirements, shall be used to determine the type of refrigeration unit.
Chiller installation:
Freezer installation:
+ 5%
reserve
reserve
100% Refrigeration power in
positive refrigeration units
Equivalent refrigeration
power in negative
refrigeration units
+ 5%
reserve
reserve
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3 REFRIGERATION OUTPUT
3.1 CHARACTERISTICS AND GENERAL PRINCIPLE
Chiller and freezer refrigeration production shall be accomplished by one or more booster
units or independent direct-expansion chiller installations, comprising an oil separator, oil
regulation system, subcooler, two liquid separators, a liquid receiver, regulating valves, the
machine electrical cabinet, all safety, control, and regulating devices (see outline diagram). It
is incumbent on the installer to respect the appropriate standards, stipulations, and orders
(e.g. OESP, EN 378: 2008).
Refrigeration production for all chiller and freezer units, cold rooms, laboratories, and freezer
rooms shall be provided using R744 refrigerant.
The distribution of the cooling/freezing units between the different installation units must be
such that refrigerated units with similar evaporation temperatures (e.g. higher) can be
connected to the same refrigeration installation. This allows the refrigeration installation to be
sized using a higher evaporation temperature.
Gas cooler/
condenser
Positive
compressors
Liquid subcooling
Negative
compressors
Positive units
Expansion
valves
Gas cooler
Liquid tank
Negative units
Sales area
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Conventional central refrigeration unit using multiplex and separated circuit piping
and air gas cooler on roof. Confined spaces, town-centre stores, etc.
Possible example of a separate factory pre-wired central refrigeration unit with outdoor gas cooler
Outdoor one-piece air condensation unit (gas cooler). Located in yard, outside, or on
roof.
Combined booster installation comprising all components such as gas cooler, gas desuperheater, etc. Ready to install outdoors. It is necessary to ensure compliance with
local orders concerning noise protection and access to the various services.
Whatever type of unit is installed, outdoor or indoor, one-piece or split production, all of them
shall be fitted in a similar way and shall group together all of the refrigeration and hydraulic
equipment in accordance with the outline diagram enclosed and the data sheets.
The weight of the central units must be communicated to the project manager in order to
check the building structure.
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Freezer installation:
90% expansion
factor
Necessary power to
compressors at
maximum output
85% expansion
factor
+ 5%
reserve
reserve
100% Refrigeration power in
positive refrigeration units
reserve
+ 5%
reserve
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The compressors must be fixed to the chassis in such a way that they do not generate
excessive vibration, and by the same token do not cause breakage of the piping (risk of
leaks) to the multiplex.
If several compressors are working in parallel on one system, each compressor must be
separately fitted onto the multiplex system in such a way that it can be changed without
interrupting operation of the system as a whole.
The refrigeration installer is responsible for complying with the prescriptions of the electricity
company for starting and running the compressors. The necessary measurements shall be
included in the price.
Compressors, gas units, and gas coolers shall be fitted on vibration dampers. Machine bases
shall be isolated accordingly. The drawings of the bases, together with any vibration
dampers, shall be prepared and supplied by the contractor.
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The liquid receiver must be sized so as to always have correct high and low levels under all
conditions (heat recovery / summer / winter).
Provision must be made for at least 4 main safety valves, to be sized according to the
standards:
1. HP valve (compressors)
2. MP valve (liquid receiver)
3. Chiller BP valve (evaporators)
4. Freezer BP valve (evaporators)
Gas cooler/
condenser
Positive
compressors
High pressure
regulator valve
Liquid
sub-cooling
Negative
compressors
Positive units
Expansion
valves
Gas cooler
Liquid tank
Medium pressure
regulator valve
Negative units
Sales area
The sizing of the safety valves along with the technical data must allow for all potential
hazards (expansion, external fire, circuit partitioning).
In order to guarantee operation of the installation even in the event of a failure in the
electronic pressure regulators, provision should be made for mechanical back-up regulators.
Refrigerant alarm:
The level in the receiver must be monitored.
If the liquid level in the receiver is indicated using a magnetic level indicator, the level
indicated must show the actual level and must be able to be isolated from the receiver. The
indicators lower connecting pipe must be connected to the lowest possible point on the
receiver to avoid siphon effects.
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Set-point
110 bar
dry gas cooler
110 bar water-cooled
gas cooler
42 bar
42 bar
42 bar
24 bar
Actual, depending
on country
____ bar
____ bar
____ bar
____ bar
____ bar
____ bar
Care must be taken to ensure that the CO2 safety release valves do not present a hazard to
personnel.
Safety instruction information such as handling CO2 and handling cylinders of CO2 shall
be legibly and prominently posted adjacent to the refrigeration installations.
Safety valve opening pressures must be 2 bar higher than the pressure of the main valves.
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The pillars shall be fitted to a depth of 100 mm into holes provided for this purpose. Fixing
shall be performed using a 2-component adhesive as per the drawing. Hence the visible
height of the protective pillars in the store will be 300 mm.
Depth of hole
Each chiller or freezer display module shall be fitted with a display giving temperature,
defrost, and alarm information. Provision shall also be made for a switch to disable the
refrigeration block in each unit.
The display must correspond to the actual temperature in the chiller and freezer cabinets.
All refrigerated sales units shall be fitted with a label indicating:
The number of defrost operations and timetable.
The regulated temperature for the unit.
This units reference on the temperature recording system.
This label shall be positioned on the units front panel adjacent to the display
thermometer, as per current legislation.
For the type of defrosting for chiller and freezer cabinets, the following instructions shall be
adhered to: Electric defrosting for chiller cabinets is not accepted. If the number of defrosting
operations set during commissioning and the optimization phase are no longer enough, the
causes must be found and eliminated. Six months after the refrigeration installation is
commissioned, the number of defrost operations may be adapted specifically to each store. If
units with glazed doors have to be fitted with electric heating elements, prior agreement from
the project owner is necessary.
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Type of display
cabinet
Chiller cabinets
Freezer cabinets
Defrosting operations must take place as far as possible outside store opening hours and
shall be kept to a strict minimum.
During the defrost cycles, the temperature of the frozen products @ 1 cm below the surface
shall not exceed the following values:
- Ice-cream 18 C
- Frozen products 15 C
Heating of frame and glazing:
For chiller cabinets, no provision is to be made for heating the frame and glazing. For freezer
cabinets, no provision is to be made for heating the glazing (Antifog surface treatment).
Frame heating for freezer cabinets shall be controlled in accordance with the heat capacity of
the store.
Satellite distribution boards for chiller and freezer cabinets:
A satellite dis. board must be positioned adjacent to each refrigerated unit. The electrical
supply and safety functions shall originate from the main refrigeration distribution board in the
plant room. In the satellite dis. board, protective devices shall be installed for the power
devices and regulation for the refrigeration unit.
The refrigeration contractor is responsible for the electrical supply and the connection
between the main distribution board and the satellite boards. The refrigeration contractor is
likewise responsible for connecting the satellite boards to the regulators and to the power
devices in the unit. The lighting shall be connected up by an electrician.
If the satellites are to be placed below the refrigerated units, they shall be raised up off the
floor.
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The armatures of chiller and freezer cabinets shall be arranged as shown below:
- Stop-valves on each cabinet module.
- All armatures must be readily accessible.
All passages of piping and electrical routing shall be sealed by the refrigeration contractor.
All holes for connecting up refrigerated units (refrigeration/drains/electricity) shall be drawn
by the refrigeration contractor on the co-ordination plan for the store, as well as being
marked in situ. Clearly, there must also be co-ordination with the other trades present, as
well as compliance with the specific features of the building (e.g. pre-stressing, etc.)
Only 3 holes must be made for each cabinet module (1 each for
refrigeration/drains/electricity). It is vital that the number of holes be optimized, in order to
minimize the number.
The installation of the water discharge (including trap) between the connection on the
refrigerated unit and the floor connection shall be carried out by the refrigeration engineer.
The drain (min. diameter 40 mm) must be installed with an adequate fall.
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piping
Copper
Copper
Stainless
fins
Bladegold
(Alu-Goldlack)
Bladegold
(Alu-Goldlack)
Gold (Goldlack)
panels
Alu
Alu
Stainless
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Freezer rooms with rendered ceilings (conventional construction) shall be fitted with a
suitable protective plate between the ceiling and the evaporator, adjoining the end wall of the
room and overhanging the evaporator by a minimum of 70 cm.
