Si-19_B

Safety Tips for

Service Engineers

Lets go
with zero
disasters.
Sure!
Sa

fe

DAIKIN INDUSTRIES, LTD. After Sales Service Division

DAIKIN FACILITIES Co, Ltd.

June 2012
Safety Tips for Service Engineers
Due to the nature of after sales service, most
servicing work is performed on customers
premises. Therefore, it is necessary for every
service engineer to be especially mindful
of safety since an accident could not only
cause bodily harm to the concerned service
engineer, but it could also cause personal or
property damage to the customers and spoil
the companys reputation.
Furthermore, servicing on-site often means
working under a variety of adverse conditions
and requires even more attention to health
and safety than the familiar conditions at the
company.
This booklet summarizes case examples of
internal and external accidents that occurred
during service work, to which all service
engineer should pay their utmost attention.
For these reasons, we ask that you diligently
observe the principles stated in this booklet
in performance of your various duties and
pay extra special attention to health and
safety to ensure good health and spirits in the
performance of your daily work.
 Table of Contents
Be Sure to Dress Decently to Make Customers
Feel Comfortable E-2
Daily Preparations E-3
Six Fundamentals of Service E-4
Safety Kit for Service Engineers E-5

Safety Tips for a Variety of Jobs

Safety Tips for Job Site
1. Elevated Job Site E-6
How to Use Safety Apparatus E-7
Slate Roofs E-8
Ceilings E-9
Ladders E-11
Stepladders E-12
2. Working in Basement or Closed Rooms E-13
3. Work in Chemical Plants E-14
4. Work in Marine Vessels E-15
Safety Tips Classified by Work Type
5. Replacement of Parts E-16
6. Driving Safety E-18
7. Transportation of Hazardous Substances
(e.g. High-pressure Gas) E-20
8. Transportation of Heavy Items E-22
9. Electrical Servicing E-24
10. Welding (Gas Welding/Arc Welding) E-26
11. Other Work E-28
Safety Tips for Products E-30

Past Disasters E-32

My Declaration of Safety E-36

E-1
Be
Be Sure
Sure toto Dress
Dress Decently
Decently toto Make
Make Customers
Customers Feel
Feel Comfortable
Comfortable
[Identify yourself first so that
customers will feel at ease]
Wear a uniform designated by Daikin.
Put your name tag.
Introduce yourself clearly.

[Be sure to keep

your personal appearance clean]
Look over your whole body in the mirror every morning
before going out.

* Think of the feelings of the customers accepting

unfamiliar people into their homes.

Your good first impression (with decent clothes

and an amiable attitude) will eliminate most of the
customers anxieties.
Never wear earrings or
Keep your hair necklace at work. Never be
clean. No long hair lazy to shave.
or loudly dyed hair is
acceptable. Wear a
cap and give a clean Always wear
impression. your name tag to
identify yourself.

Wear a Daikin
Look at the uniform to identify
customers eyes yourself. Securely
and talk. fasten the buttons
to give a clean
impression.
Talk with a smile.
Give a clear explanation Keep your
with a brisk attitude. nails short and
Be sure to dress clean hands clean.
and refreshing.
Do not wear shoes with the
heels folded over. Always wear
clean socks.

E-2
 Daily Preparations

First of all, give first priority to safety.

Get ready for your work without forgetting
anything.
Make an early start and keep your promises with
customers.
Behave responsibly as a representative of the
company.
Speak clearly and politely.
Act with precision and moderation.
Keep your hair short and combed.
Keep your appearance neat and clean.
Try to upgrade your skills.
Operate with extra caution and complete the
operation on your first attempt.
Explain the situation fully and courteously.
Listen attentively to customers opinions.
Take responsibility for your work.
Complete the days work on the same day.
Clean the workplace completely.
Never forget to bid farewell to the customers
upon completion of work.
Drive safely and observe all traffic regulations.
Make proposals for improvement.
Be thankful for accident-free days.
Continue doing your best in your next days
work.

E-3
 Six Fundamentals of Service

1) Tidying up Discard unnecessary items.

(Seiri)

2) Organization Arrange essential items for

(Seiton) quick removal.

3) Cleaning Do not leave trash or stains.

(Seiso)

4) Cleanliness Keep the workplace clean.

