HEALTH & SAFETY GAS LEAKS POSE A TRIPLE


THREAT TO FACILITIES H


eating, ventilation and air conditioning (HVAC) systems play a critical role in facilities of all sizes and across all sectors. However, leaking equipment poses a danger to workers, the environment, and the viability of a business. SHAUN EVERS, managing director of Stonegate Instruments, discusses how these hazards are driving companies to seek out the latest gas detection systems.


Operating any factory, production facility or warehouse without a functioning HVAC system is inconceivable. After all, these units are necessary to maintain air quality, employee health, and comfort levels. Unfortunately, they also have the potential to leak toxic gases, endangering facility personnel, driving operational costs higher, and raising environmental concerns.


These systems use R32 coolants which, despite their high efficacy and low Global Warming Potential (GWP), are composed of hazardous chlorofluorocarbons. If coolant leaks from a system, it can rapidly evaporate into a lethal gas which can cause asphyxiation. More commonly, however, it can cause breathing difficulties, coughing, nausea and vomiting, skin and eye irritation, and headaches.


In addition, refrigerant gas leaks can cause irreversible compressor damage, making HVAC systems extremely inefficient and consequently forcing it to work harder to compensate. This increases electricity consumption and accordingly, monthly energy bills. It has been found that a leaking air conditioning unit consumes almost 20% more electricity than a fully functioning one and that a small continuous leak, left unrepaired for three months, could use an extra 10kW in electricity once the leak becomes critical. Considering current energy prices, it is a cost facilities can ill afford.


Moreover, the evacuation of a facility equals lost productivity, not to mention the harmful environmental impacts associated with gas leaks.


TAKING A LOOK AT REGULATION


For anyone working with refrigerant gas, an understanding of F-Gas regulations is vital. In early 2020 the European Commission brought in these regulations as part of a policy to combat climate change with the aim of phasing down the CO2 equivalent emissions from hydrofluorocarbons (HFCs) by 79% (relative to 2015) by 2030. Although the UK has since left


the EU, the UK government has specified that businesses will have to apply for a new GB hydrofluorocarbon (HFC) quota while they follow the same CO2 phase down as was specified by the European Commission.


Since January 2020, under UK and EU legislation, a ban has been in force that prevents refrigerants with a GWP greater than 2,500 being used to service or refill refrigeration systems, with a refrigerant charge size of 40 tonnes of CO2 equivalent or more. In addition, the topping up with new fluid of systems that use some HFC refrigerant gases, such as R404a and R507a, has been banned.


These F-Gas regulations have also raised the requirements for regular gas leak checks. EU regulations stipulate that a system with 300kg or more of refrigerants be fitted with a leak detector, a shift that affects operators of stationary refrigeration equipment, air conditioning, heat pumps and refrigeration units on refrigerated trucks and trailers. Where gas leak detection systems are not installed on apparatus, the frequency of mandatory gas leak checks will of course increase.


Additionally, to prevent the risk of ignition posed by the flammability of some refrigerants, operators are required to maintain in-room concentration levels below the lower flammability level. This requirement is reinforced by safety legislation and standards such as ISO 5149 and EN 378. A further ban came into effect at the start of this year. From 1 January 2022, the use of F-Gas with a GWP of 150 or more in hermetically sealed refrigerant systems that are for commercial use are banned. Products with recycled or reclaimed HFCs are not exempt from the ban.


In line with F-Gas regulations, the Environment Agency has the power to impose civil penalties of up to £200,000 for various breaches, including failure to comply with provisions in the regulations or permitting another person to breach those provisions. The efficacy and impact of F-Gas regulations in the UK are currently under review, with new regulations possible by the end of this year.


Alongside F-Gas regulations, the government has shifted responsibility to building and facilities managers with additional regulations such as the DSEAR (Dangerous Substances and Explosive Atmospheres Regulation 2002).


THE ROLE OF TECHNOLOGY Unfortunately, refrigerant gas is both odourless and colourless, which can make detecting a leak challenging. While there are several things that can be done in the case of a suspected leak, nothing can replace the accuracy and efficiency of using specially designed technology for this task. Whether a leak results from mechanical damage, equipment failure or poor maintenance, a gas detection system can help prevent a minor incident from becoming a crisis.


Thanks to rapidly evolving technology, the latest generation of sensors and systems are smart, self-contained single fixed gas sensors which are particularly suited to detecting R32 gases associated with HVAC units. Many of these sensors have a proven return on investment of just two years, and that is without taking into consideration the cost of repairs to an existing faulty system. Sensor equipment with signalling alarms, LED lights that indicate the presence and status of each sensor, as well as audio/visual alarms to alert staff, is also available. These systems help ensure that leaks are quickly identified and repaired at the first opportunity, minimising the risk to the health and safety of workers, and preventing breaches in regulatory compliance.


HVAC systems are vital in any facility that needs warming up or cooling down, or where air changes and improved airflow is required. When managed in a controlled environment and coupled with modern safety and monitoring technology, these systems can operate at their most efficient level. This not only minimises the risk to the health and safety of workers, but also ensures regulatory compliance and substantial cost savings.


Stonegate Instruments stonegate-instruments.com/


14 JULY/AUGUST 2022 | FACTORY&HANDLINGSOLUTIONS


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