The drains (including trap) between the evaporator and the connection point outside the cold
room / freezer (pre-installed) shall be installed by the refrigeration engineer. The drain (min.
diameter 50 mm) must be installed with an adequate fall (cold rooms min. 5 and freezer
rooms min. 10).
In every cold room with evaporators using R744, the concentration of CO2 in the air must be
monitored using infra-red detectors. When the limit value is exceeded, an alarm must be set
off inside and outside at the entrance to the room, using a flashing illuminated warning
device clearly indicating the danger. See also Section 6.2.
Evaporators fitted with electric defrosting, fitted in both cold and freezer rooms, must be fitted
with an insulating batt in order to compartmentalize the evaporator from the room ceiling.
Cold room and freezer evaporators must be fitted with a minimum of 2 fans.
All evaporators to be used in cold rooms and freezers shall be fitted with low-consumption
fans (electronically-commutated [EC] motors).
Drain heating shall be accomplished using a self-regulating system.
Cold room and freezer evaporators shall be selected with fin spacing of at least:
Description
General cold room
Fruit & veg cold room
Dairy product cold room
Meat cold room
Bakery cold room
Store freezer room
Bakery freezer room
The evaporator shall be fitted with a readily-accessible point for measuring the pressure.
The evaporator position shall be suitable for the room conditions. It is important to guard
against air short-circuits, and to avoid blowing directly into a freezer or cold room. These
situations are to be avoided whenever possible.
The evaporator positions marked in red are only possible if no other solution is possible.
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Evaporator
vaporateur
Evaporator
Evaporator
Evaporator
Evaporator
Evaporator
Evaporator
Cold room
or
freezer room
Cold room
or
freezer room
Evaporator
Evaporator
Evaporator
Freezer room
Evaporator
Evaporator
Cold room
Evaporator
Evaporator
Cold room
or
freezer room
Evaporator
Evaporator
Each cold room shall be fitted with a display giving temperature, defrost, and alarm
information. The display must indicate the actual cold-room temperature.
Each cold room shall be fitted with a prominent label indicating defrost times and intervals.
For the type of defrosting for cold rooms and freezers, the following instructions shall be
adhered to. If the number of defrosting operations set during commissioning and the
optimization phase are no longer enough, the causes must be found and eliminated. Six
months after the refrigeration installation is commissioned, the number of defrost operations
may be adapted specifically to each store.
Description
Cold room temperature > +2 C
Cold room temperature < +2 C
Freezer room
Type of defrost
fan-assisted
electric
electric
Defrosting operations must take place as far as possible outside store opening hours and
shall be kept to a strict minimum.
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After defrosting, re-starting of freezer room evaporator fans must be delayed. When users
have to enter the freezer room, a switch shall be provided for them to stop the refrigeration
and ventilation for around 3 minutes.
The safety devices for the door frame heating and the equalizing valve must be fitted in the
satellite where the refrigeration unit regulating control is located.
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Adjacent to the door of the freezer room or near the satellite dis. board, a label must be fitted
with a message drawing users attention to the fact that the frame heating must also be
turned off when the freezer room is turned off.
Points where refrigeration and drain piping pass, as well as cables, must be sealed by the
insulation contractor.
The personnel alarm emergency button must be positioned near the door. It shall be
positioned as per the standards, but at a max. of 30 cm above floor level, in a recess
provided for this purpose. This recess shall be produced by the insulation contractor. The
personnel alarm must be repeated outside the building. The personnel alarm facilities must
be made secure by the use of a UPS. Surface wiring to the personnel alarm button.
Cold room lighting shall be controlled using a movement detector, fitted by the electrician.
The electrician is responsible for the positioning of these detectors.
Cold / freezer room cool-down must be accomplished in a staged manner, in accordance
with the indications and instructions from the floor supplier. The refrigeration engineer shall
seek information and it is imperative that they ensure the pre-determined cooling curve is
adhered to. During the cool-down phase, the ambient temperatures must be recorded and
presented to the project owner on request.
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Best Practice
commissioning
Cool-down in days
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Best Practice
Chiller evaporation
temperature
Freezer evaporation
temperature
Freezer installation
condensation temperature
Return pressure in summer
(with atomizer)
18.01.2013
Minimum values
Target values
Maximum
values
+34 C
Version 1.1
Actual
values
dependin
g on
country
C
C
C
bar
bar
bar
bar
+ C
max. +37 C,
otherwise
warning to
FCAG
max. +35 C
+ C
max. +39 C
+ C
+ C
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Best Practice
min. 0 C
+5 C
In booster
installations, the
temperature is
influenced by the
freezer installation
9 C
min. 7 C
min. 6 K
1,450 rpm
8K
1,450 rpm
min. 90%
min. 95%
95%
95%
max. +10 C
+ ____ C
max. 10 C
____ C
____ K
max. 8 K
max. 2,900
rpm
max. 110%
max. 110%
____ K
_____
rpm
____ %
____ %
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Best Practice
Freezer:
The refrigeration power to be taken into account in sizing central refrigeration units shall be
the total power with a frequency controller setting of 100%.
Voltages to be verified for each country
Freezer compressor no. 1 with speed control for proportional adjustment according to the
evaporation pressure, with sinewave filter (if necessary) and cooling provided. Compressor 1
must be sized such that the part-charge and summer and winter operation rates function
without significant fluctuation of the compressor.
The refrigeration power of the freezer stage shall comprises the power of the freezer units.
Each installation shall require a minimum of 3 compressors and a maximum of 5. Above a
refrigeration power of 50 kW, provision must be made for at least 2 installations. Above a
refrigeration power of 100 kW, provision must be made for at least 3 installations.
When 2 chiller installations have to be installed, check if it is necessary to double-up the
freezer installation from the point of view of redundancy.
3.4.2 LABORATORY OR WORKROOM
Dependent on the climatic conditions in the country. To be verified and adapted if
necessary.
Corridors are not to be cooled.
For cooling of the LABORATORY or WORKROOM, the following variants should be
examined on the basis of the power:
Connection to the booster (with no separate compressor/installation) up to a maximum
of 20 kW
Connection to the refrigeration installation booster, but with a separate, independent
compressor with higher evaporation temperature (see table below)
Completely separate CO2 refrigeration installation with several compressors and higher
evaporation pressure (see table below)
Rates
Minimum values
Target values
Maximum
values
Evaporation temperature
2 C
2 C
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Actual
values
dependin
g on
country
C
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Best Practice
Target
values
18.01.2013
min. 42 bar
+120 C
Target
values
Pressure
Input temperature
Output temperature
Input vapour content
Output vapour content
Max. pressure drop
35 bar
0 C
0 C
45 %
42 %
max. 50 kPa
Target
values
Evaporation temperature
Input vapour content
Output vapour content
Suction output temperature
Max. pressure drop
8 C
98 %
100 %
min. > 3 C
max. 30 kPa
Version 1.1
Actual
values
depending
on country
____ bar
____ C
Actual
values
depending
on country
____ bar
____ C
____ C
____ %
____ %
_____ kPa
Actual
values
depending
on country
____ C
____ %
____ %
____ C
_____ kPa
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Best Practice
Target
values
Target
values
Saturation pressure
Input temperature
Output temperature
Max. pressure drop
0 C
0 C
min. < 4 C
max. 20 kPa
Target
values
8 C
0 C
0 C
min. > 3 C
8K
Evaporation temperature
Liquid inlet saturation pressure
Liquid inlet temperature
Suction output temperature
Super-heating
18.01.2013
min. 42 bar
+120 C
Version 1.1
Actual
values
depending
on country
bar
C
Actual
values
depending
on country
____ C
____ C
____ C
_____ kPa
Actual
values
depending
on country
____ C
____ C
____ C
____ C
____ K
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Best Practice
Target values
Stainless or
copper
Alu
Galvanized
steel, composite
paint
min. 42 bar
+120 C
min. 2.1mm
max. 1.0 bar
max. 50 dB(A)
Materials (fins)
Materials (housing)
Target values
18.01.2013
+80 C
max. +45 C
+34 C
max. 40 kPa
Version 1.1
Actual
values
depending
on country
____ bar
____ C
____ mm
____ bar
____ dB(A)
Actual
values
depending
on country
____ C
____ C
____ C
_____ kPa
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Best Practice
Water
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Best Practice
Key
LT
DT
MT
Atomisation temperature
Design temperature
Mean temperature
Regional
Overall
Atomisation
Not recommended
Weight
Recommended
-Value [-]
< 31
31 33
> 33
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Best Practice
-Value [-]
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Best Practice
The refrigeration contractor shall be responsible for delivery and installation of the water
atomizing system, including the atomizer piping and valves.
