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INTRODUCTORY HELP
This "Refrigerant Charge Calculator" spreadsheet has been prepared to help estimate the amount of refrigerant in a refrigeration or air-conditioning plant. This
information is required to confirm compliance with the new EU F-Gas Regulation. The spreadsheet accompanies Defra Guidance on the F-Gas Regulation. The
following documents provide detailed information about the Regulation:
a) Defra Guidance: EC Regulation No 842/2006 on certain fluorinated greenhouse gases available from
http://www.defra.gov.uk/environment/climatechange/uk/fgas/index.htm
b) Supplementary Guidance for Refrigeration, Air-conditioning and Heat Pump Users available from www.website_address
The best way to establish the amount of refrigerant in the system is to use data supplied by the manufacturer:
Many refrigeration systems, especially small ones, have a Name Plate showing the amount of refrigerant.
Alternatively, you may have a record of the amount of refrigerant in the documentation supplied when the system was installed or commissioned.
If you cannot find information of this kind you could refer to 5 simple rules of thumb to estimate refrigerant charge. These are outlined in the Supplementary
Guidance referred to above.
This "Refrigerant Charge Calculator" spreadsheet has been prepared to help estimate the amount of refrigerant in a refrigeration or air-conditioning plant. This
information is required to confirm compliance with the new EU F-Gas Regulation. The spreadsheet accompanies Defra Guidance on the F-Gas Regulation. The
following documents provide detailed information about the Regulation:
a) Defra Guidance: EC Regulation No 842/2006 on certain fluorinated greenhouse gases available from
http://www.defra.gov.uk/environment/climatechange/uk/fgas/index.htm
b) Supplementary Guidance for Refrigeration, Air-conditioning and Heat Pump Users available from www.website_address
The best way to establish the amount of refrigerant in the system is to use data supplied by the manufacturer:
Many refrigeration systems, especially small ones, have a Name Plate showing the amount of refrigerant.
Alternatively, you may have a record of the amount of refrigerant in the documentation supplied when the system was installed or commissioned.
If you cannot find information of this kind you could refer to 5 simple rules of thumb to estimate refrigerant charge. These are outlined in the Supplementary
Guidance referred to above.
This spreadsheet provides a way of obtaining a reasonable estimate of the amount of refrigerant in a plant. This can only be done if you provide certain essential
information about each plant. It is recommended that you collect the data before you start completing the spreadsheet (although you can save your data part way
through data entry and continue later if you prefer).
The spreadsheet has been set up to store data for up to 4 different refrigeration systems. If you need to investigate more than 4 systems you could simply save the
spreadsheet with a different name and start again. There is a Clear All Data button on the Data Entry Tab that allows you to start again with an empty spreadsheet.
To navigate through this spreadsheet you can either press the grey buttons to jump to the page you want, or click on the spreadsheet tabs at the bottom of the
screen e.g. "Data_entry", in order to move to a different page.
COMMENT ON ACCURACY
It should be noted that this spreadsheet only provides an approximate estimate of the amount of refrigerant in a system. To estimate the amount of refrigerant in the
evaporator and condenser the calculations use representative average data for each type of heat exchanger. However, the actual heat exchangers used in your
systems may contain a greater or smaller amount of refrigerant. Also, to keep the data entry simple we have assumed a fairly simple configuration of system. The
spreadsheet is intended as a screening tool to assess the size thresholds in the F-Gas Regulation. If you need an accurate assessment of refrigerant charge this
spreadsheet is not suitable you will need to have the system appraised by a suitable expert.
CALCULATION METHOD
Press the button below for details on how this spreadsheet calculatres system charge.
Rule 5: Any system with a liquid storage vessel will contain more than 3 kg. Some systems are fitted with a high pressure liquid receiver which is located
under the condenser. They are usually quite large vessels containing well over 3 kg. Other types of storage vessel are also used in other locations e.g. an
evaporator surge drum or an intercooler for a 2-stage plant. Again these will contain well over 3 kg.
If cooling duty is not available, you will be prompted enter compressor motor power in kW
Enter the total compressor motor power of the system, in kW. If there is more than one compressor please ensure you enter the value of all the motor powers
summed together. Please note that the results from this spreadsheet will be inaccurate for 2 stage systems.
