May 2013ACHPI 35

DANGERS, RISKS and

ACCIDENTS TO AVOID
Anyone working on air conditioning or heat pump
equipment needs to be ever vigilant to prevent simple
accidents which can cause substantial personal harm
or damage. This bulletin draws your attention to a few
of the most common accidents that technicians have
had whilst carrying out their work. These are
highlighted to illustrate the importance of preparing a
thorough risk assessment for each task to be
undertaken, using correct personal protection
equipment and following safe working practices and
procedures.

2. Eye damage

Risk related to working with

refrigerant

Refrigerant burns are easily

prevented by the use of goggles
but some of the additional risks
include:

Electrical short circuit flashes

Arc eye due to welding flashes are a particular

risk in the industrial sector

General eye injuries from dust, grinding dust or

swarf. Even just wiping an eye with dirty hands
can cause problems.

Note that contact lenses can pose an

additional risk.

1. Cold Burns

3. Refrigerant inhalation

Liquid refrigerant released from

high pressure to atmosphere will
flash and boil to vapour. The
temperature of the refrigerant will
drop quickly to the boiling point (e.g. -46OC for
R404A) and the refrigerant will absorb heat from
whatever it is touching - if the refrigerant touches your
skin it will cause a cold burn or even frostbite.
Frostbite is particularly dangerous as it damages skin
by freezing water inside the skin cells, which can
expand and burst the cell walls. When carrying out
activities where there is a risk of coming into contact
with refrigerant (charging, recovery etc) it is essential
to wear safety goggles, gloves and protection for your
lower arms, as refrigerant released at high pressure
can extend beyond the glove wrist.

If you inhale refrigerant vapour in sufficient quantities

you could be asphyxiated and/or suffer from cardiac
sensitisation and/or have an effect on your central
nervous system. These hazards can make you feel
dizzy, lethargic or high, or you could have an irregular
heartbeat. They can be fatal. There are cases where
people entering a plant room following a significant
refrigerant loss were killed due to lack of oxygen.
(See SES Service Matters 25 Working in Machinery
Rooms)

Dont try to bring the skin back to temperature

too quickly you should run the cold burn
under cool water at first, very gradually
increasing the temperature (37 to 40C max).
Do not rub the skin or try to warm it.
Removing refrigerant saturated clothing may
damage skin further.
A cold burn may require hospital treatment.
Remember that the refrigerant released may be
mixed with oil and could be acidic as well.

All refrigerants are asphyxiants because they

displace air. This is a hazard if a large amount is
released particularly in an enclosed area, but a small
amount leaking into the base of a well type display
case is also a serious hazard. Technicians should be
very mindful of the disorienting impact of reduced
oxygen and if necessary consider the use of
breathing apparatus if a large leak is suspected.
4. Hydrofluoric acid burn
Hydrofluoric acid is formed as a result of
decomposition of HFC refrigerants at high
temperature. This can occur, for example, during a
compressor motor burn out or while brazing. Take
care when accessing systems where there has been

May 2013 - ACHPI 35

Common accidents cont..

a burn out (wear gloves), and do not braze if there is
refrigerant in the air or still in the system.
Hydrofluoric acid is toxic and highly corrosive, it will
burn skin and eyes and cause respiratory damage.
You may not feel any pain when it first comes into
contact with your skin. Exposure requires hospital
treatment.

Risks related to hot work

5. Oxy/Fuel torch use

page 2
What other risks might you be exposed to?
This Guide only highlights a small number of risks that
refrigeration technicians may need to consider. Dont
forget you also need to take steps to prevent injuries
that can occur to yourself or others in any building site
or work-related activity such as slips, trips, falls,
working at height (particularly on top of cabinets or on
cold store roofs), working near asbestos, electrical
burns, using ladders and step ladders and back
injuries due to incorrect manual handling procedures.

Hot work involved in pipework or

component jointing poses a
significant risk both to the individual
and those around them and a site specific risk
assessment must be carried out before starting the
work. Burns from lit flames are preventable by using
gloves, eye protection, fire retardant protective
clothing and suitable footwear.

Just some of the activities to consider include:

Make sure the torch is never placed loosely on a

bench where it could fall off, especially when lit.
When using a torch don't become distracted and turn
around or lift it away from the area of work without
consideration to the flame direction.
Remember pipe work and components will remain hot
enough to burn you for a significant time after brazing.
Make sure cylinders are secured adequately and you
know how to correctly move or transport them.

ALWAYS carry out a risk assessment for all the

activities to be undertaken, plan the work and ensure
you follow the task procedures.

Manual handling
Working at height
Electrical isolation
Cylinder transportation / storage
Working in confined spaces such as coldrooms
Slips and trips.

Operatives should complete an industry specified

brazing test in accordance with legal obligations under
the PSSR

Pressure Relieve Valves

6. Damage to hearing
The failure of Pressure Relief
Valves or the sound of high
pressure refrigerants such as
carbon dioxide exiting a system can lead to noises
that are loud enough to cause significant damage to
your hearing. Use of ear defenders is always
recommended in plant rooms.

Published by the Air Conditioning and Heat Pump Institute, a section of the Institute of Refrigeration.
First published by the Service Engineers Section of the IOR
The Institute of Refrigeration accepts no liability for errors and omissions.
IOR 2013 www.ior.org.uk/achpi