When a water atomizing system is used for cooling the gas cooler, provision must be made
for a water-softener in the systems water supply.
Water atomizing
Target values
min. 30fH
max. 0.5fH
min. 0.6m/hr
min. 4.0m/hr
max. 1.0 bar
max. 200 hr a year
Actual values
depending on
country
In sizing the alternating water-softener, the gas cooler manufacturers data are to be taken
into account and shall take precedence with respect to the values quoted in this document.
The following rate data shall be determining for sizing the gas cooler. But in general the
manufacturers data shall be taken into account.
Account must be taken of the manufacturers objectives / installation directions.
The following data are to be used for sizing the gas cooler. The manufacturers data take
precedence.
General observations R-744
Target values
Stainless or
copper
Alu, Epoxy
Alu
Galvanized steel,
composite paint
min. 120 bar
+150 C
< 3.5%
____ bar
____ C
____ %
min. 2
min. 2.1mm
min. 3 K
max. 1.0 bar
max. 50 dB(A)
No. ____
____ mm
____ K
____ bar
____ dB(A)
Actual
values
depending
on country
to be verified and adapted according to the location of the site and the countrys
legislation
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Best Practice
Minimum
values
Target values
Maximum
values
min. +30 C
+31 C
max. +33 C
Actual
values
depending
on country
+ C
min. 80 bar
max. 85 bar
bar
+100 C
Gas cooler
output
temperature
( C) factor of
2.55
+110 C
<0}max.
+ C
<0}max.
+ C
+55 C
+ C
min. +10 C
min. +14 C
min. +15 C
+ C
min. +5 C
min. +5 C
min. +10 C
+ C
Minimum
values
Target values
Maximum
values
min. +32 C
+34 C
max. +37 C
Actual
values
depending
on country
+ C
min. 88 bar
bar
+110 C
Gas cooler
output
temperature
( C) factor of
2.55
+120 C
max. +130 C
+ C
max. +39 C
+ C
+55 C
+ C
min. +10 C
min. +14 C
min. +15 C
+ C
min. +5 C
min. +5 C
min. +10 C
+ C
One factory-wired operating switch shall be installed per fan. All of the wiring shall be brought
together on a terminal block inside an enclosure. The refrigeration contractor shall be
responsible for ensuring that the element is delivered as requested.
For horizontally-operating gas coolers, the distance between the lower edge of the gas
cooler and the ground must be a minimum of 1 metre.
Gas cooler refrigerant content is to be kept to a minimum.
A water supply and a power socket must be provided adjacent to the gas cooler for
maintenance purposes. The refrigeration contractor is responsible for ensuring these
elements are installed.
The spacing between the fins of the gas cooler register is to be adapted in accordance with
the environment. The spacing must be 2.1 mm minimum.
Directive for locating gas coolers. Account must be taken of the manufacturers objectives /
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Best Practice
installation directions.
Clear horizontal location
(1 gas cooler)
Minimum distance
Length
Width
Minimum distance
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Best Practice
Height
Minimum distance
Length
Minimum distance
Minimum distance
Length
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Best Practice
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Best Practice
Chiller suction header in stainless, insulated, including connections for suction piping, 1
angle valve and 1 drain cock
Chiller hot gas header in stainless, insulated, including connections for hot gas piping, 1
angle valve and 1 drain cock
Freezer suction header in stainless, insulated, including connections for suction piping, 1
angle valve and 1 drain cock
Freezer hot gas header in stainless, insulated, including connections for hot gas piping,
1 angle valve and 1 drain cock
1
2
1
1
1
1
1
2
1
1
1
LIQUID SEPARATOR
Liquid tank
Level sensor
CO2 gas air
cooler, 0C
Safety valve
Changeover valve
Dryer
Lamp with humidity indication
Liquid filler valve
Safety valve
Ball valve
CO2
compressors,
+30C
Measuring valve
Safety valve
Emergency generator for
maintaining CO2 pressure
CO2 supercooler,
0C
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Best Practice
3
1
3
Chiller high-pressure safety valve, opening pressure: 110 bar, sized as per relevant
standards. Externally-fitted safety valves: fitting of external valves and piping from the
booster. Safety valve output discharge pipes, sized as per relevant standards.
Freezer high-pressure safety valve, opening pressure: 42 bar, sized as per relevant
standards. Externally-fitted safety valves: fitting of external valves and piping from the
booster. Safety valve output discharge pipes, sized as per relevant standards.
Full-bore ball valves (gas cooler bypass)
Freezer manual hot gas stop valve
Full-bore ball valves (freezer de-superheater bypass)
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Best Practice
LIQUID SEPARATOR
Suction pipe liquid separator
Manual stop valve
Magnetic valve
Oil return lamp
CO2
compressors, -9C
Oil compressors
Liquid separators shall be fitted in the chiller and freezer central refrigeration unit suction line.
These accumulators will make it possible to avoid liquid reaching the booster.
1
1
1
1
-
1
1
1
1
-
Liquid tank
Per compressor
Positive compressors
Oil filter
Negative compressors
Oil separator
Safety valve
Magnetic valve
Measuring valve
Oil tank
Positive units
Per compressor
Negative units
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Best Practice
1
1
2
1
4
1
1
1
1
1
-
Oil reservoir sized according to the power and minimum oil volume for each compressor
Safety valve
Pressure measurement connection and stop valves
Solenoid valve
Manual stop valves
Oil filter
Sight-glass on oil return pipe
Regulating valve
Discharge valve
Degassing pipe between oil reservoir and liquid receiver
Oil piping
Tapping points with isolating valves for supplying the various regulating and checking
devices (pressure gauge/switch/detector, etc.)
Manual isolating valves ahead of each compressors oil level regulator
GENERAL:
Air oil cooler, including fixing, regulation, and connecting piping (depending on
compressor type).
-
Filling with ..kg R-744 refrigerant, quality at least 4.5, guaranteed maximum humidity
100 ppm.
High-pressure filling hose, operating valve, safety relief valve, safety cable, pressure
gauge, dryer, connections.
Sturdily-built lacquered steel frame to take the above-mentioned machines and the
electrical cabinets for the machines.
The machine shall be assembled in such a way that each compressor can be removed
easily by separating each element (all pipes must be removable).
A discharge control system must be present for installations where the refrigerant
capacity exceeds 300 kg. This is to verify that the safety valves have indeed operated
and discharged gas. For example, a U-tube of oil with sight-glasses or a pressure
controller with an alarm.
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Best Practice
System
Chiller suction
Manometer, positive
suction pressure
Manometer, negative
suction pressure
Manometer,
intermediate pressure
High pressure
manometer
Positive low pressure
manometer
Manometer, negative
low pressure
Manometer,
intermediate pressure
Intermediate pressure
System
Freezer suction
System
Intermediate pressure
System
System
This panel shall include all the control and regulating organs such as:
1 High-pressure gauge (adjustable), stop valve, and connection for measuring pressure
1 Intermediate pressure gauge (adjustable), stop valve, and connection for measuring
pressure
1 Chiller suction pressure gauge (adjustable), stop valve, and connection for measuring
pressure
1 Freezer suction pressure gauge (adjustable), stop valve, and connection for measuring
pressure
1 Pre-alarm high-pressure safety pressure switch
1 Main high-pressure safety pressure switch
1
1
1
1
-
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Best Practice
Superheater
CO2 composite
refrigeration, -2C
Medium pressure
regulator valve
Tank, CO2
0C
Tank, CO2
0C
1
1
4
4
4
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Best Practice
Tank, CO2
0C
Stop valve
Electronic expansion valve
CO2
compressor,
-2C
Pressure sensor
Temperature sensor
Regulation
Measuring valve
Supercooler
Safety valve
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Best Practice
CO2 gas cooler for sub-critical and trans-critical operation with block optimized for subcritical operation
Vibration dampers, capable of withstanding the contact pressure and weather-resistant
Craning, positioning the element
Including EC fans + regulator for external 010 V signal
Where the air flow is vertical , at least 1 m of aspiration must be ensured.
