Product Overview

Summary: This Safe Operating Procedure sets out a clear, compliant process for detecting, assessing and repairing leaks in commercial and industrial refrigeration systems. It helps Australian businesses protect workers, prevent environmental harm from refrigerant release, and maintain system efficiency while meeting WHS and environmental obligations.

Leak detection and repair in refrigeration systems is both a safety-critical and environmentally sensitive activity. Uncontrolled refrigerant leaks can create asphyxiation and fire risks, damage plant and equipment, compromise food safety and product quality, and breach Australian environmental and WHS legislation. This SOP provides a structured, step-by-step method for safely identifying and rectifying leaks in systems using common refrigerants such as HFCs, HCFCs, HFOs, ammonia and hydrocarbon blends, in line with Australian conditions and regulatory expectations.

The document guides your team from initial symptom reporting and risk assessment, through system isolation, leak detection methods, repair techniques and post-repair verification. It standardises how technicians select and use leak detection equipment, handle and recover refrigerant, control ignition sources, and manage confined spaces and elevated work where relevant. By implementing this SOP, organisations reduce unplanned downtime, extend asset life, and demonstrate due diligence in managing hazardous chemicals and pressurised systems, while supporting compliance with the Ozone Protection and Synthetic Greenhouse Gas Management framework and WHS laws across Australian jurisdictions.

Designed for real-world workplaces, the SOP supports both in-house maintenance teams and contracted service providers. It clarifies roles and responsibilities, embeds permit-to-work and lock-out/tag-out practices where needed, and integrates with existing maintenance schedules, environmental management plans and safety management systems. The result is a practical, defensible procedure that technicians can follow on site, and managers can rely on as evidence of a robust leak management program.

Key Benefits

• Ensure safe, consistent leak detection and repair practices across all refrigeration plant and sites.
• Reduce the risk of worker exposure to hazardous or asphyxiating refrigerants and high-pressure system failures.
• Minimise refrigerant losses, environmental impact and the risk of non-compliance with Australian regulatory requirements.
• Improve system reliability, energy efficiency and protection of temperature-sensitive products and stock.
• Standardise documentation, record-keeping and contractor expectations for audit-ready compliance.

Who is this for?

• Refrigeration Technicians
• HVAC Service Technicians
• Maintenance Supervisors
• Facilities Managers
• WHS Managers
• Engineering Managers
• Cold Storage Operations Managers
• Food Manufacturing Plant Managers
• Property and Asset Managers
• Service Company Directors

Hazards Addressed

• Exposure to toxic or irritating refrigerants (e.g. ammonia) via inhalation or skin/eye contact
• Asphyxiation risk in plant rooms, confined or poorly ventilated spaces
• Fire and explosion risks from flammable refrigerants and ignition sources
• High-pressure release of refrigerant causing impact or injection injuries
• Cold burns and frostbite from contact with liquid or rapidly expanding refrigerant
• Electrical shock or arc flash when working around live control panels and compressors
• Slips, trips and falls around plant, condensate, and roof-mounted equipment
• Manual handling injuries when moving cylinders, tools and components
• Chemical exposure from cleaning agents, leak detection sprays and oils

Included Sections

• 1.0 Purpose and Scope
• 2.0 References, Definitions and Abbreviations
• 3.0 Roles and Responsibilities (Technicians, Supervisors, Contractors)
• 4.0 Applicable Legislation, Standards and Licensing Requirements
• 5.0 Plant and System Overview (Refrigerant Types and System Configurations)
• 6.0 Required Competencies, Training and Permits
• 7.0 Tools, Test Equipment and Materials (Leak Detectors, Gauges, Recovery Units)
• 8.0 Personal Protective Equipment (PPE) Requirements
• 9.0 Pre-Task Planning and Risk Assessment
• 10.0 Isolation, Lock-Out/Tag-Out and Permit-to-Work Requirements
• 11.0 Ventilation, Gas Monitoring and Atmospheric Testing
• 12.0 Leak Detection Methods and Selection Criteria
• 13.0 Step-by-Step Leak Detection Procedure
• 14.0 Leak Repair Methods (Mechanical Joints, Brazing, Component Replacement)
• 15.0 Refrigerant Recovery, Charging and Handling Procedures
• 16.0 Post-Repair Testing, Commissioning and Performance Verification
• 17.0 Environmental Controls and Spill/Release Management
• 18.0 Emergency Response Procedures for Refrigerant Leaks
• 19.0 Housekeeping, Waste Management and Cylinder Storage
• 20.0 Documentation, Labelling and Record-Keeping Requirements
• 21.0 Inspection, Monitoring and Continuous Improvement
• 22.0 Revision History and Document Control

Legislation & References

• Work Health and Safety Act and Regulations (as adopted in relevant Australian jurisdictions)
• Safe Work Australia – Managing Risks of Hazardous Chemicals in the Workplace Code of Practice
• Safe Work Australia – Confined Spaces Code of Practice
• AS/NZS 5149: Refrigerating systems and heat pumps – Safety and environmental requirements (series)
• AS/NZS 1677: Refrigerating systems (where still referenced by legacy plant)
• AS 4214: Gaseous fire extinguishing systems (for interaction with plant rooms where applicable)
• AS/NZS 3000: Electrical installations (Wiring Rules) – for safe isolation of associated electrical equipment
• Ozone Protection and Synthetic Greenhouse Gas Management Act 1989 (Cth) and associated Regulations
• Refrigerant Handling Code of Practice 2007 (Parts 1 & 2) – AIRAH / Australian Government