Comprehensive SWMS for Refrigerated Storage Facility Repair and Maintenance

Cool Room Repair Safe Work Method Statement

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Cool room repair involves the maintenance, troubleshooting, and repair of refrigerated storage facilities used in commercial kitchens, food processing, hospitality, healthcare, and retail environments. This specialised HVAC work requires managing multiple serious hazards including refrigerant gas exposure, confined space entry, electrical systems isolation, extreme cold stress, and work in oxygen-deficient atmospheres. This SWMS addresses the specific safety requirements for cool room repair work in accordance with Australian WHS legislation and refrigerant handling regulations, providing detailed hazard controls, gas monitoring procedures, and step-by-step repair methods to ensure worker safety and regulatory compliance.

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Overview

What this SWMS covers

Cool room repair encompasses the diagnostic assessment, maintenance, and repair of refrigerated storage facilities ranging from small walk-in cool rooms to large-scale cold storage warehouses. This work requires refrigeration mechanics holding ARCtick licences (refrigerant handling authorisation) to diagnose refrigeration circuit faults, repair or replace compressors, condensers, evaporators, expansion valves, and associated controls. Cool rooms operate at temperatures ranging from 0°C to 4°C for general refrigeration, with some freezer rooms operating at -18°C to -25°C or lower. Typical repair activities include refrigerant leak detection and repair, compressor replacement or overhaul, condenser coil cleaning or replacement, evaporator fan motor replacement, thermostatic expansion valve adjustment or replacement, door seal replacement, panel repair for insulation damage, electrical control system troubleshooting, and defrost system repair. Each repair type presents unique hazards requiring specific control measures and emergency response procedures. Cool room systems use various refrigerants including R404A, R134a, R407C, and increasingly, natural refrigerants such as ammonia (R717) or CO2 (R744) in commercial applications. Each refrigerant type has specific handling requirements, toxicity profiles, and environmental considerations. High-pressure refrigerant systems operate at pressures exceeding 1000 kPa, creating additional hazards during system opening and refrigerant recovery operations. Repair work occurs in diverse environments including commercial kitchens, supermarkets, food processing facilities, pharmaceutical storage, hospitality venues, and agricultural cold storage. Work may be scheduled during facility downtime or conducted as emergency call-outs requiring work outside normal hours. Access constraints, time pressures to restore refrigeration for perishable goods, and work in occupied facilities create additional complexity requiring careful planning and communication.

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Why this SWMS matters

Cool room repair presents serious refrigerant exposure risks that can cause asphyxiation, cold burns, and toxic gas exposure. Refrigerant gases are heavier than air and accumulate in low areas and confined spaces, displacing oxygen and creating asphyxiation hazards. According to Safe Work Australia, confined space incidents in refrigeration work have resulted in multiple fatalities when workers entered refrigerant-filled spaces without atmospheric testing or adequate ventilation. A single refrigerant leak in an enclosed cool room can reduce oxygen levels below safe limits within minutes. Refrigerants cause cold burns on contact with skin due to rapid evaporation and extreme temperatures of liquid refrigerant. High-pressure refrigerant releases during system opening can cause injection injuries forcing refrigerant under skin, requiring immediate medical treatment. Some refrigerants decompose at high temperatures (such as during brazing operations) producing toxic gases including hydrogen fluoride and carbonyl fluoride that cause severe respiratory damage. The Australian Refrigerant Handling Code of Practice requires specific handling procedures, recovery equipment, and environmental controls to prevent these injuries. Confined space entry hazards are inherent to cool room repair work. Technicians must enter cool rooms to access evaporator units, fans, and control systems located inside refrigerated spaces. These confined spaces may contain oxygen-deficient atmospheres from refrigerant leaks, carbon dioxide accumulation, or nitrogen displacement. Temperature extremes create additional stress and reduce worker tolerance to oxygen deficiency. The Work Health and Safety Regulations 2011 require documented confined space entry procedures, atmospheric testing, continuous monitoring, and rescue equipment for all confined space work. Electrical hazards exist throughout cool room repair work. Refrigeration systems include high-voltage electrical components such as compressor motors (typically 415V three-phase), condenser fan motors, evaporator fan motors, and control circuits. Electrical work in refrigerated environments presents additional risks from condensation causing tracking, ice formation affecting insulation resistance, and cold temperatures reducing cable flexibility. Electrical isolation procedures following lock-out/tag-out protocols are mandatory before commencing electrical repairs. Failure to properly isolate electrical systems has resulted in electrocution fatalities in refrigeration work. Exposure to extreme cold during repair work inside operating or recently shut-down cool rooms causes cold stress, hypothermia, and frostbite. Extended work in temperatures below 4°C impairs manual dexterity, reduces cognitive function, and increases injury risk from slowed reaction times. Workers may underestimate cold exposure duration when focused on fault diagnosis and repair. Proper SWMS implementation controls cold stress through work rotation, warming breaks, appropriate insulated clothing, and time limits for cold environment exposure. The combination of these hazards makes cool room repair one of the higher-risk activities in HVAC work, requiring comprehensive safety management and emergency response planning.