Type of evaporator (choose from drop down list)
You must select 1 of 3 evaporator types:
(1) Finned air cooler this type of evaporator is used for the majority of air cooling applications.
(2) Shell and Tube liquid cooler this type of heat exchanger is common for water chillers and other types of liquid cooler. Please note, if you select this option
you will be asked an extra question about the type of shell and tube cooler.
(3) Plate Liquid Cooler this is a modern type of heat exchanger sometimes used for water chilling or for cooling other liquids.
Type of shell and tube cooler (choose from list)
You must select 1 of 2 shell and tube cooler types:
(1) DX shell & tube the refrigerant flows through the tubes of the heat exchanger and the liquid being cooled flows through the shell.
(2) Flooded shell & tube the liquid being cooled flows through the tubes of the heat exchanger and the refrigerant evaporates in the shell.
Type of condenser (choose from drop down list)
You must select 1 of 4 condenser types:
(1) Air Cooled Condenser this type of condenser is common for small and medium sized systems. Air is blown over a finned coil to reject heat from the
condensing refrigerant in the tubes of the condenser.
(2) Water Cooled Shell and Tube Condenser this type of condenser is common for large systems. Refrigerant condenses in the shell of the heat exchanger,
being cooled by water flowing through the tubes.
(3) Water Cooled Plate Condenser this is a modern type of condenser in which refrigerant condenses inside a plate heat exchanger cooled by water.
(4) Evaporative Condenser this type of condenser is common for large systems. Refrigerant condenses in steel coil, being cooled by water sprayed the coil
which is being cooled by a blast of air.
Type of compressor (choose from drop down list)
Please select which type of compressors are used in this system.
Is this a hermetically sealed system
A hermetically sealed system is usually a small factory built unit with a hermetically sealed compressor and all welded or brazed connections. A common example
of a hermetically sealed system is a domestic refrigerator.
The exact definition used in the Regulation is: a system in which all refrigerant containing parts are made tight by welding, brazing or a similar permanent
connection which may include capped valves and capped service ports that allow proper repair or disposal and which have a tested leakage rate of less than 3
grams per year under a pressure of at least a quarter of the maximum allowable pressure.
Liquid line dimensions: diameter (mm / inches)
The liquid line is the pipe that transfers liquid refrigerant from the condenser to the expansion valve. You should measure the outside diameter of this pipe and
select the value from a drop down list that shows standard sizes in both mm and inches. On small plants the liquid line usually will be between 10mm and 20mm
in diameter. For larger plants the liquid line could be up to 50mm in diameter.
Liquid line dimensions: length (m)
You must also estimate the length of the liquid line from the condenser to the expansion valve. A good approximation will be sufficient. The length must be
entered in metres.
Do you have a high pressure liquid receiver?
A high pressure liquid receiver is a cylindrical vessel located beneath the condenser that is partially filled with liquid refrigerant.
HP liquid receiver (a cylindrical vessel): vessel diameter (mm)
Enter the approximate diameter of the liquid receiver in mm.
HP liquid receiver (a cylindrical vessel): length (mm)
Enter the approximate length of the liquid receiver in mm.
HP liquid receiver (a cylindrical vessel): orientation (horizontal or vertical)
All liquid receivers are cylindrical in shape. Most are oriented horizontally i.e. the cylinders long axis is horizontal. Some liquid receivers are oriented vertically.
Do you know the depth of liquid in the liquid receiver?
If you know the depth please state Yes and you will be prompted for a value. If you do not know the depth we will use a default value of 30%.
If known, enter the approximate depth of liquid refrigerant in mm
Please measure the depth of liquid from the bottom of the vessel. Enter the value in mm.
Do you have a low pressure receiver or surge drum?
A low pressure receiver or surge drum is a cylindrical vessel located after the expansion valve on certain types of flooded system (e.g. in large industrial plants
such as cold stores or blast freezers). It is partially filled with liquid refrigerant.
CALCULATION METHODOLOGY
This spreadsheet tool splits a refrigeration system into a number of component parts and then calculates the quantity of refrigerant in each part. These parts are
as follows:
Liquid line. The user is prompted for actual data for the diameter and length of the liquid line. The density of the liquid refrigerant at a default condensing
temperature of 30 oC is looked up in a data table. The liquid line volume is calculated from the input data and then the mass of liquid is estimated using the density
value.
