REFRIGERANT GAS DETECTION
Freezing out potentially
harmful gas leaks
Refrigerants are crucial to the efficient operation of modern cold store systems; however, they can pose a significant threat to the environment and an even greater hazard to the safety of workers if a leak occurs. Shaun Evers, managing director of Stonegate Instruments, examines what steps organisations can take to reduce gas leaks and the role the latest technology plays
T
he next set of EU F-Gas regulations is edging closer, with fresh legislation governing both new equipment and service or maintenance applications due to be introduced in 2020.
With this in mind, organisations that have not yet addressed their use of F-Gas should do so to avoid potentially excessive refrigerant costs. The regulations will see the continued phasing out of HFCs, with this year seeing the biggest drop in percentage of HFCs available on the market against the EU quota. Lower HFC production will inevitably lead to higher prices and a shortage of supply, making leaks even more costly and replacement gas more difficult to source.
Therefore, with new legislation around the corner, the last thing organisations need is for valuable time and resources to be spent trying to pinpoint refrigerant gas leaks.
Fortunately, technology is available that can alert the workforce to a leak as quickly as possible, protecting both employees and the environment.
F-gas leaks: What are the risks? Although refrigerants play an essential role in keeping industrial refrigeration systems running, exposure to such gases can be dangerous. Prolonged exposure can lead to symptoms such
14 September 2018
as irritation of the throat, eyes and skin, frostbite, and chemical burns, as well as more severe symptoms like lung and brain damage. Figures from the Carbon Trust show a typical annual leak rate of up to 20% in all refrigeration systems in the UK, leading to an 11% reduction in the efficiency of the average cold store. This inefficiency also has a detrimental effect on the amount of food wasted every year. The Waste and Resources Action Programme (WRAP) estimates that of the 15m tonnes of food wasted in the UK each year, around 3.9 million tonnes is wasted during the manufacturing process, with inefficient cold storage systems playing a significant role.
It is vital, therefore, that staff working with this type of gas are aware of the dangers as well as the precautions that should be taken against potential incidents.
In addition, gas leaks can be extremely damaging to the environment. While CFCs and HCFCs are now banned in new refrigeration equipment, replaced by HFCs, even these gases are not environmentally friendly and still have a global warming potential of more than 3,000 times that of CO2
.
Not only that, leaking equipment spells spiralling energy costs for businesses. If gas escapes, equipment must work harder to remain at the correct temperature, using increasingly
larger amounts of energy as it does so. Leaks can also be costly in terms of cost; left unrepaired for three months, for example, a small leak in a typical 300kW refrigeration system could result in increased energy costs of £1,400 – not to mention the bill for the repair itself.
Detect and protect
Gas leaks can be caused by a range of factors, including equipment failure, improper maintenance, mechanical damage, and accidental release while refrigerants are being replenished. Given the fact that 60% of gas escapes before anyone notices, it cannot simply be left to the workforce to spot potentially dangerous leaks. Current EU F-Gas regulations stipulate that any refrigeration system with 300kg or more of refrigerants must be fitted with a leak detector. Cold stores with a charge of 3-30kg are required to be tested for leaks once a year and those with a charge of 30kg or more must be tested twice a year.
The latest generation of gas leak detectors is sophisticated yet simple to install, ensuring that emissions are identified swiftly and repaired at the earliest opportunity. This not only minimises the risk to the health and safety of employees but is also a legal requirement.
Gas detection systems such as Stonegate’s DL1024 can identify a variety of commonly
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