Test Project Refrigeration & Air Conditioning -LKS 2017
Test Project – Refrigeration and Air Conditioning
National Vocational Students Skills Competition - 2017
Test Project For Skills Refrigeration and Air Conditioning
National Vocational Students Skills Competition - 2017
Page 1
DAFTAR ISI
Dokumen-dokumen dalam lembar soal berikut meliputi beberapa
bagian diantaranya adalah :
1. LKS2017_TPRA.doc Bagian A : Kisi-Kisi Lomba
2. LKS2017_TPRA.doc Bagian B : Petunjuk Lomba
3. LKS2017_TPRA.doc Bagian C : Soal – Soal Lomba
4. LKS2017_TPRA.doc Bagian D : Gambar / Drawing
5. LKS2017_TPRA.doc Bagian E : Peralatanan Perlengkapan
6. LKS2017_TPRA.doc Bagian F : Skematik Penilaian
Test Project For Skills Refrigeration and Air Conditioning
National Vocational Students Skills Competition - 2017
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LKS2017_TPRA.doc Bagian A
BAGIAN A
KISI-KISI LOMBA
Test Project For Skills Refrigeration and Air Conditioning
National Vocational Students Skills Competition - 2017
Page 3
INFORMASI LOMBA
DESKRIPSI TEKNIK
A.
Nama dan Deskripsi Kompetensi
1. Nama kompetensi adalah Teknik Pendingin dan Tata Udara
2. Jenis yang dikompetensikan pada Teknik Pendingin dan Tata Udara adalah perakitan
dan pengelasan, sistem pemipaan refrigerasi dan pemasangan sisten AC split
3. Peserta Lomba dipilih oleh propinsinya masing-masing.
4. Syarat peserta adalah siswa SMK yang sesuai dengan jurusan Teknik Pendingin dan
Tata Udara
5. Kompetisi dilakukan secara individual. Jumlah peserta dalam 1 team mewakili 1 SMK
dan 1 team terdiri dari 1 orang.
B.
Ruang Lingkup Kompetensi :
1. Peserta harus mampu :
a. Membaca gambar kerja pemipaan dan kelistrikan sistem refrigerasi dan tata udara
b. Membentuk berbagai macam pola sambungan pemipaan dan penggunaan peralatan
mekanik guna mendukung sistem refrigerasi dan tata udara.
c. Memasang AC split pada papan panel dan menguji coba hasil rakitannya,
d. Memasang sistem pemipaan refrigerasi pada display dan menguji coba hasil
rakitannya
e. Menemukan dan menganalisa kesalahan sistem kelistrikan dan sistem refrigerasi.
2. Proyek dilaksanakan dalam 3 hari dimulai pukul 08.00 sampai pukul 17.00
C.
Kerja Praktik :
1. Desain: proyek akan didesain dengan menggunakan komponen industri sesungguhnya
yaitu AC split, kompresor,evaporator, kondenser, dan alat ekspansi
2. Pemasangan: refrigerasi dan tata udara dipasang pada papan panel peraga sesuai
dengan gambar rancangan,
3. Komisioning: rancangan harus dapat difungsikan sesuai dengan instruksi/dokumentasi.
4. Tidak ada kesalahan yang disengaja dilakukan oleh peserta.
5. Troubleshooting: mencari kesalahan pada rangkaian yang kesalahannya dibuat oleh juri.
D.
Pengetahuan Teori :
1. Desain rangkaian: peserta harus mengetahui fungsi komponen-komponen utama sistem
tata udara dan refrigerasi, elektrik dan aksesories lainya serta dapat menjelaskan fungsi
rangkaian.
2. Analisa teknik: peserta harus mampu menganalisa rangkaian untuk menemukan
kesalahan-kesalahan yang terjadi pada rangkaian kontrol.
E.
