Train the Trainers Workshop

On
Good Practices
In
Refrigeration and Airconditioning
2012

Kaleem Iftikhar Siddiqui

Country Master Trainer, HPMP Project,
Pakistan
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Preface

The role of any educational or study program is very much similar to the purpose
a bridge serves in a simple traffic system. A bridge in a traffic system provides
connectivity to the vehicles approaching to the bridge, lifts them to the requisite
height, orchestrates them to match the requirements of the avenue that leads
to their ultimate destination. During all the while the direction of the moving
vehicles is also symphonized.

Likewise, a study program is designed and developed in a fashion, acceptable

to all the enlisting members. Further, it is ensured that the final outcome be in line
with professional requirements or advance study needs. Sensibly, the teachers or
the trainers are the most significant components of this program. They provide
pillars and beams of this bridge. In substance, if the study program is to meet
with success, teachers are poised to play an instrumental role.

Essentially, we can never forget the role of men or a body of people who
architect or sketch the entire act (the working methodology) from protasis to
catastasis. In real fact they envisage, design, plan and actualize a complete
education system. The entire UNEP team at Bangkok, headed by Mr. Atul Babai
and anchored by Mr. Anshu Kumar deserves congratulation for providing new
fundaments for saving the future of the world, and a preparing a complete
doctrine to be implemented worldwide.

However one should not overlook the importance of the ones who enlist that
programme as learners or trainees. Fundamentally, the programme is
developed for the learners or the trainees, and if they are in oblivion about the
importance of the program or subject, or they are in ignorance about their
future role, or working sphere, they are to assume subsequent to doing that
programme, or the responsibilities that are to be entrusted upon them, the
ultimate end will be a total disaster. Even in the case they do not meet the
prequalification or the prerequisite entry behavior of the study programme, or
less prepared, or even less motivated, result shall be even more catastrophic.
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When I learned that Four-Day, Programme on “Good Practices Training in the

Refrigeration Servicing Sector” and Training Methodologies, is being organized
jointly by the National Ozone Unit of Pakistan, and the UNEP ROAP Bangkok
Thailand at Kabul, Afghanistan, in the last week of May this year, I was also
appointed a Speaker/ Trainer (thanks to Mr. Atul Bagai and Mr. Anshu Kumar,
UNEP Bangkok) I decided to prepare this document.

Additionally, my personal experience was also in my mind, and in reality it was

that feeling that provided me much needed impetus for inscribing this write up,
otherwise everything could have been vanished somewhere between the
neurons of my hippocampus. In previous situation when I was a part of a group
of Instructors sent from Karachi and rest of the province to attend similar kind of
training programme marked „TRAIN THE TRAINERS PROGRMME‟, held in Lahore,
organized by UNIDO Pakistan, for CFCs Phaseout project, nobody knew the
purpose of training.

The trainees were in complete ignorance about the contents or agenda and
the importance of the training; hence in pertinence with future responsibilities,
they were in complete oblivion. Without any kind of doubts, that situation
affected the overall productivity of the aforesaid programme. I hope my
humble work will help a lot the future Master Trainers, to understand the kind of
responsibilities they are to shoulder subsequent to successful completion of this
programme. They will be more focused on the subject areas and greatly
motivated to learn and accept the fundamental changes that are to
encompass the whole RAC Industry as well as the servicing sector. Definitely
they are to hold key places for worldwide implementation of the pertinent
doctrine.
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OZONE-DAY MESSAGE

“Before entering into this document I must incorporate the ultimate

message for all of the trainees (either master trainers or

technicians) who are to attend this programme, in Pakistan or

outside world, need to be in clear mindset that enlisting this training

programme is merely not an act of cherishing some kind of status or

relishing monetary benefits, in actual fact taking this training means

joining immortal bands of people who are protecting the climate of

today’s world and thus saving the globe for millions of generations

that are destined to come and live. They are one community, above

a world that is divided into countries, racial and ethnic

discriminations, linguistic and religious diversifications. Time has

already lifted them to altitudes never caressed by the ones who

believe in tangibles. They all will be a part of one unique society

“the sacred global community”, the future generation will respect

and honour them as “OZONE SOUL MATES”

