Technical Training Workshop | Advanced Technologies for

Technical Training Workshop | Advanced Technologies for Commercial Food Retail

October 7, 2020

Agenda

Agenda

CCI-Hub Technical Training Workshop, October 7, 2020

Welcome (15 min)DENR, UNIDO, Cold Chain Innovation Hub

Manuel P. Azucena, Director, RACTAP (25 min)"Commercial Refrigeration Installation and Servicing Training Regulations"

Cold Front Technologies Asia, Inc. (65 min)"Case Study: Royal Duty Free Subic Store 1, R290 Water Loop System"

Coffee Break (15 min)

Agenda


Wynand Groenewald, Independent Consultant (30 min)"CO2 Transcritical Systems in High Ambient Temperatures"

Jan Dusek, Cold Chain Innovation Hub (30 min)"Global Overview: Sustainable Solutions for Food Retail”

*Post-webinar zoom meet up!Join us for an informal get-together immediately after this webinar.


Agenda


Welcome (15 min)DENR, UNIDO, Cold Chain Innovation Hub

Marcial Cabañes Amaro, Jr.Department of Environment and Natural

Resources (DENR)


October 7, 2020

Tonilyn P. LimUnited Nations Industrial Development

Organization (UNIDO)


October 7, 2020

Gilda GaribayGlobal Partnership for Improving the Food

Cold Chain in the Philippines


October 7, 2020

Project Background

Global Partnership for Improving the Food Cold Chain in the Philippines

• Funding: Global Environment Facility (GEF)• Funding amount: 2M USD + Co-financing

(around 25M USD)• Government partner: Department of

Environment and Natural Resources of the Philippines (DENR)

• Implementing agency: United Nations Industrial Development Organization (UNIDO)

• Key executing partners: TESDA, shecco(others: Cold Chain Innovation Hub, Financial Institutions)



Goal:

Identify, develop and stimulate the development of low-carbon, energy efficient refrigeration innovation technologies and business practices in the Philippines for use throughout the food cold chain whilst increasing food safety and security.



Components:

• Policy and Regulatory Assessment

• Awareness and Capacity Building

• Technology Transfer and Partnerships

• Monitoring and Evaluation



Components:

• Policy and Regulatory Assessment

• Awareness and Capacity Building

• Technology Transfer and Partnerships

• Monitoring and Evaluation


Agenda


Manuel P. Azucena, Director, RACTAP (25 min)"Commercial Refrigeration Installation and Servicing Training Regulations"

Manuel P. AzucenaDirector, Refrigeration and Air-Conditioning

Technicians for Development of the Philippines (RACTAP) Inc.


October 7, 2020

TESDA: Its Direction Towards Flammable Refrigerants

Technical Education and Skills Development Authority

CCI-Hub Technical Training Workshop | October 7, 2020

Technical Education and Skills Development Authority


TESDA is mandated to provide:

high-qualityefficientrelevant accessibleTechnical education and skills development to develop Filipino middle-level manpower responsive to Philippine development goals.

Re pu b l i c Ac t 77 9 6

R.A. 7796: The TESDA Law

Section 22 of the RA 7796 states the mandate of the TESDA on Competency Certification.

v The Authority shall develop & implement a certification and accreditation program

v Private industry groups and trade associations may be accredited to assist TESDA in the conduct of competency assessment

v The local government units to promote such assessment activities in accordance with the guidelines to be set by the Authority.

v All certificates relating to the national assessment and certification system shall be issued by the Authority through the TESDA Secretariat.







Updated last Oct 2019-present


Vent flamm

able Refrigerants (HC) in a safe m

anner




IF PROPER TRAINING IS VERY EXPENSIVE, THEN TRY

IGNORANCE..

Q&A

www.cci-hub.org

Thank you for listening!

Manuel P. AzucenaInternational Master TrainerUNEP-AHRI Refrigerant Driving [email protected]

For more information contact:

Agenda


Cold Front Technologies Asia, Inc. (65 min)"Case Study: Royal Duty Free Subic Store 1, R290 Water Loop System"

Cold Front Technologies Asia


October 7, 2020

Speakers

Speakers


EMILIO GONZALES LA’OPresident/CEO, Cold Front Technologies Asia Inc.

JAYPEE CABANASProject Engineer, Cold Front Technologies Asia Inc.

