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Heating and ventilation · United Kingdom

Method statement for F-gas leak repair

By Safety PaperworkBuilt from HSE guidance and CDM 2015 · How we write and check theseUpdated

You must assess the risks of F-gas leak repair and record the significant findings if you employ 5 or more people. On CDM sites the principal contractor will ask for RAMS before you start.

RAMS cover the hazards, who could be harmed and how, the controls and the safe sequence of work, and the crew is briefed and signs. The main hazards are electric shock from live wiring, fire from hot works, confined space entry and refrigerant leaks.

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RAMS example: F-gas leak repair

This is a complete RAMS for F-gas leak repair, with 6 job steps. Open it in the builder to add your site, crew and signatures, change anything, and download a PDF. Or download the free Word template below and fill it in by hand.

Risk Assessment and Method Statement (RAMS)
Refrigerant leak repair and regas · Heating and ventilation · Example
Document RAMS-001 · Rev 1

Risk assessment

#ActivityHazardsWho might be harmedRisk beforeControlsRisk after
1Hold the right refrigerant licence or certification for the work
  • Refrigerant leaks
Workers, OccupantsMedium (8)
  • Recover refrigerant into an approved cylinder before opening the system. Never vent it. Isolate
  • Ventilate closed spaces and use a leak detector during the work. Control (engineering)
  • Refrigerant leaks: see step 3 for the full controls Control (procedures)
Low (4)
2Isolate power, lock off and label
  • Electric shock from live wiring
Workers, OccupantsVery high (15)
  • Isolate the power before any work. Do not work live. Eliminate
  • Lock out and tag the isolation point with your own personal lock and danger tag. Isolate
  • Prove dead at the point of work with an approved voltage indicator (GS38), and prove the tester before and after. Control (engineering)
  • Only competent, qualified electricians do electrical work, following a safe isolation procedure. Control (procedures)
  • Check for back feeds from solar, batteries and generators that can keep a circuit live after the main switch is off. Control (procedures)
  • If live work cannot be avoided, use a permit, a safety observer and insulated tools. Control (procedures)
  • Wear insulated gloves, arc-rated clothing and a face shield when testing or working near live parts. PPE
Medium (5)
3Recover refrigerant into a cylinder, never vent it
  • Refrigerant leaks
  • Stored energy
Workers, OccupantsMedium (8)
  • Recover refrigerant into an approved cylinder before opening the system. Never vent it. Isolate
  • Ventilate closed spaces and use a leak detector during the work. Control (engineering)
  • Only F-gas certified engineers handle refrigerants. Control (procedures)
  • With flammable refrigerants (such as R32 or R290), remove ignition sources and use spark-free tools. Control (procedures)
  • Wear cold-rated gloves and safety glasses or a face shield. PPE
  • Release or block all stored energy before work: release the pressure in pipes, tanks and hoses, bleed hydraulics, release springs, lower loads. Eliminate
  • Lock out and tag all energy sources with personal locks. Isolate
  • Put mechanical blocks or props under raised parts like buckets, tipper bodies and doors. Control (engineering)
  • Test that the system is dead and nothing can move before you start. Control (procedures)
  • Follow the maker's procedure, for example for garage door and roller door springs. Control (procedures)
  • Wear safety glasses and gloves. PPE
Low (4)
4Braze repairs under a hot work permit with nitrogen purge
  • Fire from hot works
  • Burns from hot surfaces
  • Confined space entry
Workers, Occupants, Public, RescuersVery high (15)
  • Use cold work methods where you can, such as bolting, press fittings or cutting with a saw instead of a torch. Eliminate
  • Move anything that can burn at least 10 metres away, or cover it with fire blankets. Isolate
  • Use fire-resistant screens to stop sparks reaching people or gaps in walls and floors. Control (engineering)
  • Get a hot work permit before starting. Control (procedures)
  • Keep a charged fire extinguisher and fire blanket at the work spot. Control (procedures)
  • Isolate heating systems and let parts cool before you touch them. Eliminate
  • Fit guards or insulation on hot pipes and equipment. Control (engineering)
  • Mark hot items with chalk or a "HOT" sign so others know. Control (procedures)
  • Keep a first aid kit and cool running water nearby for burns. Control (procedures)
  • Wear heat-resistant gloves and long sleeves. PPE
  • Do the work from outside the space where you can, using cameras or long-reach tools. Eliminate
  • Isolate and lock out all pipes, power and moving parts going into the space. Isolate
  • Test the air for oxygen, flammable and toxic gases before entry, and keep testing during the work. Control (engineering)
  • Use forced ventilation to keep the air clean. Control (engineering)
  • Issue a confined space entry permit before anyone goes in. Only trained workers enter. Control (procedures)
Medium (5)
5Pressure test, evacuate and recharge
  • Pressure testing
  • Refrigerant leaks
Workers, OccupantsMedium (8)
  • Test with water instead of air or gas where the system allows it. Never put water in refrigerant pipework, which is tested with dry nitrogen. Reduce / substitute
  • Keep people out of the test area with signs and barriers. Isolate
  • Use a calibrated gauge and a relief valve set to protect the system. Control (engineering)
  • Test to the pressure the system calls for and hold it for the set time. Never go over. Control (procedures)
  • Release the pressure fully before tightening anything or fixing leaks. Control (procedures)
  • Wear safety glasses or a face shield. PPE
  • Refrigerant leaks: see step 3 for the full controls Control (procedures)
Low (4)
6Record refrigerant used and clean up
  • Poor housekeeping and waste
Workers, VisitorsMedium (8)
  • Order materials to size and send packaging back where you can. Eliminate
  • Put skips and waste chutes close to the work. Control (engineering)
  • Clean as you go, and do a full clean up at the end of each day. Control (procedures)
  • Keep exits, stairs and walkways clear at all times. Control (procedures)
  • Stack materials neatly on level ground, away from edges. Control (procedures)
  • Use a registered waste carrier and keep waste transfer notes for at least 2 years. Keep hazardous waste such as asbestos separate, with consignment notes (special waste in Scotland). Control (procedures)
  • Wear gloves when handling waste. PPE
Low (4)

