Comprehensive SWMS for Handling, Recovery, and Charging Refrigerant Systems

Refrigerant Gas Safe Work Method Statement

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Refrigerant gas handling involves the recovery, evacuation, charging, and leak detection activities associated with air conditioning, refrigeration, and heat pump systems. This specialised HVAC work requires ARCtick refrigerant handling licences, understanding of refrigerant properties and environmental regulations, and strict adherence to pressure system safety protocols. Hazards include asphyxiation in confined spaces, cold burns from liquid refrigerant contact, high-pressure system failures, toxic gas exposure, and environmental harm from refrigerant releases. This SWMS addresses the specific safety requirements for refrigerant handling in accordance with Australian WHS legislation, environmental protection regulations, and industry standards, providing detailed hazard controls, leak response procedures, and safe work practices for licensed refrigeration technicians.

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Overview

What this SWMS covers

Refrigerant gas handling encompasses all activities involving synthetic refrigerants used in air conditioning, refrigeration, and heat pump systems. Licensed refrigeration technicians perform recovery operations removing refrigerant from systems before repair or disposal, evacuation removing air and moisture from systems before charging, charging operations filling systems with new or recovered refrigerant, and leak detection identifying and repairing refrigerant losses. These activities occur in diverse environments including residential homes, commercial buildings, industrial facilities, mobile refrigeration units, and marine systems. Common refrigerants include hydrofluorocarbons (HFCs) such as R32, R410A, and R134a which are non-flammable but can cause asphyxiation; hydrochlorofluorocarbons (HCFCs) like R22 being phased out under Montreal Protocol requirements; hydrocarbons (HCs) including R290 (propane) and R600a (isobutane) which are flammable; and newer low-global-warming-potential refrigerants like R1234yf. Each refrigerant type has distinct properties, handling requirements, and regulatory controls. Working pressures range from low-pressure systems (below 200kPa) through to high-pressure systems exceeding 3000kPa in some applications. Typical refrigerant handling scenarios include air conditioning installation requiring system charging with refrigerant to manufacturer specifications, service work involving refrigerant recovery before component replacement, leak detection and repair to prevent environmental releases and system inefficiency, decommissioning work requiring complete refrigerant recovery before equipment disposal, and emergency response to refrigerant leaks in building plant rooms or cold storage facilities. The work requires specialised equipment including refrigerant recovery machines, vacuum pumps, manifold gauge sets, electronic leak detectors, and certified refrigerant cylinders. Australian regulations require all persons handling refrigerants to hold current ARCtick refrigerant handling licences issued by the Australian Refrigeration Council. Licensing categories include ARCTICK RHC (handling or recovery certificate) for basic recovery work, and ARCTICK RHTR (handling or recovery trading authorisation) for purchasing refrigerants. Environmental protection legislation prohibits intentional release of refrigerants with penalties up to $330,000 for individuals and $1.65 million for corporations under the Ozone Protection and Synthetic Greenhouse Gas Management Act 1989. Proper recovery, recycling, and documentation of refrigerant handling is legally mandated.

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Why this SWMS matters

Refrigerant gas handling presents serious asphyxiation risks in confined and poorly ventilated spaces. Most refrigerants are heavier than air and accumulate in low-lying areas displacing oxygen and creating asphyxiation hazards. Fatal incidents have occurred when technicians entered plant rooms or cool rooms where refrigerant had leaked, losing consciousness within seconds as oxygen levels dropped below 19.5%. The 2019 incident where a refrigeration technician died after entering a cool room where R404A had leaked demonstrates the rapid onset of asphyxiation when refrigerants displace breathing air. Confined space entry procedures with atmospheric testing are mandatory before entering any space where refrigerant accumulation is possible. Under the Work Health and Safety Act 2011, refrigerant handling creates duties to manage risks from hazardous chemicals, pressure equipment, and confined spaces. Refrigerants are classified as hazardous chemicals under the Globally Harmonised System requiring Safety Data Sheets, risk assessments, and emergency procedures. Pressure equipment regulations apply to refrigerant cylinders and recovery equipment which operate at pressures capable of causing explosive failures if mishandled. The 2016 incident where a refrigerant cylinder exploded during hot work nearby, killing two workers, highlights the need for strict hot work permits and cylinder storage controls. Environmental regulations impose strict controls on refrigerant handling to prevent ozone depletion and greenhouse gas emissions. Intentional venting of refrigerants is illegal with substantial penalties. Refrigerant must be recovered using certified recovery equipment and either recycled for reuse, reclaimed to original specifications, or destroyed at approved facilities. Documentation including refrigerant logs showing quantities recovered, recycled, and charged must be maintained. Technicians who release refrigerants through poor work practices, inadequate recovery, or equipment failures face loss of ARCtick licences and prosecution under environmental legislation. Refrigerant exposure risks extend beyond asphyxiation to include cold burns from contact with liquid refrigerant, toxic decomposition products from refrigerants exposed to flames or hot surfaces, and cardiac sensitisation effects where certain refrigerants increase heart attack risk. High concentrations of some refrigerants can cause dizziness, headaches, and loss of coordination even before oxygen displacement occurs. Chronic low-level exposure to refrigerant decomposition products formed during brazing or welding has been linked to respiratory sensitisation. Proper SWMS implementation controls these varied health risks through ventilation, PPE, and work practice specifications.

Reinforce licensing, insurance, and regulator expectations for Refrigerant Gas Safe Work Method Statement crews before they mobilise.

