HEALTH & SAFETY
HEALTH AND SAFETY ISSUES The gases used in HVAC and refrigeration systems can be hazardous to human health. Employees who are exposed to leaked gases can experience a number of health problems, including headaches, coughing, nausea, breathing difficulties and skin and eye irritation. Higher concentrations, most likely in confined areas like cold storage units, put occupants in immediate danger of confusion, loss of consciousness, cardiac problems and asphyxiation. Additionally, refrigerant gases like propane (R-290) are highly flammable, with higher concentrations presenting a serious risk of explosion and fire.
A major health and safety concern for employers is that these gases are imperceptible. Having no taste, colour or odour, they can be present in the air without anyone suspecting. Moreover, as the average UK HVAC and refrigeration system loses 20 percent of its gases each year and leaks are frequently undetected until 60 percent of the gas has escaped, workers can be exposed for years.
ENVIRONMENTAL DAMAGE The hydrofluorocarbon gases (F-gases) contained in these systems also have a significant greenhouse effect when released into the atmosphere. By absorbing the infrared radiation from the Earth’s surface, they prevent heat from escaping into space. Compared to CO2, their global warming potential (GWP) is several thousand times more potent. To protect against this, there are stringent regulations for companies that operate or maintain HVAC and refrigeration systems. Gas leak checks are now obligatory, with frequencies ranging from three to twelve months, depending on CO2 equivalent tonnage while systems with an F-gas equivalent to 500 tonnes of CO2 or above must have gas leak detectors installed. Companies that fail to comply face significant financial penalties.
FINANCIAL IMPLICATIONS
Given the rising cost of energy, a significant financial risk for businesses is that leaking systems cost more to operate. When gases escape, HVAC and refrigeration systems consume more energy to maintain temperature control. Studies by the Carbon Trust have shown that the 20 percent annual loss of gas from a typical UK system drives up energy usage by 11 percent. This means that companies will be paying 33 percent more to operate their systems by the time the average
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GAS DETECTORS: IMPROVING HVAC AND REFRIGERATION HEALTH AND SAFETY
leak is detected when 60 percent of gases have escaped.
Other financial risks associated with gas leaks include the costs of repairing HVAC and refrigeration systems if low gas levels lead to major damage. Breakdowns and repairs can also put a halt to operations, with the downtime resulting in significant losses. For food and drink manufacturers and others that handle perishable or time-sensitive goods, leak-related failures can also cause substantial losses of stock.
ADVANCED GAS DETECTION TECHNOLOGY
Evolving F-gas regulations have spurred the development of new and more effective gas detection systems. With intelligent sensors and superior capabilities, the latest detection technology rapidly identifies both toxic and non-toxic gases, instantly alerting employees when a leak is detected.
On a technical level, these systems utilise extremely accurate semiconductors or infrared sensing elements that have been specially configured to detect refrigerant gases across the gamut of environments, including in warehousing, processing, manufacturing and other industrial settings, as well as in extreme environments, like cold storage units. Moreover, the sensors can be configured for specific working environments by programming
APRIL 2025 | FACTORY&HANDLINGSOLUTIONS
them to detect specified mixtures of refrigerant gas and air. The use of integrated filters, meanwhile, extends the sensors’ longevity by enabling them to disregard irrelevant gases. From a health and safety perspective, built-in LEDs signify the presence and status of the sensors, while audio-visual signalling alarms immediately warn staff members of the presence of a leak. This ensures safety measures can be swiftly implemented while alerting maintenance teams of the need to carry out repairs. Modern gas detectors are designed for integration with Building Management Systems (BMS), enabling proactive monitoring and providing enhanced diagnostics and communications. For the manufacturing, engineering, logistics and handling sectors, and companies in the food and drinks industry, advanced gas detection technology offers significant safeguards. They protect employees from exposure to refrigerant gases, reduce inefficiency and energy wastage caused by leaks and prevent systems failing and stock going to waste. In addition, they reduce a business’s environmental impact and help it comply with F-gas regulations.
Stonegate Instruments
www.stonegate-instruments.com
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