leak detection repair
Leak Detection Inspection
The leak management routine for large appliances under 40 CFR 82.157.
13 steps5 criticalLimit 15 minAlways tested
Steps
- 1Confirm the appliance has a full charge of 50 lb or more of a class I or II refrigerant, and identify whether it is commercial refrigeration, industrial process refrigeration, or comfort cooling/other
- 2Critical stepPull the appliance records: full charge, refrigerant added in past service, and earlier leak inspection and verification test records
- 3Critical stepCalculate the leak rate every time refrigerant is added, unless the addition follows a retrofit, a new installation, or a seasonal variance; use the same method for every appliance at the facility
- 4Compare the leak rate with the limit: 20 percent commercial refrigeration, 30 percent industrial process, 10 percent comfort cooling and other
- 5If the rate is over the limit, have a certified technician inspect the appliance to find the leaks
- 6Critical stepLook over the appliance for signs of oil leakage, damage and corrosion
- 7Inspect all visible and accessible components with a method suited to the appliance, such as an electronic detector, ultrasonic test, gas-imaging camera or bubble test
- 8Do not rely on pressure checks, sight glass checks or charging charts alone; they show a leak exists but not where
- 9Critical stepMark and list the location of each leak found
- 10Critical stepRepair within 30 days (120 days if an industrial process shutdown is required) of the refrigerant addition that put the appliance over its rate, or create a retrofit or retirement plan within 30 days
- 11After repair, do an initial verification test before refrigerant is added back, then a follow-up verification test within 10 days of the successful initial test (or, if the appliance or component was evacuated for the repair, within 10 days of its reaching normal operating conditions)
- 12Keep inspecting on schedule until the appliance stays under its rate: every three months for 500 lb or more of commercial or industrial process, otherwise once a calendar year
- 13Keep the inspection and verification records for at least three years
What graders are watching for
Tips
- 40 CFR 82.157 applies only to appliances with a full charge of 50 lb or more of class I or II refrigerant, and not to appliances containing solely substitute refrigerants.
- The leak method is the certified technician's choice. If a detector is used it must be operated and maintained per the manufacturer, and it must be one that senses the refrigerant in the system.
- Current limits are 20, 30 and 10 percent. Older rules in 82.156(i) (35 and 15 percent, 30 days from discovery) applied only until January 1, 2019; do not mix them up.
Common mistakes
- Using 10 percent for every equipment type.
- Starting the repair clock from the wrong event. The rule text counts 30 days from the refrigerant addition to an appliance over its rate (EPA's overview page words it as from discovery of the leak), not from some later date.
- Skipping the leak rate calculation on a top-up.
- Treating one verification test as enough.
Practice this skill
Practise the sequence in the app with critical-step highlighting and a rationale for each step.
Start your 7-day free trial7 days free, then $9.99/month. Cancel anytime.
Sources and how we check them: How we verify.