Best Practices in the Indian Servicing Sector by Markus Wypior

1. Best Practices in the
Indian Servicing
Sector
Markus Wypior, GTZ-Proklima
MAC and Environment: India policy workshop on the
status of MAC replacement technologies
New Delhi, India, 7-8 June 2010
07.06.2010 Seite 1

2. Project History
07.06.2010 Page
Seite 2

3. HIDECOR (2001-2004)
Human and Institutional Development in Ecological Refrigeration
2001: HIDECOR project launched as an Indo-Swiss
collaboration
Goal: Providing training on good servicing practices and
hydrocarbon based retrofit to service technicians in the
Refrigeration and Air-Conditioning (RAC) sector
Geographic focus:
Initial states: Tamil Nadu, Karnataka, Andhra Pradesh,
Maharashtra, Gujarat, Delhi and West Bengal
States added later: Punjab, Haryana, U.P., Rajasthan and
Kerala (in anticipation of NCCoPP)
07.06.2010 Page
Seite 3

4. NCCoPP (2004-2010)
National CFC Consumption Phase-out Plan
2004: NCCoPP project launched based on the Agreement
between India and the Executive Committee of the
Multilateral Fund
Goal: Providing training on good servicing practices and
to service technicians in the Refrigeration and Air-
Conditioning (RAC) sector
Geographic focus: All over India
Funding: 6.3 million USD
07.06.2010 Page
Seite 4

5. HIDECOR/NCCoPP Target Group
Main target group: Micro, small and low income
service enterprises from the informal sector
Aim: Up-gradation of skills enabling RAC technicians
to continue in business
Not more than two technicians from one service
enterprise were considered for training to reach
larger segment
Industry partners could train their own service
technicians along with the main target group
07.06.2010 Page
Seite 5

6. HIDECOR/NCCoPP Access Routes
07.06.2010 Page
Seite 6

7. NCCoPP Steering Structure
MoEF / Ozone
Cell
Management
Core Group
GTZ PMU
GTZ INFRAS UNDP UNEP
co-financing
ITAC Foam Sector
RMO's/ Industry
Training
Technical Consultants
Refrigeration
Training Cells
(manufacturing)
15 ORG/REC/RSET
ESS Workshops / incl. transport
dealers meet
local facilitator ESS Refrigeration
Equipment
Facilitator & Principal
Distributor
ITI Eqpt. Facilitator
Awareness
National Partner National Partner
Awareness Customs & Policy
07.06.2010 Page
Seite 7

8. Training Activities under NCCoPP
Standard training for servicing of domestic
and small commercial appliances
Mobile Air-Conditioning (MAC)
Selected Commercial Systems / Open Type
Compressors (OTC) in food processing and
preservation
Selected Institutional Users
(Railways, Defence)
07.06.2010 Page
Seite 8

9. Key Achievements HIDECOR/NCCoPP
20,000+ technicians
trained
(60 % outside
metros)
1,000+ equipments
supplied
07.06.2010 Page
Seite 9

10. Improvement of Service Practices
07.06.2010 Page
Seite 10

11. Options to reduce consumption of CFCs
and other refrigerants in MAC servicing
Adoption of Good Service Practices
Recover, Recycle and Reuse of Refrigerants
Proper evacuation to eliminate flushing/purging by the refrigerants
Proper charging of refrigerant
Retrofitting
Retrofitting with HFC-134a
Retrofitting with HC Blend
07.06.2010 Page
Seite 11

12. Estimated CFC consumption
in MAC servicing in 2005/06
Estimated Annual CFC Consumption in Servicing of MAC
Year 2000 2001 2002 2003 2004 2005 2006 2007 2008 2009 2010
Production 0.24 0.26 0.23 0 0 0 0 0 0 0 0
(Million)
Population 1.49 1.71 1.9 1.83 1.76 1.68 1.58 1.49 1.39 1.3 1.26
(Million)
Servicing 491 562 623 601 352 337 317 297 278 261 251
(with recovery)
(MT)
Servicing
637 729 808 779 465 445 418 392 367 344 332
(without
recovery)
(MT)
The production of MAC completely changed to HFC-134a from 2003!
07.06.2010 Page
Seite 12

13. Strategy for Training
MAC Service Enterprises
Development of Training Conduct Action Creation of
Manual for MAC Learning Workshops Training Facilities
and Other Training Material
Training Management Unit
MAC Training Training by
Organizers Automobile/MAC
Industry
MAC Training Cell
MAC Service Enterprises
07.06.2010 Page
Seite 13

14. Training Material
07.06.2010
07.06.2010 Page
Seite 14

15. Training Material
Can be downloaded free of charge from www.nccopp.info
07.06.2010
07.06.2010 Page
Seite 15

16. Guidelines for proper MAC servicing
07.06.2010
07.06.2010 Page
Seite 16

17. Guidelines for HFC-134a retrofit
07.06.2010
07.06.2010 Page
Seite 17

18. Guidelines for HC blend retrofit
07.06.2010
07.06.2010 Page
Seite 18

19. Guidelines for HC blend retrofit
07.06.2010
07.06.2010 Page
Seite 19

20. Guidelines for HC blend retrofit
07.06.2010
07.06.2010 Page
Seite 20

21. MAC training programmes
Achievements NCCOPP: MAC training
Activity AWP 2004-05 AWP 2005-06 AWP 2006-07 AWP 2007-08
Target as per AWP 44 80 180 352
Achieved 29 199 238 275
Cumulative 29 228 466 741
Total no. of training programmes 2004 - 2008: 33
07.06.2010
07.06.2010 Page
Seite 21

22. Equipment support under HIDECOR/NCCoPP
07.06.2010
07.06.2010 Page
Seite 22

23. Changing scenario
during implementation
At time of project inception > 2 Mio CFC
MAC systems in the market
Accelerated CFC phase-out in India:
complete stop of supply 1st August 2008
Price of CFC increased thereafter (from Rs
300 to Rs 1,000+ per kg)
Price of HFC-134a decreased significantly in
2007-08 (to approx Rs 300 per kg)
CFC MAC systems were replaced with HFC-
134a systems on routine basis by official
servicing workshops
07.06.2010
07.06.2010 Page
Seite 23

24. Lessons learnt from HC retrofitting
Technically feasible, but more complicated than use of
CFC-12 (proper training required, need of weighing scale
and vacuum pump)
Supply of HC refrigerant critical bottleneck
Incorrect practices resulted in poor performance of MAC
systems after retrofit (no use of weighing scale, no proper
vacuum etc.), however this was blamed on HC refrigerant
in general
HC-290 should be preferred to HC blend (as blend does
not allow topping up of refrigerant)
Hence service technicians did not really take up HC blend
retrofitting
07.06.2010 Page
Seite 24

25. Training Partners
Training infrastructure can still be used by industry!
25 07.06.2010 Page
Seite 25

26. Thank you!
Contact: markus.wypior@gtz.de
07.06.2010
07.06.2010 Page
Seite 26