Ensuring the optimal efficiency and regulatory compliance of manufacturing and testing facilities requires continual assessment of operations to determine areas for improvement.
Whether to meet testing requirements, prepare for the introduction of flammable refrigerants, or improve instrumentation, a facility may need to undergo modifications for any number of reasons. The key is to be aware of situations in which change needs to be made and, of course, to know how to effect that change.
Meeting Testing Requirements
To comply with a standard, a facility first must meet requirements for testing. A number of factors, such as inaccurate instrumentation, incorrect measurements, or outdated software, could contribute to a facility’s failure to meet requirements. If, for instance, transducers do not meet the accuracy requirements of the applicable standard for an ISO (International Organization for Standardization)/IEC (International Electrotechnical Commission) 17025, General Requirements for the Competence of Testing and Calibration Laboratories, facility, they will need to be replaced with models that do. Regulations and standards can change without direct notification, so it is crucial facility managers and engineering departments stay up to date. Those responsible for regulatory compliance are advised to consult the Code of Federal Regulations to stay abreast of regulatory developments applicable to their facilities.
Meeting Testing Parameters
For manufacturers, time equals money, and time lost to facility testing can be expensive. Making up this time can be difficult and may require adding shifts, paying overtime, and delaying the release of product.
If a facility is unable to meet or maintain testing parameters, a root-cause analysis should be performed and proper modifications based on that analysis made. Solutions could range from adjusting control logic to relocating a controlling sensor to reconditioning equipment.
Preparing for Flammable Refrigerants
Many refrigerant gases are being phased out because of high global-warming potential. Many of the refrigerants with which they are being replaced are flammable or mildly flammable. If a facility is not equipped for flammable refrigerants, but use of flammable refrigerants is planned, precautions must be made to ensure safety.
A refrigerant leak is a serious matter. Escaped gas must be evacuated from a building swiftly and safely. This involves detection and electrical isolation. Typically, detectors are capable of monitoring hydrocarbons or Class 2 refrigerants, but not both. Thus, two sets of detectors often are installed to ensure proper detection. In preparation for the use of flammable refrigerants, a facility’s layout, operation parameters, and standard operating procedures should be reviewed. This helps to determine the best approach for adding equipment for gas detection, isolation, and evacuation.
If flammable refrigerants are used in the manufacture of products, the facility must be evaluated as a hazardous location. If classified as a hazardous location, a facility will require additional modifications, such as the establishment of explosive limits, the installation of emergency stops, and the use of personal protective equipment. Furthermore, the facility will be required to comply with any applicable standards and/or regulations for such environments.
Expanding Facility Size or Product Scope
Over time, manufacturers may shift or expand the scope of their production. As a result, their facilities may become too large, too small, or too inefficient for production and/or testing. For example, if a facility was designed for production of units of up to 5 tons and the manufacturer wants to expand production to units of up to 10 tons, evaluation is needed to determine which pieces of equipment are adequate for manufacturing and/or testing at the larger sizes. In such cases, some equipment may need to be upgraded.
Lack of Capacity Because of HVAC Issues
Over a manufacturing facility’s 20-plus-year useful life, HVACR-equipment selection, sizing, and maintenance are critical to the ability to perform effective product testing. In some cases, a faulty cooling, heating, or humidification system may need to be replaced to improve overall testing performance.
Instrumentation Reliability
Unreliable instrumentation is another precipitator of facility modifications. If equipment no longer can maintain tolerance, corrections are needed. For instance, if mercury thermometers are used for temperature readings, results may vary because of the subjective nature of the measurements and the fact different personnel perform them. In such a situation, the mercury thermometers should be phased out and replaced with highly accurate resistance temperature detectors, with measurements sent directly to a data acquisition system.
Improving Facility Data Collection and Automation
Many facilities staffs collect data for calculating capacity and efficiency manually. This is an added burden on the staffs, increases the likelihood of errors, and can result in non-compliance with regulatory requirements. Installing a data-acquisition system along with a software package that automatically records, calculates, and provides final reports saves time, reduces errors, and allows for a more complete set of data on the overall performance of a facility.
Likewise, conducting cyclical testing by having multiple technicians manually open and close valves and turn reconditioning equipment on and off can delay not only testing processes, but product releases. Employing a control software system with each valve and reconditioning system integrated into the control scheme allows for the control of all of the parameters of a facility during cyclic testing.
Conclusion
Facility owners and engineers should continually assess their facilities to identify when modifications are needed. Swiftly identifying underperforming components and systems and taking corrective action ensures not only that a facility operates at peak performance, but that it will continue to comply with regulatory requirements.
Michael Shows is design-services program manager for Intertek. His more than 20 years of HVACR-industry experience includes project management, as well as the design and construction of HVACR testing laboratories and fixtures around the world. He has managed various testing, certification, and verification programs and overseen global engineering teams in the United States, Europe, and Asia.
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