Examination of the Reactions of R40 with R134a and POE Refrigeration System Materials (RP-1665) (ST-16-007)

Instances of counterfeit refrigerants causing violent and unexpected explosions, resulting in multiple fatalities, have been reported in mobile refrigeration units around the world. In addition, counterfeit refrigerants have caused system reliability issues in numerous air-conditioning applications. It was initially believed the inclusion of methyl chloride (R40) in the refrigerant composition caused these explosions and reliability issues. ASHRAE research project RP-1665 was commissioned to examine reactivity of R40 with R134a refrigeration system materials. R40 reactivity, in concentration ranges of 0.01 to 10 percent, was studied in the presence of R134a, polyolester lubricant (POE), aluminum 1100 metal, aluminum 380 metal, in the presence of iron metal, copper metal, sodium aluminum silicate zeolite and alumina catalysts. R40 was shown to have varying levels of reactivity, generally mild, but showing the potential for catastrophic reactivity. This paper contains a summary of the work from ASHRAE Research project 1665 and will provide insights into the impact of R40 contamination, by providing the chemistry of the reactions, preventative safeguards, threshold levels, and assessment procedures. RP-1665 was conducted by McCampbell Analytical Inc., located in Pittsburg, California.