Factory-fitted operating switches (1 per fan), fitted adjacent to each fan and wired back
to a terminal block
The permitted sound level for the gas cooler for the execution phase must be in line with the
Noise Protection Order. The constraints due to the location, including the outdoor
temperature, must likewise be taken into account and must be adapted according to the
project.
Reminder:
The gas cooler must be selected for the booster power as per the rates in Section 3.4.6 and
for the outdoor air temperature, depending on the climate in the country.
When an atomizer system is used with a gas cooler, it is wise to make provision for a device
for demineralizing the water.
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Best Practice
1
Outside temperature
Ta = +34C
Salt reservoir
Flexible pipes
Magnetic valve, water
vapour and drainage
Drainage valve
Stop valve
Non-return valve
Pressure reducer
Interface,
refrig. contr.
Sanitary
interface
Mains water
Automatic
draining
Water softener
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Best Practice
Negative CO2
compressors, +80C
Positive CO2
compressors, +45C
De-superheater
Service valve
Temperature sensor
Regulator
The de-superheater shall make it possible to cool the freezer CO2 return down to a
temperature 10 degrees above ambient temperature. No account shall be taken of the desuperheater in sizing the compressors and gas cooler. As per the technical specifications
1 Air-cooled de-superheater for cooling the hot gas in the freezer installation
Vibration dampers, capable of withstanding the contact pressure and weather-resistant
Craning, positioning the element
Including EC fans + regulator for external 010 V signal
2 Measurement valves
Provision must be made for bypass valves for bypassing the de-superheater in the event
of low outdoor temperatures
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Best Practice
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Best Practice
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Best Practice
1
Example of a temperature transducer and thermometer panel in cold rooms and freezers
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Best Practice
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Best Practice
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Best Practice
The minimum quantity of ice can be calculated using the diagram available below.
Quantit de glace
(kg)
Frozen surface
Ice machine
Target value
Housing/body material
Ice machine material
Ice discharge pipe material
Stainless steel
Stainless steel
Plastic or
stainless steel
as per Carrefour
instructions
as per minimum
daily quantity
diagram or
Carrefour
instructions
Type of ice
Daily ice output
Actual value,
depending on
country
1
1
1
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Best Practice
4
2
1
1
2
-
Schrader connections
Ice machine stop valves
Refrigeration unit with liquid receiver, including all necessary safety devices (pressure
switches)
Outdoor air condenser with fan speed control (condenser installed outside the building)
Condenser stop valves
connecting pipework (suction and liquid / hot gas and condensate pipes) insulated as
per Section 5.2.
Ice machine and refrigeration unit alarm contact to main refrigeration plant electrical
cabinet under this contract.
Filled salt bin, size as per project owners information (including 1 spare fill)
1
-
Ice guide channel in stainless steel or transparent plastic, as per project owner data
Vibration-damping supports
Sturdy stainless steel wall brackets or ceiling hangers for ice machine.
In the event of the ice machines being installed on the roof of the cold room, a retaining
tray shall be installed under the machine, including water outlet/drain pipe
Truck presence detector kit (automatic stop) and bin-full stop
Stainless steel or plastic channel, insulated using e.g. 19 mm Armaflex outside the cold
room
e.g. using Aeroflex insulation (passing through the cold-room wall), including fitting and
sealing
Vibration-damping supports
Small hardware and mounting hardware
1
2
Insulated plastic wheeled truck for transporting the ice, with inspection grille and drain
cock, capacity for approx. 400 litres of ice.
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Best Practice
Target value
Refrigerant
R410A,
if possible CO2 or
other natural liquid
min. 613 kW
+5 C
+46 C
+35 C
50 dB(A)
Refrigeration power
Evaporation temperature
Condensation temperature
Incoming air temperature
SPL @ 5 m
1
1
1
1
-
Actual value,
depending on
country
____ kW
+ ____ C
+ ____ C
+ ____ C
____ dB(A)
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Best Practice
Indoor unit technical data
Refrigerant
Refrigeration power
Evaporation temperature
Incoming air temperature
SPL @ 5 m
1
-
R410A, if possible
CO2 or other
natural liquid
min. 613 kW
variable
+5 C
+27 C
50 dB(A)
Actual value,
depending on
country
____ kW
+ ____ C
+ ____ C
Indoor unit
Small hardware and mounting hardware such as unions, weldable materials, clamps,
bolts, etc.
Refrigeration connections
Commissioning and start-up
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Best Practice
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Best Practice
All refrigeration pipes are to be fitted to the concrete floor slab. Fixing hardware such as
stirrups, pipe collars, etc. shall be supplied and fitted by the refrigeration engineer. All
refrigeration piping is to be fitted in such a way as to be free of oscillations and structureborne noise (insulation level 98%).
All piping is to be fitted with a sufficient number of flow direction arrows. The arrows must
indicate the type of liquid and the physical state (in the case of refrigerant pipes). See
Section 12.5
Calculation and operating points:
In direct expansion installations, the pressure loss in the suction pipe, measured between the
evaporator output of the most distant refrigerated unit and the compressor suction connector
must not exceed the values below:
Chiller installation:
1.5 bar and 2 K
Freezer installation: 0.9 bar and 2 K
In the case of execution using buried pipework, the contractor shall be responsible for the
plastic sleeves, soldering/brazing/welding points shall be grouped together in the inspection
chambers; in cases where there are no inspection points, the locating plans and the
application of marker points on the tiling (to look into on site during the works) must allow
reliable, fast, easy location for repair work in the event of leaks.
All pipework that will be subsequently inaccessible shall have been pressure and vacuum
tested. The contractor will be required to provide certification of its sealing.
Upward-flow areas (see industrial refrigeration section of fitting instructions document):
In the case of short areas of upwards flow on suction pipes, elbows and counter-elbows shall
be installed. In the case of longer areas of upwards flow, double risers shall be fitted.
In the case of short areas of upwards flow on hot gas pipes, elbows and counter-elbows shall
be installed. In the case of long areas of upwards flow on hot gas pipes, elbows and counterelbows shall be installed approx. every 46 m.
In the case of long areas of upwards flow on gas cooler return pipes or liquid pipes,
allowance shall be made for hammer because of the height difference. If the refrigeration
installation is located lower than the refrigerated units, the risk of flashgas shall be taken into
account.
All soldered/welded/brazed joints concealed by insulation must be marked using adhesive
tape.
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Best Practice
Implementation
The R744 and Polyolester oil together form an aggressive solution. Hence special attention
shall be paid to cleaning tubing: elimination of:
Oils and grease
Carbon and oxidation deposits, rust, etc.
Metal shavings, filings, burrs
Consequently, it is imperative that tubing is cut using a pipe cutter; using a hacksaw is
forbidden. Deburring, together with re-rounding of the tube if necessary, are obligatory in
order to avoid creating additional resistance losses. Surfaces to be brazed shall be cleaned
using steel wool or emery cloth; any other abrasives are prohibited.
Brazing
Brazing or silver-soldering must be carried out in a controlled inert gas atmosphere (Nitrogen
R, forming gas) to avoid any internal oxidation that might generate carbon deposits or slag.
Surface mounting
Surface-mounted pipework shall be in stainless or refrigeration-quality copper tubing.
Connections such as tees, elbows, etc. may be produced on site by tapping-in, bending, etc.
or by the use of standard fittings.
Embedded installation
Embedded installation shall be carried out using annealed tubing; cold-drawn tubing may be
used, but only on runs shorter than one length of pipe, with elbows produced by bending.
In embedded installation, unions and even butt-joining pipe lengths is forbidden.
The pipes shall be fitted in ducts or within insulating sleeves. This work package is
responsible for these sleeves.
The contractor shall take care that piping is not crushed, pinched, or deformed during the
embedding operations, whether this work is performed by themselves or by the structural
contractor.
In the event of damage, the contractor is liable for replacing the part concerned; the circuit
must then be pressurized in order to verify the sealing.
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Target
min. 5,000
min. 5,000
min. 5,000
Liquid pipes
min. 10,000
min. 10,000
Liquid receiver/separator
min. 10,000
min. 10,000
min. 10,000
18.01.2013
Actual
min. 10,000
min. 10,000
Version 1.1
Thermal
transmission
(W/m*K)
for 0 C
Target
Actual
min.
0.032
min.
0.032
min.
0.032
min.
0.033
min.
0.033
min.
0.033
min.
