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 IP 14/95
BRE Information Paper September 1995

Latest research information and how to apply it CI/SfB (57)(L7)

Phase-out of CFCs and HCFCs:

options for owners and operators of air-conditioning systems
D J G Butler, BTech, MSc

The production and import of new CFCs in the European Union was banned from
the beginning of 1995. A new EC Regulation has capped the supply of HCFCs and
will completely phase out the supply of new HCFCs by 2015 — a date which is
likely to be brought forward. The Regulation also restricts the use of HCFCs in
certain new equipment. This paper gives owners and operators of air-conditioning
systems (and their consultants) advice on options for coping with the CFC and
HCFC phase-outs and end-use controls. It updates and replaces IP 8/93.
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NEW EC REGULATION ON CFCs AND HCFCs

DEFINITIONS AND APPLICATIONS
Within the European Union (EU) the production and import
of CFCs was banned from the start of 1995, one year ahead ODP (ozone depletion potential)
of the Montreal Protocol. A new EC Regulation came into ODPs are compared with that of CFC11, which is taken to have
force on 23 December 1994 which replaced and reaffirmed an ODP of 1.0.
the earlier regulations on ozone-depleting substances, and GWP (global warming potential)
also introduced a ‘cap’ on the supply of HCFCs. The cap is to GWPs are compared with that of CO2, which is taken to have a
be followed by a scheduled phase-out (see Table 1 inside). GWP of 1.0.

HCFC end-use controls CFCs (chlorofluorocarbons)

From 1996 HCFCs will be banned in new car and road
public-transport air-conditioning, and in new rail-transport
air-conditioning from 1998. From the year 2000 HCFCs will
be banned as refrigerants in new equipment in public and
distribution cold stores, in warehouses and in refrigeration
equipment with a shaft input power of 150 kW and greater.
The only exceptions will be where codes, safety regulations or
other such constraints prevent the use of ammonia. This will
effectively ban the use of HCFC22 (R22) in new, large,
central-plant chillers used for building air-conditioning. HCFC22
is currently the most popular choice for this application.
Recovery of used CFCs and HCFCs
From 1 April 1995 it became mandatory to recover all CFC
and HCFC refrigerant contained in refrigeration systems
before opening-up or dismantling during servicing, repair or
decommissioning. If the recovered refrigerant is not recycled
or reclaimed, it must be destroyed by an approved and
environmentally acceptable method (see page 4 of this paper).
Refrigerant leakage
From 1 April 1995 all precautionary measures practicable
must be taken to prevent leakages of CFCs and HCFCs from
refrigeration equipment.
Contain chlorine and have high ODPs. Used as refrigerants in
some air-conditioning systems, eg centrifugal chillers.
HCFCs (hydrochlorofluorocarbons)
Contain chlorine but have low ODPs. They have shorter
atmospheric lifetimes than the CFCs (because they contain
hydrogen), and are thought to be much less damaging to
stratospheric ozone. HCFCs are used widely as refrigerants in
air-conditioning systems.
HFCs (hydrofluorocarbons)
Contain no chlorine and have zero ODPs, but are greenhouse
gases. Being developed as refrigerants to replace the CFCs and
HCFCs. Used in some new air-conditioning systems.
HCs (hydrocarbons)
Do not damage the ozone layer and have negligible GWPs.
Effective refrigerants. Used in some new domestic refrigerators
and can be used in some air-conditioning systems.
Ammonia (NH3 or R717)
Does not damage the ozone layer and is not a greenhouse gas.
An effective refrigerant, which can be used in some new
air-conditioning systems.
All CFCs, HCFCs and HFCs are greenhouse gases, although there
is still some uncertainty about their overall contribution to global
warming.

Technical enquiries to:

Building Research Advisory Service
Building Research Establishment Garston, Watford, WD2 7JR
Tel: 01923 664664 Fax: 01923 664098
 Table 1 HCFC phase-out dates operation of pressure-relief devices and accidental releases
during servicing. Many systems operate at relatively high
Montreal Protocol New EC Regulation refrigerant pressures and are vulnerable to stress-induced
(after 1992 Copenhagen review) (Dec 94, No 3093/94) failure caused by vibration from compressors.

1995 — Cap supply of new HCFCs For maintaining existing systems, CFC refrigerant is available
at 1989 level + 2.6% 1989 from two types of source: redundant equipment and
CFC supply (in ODP tonnes*)
stockpiles. The Refrigerant Users Group (RUG) is an
1996 Cap consumption at 1989 — independent non-profit making organisation that has been
level + 3.1% 1989 CFC set up by government and industry to help users who need
consumption (in ODP tonnes*) supplies to get in touch with users who have a surplus of
recovered refrigerant. RUG’s address is 46 Bridge St,
2004 35% cut from 1996 cap 35% cut from 1995 cap
Godalming, Surrey GU7 1HL (tel: 01483 414125). However,
2007 — 60% cut from 1995 cap the supply of recovered CFCs is likely to be very limited and
its price is expected to rise very rapidly. Owners of CFC-
2010 65% cut from 1996 cap 80% cut from 1995 cap based systems are therefore urged to reduce their reliance on
2013 — 95% cut from 1995 cap CFCs, otherwise their machines may become unserviceable.

