Unit 2 — Introduction to Refrigerants & Handling Practices
Section 1 — Refrigerants, Gases and Oils
1.1 Refrigerants, Gases & Oils
Core terminology, hazards, codes, safety classifications, and environmental
effects of refrigerants, gases, and oils used in refrigeration and air
conditioning systems.
1.1.1 — Terminology Associated with Refrigerants, Gases, and Oils
Refrigeration and air conditioning systems rely on specific fluids and lubricants
to transfer heat, provide pressure, and protect moving parts. Understanding common
terminology is essential for safe and effective work in both 313A (Refrigeration and
Air Conditioning Systems Mechanic) and 313D (Residential Air Conditioning Systems
Mechanic) Level 1 apprenticeship training.
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Refrigerant
A working fluid that circulates through the refrigeration or air conditioning
system. It absorbs heat at low temperature and pressure in the evaporator and
rejects heat at higher temperature and pressure in the condenser. Refrigerants
change state between liquid and vapour as they move through the system.
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Primary Refrigerant
The refrigerant that circulates directly between the evaporator and condenser,
undergoing phase change. Common examples include HCFCs, HFCs, HFOs, and some
natural refrigerants such as ammonia and carbon dioxide.
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Secondary Refrigerant
A fluid used to transfer heat from the conditioned space to a remote primary
refrigeration system. Secondary refrigerants do not usually change phase in the
distribution piping. Typical examples are water, brine solutions, and glycol
solutions.
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Refrigerant Oil
A specially formulated lubricant used inside compressors to reduce friction,
remove heat, and provide sealing. The oil must be compatible with the refrigerant
and the materials used in the system.
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Refrigerant Charge
The total mass of refrigerant in the system. Proper charging is critical to
performance, efficiency, and reliability.
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Contamination
The presence of unwanted substances (such as air, moisture, acids, sludge,
non-condensables, or mixed refrigerants) within a refrigerant or oil. Contamination
can cause corrosion, restricted flow, reduced heat transfer, and compressor
failure.
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Global Warming Potential (GWP)
A measure of how much heat a greenhouse gas traps in the atmosphere compared
to carbon dioxide over a defined time period. Higher GWP values indicate greater
contribution to global warming.
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Ozone Depletion Potential (ODP)
A measure of a substance's ability to destroy stratospheric ozone compared
to a reference substance (usually CFC-11). Substances with ODP greater than zero
damage the ozone layer.
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Leak
An unintentional release of refrigerant or gas from a system to the atmosphere.
Leaks are both an environmental concern and a performance issue and must be
located, repaired, and verified.
Recovery
Removing refrigerant from a system and storing it in an approved cylinder
without recycling or reclaiming at that time.
Recycling
Cleaning of recovered refrigerant for reuse by oil separation and filtration,
usually performed on site, without meeting the higher standards of reclamation.
Reclamation
Processing of used refrigerant to meet the purity standards of new virgin
product. Reclamation is typically conducted by specialized facilities.
1.1.2 — Hazards and Safe Work Practices for Refrigerants, Gases and Oils
Work with refrigerants, compressed gases, and oils exposes technicians to chemical,
physical, and environmental hazards. 313A/313D Level 1 training emphasizes risk
recognition and the use of proper controls.
Many refrigerants evaporate rapidly at low temperatures. Direct skin or eye
contact with liquid refrigerant or rapidly expanding vapour can cause frostbite
or cold burns. Technicians must wear safety glasses or goggles, appropriate gloves,
and avoid opening systems without proper tools and procedures.
Most fluorocarbon refrigerants are heavier than air and can displace oxygen in
confined spaces. Accumulation of refrigerant can cause dizziness, loss of
consciousness, or death. Adequate ventilation, continuous monitoring in mechanical
rooms, and adherence to occupancy and machinery room codes are essential.
Some refrigerants and gases, such as ammonia or high-concentration CO₂, can be
toxic or immediately dangerous to life and health. Exposure may occur through leaks,
venting, or accidental mixing. Technicians must know the safety data sheet (SDS)
information for each substance and follow established exposure limits and emergency
procedures.
Hydrocarbon refrigerants, some HFO blends, and acetylene are flammable or
combustible. Improper handling can result in fire or explosion. Ignition sources,
including open flames, hot surfaces, and electrical sparks, must be controlled,
and equipment rated for the correct hazardous location classification must be used
where required.
Compressed gases and high-pressure refrigerants (such as R-410A or R-744/CO₂)
present explosion and projectile hazards if cylinders, hoses, or components are
mishandled. Only approved cylinders, regulators, gauges, and hoses rated for the
working pressure are to be used.
When refrigerants contact open flames, welding arcs, or extremely hot surfaces,
they can decompose into toxic, corrosive gases. Smoking, brazing, or open flames
must not occur in areas contaminated with refrigerant leaks, and systems must be
properly evacuated and purged prior to hot work.
Refrigeration oils can be irritating to skin and eyes and may contain dissolved
refrigerant under pressure. Containers must be kept sealed to prevent moisture
absorption, and used oil must be collected and disposed of according to
environmental regulations.
- Follow all relevant occupational health and safety legislation and employer safety policies.
- Wear personal protective equipment (PPE) such as eye protection, gloves, safety footwear, hearing protection, and respiratory protection where required.
- Verify system pressures and isolate energy sources (lockout/tagout) before opening piping or components.