Hazard identification

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

Risk register

Asphyxiation from Refrigerant Accumulation in Confined Spaces

High

Refrigerants are heavier than air and displace oxygen when released in confined or poorly ventilated spaces. Plant rooms, cool rooms, under-floor spaces, ceiling cavities, and service pits can accumulate refrigerant from leaks or during recovery operations. Oxygen levels below 19.5% cause rapid unconsciousness and death. Technicians entering spaces where refrigerant has leaked face immediate asphyxiation risk as refrigerant displaces breathing air at ground level where faces are positioned when kneeling or bending. Large refrigerant leaks in confined spaces can reduce oxygen to fatal levels within minutes.

Consequence: Rapid unconsciousness and death from oxygen deficiency, brain damage from hypoxia if rescue is delayed, multiple casualties if rescue personnel enter contaminated space without breathing apparatus, and long-term neurological damage in survivors of asphyxiation incidents.

Cold Burns from Liquid Refrigerant Contact

High

Liquid refrigerant released from pressurised systems undergoes rapid expansion and evaporative cooling to temperatures as low as -50°C depending on refrigerant type. Skin contact with liquid refrigerant or refrigerant spray from leaks causes immediate freeze burns similar to frostbite. Eyes exposed to refrigerant spray can suffer permanent vision damage. Gloves and clothing contaminated with liquid refrigerant cause prolonged cold exposure. Rapid depressurisation when disconnecting refrigerant lines releases refrigerant spray toward worker faces and hands.

Consequence: Severe cold burns requiring skin grafts and prolonged treatment, permanent vision loss or impairment from eye exposure, tissue necrosis requiring amputation in extreme cases, scarring and disfigurement from deep freeze injuries, and chronic pain from nerve damage in affected tissues.

High-Pressure System Failures and Component Rupture

High

Refrigerant systems operate at high pressures often exceeding 2000kPa on high-pressure sides and 1500kPa on low-pressure sides. Overpressurisation from overcharging, blockages, or exposure to heat causes pressure vessel failure. Hoses, fittings, and equipment subjected to pressures exceeding ratings can rupture explosively releasing refrigerant and metal fragments. Refrigerant cylinders exposed to heat or flame can catastrophically fail with explosion force. Incorrect connection of gauges or recovery equipment to high-pressure systems exceeding equipment ratings causes equipment failure.

Consequence: Explosive rupture causing metal fragmentation and penetrating injuries, refrigerant release causing asphyxiation in enclosed spaces, severe cold burns from released refrigerant, impact injuries from failed components, and fire if flammable refrigerants are released near ignition sources creating explosion risk.

Toxic Decomposition Products from Refrigerant Heating

Medium

Refrigerants exposed to flames, hot surfaces above 250°C, or electrical arcs decompose forming highly toxic products including hydrofluoric acid, hydrochloric acid, phosgene gas, and other halogenated compounds. Brazing or welding refrigerant lines containing residual refrigerant generates toxic fumes. Refrigerant leaks near open flames, gas appliances, or electrical equipment create toxic decomposition products. These compounds cause severe respiratory irritation, chemical pneumonitis, and long-term lung damage even from brief exposures.

Consequence: Chemical pneumonitis requiring hospitalisation and prolonged treatment, permanent lung damage and reduced respiratory capacity, acute respiratory distress requiring ventilation support, chronic respiratory sensitisation, and long-term health effects including pulmonary fibrosis from severe exposures.

Flammable Refrigerant Fire and Explosion Risks

High

Hydrocarbon refrigerants including R290 (propane), R600a (isobutane), and R1270 (propylene) are highly flammable with ignition energies as low as 0.25mJ. Leaks in confined spaces create flammable atmospheres that can ignite from electrical equipment, static discharge, hot surfaces, or open flames. Flammable refrigerant concentrations between lower explosive limit (LEL) and upper explosive limit (UEL) present explosion risks. Some newer low-GWP refrigerants are classified as A2L (mildly flammable) requiring additional safety measures. Cylinder storage near heat sources or ignition sources presents fire risks.

Consequence: Fire and explosion causing severe burns and inhalation injuries, building fires extending beyond immediate work area, fatalities to workers and building occupants, extensive property damage from explosions, and secondary injuries from structural collapse or fleeing occupants during evacuations.

Cardiac Sensitisation from High Refrigerant Concentrations

Medium

Certain refrigerants including HCFCs and HFCs sensitise heart muscle to adrenaline when inhaled at high concentrations (typically above 10% by volume). This sensitisation increases risk of sudden cardiac arrest particularly if worker experiences stress, exerts physically, or receives adrenaline shock during refrigerant exposure. Cardiac sensitisation can occur at concentrations below those causing asphyxiation. Workers with pre-existing cardiac conditions face increased risk.

Consequence: Sudden cardiac arrest during or shortly after refrigerant exposure, death if defibrillation and CPR are not immediately available, long-term cardiac rhythm abnormalities in survivors, and increased risk for workers performing physically demanding tasks while exposed to refrigerant concentrations.

Pressure Equipment Connection Failures and Blowback

Medium

Connecting and disconnecting refrigerant hoses, gauge manifolds, and recovery equipment to pressurised systems presents risks of connection failure, hose blowoff, and refrigerant spray release. Improperly tightened fittings blow off under pressure. Damaged or degraded hoses fail explosively. Quick-connect fittings may release under vibration if not properly locked. Attempting to disconnect pressurised hoses releases refrigerant spray toward worker. Cross-threading or incorrect adapter use causes fitting failure under pressure.

Consequence: Cold burns from refrigerant spray released during connection failures, eye injuries from refrigerant or oil spray hitting face, hand and finger injuries from recoil of failed hoses under pressure, refrigerant release causing environmental violations and equipment damage, and equipment damage from uncontrolled refrigerant loss.

Control measures

Deploy layered controls aligned to the hierarchy of hazard management.