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Hazard identification

Surface the critical risks tied to this work scope and communicate them to every worker.

Risk register

Refrigerant Gas Asphyxiation in Confined Cool Room Spaces

High

Refrigerant gases including R404A, R134a, and R407C are heavier than air and displace oxygen when released in confined spaces. Cool rooms are enclosed environments with limited ventilation, particularly when doors are closed. A refrigerant leak from damaged pipework, loose fittings, or during system opening can rapidly reduce oxygen concentration below the safe limit of 19.5%. Workers entering cool rooms without atmospheric testing may lose consciousness within seconds in severely oxygen-deficient atmospheres, with death occurring within minutes without rescue.

Consequence: Unconsciousness, asphyxiation, permanent brain damage from oxygen deprivation, or death. Secondary injuries from falls when losing consciousness. Rescuer casualties if entering space without breathing apparatus.

Cold Burns from Liquid Refrigerant Contact

High

Liquid refrigerant evaporates rapidly when released to atmospheric pressure, reaching temperatures as low as -40°C. During refrigerant recovery, system opening, or leak repair, liquid refrigerant can contact skin or eyes causing instant cold burns similar to frostbite. High-pressure refrigerant releases can inject refrigerant under skin, causing severe tissue damage and requiring surgical intervention. Refrigerant spray to eyes causes corneal freezing and potential permanent vision damage.

Consequence: Severe cold burns requiring skin grafts, tissue necrosis, injection injuries requiring surgery, permanent vision impairment from eye exposure, and long-term nerve damage in affected areas.

Electrocution from Energised Refrigeration Electrical Systems

High

Cool room refrigeration systems operate on 415V three-phase electrical power for compressors and 240V single-phase for fans and controls. Electrical work is required for compressor replacement, fan motor repair, control system troubleshooting, and safety cutout testing. Condensation in refrigerated environments creates tracking pathways on electrical components. Ice formation on electrical terminals reduces insulation effectiveness. Workers may contact live conductors when replacing components, testing circuits, or diagnosing electrical faults if proper isolation procedures are not followed.

Consequence: Electrocution causing cardiac arrest and death, severe electrical burns, arc flash injuries, falls from elevated positions when shocked, and long-term neurological damage from electrical current exposure.

Toxic Gas Exposure During Brazing and Welding Operations

High

Refrigerant repair requires brazing copper pipework to seal leaks or connect replacement components. When refrigerant or residual refrigerant oil contacts brazing torch flames, it decomposes producing highly toxic gases including hydrogen fluoride, carbonyl fluoride (phosgene), and hydrogen chloride. These gases cause severe respiratory irritation, chemical pneumonitis, and pulmonary oedema. Inadequate purging of refrigerant from lines before brazing increases toxic gas generation. Working in poorly ventilated cool room spaces concentrates these toxic gases.

Consequence: Acute respiratory distress, chemical burns to airways, pulmonary oedema requiring hospitalisation and ventilator support, long-term lung function impairment, and potential fatality from severe toxic gas inhalation.

Hypothermia and Cold Stress from Extended Work in Refrigerated Environments

Medium

Repair work inside operating or recently shut-down cool rooms exposes workers to temperatures from 0°C to 4°C for general refrigeration, or -18°C to -25°C in freezer rooms. Extended exposure causes progressive cold stress, reducing core body temperature and impairing physical and cognitive function. Manual dexterity decreases in cold temperatures, affecting ability to operate tools safely. Workers focused on fault diagnosis may not recognise hypothermia symptoms including shivering, confusion, and impaired judgement. Wet clothing from condensation accelerates heat loss.

