FEATURE COLD STORAGE
KEEPING YOUR COOL about refrigerant gas leaks
To reduce gas leaks and the associated costs companies are turning to sophisticated gas detection systems. Managing director of Stonegate Instruments Shaun Evers explains
V
ital to the safe handling of materials, refrigeration is a key component
across a wide range of industries with refrigerant gases critical to keeping these systems running. However, if a gas leak occurs the impact on energy and the environment can be significant. Steps are being taken to ensure potentially damaging refrigerants are not in use. Chlorofluorocarbons and HCFC gases have been banned in new equipment due to their ozone depleting properties and gradually replaced. Hydrofluorocarbons (HFC) refrigerants have become more popular as a like-for- like substitute. However, these gases are still not environmentally friendly. While safer than HCFCs and Chlorofluorocarbons research has revealed that when released in to the atmosphere HFCs have a global warming potential of over 3,000 times that of CO2. This significant discovery has led to a call for urgent action to reduce gas leaks from refrigeration systems. Equipment failure, improper
maintenance, mechanical damage and accidental release during refrigerant replenishment can all cause a potentially costly leak. In addition, UK systems have an average annual leak rate of 20% which leads to an 11% reduction in efficiency in a typical cold store; the need for reducing leaks is evident. These figures increase the longer a leak
is ignored. A typical 300kW refrigeration system with a small but continuous leak left unrepaired for three months could incur an energy penalty of 10kW in electricity once the leak becomes critical. This means an increased energy cost of £1,400 not including repair costs which will be higher than if immediately repaired as more refrigerant will be required. Although gas leaks cannot be stopped completely action can be taken to ensure they are spotted immediately and promptly repaired using a high-tech gas detection system.
GAS LEAK DETECTION The installation of a gas detection system can help ensure that leaks are quickly identified and repaired at the earliest opportunity. This not only
S6 JANUARY/FEBRUARY 2016 | MATERIALS HANDLING & LOGISTICS
Stonegate’s DL1024 gas detection system meets all these requirements. Accommodating up to 24 remote refrigerant sensors it can be programmed to detect a wide range of both toxic and non-toxic gases including HFCs. Sensors are arranged in three zones of eight channels with four relay outputs for signalling an alarm, one for each zone. Staff are alerted to any sensed gas leak with an audio and visual alarm while LED colours indicate the presence and status of each sensor. This ensures that any problem can be quickly rectified.
minimises the amount of energy loss but is a legal requirement as part of the EU F-Gas Regulations. This legislation states that any refrigeration system with 300kg or more of refrigerants must be fitted with a leak detector; cold stores that have a charge of 3-30kg are required to be tested for gas leaks once annually and those with a charge of 30kg or more twice a year.
Fitted gas detectors must have a
sensitivity of 5g/year, checked after 25 hours of continuous use and calibrated with a 1,000ppm gas to air mix.
Wall-mounted devices use a flashing Xenon beacon and two sounders to warn staff of open doors
Staff are alerted to any sensed gas leak with an audio and visual alarm while LED colours indicate the presence and status of each sensor
SHUTTING THE DOOR ON ENERGY LOSS While gas leaks are the main contributor to energy loss in modern refrigeration systems, equally detrimental to a cold store’s energy performance is leaving doors open. This can force a system to work harder to stay cool, using more energy that leads to higher costs. Alarms can be installed to ensure doors are not left open for an extended period. Wall-mounted devices use a flashing Xenon Beacon and two 100bB sounders which produce audible and visual warnings to alert staff of open doors.
EMPLOYEE SAFETY The demand for gas detection systems is growing in industries which are keen to cut down the carbon emissions from their cold store and refrigeration systems. The benefits are evident: reduced carbon emissions and energy costs, legislative compliance and ensuring the safety of employees. With the installation of a Stonegate gas detection system a company can ensure they reap these benefits and with a payback period of less than two years this technology offers a cost-effective and simple solution for firms. Stonegate Instruments designs,
develops and manufactures electronic equipment for the refrigeration industry. The company’s products are proven in cold storage facilities for reducing energy, carbon emissions and the associated costs.
Stonegate Instruments T: 0113 224 4440
www.stonegate-instruments.com
/ MATERIALSHANDLINGLOGISTICS
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