Kaleem Iftikhar Siddiqui

Country Master Trainer, HPMP Project,
Pakistan
SENIOR INSTRUCTOR
GCT SITE KARACHI
kaleemifti@gmail.com
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S No. Contents Page

No.
1 Preface 3
2 Ozone-day Message for Trainers and Technicians 5
from the writer
3 Global Warming, Climate Changes and Concern 8
of the World Community,
4 Ozone, the Natural Shield of This Planet, 10
5 The Mechanism of Ozone Depletion, 12
6 Backdrop 15
7 Harmonization of Training Material and 16
Methodologies, Four-Day Training Workshop
Arranged By UNEP Bangkok, Thailand 12th –
15th March 2012
8 The Main Themes at the Agenda of Bangkok 17
Thailand Training Programme.
9 The Subthemes Focused for Deliberations, and 18
Resultant Outcome,
10 The Knowledge Areas To Be Focused In The 18
„Train-The-Trainers‟-Programme,
11 Good Practices, Technicians Need To Be 19
Educated and Motivated,
12 The Areas To Be Focused During The 20
Technicians-Training Programme,
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S No. Contents Page

No.
ANNEXURE A List of Minimum Equipment and Tools Required 21
for Technicians‟ Training Workshop, Initiated
from Bangkok Thailand.
ANNEXURE B List of Minimum Consumables required for 24
Technicians‟ Training Workshop
ANNEXURE C Bibliography 25
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Global Warming, Climate Changes and Concern of World Community

Despite geographical divisions, linguistic diversifications, ethnic and religious

assortments, world community always seems totally resolute and tough, holds its
firm and unanimous stance on one point agenda and it is preserving future of
this world for the current generation as well as the generations that are to come.

Subsequent to completion of the United Nations Conference on Sustainable

Development, “Rio+20,” that was held in June 2012 in Rio de Janeiro, Brazil, the
same commitment was reiterated with the following words,

We, the Heads of State and Government and high-level representatives, having met at Rio
de Janeiro, Brazil, from 20 to 22 June 2012, with the full participation of civil society,
renew our commitment to sustainable development and to ensuring the promotion of an
economically, socially and environmentally sustainable future for our planet and for
present and future generations.

In the later part of the joint document process of gradual phase-down in the
consumption and production of hydrofluorocarbons was also stressed with the
following lines,

We recognize that the phase-out of ozone-depleting substances is resulting in a rapid

increase in the use and release of high global-warming potential hydrofluorocarbons to
the environment. We support a gradual phase-down in the consumption and production of
hydrofluorocarbons.

The matter of climatic changes and ozone depletion are no more new issues, in
actual fact these topics, have been at the forefront of the international
community‟s environmental agendas for last three decades. It is now accepted
worldwide that manmade chemicals (very specially the chemicals used in the
sphere of RAC) and human activities are seriously affecting the climate of this
planet adversely.
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Another Threat – Global Warming

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Ozone, the natural shield of this planet

Ozone is a tri-atomic form of oxygen, its naturally occurring gas, yet ninety
percent of the total available on the planet is found in the stratosphere. The
remaining part exists all around us. Stratosphere is second major layer of the
atmosphere, forms between 10 and 50 kilometers above the globe. Ozone is
essential for continuation of life on earth. It safeguards the earth against inward
bound, the harmful ultraviolet-B radiations.

Formation of Ozone

UV

O O
O O

O O
O

O O
O O
oxygen (O2)
Ozone (O3)
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Understandably the greater the presence of ozone gas the greater the shielding
capacity of the stratosphere. However presence of the ozone gas varies with
location on timescales that range from daily to seasonal basis. Stratospheric
winds and the chemical production as well as destruction of ozone, provides
fundaments for these deviations. As a general rule, at equator the amount of
ozone is lowest however it is highest at the Polar Regions.