Consequence: Hypothermia requiring medical treatment, frostbite to extremities, impaired judgement leading to errors and secondary accidents, reduced manual dexterity causing tool-related injuries, and increased musculoskeletal injury risk from cold-stiffened muscles.

High-Pressure Refrigerant System Failures and Releases

Medium

Refrigeration systems operate at high pressures, with discharge pressures exceeding 1500 kPa in hot ambient conditions. Compressor discharge lines, condensers, and receivers contain refrigerant at these elevated pressures. Component failure, incorrect recovery procedures, or opening systems without proper depressurisation can cause violent refrigerant releases. High-pressure releases create projectile hazards from loose components, injection injuries from refrigerant entering skin, and noise exposure from rapid decompression.

Consequence: Injection injuries requiring surgical treatment, impact injuries from projectile components, hearing damage from explosive decompression, lacerations from failed components, and severe cold burns from high-volume refrigerant releases.

Manual Handling of Heavy Refrigeration Components

Medium

Cool room compressors weigh 50-200kg depending on refrigeration capacity. Condensers, evaporators, and refrigerant receivers are bulky and heavy. Access to components may be restricted by cramped plant rooms, elevated mounting positions, or installation within cool room ceiling spaces. Lifting compressors onto mounting brackets, manoeuvring condensers into position, or removing ceiling-mounted evaporators creates significant manual handling demands. Awkward postures are required when working in confined plant rooms or overhead positions.

Consequence: Lower back strain and disc injuries, shoulder and rotator cuff damage, crushed fingers and toes from dropped components, hernias from lifting heavy compressors, and chronic musculoskeletal disorders from repeated heavy manual handling.

Slip and Fall Hazards on Wet and Icy Surfaces

Medium

Cool room floors accumulate ice, frost, and condensation creating extremely slippery surfaces. Defrost cycles produce water that freezes on floors when cool room temperature drops. Door areas experience ice buildup from warm air infiltration. Workers carrying tools and parts have reduced ability to react to slips. Freezer room floors can develop thick ice layers requiring careful removal before repair access. Walking surfaces inside cool rooms may have height differences at door thresholds or between floor sections.

Consequence: Slip and fall injuries including head trauma, fractures to wrists and arms from impact, hip and pelvis fractures in older workers, soft tissue injuries, and potential secondary injuries from falling onto tools or equipment.

Control measures

Deploy layered controls aligned to the hierarchy of hazard management.

Implementation guide

Atmospheric Testing and Continuous Gas Monitoring

Engineering Control

Implement mandatory atmospheric testing before entering cool rooms for repair work and continuous monitoring during all work inside refrigerated spaces. Use calibrated multi-gas monitors testing for oxygen concentration, refrigerant gas levels, and carbon dioxide. Establish trigger levels for evacuation and emergency response. Provide audible and visual alarms alerting workers to hazardous atmosphere development.

Implementation

1. Test atmosphere using calibrated multi-gas monitor before entering cool room - verify oxygen above 19.5% and refrigerant concentration below permissible exposure limit 2. Attach continuous monitor to worker entering cool room, positioned at breathing zone height 3. Set monitor alarms to activate at oxygen concentration below 19.5% or refrigerant concentration above 50% of permissible exposure limit 4. Position second gas monitor at floor level inside cool room to detect heavier-than-air refrigerant accumulation 5. Maintain continuous monitoring throughout all work inside cool room spaces 6. Evacuate immediately if monitor alarms activate - do not continue work until atmosphere is restored to safe levels 7. Document all atmospheric test results in work log including oxygen percentage, refrigerant concentration, and test time

Refrigerant Recovery Before System Opening

Elimination

Eliminate refrigerant exposure risk by recovering all refrigerant into approved recovery cylinders before opening refrigeration systems for repair. Use refrigerant recovery equipment rated for system refrigerant type and pressure. Verify system is fully evacuated using pressure gauges before breaking into refrigerant circuits. This eliminates the primary source of refrigerant exposure during repair work.