(Seiketsu)

5) Discipline Make rules in consultation

(Sitsuke) with all staff members and
observe them together.

6) Morale All staff members should

(Shiki) have the can-do spirit.

E-4
 Safety Kit for Service Engineers

[Always carry the following safety kit in your

service car]
Safety apparatus Number required
Warning sign stating
HIGH PRESSURE Two per service car
GAS
Prevention tools for
high-pressure gas One set per service car
disaster prevention
Fire extinguisher One per service car
Helmet One per person
Safety belt One per person
Two large ones per service
car
Running board
One small one per service
car
Triangle reflector One per service car
Dust mask One per service car

[Keep the following safety apparatus in your

service car as necessary]
Alarm detecting lack of oxygen
Ventilation apparatus

E-5
 Safety
Safety Tips
Tips for
for aa Variety
Variety of
of Jobs
Jobs
Safety Tips for Job Site
1. Elevated Job Site
Remember that accidents caused by electric shocks
or falls from elevated places tend to be fatal when they
happen.
Definition of elevated places:
Footholds, rooftops with no fences, roofs, eaves, gypsum board
ceilings, and high interior ceilings as wide as or wider than 2 m
posing a risk of falling.

Do not fall or drop anything

Put tools into a tool bag and tie the
bag to a rope in order to prevent the
tool from dropping. Danger

Keep from slipping or

tripping
Roofs and stairs are slippery.
Remember that you may easily break
slate roofs and gypsum boards when
you step on them. (It is recommended
to use running boards.)

Use a safety belt

When conducting any elevated work, be
sure to use a safety belt and a life rope.

Wear a hard helmet

When conducting any elevated work, be
sure to wear a hard helmet. Furthermore,
when working in a plant, in a machine
room, on a construction site, on the rooftop
of a building, or other job site, it goes
without saying that you should wear a hard
helmet.

E-6
How to Use Safety Apparatus
[Safety Belt]
1) Be sure to wear a safety belt in the order engraved
on the buckle and tighten the safety belt above the
top of your hipbone.
2) Connect the hook straight downward to an object at
a position higher than your waist. The object must be
strong enough to withstand impact to prevent your
fall.

<Belt tightening position> <Correct hooking>

* Adjust the D-ring so that Back D-ring applicable

D-ring will not come to range
the front of either side of
your body.
D-ring

Buckle
Front

[Running Board]
1) Put running boards onto roof slates, gypsum boards,
or other materials that may be easily broken when
you step on them. However, do not put running
boards onto system ceilings.
2) Stabilize the running boards hooked onto bolts or
similar parts on the supporting materials.

E-7
Slate Roofs
[Basics for Slate Roofs]
1) There are no foundations under slate roofs.
Therefore, slate roofs are not sturdy enough to
withstand your weight. Slate roofs are secured with
supports at several points only.
2) Slates are easily broken. Keep in mind that
corrugated slate boards are as fragile as corrugated
PVC.
3) Always put running boards onto slates. Do not stand
directly on slates. Secure the running boards with the
frames under the hooks.

[Structure of Slate Roofs]

Hook bolt
Running board (900L)

Pitch (usually 835)

in the up-and-down
directions

Corrugated slate board

This part is sturdy
(under the hook). E.g., H-shaped
steel
Main building
Support

The slate roof supports are placed in parallel to the

building, where sufficient strength is maintained.
The slates in the up-and-down directions cannot maintain
sufficient strength, where you cannot stand directly.
Put running boards onto the supports and walk on the
running boards in the upward direction.

E-8
Ceilings
[Basics for Ceiling Structures]
1) There are varieties of ceiling materials. Not all of
them are sturdy enough to withstand your weight,
which must be kept in mind.
2) Ceilings are of wooden structure, lightweight
steel-based structure, or system ceiling structure.
System ceilings are not sturdy enough to withstand
your weight. Never work on top of the system
ceilings, where no running boards will work. Remove
the ceiling materials on the bottom of system ceilings
instead and work.