Method statement: sequence of work

  1. Hold the right refrigerant licence or certification for the work
  2. Isolate power, lock off and label
  3. Recover refrigerant into a cylinder, never vent it
  4. Braze repairs under a hot work permit with nitrogen purge
  5. Pressure test, evacuate and recharge
  6. Record refrigerant used and clean up

PPE

Safety glassesRigger glovesSafety bootsFace shieldInsulated electrical glovesArc-rated clothing and face shieldWelding gauntletsCoveralls

Plant and equipment

Hand toolsElectrical test equipment (multifunction tester)Propane gas torch

Permits and plans

Permit to work (electrical isolation)Hot works permit (fire watch at least 60 minutes after)

Emergency

Call 999. Add the nearest A&E, the assembly point and the first aider for your site.

Sign-off

Supervisor and every worker sign to confirm they have read and understood this RAMS.

Free RAMS template for F-gas leak repair

Word (.docx) and PDF, A4 landscape, no email needed. Fill in your site details, then print or send it.

Word template (.docx)PDF template

Make yours in 2 minutes

Same document, filled in for your job. Answer a few yes or no questions, the crew signs on the phone, and you send the PDF.

Start this RAMS

Pre-start checklist for F-gas leak repair

Tick these off before work starts. They come from the hazards, permits and equipment in this job.

The safe sequence of work

  1. Hold the right refrigerant licence or certification for the work
  2. Isolate power, lock off and label
  3. Recover refrigerant into a cylinder, never vent it
  4. Braze repairs under a hot work permit with nitrogen purge
  5. Pressure test, evacuate and recharge
  6. Record refrigerant used and clean up

Hazards to watch on F-gas leak repair

The hazards most specific to this job, and the step where each one comes up.

Step 4Confined space entryBad air, toxic gas or engulfment in a tank, pit, sewer or manhole overcomes workers and the people who try to rescue them.
Step 1, 3, 5Refrigerant leaksRefrigerant gas causes frostbite, pushes oxygen out of small rooms, and some types catch fire.
Step 4Burns from hot surfacesTouching hot pipes, tools, bitumen, solder or freshly welded metal burns the skin.
Step 5Pressure testingA pipe, fitting or cap fails under test pressure and blows apart, hitting people nearby.
Step 3Stored energyEnergy left in springs, hydraulics, compressed gas, raised loads or capacitors releases suddenly and crushes or injures workers.
Step 4Fire from hot worksSparks and heat from welding, grinding or flame torches set fire to timber, insulation, rubbish or fuel nearby.
Very likelyLikelyPossibleUnlikelyVery unlikelyHow bad it could be: Negligible to FatalBA
Highest risk on F-gas leak repair: Very high before controls (B), down to Medium after controls (A), on the United Kingdom 5 by 5 risk matrix (possible and fatal becomes very unlikely and fatal).

What changes on your site

This example covers the job itself. Your site may add more. Add controls for any of these that apply (the builder asks you these as yes or no questions):

  • Will anyone work at height, anywhere a fall could hurt them?
  • Will anyone use a ladder or stepladder?
  • Will anyone work on a roof?
  • Is there a fragile roof, skylight or clear roof sheet?
  • Will you use a scaffold or mobile tower?

Why RAMS get rejected

Principal contractors send documents back for these reasons. This example avoids them, but check yours too.

  • The method statement is only a list of headings that repeats the risk table and never says how the work is done.
  • The method sequence does not match the risk assessment, for example the method strips the roof before the scaffold is handed over.
  • Residual risk is still High after controls with no extra measures or explanation.
  • It reads as copied: another firm, another address, or wording that does not fit UK sites. HSE warns that copying an example and adding your name does not satisfy the law.
  • Work on an older building with no reference to an asbestos survey.
  • Plant and access equipment listed with no inspection, thorough examination or competence evidence.
  • No briefing record, no revision history, or no named supervisor.

Questions

Do I need RAMS for F-gas leak repair?

You must assess the risks of F-gas leak repair and record the significant findings if you employ 5 or more people. On CDM sites the principal contractor will ask for RAMS before you start.

Who signs the RAMS?

The person who wrote it and the person who approved it sign and date it. Every worker signs the briefing register after it is explained to them, and the principal contractor reviews and accepts it before you start.

How long do I keep it?

Keep this RAMS, every revision and the signed briefing register with the site file for the length of the job, and keep a copy in your records afterwards.

What PPE is needed for F-gas leak repair?

Usually Safety glasses, Rigger gloves, Safety boots, Face shield, Insulated electrical gloves, Arc-rated clothing and face shield, Welding gauntlets, Coveralls. The site rules may add more, so check with the principal contractor.

More heating and ventilation RAMS

RAMSAir Conditioning Installation10 stepsRAMSDucted Air Conditioning6 stepsRAMSBoiler Replacement6 stepsRAMSAir Conditioning Maintenance5 stepsRAMSRooftop AHU Replacement6 stepsRAMSDuctwork Installation5 steps

Related jobs in other trades

ElectricalConsumer Unit ReplacementAlso involves electric shock from live wiringDemolitionSoft StripAlso involves electric shock from live wiring

Toolbox talks for this job

Toolbox talkHot Works SafetyToolbox talkConfined Spaces

Blank RAMS template: free RAMS templates. Also for other countries: Australia (SWMS) · United States (JHA) · Canada (FLHA)

Sources