Implementation guide

Atmospheric Testing Before Confined Space Entry

Engineering Control

Eliminate asphyxiation risks by testing atmosphere with calibrated gas detection equipment before and during entry to any space where refrigerant may have accumulated. Testing must measure oxygen levels (must be 19.5%-23.5%), refrigerant concentrations, and presence of toxic decomposition products. Continuous monitoring is required during work. Forced ventilation must be provided to maintain safe atmosphere. Entry prohibited if unsafe levels detected.

Implementation

1. Calibrate multi-gas detector within 24 hours of use checking oxygen sensor, combustible gas sensor (for flammable refrigerants), and refrigerant-specific sensor if available 2. Sample atmosphere at multiple heights in space before entry - refrigerants accumulate at low levels so sample within 300mm of floor as well as breathing zone height 3. Verify oxygen level is between 19.5% and 23.5% - do not enter if oxygen is outside this range 4. Check for refrigerant presence using refrigerant-specific detection if possible, or monitor for unexpected oxygen displacement indicating gas presence 5. Establish forced ventilation using portable fans or extraction equipment positioned to remove refrigerant from low areas - maintain minimum 6 air changes per hour 6. Maintain continuous atmospheric monitoring during work - assign observer outside space monitoring detector readings and maintaining communication 7. Evacuate immediately if oxygen falls below 19.5% or refrigerant is detected - do not attempt to continue work until safe atmosphere is restored and maintained for 15 minutes 8. Document monitoring results including time, oxygen readings, refrigerant concentrations, and ventilation status

Pressure Relief and System Depressurisation Procedures

Administrative Control

Eliminate high-pressure hazards by depressurising refrigerant systems before disconnecting components or fittings. Use controlled recovery methods removing refrigerant to external cylinders rather than venting. Verify system pressure using gauges before disconnecting hoses. Implement slow-release procedures when residual pressure remains. Never disconnect pressurised components. Provide pressure relief paths preventing overpressurisation during charging or recovery operations.

Implementation

1. Connect manifold gauge set to system service ports verifying both high-side and low-side pressures before any disconnection 2. If system contains refrigerant charge, connect recovery machine and recover refrigerant to external cylinder following manufacturer procedures - never vent refrigerant to atmosphere 3. Operate recovery machine until system pressure drops below 100kPa on both high and low sides - verify using gauges 4. If disconnecting components with residual pressure, crack fittings slowly allowing pressure to bleed gradually - use cloth to catch any refrigerant spray 5. Install pressure relief devices on recovery cylinders preventing overpressure during recovery - relief valves must vent to safe location not creating confined space hazards 6. During charging operations, monitor system pressures continuously - cease charging if pressures approach maximum design pressures for system components 7. Never apply heat to refrigerant cylinders to increase pressure - use only specified heating methods if required (typically 40°C maximum water bath) 8. Develop and follow pressure limits chart for refrigerant being handled showing maximum allowable pressures for equipment and system components

Evacuation Procedures Before Brazing or Hot Work

Elimination

Eliminate toxic decomposition product formation by completely removing all refrigerant and oil from lines before any brazing, welding, or hot work. Evacuate systems to deep vacuum removing residual refrigerant vapours. Purge with nitrogen preventing oxidation and ensuring no refrigerant remains. Never apply heat to lines or components containing refrigerant. Verify lines are empty using leak detector before hot work approval.

Implementation

1. Recover all refrigerant from system section to be brazed using recovery equipment - verify recovery is complete by checking system pressures drop below 100kPa 2. Connect vacuum pump to system evacuating to minimum 500 microns absolute pressure - maintain vacuum for 15 minutes verifying pressure holds indicating no refrigerant remains 3. Break vacuum with dry nitrogen to atmospheric pressure purging any residual refrigerant vapours from lines 4. Repeat evacuation and nitrogen purge cycle if line sections are long or complex - single purge may not remove all refrigerant from fittings and low points 5. Use refrigerant leak detector to check for any refrigerant presence at proposed brazing locations - detector must show zero refrigerant before hot work commences 6. Maintain nitrogen flow through lines during brazing at 2-5kPa to prevent oxidation and ensure any residual refrigerant is purged away from heat 7. Issue hot work permit only after verification refrigerant evacuation is complete and leak detector confirms zero refrigerant at work location 8. Position fire extinguisher within 3 metres of brazing location and assign fire watch for duration of hot work and 30 minutes after completion

Flammable Refrigerant Leak Detection and Elimination

Engineering Control

For systems using flammable refrigerants (HC or A2L classifications), install fixed refrigerant detection systems in plant rooms and enclosed spaces triggering alarms and ventilation at 25% LEL. Prohibit ignition sources in areas where flammable refrigerants are used or stored. Use spark-proof tools and equipment rated for explosive atmospheres. Limit flammable refrigerant charge quantities per AS/NZS 60335.2.40 requirements. Implement hot work permit systems preventing ignition sources near flammable refrigerant systems.