[Ceiling Differences]
Ceiling of lightweight
System ceiling
steel-based structure
Ceiling materials range
from seamless materials Each ceiling material
to those in a pitch of 300 x is large and has a
300 mm. seam.
Bottom Many ceiling materials are No ceiling materials
view staggered in a pitch of 300 are staggered.
x 600 mm. Lighting fixtures
Lighting fixtures and fire and fire alarms are
alarms are designed modularized.
independently.
A ceiling joist always exists No ceiling joists are
in a pitch of 300 mm. used.
A ceiling joist receiver Ceiling joist
Top (C-channel) always exists receivers
view in a pitch of 900 mm. (C-channel) are in
Ceiling materials are rough pitches.
secured with tapping Ceiling materials are
screws to ceiling joists. just placed.

E-9
Ceiling of Lightweight Steel-based Structure
S-bar: 19 25 0.4 t W-bar: 19 50 0.4 t
Channel: 38 12 1.2 t (Used for the joints of ceiling materials)

Decorated gypsum boards placed

W-bar ceiling joist pitch.... 227 alternately

S-bar ceiling joist pitch .... 227 alternately
Board dimensions............ 455 x 910
455
227 Hanger
Ceiling joint receiver S-bar W-bar
(channel)
0
90

Decorated gypsum board

455 x 910

No loads are allowed on them.

(S-bars, W-bars, or ceiling joists) Always put a board
between channels.

Do not stand on the channel, otherwise

the load will bend and deform the channel.

System ceiling

Steel bar
Channel bracket

Channel cross
High-rocky shiplap
bracket
Spline bar

500
max.

1200
max.

1200
max.

Installation plate 1200

max.

Steel T-bar
T-bard
(equivalent to
Lighting fixture
ceiling joint)

Channel hanger

C-channel

E-10
Ladders
[Precautions for Using Ladders]
Use a ladder provided with anti-slip legs.
Apply a bottom board to the legs if the ground is soft.
Make sure that the angle of the ladder to floor does
not exceed 75 and that the height of the ladder over
roof is at least 60 cm.
Bind and secure the upper part of the ladder if the
ladder is slippery.
Do not climb up or down the ladder with your back
faced to the ladder.
Do not work with your body leaned out. Move the
ladder instead.
Be sure to work with another engineer if you use
a ladder with two or more stages. Do not climb the
ladder with tools in your hands. Sling up the tools or
have the partner deliver the tools by hand.
Make sure that both your hands are free when you
climb up or down the ladder.

Fixed Ladders
If you use a fixed ladder, check the appearance of
the ladder in advance. If excessive deterioration or
corrosion is found on the surface, stop the work and
report the condition of the ladder to the customer.
Do not use the fixed ladder until the condition is
improved and your safety is confirmed.

E-11
Stepladders
[Precautions for Using Stepladders]
Prepare and use a stepladder of an appropriate
height.
Make sure that the stepladder is provided with anti-
slip legs.
Apply a bottom board to the legs if the ground is soft.
Always lock the opening stopper of the stepladder.
Do not stand on the top plate to work. Do not roll
back your body on the stepladder.
Do not work with your body leaned out. Move the
stepladder instead.
Do not use the stepladder in place of a ladder.
Make sure that both your hands are free when you
climb up or down the stepladder.
If you work in front of a door, put a warning tag on
the door so that nobody will open the door without
notice. Lock the door as well if possible.

<Tips on Using Stepladders>

Point [1] How to select a stepladder (Height) Point [2] Where to stand on
the stepladder.
Stepladder height (hm) = Support the stepladder with
Air conditioner height (Hm) three points.
(Your height (m) x 0.5)
Do not
Example: 2.5 m (1.6 x 0.5)
stand on the
= 1.7 m
Air conditioner top plate.
Therefore, use the sixth rung
Do not
of the stepladder.
stand on the
top rung,
Hm either.
hm
Use rungs excluding the
top two rungs.

E-12
2. Working in Basement or Closed Rooms
Remember that refrigerant leakage in closed rooms may
cause a fatal accident resulting from oxygen deficiency.

[Precautions]
Carry audible alarms for detecting lack of oxygen.
Conduct work in basements in teams of two people.
Locate emergency exits prior to working in
basements.
Make sure that you know where to report in the event
of an emergency.
Check to be sure the ventilating equipment (exhaust)
is operational.
Put the tools in order so that you can pick up
whenever you need promptly.
Keep a flashlight in your pocket (used for evacuation
in case of power failure).

