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HVAC · United States

JHA for refrigerant recovery

By Safety PaperworkBuilt from OSHA standards and guidance · How we write and check theseUpdated

OSHA expects employers to find and control hazards on every job, and many general contractors require a written JHA for refrigerant recovery before you start.

A JHA breaks the job into steps, lists the hazards in each step and the controls that protect the crew, and the crew signs it. The main hazards are electric shock from live wiring, fire from hot works, confined space entry and refrigerant leaks.

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JHA example: refrigerant recovery

This is a complete JHA for refrigerant recovery, 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.

Job Hazard Analysis (JHA)
Refrigerant leak repair and regas · HVAC · Example
Document JHA-001 · Rev 1

Job steps, hazards and controls

#Job stepHazardsRisk beforeControlsRisk after
1Hold the right refrigerant licence or certification for the work
  • Refrigerant leaks
Medium
  • Recover refrigerant into an approved cylinder before opening the system. Never vent it. Engineering (guarding)
  • Ventilate closed spaces and use a leak detector during the work. Engineering
  • Refrigerant leaks: see step 3 for the full controls Administrative
Low
2Isolate power, apply lockout/tagout
  • Electric shock from live wiring
Critical
  • Isolate the power before any work. Do not work live. Elimination
  • Lock out and tag the disconnecting means with your own personal lock and tag so the circuit cannot be energized (29 CFR 1926.417). Engineering (guarding)
  • Test before you touch: prove dead at the point of work with a tested voltage tester. Engineering
  • Only qualified persons work on or near exposed energized parts. Administrative
  • Check for back feeds from solar, batteries and generators that can keep a circuit live after the main switch is off. Administrative
  • If energized work cannot be avoided, use an energized work permit, a safety observer and insulated tools, following NFPA 70E. Administrative
  • Wear insulated gloves, arc-rated clothing and a face shield when testing or working near live parts. PPE
Medium
3Recover refrigerant into a cylinder, never vent it
  • Refrigerant leaks
  • Stored energy
Medium
  • Recover refrigerant into an approved cylinder before opening the system. Never vent it. Engineering (guarding)
  • Ventilate closed spaces and use a leak detector during the work. Engineering
  • Only EPA Section 608 certified technicians handle refrigerants. Administrative
  • With flammable refrigerants (such as R32 or R290), remove ignition sources and use spark-free tools. Administrative
  • 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. Elimination
  • Lock out and tag all energy sources with personal locks. Engineering (guarding)
  • Put mechanical blocks or props under raised parts like buckets, tipper bodies and doors. Engineering
  • Test that the system is dead and nothing can move before you start. Administrative
  • Follow the maker's procedure, for example for garage door and roller door springs. Administrative
  • Wear safety glasses and gloves. PPE
Low
4Braze repairs under a hot work permit with nitrogen purge
  • Fire from hot works
  • Burns from hot surfaces
  • Confined space entry
Critical
  • Use cold work methods where you can, such as bolting, press fittings or cutting with a saw instead of a torch. Elimination
  • Move anything that can burn at least 35 feet away, or cover it with fire blankets. Engineering (guarding)
  • Use fire-resistant screens to stop sparks reaching people or gaps in walls and floors. Engineering
  • Get a hot work permit before starting. Administrative
  • Keep a charged fire extinguisher and fire blanket at the work spot. Administrative
  • Isolate heating systems and let parts cool before you touch them. Elimination
  • Fit guards or insulation on hot pipes and equipment. Engineering
  • Mark hot items with chalk or a "HOT" sign so others know. Administrative
  • Keep a first aid kit and cool running water nearby for burns. Administrative
  • Wear heat-resistant gloves and long sleeves. PPE
  • Do the work from outside the space where you can, using cameras or long-reach tools. Elimination
  • Isolate and lock out all pipes, power and moving parts going into the space. Engineering (guarding)
  • Test the air for oxygen, flammable and toxic gases before entry, and keep testing during the work. Engineering
  • Use forced ventilation to keep the air clean. Engineering
  • Use a permit-required confined space program with a written entry permit (29 CFR 1926 Subpart AA). Only trained workers enter. Administrative
Medium
5Pressure test, evacuate and recharge
  • Pressure testing
  • Refrigerant leaks
Medium
  • 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. Substitution
  • Keep people out of the test area with signs and barriers. Engineering (guarding)
  • Use a calibrated gauge and a relief valve set to protect the system. Engineering
  • Test to the pressure the system calls for and hold it for the set time. Never go over. Administrative
  • Release the pressure fully before tightening anything or fixing leaks. Administrative
  • Wear safety glasses or a face shield. PPE
  • Refrigerant leaks: see step 3 for the full controls Administrative
Low
6Record refrigerant used and clean up
  • Poor housekeeping and waste
Medium
  • Order materials to size and send packaging back where you can. Elimination
  • Put dumpsters and waste chutes close to the work. Engineering
  • Clean as you go, and do a full clean up at the end of each day. Administrative
  • Keep exits, stairs and walkways clear at all times. Administrative
  • Stack materials neatly on level ground, away from edges. Administrative
  • Wear gloves when handling waste. PPE
Low

