7

Handling and
Safety issues of
HC refrigerants
Training Material Reference

Handling and Safety issues of HC refrigerants - 2012.ppt

Target Group

Trainers and Technicians

Duration of the Session

30 minutes

Purpose of the Session

To make the participants aware of critical characteristics of hydrocarbons, hydrocarbon

issues, precautions to be taken while handling and storing the cylinders. Also make them

aware for general safety.

Terminal Performance Objectives

At the end of the session, the participants should know:

(a) Important characteristics of HCs.

(b) Flammability aspects of HCs like flammability limits, practical limits and classification.

(c) General safety issues.

(d) Precautions to be taken while handling cylinders and storage.

Key Message being delivered through this Session

Hydrocarbons are fast emerging as appropriate substitutes to HCFCs in the RAC sector. As

a result, their share in this sector is likely to increase. Their usage in a variety of applications

will entail servicing and repair of these appliances by service sector technicians. Therefore,

it is essential for these technicians to be fully aware of the characteristics, flammability limits,

safety issues and other precautionary measures while handling these refrigerants. Knowledge

of these aspects of hydrocarbons is of paramount importance for those who directly deal with

such refrigerants.

Tools & Equipments (if any) required for the session

None.
7 Handling of Hydro Carbons (HC) Refrigerants
Handling and Safety issues of HC refrigerants

The trainer should emphasize on the issue of flammability of HC refrigerants while

handling it. Technicians must know what are the pros and cons of HC refrigerants.

Safe HC Handling - Flammability

There are three essential requirements for the ignition of combustion of substance.
These are fuel, oxygen and ignition source. All the three factors are inter-related.
Flammability is an issue only in the simultaneous presence of all these factors in
adequate proportion.

An example of torch ignition for brazing can be shared that why it is not igniting even
the spark from igniter is there. The composition of fuel and oxygen is not adequate for
combustion and so there is no flame.
Flammability Limits of HCs

This slide highlights the flammability limits of HCs. HCs are flammable when mixed with air
and ignited. Ignition of a flammable fluid is more easily accomplished, and combustion is
more rapid in pure oxygen or in oxygen enriched air.

A The lowest concentration / percentage of a fluid vapour capable of producing flash of fire
in the presence of ignition source like flame or arc is the Lower Explosive Limit or Lower
Flammability Limit (LFL) of the fluid. As a concentration in are lower than LFL are too lean
to burn. Conversely, the highest concentration(percentage)of the fuel vapours capable of
producing flash of fire in the presence of ignition source is the Upper Explosive Limit or Upper
Flammability Limit (UFL). As a concentration in are lower than LFL are too rich to burn.

The intermediate range is the flammable range; within these limits any mixture of fluid and air
can burn. A vapour or gas with relatively wide limits of flammability is more hazardous; the
flammability ranges are 2.2 to 9.5% for propane, 1.9 to 8.5% for butane, 2.0% (in air), Upper
flammability limit 11.1% for Propylene, for 2.5 to 81% for acetylene, 16 to 25% for ammonia
and 1.5 to 7.8% for pentane. Therefore, acetylene is the most dangerous of these gases.

Generally, the LFL for HCs can be taken as about 2% and the UFL as about 10% in air.
7 Practical Limits for Safe HC handling*
Handling and Safety issues of HC refrigerants

The allowable charge sizes are typically based on the assumption that under the
worse case, the entire refrigerant charge from a circuit will leak into a space almost
instantaneously, and since the vapour is denser than air, it will partially stratify – thus
the allowable charge normally accounts for this by adopting a 20% safety margin. (In
certain cases, this safety margin is extended to factors approaching less than 5%.) On
the other hand, the values for maximum charge size have been chosen on a broadly
arbitrary basis, having little or no technical basis, although it can be seen that there is a
general correspondence between lower charge sizes and the number and vulnerability
of the occupants. In the case of systems located below ground level, a common value is
applied throughout on the basis that it is difficult for a denser-than-air vapour to disperse
upwards.

In general, HC refrigerants should be used only in sealed systems with restricted charge
or otherwise in occupancy categories where only competent members of staff are
present. In any case, the refrigerant charge in a system with any refrigerant-containing
part situated below ground level is restricted to no more than 1.0 kg. Sealed systems
with refrigerant charge of 4 × LFL (for example, 4 × 0.038 = 0.15 kg for R290) or less
may be sited in any location or category of occupancy provided there are no sources of
ignition associated with the refrigerating system

* More info available in “Guidelines for the safe use of hydrocarbon refrigerants” by GIZ
Proklima
Practical Limits for Safe HC handling

For HCs, LFL corresponds to approximately 35 g of HCs per m3 of air. For safety reasons,
a practical limit of 8g of HCs per m3 of air should not be exceeded in a closed space. This
means that there is no problem, if the charge used is within this practical limit. If the amount of
HC goes beyond this limit, precautions have to be taken to monitor sealed space and ignition
sources, or appropriate safer designs have to be incorporated.