Implementation

1. Connect refrigerant recovery equipment to system high and low pressure service ports using appropriate hoses 2. Verify recovery cylinder has adequate capacity for system refrigerant charge - check cylinder weight and maximum fill capacity 3. Open service valves and activate recovery equipment, monitoring pressure gauges throughout recovery process 4. Continue recovery until system pressure reaches 0 kPa gauge pressure (atmospheric pressure) 5. Close service valves and monitor system for 15 minutes - if pressure rises, additional refrigerant remains and further recovery is required 6. Only open refrigeration circuits once system pressure remains at 0 kPa for 15 minutes with service valves closed 7. Label recovered refrigerant cylinder with refrigerant type, quantity, and recovery date for proper disposal or reclamation

Electrical Isolation Using Lock-Out/Tag-Out Procedures

Elimination

Eliminate electrocution risk by isolating electrical supply to refrigeration system at switchboard before commencing electrical repair work. Apply personal safety locks and danger tags to isolation points preventing re-energisation. Test circuits with voltage tester to confirm isolation before commencing work.

Implementation

1. Identify electrical supply to cool room refrigeration system at main switchboard or local isolator 2. Notify facility management and users that cool room will be shut down for repair work - obtain authorisation for isolation 3. Switch off refrigeration system and turn isolator to OFF position 4. Apply personal safety lock to isolator preventing operation - use unique key that remains in worker possession 5. Attach danger tag to locked isolator stating 'DANGER - DO NOT OPERATE - REFRIGERATION WORK IN PROGRESS' with worker name and date 6. Test electrical circuits using voltage tester at compressor terminals and control circuit to verify no voltage present 7. Only remove lock and tag after completing all electrical work and verifying system is ready for re-energisation

Nitrogen Purging Before Brazing Operations

Substitution

Substitute air with nitrogen gas flowing through refrigerant lines during brazing operations to prevent refrigerant and oil decomposition. Low-pressure nitrogen flow displaces oxygen and any residual refrigerant preventing toxic gas formation when brazing torch heat is applied. This eliminates the primary source of toxic gas exposure during refrigerant line repairs.

Implementation

1. Connect nitrogen cylinder with pressure regulator to refrigerant line being brazed using appropriate fittings 2. Set nitrogen flow to 2-5 litres per minute - sufficient to displace air but not excessive causing turbulence 3. Open nitrogen valve and verify flow using soap solution at line exit point - bubbles indicate adequate nitrogen flow 4. Maintain nitrogen flow throughout brazing operation from initial heating through cooling phase 5. Position brazing work in well-ventilated area or use portable extraction to remove brazing fumes 6. Continue nitrogen flow for 30 seconds after removing brazing torch flame to purge any decomposition products 7. Close nitrogen valve and remove regulator only after joint has fully cooled to below 100°C

Insulated Protective Clothing and Work Time Limits

Administrative Control

Provide insulated protective clothing rated for work in refrigerated environments and implement work time limits preventing hypothermia and cold stress. Rotate workers between cold environment repair work and ambient temperature tasks. Schedule warming breaks in heated areas during extended cool room repair work.

Implementation

1. Provide insulated coveralls rated to minimum -5°C working temperature for cool room work, and -20°C rated clothing for freezer work 2. Issue insulated gloves allowing adequate manual dexterity for tool operation while providing thermal protection 3. Provide thermal socks and insulated safety boots with steel toecaps for cold environment work 4. Limit continuous work inside cool rooms to maximum 30 minutes per work period at 0-4°C 5. Limit continuous work inside freezer rooms to maximum 15 minutes per work period at -18°C or below 6. Schedule 15-minute warming breaks in heated area after each cool room work period 7. Rotate workers between cold environment tasks and ambient temperature preparation work to limit total cold exposure

Mechanical Lifting Aids for Heavy Component Handling

Engineering Control

Provide mechanical lifting equipment for moving heavy compressors, condensers, and evaporators during replacement work. Use engine hoists, gantry cranes, or chain blocks rated for component weight plus safety factor. Design lifting points and sequences to eliminate manual lifting of components exceeding 15kg.

