Putting a freeze on gas leaks in refrigeration

Gas leaks can occur for a number of reasons. Equipment failure, improper maintenance, mechanical damage, or accidental release during refrigerant replenishment can all cause a leak, which could be potentially dangerous for employees.

It is vital that all members of staff working in cold storage and industrial refrigeration units are aware of the dangers and the precautions that must be taken against refrigerant gas leaks, as despite increasingly stringent regulations placed on companies who use refrigerants, accidents still occur.

Ammonia and halocarbons

Although there are now laws in place preventing companies from using some of the most damaging refrigerant gases, such as HFCs and F-Gases, employees are still exposed to potentially harmful gases on a daily basis.

The most common gases used in refrigeration are ammonia and halocarbons, and although not as harmful as some of the gases previously used, ammonia is classed as a hazardous substance under Part 6 of the Occupational Health and Safety Regulations due to its toxicity and explosive nature, and halocarbons also pose a substantial health risk.

Ammonia (R717) is used mainly in large scale applications and has been since the 1930s. Although, it is generally recognised as the most efficient refrigerant and is difficult to beat from an environmental perspective, as it has zero ODP (ozone depletion potential) and zero GWP (global warming potential), it is considered a high health hazard because it is corrosive to the skin, eyes, and lungs. Exposure to just 300 parts per million (ppm) is immediately dangerous to life and health.

Halocarbons have a lower toxicity than ammonia, however they still pose a substantial health risk. Organic chemical compounds containing hydrogen and one or more atoms of carbon, fluorine, bromine, chlorine, or iodine, they are especially dangerous when used in high concentrations in confined or poorly ventilated spaces, and can produce toxic decomposition products if exposed to fire.

Gas detection systems

Under the Management of Health and Safety at Work Regulation (1999), employers have a legal duty to ensure their employees are working in a safe environment. With gas leaks potentially lethal, they are one key area that employers need to look at minimising.

One preventative measure that can be used is a gas detection system. Gas detection systems can help ensure that leaks are identified and repaired, which is especially essential just before the refrigerant gas is topped up. This is not only to minimise environmental damage or the impact on the health and safety of the workforce but it is a legal requirement as part of the EU F-Gas Regulations.

EU F-Gas legislation states that cold stores with a charge of 3-30kg must be tested for gas leaks once a year, cold stores with a charge of 30kg or more must be tested twice a year, and all units with a charge of over 300kg must have a fixed gas detector installed. These gas detectors must have a sensitivity of 5g/year and should be checked after 25 hours of continuous use. They should also be calibrated with a 1,000ppm gas to air mix. Stonegate’s DL1024 gas detector meets all these requirements.

The ability to detect a potentially deadly gas leak plays an essential part in the reduction of potential risks. Gas leak detectors with a sensitivity calibrated to a 1,000ppm gas to air mix using the customer specified refrigerant gas should be fitted to ensure compliance with the Health & Safety Executive (HSE) Occupational Exposure Limits.

With a recent study finding that 60% of gas escapes before an employee notices, implementing effective gas detection methods can help ensure the health and safety of employees, as well as ensuring your business complies with the latest legislation.