E-13
3. Work in Chemical Plants
Work in chemical plants may risk ignition, explosion, fire,
or other serious disasters, depending on materials that
chemical plants handle.
Observe customer rules and be sure to have preliminary
meetings with the customers representative prior to
work.
Request the local representative to accompany you and
receive instructions from this representative on the job
site.

Do not use open flames NO

SMOKING
Do not use open flames in any places
other than those designated.

Do not use gas leak detectors

(halide type or electric type)
Use soapy water or similar media.

Do not make sparks

Conduct performance tests on
switches and other items without
removing the explosion proof
enclosures. Be sure to turn off the
power supply before making any
adjustments.
Pay extra attention not to make
sparks by hitting metal with tools.

Car traffic
Park the service car in places
specified by the customer.
You may need to attach a flame
protection device to the exhaust
pipe of the service car in the High-pressure gas

specified traffic area. STOP

E-14
4. Work in Marine Vessels
When conducting marine vessel-related work, always
complete customs procedures for embarkation and
disembarkation.

Never jump onto or off the vessel

For transferring from a boat to the vessel, board the vessel after the
boat has been secured to the vessel. Watch your step, especially
when the water is choppy.
The gangway is slippery. Pay utmost attention when carrying tools.
Be sure to follow instructions of authorized personnel before
transporting heavy items.
For inboard work, be sure to carry a flashlight in your pocket. If a
power failure occurs, you will be able to watch your step.

Fire prevention on vessels

When using open flames, keep a fire extinguisher handy.
Do not use welding equipment or smoke in any places other than
those designated.
After using open flames, confirm with the chief engineer that
cleaning is finished and there is no danger of fire.
Operate the unit in the presence of the chief engineer.

E-15
 Safety Tips Classified by Work Type
5. Replacement of Parts
Before disassembling the product, be sure to shut off all
power supplies and check with a multimeter that there is
no electricity after the product comes to a perfect stop.

Replacement of V-belt

Wear protective gear

Wear gloves in the case of V-belt
replacement and be careful not to put
your fingers under the belt.

Precautions for belt installation

Loosen the belt adjustment nut on the
motor before attaching the belt.
* Do not attach the belt forcibly.

E-16
Replacement of Refrigerant System Parts

Wear leather gloves

Wear leather gloves to prevent
frostbite before handling refrigerant.
Do not use cotton work gloves.

Refrigerant recovery
Be sure to continue working after checking that the gas in the
refrigerant system has been recovered into recovery equipment to
a specified level.
Recovery standard
Pressure classification of chlorofluorocarbon
pressure (MPa)
Pressure at normal temperature Absolute pressure: 0.03
Less than 0.3 MPa (Gauge pressure: -0.07)
Absolute pressure: 0.1
Pressure at normal Charging quantity2 kg
(Gauge pressure: 0.0)
temperature
0.3 to less than 2.0 MPa Absolute pressure: 0.09
Charging quantity2 kg
(Gauge pressure: -0.01)
Pressure at normal temperature Absolute pressure: 0.1
2.0 MPa or over (Gauge pressure: 0.0)

Precautions for welding

Use a copper tube cutter and cut the piping
to separate the refrigerant circuit before
welding, otherwise the refrigerant oil in the
piping may catch fire.

In case of refrigerant leakage

Evacuate to a safe place promptly, report the accident to the
customer at the same time, and follow the customers instructions if
oxygen deficiency is feared in underground or sealed rooms.
If possible, stop the operation of the facilities and take measures to
prevent the refrigerant leakage as much as possible.

E-17
 Safety Tips Classified by Work Type
6. Driving Safety
Observe the road traffic laws to ensure safe driving.

Safe driving

Be sure to conduct daily start-up inspections

Prior to departure, always be sure to
conduct the daily start-up inspections.
Check List

Car
No. 1

Strictly observe traffic rules

Keep patient and drive safely
even when you are in a hurry. ST
Be sure to drive with your seat OP
belt fastened.
Reckless driving such as driving
a car at excessive speed,
ignoring traffic lights, or other
violations may result in an
accident.
Never use your mobile phone while
driving. Set your mobile phone to
answering machine mode or message
mode.

E-18
Driving while feeling sleepy or looking aside
while driving may result in an accident
Do not drive if you are sick or
exhausted.
Never drive if you feel sleepy.
Immediately stop your car and have
a break.
Your fellow passenger should confirm
safety when making turns across
intersections.
When driving in rainy conditions,
drive with caution and pay attention to
slippery conditions.