Implementation

1. Assess component weight and dimensions before removal - compressors typically 50-200kg, condensers 40-150kg 2. Select appropriate lifting equipment rated to minimum 1.5 times component weight 3. Position engine hoist or gantry crane to provide vertical lift path for component removal 4. Attach lifting slings or chains to compressor lifting points - verify sling condition and weight rating 5. Lift component smoothly, monitoring for binding or obstruction requiring repositioning 6. Use tag lines to control component position during lifting - never position body parts beneath suspended loads 7. Lower component onto trolley or suitable support for transport to work area - do not manually carry heavy components

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Personal protective equipment

Requirement: Chemical-resistant gloves per AS/NZS 2161.10.2, rated for refrigerant exposure

When: When handling refrigerant cylinders, connecting recovery equipment, or working on refrigerant circuits where refrigerant exposure is possible

Requirement: Impact-rated per AS/NZS 1337 with side protection

When: During all cool room repair activities including brazing, refrigerant recovery, and component replacement to protect against refrigerant spray and debris

Requirement: Cold-rated protective clothing per AS/NZS 4501.2

When: When working inside operating cool rooms or recently shut-down refrigerated spaces below 10°C for extended periods

Requirement: Category 1 impact protection per AS/NZS 2210.3 with slip-resistant sole

When: Throughout all cool room repair work to protect against dropped components and provide grip on wet or icy surfaces

Requirement: Half-face respirator with organic vapour cartridge per AS/NZS 1716

When: When refrigerant concentrations exceed permissible limits or when toxic gas generation is possible during brazing operations

Requirement: Class 4 protection per AS/NZS 1270

When: When operating refrigerant recovery equipment, compressors, or power tools in enclosed cool room spaces where noise levels exceed 85dB(A)

Inspections & checks

Before work starts

✓Test atmospheric conditions inside cool room using calibrated multi-gas monitor before entry - verify oxygen above 19.5%
✓Inspect refrigerant recovery equipment for serviceability including hoses, gauges, and recovery cylinder certification dates
✓Verify refrigerant handling licence (ARCtick) is current for all workers handling refrigerants
✓Check electrical isolation equipment including personal safety locks, danger tags, and voltage testers for serviceability
✓Confirm confined space rescue equipment is available including harness, retrieval line, and emergency breathing apparatus
✓Verify communication equipment is functional for workers inside cool room to contact external standby person
✓Inspect insulated protective clothing for damage, tears, or compression reducing thermal protection
✓Review cool room refrigerant type, charge quantity, and system pressures from service records before commencing work

During work

✓Monitor gas detection equipment continuously - evacuate immediately if oxygen falls below 19.5% or refrigerant exceeds permissible limits
✓Verify electrical isolation remains in place with lock and tag before commencing any electrical work
✓Check worker condition every 15 minutes during cold environment work for signs of hypothermia or cold stress
✓Monitor refrigerant recovery progress using pressure gauges - verify system pressure reaches 0 kPa before opening circuits
✓Verify nitrogen purge flow is maintained throughout brazing operations using soap solution bubble test
✓Inspect brazing joints after cooling using leak detection spray or electronic leak detector before system recharge
✓Monitor work time inside cool room - enforce maximum 30-minute work periods with warming breaks
✓Check communication with external standby person at 10-minute intervals during all cool room entry

After work

✓Complete leak testing of all brazed joints and recovered fittings using electronic leak detector or soap solution
✓Vacuum system to remove moisture and air before refrigerant recharge using vacuum pump to achieve minimum 500 microns
✓Document refrigerant quantities recovered, recycled, and recharged in refrigerant handling logbook per regulations
✓Remove electrical isolation locks and tags only after verifying all electrical work is complete and system is safe to energise
✓Clean and store insulated protective clothing in dry location maintaining thermal properties
✓Calibrate gas monitoring equipment per manufacturer schedule and document calibration in equipment log
✓Test cool room operation including temperature pulldown, defrost cycle, and safety cutouts before returning to service
✓Report any near-misses or safety concerns including refrigerant leaks, electrical issues, or atmospheric hazards in work log

Step-by-step work procedure

Give supervisors and crews a clear, auditable sequence for the task.

Field ready

Site Assessment and Atmospheric Testing

Assess cool room condition and identify reported fault from client or facility management. Review system service history including refrigerant type, charge quantity, and previous repairs. Conduct atmospheric testing before entering cool room using calibrated multi-gas monitor to verify oxygen concentration above 19.5% and absence of refrigerant accumulation. Test at floor level where heavier-than-air refrigerants accumulate. If refrigerant leak is suspected, ventilate cool room thoroughly by opening doors and using portable fans before entry. Document atmospheric test results including oxygen percentage, refrigerant concentration if detectable, and ambient conditions. Brief all workers on emergency procedures including evacuation signals and rescue equipment location.