FRITZ PAGADUANProject Manager, Cold Front Technologies Asia Inc.

Agenda

I. Store Information

II. Installation Process

III. Q&A


Store Information

Royal Duty Free Subic Store 1Water Loop System – R290

Cold Front Technologies Asia, Inc.

www.ColdFront.com.ph

“Where Innovation Meets Solution”

http://www.coldfront.com.ph/

Royal Duty Free Shops

• Royal Duty Free, 1109 Palm Street Rizal Hwy, Subic Bay Freeport Zone, Zambales

• 152 kilometers away from Metro Manila, or a 2 hour and 15 min Drive

Store InformationProject location


• From the turn of the 19th century to 1991, Subic grew from a Spanish naval facility to the largest U.S. military naval base in Asia.

• In 1991, after the volcanic eruption of Mt. Pinatubo, Subic was returned to the Philippine government and then developed into the Subic Bay Freeport Zone (SBFZ).

• In 1993, Royal Duty Free Shops opened its doors to customers hungry for imported products and for premium imported goods previously unavailable to the average Filipino.

Store InformationBrief history


Store Information


Supermarket Selling Area > 1,600 SQM

Chilled/Frozen Goods Selling Area = 782 SQM

Cold Storage Area = 624 SQM

Store Information


8 units plug in Dairy Produce Upright Chillers3 units Beverage Upright Chillers2 units Seafoods Glass Door Freezers7 units Meat & Deli Serve Over Chillers

Store Information

6 units Dairy Produce Upright Chillers (zone 3)2 units Beverage Upright Chillers (zone 2)1 unit Seafoods Glass Door Freezer (zone 2)3 units Cheese Serve over Chillers (zone 4)4 units Meat & Deli Serve over Chillers (zone 5)


Store Information


• Why renovate ROYAL 1?• It’s a 26 year old store, inside a 50 year old building,

with 11-15 year old Refrigeration system• Cold rooms are over 40 years and were

used by the Americans

• Status of present refrigeration• All Store refrigeration are Stand alone producing

heat inside the store.• Frequent breakdown of units due to high pressure

as a result of the heat emitted.• Inefficient air-conditioning system• High maintenance vost

* Roy Taneda – RDFS AVP; ATMOS Sept 2019

Keeping the Flagship Store Going

Store Information


PRIMARY OBJECTIVES• Find a solution / system that would address the heat

problem (Water Loop system)

• Eliminate unnecessary expenses

• Flexibility to change the Layout for Future Expansion Plans

• Zero Downtime during Installation (as we are now in peak season) and fast completion

• Support GREEN Initiatives (R290)• Advocate Environmental protection• New primary customers (millennials)• Support GO GREEN projects

* Roy Taneda – RDFS AVP; ATMOS Sept 2019

Keeping the Flagship Store Going


REFRIGERATION SYSTEM

HEAT REJECTION (KW)

ACU EER*

ADDITIONAL HEAT LOAD IN STORE

CONDENSING CAPACITY (KW) BTU WATTS/HR OPERATION

/24 HRSKWHR/DAY

R290 Water Loop 0.00 0.00 12 0.00 16 0.00

R404A PLUG-IN 85.2 290,702.40 12 24,225.20 16 387.60

* Assumed at 12.0 EER for inverter type aircon. Formula: EER = BTU/(WATTS/HR)

REFRIGERATION SYSTEMENERGY

CONSUMPTION/DAY(KWHR/24 HRS)

RATE(PHP/KWHR)

MONTHLY COST(CONSUMPTION/DAY

x RATE x 30 DAYS)

YEARLY COST(MONTHLY COST x 12 MONTHS)

R290 WATER LOOP 0.00 10 PHP 0.00 PHP 0.00USD 0.00**

R404A PLUG-IN 387.60 10 PHP 116,280.96 PHP 1,395,371.52USD 26,327.76**

** Based on FX rate of PHP 53.00 = USD 1.00

Energy consumption comparison: additional heat load on AC

Store Information


REFRIGERATIONSYSTEM

TOTAL ENERGY CONSUMPTION*

SAVINGS WITHR290 WATER LOOP

ANNUAL ENERGY COST

ANNUAL SAVINGS WITHR290 WATER LOOP

R290 WATER LOOP 261,932.40 kWh PHP 2,619,344.66

USD 49,421.41**

R404A PLUG-IN 466,952.83 kWh 205,020.43 kWh PHP 4,669,539.84

USD 88,104.53PHP 2,050,205.18

USD 38,683.12

R404AREMOTE 416,970.00 kWh 155,037.60 kWh PHP 4,170,054.24

USD 78,680.27PHP 1,550,719.58

USD 29,258.86 37.19%

43.91%

* Refrigeration and AC Heat Load Combined** Based on FX rate of PHP 53.00 = USD 1.00