Material :
Disediakan oleh panitia lomba :
1. AC Split set
2. Condensing Unit
3. Recovery unit
4. Sumber listrik 220 VAC
5. Bahan Utama sistem pendingin
Test Project For Skills Refrigeration and Air Conditioning
National Vocational Students Skills Competition - 2017
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Test Project For Skills Refrigeration and Air Conditioning
National Vocational Students Skills Competition - 2017
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Disediakan oleh peserta :
1. Diperbolehkan membawa multi meter sendiri
2. Diperbolehkan membawa manifold gauge sendiri
3. Membawa peralatan tulis.
4. Peralatan yang diperlukan untuk perakitan dan pengelasan pipa, pemasangan air
conditioner, dan pemasangan sistem refrigerasi pada refrigerator dan display case.
F.
Ruangan :
Minimal ruangan adalah 18 x 21 m dan dilengkapi dengan meja dan kursi untuk peserta,
meja untuk peralatan komponen, meja untuk juri/panitia, dan dilengkapi dengan sumber
listrik 220V
G.
Kriteria Penilaian :
1. Ketepatan ukuran dan kerapihan hasil kerja para peserta
2. Peralatan yang dirancang dapat bekerja sesuai dengan lembar kerja yang diberikan ,
3. Tidak melebihi waktu yang diberikan dalam merakit, realisasi, dan mencari kesalahan
(troubleshooting),
4. Waktu yang dinilai adalah waktu sebelum waktu maksimum dengan hasil pekerjaan
benar.
5. Kebenaran rangkaian setelah proses trouble-shooting.
GAMBARAN UMUM SOAL LOMBA
A. Bentuk Soal
Soal yang dikompetensikan adalah perakitan sistem refrigerasi dan tata udara, bentuk detail
soal dalam bahasa Inggris.
B. Soal
1. Fabrikasi Komponen
a. Membentuk pipa sesuai dengan tuntutan gambar kerja dan mengelasnya sehingga
membentuk sambungan yang kokoh dan tidak bocor.
b. Melakukan proses perakitan.
2. Perakitan Sisten Refrigerasi
a. Merakit sistem refigerasi dan sistem kelistrikan sesuai gambar dan melakukan
pengaturansuhu sesuai menu yang ada pada sistem kontrol alat tersebut.
b. Menjalankan sistem refrigerasi dan control
c. Melakukan pressure test, evaluasi dan charging with refrigerant
d. Melakukan komisioning sistem refrigerasi
3. Pemasangan sistem tata udara (unit AC) pada papan peraga :
Memasang (instalasi) unit AC sesuai dengan spesifikasi produk yang telah dibuat oleh
manufakturing, detail berupa :
a. Membangun sistem pemipaan untuk AC Split
b. Merakit sistem kelistrikan AC Split pada papan peraga sesuai gambar yang ditentukan.
c. Mencari dan menganalisa gangguan sistem kelistrikan dan mekanik yang ada pada
Split Air Conditioner
d. Melakukan proses recovery refrigeran pada unit air conditioning
Test Project For Skills Refrigeration and Air Conditioning
National Vocational Students Skills Competition - 2017
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Test Project For Skills Refrigeration and Air Conditioning
National Vocational Students Skills Competition - 2017
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5. Kriteria Soal Lomba, Nilai dan Waktu
Soal Lomba
a. Component Fabrication
b. Refrigeration System Installation & Commissioning
c. Air-Conditioning System Installation & Commissioning
Nilai
15poin
55 poin
30poin
Waktu
4.0 jam
8.0jam
6.0jam
C. Jadual Kegiatan :
1. Hari ke 1 :
• Familiarisasi peralatan,
• Pembukaan
2. Hari ke 2 :
• Test Project 1: Component Fabrication
3. Hari ke 3 :
• Test Project 2: Refrigeration system installation & commisioning
4. Hari ke 4 :
• Test Project 3: Air conditioning Installing & Commissioning
5. Hari ke 5 :
Penutupan
Test Project For Skills Refrigeration and Air Conditioning
National Vocational Students Skills Competition - 2017
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LKS2017_TPRA.doc Bagian B
BAGIAN B
PETUNJUK LOMBA
Test Project For Skills Refrigeration and Air Conditioning
National Vocational Students Skills Competition - 2017
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PETUNJUK UNTUK PESERTA LOMBA
Soal LKS ini dibuat untuk menguji peserta Lomba dalam memasang atau merakit peralatan sistem
refrigerasi dan Tata Udara (split air conditioner), termasuk melakukan proses perbaikan pada
peralatan tersebut.