For example current charge size from the data plate > 0.68 kg of R22.
The charge size is generally indicated with the data plate. If there is no information available at
the outdoor unit (e.g. weather-beaten) check if there is information available at the indoor-unit.
Finally, the charge amount can also be estimated from the amount of recovered (old) HCFC
refrigerant charge amount (assuming there was no leak prevailing). Estimate equivalent HC
charge -> Conversion to R290, R22 charge is 0.68 kg and equivalent HC charge is 0.28 kg
of HC R290

Maximum charge amount for existing room size; Check charge size limits> Charge size is
below maximum limit of 1.5 kg (0.28 kg < 1.5 kg); -> Room size is 6 m × 5 m = 30 m2, so
below allowable charge (0.28 kg < 0.48 kg).
7 Refrigerant Safety Group
Handling and Safety issues of HC refrigerants

On the bases of toxicity and flammability refrigerants are classified into different safety
groups.. The classification scheme is adopted by such standards as ISO 817 and EN
378. the overview is given in the slide.

The toxicity classification is based on toxicityof refrigerant at concentrations of less

than400 ppm by volume. Based on data we determine the threshold limit value – time
weighted average (TLV-TWA) or consistent indices. There are two toxicity classes:

• Class A refrigerants are those where no toxicity has been observed below 400 ppm

• Class B refrigerants are those where toxicity has been observed below 400 ppm

The flammability classification depends upon whether or not the substances can be
ignited in standardized tests, and if so, what the lower flammability limit (LFL) and
the heat produce during combustion. There are three flammability classes (Currently
introduction of new “lower” lower flammability class (“Class 2L”) into certain safety
standards, which are intended to advantage certain flammable HFC refrigerants).

• Class 1 refrigerants are those that do not show flame propagation when tested in air
at 60°C and standard atmospheric pressure.

• Class 2 refrigerants are those that exhibit flame propagation when tested at 60°C and
atmospheric pressure, but have a LFL higher than 3.5% by volume, and have a heat of
combustion of less than 19,000 kJ/kg.
• Class 3 refrigerants are also those that exhibit flame propagation when tested at 60°C and
atmospheric pressure, but have an LFL at or less than 3.5% by volume, or have a heat of
combustion that is equal to or greater than 19,000 kJ/kg.

Since the common HC refrigerants (R290, R600a, R1270) have a TLV-TWA of 1,000 ppm
or higher (depending upon the source of the information), they have a Class A toxicity
classification. However, these refrigerants do exhibit flame propagation under standard
atmospheric conditions, and the LFL is typically around 2% with the heat of combustion
around 50,000 kJ/kg. Thus the flammability classification is Class 3. Overall, this renders
them with an A3 safety classification according to the relevant standards.

By comparison, most common CFC, HCFC and HFC refrigerants, as well as R744 (carbon
dioxide) have an A1 classification, although some HFCs have an A2 classification. A few
HCFCs and HFCs have a B1 classification, whilst R717 (ammonia) has a B2 classification.
There are no B3 refrigerants (although this may be possible with certain mixtures).

Typically, a “higher” classification – that is toxicity Class B instead of Class A, and flammability
Class 3 instead of Class 1 – means that the refrigerating system has more onerous design
requirements associated with it, in order to handle the higher risk presented by the refrigerant.
7 Ignition sources
Handling and Safety issues of HC refrigerants

This slide illustrates different possible sources of ignition while servicing the system.
These include flames due to brazing torches, match or cigarette lighter or sparks from
unsealed electrical components such as relays, OLPs or loose wires on capacitors or
otherwise and even static electricity.

The basic safety rule is that in order to have an explosion, there should be a combustible
mixture of gas and air (Oxygen) within the flammable limits, and simultaneously, there
should be an ignition source with sufficient intensity for combustion of mixture.