PPE

Safety glasses (ANSI Z87.1)Work glovesSafety-toe boots (ASTM F2413)Face shield (ANSI Z87.1)Rubber insulating glovesArc flash PPE (NFPA 70E)Welding glovesCoveralls

Plant and equipment

Hand toolsElectrical test meterPropane torch

Permits and plans

Lockout/tagout (1926.417)Hot work permit (fire watch at least 60 minutes after, NFPA 51B)

Emergency

Call 911. Add the nearest hospital, the assembly point and the first aid / cpr person for your site.

Sign-off

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

Free JHA template for refrigerant recovery

Word (.docx) and PDF, Letter 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 JHA

Pre-start checklist for refrigerant recovery

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, apply lockout/tagout
  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 refrigerant recovery

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, asphalt, 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.
Almost certainLikelyPossibleUnlikelyRareHow bad it could be: First aid only to FatalityBA
Highest risk on refrigerant recovery: Critical before controls (B), down to Medium after controls (A), on the United States 5 by 5 risk matrix (possible and fatality becomes rare and fatality).

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 6 feet or more above a lower level?
  • Will anyone use a ladder or stepladder?
  • Will anyone work on a roof?
  • Is there a skylight, fiberglass panel or other fragile roofing?
  • Will you use a scaffold or rolling tower?

Why JHAs get rejected

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

  • Generic steps such as "work safely" or "use PPE" with no task-specific hazards or controls.
  • No OSHA standards referenced for the hazards that have them, such as fall protection, ladders, scaffolds or silica.
  • No competent person named for fall protection, excavation, scaffolds or silica where those hazards exist.
  • Equipment listed without inspection requirements, and no training listed for the people using it.
  • Respirators listed with no respiratory protection program, medical clearance or fit test.
  • Controls rely only on PPE when engineering controls such as guardrails, wet cutting or extraction are feasible.
  • No crew sign-off, or no date and revision when the job has changed.

Questions

Do I need a JHA for refrigerant recovery?

OSHA expects employers to find and control hazards on every job, and many general contractors require a written JHA for refrigerant recovery before you start.

Who signs the JHA?

The supervisor or competent person who prepared it signs, and every crew member signs to show they were trained on the hazards and controls before the job starts. Many general contractors also sign to accept it.

How long do I keep it?

Keep this JHA on site during the job, and keep it with the training and inspection records for at least 1 year after the job (longer if your state plan or general contractor requires it). OSHA does not set a retention period for JHAs themselves.

What PPE is needed for refrigerant recovery?

Usually Safety glasses (ANSI Z87.1), Work gloves, Safety-toe boots (ASTM F2413), Face shield (ANSI Z87.1), Rubber insulating gloves, Arc flash PPE (NFPA 70E), Welding gloves, Coveralls. The site rules may add more, so check with the general contractor.

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Toolbox talks for this job

Toolbox talkHot Works SafetyToolbox talkConfined Spaces

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

Sources