A. Soal Lomba
Ada Lima (3) soal lomba yang akan diujikan dengan total waktu adalah 18 jam.
1. Component Fabrication
2. Refrigeration System Installation & Commissioning
3. Air-Conditioning System Installation & Commissioning
15 poin
55poin
30poin
4.0 jam
8.0jam
6.0jam
B. Informasi Tambahan
Beberapa informasi tambahan berkenaan dengan lomba akan diberikan pada saat kompetisi
diantaranya adalah :
- Jadwal detail lomba.
- Persyaratan yang berhubungan dengan keselamatan dan kesehatan kerja (K3)
- Kategori peraturan dan prosedur lomba
- Dan beberapa informasi lain yang dianggap perlu untuk disampaikan
C. Alokasi Waktu Penyelesaian Soal
Setiap peserta lomba diwajibkan untuk dapat menyelesaikan soal sesuai dengan waktu yang
telah ditetapkan dan tidak diberikan penambahan nilai pada saat peserta dapat menyelesaikan
soal lebih cepat daripada waktu yang telah ditetapkan. Penambahan waktu tidak akan diberikan
kepada seluruh peserta.
Pada saat peserta telah menyelesaikan pemipaan peserta harus meminta juri menilai
pekerjaannya dengan melakukan test kebocoran kurang lebih 15 menit sebelum melanjutkan
pada tahap berikutnya, dan juga 10 menit untuk menilai hasil proses pemvakuman yang
dilakukan oleh peserta.
D. Poin Pengecekan
Hal penting dalam lomba ini adalah adanya prosedur yang menghendaki setiap peserta untuk
meminta kepada juri untuk mengobservasi setiap langkah kerja yang dilakukannya. Sebagai
contoh pada saat peserta telah menyelesaikan proses pemvakuman unit, maka peserta meminta
salah seorang juri untuk melakukan observasi hasil pekerjaannya dan meminta juri untuk
menandatangani kotak proses vakum yang tersedia dalam soal. Silahkan lihat pada contoh
berikut :
Proses Pemvakuman Sistem
Juri:
Test Project For Skills Refrigeration and Air Conditioning
National Vocational Students Skills Competition - 2017
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Informasi Keselamatan (Safety)
Selama Lomba, seluruh peserta diwajibkan mengikuti dan melaksanakan aturan keselamatan yang
telah ditetapkan, yaitu :
1.
Sepatu Kerja :
Diwajibkan untuk menggunakan sepatu keselamatan (Safety Shoes).
2.
Pakaian Kerja :
• Menggunakan baju kerja dengan bagian tangan dan kaki sepenuhnya terlindungi (trousers
or overalls).
• Tubuh bagian atas selalu tertutup.
• Lengan harus tertutup dengan menggunakan pakaian lengan panjang pada saat
pengelasan dan penanganan Refrigerant.
3.
Pelindung Mata
• Wajib mengenakan pelindung mata (Kaca Mata) putih atau Clear Glasses.
• Terutama untuk pekerjaan brazing, soldering, filing, reaming, hack-sawing, drilling, grinding
dan penanganan refrigerant, dry nitrogent dan udara bertekanan., termasuk ketika sedang
mengerjakan pekerjaan kelistrikan.
4.
Sarung Tangan
• Harus digunakan pada saat Brazing dan penanganan refrigerants
• Wajib digunakan pada saat melakukan pekerjaan kelistrikan termasuk pengujian kelistrikan.
5.
Kelistrikan
Seluruh peserta wajib untuk meminta izin dari Juri pada saat ingin mengoperasikan semua
peralatan listrik kecuali peralatan kerja seperti Bor dan hand power tools lainnya.
Setiap peserta yang terindikasi tidak menggunakan peralatan keselamatan yang telah ditentukan
dapat diberhentikan aktivitasnya oleh Juri sampai peserta tersebut memenuhi persyaratan
keselamatan yang dimaksud.