Implementation

1. Install fixed refrigerant detectors in plant rooms at low level (refrigerants sink) setting alarm point at 25% of lower explosive limit for specific refrigerant 2. Connect detector alarms to building management system triggering automatic ventilation activation and visual/audible alarms when threshold reached 3. Test detector operation monthly using calibration gas verifying alarm activation and ventilation system response 4. Post signage at all entrances to flammable refrigerant areas: 'FLAMMABLE REFRIGERANT - NO SMOKING - NO IGNITION SOURCES' 5. Provide spark-proof tools for work on flammable refrigerant systems - tools must be bronze, brass, or plastic materials that do not create sparks 6. Verify electrical equipment in flammable refrigerant areas meets ATEX or IECEx certification for Zone 2 explosive atmospheres 7. Implement hot work permit requiring verification flammable refrigerants are recovered, ventilation is operating, and atmospheric testing confirms below 10% LEL before hot work approval 8. Limit flammable refrigerant charges to maximum quantities specified in AS/NZS 60335.2.40 based on room volume and ventilation - calculate allowable charge before system installation 9. Store flammable refrigerant cylinders in well-ventilated outdoor locations minimum 3 metres from ignition sources, air intake vents, and building openings

Refrigerant Recovery and Environmental Compliance

Administrative Control

Implement mandatory refrigerant recovery for all work on systems containing refrigerant. Intentional venting is prohibited under environmental legislation. Use certified recovery equipment meeting Australian standards. Document all refrigerant recovered including type, quantity, and disposition (recycled, reclaimed, or destroyed). Maintain refrigerant logs for compliance audits. Dispose of contaminated refrigerant through approved reclaimers. Report significant refrigerant losses to authorities as required.

Implementation

1. Provide certified refrigerant recovery machines meeting AS/NZS 1677 specifications with current service and certification tags 2. Before recovering refrigerant, verify recovery cylinder is evacuated, certified for refrigerant type being recovered, and has adequate remaining capacity for recovered quantity 3. Connect recovery machine to system following manufacturer procedures - verify hose connections are secure and appropriate for system pressures 4. Operate recovery machine until system pressure drops below 100kPa and recovery ceases - some refrigerants require evacuation to deeper vacuum for complete recovery 5. Weigh refrigerant cylinder before and after recovery recording net refrigerant weight recovered on refrigerant log 6. Document recovery on refrigerant handling log including date, site location, equipment details, refrigerant type, quantity recovered, cylinder serial number, and disposition 7. Label recovered refrigerant cylinders with refrigerant type, recovery date, and contamination status (clean or contaminated with other refrigerant types) 8. Arrange disposal of contaminated refrigerant through approved refrigerant reclaimer - never mix refrigerant types in single cylinder 9. Maintain refrigerant logs for minimum 7 years for environmental compliance audits - logs must reconcile refrigerant purchased, recovered, recycled, and disposed 10. Report refrigerant losses exceeding trigger quantities to environmental protection authority as required by state/territory regulations

Personal Protective Equipment for Refrigerant Handling

Personal Protective Equipment

Provide task-specific PPE including safety glasses or face shields for refrigerant connection and disconnection work, insulated gloves or cryogenic gloves for handling refrigerant lines and components, long-sleeve clothing preventing skin exposure, and respiratory protection for work in areas where refrigerant concentrations may exceed safe limits. Self-contained breathing apparatus required for confined space rescue. Chemical-resistant gloves for handling refrigerant oils and lubricants.

Implementation

1. Issue safety glasses with side shields meeting AS/NZS 1337 for all refrigerant handling work - full face shields required when connecting or disconnecting pressurised hoses or fittings 2. Provide insulated gloves or cryogenic gloves rated to -50°C for handling refrigerant lines, components, or cylinders where cold contact is possible 3. Require long-sleeve clothing (minimum cotton or flame-resistant material) preventing skin exposure to refrigerant spray or cold surfaces 4. Supply P2 respirators or supplied air respirators for emergency work in contaminated atmospheres - respiratory protection required if refrigerant concentrations exceed workplace exposure standards 5. Provide self-contained breathing apparatus (SCBA) for confined space rescue - minimum two sets of SCBA required on site where confined space entry for refrigerant work occurs 6. Issue nitrile gloves for handling refrigerant oils and lubricants which can cause dermatitis through prolonged skin contact 7. Inspect all PPE before each use - safety glasses must be scratch-free, gloves must have no punctures or cold damage, respirators must pass fit check 8. Maintain PPE replacement schedule - cryogenic gloves lose insulation effectiveness with age and must be replaced annually regardless of visible condition

Download complete control procedures

Personal protective equipment

Requirement: AS/NZS 1337 impact rated with side protection

When: For all refrigerant handling work; upgrade to full face shield when connecting or disconnecting pressurised refrigerant hoses or fittings

Requirement: Insulated to minimum -50°C temperature rating

When: When handling refrigerant lines, components, cylinders, or any surfaces that may contact liquid refrigerant during connection, disconnection, or leak events

Requirement: Cotton or flame-resistant material covering all skin

When: Throughout all refrigerant handling activities to prevent skin exposure to refrigerant spray or contact with cold surfaces

Requirement: P2 respirator per AS/NZS 1716 or supplied air for high concentrations

When: When working in areas with refrigerant concentrations above exposure limits, or during emergency leak response before adequate ventilation is established

Requirement: Steel toe cap per AS/NZS 2210.3 with slip-resistant sole

When: Throughout refrigerant handling work particularly when handling heavy refrigerant cylinders or compressor components

Requirement: Nitrile construction per AS/NZS 2161.10.2

When: When handling refrigerant oils, compressor lubricants, or performing oil changes on refrigeration equipment

Requirement: Class D per AS/NZS 4602.1

When: When working in plant rooms, mechanical spaces, or outdoor locations where visibility to other workers or equipment operators is required