Reverse or turn the car with caution

Check that there are no obstructions around the car and then put
the car in motion. Your fellow passenger should get out of the car to
give instructions.

High-pressure gas

Securely store tools and parts on vehicles

Securely store the car keys to discourage theft of the car and/or
theft or loss of tools and parts.

E-19
7. Transportation of Hazardous Substances
(e.g. High-pressure Gas)
Carefully handle and transport hazardous substances in
compliance with laws and regulations.

Check warning signs

Make sure that the front and rear
of the service car is attached with a
warning sign.

High-
pressure
gas

Check that accessories for high-pressure gas

use are in the service car
Always have and check accessories
(e.g. fire extinguisher, safety tag and
other tools and equipment).
Also, make sure that the document
Advisory Notes for Disaster
r he

Prevention in Transport is in the

guis
extinFire

service car.

E-20
Precautions for cylinder loading
No lay down permitted to transport chlorofluorocarbon, acetylene
gas, or oxygen cylinders by car. Secure the cylinders with ropes or
clamping device to prevent the cylinders from toppling.
Securely fix to prevent them from
swaying and further arrange the
cylinder caps not to face each
other.

High-pressure gas

Keep container temperatures at 40C or less

Parking a car under the scorching sun causes a sudden rise in
temperatures inside the car. Take measures such as opening the
windows or covering with a sheet.

High-pressu
re gas

Precautions for transportation of dry ice

Dry ice will generate carbon dioxide as a result of sublimation. Keep
opening the windows while transporting dry ice.

Drive service cars with great care

Do not make sudden starts or stops.
Pay attention to tight turns and carefully steer the service car.

E-21
8. Transportation of Heavy Items
Devise a proper method for transporting equipment and
materials. For heavy items, use carts, lifts, dollies and
similar equipment. Avoid depending on human power.
If you feel it is impossible to transport the goods by
yourself, request professionals.

Ensure transportation methods and work setup

Transport heavy items
under the supervision
of skilled, experienced
workers. Failure to do so is
likely to cause accidents.
Careful thought should be
given to the transportation Job site
methods, the work setup,
and other work-related
considerations.

Watch your step

Keep workplaces and passages First
clean and tidy. Safety
Clean and Tidy

In dark places, provide proper

daylight and lighting.
For transportation on rainy days
or on a wet floor, particular
Trash

attention should be given to

bin

your step.

E-22
Precautions for rope hoisting
Wear leather gloves to prevent skin burns that
may result if the rope slips from your hands.
Familiarize yourself with the correct knotting
and winding of the rope.
Do not tie the rope to your body.

Precautions for cart transportation

Push the cart with the cart handle
set on the lower side during cart
transportation on a hill.
When transporting cylinders, secure
the cylinders with rubber bands.
Do not leave the cart loaded with
goods.
Slope

Precautions for transportation by human power

Kneel down and straighten the
muscles of your back when carrying
goods. Do not arch your back, or
otherwise lower back pain may result.
Lift up the goods without

Carefully transport cylinders or other

arching your back.

goods that are difficult to carry on

stairs.

E-23
9. Electrical Servicing
Receiving an electric shock regardless of amount of
voltage will result in a serious accident.
An electric shock received in an elevated place is
especially dangerous since this shock could result in a
fatal accident from falling.

First, turn switches OFF

Be sure to turn the switches OFF
before starting any work.
Do not turn the switch ON with a wet
hand.
Ask the customers staff to turn the
breaker ON and OFF.
* Do not turn any power supply switches
OFF without permission from the
customers representative, because
power may be supplied to the
customers computers or production
equipment through the power supply
switches.

Indicate that work is in progress

Be sure to put a safety tag indicating
WORK IN PROGRESS. DO NOT
TURN ON POWER SUPPLY at the ELECTRICAL
power supply switchbox in use. WORK IN
PROGRESS
NEVER turn the
switch ON. Fuses
or secondary-side
terminals are
disconnected.
DAIKIN INDUSTRIES, LTD.

Shutoff check
Before starting work, be sure to check
with a multimeter that the power
circuits are shutdown.

E-24
Discharge of capacitors
Capacitors will keep charge for
a while after the power is turned
OFF. Therefore, an electric
shock may be received if you
touch a capacitor. Be sure to
Crackle
ground the capacitors before
starting work.