Total energy consumption and energy savings

Store Information

Installation Process

Royal Duty Free Subic Store 1Water Loop System – R290

Cold Front Technologies Asia, Inc.

www.ColdFront.com.ph

“Where Innovation Meets Solution”


Installation ProcessPreparation of piping materials and tools

Gate valve

Stainless Pipe Tee Reducer

Male Brass connectors Heavy Duty Hose with female connectors

304 Stainless Steel Seamless Pipes

Crimping ToolsCCI-Hub Technical Training Workshop | October 7, 2020

Installation ProcessList of equipment

1. One set Outdoor Dry Cooler with Three Fans

2. One set Twin Pump

3. Eight Units Upright Chillers

4. One Unit Glass Door Freezer

5. Seven Units Serve Over Chillers


Installation ProcessPiping layout


ZONE 2

ZONE 5

ZONE 4

ZONE 3

ZONE 1

Installation ProcessElectrical plan


Installation ProcessInstallation of hangers and stainless pipes


Installation ProcessInstalled water loop piping


Installation ProcessInstallation of pump and dry cooler


Installation ProcessAir pressure testing of stainless pipes and connections


Installation ProcessCharging of water and glycol


Installation ProcessTesting and commissioning of pumps and dry cooler


Installation ProcessInstallation of R290 compressor on water loop showcases


Installation ProcessCharging of R290 refrigerant

150 GRAMSOF R290 PER COMPRESSOR CIRCUIT


Installation ProcessCharging of R290 refrigerant

Proper Handling of Refrigerant

• Ensure good room ventilation at floor level. • Use only grounded apparatus.• Take measures against electrostatic charge.• Keep vessels away from electric devices, sparks, heat sources, and open light. • Safety shoes, antistatic and non-combustible clothes, protective gloves and eye

goggles are to be provided for every person concerned with maintenance, repair and recovery

• Do not add anything to the Refrigeration System except Flushing Agent, Nitrogen, R290 and Refrigerant Oil.


Installation ProcessDismantling of existing old units and clearing of areas


Installation ProcessPositioning of water loop R290 units


Installation ProcessAlignment and connection of common ends


Installation ProcessInstallation of drain lines


Installation ProcessFastening of water loop connections


Installation ProcessConnection of power supplies


Installation ProcessProduce and dairy showcase before and after pictures


Installation ProcessCheese and deli serve overs before and after pictures


Installation ProcessBeverage chiller before and after pictures


Installation ProcessMeat and poultry chiller before and after pictures


Installation ProcessTemperature and operations monitoring


Installation Process (Non Water Loop Installation)

Positioning of 25 units non water loop R290 plug-in island freezers


Installation ProcessMaintenance Of R290 refrigerant system

The System uses a completely Hermetic Compressor with 150 grams of R290 Refrigerant charge per system.

No change oil needed for every Preventive Maintenance Schedule (PMS), which makes it more cost efficient on the client’s end.

There will be monthly spring-cleaning, which is essential in every Refrigeration cabinet and is required for sanitation purposes – regardless of the refrigerant used.


Installation ProcessMaintenance Of R290 refrigerant system

Electrical Re-Torque is required to prevent loose connections that may cause fire. The system is R290, which is a propane based refrigerant and is flammable.

Flameless reparation is recommended for the system using the Crimping Tools and Copper Tube.

R290 Refrigerant System and Conventional Refrigerant System have similar maintenance standards. However, the preparation and maintenance of the R290 Refrigerant System requires competitive knowledge of the system to successfully

undergo procedures and prevent incidents that may lead to system failure of equipment.


