Flare Leak Emergency Fix — Cut, Re-Flare, Torque

Identify leak, recover refrigerant, then work

Check: **Safety first**: on detected leak = ventilate fully before work. R-32/R-454B = A2L flammable, remove ignition sources. **Confirm leak location**: soap bubble or A2L electronic detector. **Recovery procedure** (separate case): recovery machine → cylinder (same refrigerant) → pressure reaches 0. **Ready conditions**: system pressure = 0 / residual gas vented / no ignition / PPE (gloves, safety glasses). **Common leak patterns**: ① over-torque = flare crack (install defect) ② vibration = loosens over time (aging) ③ tube rotation = scratched seat ④ corrosion (coastal/industrial 5+ yrs).

What to do: **Standard field procedure**: 1) Cut affected section about 5–10 cm (tube cutter, square). 2) Ream new copper edge to remove burrs. 3) **Flaring**: ratchet or clutch flaring tool, exposure 1–1.5 mm. 4) Flare face must be free of cracks/oval/rough surface. 5) Apply small amount of Nylog Blue or refrigerant oil to flare face. 6) **Torque**: 1/4" = 17–24 N·m (13–18 ft·lb, 15 sweet spot), 3/8" = 33–41 N·m, 1/2" = 49–62 N·m. Torque wrench + 90° crowfoot mandatory. 7) Vacuum → weighed charge → re-test for leaks. **NEVER re-tighten a cracked flare** — always cut and redo.