Product Overview

Summary: This SOP sets out a clear, compliant process for safely recovering, handling and reclaiming used refrigerants from refrigeration and air conditioning systems in Australia. It helps your business control environmental and WHS risks, protect technicians from exposure and pressure-related hazards, and demonstrate due diligence under refrigerant handling and environmental legislation.

Recovery and reclamation of used refrigerants is a critical activity for any business working with refrigeration and air conditioning systems, from small split systems through to industrial plant. Poorly managed recovery can lead to refrigerant leaks, environmental harm, breaches of licence conditions, and serious safety risks including frostbite, eye damage, and over‑pressurisation incidents. This SOP provides a structured, step‑by‑step method for planning and carrying out refrigerant recovery and transfer, from pre‑job checks and system isolation through to cylinder labelling, storage, documentation and coordination with licensed reclaim facilities.

Developed for the Australian regulatory environment, the procedure aligns with national refrigerant handling requirements and WHS obligations, helping organisations integrate safety, environmental responsibility and operational efficiency. It clarifies who does what on site, the controls required for different refrigerant types (including high‑pressure and flammable refrigerants), and the records needed to satisfy audits and inspections. By implementing this SOP, businesses can standardise technician practices across multiple sites, minimise accidental releases, and reduce the risk of costly non‑compliance or system damage during service and decommissioning activities.

Key Benefits

• Ensure compliant recovery, storage and transfer of used refrigerants in line with Australian WHS and environmental requirements.
• Reduce the risk of refrigerant leaks, environmental harm and associated regulatory penalties.
• Protect technicians from exposure, frostbite, eye injuries and high‑pressure system failures during recovery operations.
• Standardise recovery and reclamation practices across teams, contractors and sites for consistent, high‑quality service.
• Improve traceability and documentation of refrigerant movements to support audits, licence conditions and sustainability reporting.

Who is this for?

• HVAC Technicians
• Refrigeration Mechanics
• Air Conditioning Installers
• Service and Maintenance Supervisors
• Workshop Managers
• WHS Managers
• Facilities Managers
• Compliance and Environmental Officers
• Fleet and Asset Managers

Hazards Addressed

• Exposure to refrigerant gases causing respiratory irritation or asphyxiation in poorly ventilated spaces
• Cold burns and frostbite from contact with liquid or rapidly expanding refrigerant
• Eye injuries from splashes or flying debris during hose disconnection or component failure
• Over‑pressurisation and rupture of recovery cylinders, hoses or system components
• Fire and explosion risks when handling flammable refrigerants (e.g. hydrocarbons, mildly flammable HFOs)
• Manual handling injuries from moving recovery units, cylinders and associated equipment
• Environmental contamination from accidental release of ozone‑depleting or high global warming potential refrigerants
• Electrical shock or arc flash when working on or near live refrigeration and air conditioning equipment

Included Sections

• 1.0 Purpose and Scope
• 2.0 Definitions and Terminology (including refrigerant types and classifications)
• 3.0 Roles, Responsibilities and Competency Requirements
• 4.0 Licensing, Permits and Regulatory Obligations
• 5.0 Required Tools, Equipment and Calibration Requirements
• 6.0 Personal Protective Equipment (PPE) Requirements
• 7.0 Pre‑Task Planning, Risk Assessment and Site Preparation
• 8.0 System Isolation, De‑energisation and Lockout/Tagout
• 9.0 Refrigerant Identification, Labelling and Compatibility Checks
• 10.0 Step‑by‑Step Refrigerant Recovery Procedure
• 11.0 Handling of Flammable and High‑Pressure Refrigerants (Additional Controls)
• 12.0 Cylinder Filling Limits, Weighing, Leak Checking and Integrity Checks
• 13.0 Storage, Segregation and Transport of Recovered Refrigerant Cylinders
• 14.0 Transfer to Reclamation or Destruction Facilities and Chain‑of‑Custody Records
• 15.0 Environmental Protection Measures and Spill/Release Response
• 16.0 Emergency Procedures and First Aid
• 17.0 Housekeeping, Waste Management and Decontamination
• 18.0 Training, Induction and Competency Verification
• 19.0 Documentation, Recordkeeping and Reporting Requirements
• 20.0 Review, Audit and Continuous Improvement of the Procedure

Legislation & References

• Ozone Protection and Synthetic Greenhouse Gas Management Act 1989 (Cth)
• Ozone Protection and Synthetic Greenhouse Gas Management Regulations 1995 (Cth)
• Refrigerant Handling Code of Practice 2007 (Parts 1 & 2) – Australian Government
• Work Health and Safety Act 2011 (Cth) and equivalent state and territory WHS legislation
• Work Health and Safety Regulations 2011 (Cth) – Hazardous chemicals and plant
• AS/NZS 5149 series: Refrigerating systems and heat pumps – Safety and environmental requirements
• AS/NZS 1677: Refrigerating systems (where still referenced in legacy plant)
• AS 2030.1: Gas cylinders – General requirements
• AS 4332: The storage and handling of gases in cylinders
• Safe Work Australia – Code of Practice: Managing risks of hazardous chemicals in the workplace
• Safe Work Australia – Code of Practice: Managing the risk of falls and working in confined spaces (where applicable to plant location)