LKS2017_TPRA.doc Bagian C
Test Project For Skills Refrigeration and Air Conditioning
National Vocational Students Skills Competition - 2017
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BAGIAN C
SOAL – SOAL LOMBA
Test Project For Skills Refrigeration and Air Conditioning
National Vocational Students Skills Competition - 2017
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Competition Details - Module 1
Component Fabrication
Maximum Time Allowed – 4 hours
15 Marks
SCOPE
The Competitors are required to fabricate a copper tubing circuit for the secondary refrigerant circuit
that will form the ice rink surface, this coil will be incorporated into the design of the system at a later
stage. The coil is constructed using 13 lengths of 1/2” copper tubing, fed by a 7/8” copper header as
per supplied drawing. This entire unit will sit in the bottom of a tank and form the secondary
refrigerant coil for the ice rink being installed in Module B.
TIMING
Competitors are to all complete the ice rink piping at the same time in the morning of C1, this will
allow for marking to take place in the afternoon, any Competitors that do not finish Module A in the
allocated time will be required to submit the unfinished project for assessment. Competitors will
receive additional points for completing this module in less than the allocated time (as defined in the
marking summary) providing that the fabricated component does not leak when pressure tested.
ASSESSMENT
Competitors will be assessed as per technical description, the marking scale will reflect dimensions
and tolerances for assessment in addition to the quality of brazed joints. Fabricated component will
be tested for leaks by pressure testing with dry nitrogen to ensure no leaks are present. Any
Competitor who does not complete Module A in the required time (4 hours) will be allowed to
complete it after it is assessed and handed back to them during Module B – no additional time will
be allowed for either Module A or Module B for those who do not complete the fabrication in the
allotted time.
DRAWINGS
R.001 Ice Ring Coil
Test Project For Skills Refrigeration and Air Conditioning
National Vocational Students Skills Competition - 2017
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Competition Details - Module 2
Refrigeration System Installation and Commissioning
Maximum Time Allowed – 8 hours
55 Marks
SCOPE
Competitors are to install a refrigeration system to refrigerate a small scale ice rink, the system uses
a secondary refrigerant to remove heat from the ice rink and mimics a small industrial plant
commonly used to carry out a much larger duty.
The Competitors are required to use the supplied components along with the coil fabricated in
Module A to form a low pressure flooded system that utilizes a brazed plate heat exchanger to
refrigerate propylene glycol to remove heat from water to form the ice rink. A small condensing unit
is used to draw vapour off the top of the vessel and compress and condense the refrigerant, an
electric expansion valve is used to meter the refrigerant into the vessel. Two level switches are used
to control the liquid level inside the vessel, a capacity control valve is used to ensure suction
pressure does not drop below design. Refrigerant is R134a.
Secondary refrigerant circuit for ice rink is to be constructed using copper pipe, copper pipe will be
used to form the secondary refrigerant pipe circuit joining heat exchanger, ice rink coil and glycol
tank with a flexible hose connection used to connect the copper pipe to the circulating pump.
Competitors are required to connect all components to a prewired electrical panel
TIMING
Competitors are to all complete the installation over C1, C2 and C3. The secondary refrigerant
circuit (glycol) pipework must be completed by the end of C2 for assessment overnight, the entire
installation will be completed by the end of C3 for assessment. The completed project with ice rink
frozen may be left running and displayed on C4.
ASSESSMENT
Competitors will be assessed as per technical description with particular weighting on the
commissioning and operation of the project.
DRAWINGS
R.002 Primary refrigerant flow circuit
R.003 Tube in tube heat exchanger
R.004 Ice ring & glycol tank
R.005 Refrigeration Installation Bay Frame
R.006 Refrigeration Installation
R.007 Electrical Control Diagram
R.008 Electrical Control Panel
Test Project For Skills Refrigeration and Air Conditioning
National Vocational Students Skills Competition - 2017
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COMPONENTS
Basic air cooled condensing unit with liquid receiver
Expansion valve (Danfoss AKV)
Tube in tube heat exchanger (Danfoss)
Circulating pump (submersible type)
Ice ring coil
Electrical switchboard
Temperature controller (Danfoss)
SYSTEM DESIGN SPECIFICATIONS
The following system design specifications for the installation should be used for commissioning and
control setting and are as follows:
SPESIFICATION DESIGN SYSTEM
Primary refrigerant = R134a
Secondary refrigerant = Propylene Glycol (40% by volume)
Maximum ambient temperature = 35°C Db, 28°C Wb
Design saturated suction temperature = -15 °C
Suction line pressure drop = 1 K
Design Glycol temperature = -10°C supply to ice rink
CONTROL AND SAFETY SETTING
Low Pressure Controller cut off 5K lower than design saturated suction temperature (SST).