High pressure liquid receiver. The user is prompted for actual data for the diameter and length of the liquid receiver and the orientation of the vessel (it is
assumed the vessel is a cylinder, either in a horizontal or vertical configuration). The density of the liquid refrigerant at a default condensing temperature of 30 oC
is looked up in a data table. The receiver vessel volume is calculated from the input data. The user has an option of entering a liquid depth. This is used to
calculate the volume of liquid in the vessel and then the mass of liquid is estimated using the density value. If the depth is not known we use a default depth of
30% of the height of the vessel.
Low pressure receiver. The calculations are similar to those for the high pressure receiver, except that the density is based on a user entered cooling
CALCULATION METHODOLOGY
This spreadsheet tool splits a refrigeration system into a number of component parts and then calculates the quantity of refrigerant in each part. These parts are
as follows:
Liquid line. The user is prompted for actual data for the diameter and length of the liquid line. The density of the liquid refrigerant at a default condensing
temperature of 30 oC is looked up in a data table. The liquid line volume is calculated from the input data and then the mass of liquid is estimated using the density
value.
High pressure liquid receiver. The user is prompted for actual data for the diameter and length of the liquid receiver and the orientation of the vessel (it is
assumed the vessel is a cylinder, either in a horizontal or vertical configuration). The density of the liquid refrigerant at a default condensing temperature of 30 oC
is looked up in a data table. The receiver vessel volume is calculated from the input data. The user has an option of entering a liquid depth. This is used to
calculate the volume of liquid in the vessel and then the mass of liquid is estimated using the density value. If the depth is not known we use a default depth of
30% of the height of the vessel.
Low pressure receiver. The calculations are similar to those for the high pressure receiver, except that the density is based on a user entered cooling
temperature level.
Evaporator. The user selects which type of evaporator is used. For each type of evaporator we use a refrigerant coefficient expressed in kg of refrigerant per
kW of heat exchanger duty. High and low values of each coefficient have been estimated - these represent the typical design variations that exist for each heat
exchanger type. The values used are as follows (low / high values):
Finned Air cooler
0.2 to 0.35
kg/kW
DX shell and tube
0.15 to 0.25
kg/kW
Flooded shell and tube 0.4 to 0.7
kg/kW
Plate liquid cooler
0.3 to 0.5
kg/kW
The user is able to enter either a cooling duty or, alternatively, the compressor power. If the cooling duty is entered this is used directly in the calculation. If the
compressor power is entered then we estimate the COP of the system based upon the user entered cooling temperature. A Carnot COP based on a condensing
temperature of 35 oC and evaporating temperature 10 oC lower than the cooling temperature is calculated and then a Carnot Ratio of 60% is applied.
Condenser. The user selects which type of condenser is used. For each type of condenser we use a refrigerant coefficient expressed in kg of refrigerant per
kW of heat exchanger duty. High and low values of each coefficient have been estimated - these represent the typical design variations that exist for each heat
exchanger type. The values used are as follows (low / high values):
Air cooled
0.1
to 0.17
kg/kW
Water cooled shell and tube
0.15 to 0.25
kg/kW
Water cooled plate
0.15 to 0.25
kg/kW
Evaporative
0.2 to 0.35
kg/kW
The condenser duty is the evaporator duty plus the compressor power (calculated using the estimated COP as described above).
Compressor. The user selects which type of compressor is used. For each type of compressor we use a refrigerant coefficient expressed in kg of refrigerant
per kW of compressor power. The values used are as follows:
Scroll
0.02 kg/kW
Reciprocating
0.05 kg/kW
Screw
0.075 kg/kW
Centrifugal
0.01 kg/kW
The compressor power is the user entered value or is calculated using the estimated COP as described above.
System number
System 1 high estimate
System Name
0
Hermetic
HCFC
charge
#VALUE!
Other
#VALUE!
Hermetically sealed?
#VALUE!
#VALUE!
#VALUE!
Hermetically sealed?
#VALUE!
#VALUE!
#VALUE!
#VALUE!
Hermetically sealed?
0.0 kg
#VALUE!
#VALUE!
#VALUE!
#VALUE!
Hermetically sealed?
#N/A
0.0 kg
#VALUE!
#VALUE!
#VALUE!
#VALUE!
Hermetically sealed?
#VALUE!
#N/A
0.0 kg
#VALUE!