Installation Process (Non Waterloop Installation)

Rehabilitation of cold storage before and after installation pics


Installation ProcessProject timeline

Durations of Zoning Installation (Working Hours 10PM – 6AM)

• Water Loop Piping and Bracketing Works – Zone 1– 112hrs installation

• Water Loop DryCooler and Pump including Platforms Installation – Zone 1– 56hrs installation

• Water Loop 3Units Showcase Beverage – Zone 2 – 8hrs installation

• Water Loop 3Units Showcase Dairy – Zone 3A – 8hrs installation

• Water Loop 3Units Showcase Produce – Zone 3B – 8hrs installation

• Water Loop 4Units Showcase Meat – Zone e 4 – 8hrs installation

• Water Loop 3Units Showcase Cake cheese – Zone 5 – 8hrs installation

• Cold Room rehabilitations – Zone A to D– 122 days installation


Installation ProcessCompleted showcase installation


Installation ProcessCompleted showcase installation


Installation ProcessR290 installation outside the PhilippinesPositioning and setting up of R290 Water Loop units with Nihon Netsugen Systems (NNS), Freor and Cold Front at 2019 Japan Supermarket Trade Show at Makuhari Messe, Tokyo. 3 days installation on site.


Installation ProcessR290 installation outside the PhilippinesPositioning and setting up of R290 Water Loop units with Nihon Netsugen Systems (NNS), Freor and Cold Front at 2019 Japan Supermarket Trade Show at Makuhari Messe, Tokyo. 3 days installation on site.


Installation ProcessR290 installation outside the PhilippinesSuccessful Launch of R290 Water Loop units by Nihon Netsugen Systems (NNS) at the 2019 Japan Supermarket Trade Show at Makuhari Messe, Tokyo.


Installation ProcessR290 installation outside the PhilippinesPositioning and setting up of 65 AHT Athens R290 units at Metro Supermarket in Tokyo, Japan (NNS Project). 4 nights installation.


Installation ProcessR290 installation outside the PhilippinesPositioning and setting up of 65 AHT Athens R290 units at Metro Supermarket in Tokyo, Japan (NNS Project). 4 nights installation.


Q&A

www.cci-hub.org


Cold Front Technologies Asia, Inc.www.ColdFront.com.ph“Where Innovation Meets Solution”



Agenda


Coffee Break (15 min)

Agenda


Wynand Groenewald, Independent Consultant (30 min)"CO2 Transcritical Systems in High Ambient Temperatures"

Wynand GroenewaldSustainable Refrigeration Expert


October 7, 2020

CO2 Transcritical vs Subcritical


What is the difference?

• Subcritical• Operate below critical point

• Transcritical• Operate above critical point

• TC system will operate in SC manner most of the time• Depend on ambient

CO2 Transcritical Operation

• No Pressure-Temperature Correlation• Do not condense, no phase change• Gradual temperature loss• Closer approach to air

• SC: 5 to 8’C• TC: 2’C

• Improved heat rejection

Any benefits?


CO2 Transcritical System

• High Pressure Control• High pressure valve to control discharge

pressure• Control according to ambient • Optimum efficiency

• Flash Gas Control• Flash gas valve to control receiver

pressure• The higher the pressure the more FG• FG focus of most efficiency improvement

technologies

Main difference?


Source: Danfoss

Source: Dorin

CO2 Transcritical Technologies

• System:• Basic system, benchmark• Low ambient conditions• Flash gas reduced to MT suction• Suitable for SC operation

• Efficiency:• Compared to R404a System• CO2 more efficient up to 27’C ambient• R404a more efficient above 27’C ambient• CO2 -11% at 32’C ambient

Transcritical booster

CCI-Hub Technical Training Workshop | October 7, 2020Source: Danfoss


• System:• Additional compressor group• High ambient conditions• Flash gas compressed by PC group• Suitable for TC operation

• Efficiency:• Compared to R404a System• CO2 more efficient up to 37’C ambient• R404a more efficient above 37’C ambient• CO2 +7% at 32’C ambient

Transcritical booster with parallel compression



• System:• Additional compressor group with ejector• All ambient conditions• Flash gas compressed by PC group• % off MT suction compressed by PC group• Suitable for TC operation

• Efficiency:• Compared to R404a System• CO2 more efficient for all ambient conditions• CO2 +10% at 32’C ambient