- Use calibrated instruments, approved recovery equipment, and rated hoses and cylinders.
- Work in adequately ventilated areas and avoid confined-space entry without proper procedures and monitoring.
1.1.3 — Codes, Regulations and Certification Requirements
In Canada, handling refrigerants and compressed gases is controlled by federal,
provincial, and territorial regulations, as well as municipal bylaws and national
model codes adopted in law. Technicians must understand the legal framework that
guides their work.
Federal and provincial regulations control the use, handling, recovery,
recycling, and disposal of ozone-depleting substances (ODS) and certain
alternatives. These regulations typically:
- Prohibit venting of regulated refrigerants to the atmosphere.
- Require certified technicians to perform work on systems containing regulated refrigerants.
- Prescribe requirements for storage, transport, and labeling of refrigerant cylinders.
National and provincial building codes, mechanical codes, and fire codes set out
requirements for refrigerating machinery rooms, emergency ventilation, detection
and alarm systems, egress, and equipment location. These codes often reference
safety standards such as CSA and ASHRAE.
Transport of Dangerous Goods (TDG) regulations, along with workplace safety
rules, govern how cylinders of refrigerant and gas are filled, labeled, secured,
and transported.
- Cylinders must be protected from heat and physical damage.
- Cylinders must not be stored in confined or occupied spaces.
To legally handle regulated refrigerants in Canada, technicians must complete an
approved environmental awareness training program and obtain the appropriate
certification card. Apprentices may work under supervision while they complete
training.
1.1.4 — Safety Classifications of Refrigerants
Refrigerants are grouped into safety classes to describe their flammability and
toxicity. Classification helps designers and technicians choose appropriate
refrigerants and define installation standards for occupied spaces.
International standards such as ASHRAE Standard 34 classify refrigerants using a
letter-number code. The letter indicates toxicity, and the number indicates
flammability.
Flammability classes describe the refrigerant's tendency to ignite and sustain
combustion.
Class 1 — Non-Flammable
No flame propagation under specified test conditions. Considered non-flammable
in normal service. Examples: R-134a, R-404A.
Class 2 / 2L — Lower Flammability
Class 2 has lower heat of combustion. Subclass 2L identifies
refrigerants with low burning velocity (mildly flammable), such as many HFOs
used to replace higher-GWP HFCs.
Class 3 — Highly Flammable
High burning velocity — hydrocarbons such as propane and isobutane. Require
strict charge size limits, ventilation, spark-proof equipment, and detailed
risk assessments.
Toxicity classes indicate the potential for refrigerants to cause acute or
chronic health effects when inhaled.
Class A — Lower Toxicity
Occupational exposure limit above a specified threshold. Many HFCs and HFOs
are Class A.
Class B — Higher Toxicity
Can cause serious health effects at lower concentrations. Ammonia (R-717) is
Class B because of its toxicity and irritant properties.
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Combined Classification
The full classification combines both aspects — for example: A1
(low toxicity, non-flammable), A2L (low toxicity, mildly flammable),
B2 (higher toxicity, lower flammability), or B3
(higher toxicity, highly flammable). System design, allowable charge size, and
permitted applications are strongly influenced by this safety classification.
1.1.5 — Environmental Effects of Refrigerants, Gases and Oils
Refrigeration and air conditioning work has direct impact on the environment through
emissions, energy consumption, and waste handling. Modern training and codes emphasize
environmentally responsible practices.
Contamination is both an operational and environmental concern. When a system
becomes contaminated with air, moisture, acids, sludge, or mixed refrigerants:
- Heat transfer efficiency decreases, leading to higher energy use and operating cost.
- Corrosion and chemical reactions can form acids that damage copper, steel, and insulation.
- Compressors may overheat or fail due to poor lubrication and restricted refrigerant flow.
- Contaminated refrigerant and oil often cannot be reused and must be disposed of or reclaimed, increasing environmental burden.
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Prevention
Preventing contamination involves following correct recovery, evacuation, and
charging procedures, using clean tools and hoses, and keeping containers sealed
from ambient air and moisture.
Many synthetic refrigerants are potent greenhouse gases. If released to the
atmosphere, they contribute directly to global warming. Refrigerants with very high
GWP (such as some older HFC blends) are being phased down in favour of lower GWP
HFOs, natural refrigerants, and optimized system designs.
Technicians must:
- Recover and recycle or reclaim refrigerants rather than venting to atmosphere.
- Locate and repair leaks promptly.
- Follow best practices for charging, testing, and maintenance to minimize losses.
Chlorinated refrigerants such as CFCs and many HCFCs have non-zero ODP and can
damage the stratospheric ozone layer. This ozone layer protects life on earth from
harmful ultraviolet (UV) radiation. International agreements and Canadian regulations
have largely phased out CFCs and are phasing out HCFCs. Modern systems increasingly
use zero-ODP refrigerants, but legacy equipment may still contain older substances
which must be handled and disposed of carefully.
Beyond direct emissions, refrigeration systems affect the environment through:
- Energy consumption and the associated emissions from power generation.
- Improper disposal of oil, filters, and components contaminated with refrigerant or acids.
- Leaks of secondary refrigerants such as brines and glycols into soil or water.
Technicians help reduce overall environmental impact by maintaining system efficiency,
using proper recovery and recycling procedures, and ensuring that waste streams are
handled through approved recycling and disposal channels.