#VALUE!
#VALUE!
#VALUE!
Hermetically sealed?
#VALUE!
#VALUE!
#N/A
0.0 kg
#VALUE!
#VALUE!
#VALUE!
#VALUE!
Hermetically sealed?
#VALUE!
#VALUE!
#N/A
0.0 kg
#VALUE!
#VALUE!
#VALUE!
#VALUE!
Hermetically sealed?
Evaporator
#VALUE!
Condenser
#VALUE!
Compressor
#VALUE!
Liquid line
#N/A
Vessels
0.0 kg
#VALUE!
#VALUE!
#VALUE!
#N/A
0.0 kg
#VALUE!
#VALUE!
#VALUE!
#VALUE!
#N/A
0.0 kg
#VALUE!
#VALUE!
#VALUE!
#N/A
#VALUE!
#VALUE!
#VALUE!
#VALUE!
#VALUE!
#VALUE!
#VALUE!
TOTAL (kg)
System charge
high & low
HFC charge
estimate
#VALUE!
#VALUE!
Note - status is given seperately for the high and low estimate for each system
System
name
0
Refrigerant
name
Select
refrigerant
Refrigerant
type
#N/A
and on the
Ozone Regulation if relevant
#VALUE!
#VALUE!
Select
refrigerant
#N/A
#VALUE!
#VALUE!
Select
refrigerant
#N/A
#VALUE!
#VALUE!
Select
refrigerant
#N/A
#VALUE!
#VALUE!
Select
refrigerant
#N/A
#VALUE!
#VALUE!
Select
refrigerant
#N/A
#VALUE!
#VALUE!
Select
refrigerant
#N/A
#VALUE!
#VALUE!
Select
refrigerant
#N/A
#VALUE!
#VALUE!
The obligations in the new Regulation for stationary refrigeration plants with more than 3 kg of HFC refrigerant come into force on July 4th
2007 and are as follows:
a) General obligation to prevent leakage. Using all measures which are technically feasible and do not entail disproportionate cost
operators must: (a) prevent leakage of HFC refrigerants and (b) as soon as possible repair any detected leakage.
b) Regular Leak Testing. Plants must be checked for leakage by certified personnel on a regular basis. Checked for leakage means
that the equipment or system is examined for leakage using direct or indirect measuring methods, focusing on those parts of the equipment
or system most likely to leak. The frequency of testing depends on refrigerant charge:
Plants with 3 kg to 30 kg must be checked annually.
Plants with 30 kg to 300 kg must be checked once every 6 months.
Plants with more than 300 kg must be tested once every 3 months.
Plants must be rechecked within one month after a leak has been repaired to ensure that the repair has been effective.
Plants with more than 300 kg must be fitted with a leakage detection system, which is defined as: a calibrated mechanical, electrical or
electronic device for detecting leakage of refrigerants which, on detection, alerts the operator. The detection system must be checked at
least once a year to ensure proper functioning.
For any plant fitted with a leakage detection system, the frequency of leak checking can be halved, although an annual check remains the
minimum frequency.
c) Maintaining Records. Records must be kept about each system with more than 3 kg of HFC refrigerant. The records must include:
The quantity and type of HFC refrigerants installed in each system
Any quantities of refrigerant added
The quantity of refrigerant recovered during servicing, maintenance and final disposal.
Other relevant information including the identification of the company or technician who performed the servicing or maintenance, as well
as the dates and results of leakage checks and leakage detection system checks.
These records shall be made available on request to the competent authority and to the Commission.
d) Gas Recovery. If refrigerant needs to be removed from a system (e.g. to gain access to part of a system for maintenance or during
system decommissioning at the end of life) it must be properly recovered by certified personnel. After recovery the refrigerant can be
reused or sent for reclamation or destruction.
e) Use of Adequately qualified staff. Personnel carrying out leak testing, gas recovery, installation and maintenance must have a suitable
refrigerant handling qualification.
f) Labelling. Any new system placed on the market must be fitted with a label clearly stating the type and quantity of HFC refrigerant used.
Stationary HFC refrigeration systems with less than 3 kg of refrigerant and mobile systems (e.g. car air-conditioning and transport
refrigeration) do not need to comply with (b) and (c) above. However, all the other items i.e. (a), (d), (e) and (f) apply to all types of HFC
refrigeration system.