A hole in the stratospheric ozone layer in the skies of the Antarctic was
discovered by the researchers. Further researches revealed that certain
manmade substances, emitted from the earth were influencing depletion of
ozone layer. Now we all comprehend that refrigerant fluids were the main
culprits in this course, however the foam industry too contributing substantially.
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The Mechanism of Ozone Depletion

Tiny particles of frozen water are the main constituents of high stratospheric
clouds that include chlorine held in inactive compounds such as hydrogen
chloride, hydrochloric acid and chlorine nitrate at temperatures lower than
around –85° C. These compounds in certain seasons react with ozone; ultraviolet
radiation from the sun plays a catalyst and consequences reactions on the
surfaces of the water particles, converting the inactive compounds to reactive
chlorine monoxide, destroys ozone with great rapidity. Similarly bromine too
does same kind of damages to ozone with much greater rapidity.
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The chlorine and bromine artificial substances that are causing damage to
ozone are methyl bromide, methyl chloroform, carbon tetrachloride and families
of chemicals known as halons, chlorofluorocarbons (CFCs) and hydro
chlorofluorocarbons (HCFCs). Stratospheric ozone depletion has a direct
relevance with the issue of climate changes. Ozone and some substances that
deplete ozone, especially CFCs, are greenhouse gases.
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Backdrop

Pakistan is a signatory to the Montreal Protocol on Substances that Deplete the

Ozone Layer. Under this document the signatory countries have consented to
set year 2013 as the time to freeze the consumption and production of HCFCs.
Furthermore by 2015, they are determined to play down consumption and
production to 90 percentile. This process is specifically known as HPMP (Hydro
chlorofluorocarbons Phaseout Management Plan) Stage I.

From 2005 to 2008, in collaboration with UNIDO Pakistan, combating ozone

depletion and climatic changes process, in the primary phase countrywide
training programmes were carried out in pertinence with CFC Refrigerants and
Good Refrigerant Management Practice.

In the recent past the Parties to the Montreal Protocol reached a remarkable
conclusion: i.e. to speed up the freeze and the phase-out of hydrofluorocarbons
(HCFCs). It was a resolution not just in favour for refurbishing of the ozone layer,
conversely also, and possibly more radically, in favour of combating climate
change as a result of new and emerging science that highlights potential
greenhouse effect of these substances.

The refrigeration and airconditioning industry and the servicing sector has
substantial share in the consumption of HCFC Refrigerants worldwide. For
achievement of 2013 and 2015 targets, the refrigeration and airconditioning
industry and servicing sector is poised to play a most important role. In other
words for making these targets a reality the refrigeration and airconditioning
industry and servicing sector has to go through revolutionary changes.
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„Harmonization of Training Material and Methodologies, for the Good

practices in the refrigeration servicing sector,‟ Four-day workshop
arranged by UNEP Bangkok, Thailand 12th – 15th March 2012

Keeping in view the changes that were in the offing UNEP ROAP organized a 4-
day Regional Workshop (for the Asia Pacific Countries) on “Harmonization of
Training Material, Training Methodologies for the good practices training in the
refrigeration servicing sector” from March 12 to, March 15, 2012, in Bangkok
Thailand. Total twenty seven experts from Asia Pacific countries, were invited to
deliberate on the contents of the training module and preparing model training
templates, could be used for training programmes on national/country level,
with slight modification with as per the needs of the particular country.
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The main themes at the agenda of Bangkok Thailand Training

programme.

 ENVIRONMENTAL IMPACT OF REFRIGERATION AND AIR CONDITIONING

(RAC) SYSTEMS,
 REFRIGERANTS,
 REFRIGERANTS MANAGEMENT (INCLUDING RECOVERY & RECLAMATION
ECONOMICS),
 SERVICING PRACTICES, WORKSHOP ON “GOOD SERVICING PRACTICE”,
 RETROFITTING WITH AVAILABLE TECHNOLOGIES,
 SAFETY ISSUES,
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The deliberations on the subthemes that went on under the

previously referred headlines are also being incorporated here.

 Environmental Impact & ODS Phase-out in the pertinent country,

 Alternatives to HCFC and their Characteristics,
 Handling of HFC Refrigerants,
 Servicing of HFC blend based Appliances,
 Tools and Equipment for Servicing,
 Recovery and recycling of Refrigerants,
 Economics of Reclamation & Good Service Practices,
 Contaminated refrigerants and Gas Identifiers,
 Selection & Safe Usage of Cleaning Solvents,
 Installation Procedures of Split Air-conditioners,
 Service Practices Do‟s and Don‟ts,
 Handling of HC Refrigerants and safety issues,
 Servicing of HC Based Airconditioners and Airconditioning Units,
 Energy conservation v/s Service Sector,

The Knowledge Areas to be Focused in the Train-The-Trainers‟-

Programme.