0.033
min.
0.033
min.
0.033
min.
0.033
Minimum insulation
thickness
Target
min.
25 mm
min.
20 mm
min.
20 mm
min.
20 mm
min.
20 mm
min.
20 mm
min.
32 mm
min.
32 mm
min.
20 mm
min.
20 mm
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Actual
Best Practice
Insulating materials for DHW components: e.g. PIR-Alu polyisocyanate duromer insulating
materials
Tank insulation using soft foam and quick-fit technique.
Water permeability
()
Target
Actual
Thermal
transmission
(W/m*K) for 0 C
Target
Actual
min.
0.035
min.
0.035
Minimum insulation
thickness
Target
min.
100 mm
30 mm
Actual
Insulating materials for heating components: e.g. PIR-Alu polyisocyanate duromer insulating
material
Tank insulation using soft foam and quick-fit technique.
Water permeability
()
Target
Heat recovery, heating hot
water (tank)
DHW heat recovery, water
side
Actual
Thermal
transmission
(W/m*K) for 0 C
Target
Actual
min.
0.035
min.
0.035
Minimum insulation
thickness
Target
min.
100 mm
30 mm
Actual
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Best Practice
Insulating materials for clamps/shells: e.g. PUR/PIR (elastomer) body (e.g. EPDM)
Water permeability
()
Liquid pipes
Chiller suction piping
w/o flashgas
Chiller suction piping
with flashgas
Freezer suction piping
Target
min.
7,000
min.
7,000
min.
7,000
min.
7,000
Actual
Thermal
transmission
(W/m*K) for 0 C
Target
Actual
min.
0.033
min.
0.033
min.
0.033
min.
0.033
Minimum insulation
thickness
Target
min.
20 mm
min.
20 mm
min.
20 mm
min.
32 mm
Actual
Hot gas, gas cooler flow/return, and heating and DHW piping are to be installed with
traditional pipe clamps fitted with noise-reducing material. After installation, these shall be
insulated using insulation as per Section 5.2.
Clamps with shells shall be fitted externally with a layer of aluminium which contributes to
stability as a vapour block for PUR/PIR sections. Tube fixing shall be provided by means of a
rigid foam compartment.
Fitting of PVC half-shells will be rejected and the installer will have to replace them with
insulated supports at their own expense.
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Implementation
It is obligatory for adjoining sleeves to be bonded together. The collars used shall be of
standard type, with no resilient material.
Valves and accessories to which access is required for verifying, maintenance, or other
reasons, shall be fitted with removable insulating shrouds with quick-release catches.
Operating hand-wheels and handles must remain accessible.
Other refrigeration valves shall be insulated using a product identical to that used for
insulating the pipe.
Exterior coverings
All insulation, piping and accessories, shall be protected by PVC cladding (UV- and volatile
compound resistant). This cladding must be guaranteed.
In all cases, sheet aluminium-type cladding must include 8 mm holes every 50 cm, to drain
off water ingress and/or condensation. Not necessary for suction pipes.
All plaster cladding is strictly PROHIBITED.
Prior to using any other insulation or cladding not described but equivalent or more suitable
for certain uses, this must be proposed to the project owner or their consulting engineers in
order to obtain their approval in writing.
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6 SAFETY
6.1 PLANT ROOM CO2 DETECTION
A CO2 detector shall be installed in the plant room, 40 cm above the floor, and shall operate:
- the extract fan which must discharge the air outside the building
- the flashing emergency warning signs inside and outside the plant room, marked:
- CO2 alarm leave the room
- CO2 alarm do not enter room
A remote alarm shall be connected into the remote refrigeration monitoring system and as
per local legislation.
The electrical ventilation control shall be incorporated into the refrigeration control cabinet.
The plant room ventilation is run by:
a) The refrigerant gas alarm
b) Manually, using a switch located on the front panel of the refrigeration control cabinet
c) Manually, using a switch located outside the refrigeration plant room, adjacent to the
entrance door.
Proposed limit values to be monitored as per EN 378. See in relation to local legislation
Main alarm
Target
Actual
CO2 concentration in the air
Min. 1.9 % vol. (19,000 ppm)
______ %vol. (_______
ppm)
Emergency illuminated visual Automatic triggering
and audible warning signals
Plant room ventilation
Automatic triggering
Generating a technical alarm Priority 1
Alarm transmission
to the refrigeration contractor
automatically
Alarm reset
Example of gas detection sensor device with Do not enter room warning
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6.2 CO2 DETECTION FOR COLD ROOMS, FREEZER ROOMS, SALES AREA,
AND ADJOINING ROOMS
A CO2 detector shall be installed in each cold room, preparation cold room, and freezer room
at 40 cm above the floor and shall operate flashing illuminated emergency signs inside and
outside the spaces marked:
- CO2 alarm - / leave the room
- CO2 alarm - do not enter room
A remote alarm shall be connected into the remote refrigeration surveillance system and as
per local legislation.
Main alarm
Target
Actual
CO2 concentration in the air
Min. 1.9 % vol. (19,000 ppm) ______ %vol. (_______
ppm)
Emergency illuminated visual Automatic triggering
and audible warning signals
Room ventilation
Automatic triggering
Generating a technical alarm priority 1
Alarm transmission
to the refrigeration contractor
automatically
Alarm reset
Example of gas detection sensor device with Do not enter room warning
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CO2
compressors
CO2 supercooler
CO2
compressors
CO2 supercooler
Three-way valve
Stop valve
NEW: Equipment for refrigeration units without safety valves
CO2
compressors
CO2 supercooler
Safety valve
Manual overpressure valve
Electronic expansion valve
Refrigeration unit
Stop valve with integral discharge flap-valve
CAUTION!
Closure valves can be activated only by trained
authorised personnel After closure, the pressure
should immediately be reduced to under 6 bar.
In refrigeration units, it is possible to use shut-off valves instead of safety valves, but this
requires that the shut-off valves be sealed and labelled to indicate that the pressure in the
closed sector must be reduced below 6 bar.
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6.5 COMPRESSORS
Depending on flow rate, compressors shall be fitted with a pressure switch or/and a pressure
switch discharge device. A compressor pressure discharge device is usually set higher than
the maximum permitted pressure for the installation and should not be used for protecting the
installation or other components, unless it is set to the maximum permitted pressure. The
statutory base is based on EN 378-2: 2008 +A1: 2009. Table 3 summarizes the requirement
concerning pressure switches.
Terminology and definitions:
Designation as per EN 378
PSL
Pressure switch (falling pressure)
PSH
Pressure switch (rising pressure)
PZL
Pressure limiter (falling pressure)
PZH
Pressure limiter (rising pressure)
PZLL
Safety pressure limiter (falling pressure)
PZHH
Safety pressure limiter (rising pressure)
Previous names
Low pressure switch
High pressure switch
Safety low pressure switch
Safety high pressure switch
Safety low pressure switch
Safety high pressure switch
1 approved pressure
switch (PSH)
Charge 100 kg
(electrical in series): 1
approved pressure limiter
(PZH)
1 Approved safety
pressure limiter (PZHH)
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Corridors
Firestop
flapvalve
From warehouse or
outside
Voltage-free switch
Light switch
Example of an air extract ventilation device, including the switch fitted outside
The mechanical ventilation is only started up as a safety facility in the event of malfunction.
The installation of this ventilation must comply with the relevant standards and directives.
The extract fan is started either when the refrigerant detector is triggered or by manual
operation of the switch. It discharges the extracted air directly to outside the refrigeration
plant room. Fan starts immediately refrigeration plant room motorized air extract and air
intake flaps open fire dampers already open.
The expelled air must be discharged outdoors.
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The incoming air shall be drawn from outdoors or via a fire damper.
Care shall be taken in positioning the air inlets and extracts to ensure that transverse
ventilation occurs across the plant room.
The refrigeration engineer shall scale the extract flow on the basis of the EN 378 standard,
which gives the air flow calculation as follows:
-3
3600 =
rounded up to 1,800
In all cases, the minimum air flow must not be less than 1,000
If, when the size of the plant room is taken into account, the air renewal is less than 15 per
hour, the ventilation shall be sized on the basis of air renewal. This means that a greater air
flow will be necessary.
