
A fixed leak detection system offers plenty of benefits to both businesses and the environment. In the first instance, a system will provide real-time monitoring of the refrigeration plant, ensure early notification, and indicate the location of any possible leak. Having this early warning system will help to prevent any bigger, more costly and more damaging issues and incidents from happening. It will also reduce any refrigerant loss.
From a safety aspect, a functioning leak detection system will enhance the workplace and ensure that when a leak occurs, an alarm will alert any personnel within a specified space to evacuate and leave the area. This could potentially be a serious issue when gases such as ammonia are involved. It will reduce the risk of exposure to any harmful gas concentrations.
Certain aspects of leak detection are covered under EN-378, which is the European standard that focuses on the safety and environmental requirements for refrigerating systems and heat pumps. A DSEAR (Dangerous Substances and Explosive Atmosphere Regulations 2002) inspection will aid in compliance with explosive atmospheres. DSEAR was brought into force to require employers to review all potential risks to people (employees and others) whose safety may be at risk of fires and explosions caused by dangerous substances in the workplace. These include:
- HAC Study (Hazardous Area Classification)
- Testing for the explosivity/flammability of potentially dangerous substances or chemicals
- Identification of dangerous substances that may apply under DSEAR
Areas that contain hazardous substances such as ammonia or other refrigerants must have control measures in place to eliminate risks from dangerous substances or reduce them as far as is reasonably practicable. Where it is not possible to eliminate the risk completely, employers must take measures to control risks and reduce the severity (mitigate) of any harmful event. This will include the installation and management of a fixed leak detection system.
Components of a fixed leak detection system:
- Gas sensors: The sensors are specifically designed to detect a wide range of gases and refrigerants. They are capable of identifying various types of refrigerants that they have been calibrated to monitor while discounting others that may also be in the atmosphere (such as carbon monoxide from exhaust fumes).
- Control panel: The central unit that receives signals from the gas sensors. This panel displays the PPM levels of each sensor, provides alerts and alarms at preset levels, and provides details on the status of the system.
- Relays: These relays can be used to start or increase fan speeds, shut down the plant and various other applications that the plant might operate.
- Data Logging: Sensors can be monitored over a period of time via data logging, which can provide information on what, and when the sensor is detecting a leak. This can be beneficial to see if the leak occurs at certain times that may also coincide with another operation that the plant is going through at the same time.
- Remote monitoring: The control panel can be linked to a BMS system which will allow central monitoring and help to ensure early detection and reaction to a leak.
Steps for Implementation:
- Site Survey: Conduct a survey by a competent person with leak detection experience to evaluate the area where the refrigeration system is to be located and determine the optimal placement of sensors to ensure full coverage of the plant and any possible areas of a suspected leak.
- Installation: Once the correct equipment to suit the site and type of refrigerant to be detected has been selected, then the leak detection system can be installed ensuring the sensors are placed in strategic positions – near to equipment, confined spaces, and at ventilation points. Make sure they are mounted in accordance with the manufacturer’s recommendations.
- Calibration: Regularly calibrate the sensors to ensure accurate readings and that the sensors are operating at their full capacity.
- Integration: If applicable, integrate the control panel with the BMS system for centralized monitoring.
- Regular servicing: Schedule periodic checks to ensure the sensors are functioning correctly and that any sensors not reaching their required limit are replaced.
- Training: Ensure the correct personnel receive adequate training in interpreting data on the control panel and appropriately responding to alarms.
Fixed leak detection systems provide the following benefits:
- Early detection: Prevents larger issues and reduces refrigerant loss.
- Safety: Continuous monitoring for leaks will enhance safety in the workplace. It can alert personnel to potentially harmful gas concentrations and reduce the risk of exposure.
- Environmental Protection: Refrigerants are harmful to the environment, particularly to ozone depletion and global warming. A fixed leak detection system will help minimize this by early warning of any possible leaks.
- Cost saving: By detecting any leaks at an early stage and addressing the leak promptly, it will cut down on the amount of refrigerant lost and also prevent the system from operating at reduced capacity.
- Regulatory Compliance: A requirement in most cases for ammonia systems, which can also be a requirement depending on the size and amount of refrigerant.
- Reduced downtime: Early identification of a leak will ensure the system can be repaired and back to full capacity as soon as possible, cutting down on the time that the plant is out of action.
- Integration with Building Management Systems: TQ leak detection control panels can be fully integrated with a business's BMS, which helps with centralizing the control and monitoring, thus enhancing plant efficiency.
Overall, a fixed leak detection system is a proactive investment that enhances the safety and efficiency of the plant.