The local Master Trainers should essentially and fundamentally have a proven
teaching experience at a technical college, vocational training institute or at a
polytechnic institute level. They are needed to be trained in a way that after
successfully completing the TRAIN-THE-TRAINERS WORKSHOP including the
examination, they should be able to impart knowledge, skills and good
practices relates to the sphere of refrigeration and airconditioning field.
Furthermore “the Four-Day Train the Trainers Workshop 2012” should essentially
serve to broaden their visual axis and knowledge with substantial depth in
pertinence with the below appended operational areas.
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Ozone depletion - its causes and effects

Global warming - its causes and effects
Montreal Protocol and other global measures
Country Programme and Refrigerant Management Plan
Local regulations and way forward
Basic principles of refrigeration
ODS and non-ODS refrigerants
Handling, transport and storage of refrigerants
Refrigerant safety and personal protective measures
Leak prevention and leak detection
Installation, pressure testing, evacuation, dehydration, charging and
running a system
Decommissioning and disposal
Redesign, installation
Preventive inspection
Refrigerant recovery procedures
Refrigerant recycling and reclaim
Vision of future development of refrigeration sector.

Good Practices, Technicians Need To Be Educated and Motivated

Specifically for the regions where technicians working in poor economic

conditions, not only we need to educate our technicians good practices in the
refrigeration and airconditioning service sector but also need to motivate them
to follow good servicing practices. In actual fact adhering proper
methodologies, in the long run produce economic results. Insufficient
knowledge as well as lack of training or improper training, coupled with
absence of commitment results in poor performance of the equipment,
increased first and running costs, severe curtailment of the life of the equipment.
Additionally the workforce, occupancy and the property are exposed to severe
fatal threats.
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Furthermore the more frequently a system needs to undergo repairing work, the
more refrigerants fluids emitted to the atmosphere. It is also an established reality
that during repairing, usually the refrigerant is not recovered especially from the
smaller units or systems, in handling of heavy machines situation may differ from
case to case.

Technicians trained on „good service practices‟ as well as on „good brazing

skills‟, and following proper installation and working code will make sure
lessened possibilities of leakages, much reduced possibilities of choking,
reasonably good performance and ultimately increased equipment life.
Adoption of proper methodologies, chained with containment practices like
recovery, recycling and reclamation and switching to modern day technologies
would definitely have its role in minimizing economic repercussions of the phase-
out for the end users. This is why training programme for the technicians is going
to have special focus on the following working areas.

The Areas To Be Focused During The Technicians-Training

Programme,

 General Safety Practice

 Brazing Skills
 Leakage Detection
 Developing Proper understanding of Vacuuming
 Flushing and Cleaning System
 Charging Procedures
 Standard Test Parameters
 Installation Protocols
 Bending Techniques
 Safely Handling of Refrigerant
 Recovery and Recycling of Refrigerant
 Reclamation of Refrigerant
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Annexure A
List of Minimum Equipment and Tools required for Technicians‟
Training Workshop (initiated from Bangkok, Thailand)

The following is the list of minimum tools and equipment requirement for
conduction of this kind of training programme that is to be conducted. It was
initiated from UNEP, Bangkok, Thailand.

Recomme Available
Items Unit
nded Qty Qty.

A Main equipment
1 Evacuation & Charging Unit (E & C unit) 100 lpm, double stage Unit 2
2 Recovery unit portable suitable for all refrigerants pc 2
3 Air conditioner with R-22 window-1, split-1 pc 2
4 Air conditioner with R-410, window-1, split-1 pc 2
5 Air conditioner with R-290, window-1, split-1 pc 2
6 Refrigerant Gas identifier set 1
7 Oxygen & LPG gas Cylinder for brazing set 1
8 Brazing Kits / Powerjet set 2
9 Nitrogen Cylinder set 1
10 Double stage Nitrogen Regulator pc 1
11 Thermocouple vacuum (Micron) gauges digital pc 2
12 Fire Extinguisher 2 Kgs capacity Pc 2
13 Recovery cylinders Pc 2
14 Electronic Leak detectors (HCFCs, HFCs and HCs) Pc 2
15 Recycling unit Pc 1
B Special Components
1 Solid state accessories, electronic controls, safety items set 3
C Measuring Instruments
1 Clamp on digital multi meter with case pc 3
2 Electronic thermometer with sensor (-25°C to 100°C) pc 3
3 Measuring tape (3 m) pc 3
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4 Electric Tester (814) pc 3

