Trane converts unitary products from R-22 to R-410A ahead of schedule

In a three-year global effort to beat federal regulatory due date of Jan. 1, 2010, Trane reengineered products and production plants to phase out R-22 from all unitary products and some chillers. Along the way, Trane introduced 17 new products over 18 months leading up to the completion of the refrigerant conversion project.

10/28/2009


 

On Oct. 14, 2009, Trane, a business of Ingersoll Rand, completed a global conversion effort from HCFC R-22 to the non-ozone-depleting HFC refrigerant, R-410A, for its entire unitary product line in the Americas to ensure full compliance with federal U.S. Clean Air Act provisions implementing the Montreal Protocol's phase out of HCFCs. Unitary products are packaged products that are designed, built, and tested in manufacturing facilities, then delivered to the customer for quick installation and operation. The Clean Air Act has mandated that no new R-22 products can be shipped after Dec. 31, 2009.

Trane made the announcement at a celebration and Town Hall meeting at the company's plant in Clarkesville, Tenn. ( Click here for videos created by Trane from the event ). At a press briefing held before the Town Hall meeting, Jeff Moe, Director-Global Regulatory Planning & Conformance, Ingersoll Rand, said that Trane was faced with "the most significant regulatory impact the HVAC industry has faced. In the U.S., total conversion away from R-22 use in new equipment must occur by Jan. 1, 2010. At the same time, [mandatory] increased minimum efficiency requirements for commercial unitary are driving additional product change."

Rather than work on the converging refrigerant and efficiency requirements in series, Trane addressed both of them in parallel by redesigning and reengineering all commercial unitary products and some chiller products over a three year period. In the end, marked by the celebration and press event at the Clarkesville plant, not only are these products using non-ozone-depleting refrigerants, they are said to have improved efficiency, reliability, serviceability, manufacturability and safety.

During a tour of the Clarksville manufacturing plant, Larry Griffith, Trane Manufacturing Engineering Leader said, "U.S. commercial factories are no longer taking orders to produce R-22 equipment. Last U.S. production of commercial R-22 units will occur in December." For a video of the Clarksville plant tour, click here .

The following statistics underscore the size and significance of Trane's achievement:
• $100 million invested in new manufacturing systems and equipment in our facilities to manufacture these new products in the Americas.
• More than $11 million in research, testing and development costs.
• More than 500 employees from the U.S., China, and France worked more than 3 million man-hours on the design and engineering side alone.
• Project completed on time.

As part of this reengineering and redesign effort, Commercial Systems launched 17 new products over the past 18 months. According to Trane, this is more new products in a year and a half than all of the new products that the company has introduced over the past 20 years. The new products were the result of direct customer feedback requesting more comfort-system options to navigate the current economic environment as well as Read about the key product highlights from the recently revealed products at the following links:

Model CGAM air-cooled scroll chiller :

Odyssey split-system

Precedent rooftop units

Tracer SC system

Performance Climate Changer air handler

 

 



No comments
The Top Plant program honors outstanding manufacturing facilities in North America. View the 2015 Top Plant.
The Product of the Year program recognizes products newly released in the manufacturing industries.
The Engineering Leaders Under 40 program identifies and gives recognition to young engineers who...
Strategic outsourcing delivers efficiency; Sleeve bearing clearance; Causes of water hammer; Improve air quality; Maintenance safety; GAMS preview
World-class maintenance: The three keys to success - Deploy people, process and technology; 2016 Lubrication Guide; Why hydraulic systems get hot
Your leaks start here: Take a disciplined approach with your hydraulic system; U.S. presence at Hannover Messe a rousing success
Flexible offshore fire protection; Big Data's impact on operations; Bridging the skills gap; Identifying security risks
The digital oilfield: Utilizing Big Data can yield big savings; Virtualization a real solution; Tracking SIS performance
Getting to the bottom of subsea repairs: Older pipelines need more attention, and operators need a repair strategy; OTC preview; Offshore production difficult - and crucial
Applying network redundancy; Overcoming loop tuning challenges; PID control and networks
Putting COPS into context; Designing medium-voltage electrical systems; Planning and designing resilient, efficient data centers; The nine steps of designing generator fuel systems
Package boilers; Natural gas infrared heating; Thermal treasure; Standby generation; Natural gas supports green efforts

Annual Salary Survey

Before the calendar turned, 2016 already had the makings of a pivotal year for manufacturing, and for the world.

There were the big events for the year, including the United States as Partner Country at Hannover Messe in April and the 2016 International Manufacturing Technology Show in Chicago in September. There's also the matter of the U.S. presidential elections in November, which promise to shape policy in manufacturing for years to come.

But the year started with global economic turmoil, as a slowdown in Chinese manufacturing triggered a worldwide stock hiccup that sent values plummeting. The continued plunge in world oil prices has resulted in a slowdown in exploration and, by extension, the manufacture of exploration equipment.

Read more: 2015 Salary Survey

Maintenance and reliability tips and best practices from the maintenance and reliability coaches at Allied Reliability Group.
The One Voice for Manufacturing blog reports on federal public policy issues impacting the manufacturing sector. One Voice is a joint effort by the National Tooling and Machining...
The Society for Maintenance and Reliability Professionals an organization devoted...
Join this ongoing discussion of machine guarding topics, including solutions assessments, regulatory compliance, gap analysis...
IMS Research, recently acquired by IHS Inc., is a leading independent supplier of market research and consultancy to the global electronics industry.
Maintenance is not optional in manufacturing. It’s a profit center, driving productivity and uptime while reducing overall repair costs.
The Lachance on CMMS blog is about current maintenance topics. Blogger Paul Lachance is president and chief technology officer for Smartware Group.
This article collection contains several articles on the vital role that compressed air plays in manufacturing plants.
This article collection contains several articles on the Industrial Internet of Things (IIoT) and how it is transforming manufacturing.
This article collection contains several articles on strategic maintenance and understanding all the parts of your plant.
click me