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Target
De-superheating power
Flow rate
High pressure
Incoming refrigerant temperature
Outgoing refrigerant temperature
Incoming water temperature
Outgoing water temperature
Pressure drop, refrigeration side
Pressure drop, water side
Actual value,
depending on country
____ kW
____ bar
+ ____ C
+ ____ C
+ ____ C
+ ____ C
_____ kPa
_____ kPa
Flowrate
regulator
valve
Optional
Heating water
heat recovery
Emergency
water cooler
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Example No entry to
unauthorized persons
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7 HEAT RECOVERY
7.1 DEFINITION OF TERMS
HR
DHW
CW
HHW
HE
HW
= Heat recovery
= Domestic hot water
= Cold water
= Heating hot water
= Heat exchanger
= Hot water
Identify the consumers in detail and measure the additional pipe runs needed for
connection to the industrial refrigeration system.
Standard
Additional,
plus-value
Connection to heat
recovery circuit i.a.w.
schematic diagram
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2.
Graph for determining the gain from DHW heat recovery of a given consumer
3.
On the basis of the graph, it is possible to determine whether or not the consumer
should be connected to the DHW heat recovery system.
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7.3 GENERAL
Heat recovery for DHW shall always have a higher priority than for heating hot water.
Heating hot water recovery is described in a separate document Best Practice for heating
hot water recovery.
Special country or local stipulations shall be taken into account.
The refrigeration engineer remains responsible for installing, controlling, and regulating the
recovery system, as well as for its faultless operation. If the set values are wrong or
inappropriate handling of the hot water recovery system is noted, all related expenses
together with the cost of the energy lost will be billed to the refrigeration engineer.
Flow rate calculation:
Example of a flow rate calculation for a plate heat exchanger with a de-superheating power
of 50 kW:
Target value
+ ____ C
____ m/h
____ m WATER
____ V
____ %
Electrical power
Gas cooler power
Local specifications shall take priority over the above information.
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CO2 compressors,
+110C
Heat recovery
fault
Heating water heat
recovery or CO2 gas
cooler, +45C
Monitoring
Commercial refrigeration
Sanitari
Pressure monitor
Safety thermostat
Circulating pump
Safety valve
Temperature regulator
NO magnetic valve
Temperature sensor
Progressive valve
NC magnetic valve
Circulation
Ball valve
Regulator
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Target value
____ bar
+140 C
+ ____ C
Flow rate
High pressure
Incoming refrigerant
temperature
Outgoing refrigerant
temperature
Incoming water temperature
Outgoing water temperature
Pressure drop, refrigeration
side
Pressure drop, water side
+ ____ C
+25 C
+58 C
max. 40 kPa
+ ____ C
+ ____ C
_____ kPa
max. 25 kPa
_____ kPa
+100 C
Same as exchanger 1
Same as exchanger 1
+ ____ C
Same as exchanger 1
+ ____ C
+15 C
+ ____ C
+55 C
+ ____ C
max. 25 kPa
_____ kPa
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Heat
recovery
fault
CO2 compressors,
+110C
Monitoring
Commercial refrigeration
Sanitary
Pressure monitor
Safety thermostat
Circulating pump
Safety valve
Temperature regulator
NO magnetic valve
Temperature sensor
Progressive valve
NC magnetic valve
Circulation
Ball valve
Regulator
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Boiler equipment:
1 Boiler insulated using soft PU foam and PVC sheath, including cutting out holes ready
for the quick-fit connections (insulation as per Section 5.2), in gas-welded stainlesssteel, and full insulation. Certified as per the stipulations specific to the country.
1 Introducing and positioning the boiler (water connection by the sanitation work package)
1 Cold water connection, min 1", at bottom
1 Hot water connection, min. 1", at top
1 Circulation connection, min. 1", located in centre (if necessary)
1 Boiler internal coil, sized on the basis of the necessary capacity, located at the bottom,
as per outline diagram
1 6 bar safety valves (security valve) including discharge to drain
min. 4 probes, including thermowells (regulation)
1 Safety thermostat to shut down heat recovery in the event of overheating
min. 3 thermometers, including thermowells
1 230 V protective anode, if necessary
1 Additional electrical heating (sized according to the size of the boiler, to heat the water
within the boiler up to +60 C within 12 hr); the heater unit will be verified by the heating
installation, country-specific
1 Thermal discharge safety device, including discharge to drain
Service/inspection opening
The sanitary plumbing installer will provide the following elements:
Main cold- and hot-water supply connections
Hot water circulating pump connection, including pump (if necessary)
Delivery, fitting, regulating, and commissioning hot water circulating pump
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Heat
recovery
fault
CO2 compressors,
+110C
Monitoring
Commercial refrigeration
Sanitary
Pressure monitor
Safety thermostat
Circulating pump
Safety valve
Temperature regulator
NO magnetic valve
Temperature sensor
Progressive valve
NC magnetic valve
Circulation
Ball valve
Regulator
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Safety:
The boiler must be protected against overheating on the one hand and over-pressure on the
other. In the event of too high a temperature in the boiler, the heat recovery must be stopped
via the probe (no. 1) or a safety thermostat and only started again when the water
temperature reaches the predefined value.
If excess pressure builds up in the boiler (e.g. because of a leak), the pressure monitoring
shall stop the heat recovery system and the hot gas shall be bypassed directly to the gas
cooler. The boiler must likewise be protected against over-pressure by a safety release
valve. Excess temperature and over-pressure are both to be notified to remote management
as Prio. 1 breakdowns.
Setting parameters:
The setting parameters are given as an indication only. They are to be optimized and
adapted specifically for the purpose.
Regulation setting parameters
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Target value
+50 C
+52 C
+45 C
+45 C
+45 C
+50 C
+70 C
+65 C
DHW
DHW
5 bar
Actual value,
depending on
country
+ ____ C
+ ____ C
+ ____ C
+ ____ C
+ ____ C
+ ____ C
+ ____ C
+ ____ C
____ bar
4 bar
____ bar
+40 C
+ ____ C
5K
____ K
30 sec.
180 sec.
____ sec.
____ sec.
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8 REGULATION DESCRIPTION
The regulation of CO2 installations is inherently more sensitive with respect to variations in
refrigeration power requirements. Primarily because of the high pressures (small cushions
of gas) and the high volumetric heat capacity of CO2. It may be wise to adjust the setting
parameters to a little faster.
In practice, the objectives are generally achieved using the usual settings however, very
particular attention must be paid to the setting of the refrigeration points in order to avoid
liquid reaching the compressors.
Attention must be paid to the specific features of the different regulation system
manufacturers.
The regulation systems must have a read only function for the remote monitoring system
(no management function) with the help of all the parameters, and the Log evaluations shall
be able to be consulted remotely.
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Pressure P [bara]
High pressure
setpoint
Critical point
[+31C / 74 bara]
Two-phase region
Enthalpy [kJ/Kg]
Towards the high and low ends, the theoretical values are limited by a number of threshold
values: the minimum high pressure and the condensation pressure depend on the
compressor use limit and the maximum high pressure as a function of the application point
with a maximum outdoor temperature or as a function of the sizing of the installation. This
last point includes the compressor use limit, as well as the maximum pressures and
temperatures for the installation with respect to high pressures.
When setting the high and medium pressures, it is important to keep them as stable as
possible.
Instabilities may lead to the following:
Pressure peaks and triggering of the safety valves or pressure switches
The flashgas bypass stays closed too long: insufficient motor cooling and tripping of
the motor protection contactor and high suction gas temperatures
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Provision must be made for freezer unit regulators with the following adjustable MOP values:
t0 reaches MOP1: electronic expansion valve fully closed, setting e.g. 20 C
t0 reaches MOP2: in addition, the refrigerated unit fans are stopped, setting e.g.
19 C
This function makes it possible to avoid constant opening of the safety valve because of the
heat input, which creates a pressure increase.
Also advisable is a type of control such that complete failure of the freezer multiplex safety
chain closes the electronic expansion valves on the freezer refrigeration units.
Remark:
Danfoss (AKV) pulse-modulated electronic expansion valves require special (more
powerful) solenoid coils for CO2. This is why it is vital to specify the refrigerant used
(CO2) when ordering.
When electronic expansion valves are being commissioned on refrigeration units, the
superheating must be set to a high enough value and then reduced.
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On:
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External
switch for
blind
Lighting
Caution external voltage
Separate switch
for blind
Night-blind motor
(optional)
Off:
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the night offset signal is activated when the lighting is turned off in the chiller and
freezer units.