Inspections & checks

Before work starts

✓Verify current ARCtick refrigerant handling licence for all personnel performing refrigerant work - check licence expiry dates and scope
✓Calibrate refrigerant leak detector and multi-gas atmospheric monitor within last 24 hours - test using calibration gas to verify operation
✓Inspect refrigerant recovery machine certification - verify current service tag, oil level, filter condition, and hose integrity
✓Check refrigerant cylinders for current hydrostatic test dates (must be within 10 years), damage, corrosion, and proper labelling of contents
✓Verify recovery cylinder has adequate remaining capacity for refrigerant quantity to be recovered - weigh cylinder and compare to tare weight
✓Inspect manifold gauge set for damage, gauge accuracy (compare to known pressure source), and hose condition - replace if hoses are stiff or cracked
✓Review Safety Data Sheet for specific refrigerant being handled - identify health hazards, exposure limits, first aid, and emergency procedures
✓Assess work environment for confined space hazards, ventilation adequacy, ignition source presence (for flammable refrigerants), and emergency access
✓Test atmospheric conditions if working in plant rooms or enclosed spaces - verify oxygen levels and check for refrigerant presence from previous leaks
✓Verify availability of emergency equipment including eyewash station, shower facilities, fire extinguisher (for flammable refrigerants), and first aid kit

During work

✓Monitor atmospheric conditions continuously when working in plant rooms or enclosed spaces - verify oxygen levels remain above 19.5%
✓Check refrigerant system pressures using manifold gauges before any connection or disconnection activity - never disconnect pressurised components
✓Verify recovery cylinder pressure does not exceed 80% of maximum allowable working pressure - cease recovery if pressure approaches limits
✓Inspect hose connections for leaks during recovery or charging operations - use leak detector to check all connection points immediately after connection
✓Monitor recovery machine operation for unusual sounds, vibrations, or oil contamination indicating equipment problems requiring shutdown
✓Verify forced ventilation remains operating when working in plant rooms - check airflow at exhaust points to confirm fans are functioning
✓Check for refrigerant odour or cold surfaces indicating leaks during work - investigate immediately if refrigerant odour is detected
✓Monitor cylinder temperatures during recovery operations - cease recovery if cylinders become excessively hot indicating overcharging or inadequate cooling
✓Verify workers maintain required PPE particularly safety glasses before any connection or disconnection activity where spray release is possible
✓Check recovery cylinder weight periodically during recovery to verify refrigerant is being recovered and capacity limits are not exceeded

After work

✓Verify all refrigerant has been recovered from system before leaving site - system pressure should be below 100kPa unless system is being charged
✓Document refrigerant quantities recovered on refrigerant log including type, amount, cylinder serial number, site location, and date
✓Label refrigerant cylinders with contents, recovery date, and contamination status - store cylinders in secure, well-ventilated location
✓Check all service port caps are replaced and tightened on system after disconnecting gauges - prevents refrigerant loss and contamination entry
✓Inspect work area for refrigerant leaks using leak detector - verify all connections are sealed and no leaks exist before leaving site
✓Clean and inspect recovery equipment after use - check oil level, replace filters if contaminated, inspect hoses for damage
✓Restore ventilation systems to normal operation if modified for work - verify plant room ventilation is functioning before leaving
✓Dispose of used refrigerant oil and filters appropriately - contaminated oil is hazardous waste requiring approved disposal
✓Complete work documentation including refrigerant quantities charged, system operating pressures, leak repairs performed, and any abnormalities noted
✓Report any refrigerant releases or equipment failures to supervisor - document near-miss events and contributing factors for improvement

Step-by-step work procedure

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

Field ready

Pre-Work Planning and Refrigerant Identification

Review job scope identifying refrigerant type, system operating pressures, refrigerant quantity in system, and work requirements (recovery, charging, leak detection, or repair). Obtain refrigerant Safety Data Sheet identifying health hazards, flammability classification, global warming potential, and required controls. Verify all technicians hold current ARCtick licences appropriate for work type. Check refrigerant cylinder availability if charging will be required - verify cylinder contains correct refrigerant type and adequate quantity. Review system information including nameplate data, previous service history, and any known leak locations. Identify confined space hazards if system is located in plant room, cool room, or enclosed mechanical space. Develop site-specific risk assessment documenting hazards, required PPE, ventilation requirements, and emergency procedures. For flammable refrigerants (HC or A2L types), identify all ignition sources in work area and implement hot work permit procedures if brazing will be required. Notify building occupants if work may result in air conditioning or refrigeration outage. Establish emergency contact procedures for refrigerant leak emergencies.

Safety considerations

Never assume refrigerant type based on system age or appearance - always verify using refrigerant identifier or system documentation. Mixing refrigerant types creates unsafe pressures and contaminated refrigerant requiring costly disposal. Flammable refrigerants require additional precautions beyond standard refrigerant handling - verify ignition source controls before commencing work. Review emergency procedures for refrigerant exposure including first aid for cold burns and evacuation procedures for large leaks.

Atmospheric Testing and Ventilation Establishment

Before entering plant room or enclosed space where refrigeration equipment is located, test atmosphere using calibrated multi-gas monitor. Sample air at multiple heights including low level where refrigerants accumulate (within 300mm of floor) and breathing zone height (1.5m). Record oxygen level which must be between 19.5% and 23.5% for safe entry. If refrigerant detector is available, check for refrigerant presence particularly in low areas, under equipment, and in service pits. If oxygen is below 19.5% or refrigerant is detected, do not enter - establish forced ventilation before entry. Position portable extraction fan at low level (floor mounted) to remove refrigerant from accumulation points. Direct exhaust to outdoors ensuring extracted air does not re-enter building through air intakes or openings. Operate ventilation for minimum 15 minutes allowing 6 complete air changes before re-testing atmosphere. Maintain forced ventilation continuously during work. If natural ventilation is adequate (outdoor work or very large, well-ventilated spaces), verify with atmospheric testing before relying on natural ventilation alone. Assign observer outside space monitoring atmospheric conditions if confined space entry occurs - observer maintains visual contact and atmospheric monitoring throughout work.