Capacitor

Insulation tests
When turning electricity ON for
the first time, be sure to perform
insulation tests.

Signal to turn electricity ON

When turning electricity ON, be
sure to signal your co-worker and
exchange signals for establishing
readiness.

Data measured by instruments

Use a multimeter with a suitable capacity at the time of voltage
measurement.
Check the mode of the multimeter before measurement. Do
not measure voltages with the multimeter set to resistance
measurement mode. Otherwise, the multimeter will be short-
circuited, thus causing a danger.
Be sure to wear high-voltage protective gear (i.e., insulating gloves
and boots) at the time of data measurement. Do not use measuring
instruments inside cubicle (power receiving equipment).

E-25
10. Welding (Gas Welding/Arc Welding)
No one shall be permitted to weld unless he/she has
been authorized to perform welding.
Obtain permission from the customers representative to
conduct welding work.

Oil

Wear protective gear

Be sure to wear proper protective gear.
When performing any type of arc
welding, always be sure to wear
leather gloves.

Keep the area clear of hazardous substances or

flammable material
Make sure there are no
hazardous substances or
flammable material around Fire
the welding job site, and
perform the work with a
bucket of water or a fire
extinguisher handy.
Extinguisher
Oil

E-26
Protective care
When welding in the vicinity
of flammable material,
protect the material with
the use of a nonflammable
protective covering (e.g.
steel plates or fire-resisting
sheets).

Pay close attention

Since the welded object retains a
high temperature for a long time,
be careful not to burn any part of HOT!
your body.
After the completion of welding,
confirm that no flames have
leaped. (Always clean up after
welding and ensure that no
source of ignition remains.)

Be sure to provide ventilation (exhaust)

When you work in an closed room
or inside a tank, take extra care to
provide ventilation (exhaust) to the
workplace due to high possibility
of explosion, fire disaster, oxygen
deprivation, or gas poisoning. When
required, provide forced ventilation to
the workplace (using a fan or other Paint thinner
device).

Never weld in an atmosphere containing

chlorofluorocarbon
Welding in area containing
chlorofluorocarbon gas
Chloro
will generate phosgene, fluoro
carbo
resulting in an imminent n
hazardous situation. In this rocarbon
Chlorofluo
case, be sure to provide
thorough ventilation. Chlorofluorocarbon
on
uorocarb Poisoning
Chlorofl

E-27
11. Other Work

Airtight test
Use nitrogen gas for on-site gas leak (airtight) tests.
Never use oxygen or other types of gas.

Handling of pressure vessels

Take fall prevention measures when using cylinders upright.
Check for residual internal pressure prior to disassembly or welding
of pressure vessels.

Valve opening/closing
When starting a test run of the refrigeration unit, recheck the valves
to ensure proper opening and closing.

Outdoor unit inspection

Take appropriate measures so that customers will not turn the
power ON during outdoor unit inspection. (Put a sign warning not to
turn on the power.)

Working under the scorching sun

Wear breathing clothing under your work clothes and work cap.
Stay well hydrated. Sports drinks are recommended.

E-28
Remedial measures if the replacement of air-
conditioning refrigerant with hydrocarbon (HC)
refrigerant (propane gas) is suspected
Confirm with the user first if the replacement of the air-conditioning
refrigerant with HC is suspected during servicing work.
Suspected cases
The nameplate for the air-conditioning refrigerant has been
rewritten.
The nameplate for HC refrigerant is pasted.
You obtained information on the replacement of the air-
conditioning refrigerant from the user or customer.
You have a suspicion of the replacement of the air-conditioning
refrigerant with HC refrigerant while you are conducting a failure
diagnosis.
If you find that the air-conditioning refrigerant has been replaced
with HC refrigerant, explain to the customer that the restoration of
the condition is beyond the manufacturers warranty and that it is
a dangerous job, and ask the customer to arrange an authorized
contractor to restore the condition. Never work on the air conditioner
unless the condition is restored.

E-29
 Safety Tips for Products
Ammonia refrigerating machine
Ammonia is a deleterious substance, which should be handled with
utmost care.
Make preparations including protective gear and check on tap water
availability for emergency.

