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• This shall include damage to cables, excessive number of connections, terminals not made to original specification,
damage to seals, incorrect fitting of glands, etc.
• Ensure that apparatus is mounted securely.
• Ensure that seals or sealing materials have not degraded such that they no longer serve the purpose of preventing
the ingress of flammable atmospheres. Replacement parts shall be in accordance with the manufacturer's
specifications.
• NOTE: The use of silicon sealant may inhibit the effectiveness of some types of leak detection equipment.
Intrinsically safe components do not have to be isolated prior to working on them.
8 Repair to intrinsically safe components
Do not apply any permanent inductive or capacitance loads to the circuit without ensuring that this will not exceed the
permissible voltage and current permitted for the equipment in use. 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.
9 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.
10 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.
11 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 re-calibration. (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.
12 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. Opening of the
refrigeration systems shall not be done by brazing. 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
pipe-work are to take place.
Ensure that the outlet for the vacuum pump is not close to any ignition sources and there is ventilation available.
13 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.
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