2015 90% cut from 1996 cap
2020 99.5% cut from 1996 cap
2030 100% cut from 1996 cap
* ODP tonnes = tonnes multiplied by ODP
(1 ODP tonne = 1 tonne CFC11 or 20 tonnes HCFC22)
100% cut from 1995 cap
STRATEGIES FOR COPING WITH THE CFC PHASE-OUT
—
1 Adapt to the CFC phase-out:
—
Either take steps to conserve refrigerant: this will
minimise dependence on supplies of CFCs, but is no
guarantee against leakage or accidental refrigerant loss
which could render a machine inoperative,

Further restrictions on HCFCs Or convert machine to a non-CFC refrigerant: this is not

always possible and can be uneconomic.
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It is widely expected that the HCFC phase-out dates may be

brought forward and the end-use controls tightened, especially
for air-conditioning applications. Some individual EU states
already have, or have proposed, tighter restrictions: Germany
will ban HCFC22 in new equipment from 2000, Sweden from
1998, and Denmark and Italy have similar proposals.
HFCs
HFCs are seen as important long-term alternatives to the
CFCs and HCFCs. However, because HFCs are powerful
greenhouse gases (as are CFCs and HCFCs), it is important
to minimise HFC emissions. The Government is seeking
voluntary agreements from industry to minimise HFC
emissions, and, where emissions are unavoidable, to avoid
the use of HFCs if safe, practical and more environmentally
acceptable alternatives are available.
2 Buy new, CFC-free equipment
This is the safest option, but also the most expensive.
3 Do without air-conditioning
This may be a viable option: assess the possibility of
achieving the required indoor conditions by mechanical
or natural ventilation. However, the design of the building,
or its use, may dictate the need for air-conditioning.
Figure 1 illustrates the step-by-step process involved in
choosing the right strategy. Forward planning is essential:
plant replacement or conversion may be subject to long
lead-in times, possibly as long as two years for the
replacement of large centrifugal machines.

SYSTEMS AFFECTED BY THE CFC PHASE-OUT CONVERTING TO AN ALTERNATIVE REFRIGERANT

Table 2 indicates which systems may use a CFC refrigerant.
They are most likely to be large central-plant centrifugal
chillers, using either CFC11 or CFC12, and sometimes
CFC113 or CFC114. Most other systems use HCFC22,
although some older systems may use a CFC refrigerant.
Refrigeration systems often require new refrigerant to
replace refrigerant lost through leaks and losses during
maintenance and servicing work. Larger, unpredictable
losses
can also occur, eg from ruptured pipework and joints, the
Table 2 Refrigerant types used in different categories of air-conditioning systems
Systems should be fully appraised before conversion is
considered. Unreliable, leaking or very old machines should
not be converted. Conversion is most likely to be viable for
larger machines, especially where replacement might be difficult
or expensive, eg where plant room access or space is restricted.
Success depends on high quality workmanship and strict
adherence to manufacturers’ recommendations and guidelines.
Incorrect handling of new refrigerants and lubricants, and
failure to identify and replace components incompatible with
the new refrigerants, can cause long-term problems.