Safety considerations

Refrigerant leaks may have occurred before arrival creating unsafe atmospheres - never assume spaces are safe without testing. Refrigerants are colourless and often odourless at dangerous concentrations - cannot rely on smell to detect presence. Oxygen displacement occurs rapidly in confined spaces - technicians have lost consciousness within 30 seconds in severely contaminated atmospheres. Continuous monitoring is essential as leaks can occur during work releasing refrigerant into work space. Forced ventilation must continue throughout work period not just during initial setup.

Refrigerant Recovery from System

Connect manifold gauge set to system service ports on both high and low sides verifying correct hose colours (red to high pressure, blue to low pressure). Open manifold valves checking system pressures on gauges. Connect refrigerant recovery machine to manifold centre port using appropriately rated hose. Connect recovery cylinder to recovery machine outlet verifying cylinder is certified for refrigerant type being recovered. Check recovery cylinder is evacuated (internal pressure below atmospheric) or contains only same refrigerant type. Weigh recovery cylinder recording tare weight plus any refrigerant already in cylinder. Open recovery cylinder valve and start recovery machine following manufacturer starting procedures. Monitor pressures on manifold gauges observing gradual pressure reduction as refrigerant is recovered. Recovery machines typically operate in two phases - vapour recovery while system pressure is above atmospheric, then deep vacuum recovery for remaining refrigerant. Operate recovery machine until system pressure drops below 100kPa and recovery ceases (machine will auto-shutoff when recovery is complete). Some regulations require deeper evacuation - verify local requirements. Weigh recovery cylinder after recovery calculating net refrigerant recovered. Document recovered quantity on refrigerant log including refrigerant type, system location, and cylinder serial number. If recovery cylinder becomes full before system is completely evacuated, close cylinder valve, remove from recovery machine, and connect fresh cylinder to continue recovery.

Safety considerations

Never vent refrigerant to atmosphere - intentional venting is illegal with penalties up to $330,000 for individuals. Wear safety glasses and cryogenic gloves when connecting hoses as residual pressure may cause small refrigerant spray. Verify recovery cylinder does not exceed 80% of maximum fill capacity - overcharged cylinders present explosion risk. Never apply heat to recovery cylinders to speed recovery - excessive temperatures can cause cylinder rupture. Monitor recovery cylinder pressure during recovery - some refrigerants liquify at low pressures while others remain vapour requiring pressure monitoring to prevent overfilling. Use appropriate recovery machine designed for refrigerant type - some machines cannot recover flammable refrigerants safely.

System Evacuation and Dehydration

After refrigerant recovery is complete, connect vacuum pump to manifold centre port in place of recovery machine. Verify vacuum pump oil is clean and at correct level - contaminated oil reduces pump efficiency. Open manifold valves to both high and low side service ports. Start vacuum pump and monitor system pressure on compound gauge reading in microns or kPa absolute. Evacuate system to deep vacuum removing air and moisture - target minimum 500 microns (0.067kPa) absolute pressure. For larger systems or critical applications, deeper vacuum to 200-300 microns may be required. Maintain vacuum for minimum 15 minutes after target pressure is reached allowing moisture evaporation. Monitor vacuum pressure during hold period - if pressure rises significantly (more than 200 microns) it indicates moisture remains in system requiring continued evacuation. For systems that have been opened to atmosphere for extended periods, evacuate for several hours or use multiple evacuation cycles breaking vacuum with dry nitrogen between cycles. After successful evacuation verified by pressure holding steady, close manifold valves and shut off vacuum pump. Monitor system pressure for 10 minutes - pressure should not rise more than 50 microns indicating system is sealed and dehydrated. If pressure rises rapidly, leak exists requiring repair before proceeding. Record final vacuum level achieved and hold time on service documentation.

Safety considerations

Vacuum pump oil becomes acidic when moisture is absorbed from systems - change oil regularly per manufacturer schedule and always after evacuating wet systems. Vacuum pumps can draw oil into system if pump stops while connected under vacuum - close manifold valves before stopping pump or use check valve preventing backflow. Deep vacuum can implode thin-walled components if system is not pressure-rated for vacuum - verify system design can withstand full vacuum before evacuating. Never use vacuum pump for refrigerant recovery - contaminates pump oil and releases refrigerant to atmosphere through pump exhaust.

Refrigerant Charging to System Specifications

Verify refrigerant cylinder contains correct refrigerant type using refrigerant identifier - never charge system without positive identification. Check system specifications for refrigerant charge quantity - typically shown on nameplate in grams or kilograms. Position refrigerant cylinder on electronic scales recording initial weight. Connect refrigerant cylinder to manifold centre port using appropriate hose and fittings. For vapour charging (most systems), keep cylinder upright. For liquid charging (some systems require liquid), invert cylinder or use cylinder with liquid port. Open refrigerant cylinder valve slowly. For systems under vacuum, open manifold high-side valve allowing refrigerant to flow into high-pressure side of system. Monitor cylinder weight on scales adding refrigerant until specified charge quantity is reached. For larger charges, system may need to be operated in stages - charge partial amount, operate system to circulate refrigerant, then add remaining charge while system operates. When charging is complete (weight reduction equals specified charge), close manifold valves and cylinder valve. Start system and monitor operating pressures and temperatures against manufacturer specifications. Add small amounts of refrigerant as needed to achieve correct superheat and subcool temperatures. Record final operating pressures, superheat, subcool, and total refrigerant charged on service documentation. Verify system operates correctly at design capacity with no abnormal sounds, vibrations, or temperature issues.

