Though refrigeration systems are crucial for controlling temperatures in cold storage facilities, gas leaks are a common problem that puts employees at risk, diminishes the energy efficiency of the refrigeration system and causes damage to the environment. Shaun Evers, Managing Director of Stonegate, explains how modern gas detection technology helps logistics and warehouse managers prevent leaks and their associated issues.
Imperceptible hazards
Refrigerant gas leaks are imperceptible to human senses. Having no colour, taste or smell, they are difficult to discover, which is why, despite the average UK system losing 20% of its gas every year, most leaks remain undetected until 60% of the gas has escaped. This means gases could have been leaking for around three years.
When leaks occur, a refrigeration system cannot work efficiently and consumes more energy to maintain temperatures. The lower the gas levels, the more expensive the system will cost to run, until, finally, so much is lost that it cannot maintain the required temperature. This, of course, puts the goods being kept in cold storage at risk of spoilage. In terms of costs to the business, the Carbon Trust states that for every 20% of refrigerant gas lost, a system’s energy consumption rises by 11%, which, given the cost of energy, could be a considerable sum for businesses.
For logistics and warehouse managers with cold storage facilities, a more pressing concern is the risk to employees working in these areas. Refrigerant gases are hazardous and potentially fatal. Exposed workers can suffer from headaches, nausea, coughing, irritation of the skin and eyes, and breathing difficulties. In confined areas, higher concentrations can cause unconsciousness and asphyxiation. Fire is also a risk due to some gases being combustible.
Regulatory compliance
The considerable global warming impact of refrigerant gases means businesses with cold storage facilities must now comply with F-gas regulations. Gas check leaks are now compulsory, with frequencies ranging from every three to every 12 months, depending upon a system’s CO2 equivalent tonnage. Companies whose systems have an F-gas equivalent to 500 tonnes of CO2 or higher, meanwhile, must install gas leak detectors.
Next-gen gas detection
Evolving F-gas regulations have spurred innovation in gas detection technology. Today’s intelligent systems feature high-precision semiconductors or infrared sensing elements that swiftly detect hazardous and non-hazardous gases. Moreover, they can even be programmed to identify predetermined refrigerant gas and air mixtures, allowing them to be customised for operating in cold storage facilities and large warehouses. A sensor’s durability can also be extended by calibrating its integrated active filters to ignore irrelevant gases.
To ensure employee safety, modern gas detectors have audio-visual alarms that alert occupants when a leak is detected, as well as integrated LEDs that indicate the presence and status of the sensors. Crucially for logistics and warehouse managers, the gas detectors can be integrated with Building Management Systems, enhancing communications and diagnostics by enabling proactive monitoring either centrally or online.
For warehouse managers responsible for cold storage facilities, modern gas detectors provide several key benefits. They protect employees from refrigerant gas leaks; assist with F-gas regulation compliance; prevent energy wastage and associated costs and ensure goods are stored at the right temperatures.
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