Refrigerants
Category CFC11 CFC12 CFC113 CFC114 CFC500 CFC502 HCFC22

Packaged self-contained, or split — * — — * * ***

and multi-split systems

Central plant (DX or chiller): air-cooled — ** — — ** * ***

Central plant chillers: water cooled *** *** ** ** *** * ***

*** Very common ** Quite common * Possible — Very unlikely

 1 Survey site
Identify refrigeration plant and set up database. For each
system, determine:
What it is used for
Type of refrigeration system
Refrigerant type and quantity
Manufacturer/supplier and model/serial number
Rated cooling capacity
Age and cost when new
The information collected and recorded is an essential
prerequisite for making future decisions. The survey may
have to be carried out by a refrigeration engineer or consultant
if the necessary expertise is not available in-house.
4 Appraise each system
This may have to be done by building services consultants or specialist energy
consultants. The appraisal should address the following questions:
Is the system really needed? Free cooling may be possible; cooling may not be
needed if thermal comfort requirements are relaxed, or cooling may no longer
be necessary, eg after a change in occupancy
What is its remaining economic life? Conversion to an alternative refrigerant
may not be appropriate for a machine nearing the end of its economic life
What is its strategic importance? A system providing essential cooling
throughout the year to a computer room or dealing room would have a very
high strategic importance; comfort cooling of an office may not. The cost to an
organisation of disruption to operation of air-conditioning must be carefully
evaluated
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Is there an economic case for replacement with another machine? Replacement
with a more efficient, more suitably sized, more reliable or different type of
machine may provide cost savings. This should be considered in conjunction
with other measures, eg ice thermal storage, precooling of the building structure,
solar shading, etc
5 HCFC systems 6 Strategically important CFC
Annually review availability of HCFC systems which expire before 2000
refrigerants and conversion possibilities Start to plan machine
replacement now: it may be
Consider conversion of HCFC systems if
uneconomic to convert any
they need major overhaul or refurbishment:
machine with less than around
many HCFC22 systems could be converted
five years of remaining life
to an HFC-based alternative (such as
R407C) and some small systems could be
converted to an HC-based refrigerant
Figure 1 Step-by-step strategy for coping with the CFC phase-out
CFC11 systems
It is possible to convert some CFC11 centrifugal chillers to
HCFC123, but this requires the replacement of major
internal components, and may therefore not be economic.
HCFC123 caused benign tumours in rats during toxicity
testing and special care should therefore be taken to
minimise human exposure to it. Plant room detectors and
alarms are essential, and the chiller purge unit and relief
valves should be vented to a safe place outside the plant
room, away from any fresh air inlet.
Where CFC11 machines are retained, the following additional
refrigerant containment precautions are recommended.
● Fit a high-efficiency (low refrigerant loss) purge system.
CFC11 machines are prone to air ingress, and this air must
be regularly purged from the machine
● Fit an evaporator anti-vacuum heater, which reduces air
ingress when the machine is idle
● Fit self-reseating safety valves to all pressure-relief
bursting discs to minimise loss of refrigerant
2 Check legal compliance
It is mandatory to comply with all the requirements of the new
EC Regulation on ozone-depleting substances, and all health
and safety statutory requirements. Ensure that:
All reasonably practical measures have been taken to
prevent refrigerant leakage
Refrigerant is recovered during servicing, repair and
decommissioning: deliberate venting is illegal
All systems are regularly maintained and inspected
All health and safety hazards have been assessed and are
controlled or prevented
3 Establish an operating and maintenance log
Record all refrigerant and lubricant usage to identify
whether leakage or bad practice is taking place during
servicing/maintenance
Keep records of all maintenance and repairs
A detailed machine investigation should be carried out
by a competent refrigeration engineer if annual
refrigerant consumption to replace leakage exceeds
around 5% of the machine charge per year.
7 All other CFC systems
Maintain system from existing CFC stocks (if available),
in which case it is essential to minimise refrigerant
emissions through regular servicing and leak checks, or
Convert machine to a zero-ODP refrigerant (if practical
and economic), or
Replace machine with one using a zero-ODP refrigerant, or
Decommission plant if cooling is no longer needed
CFC12 and CFC500 systems
It is possible to convert many CFC12 and CFC500 centrifugal
chillers to HFC134a, although it may not always be
economic. Small packaged systems, eg through-the-wall air
conditioners, have few components likely to require
maintenance and rarely need new refrigerant. These systems
may be best left alone if working satisfactorily. Many other
systems can be converted to one of a range of HFC-based
alternatives, and in some cases an HC-based refrigerant. The
Standard for the safety of refrigerating systems, BS 44345, is
being revised, and is expected to allow sealed systems with
up to 2.5 kg of an HC refrigerant in certain occupied areas,
and up to 10 kg in chillers located in special plant rooms or
out of doors.
CFC113 and CFC114 systems
There are no known conversion options for these machines.
If replacement is not viable, a tight refrigerant containment
policy should be implemented (as for CFC11 systems).
CFC502 systems
Only a few air-conditioning systems use CFC502. Most CFC502
machines can be converted to one of several HFC-based
alternatives, or in some cases an HC-based alternative.
 NEW AIR-CONDITIONING SYSTEMS
Before deciding to install air-conditioning, assess whether the
desired internal environment could be achieved with simpler
mechanical ventilation or natural ventilation. As well as
using potentially environmentally-harmful refrigerants, a
fully air-conditioned building can consume around twice the