Parallel compression with ejector



• System:• Work on any system• Uses water on condenser• Reduce ambient conditions from Dry Bulb to Wet bulb temperature• Works best in high temperature and dry conditions

• Philippines:• Average RH of 72 to 83%• Natural adiabatic effect• Not optimum• Can still reduce by up to 6’C

Adiabatic condensers


CO2 Transcritical TechnologiesAmbient conditions Manila


• Manila:

• Suited for TC Booster with Parallel compression

• Ejector system as experience and confidence grows

• Can consider adiabatic where water is freely available

Q&A + Live Stream

Leading manufacturer of modular packaged refrigeration systems

Johannesburg, South [email protected]

www.cci-hub.org


Wynand [email protected]://www.linkedin.com/in/wynand-groenewald-ba13081b/


mailto:[email protected]

https://www.linkedin.com/in/wynand-groenewald-ba13081b/

Agenda


Jan Dusek, Cold Chain Innovation Hub (30 min)"Global Overview: Sustainable Solutions for Food Retail”

Jan DusekHead of Global Partnership, Cold Chain

Innovation Hub


October 7, 2020

Global Overview: Sustainable Solutions for Food Retail

Sustainable solutions for food retail


Propane plug-ins

Lidl France

100% propane for all new stores

• Lidl Valenton (Paris)• Opened August 2018• First Lidl France store to use 100%

propane for cooling• Retrofit 100 R404A stores per year• 1,500 stores in France

Source: "Lidl France banking on propane”, Accelerate Europe Magazine Spring 2019

https://issuu.com/shecco/docs/ae_1903_33d31f1e897942/34



Propane chillers/propylene glycol

Colruyt Group

R290 compact chillersPropylene glycol secondaryR600a chest freezers

• Mons, Belgium• November 2015• Compact chillers: 2.5kg of propane• Capacity: 30 to 50 kW• Secondary: propylene glycol

Source: "Colruyt charts course for 100% hydrocarbons in stores”, Accelerate Europe Magazine, Autumn 2016

https://issuu.com/shecco/docs/ae1609/34



Transcritical CO2 condensing units

Lawson


• Lawson, Japan• Convenience store operator• 10HP outdoor condensing units• 2 HP outdoor condensing units

Source: "LAWSON’s Efforts to Phase Out Freon”, ATMOsphere Japan, February 2020

https://drive.google.com/file/d/1IskYL6mjybD3xwvCcCsP0pMp5DqiM09S/view




Lawson


• 4,100 stores by the end of February 2021

Source: "LAWSON’s Efforts to Phase Out Freon”, ATMOsphere Japan, February 2020

https://drive.google.com/file/d/1IskYL6mjybD3xwvCcCsP0pMp5DqiM09S/view



CO2 condensing units and hydrocarbons

Lawson

R290 plug-in upright refrigeratorR600a under-counter refrigeratorR600a ice makerCO2 outdoor condensing units

• First freon-free store• Keio University, Kanagawa• Opened September 2020

Source: "Japanese C-Store Chain Lawson Opens First 100% NatRefs Store”, Accelerate24.news, December 20, 2019

https://accelerate24.news/regions/japanese-c-store-chain-lawson-opens-first-100-natrefs-store/2019/



Transcritical CO2 rack systems

ALDI US

Transcritical CO2 system

• Baldwinsville, New York• Rooftop CO2 rack system• ALDI US: 130 CO2 stores (2018)• ALDI Süd (South): 1,496 CO2 stores

worldwide (2017)

Source: "Leader of the Rack”, Accelerate America Magazine, September 2017

https://issuu.com/shecco/docs/aa1709/36



HVAC integrated transcritical CO2 rack systems

Migros Ticino

Fully integrated transcritical CO2refrigeration and HVAC system

• Riazzino, Switzerland• Opened February 2019• Transcritical CO2 compressor rack• Sub-cooling• Heat pump• Chiller • All stores to convert to CO2 by 2025

Source: "Migros Ticino Installs its First Integrated CO2 System", Accelerate Magazine, July/August 2019

https://issuu.com/shecco/docs/am_102/54



Transcritical CO2 rack and heat-pump

Lidl Net-Zero Store

Transcritical CO2 refrigerationTranscritical CO2 ground-source heat pumpRooftop solar (1,766 panels)