Safety considerations

Never enter cool room without atmospheric testing if refrigerant leak is suspected. Position atmospheric monitor sensor at floor level for accurate refrigerant detection. Ensure standby person remains outside cool room with rescue equipment during all interior work. Verify communication equipment functionality before entry.

Electrical Isolation and Lock-Out/Tag-Out

Identify electrical supply to refrigeration system at main switchboard or local isolator. Notify facility management and cool room users of planned shutdown and obtain authorisation for electrical isolation. Switch off refrigeration system using normal shutdown procedure to prevent damage to components. Locate electrical isolator and switch to OFF position. Apply personal safety lock to isolator using unique key that worker retains. Attach danger tag stating work in progress, worker name, and date. Test electrical circuits at compressor terminals, control circuit, and evaporator fan connections using voltage tester to confirm complete isolation. Document isolation in electrical work log including isolation point location and worker responsible.

Safety considerations

Apply only your personal lock to isolator - never rely on another worker's lock. Verify voltage tester is functioning by testing on known live circuit before using to verify isolation. Test all phases of three-phase compressor supply. Keep isolation key in personal possession throughout repair work.

Refrigerant Recovery and System Depressurisation

Connect refrigerant recovery equipment to system high and low pressure service ports using refrigerant hoses rated for system pressures. Verify recovery cylinder is approved for refrigerant type and has adequate remaining capacity by checking cylinder weight against maximum fill weight. Ensure recovery cylinder valve is closed. Open high and low side service valves on refrigeration system. Activate recovery equipment and monitor manifold gauge pressures during recovery process. Continue recovery until both high and low pressure gauges indicate 0 kPa gauge pressure. Close service valves and monitor system pressure for 15 minutes - if pressure rises above 0 kPa, additional refrigerant remains in system and further recovery is required. Document recovered refrigerant quantity, type, and condition in refrigerant handling logbook. Label recovery cylinder with refrigerant type and recovery date.

Safety considerations

Wear refrigerant-resistant gloves during all connection and disconnection operations. Position recovery equipment in well-ventilated area outside cool room. Never overfill recovery cylinders - verify weight limits before commencing recovery. Monitor for refrigerant leaks at hose connections using leak detector.

Fault Diagnosis and Component Inspection

With refrigerant recovered and electrical supply isolated, conduct systematic fault diagnosis. Inspect compressor for mechanical damage, oil leaks, or electrical winding issues. Test compressor windings using multimeter for continuity and insulation resistance to ground. Inspect condenser coils for blockage, damage, or excessive dirt accumulation - clean using appropriate methods if required. Examine evaporator coils for ice blockage, fin damage, or air flow restriction. Test evaporator fan motors for winding continuity and bearing condition. Inspect thermostatic expansion valve for correct sensing bulb attachment and valve operation. Check refrigerant line insulation for deterioration or moisture ingress. Identify failed components requiring replacement and source replacement parts matching system specifications.

Safety considerations

Maintain atmospheric monitoring during all work inside cool room. Enforce work time limits - maximum 30 minutes continuous work at cool room temperatures. Wear insulated clothing for extended diagnosis work in cold environments. Use portable lighting for adequate visibility in cool room ceiling spaces.

Component Replacement Using Mechanical Aids

Remove failed components using appropriate mechanical lifting aids for heavy items. For compressor replacement, disconnect electrical connections and refrigerant line fittings. Position engine hoist or gantry crane with lifting sling attached to compressor lifting points. Lift compressor vertically clear of mounting bracket and lower onto trolley for removal from plant room. Transport replacement compressor to installation location using trolley or pallet jack. Lift replacement compressor onto mounting bracket ensuring alignment with fixing holes. Secure compressor to bracket using appropriate bolts torqued to manufacturer specifications. For condenser or evaporator replacement, use similar mechanical lifting methods preventing manual handling of components exceeding 15kg. Verify all mechanical and electrical connections are accessible before final positioning.