If the lighting is turned on on the chiller and freezer units, the night set-point offset
must be disabled.
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The electrical diagram shall be drawn with current off, the switches being in the "cooling"
position. All electrical diagrams shall be spontaneously submitted to the Owner before
installation.
The neutral earthing schemes shall be: TN neutral, TT or unearthed neutral.
The short-circuit currents (SCC) shall be as follows:
Supermarket smaller than than 2500 m: 15KA
Supermarket larger than 2500 m: 20 Ka.
Hypermarket: 25Ka
The electrical distribution panel shall include:
2 No. sockets,
lighting system,
thermostat-controlled ventilation system as shown in the drawing below:
Natural ventilation
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A transparent, Plexiglass covering shall be fitted behind the doors and suitably divided. The
control and signage devices shall be integrated into the door and be covered on the inside
face with a safety contact device. The signage devices shall be located within the cabinet
insofar as the special windows in the cabinet door enable easy reading and visibility.
Safety and control devices as well as equipment shall be durably labelled. The layout of
connection terminals shall be arranged beforehand with the competent electricity company.
Each control cabinet shall be equipped with a main switch with latch. Waterproofing of the
cable ducts shall be checked by the service provider after completion.
The control cabinets shall be constructed and installed in such a way that the doors can be
freely opened and complying with the requirements of the country concerned with regard to
the minimum space between the control cabinet and components and with regard to the
minimum escape route that shall not be obstructed.
The control cabinet shall have clear marking and inscriptions compliant with the electrical
engineer's instructions. The main circuit breaker shall be labelled with the plant room number
and the name/description of the control cabinet containing the supply fuse.
A main switch shall be provided on the front of the control cabinet for each main feed (heavy
current).
The control devices, control safety devices, operating switches, heating, defrost heating,
ventilator fans, timers, signal lights, terminals etc. shall also be durably marked with clear text
and location numbers.
The compressors must be restarted in stages after an emergency stop or any other fault.
Moreover, the multiplex control shall be equipped to limit current peaks to the compressors,
with regard to local conditions.
All operating states (e.g. heat recovery operation etc.) shall be clearly, visibly indicated.
Fault messages shall be indicated by a flashing light until the fault is resolved. An indicator
lamp shall be installed to all signage displays. All the alarm displays shall have automatic
UPS and a reset button.
Regulations applying to electrical installations and control installations must be complied
with.
All major safety-related alarms shall be operated in a closed circuit with no electrical current
(phase monitoring).
Transmission of alarm signals shall be supported by an inverter. The refrigeration contractor
shall deliver install and test it and maintain it.
Frequency switches shall be mounted on a wall, outside the electrical control cabinets. The
requirement for sine filters for the frequency controllers shall be determined by the
refrigeration contractor.
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The switch being in the STOP position shall cut out the power and control circuit for the
energy-consuming device concerned. Unless required by local law, it is not necessary to
install isolation switches on the compressors once the electrical control cabinet is located
within visual range of the energy-consuming device concerned.
Temperature fault alarms shall be indicated on the corresponding group alarm systems.
There shall be three indicator lights on the electrical cabinet doors:
Power on: white/yellow,
Fault: red,
Unit operated manually: orange.
The front of the cabinet shall also include the emergency-stop, mushroom-head button, wired
in parallel with that situated at the plant room entrance.
1 No. AUTO/STOP/MANUAL manual switch shall be provided for:
each compressor, pump, gas cooler fans;
the plant room ventilation control, linked to the R744 monitoring system.
Operating hours metering shall be provided for:
each compressor,
all gas cooler fans,
emergency mains-water cooling (if available),
gas cooler atomising (if available).
A meter to register the number of activations per day shall be provided for:
each compressor,
The following indicators are mandatory:
per compressor
operating,
overload (thermal),
coil (thermal resistor),
high pressure,
oil pressure
hot gas.
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9.1.2 EQUIPMENT
Example of electrical control cabinet for refrigeration blocks and booster (with removable, hinged door leaves)
Panel comprising multiplex cabling for all components on the booster or chiller
installation. A main circuit breaker for supply to the whole installation.
Main module with control timer, including grouping and clear signage of operation and
fault messages.
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Display of all pressures, temperatures, valve position signals and turning speeds, as well
as operating status and fault messages on the remote monitoring system.
1 No. kWh meter according to measurement design, calibrated and sealed for the main
power supply, transformer ratio (calculation factor for meter reading) on a clearly visible,
engraved plate on the meter with M-Bus connection.
Distribution and securing of all glass door freezer cabinets, freezer rooms, ice machines
and fermentation chambers.
Necessary pressure sensors for electronic expansion valves, with a 1/4 inch shut-off
valve for refrigeration freezer units.
Regulation of heating for frames of all glass door freezer cabinets and for evaporation
pressure according to the dew point.
Indication of door position for each cold room and freezer room "door open" with Alarm
Priority 2 (delivery of door contacts: refrigeration work package). Three-minute timing
(adjustable).
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Voltage-free switch for CO2 alarm for each cold room and freezer room (230V/13A);
Voltage-free switch for trapped person alarm for each freezer room (230V/13A);
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If this is not provided for on the low voltage master distribution board, overload
protection shall be provided. It shall be ensured that the protection and the conductor are
as close together as possible.
Interface with the building management system compliant with Section 11.4.
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Store No.1
Store No.2
Store No.3
Store No.4
Store No.
Firewall
Danfoss
Server
Eckelmann
Server
Wum
Server
Server
Contractor 3
Contractor 4
Firewall
Contractor 1
Contractor 2
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Gas cooler
Systems
Sanitary hot
water recovery
Chiller and
freezer
refrigeration
units
Alarm
High pressure
Low pressure
Oil level
Oil pressure
Motor
Frequency regulator compressor fault
Motor fans
Regulation fault
Sensor fault
Gas outlet temperature too high/low
Each gas detection alarm, individually
Pre-alarm: low refrigerant level
Main alarm: low refrigerant level
Alarm: refrigerant level too high
Regulation sensor fault
Display sensor fault
Defective pressure sensor
Suction gas temperature too high/low
Hot gas temperature too high/low
Power outage fault
Safety low-pressure
Safety high-pressure
Safety average pressure
HP regulating valve fault
Flash-gas regulating valve fault
Freezer installation, gas de-superheater
dysfunction
Emergency stop button activated
Emergency cooling in operation
Refrigeration pressure maintenance unit
fault
Operation of refrigeration unit and pressure
maintenance
UPS fault
Heat recovery in operation
Safety thermostat
Heat recovery pump fault
Too hot
Too cold
Defrost time exceeded
Sensor fault
Each gas detection alarm, individually
Trapped person alarm
Priority 1
X
X
X
X
X
Priority 2
Priority 3
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
Negative logic physical contacts (power on in normal operation and cut off in the event of a
fault).
Malfunctions are indicated by means of an alarm contact as group faults:
Priority 1: requiring immediate action (group technical and temperature fault);
Priority 2: requiring action within three working days (group technical and temperature
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fault);
Priority 3: not requiring immediate action, status indicators, not communicated
externally.
Transmission of alarms is mandatory from the time that an item of equipment is made
available to the operator (cold rooms and glass-door display cabinets).
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Alarms/
Faults
Alarms/
Faults
Fault/ Message
from store
Alarm/Fault
via remote
monitoring
Refrigeration contractor
Action by the
remote
monitoring
service
Refrigeration contractor
Direct action on
site
Action by the
remote
monitoring
service
Direct action on
site
Access procedure
Action sheet
Clearing the fault
Information to technical manager
Action sheet
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Both R744 and Polyol Ester fluid are very moisture sensitive.
If this precaution is not taken, hydrofluoric acid may be formed, considerably reducing the
service life of the installation (especially compressors)..
This operation shall be carried out to the entire installation.
If particular site conditions obtain, pipework shall be isolated segment by segment.
This work package shall apply the same method to each segment as to the entire installation.
The various segments shall be commissioned in such a way that introduction of air into the
circuit is prevented.
These vacuum evacuations shall be carried out once all soldering and connections have
been carried out to the part concerned.
The vacuum evacuation shall be carried out:
with a vacuum pump: in two stages, with sufficient capacity to obtain a final vacuum
of 0.03 mbar (3 Pa) suitable for R744 fluid containing Polyol Ester oil;
using R744-compatible hoses (lined with nylon or polyamid) of sufficient diameter to
limit loss of pressure.