energy of a similar non-air-conditioned building. Table 3
presents possible refrigerant options which are currently
recommended where mechanical cooling is judged to be
necessary. Further guidance on alternative refrigerants is
provided in BRE Digest 358.
REFRIGERANT EMISSIONS
Refrigerant emissions should be minimised through regular
servicing and leak checks, and by ensuring that contractors
rigorously follow good working practice guidelines1,2,3,4.
Permanent refrigerant detection systems can be useful,
although they may not be effective for all types of machine
and location — it is important to seek the advice of equipment
manufacturers and refrigeration specialists. However, it is
difficult to detect or prevent all leaks, and it is impossible to
predict or guarantee against the sudden unexpected
refrigerant loss which may result from component failure,
mechanical damage or accidents during maintenance.
Refrigerant loss can cause a reduction in system efficiency
and therefore result in increased electricity consumption and
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power station CO2 emissions. It can also result in reduced
cooling capacity, and can cause compressor failure.
Repair or maintenance
It is essential that only competent refrigeration engineers
are used. The contract should stipulate that:
● Deliberate venting of any refrigerant is expressly forbidden
● Before a machine is opened for repair, its refrigerant
charge must either be isolated in a valved-off part of the
machine or removed from the machine for subsequent
re-use or safe disposal
● Before a machine is recharged or topped up with
refrigerant, it should be thoroughly checked for leakage,
and any leaks found should be repaired
● The contractor should advise the machine
owner/operator of the exact quantity of refrigerant used
Re-use of old refrigerant
Used refrigerant should normally be recycled or reclaimed
before it is re-used in another machine. Recycling involves
the removal of excess oil, moisture and other contaminants.
Reclamation is a more thorough process that returns the
refrigerant to an as-new condition.
Refrigerant disposal
In most cases the refrigerant removed from a machine during
servicing, maintenance or decommissioning becomes controlled
waste. Section 34 of the Environment Protection Act 1990
places a duty of care on all those who handle controlled
wastes. Section 33 of the Act makes it illegal to ‘treat, keep
or dispose of controlled waste in a manner likely to cause
pollution to the environment or harm to human health’. Waste
refrigerant must only be handled by competent persons who
are licensed by the Waste Regulation Authorities.
Information Papers are available on subscription. For current prices please contact CRC Ltd, 33–39 Bowling Green Lane, London, EC1R 0DA
(telephone 01923 664444; fax 01923 664400). Full details of all recent issues of BRE publications are given in BRE News, sent free to subscribers.
© Crown copyright 1995.
Published by Construction Research Communications Ltd by permission of the controller of HMSO and the Building Research Establishment.
Applications to copy all or any part of this publication should be made to Construction Research Communications Ltd, PO Box 202, Watford, Herts, WD2 7QG.
Table 3 Options for new air-conditioning systems*
Option Comments
HFC134a An option for centrifugal chillers. In other machines it
may be more expensive than other HFC-based refrigerants
(because it requires a larger compressor), and may be
slightly less efficient
HFC-based R407C is the first HFC-based blend to become widely
blends available in a large number of machines. It has a
performance similar to HCFC22. Other HFC-based blends
are being developed which may improve energy efficiency
HC-based These are effective refrigerants with low environmental
refrigerants impact, but their flammability limits their application to
small, limited-charge systems
Ammonia An effective refrigerant with low environmental impact.
Special safety precautions are necessary (set out in BS 4434)
because it is toxic and flammable. This limits its application
Absorption Should be considered for large sites, particularly where
cycle there is a source of waste heat
* Although new systems using HCFCs are still widely available, they
are not recommended where suitable and more environmentally
acceptable alternatives are available
HEALTH AND SAFETY
All relevant heath and safety legislation should be complied
with, including the following:
● The Control of Substances Hazardous to Health
(COSHH) Regulations 1988
● Pressure Systems and Transportable Gas Containers
Regulations 1989
● Management of Health and Safety at Work Regulations
1992 (Management Regulations)
● Construction (Design and Management) Regulations 1994
(CDM Regulations)
It is recommended that all converted and new machines
comply with British Standard BS 4434:19895 and the Institute
of Refrigeration safety code6. Compliance with the standard
and the code is not a statutory requirement. However,
non-compliance may be regarded by a Court of Law as
failure to take reasonable care and precautions or to use
reasonable skill, and this could lead to criminal prosecution
in the case of death or serious injury.
REFERENCES
1 Building Research Establishment. Minimising refrigerant emissions from air
conditioning systems in buildings. BRE Information Paper IP1/94. Garston,
CRC, 1994.
2 Institute of Refrigeration. Code of practice for the minimisation of
refrigerant emissions from refrigerating systems. Carshalton, Institute of
Refrigeration, 1995.
3 European Committee of Manufacturers of Refrigeration Equipment
(CECOMAF). Reduction of chlorofluorocarbon emissions from refrigerating
systems. CECOMAF GT1–001. Frankfurt-Main, CECOMAF, 1989.
4 Heating and Ventilating Contractors Association. Guide to good practice:
refrigeration. London, HVCA, 1992.
5 British Standards Institute. Specification for safety aspects in the design,
construction and installation of refrigerating appliances and systems. British
Standard BS 4434:1989. London BSI, 1989.
6 Institute of Refrigeration. Safety code for refrigerating systems utilising
chlorofluorocarbons. Part 1: Design and construction. Part 2: Commissioning,
inspection and maintenance. Carshalton, Institute of Refrigeration, 1984.
ISBN 1 86081 035 7