Low Pressure Controller cut in at -10 °C saturated suction temperature
Capacity control valve to maintain -15 °C saturated suction temperature
High Pressure cut out the system when the Condensing temperature reaches 55 °C
Temperature controller cut out at -15 °C
Temperature controller cut in at -10 °C
Temperature sensor to be submerged in glycol tank
SYSTEM OPERATION
Low level liquid level sensor to cycle on electric expansion valve
High level liquid level sensor to cycle off electric expansion valve
Test Project For Skills Refrigeration and Air Conditioning
National Vocational Students Skills Competition - 2017
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Temperature controller to cycle off expansion valve if glycol tank temperature falls below -15
°C
Temperature controller to cycle on expansion valve if glycol tank temperature rises above
-10 °C
Capacity control valve set to maintain -15 °C saturated suction temperature and limit
temperature cycling to safety only (unit should run continually and not cycle on and off)
Test Project For Skills Refrigeration and Air Conditioning
National Vocational Students Skills Competition - 2017
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INSTALL AND COMMISSION REFRIGERATION SYSTEM
1.
INSTALL REFRIGERATION SYSTEM
All Competitors will supplied with all necessary equipment and materials to complete the installation
of the refrigeration system in accordance with test project drawings and WorldSkills International
Standard for Refrigeration and Air Conditioning.
Refer to the following project drawings to assist to complete this task
R.002 Primary refrigerant flow circuit
R.003 Tube in tube heat exchanger
R.004 Ice ring & glycol tank
R.005 Refrigeration Installation Bay Frame
R.006 Refrigeration Installation
2.
INSTALL ELECTRICAL SYSTEM
All Competitors will supplied with all necessary equipment and materials to complete the installation
of the refrigeration system in accordance with test project drawings and WorldSkills International
Standard for Refrigeration and Air Conditioning.
All cabling to be installed in double insulated, flexible cable or single insulated cable protected by
conduit, no single insulated cable is to be left without additional protection.
All temperature probe cables to be protected by conduit.
Refer to the following project drawings to assist to complete this task
R.007 Electrical Control Diagram
R.008 Electrical Control Panel
3.
PRESSURE TEST SYSTEM
Carry out a staged pressure test of the primary refrigeration system (R134a) to a value of 9.5 bar
gauge (950kpa). The pressure test point should not drop from the starting point in the fifteen (15)
minutes after the pressure test is isolated from the Nitrogen cylinder. If the pressure test has not
been achieved, the Competitor can continue to fix the leak and achieve the pressure test, however
the full mark for Pressure Test will be lost. The pressure test will be monitored remotely via a data
logging process to ensure all Competitors achieve the required pressure and standing time.
Test Project For Skills Refrigeration and Air Conditioning
National Vocational Students Skills Competition - 2017
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To be filled in by COMPETITORS
PRESSURE TEST ATTEMPT #1
Starting test pressure
:
Starting Time
:
Test pressure after standing time
:
Finishing Time
:
PRESSURE TEST ATTEMPT #2
Starting test pressure
:
Finishing Time
:
Test pressure after standing time
:
Finishing Time
:
Test Project For Skills Refrigeration and Air Conditioning
National Vocational Students Skills Competition - 2017
□ kPa □ psi
□ kPa □ psi
□ kPa □ psi
□ kPa □ psi
Page 18
4.