• Woerden, Netherlands• 2,057m² store and warehouse• Opened September 2019

Source: "Lidl Net-Zero Store Uses CO2 Ground-Source Heat Pump”, Accelerate24.news, June 19, 2020

https://accelerate24.news/regions/europe/lidl-net-zero-store-uses-co2-ground-source-heat-pump/2020/



Transcritical CO2 rack and heat-pump

Lidl Net-Zero Store

Transcritical CO2 rack refrigeration system • MT: 112kW (32TR) at -8°C (17.6°F)• LT: 4kW (1.2TR) at -33°C (-27.4°F)

Transcritical CO2 ground-source heat pump• 50kW (14.2TR)• Also used as chiller for air-conditioning

Source: "Lidl Net-Zero Store Uses CO2 Ground-Source Heat Pump”, Accelerate24.news, June 19, 2020

https://accelerate24.news/regions/europe/lidl-net-zero-store-uses-co2-ground-source-heat-pump/2020/



Region 2008 2018 2020 % Growth (2018 to 2020)

Europe 140 16,000 29,000 81%

U.S. 370 650 76%

Canada 245 340 39%

Japan 3,530 5,000 42%

Australia 20 95 375%

New Zealand 40 100 150%

South Africa 110 220 100%

Transcritical CO2 installations

35,000+ transcritical CO2 installations (2019)

Source: "World Guide to Transcritical CO2 Refrigeration”, shecco, June 2020

https://issuu.com/shecco/docs/r744-guide-part2



Centralized propane/CO2 cascade

Whole Foods

Centralized propane/CO2 cascade system

• Whole Foods• Santa Clara, California• 49,000 ft2

• Opened July 2016

Source: "Whole Foods Pushes the Propane Envelope”, Accelerate America Magazine, October 2016




Centralized propane/CO2 cascade

Whole Foods

Centralized propane/CO2 cascade system

• 3x LT rooftop chillers: 25 lbs of R290 each

• 4x MT rooftop chillers: 39 lbs of R290 each

• CO2 charge: 1,730 lbs• Cascade CO2 rack: LT cases• Liquid overfeed: MT cases

Source: "Whole Foods Pushes the Propane Envelops”, Accelerate America Magazine, October 2016




Ammonia/CO2 System

Raley’s

Ammonia (NH3)/CO2 refrigeration system

• Sacramento, California, United States

• Opened April 15, 2020• Supermarket• 55,000 ft2

Image source: "Raley’s unveils new flagship store in Sacramento”, Supermarket News, April 16, 2020Source: "Raley’s Unorthodox Ammonia/CO2 System”, Ammonia21.com, September 26, 2020

https://www.supermarketnews.com/store-design-construction/raley-s-unveils-new-flagship-store-sacramento

http://ammonia21.com/articles/9739/raley_s_unorthodox_ammonia_co2_system



Ammonia/CO2 System

Raley’s

Ammonia (NH3)/CO2 refrigeration system

• Air conditioning and refrigeration• Heat reclaim for space heating and

domestic hot water • CO2 compressor-free pumped

liquid-overfeed system• Very low ammonia charge

(135lbs/61.2kgs)

Image source: "Raley’s unveils new flagship store in Sacramento”, Supermarket News, April 16, 2020Source: "Raley’s Unorthodox Ammonia/CO2 System”, Ammonia21.com, September 26, 2020

https://www.supermarketnews.com/store-design-construction/raley-s-unveils-new-flagship-store-sacramento

http://ammonia21.com/articles/9739/raley_s_unorthodox_ammonia_co2_system

Accelerate Magazine: Special Issue


Food Retail Best Practices

Focus: Global Food Retail Case Studies

• Sharing best practices from leading retail end users around the world.

• First-hand experiences on all major natural refrigerant technologies and approaches

• Transcritical CO2, propane, ammonia/ CO2, integrated refrigeration/air conditioning/heating, net-zero energy, servitization, and more.

• https://accelerate24.news/magazines/

https://accelerate24.news/magazines/

Q & A

www.cci-hub.org


Jan DusekHead of Global PartnershipCold Chain Innovation [email protected]


Agenda


Post-webinar zoom meet up!Join us for an informal get-together immediately after this webinar.

Documents

Technical Training Workshop | Advanced Technologies for