R123 centrifugal chiller

R123, an alternative CFC product to R11, is hazardous, the
handling of which needs careful attention. (The maximum allowable
concentration is 10 ppm.)
Basically, do not touch, inhale, or leak R123.
Provide proper ventilation in preparation for accidental leakage and
wear protective gear.
Do not work alone.

Brine chiller
Although brine is weak in toxicity and easy to handle, pay utmost
attention when handling it because leaked brine will cause water
and soil contamination.

Absorption chiller
Pay utmost attention when handling the solution because it contains
a deleterious substance.
When handling the solution, prepare protective gear according to
the solution type.

E-30
CO2 water heater
When transporting CO2 refrigerant in cylinders, protect the cylinders
with covers so that the cylinder temperature will not exceed 40C.
Work on CO2-dedicated components with special tools and
equipment.
CO2 is heavier than air. Therefore, do not discharge CO2 refrigerant
in places where the refrigerant will stagnate. Furthermore, pay
attention so that the refrigerant will not come in direct contact with
people or buildings.

<Cylinder protection cover> <Special tools for CO2 refrigerant>

<Reference: Pressure of each type of refrigerant

at a cylinder temperature of 40C>

Refrigerant Absolute pressure (MPa)

CO2 (R744) 13.3

R410A 2.4

R22 1.5

E-31
 Past
Past Disasters
Disasters
This section introduces case examples that actually
occurred in the past.
According to the famous 1-29-300 Heinrichs triangle,
one disaster has 29 minor injuries and 300 hazardous
actions that may result in injuries.
There are many disaster factors hidden around us.
With the Safety Tips for Service Engineers in mind,
draw lessons from past disasters and gain mastery of
them.

A worker ignited a match on board a vessel unaware of an oxygen

leak from welding. The match caused the oxygen to ignite and
resulted in an explosion that killed the worker.

BANG

Gas leakage from a refrigeration unit in the basement machine room

suffocated and killed a security guard taking a nap.

Supermarket Supermarket

Basement
Basement

Gas

Gas
Gas
Gas

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A co-worker turned a switch ON during the inspection of an outdoor
unit without checking with the other worker. The fan started operating
and hit the other worker on the head, killing the worker.

CLANG

A service engineer was using a thermometer and measuring the inner

temperature of cubicle (power receiving equipment). Then the service
engineer received an electric shock and suffered burns, because the
service engineer touched a high-voltage part of the cubicle (power
receiving equipment) with the thermometer.

A service engineer stepped on and broke a running board and system

ceiling board, fell, and had a bone fracture while the service engineer
was walking on them to make indoor unit checks.

E-33
 A service engineer stepped on and broke a day-lighting glass sheet,
fell 15 m, and died while the service engineer was walking on a tin
roof.
A service engineer stepped on and broke a slate ceiling, fell 9 m,
and died.
* Neither of them wore a helmet.

A worker climbing a corroded and

deteriorated roof ladder fell to the
ground and died because the roof
ladder was disconnected from the roof.

A service engineer lost his balance, fell from a stepladder, and had
a bone fracture while the service engineer was working in front of
an emergency door, when the door opened suddenly and came in
contact with the stepladder.
A service engineer lost his balance and toppled while the service
engineer was moving his right foot from the top plate to a rung
where his left foot was on while the service engineer was stepping
down from the stepladder.
Eme
rgen
cy e
xit

E-34
A service engineer did not notice a level difference, toppled, and had
a bone fracture when the service engineer was getting out from a roof
door with a tool bag and parts in both his bands, because he could
not see ahead clearly due to the contrast difference between indoors
and outdoors.

A service engineer sat on a stepladder and tried to tighten a mounting

bolt of a screw chiller motor. The spanner slipped out of the bolt, when
the service engineer fell off the stepladder and had a bone fracture.

Motor

Ring
90cm

spanner

Refrigerant gushed out from a union where no check valve was

provided when the service engineer opened the union by mistake
in order to replenish refrigerant through the half union of a screw
compressor. The engineer had frostbite because he was upset and
put his hands to the union.

E-35
 My Declaration of Safety

Date of description:

Name:

Signed by supervisor:

* Make use of the introduced case examples for on-site hazard

prediction (or kiken yochi (KY) in Japanese) meetings.

E-36
Lets follow the rules and create
an accident-free workplace.

Si-19_B (2012. 6. 0020) NK