EVACUATION
Evacuate the primary refrigeration system (R134a) in accordance with manufacturer’s instructions
and WorldSkills standards using the Deep Vacuum Method to hold a vacuum of at least 1000
microns (130Pa absolute) of mercury. The evacuation point should not rise to a value greater than
1000 microns in the Ten (10) minutes after the vacuum pump is isolated from the system under test.
To be filled in by EXPERTS ONLY
EVACUATION TEST ATTEMPT #1
Starting evacuation level
:
Starting Time
:
Evacuation level after standing time
:
Finishing Time
:
□ Microns
□ Microns
EVACUATION TEST ATTEMPT #2
Starting evacuation level
:
Starting Time
:
Evacuation level after standing time
:
Finishing Time
:
□ Microns
□ Microns
Comments :
Refrigeration Evacuation Test
Expert 1 Initials :
Expert 2 Initials :
Expert 3 Initials :
Test Project For Skills Refrigeration and Air Conditioning
National Vocational Students Skills Competition - 2017
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5.
CHARGING WITH REFRIGERANT – PRIMARY CIRCUIT
Charge the primary refrigeration system (R134a) with the required weight of refrigerant to ensure
operation according to specification above, and in accordance with acceptable trade and
environmental practices.
To be filled in by EXPERTS ONLY
Bottle weight prior to charging
:
□ Kg □ Lb
Bottle weight at completion of charging
:
□ Kg □ Lb
Comments :
6.
CHARGING WITH REFRIGERANT – SECONDARY CIRCUIT
Charge the secondary refrigeration system (propylene glycol) with the required quantity of glycol
and water to ensure operation according to specification above, and in accordance with acceptable
trade and environmental practices.
To be filled in by EXPERTS ONLY
Bottle volume prior to charging
:
□ L □ fl oz
Bottle volume at completion of charging
:
□ L □ fl oz
Comments :
7.
ELECTRICAL TESTING
Under the supervision of an Expert, perform all necessary safety checks to ensure the Test Project
is safe to energize.
Competitor Name
:
All wiring inspected by Expert prior to energizing
: □ Yes
Electrical safety checks performed prior to energizing
: □ Yes
Comments :
Refrigeration Evacuation Test
Expert 1 Initials :
Expert 2 Initials :
Test Project For Skills Refrigeration and Air Conditioning
National Vocational Students Skills Competition - 2017
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Expert 3 Initials :
8. COMMISSION THE SYSTEM
Competitors are to commission the system for operation in accordance with the design
specifications supplied. Please fill out the following commissioning document with the system fully
operational and as close to operating temperatures as possible. Please indicate units by checking
appropriate boxes.
Ambient Temperature
: _____________ □ Celsius □ Fahrenheit
Refrigerant Type
: _____________ □
Mass of Refrigerant Charge
: _____________ □ grams □ pounds
Suction Pressure
: _____________ □ kPa □ psi
Discharge Pressure
: _____________ □ kPa □ psi
Condenser Subcooling
: _____________ □ Kelvin □ Fahrenheit Degrees
Total System Superheat
: _____________ □ Kelvin □ Fahrenheit Degrees
LP Control Cut In
: _____________ □ kPa □ psi
LP Control Cut Out
: _____________ □ kPa □ psi
HP Control Cut Out
: _____________ □ kPa □ psi
HP Control Cut In
: _____________ □ kPa □ psi
Capacity regulator setting
: _____________ □ Celsius □ Fahrenheit
Glycol supply to ice rink temp
: _____________ □ Celcius □ Fahrenheit
Glycol return from ice rink temp
: _____________ □ Celsius □ Fahrenheit
Condensing Unit Operating Current
: _____________ □ Amps
Glycol Pump Operating Current
: _____________ □ Amps
Test Project For Skills Refrigeration and Air Conditioning
National Vocational Students Skills Competition - 2017
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Test Project For Skills Refrigeration and Air Conditioning
National Vocational Students Skills Competition - 2017
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Competition Details - Module 3
Air Conditioning System Installation, Fault Finding,
Repair and Commissioning
Maximum Time Allowed – 6 hours
30Marks
SCOPE
Competitors will be provided with an air conditioning system that has been leak tested and verified
to have no leaks, pressure testing of the system is not required at any point in time. Competitors will
be required to identify 1x electrical fault and 1x refrigeration system fault on the supplied air
conditioning systems, once faults have been identified the Competitors will be required to repair the
faults including full refrigerant recovery and recharging of refrigerant charge to manufacturer’s
specifications. Competitors will then be required to commission the system and plot operating
conditions on a psychometric chart.
