Don't lick your installation for a leak test
You really don't need to lick your installations for a leak test. Owners and operators of refrigeration systems are not always aware of the regulations regarding the (correct) maintenance of their installations.
What is a leak test ?
By conducting periodic leak tests on refrigeration systems, safety and environmental risks can be reduced. A certified refrigeration technician will check for leaks and, using a leak-tightness test, determine how to prevent leakage losses in the system. The leakage test is often performed together with the legally required maintenance.
Flanders enforces strict regulations regarding the leak-tightness of systems containing F-gases, such as certain refrigeration systems. F-gases are fluorinated greenhouse gases that contribute to global warming. Leak tests are only mandatory for refrigeration systems containing ozone-depleting substances (CFCs, HCFCs - e.g. R22) and for fluorinated greenhouse gases with ≥5 tonnes CO2eq (HFCs - e.g. R134a, R410a, R407a, R404a), and therefore not for all systems.
Maximum permitted leak losses
A refrigeration system is allowed a maximum of 5% relative leak loss per year. The calculation of the leakage loss is documented in an installation logbook. The logbook is updated each time the refrigeration system is refilled.
If the relative leak loss exceeds 10% for two consecutive calendar years, the system must be taken out of service within twelve months of the detection. The findings must be reported in writing to the Environmental Enforcement Division within 14 days.
Systems with excessive leak loss cannot continue to operate. Systems containing ozone-depleting or fluorinated greenhouse gases cannot not be refilled if leakage is present.
Prevention is better than cure
Production downtime is a costly affair for companies. Therefore, it is essential to properly maintain your refrigeration systems. In addition to reducing the chance of downtime, you also increase the lifespan of your equipment. Preventing leaks is crucial for optimizing the performance of process installations .
If no leaks are found, the refrigeration system is inspected by a certified refrigeration technician. Following this, a leak test certificate is issued. The leak test certificate confirms that the systems are safe.
In case of a positive leak test or leak detection, actions must be taken within fourteen days. A certified refrigeration technician will locate and seal the leak. Only after sealing the leak can a technician refill refrigerant. Finally, a follow-up inspection should be scheduled within a month to to confirm that the repair was successful.
How to maintain a refrigeration system yourself
Always have your maintenance performed by a qualified technician. If an error message appears, always consult an expert. Be sure not to press the 'agree to the emergency measure' button to keep the process running, as you may lose your warranty and could cause significant damage to your unit.
However, there are some checks you can do yourself:
- Check daily for unusual sounds and vibrations
- Check daily for leaks or excessive condensation
- Check weekly for loose parts around or in your equipment
- Check unit fastenings and seals monthly
- Monthly check the hinges, locks and screws of all electrical cabinets and enclosures
Is a leak test mandatory?
The legal obligation to perform maintenance depends on the amount of refrigerant in the system. Are you legally obliged to maintain your refrigeration system? If so, this always includes a leak test.
- Less than 3kg of refrigerant: No mandatory maintenance
- More than 3 kg of refrigerant: Annual mandatory maintenance
- More than 30kg of refrigerant: Six-monthly maintenance
- More than 300kg of refrigerant: Three-Monthly mandatory maintenance
In addition to the amount of refrigerant, the monitoring frequency for fluorinated greenhouse gases also depends on the GWP (Global warming potential)value of the refrigerant.
- 5 tonnes CO2-eq or more: 12 monthly inspection
- More than 50 tonnes CO2-eq: 6-month inspection
- More than 500 tonnes of CO2-eq: 3 monthly inspection
It is also mandatory to keep a logbook . This logbook records details such as intervention reports, maintenance activities, installation data, and installer details. You receive it when the refrigeration system is installed and it must always be available during the next inspection, repair, etc.
If you fail to comply with the legal requirements, fines can be substantial, up to € 10.000. Therefore, always ensure that a leak test is performed in good time and repair installations with leaking fluids as soon as possible.