Safety considerations

Never overcharge systems - excessive refrigerant creates dangerous high pressures and reduces system efficiency. Monitor high-side pressure continuously during charging - cease charging if pressure approaches maximum design pressure for components. Some refrigerants must be charged as liquid to prevent composition changes (refrigerant blends separate if charged as vapour). Never heat refrigerant cylinder above 40°C - excessive heat creates dangerous pressures. Use only refrigerant charging hoses rated for refrigerant type and expected pressures. Wear safety glasses during charging operations as connections can leak causing refrigerant spray. Flammable refrigerants require special charging procedures limiting charge rates to prevent static discharge.

Leak Detection and Repair Verification

Use electronic refrigerant leak detector to check all refrigerant connections, joints, valve stems, and potential leak points. Select detector sensitivity appropriate for refrigerant type - some refrigerants require more sensitive detectors. Position detector probe within 3-5mm of surfaces moving slowly around joints and connections. Concentrate on high-leak-probability areas including brazed joints, mechanical connections, valve packings, shaft seals, and areas with oil staining indicating refrigerant leakage. Detector will alarm when refrigerant is sensed - mark leak location for repair. Quantify leak rate if possible using bubble test with leak detection solution confirming leak presence and estimating severity. For small leaks, monitor system over extended period checking for pressure loss indicating leak is present but too small for immediate detection. Repair leaks as required using appropriate methods - replace gaskets for mechanical connections, re-braze joints if brazing defects exist, tighten packings if valve stems leak, or replace components if repairs are not feasible. After leak repair, recover remaining refrigerant, evacuate system to verify repair holds vacuum, then recharge and retest for leaks. Document leak locations, repair methods, and verification testing results. For systems with chronic leaks that cannot be repaired, recommend system replacement to prevent ongoing refrigerant loss and environmental harm.

Safety considerations

Leak detectors are sensitive instruments requiring calibration - test detector response using refrigerant source before each use to verify operation. Some electronic detectors can be saturated by high refrigerant concentrations requiring recovery period before they detect again - if detector stops responding, move to fresh air allowing sensor recovery. Never use open flames or heated filament detectors as they create toxic decomposition products from refrigerants. Wear respiratory protection if working in areas with significant refrigerant leaks - high concentrations can cause asphyxiation before detector alarms. Repair leaks before recharging systems - adding refrigerant to leaking systems wastes refrigerant and violates environmental regulations.

System Performance Testing and Documentation

Operate system at design conditions monitoring performance parameters against manufacturer specifications. Measure and record high-side pressure, low-side pressure, discharge temperature, suction temperature, liquid line temperature, and ambient conditions. Calculate superheat (suction temperature minus evaporating temperature derived from suction pressure) verifying it matches specifications (typically 5-15°C for fixed orifice systems). Calculate subcool (condensing temperature derived from high-side pressure minus liquid line temperature) verifying it matches specifications (typically 5-15°C). Check that system achieves design capacity - for air conditioning, verify supply air temperature drop and airflow rates meet specifications. For refrigeration, verify space temperature reaches and maintains target temperature within specified time. Monitor system operation for minimum 30 minutes ensuring stable operation and no abnormal sounds, vibrations, or cycling. Check electrical current draw on compressor verifying it is within nameplate ratings - high current indicates problems with system charge, mechanical issues, or electrical faults. Complete service documentation recording all pressures, temperatures, refrigerant quantities charged, leak repairs, test results, and system performance. Provide documentation to customer including summary of work performed, refrigerant quantities handled, and recommendations for ongoing maintenance. Photograph system nameplate and final operating conditions for service records.

Safety considerations

Systems operating outside normal parameters may have safety issues - investigate abnormal pressures or temperatures before leaving system in operation. High discharge temperatures above 120°C indicate problems potentially causing compressor failure or refrigerant breakdown forming acids. Low suction pressures can cause evaporator frosting or icing creating secondary hazards. Never bypass safety controls or pressure switches to make system operate - controls are present for safety reasons and bypassing them creates hazards. Verify all electrical connections are secure and properly terminated before energising system - loose connections cause arc flash and fire hazards.

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Frequently asked questions

What ARCtick licence is required for refrigerant handling work and how do I verify licensing?

All persons handling refrigerants in Australia must hold current ARCtick refrigerant handling licences issued by the Australian Refrigeration Council. Two licence types exist: ARCTICK RHC (Refrigerant Handling Certificate) allows recovery and handling of refrigerants for service work, and ARCTICK RHTR (Refrigerant Handling Trading Authorisation) allows purchasing refrigerants from wholesalers. Licences are issued after completing approved training and passing competency assessments. Trainees can handle refrigerants only under direct supervision of licensed technicians. Licence holders must complete continuing professional development (CPD) requirements maintaining licence validity. Employers must verify all technicians hold current licences before allowing refrigerant work - check licence cards and verify status on ARC website using licence numbers. Keep copies of licence cards in employee records. Unlicensed refrigerant handling violates Ozone Protection and Synthetic Greenhouse Gas Management Act with penalties including fines and prosecution.

What are the legal requirements for refrigerant recovery and disposal in Australia?

Intentional release of refrigerants to atmosphere is prohibited under Ozone Protection and Synthetic Greenhouse Gas Management Act 1989 with penalties up to $330,000 for individuals and $1.65 million for corporations. All refrigerant must be recovered using certified recovery equipment before system repairs, decommissioning, or disposal. Recovered refrigerant must be either recycled for reuse in same system, reclaimed to original specifications by approved reclaimers, or destroyed at approved facilities. Mixing refrigerant types creates contaminated refrigerant requiring disposal through approved reclaimers - never mix refrigerants in recovery cylinders. Technicians must maintain refrigerant logs documenting all refrigerant purchased, recovered, charged, and disposed including type, quantity, date, site location, and cylinder serial numbers. Logs must be retained minimum 7 years for government audits. Refrigerant disposal must be through businesses holding Ozone Protection and Synthetic Greenhouse Gas Management import/export licences. Obtain documentation from disposal facility confirming quantities and refrigerant types received. Significant refrigerant releases must be reported to environmental authorities - trigger quantities vary by state but typically include releases exceeding 50kg in single event.