TIMING
Competitors will be assessed as per technical description with particular weighting on the fault
finding and commissioning of the project.
ASSESSMENT
Competitors will be assessed as per technical description with particular weighting on the fault
finding and commissioning of the project.
DRAWINGS
R.009 Air Conditioning Installation Bay Frame
R.010 Air Conditioning Installation
R.011 Psychometric chart (SI units)
R.012 Psychometric chart (IP units)
1.
FAULT FINDING
All Competitors are required to identify 1 x electrical fault and 1 x refrigeration system fault with the
operation of the unit, the root cause must be found and repaired. Once the fault is identified
Competitors are to fill in this sheet of paper identifying what they believe to be the fault with the
equipment. An Expert then needs to sign this sheet of paper.
All fault finding MUST be done with all relevant safety rules adhered to.
Once faults are found and recorded the Competitor is free to continue by running the unit and
progressing to the next stage of the Module.
ELECTRICAL SYSTEM FAULT
Please write down what the fault with the equipment is and any supporting information that indicates
what the fault was.
_______________________________________________________________________________
_______________________________________________________________________________
__________________________________________________________
Test Project For Skills Refrigeration and Air Conditioning
National Vocational Students Skills Competition - 2017
Page 23
_______________________________________________________________________________
_____________________________
Please indicate what repairs need to be done to the system to return it to normal operation
_______________________________________________________________________________
_______________________________________________________________________________
_______________________________________________________________________________
_______________________________________________________________________________
________
REFRIGERATION SYSTEM FAULT
Please write down what the fault with the equipment is and any supporting information that indicates
what the fault was.
_______________________________________________________________________________
_______________________________________________________________________________
_______________________________________________________________________________
_______________________________________________________________________________
________
Please indicate what repairs need to be done to the system to return it to normal operation
_______________________________________________________________________________
_______________________________________________________________________________
_______________________________________________________________________________
_______________________________________________________________________________
________
2.
REPAIR SYSTEM
All Competitors are required to repair the faults they have identified on the unit, refrigerant must be
removed from the system to repair the refrigeration fault. All necessary materials will be provided to
repair the equipment and return it to an operating state
All repairs MUST be done with all relevant safety rules adhered to.
3.
RECLAIM SISTEM
All Competitors are required to repair the fault they have identified on the unit, the refrigerant will
need to be removed from the system to complete the repair then the system pressure tested,
evacuated and recharged with refrigerant. All necessary materials will be provided to repair the
equipment and return it to an operating state.
All repairs MUST be done with all relevant safety rules adhered to.
Test Project For Skills Refrigeration and Air Conditioning
National Vocational Students Skills Competition - 2017
Page 24
To be filled in by EXPERTS ONLY
Reclaim system
Reclaim bottle weight prior to reclaim
:
Reclaim bottle weight at completion of reclaim :
Test Project For Skills Refrigeration and Air Conditioning
National Vocational Students Skills Competition - 2017
□ Kg □ Lb
□ Kg □ Lb
Page 25
4.
EVACUATION
Evacuate the refrigeration system in accordance with manufacturer’s instructions and WorldSkills
standards using the Deep Vacuum Method to hold a vacuum of at least 1000 microns (130Pa
absolute) of mercury. The evacuation point should not rise to a value greater than 1000 microns in
the Ten (10) minutes after the vacuum pump is isolated from the system under test.
To be filled in by EXPERTS ONLY
Evacuation Test
Starting evacuation level
:
Starting Time
:
Evacuation level after standing time
:
Finishing Time
:
□ Microns
□ Microns
Comments :
Refrigeration Evacuation Test
Expert 1 Initials :
Expert 2 Initials :
Expert 3 Initials :
5.
CHARGING WITH REFRIGERANT
Charge the refrigeration system with the required weight of refrigerant to ensure operation
according to specification above, and in accordance with acceptable trade and environmental
practices.
