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Intrinsically safe components are the only types that can be worked on while live in the presence of a
flammable atmosphere. The test apparatus shall be at the correct rating. Replace components only
with parts specified by the manufacturer. Other parts may result in the ignition of refrigerant in the
atmosphere from a leak.
4 CABLING
Check that cabling will not be subject to wear, corrosion, excessive pressure, vibration, sharp edges or
any other adverse environmental effects. The check shall also take into account the effects of aging or
continual vibration from sources such as compressors or fans.
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
The following leak detection methods are deemed acceptable for systems containing flammable
refrigerants. Electronic leak detectors shall be used to detect flammable refrigerants, but 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. 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, 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. 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 this task. 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 pipework are to take place.
Ensure that the outlet for the vacuum pump is not close to any ignition sources and there is ventilation
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 OFN. 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.