How do I safely work with flammable hydrocarbon refrigerants like R290 and R600a?

Flammable refrigerants including R290 (propane), R600a (isobutane), and A2L refrigerants require additional safety controls beyond standard refrigerant handling. Eliminate all ignition sources from work areas including open flames, electrical equipment not rated for explosive atmospheres, hot work, and static discharge sources. Use spark-proof tools made from bronze, brass, or plastic when working on systems containing flammable refrigerants. Verify electrical equipment in plant rooms meets ATEX or IECEx certification for Zone 2 explosive atmospheres. Install fixed refrigerant detection systems in enclosed spaces setting alarms at 25% of lower explosive limit (LEL) - for propane this is approximately 5,000ppm. Connect detection alarms to automatic ventilation systems and building alarms. Limit refrigerant charge quantities per AS/NZS 60335.2.40 based on room volume and ventilation rates - typical maximum for residential systems is 150g in occupied spaces without additional protection. Never apply heat to flammable refrigerant cylinders or systems. Implement hot work permit systems requiring verification flammable refrigerants are completely recovered and spaces are ventilated to below 10% LEL before brazing approval. Store flammable refrigerant cylinders outdoors in well-ventilated locations minimum 3 metres from ignition sources. Use appropriate signage warning of flammable refrigerant presence. Provide fire extinguishers rated for Class B (flammable liquid) fires near flammable refrigerant work areas.

What emergency procedures should be followed for large refrigerant leaks or exposure incidents?

For large refrigerant leaks creating asphyxiation hazards or high airborne concentrations, immediately evacuate contaminated area closing doors to limit spread. Do not enter contaminated spaces to shut off equipment unless wearing self-contained breathing apparatus (SCBA) - asphyxiation occurs rapidly in oxygen-depleted atmospheres. Activate building alarm systems alerting occupants to evacuate. Call emergency services (000) reporting refrigerant type, estimated quantity released, location, and whether anyone is trapped or injured. Establish forced ventilation from safe location if possible without entering contaminated space - open windows and doors creating air flow. Use remote controls for ventilation systems if available. Post personnel at entry points preventing unauthorised entry until atmosphere is confirmed safe through testing. Only enter after atmospheric testing confirms oxygen levels above 19.5% and refrigerant concentrations below hazardous levels. For workers exposed to refrigerant, move to fresh air immediately. Remove contaminated clothing if refrigerant contact occurred. For cold burns from liquid refrigerant, flush affected skin with lukewarm water (never hot water) for minimum 15 minutes and seek medical attention. For eye exposure, flush with water for 15 minutes and obtain medical treatment urgently. If worker loses consciousness from asphyxiation, do not enter to rescue without SCBA - multiple fatalities occur when rescuers enter oxygen-deficient atmospheres. Call emergency services and wait for trained rescue teams with breathing apparatus. Provide oxygen to affected workers if trained and equipment is available. Implement CPR if worker is not breathing and pulse is absent.

How often must refrigerant recovery equipment and leak detectors be calibrated and serviced?

Refrigerant recovery machines must be serviced annually by qualified technicians verifying operation, checking internal components, replacing filters, changing oil, and testing to ensure they achieve required vacuum levels per AS/NZS 1677. Recovery machines must display current service tags showing service date and next due date. Between services, technicians should check recovery machine oil level before each use, replace filter driers when contaminated (indicated by restricted flow or prolonged recovery times), and inspect hoses for damage or degradation. Refrigerant leak detectors must be calibrated using known concentration calibration gas minimum annually and preferably before each use. Test detector response by exposing sensor to calibration gas (typically 100ppm or 1000ppm depending on detector type) verifying alarm activates at correct concentration. Replace detector sensors per manufacturer schedules - typical sensor life is 2-3 years for semiconductor sensors and 5 years for infrared sensors. Multi-gas atmospheric monitors for confined space entry must be calibrated before each day of use using calibration gas mixtures containing known oxygen, combustible gas, and toxic gas concentrations. Bump test monitors before each use exposing to gas and verifying alarm activation. Replace sensors when they fail calibration or fail bump tests. Maintain calibration records for all equipment documenting calibration dates, results, and next due dates. Equipment failing calibration must be removed from service and repaired or replaced before use.

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Refrigerant Gas Safe Work Method Statement

What this SWMS covers

Why this SWMS matters

Hazard identification

Asphyxiation from Refrigerant Accumulation in Confined Spaces

Cold Burns from Liquid Refrigerant Contact

High-Pressure System Failures and Component Rupture

Toxic Decomposition Products from Refrigerant Heating

Flammable Refrigerant Fire and Explosion Risks

Cardiac Sensitisation from High Refrigerant Concentrations

Pressure Equipment Connection Failures and Blowback

Control measures

Atmospheric Testing Before Confined Space Entry

Pressure Relief and System Depressurisation Procedures

Evacuation Procedures Before Brazing or Hot Work

Flammable Refrigerant Leak Detection and Elimination

Refrigerant Recovery and Environmental Compliance

Personal Protective Equipment for Refrigerant Handling

Personal protective equipment

Inspections & checks

Before work starts

During work

After work

Step-by-step work procedure

Pre-Work Planning and Refrigerant Identification

Atmospheric Testing and Ventilation Establishment

Refrigerant Recovery from System

System Evacuation and Dehydration

Refrigerant Charging to System Specifications

Leak Detection and Repair Verification

System Performance Testing and Documentation

Frequently asked questions

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