Safety considerations

Never position body parts beneath suspended loads. Use tag lines to control swinging during lifting operations. Verify lifting equipment is rated for component weight plus safety factor. Check sling condition for cuts or damage before use. Maintain clear communication between workers during coordinated lifts.

Refrigerant Line Brazing with Nitrogen Purge

Prepare refrigerant line connections for brazing by cleaning copper surfaces and applying flux. Connect nitrogen cylinder with pressure regulator to refrigerant line being brazed. Set nitrogen flow to 2-5 litres per minute and verify flow using soap solution at line exit. Position brazing torch and heat joint to brazing temperature (approximately 600-700°C for silver brazing alloy). Maintain nitrogen purge throughout heating, brazing, and cooling phases to prevent oxidation and eliminate toxic gas formation. Apply silver brazing rod to heated joint allowing capillary action to draw braze material into fitting. Continue heating until braze material flows completely around joint. Remove heat and maintain nitrogen flow for additional 30 seconds to purge any decomposition products. Allow joint to cool naturally without water quenching. Inspect completed joint for complete braze penetration and absence of voids.

Safety considerations

Work in well-ventilated area or use portable extraction to remove brazing fumes. Never braze refrigerant lines containing refrigerant - always recover refrigerant first. Wear safety glasses to protect against brazing sparks and molten braze material. Maintain nitrogen purge to prevent toxic gas formation. Allow joints to cool before handling.

Vacuum Testing and Refrigerant Recharge

Connect vacuum pump to system service ports and evacuate system to remove air and moisture. Monitor vacuum gauge and continue evacuation until system pressure reaches 500 microns or lower. Maintain vacuum for minimum 30 minutes and monitor for pressure rise indicating leaks. If pressure remains stable, system is ready for refrigerant recharge. Weigh refrigerant charge using electronic scales for accuracy - refer to system nameplate for correct charge quantity. Connect refrigerant cylinder to high side service port for liquid charging or low side for vapour charging depending on refrigerant type and manufacturer recommendations. Charge system slowly while monitoring manifold gauges and refrigerant weight. Stop charging at specified refrigerant weight. Close service valves and remove charging equipment. Conduct leak testing of all newly brazed joints using electronic leak detector. Document refrigerant type, quantity charged, and system pressures in service log.

Safety considerations

Charge refrigerant slowly to prevent component damage from liquid slugging. Monitor refrigerant weight continuously during charging to prevent overcharging. Wear refrigerant-resistant gloves during cylinder connection and disconnection. Verify refrigerant type matches system requirements - do not cross-contaminate refrigerants.

System Testing and Handover

Remove electrical isolation lock and tag only after verifying all electrical connections are secure and work is complete. Restore electrical supply and activate refrigeration system. Monitor initial operation including compressor start, sound and vibration levels, and absence of unusual noises. Verify evaporator fan operation and air flow through cooling coils. Check condenser fan operation and air flow through condenser coils. Monitor system pressures on manifold gauges during initial operation - compare to normal operating pressures for refrigerant type and ambient conditions. Set thermostatic controls to desired cool room temperature. Monitor cool room temperature pulldown over initial 30-60 minute period. Test defrost cycle operation if applicable to system type. Document all system operating parameters including suction pressure, discharge pressure, cool room temperature, and compressor amperage. Provide handover documentation to client including work completed, refrigerant quantities, and recommended maintenance schedule.

Safety considerations

Stand clear of compressor during initial start-up in case of mechanical failure. Monitor for refrigerant leaks during initial operation using leak detector. Verify all tools and equipment are removed from cool room before final system start. Check electrical connections for heating during initial operation indicating loose connections.

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Frequently asked questions

What refrigerant handling qualifications are required for cool room repair work in Australia?

All workers handling refrigerants during cool room repair must hold a current ARCtick licence (Australian Refrigeration Council refrigerant handling licence). This licence is issued after completing approved training in refrigerant handling, environmental regulations, and safe work practices. The licence must be renewed every five years. Additionally, workers must maintain records of all refrigerant recovered, recycled, and recharged as required by the Ozone Protection and Synthetic Greenhouse Gas Management Regulations. Some states may have additional electrical licensing requirements for refrigeration mechanics performing electrical work on refrigeration systems. It is illegal to purchase, handle, or charge refrigerant systems without appropriate licensing, with significant penalties for non-compliance including fines exceeding $10,000 for individuals.