5 Anemometer Digital Pc 1
6 Digital sight glass Pc 1
D Refrigeration tools
1 Pinch off pliers pc 3
2 Piercing Pliers and valves (two each) pc 4
3 Tool for Deburring pc 3
4 Tube cutter pc 3
5 Capillary Tube cutter pc 3
6 Flaring set (Block and Yoke) with expander (swedging) tool kit Set 3
7 Swedging Tools (Punches) Set of 5 3
8 Tube bender Mechanical – various sizes as per product Pc 4
9 Schrader valve remover (Valve die) pc 3
10 Hand shut off valve pc 9
11 Safety goggles, lab coat, hand gloves set Set of 3 4
E Standard tools
1 Knife pc 3
2 Set of Allen keys set of 9 3
3 Allen Keys with T handle Set of 6 3
4 Adjustable spanner 6" pc 3
5 Adjustable spanner 6" pc 3
set of
6 Spanner set ( open end - Metric) 3
12
7 Key spanners for gas cylinder valves pc 3
8 Electrician insulated crimping tool pc 3
9 Multi grip pliers pc 3
10 Insulated Hand Pliers pc 3
11 Insulated Nose/Pointed pliers (Long nose) pc 3
12 Cutting pliers pc 3
13 Ratchet Wrench (3/16" - 5/16") pc 3
14 Handle for assorted bits pc 3
set of
15 Box of assorted bits 3
15
16 Screw driver ordinary slot set of 4 3
17 Screw driver, cross head set of 2 3
18 Flat fine file with handle, 150 mm pc 3
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19 Round fine file with handle, 150 mm pc 3

20 Small saw with blades pc 3
set of
21 Small saw blades 3
20
22 Ordinary Hammer pc 3
23 Plastic hammer pc 3
24 Brass wire brush pc 3
25 Empty Tool Box pc 3
26 Lock and key for tool box Pair 3
27 Hand Drilling machine (15 mm size) Pc 1
28 Double flare making tool Set 1
29 Torque wrench with assorted bits set 1
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Annexure B
List of Minimum Consumable required for Technicians’ Training
Workshop

Items Unit Recommended Qty

1 Copper brazing rods Pc 10

2 Silver Brazing rods Pc 2
3 Driers/filters Pc 10
4 Flux Powder Grams 20
5 Emery paper Pc 8
6 Refrigerant (different type) Kgs As per need
7 Oxygen, LPG and Nitrogen refilling
8 Gas lighters Pcs 4
9 Copper Pipe ¼”, 3/8”, 5/16” feet 10 ft each
10 Capillary tube .055” Feet 10 feet
11 Hexane for flushing (if required) Liters 2
12 hand gloves Pc 3
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Annexure C

Bibliography

Background Note,
Harmonization of Training Material, Training Methodologies for the Good
practices training in the refrigeration servicing sector,
Organised by, United Nations Environment Programme,
Bangkok, Thailand, 12th – 15th March 2012

„THE FUTURE WE WANT‟ (FWWEnglish)

The joint document issued following the completion of the United Nations
Conference on Sustainable Development, “Rio+20,” that was held in June
2012 in Rio de Janeiro, Brazil,

Phasing out ODS in Developing Countries,

„NATIONAL TRAINING ON GOOD PRACTICES IN REFRIGERATION‟
A SUPPORT GUIDE FOR NOUs, 2001
United Nations Environment Programme

Support Guide,
Preparing for HCFC phase-out:
Fundamentals of uses, alternatives, implications and funding for
Article 5 countries
UNITED NATIONS INDUSTRIAL DEVELOPMENT ORGANIZATION

Presentations received from Mr. Anshu Kumar/ UNEP ROAP Bangkok,

Thailand.