The first step is to avoid the possibility of any leak. Even if there is a leak, make sure
that a combustible mixture is not formed. In addition to this, the working area should be
well ventilated and maintained in such a way that the sources of ignition are eliminated.
Simple precautions

Taking into consideration the safety issues, the following simple precautions must be
implemented.

a) Smoking while working will have dangerous consequences and should be strictly
prohibited in the work area.

b) Do not work within 2 meters of any ignition source.

c) Any kind of repair / servicing work must be carried out in a well-ventilated area so as
to prevent accumulation of refrigerant, if leaked out.

d) Always wear protective gadgets like goggles and gloves and clothing that covers, as a
precautionary measure.

e) Keep minimum amount of HCs in the work / storage area so that there is no possibility
of HC accumulation.

f) Use dry powder fire extinguishers only.

g) A suitable ventilation fan should be used when working inside if there is insufficient
natural ventilation. An example is shown in the photo which has an ex rated fan motor and a
5 m extension lead so the fan can be switched outside the 2 m work area.
7 Cylinder Handling and Storage
Handling and Safety issues of HC refrigerants

This slide explains proper way to handle and store the HC refrigerants. HC refrigerants
should be handled and stored in the same way as LPG or any other flammable gases.
Cylinders should be stored in dry and ventilated areas away from fire. Any build-up of
static electricity should be avoided. It is ideal to store the cylinders outside in a secure
and locked compound, protected from weather and direct sun light. The cylinders should
be kept upright with valves closed and capped. There should be no ignition sources in
the proximity of the storage area.

Cylinders can also be kept inside provided all safety measures are implemented.
However, they should not be stored residential premises. In refrigeration workshops store
minimum possible hydrocarbon cylinder (or 14 kg of hydrocarbons) inside. A flammable
gas alarm should be fitted in the bulk storage area. Cylinders should preferably be
stored on the ground floor and never store it in basements. If you stored in a basement,
any leakage of HCs will accumulate there and will not be easily dispersed. This can
eventually lead to an explosion, if there is any spark in the room. HC cylinders should
not be stored with other flammable substances, particularly flammable gases. Storage
of empty cylinders should be segregated from that of the filled-up cylinders.

If it is necessary to warm the cylinder, use only water or air (with temperature not
exceeding 40°C). No naked flames or radiant heaters should be used.
Safety Precautions – Cylinder Safety

Always transport and store the cylinders in upright and secured position, in no more than four
rows deep, for easy access of the valve in case of any leak. The storage yard and vehicle
should have adequate ventilation to avoid the build up of flammable mixture in case of any
leak. Never leave the cylinders in a closed van unattended or for longer than necessary.
Never allow smoking or naked flames near the vehicle.

Code of Practice for Liquefied Petroleum Gas Cylinder Installation must be taken care of with
respect to the country law.

[In general, guidelines for HCFC cylinders and hydrocarbon cylinders do not vary much. Most
of the regulations applicable to local LPG (cooking gas) are also applicable to hydrocarbons.
Always weigh the cylinder to check if it is empty - its pressure is not an accurate indication of
the amount of refrigerant remaining in the cylinder.

During the transport of cylinders charged with hydrocarbon refrigerants, it is recommended

to carry two dry chemical powder (sodium bicarbonate) fire extinguishers of at least 1 kg
capacity each, one in the drivers cabin and the other in the load compartment. The driver and
the helper should be trained in the practical use of the fire extinguisher. The cylinders may be
gently off-loaded on a thick and heavy rubber mat, taking care that the cylinders do not bump
against each other.

If a cylinder is burning, water can be used to cool the other cylinders and the area around. If
the valve is not closed, the burning cylinder should be rolled on its foot ring, keeping it upright,
to a safe and open area and letting the gas burn off.

Cylinders should always be labelled and should also indicate the amount of gas inside.
Never puncture the cylinder with some sharp edge tool as it can cause spark and risk of fire
can be there. Better to remove 100% refrigerant out of the cylinder and then remove the valve
and after crushing the same put the same to scrap.
7 Safety check of working area
Handling and Safety issues of HC refrigerants

When technician is working with Hydrocarbons he must avoid the confined space as
earlier discussed. He must work in well ventilated area. The area where he is using HC
must be cordoned off by two meters to avoid any untoward incident. Always put one HC
refrigerant leak detector in the work area; in case of any leakage it can give the warning
signal.

Safety Precaution – Eye Protection

As we all know that refrigerant operate at extreme pressure and temperature changes,
high speed discharges may occur and can cause eye irritation and even frostbite and
direct contact to skin with liquefied product or cold vapor may cause freeze burns and
frostbite. This must be avoided during safe practices to handle refrigerants. HCs are
non-toxic by inhalation but high concentrations may cause central nervous system
depression such as dizziness, drowsiness, headache, and similar narcotic symptoms,
but no long-term effects. So do not inhale HCs. Always try to wear PPEs like hand
gloves, goggles and nose mask.
Evaluation Questions
1. What are the main safety issues for handling HCs?

2. Which are the three important factors associated with flammability?

3. What is the flammability limit of HCs? What is the significance of this limit?

4. What are the possible ignition sources for HCs?

5. Can a switch be regarded as an ignition source?

6. How should HC cylinders be stored?