Since chlorofluorocarbons and HCFCs gases were banned in new refrigeration equipment, due to their ozone depleting properties, hydrofluorocarbons (HFC) refrigerants have become more popular as a like-for-like substitute. However, these gases are still not environmentally friendly.

 

A number of issues can lead to gas leaks occurring. Equipment failure, improper maintenance, mechanical damage, or accidental release during refrigerant replenishment can all cause a potentially pricy leak. However, gas leaks are inevitability, with a recent study finding that UK systems have an average annual leak rate of 20%. In a standard refrigeration unit, this refrigerant loss would mean an 11% reduction in efficiency and a direct increase in energy costs.

 

And these figures get even worse if a leak is not spotted and repaired immediately. A typical 300kW refrigeration system with a small but continuous leak, left unrepaired for three months, could incur an energy penalty of 10kW in electricity once the leak becomes critical. This means an increased energy cost of £1400, not including the repair costs, which will be higher than if immediately repaired as more refrigerant will be required.

 

Although not much can be done to stop gas leaks occurring altogether, action can be taken to ensure gas leaks are spotted immediately and ensure they are promptly repaired. The solution is quite simple – the use of a high-tech gas detection system.

 

Gas leak detection

 

A gas detection system can help ensure that leaks are identified and repaired at the earliest opportunity, which is key when you consider that a 15% loss in refrigerant can result in a 100% increase in energy consumption. Preventing leaks not only minimises environmental damage or the impact on the health and safety of the workforce but it is actually a legal requirement, as part of EU F-Gas Regulations. 

 

The legislation states that any system with 300kg or more of refrigerants must be fitted with a leak detection system, with cold stores that have a charge of 3 to 30kg needing to be tested for gas leaks once a year and those with a charge of 30kg or more needing to be tested twice a year. 

 

Fitted gas detectors must have a sensitivity of 5g/year and should be checked after 25 hours of continuous use. They should also be calibrated with a 1000ppm gas to air mix.

 

A gas detection system such as Stonegate’s DL1024 meets all these requirements. It can be programmed to detect a wide range of both toxic and non-toxic gases, including HFCs, accommodating up to 24 remote refrigerant sensors. The sensors are arranged in three zones of eight channels, with four relay outputs for signalling an alarm, one for each zone. 

 

LED colours indicate the presence and status of each sensor and any sensed gas leak sends an audio and visual alarm to alert staff members immediately so that the problem can be quickly rectified. 

 

The typical cost to locate and repair a leak, including replacing any lost refrigerant gases, is £700 for a commercial unit. With the installation of a Stonegate gas detection system a business can ensure they spot and repair gas leaks immediately, to avoid increased energy costs, cut carbon emissions and demonstrate corporate responsibility. With a payback period of less than two years, this technology offers a simple solution for businesses across all sectors.