A vacuum meter, located in the proximity of or on the installation, shall be used to monitor
pressure. Under no circumstances shall vacuum pressure be measured in the proximity of
the pump (measurement error due to pressure loss in the hoses).
The vacuum shall be maintained for 24 hours (pump stopped) in the first instance. Changes
to the vacuum shall be measured each hour. The test shall only be deemed successful if the
pressure rise does not exceed 0.3 mbar.
The refrigeration plant being delivered pressurised by dehydrated nitrogen, the plant isolation
valves shall remain closed during the first vacuum evacuation.
Once the vacuum has been maintained 24 hours without a pressure rise greater than 0.3
mbar, the vacuum shall be released with dehydrated nitrogen in order to absorb residual
moisture. The unit valves shall, thus, be open. The vacuum shall be released at least once
with the nitrogen and recreated once more.
The vacuum shall, thus, be created a second and final time over the whole installation (the
circuit plus the central refrigeration unit), to the same levels as the first time.
Following these two operations and after the installation has been in operation for 72 hours,
the residual moisture, which should not exceed 40 ppm, shall be measured by the contractor
for this work package. This measurement shall be clearly shown in the oil sample analysis
required.
After commissioning the refrigeration installation, and oil test is required and shall be the
subject of a written confirmation during technical acceptance of the installations.
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12.3 COMMISSIONING
12.3.1 GENERAL
The finished installations shall be brought into operation as soon as possible.
The contractor shall the proceed with the commissioning, safety and alarm operations
described in the "Acceptance conditions" Section.
The contractor shall produce written instructions for both routine monitoring and checks of
proper functioning.
Electrical installations insulation check.
Programming and adjusting the automatic controller regulators.
All commissioning of refrigeration equipment shall be carried out by the equipment
manufacturer.
The contractor shall supply the necessary calibrated measuring instruments to take accurate
readings and these instruments shall remain its property.
The schedule of checks of performance, temperature compliance, hygrometry etc. shall be
carried out and reported upon in the acceptance report according to the terms of the
"Acceptance conditions" Section.
The following points, set out between Section 12.3.2 and Section 12.3.9, are only a partial
extract of the relevant points. Checks and commissioning shall be carried out according to
Standard EN-378 and the pressurised equipment regulations, as well as in relation to local
conditions.
12.3.2 PRIOR TO COMMISSIONING
Check the safety valves degassing device.
Check the position of the safety valves for the various sectors.
Check the markings/labelling on the safety valves (regulating pressure, rated
decompression power, flow rates and diameter of opening).
Check positioning of gas detectors.
12.3.3 PREPARATION FOR COMMISSIONING
Check operation of alarms.
Check operation of gas detection.
Check and re-tighten all terminals, protective systems, relays etc.
Create vacuum.
Air extraction to plant room operational.
Verify leak tightness of plant room.
Remote monitoring operational.
12.3.4 COMMISSIONING
Regulation and testing of emergency circuits.
Regulation and checking all safety devices.
Checking temperatures, regulation of expansion valves.
Measurement of air and hydraulic flows as well as balancing them.
Measurement of pressure loss to the most vulnerable refrigerant circuits, under
maximum load.
Measurement of electrical current drawn.
Regulation of calibration and reference points of probes and other sensors.
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12.3.11 MARKING
After official commissioning, technical acceptance or quality checking shall be undertaken
with the Project Owner or their consulting engineers. Two weeks in advance, the company
shall inform the Project Owner or their consulting engineers, in writing, of their availability for
the acceptance meeting (by sending the "Ready for acceptance" declaration form, and
instructions for installation of the technical refrigeration section).
This work package is responsible for completes labelling of its installations and, in particular:
Labelling service valves, compressors and all safety and emergency devices;
Installation of a general installation plan, in the plant room. This plan shall be
mounted on a board and protected with plastic film. It shall show the marking of
regulator devices for all cold rooms, display cabinets and other installed equipment.
This plan shall set up clear references between the terms used for automated
temperature recording of the refrigeration units and the physical units As shown on
the plan. E.g. if the self-service meat display unit is coded "48", the number "48" shall
be shown on the plan;
Labelling all refrigeration units, showing the number of defrostings, the regulatory
temperature for the unit, the unit's reference in the temperature recording system.
E.g., if the self-service meat display unit is coded "48" on the recording system, the
number "48" shall be marked on the unit's label.
12.4 DOCUMENTATION*
*According to current local legislation
Display on installations:
a list of refrigerated units showing temperature and cooling power;
booster configuration showing main technical data;
heat exchanger information;
gas cooler information;
liquid cooler information;
de-superheater information;
compressor information;
- store layout drawing;
safety valves design calculation;
all design calculations other than those furnished by the thermal energy audit
(TEA).
3.
4.
Commissioning and refrigeration output test protocols, showing settings, pressure tests
and inspection for leakproofness of the installation (according to current legislation).
5.
Commissioning and test protocol for refrigeration points, showing settings (according to
current legislation).
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6.
Refrigeration and hydraulic diagram on a single plan: one copy, under glass, mounted
on the wall in the plant room;
7.
8.
9.
10.
Service notice for particular cases (Danfoss, Bitzer, Gntner, speed regulators etc.);
11.
Coordination plans;
12.
13.
List of spare parts for the main components showing the make, type and reference
number and a suppliers address list;
14.
15.
Certificate from the authorised body, confirming collection for recycling of used
refrigerant fluids collected during the works.
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= Roof Level
= 1st floor
= Mezzanine floor
= Ground floor
= 1st basement level
Colour:
Colour
CR
S
H
Colour of
background/panel
Black RAL 9005
Green RAL 6024
Red RAL 3020
Commercial refrigeration
Sanitary installations
Heating installations
Colour of
inscription
White
White
White
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Label
dimensions
a1 x b1
126 x 148
52 x 297
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b2
18
37
74
148
12,5
25
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Booster
R744 / CO2
12.5.3.3 Compressor
Black colour plastic label
White colour, engraved inscription
Dimensions according to the above instructions
- Type of mounting: rivets or screws
Chiller refrigeration
compressor 1
Freezer refrigeration
compressor 3
Installation
number/description
Electrical distribution
panel description
Chiller refrigeration
compressor 1
HP Pressure switch
Description of peripheral
unit / description
Number on electrical
diagram
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Electrical distribution
panel description
Installation
number/description
Chiller refrigeration
booster
Self-service, glass-door
display cabinet: cheese
Description of
refrigeration cabinet
Position No.
00
01
02
03
04
05
06
07
08
09
10
11
Time
12
13
14
15
16
17
18
19
20
21
22
23
Pos. ______ Target temperature ______ Name ______ Date __/__/____ Signature _________________
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13. WARRANTY
Warranty:
This two-year, on-site warranty is specific to and assignable with the store and only concerns
installations modified during the works.
The Project Owner shall retain responsibility for water and electricity consumed.
Overall upkeep, maintenance, fault repair, cleaning, optimising energy performance and
remote monitoring of the refrigeration installations shall be the subject of a separate proposal
according to the following documents:
Framework contract for provision of comprehensive maintenance services for CO2
refrigeration installations;
Comprehensive service contact for CO2 refrigeration installations;
Worksheets for maintenance tasks on CO2 installations
A bid must be attached to this food products refrigeration work package, based on the
above-mentioned documents.
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6)
7)
8)
9)
10)
11)
12)
13)
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14.7 MISCELLANEOUS
As well as the works and installations set out in the Best Practice document and the
drawings, the overall lump sum price also includes, in a specific provision, costs in
connection with execution of works and supply of goods and services with regard to:
Bringing the refrigeration into operation before opening of the store.
Conduct, supervision and maintenance until acceptance and opening of the store.
Training operational staff and providing As Built file.
14.7.1 CONDUCT SUPERVISION MAINTENANCE UNTIL ACCEPTANCE
At completion of installation works of this work package, the contractor shall be required to
conduct, supervise and maintain the installations in good operational order.
Maintenance shall include all works and equipment according to the maintenance contract.
14.7.2 TRAINING OPERATIONAL STAFF AND PROVIDING AS BUILT FILE
This work package is responsible in particular for:
Training in operation of installations, to take place prior to acceptance.
Furnishing 4 No. copies of a maintenance manual including, in addition, contact
details of all suppliers, all plans and schematic diagrams as executed (see: Scope of
Services).
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