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5. Detection of Flammable Refrigerants
Under no circumstances shall potential sources of ignition be used in the searching for or detection of refrigerant leaks. A halide torch (or any other detector
using a naked flame) shall not be used.
6. Leak Detection Methods
Electronic leak detectors may be used to detect refrigerant leaks but, in the case of flammable refrigerants, the sensitivity may not be adequate, or may
need recalibration. (Detection equipment shall be calibrated in a refrigerant-free area.) Ensure that the detector is not a potential source of ignition and is
suitable for the refrigerant used. Leak detection equipment shall be set at a percentage of the LFL of the refrigerant and shall be calibrated to the refrigerant
employed, and the appropriate percentage of gas (25 % maximum) is confirmed.
Leak detection fluids are suitable for use with most refrigerants but the use of detergents containing chlorine shall be avoided as the chlorine may react with
the refrigerant and corrode the copper pipe-work.
If a leak is suspected, all naked flames shall be removed/extinguished.
If a leakage of refrigerant is found which requires brazing, all of the refrigerant shall be recovered from the system, or isolated (by means of shut off valves)
in a part of the system remote from the leak. For appliances containing flammable refrigerants, oxygen free nitrogen (OFN) shall then be purged through the
system both before and during the brazing process.
7. Removal and Evacuation
When breaking into the refrigerant circuit to make repairs - or for any other purpose conventional procedures shall be used. However, for flammable refriger-
ants it is important that best practice is followed since flammability is a consideration. The following procedure shall be adhered to:
▪ remove refrigerant
▪ purge the circuit with inert gas
▪ evacuate
▪ purge again with inert gas
▪ open the circuit by cutting or brazing.
The refrigerant charge shall be recovered into the correct recovery cylinders. For appliances containing flammable refrigerants, the system shall be "flushed"
with OFN to render the unit safe. This process may need to be repeated several times. Compressed air or oxygen shall not be used for purging refrigerant
systems.
For appliances containing flammable refrigerants, flushing shall be achieved by breaking the vacuum in the system with OFN and continuing to fill until the
working pressure is achieved, then venting to atmosphere, and finally pulling down to a vacuum. This process shall be repeated until no refrigerant is within
the system. When the final OFN charge is used, the system shall be vented down to atmospheric pressure to enable work to take place. This operation is
absolutely vital if brazing operations on the pipe-work are to take place.
Ensure that the outlet for the vacuum pump is not close to any ignition sources and that ventilation is available.
8. Charging Procedures
In addition to conventional charging procedures, the following requirements shall be followed:
▪ Ensure that contamination of different refrigerants does not occur when using charging equipment. Hoses or lines shall be as short as possible to minimize
the amount of refrigerant contained in them.
▪ Cylinders shall be kept upright.
▪ Ensure that the refrigeration system is earthed prior to charging the system with refrigerant.
▪ Label the system when charging is complete (if not already).
▪ Extreme care shall be taken not to overfill the refrigeration system.
Prior to recharging the system, it shall be pressure-tested with the appropriate purging gas. The system shall be leak-tested on completion of charging but
prior to commissioning. A follow up leak test shall be carried out prior to leaving the site.
9. Decommissioning
Before carrying out this procedure, it is essential that the technician is completely familiar with the equipment and all its detail. It is recommended good
practice that all refrigerants are recovered safely. Prior to the task being carried out, an oil and refrigerant sample shall be taken in case analysis is required
prior to reuse of reclaimed refrigerant. It is essential that electrical power is available before the task is commenced.
(1) Become familiar with the equipment and its operation.
(2) Isolate system electrically.
(3) Before attempting the procedure, ensure that:
▪ mechanical handling equipment is available, if required, for handling refrigerant cylinders;
▪ all personal protective equipment is available and being used correctly;
▪ the recovery process is supervised at all times by a competent person;
▪ recovery equipment and cylinders conform to the appropriate standards.
(4) Pump down refrigerant system, if possible.
(5) If a vacuum is not possible, make a manifold so that refrigerant can be removed from various parts of the system.
(6) Make sure that cylinder is situated on the scales before recovery takes place.
(7) Start the recovery machine and operate in accordance with manufacturer's instructions.
(8) Do not overfill cylinders. (no more than 80 % volume liquid charge).
(9) Do not exceed the maximum working pressure of the cylinder, even temporarily.
(10) When the cylinders have been filled correctly and the process completed, make sure that the cylinders and the equipment are removed from site
promptly and all isolation valves on the equipment are closed off.
(11) Recovered refrigerant shall not be charged into another refrigeration system unless it has been cleaned and checked.
10. Labeling
Equipment shall be labeled stating that it has been de-commissioned and emptied of refrigerant. The label shall be dated and signed. For appliances con-
taining flammable refrigerants, ensure that there are labels on the equipment stating the equipment contains flammable refrigerant.
11. Recovery
When removing refrigerant from a system, either for servicing or decommissioning, it is recommended good practice that all refrigerants are removed safely.
When transferring refrigerant into cylinders, ensure that only appropriate refrigerant recovery cylinders are employed. Ensure that the correct number of cyl-
inders for holding the total system charge are available. All cylinders to be used are designated for the recovered refrigerant and labeled for that refrigerant
(i.e. special cylinders for the recovery of refrigerant). Cylinders shall be complete with pressure-relief valve and associated shut-off valves in good working
order. Empty recovery cylinders are evacuated and, if possible, cooled before recovery occurs.
The recovery equipment shall be in good working order with a set of instructions concerning the equipment that is at hand and shall be suitable for the
recovery of all appropriate refrigerants including, when applicable, flammable refrigerants. In addition, a set of calibrated weighing scales shall be available
and in good working order. Hoses shall be complete with leak-free disconnect couplings and in good condition. Before using the recovery machine, check
that it is in satisfactory working order, has been properly maintained and that any associated electrical components are sealed to prevent ignition in the event
of a refrigerant release. Consult manufacturer if in doubt.
The recovered refrigerant shall be returned to the refrigerant supplier in the correct recovery cylinder, and the relevant waste transfer note arranged. Do not
mix refrigerants in recovery units and especially not in cylinders.
If compressors or compressor oils are to be removed, ensure that they have been evacuated to an acceptable level to make certain that flammable refriger-
ant does not remain within the lubricant. The evacuation process shall be carried out prior to returning the compressor to the suppliers. Only electric heating
to the compressor body shall be employed to accelerate this process. When oil is drained from a system, it shall be carried out safely.
OBH832C
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