How do I safely enter a cool room when a refrigerant leak is suspected?

Never enter a cool room where refrigerant leaks are suspected without proper atmospheric testing and ventilation. Before entry, open cool room doors fully and position portable fans to ventilate the space for minimum 15 minutes. Use a calibrated multi-gas monitor to test atmospheric conditions from outside the cool room, positioning the sensor at floor level where heavier-than-air refrigerants accumulate. Only enter if oxygen concentration exceeds 19.5% and refrigerant concentration is below permissible exposure limits. Wear continuous atmospheric monitoring equipment attached to your person at breathing zone height. Maintain communication with a standby person positioned outside the cool room who is equipped with rescue breathing apparatus. Have emergency rescue procedures in place before entry. If atmospheric alarms activate, evacuate immediately and do not re-enter until the space is properly ventilated and safe atmospheric conditions are confirmed.

What are the time limits for working inside cool rooms and freezer rooms?

Work time limits for refrigerated environments depend on temperature and worker acclimatisation. For cool rooms operating at 0-4°C, limit continuous work to maximum 30 minutes per work period, followed by minimum 15-minute warming break in a heated area. For freezer rooms operating at -18°C or colder, reduce continuous work time to maximum 15 minutes per work period with 15-minute warming breaks. Workers must wear appropriate insulated protective clothing rated for the working temperature. Total accumulated cold exposure should not exceed 4 hours per day without additional warming breaks and medical assessment. Monitor workers for cold stress symptoms including shivering, reduced manual dexterity, confusion, or complaints of numbness in extremities. Evacuate workers showing hypothermia symptoms immediately and seek medical attention. Consider rotating workers between cold environment tasks and ambient temperature preparation work to limit individual cold exposure.

What emergency equipment must be available during cool room repair work?

Essential emergency equipment for cool room repair includes: calibrated multi-gas monitors with oxygen and refrigerant detection; emergency breathing apparatus (SCBA or escape respirator) for rescue personnel; full-body harness and retrieval line for confined space rescue; first aid kit including thermal blankets for hypothermia treatment; emergency eyewash station for refrigerant eye exposure; fire extinguisher rated for electrical fires; emergency communication equipment such as two-way radio or mobile phone; and emergency lighting for power failure scenarios. A standby person must remain outside the cool room during all interior work, equipped with rescue breathing apparatus and trained in emergency rescue procedures. Emergency contact numbers for ambulance, poison information (13 11 26), and refrigeration emergency services should be immediately accessible. All workers must be briefed on emergency procedures including evacuation signals, assembly points, and rescue protocols before commencing work.

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Risk Rating

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After ControlsLow

Key Controls

• Pre-start briefing covering hazards
• PPE: hard hats, eye protection, gloves
• Emergency plan communicated to crew

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Cool Room Repair Safe Work Method Statement

What this SWMS covers

Why this SWMS matters

Hazard identification

Refrigerant Gas Asphyxiation in Confined Cool Room Spaces

Cold Burns from Liquid Refrigerant Contact

Electrocution from Energised Refrigeration Electrical Systems

Toxic Gas Exposure During Brazing and Welding Operations

Hypothermia and Cold Stress from Extended Work in Refrigerated Environments

High-Pressure Refrigerant System Failures and Releases

Manual Handling of Heavy Refrigeration Components

Slip and Fall Hazards on Wet and Icy Surfaces

Control measures

Atmospheric Testing and Continuous Gas Monitoring

Refrigerant Recovery Before System Opening

Electrical Isolation Using Lock-Out/Tag-Out Procedures

Nitrogen Purging Before Brazing Operations

Insulated Protective Clothing and Work Time Limits

Mechanical Lifting Aids for Heavy Component Handling

Personal protective equipment

Inspections & checks

Before work starts

During work

After work

Step-by-step work procedure

Site Assessment and Atmospheric Testing

Electrical Isolation and Lock-Out/Tag-Out

Refrigerant Recovery and System Depressurisation

Fault Diagnosis and Component Inspection

Component Replacement Using Mechanical Aids

Refrigerant Line Brazing with Nitrogen Purge

Vacuum Testing and Refrigerant Recharge

System Testing and Handover

Frequently asked questions

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