To be filled in by EXPERTS ONLY
Refrigerant Charging
Bottle weight prior to charging
:
□ Kg □ Lb
Bottle weight at completion of charging
:
□ Kg □ Lb
Comments :
Test Project For Skills Refrigeration and Air Conditioning
National Vocational Students Skills Competition - 2017
Page 26
6.
COMMISSION THE SYSTEM
Competitors are to commission the system for operation in accordance with the manufacturers
specifications supplied. Please fill out the following commissioning document with the system fully
operational, on “Cooling” mode, indoor fan on highest speed and as close to operating temperatures
as possible. Please indicate units by checking appropriate boxes.
Ambient Temperature
:
_____________ □ Celsius □ Fahrenheit
Return Air Dry Bulb Temperature
:
_____________ □ Celsius □ Fahrenheit
Return Air Wet Bulb Temperature
:
_____________ □ Celsius □ Fahrenheit
Supply Air Dry Bulb Temperature
:
_____________ □ Celsius □ Fahrenheit
Supply Air Wet Bulb Temperature
:
_____________ □ Celsius □ Fahrenheit
Air Velocity of indoor unit
:
_____________ □ m/sec □ ft/sec
Air Volume of indoor unit
:
_____________ □ m3/sec □ cfm
Indoor Fan Speed
: □ High □ Medium □ Low
Mode of Operation
: □ Cooling □ Heating
Refrigerant Type
:
_____________ □
Mass of Refrigerant Charge
:
_____________ □ grams □ pounds
Suction Pressure
:
_____________ □ kPa □ psi
Discharge Pressure
:
_____________ □ kPa □ psi
Condenser Subcooling
:
_____________ □ Kelvin □ Fahrenheit Degrees
Total System Superheat
:
_____________ □ Kelvin □ Fahrenheit Degrees
Compressor Operating Current
:
_____________ □ Amps
Indoor Fan Operating Current
:
_____________ □ Amps
Test Project For Skills Refrigeration and Air Conditioning
National Vocational Students Skills Competition - 2017
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7.
COOLING PROCESS
Plot the supply and return air conditions as specified in your commissioning report on the
psychrometric chart supplied. Join the supply and return conditions with a line as per below
example.
Test Project For Skills Refrigeration and Air Conditioning
National Vocational Students Skills Competition - 2017
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LKS2017_TPRA.doc Bagian D
BAGIAN D
GAMBAR / DRAWING
Test Project For Skills Refrigeration and Air Conditioning
National Vocational Students Skills Competition - 2017
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DrawingR.001
Test Project For Skills Refrigeration and Air Conditioning
National Vocational Students Skills Competition - 2017
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Drawing R.002
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National Vocational Students Skills Competition - 2017
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Drawing R.003
Test Project For Skills Refrigeration and Air Conditioning
National Vocational Students Skills Competition - 2017
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Drawing R.004
Test Project For Skills Refrigeration and Air Conditioning
National Vocational Students Skills Competition - 2017
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Drawing R.005
Test Project For Skills Refrigeration and Air Conditioning
National Vocational Students Skills Competition - 2017
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DrawingR.006
Test Project For Skills Refrigeration and Air Conditioning
National Vocational Students Skills Competition - 2017
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DrawingR.007
Test Project For Skills Refrigeration and Air Conditioning
National Vocational Students Skills Competition - 2017
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DrawingR.008
Test Project For Skills Refrigeration and Air Conditioning
National Vocational Students Skills Competition - 2017
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DrawingR.009
Test Project For Skills Refrigeration and Air Conditioning
National Vocational Students Skills Competition - 2017
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DrawingR.010
Test Project For Skills Refrigeration and Air Conditioning
National Vocational Students Skills Competition - 2017
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Test Project For Skills Refrigeration and Air Conditioning
National Vocational Students Skills Competition - 2017
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Test Project For Skills Refrigeration and Air Conditioning
National Vocational Students Skills Competition - 2017
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LKS2017_TPRA.doc Bagian E
BAGIAN E
PERALATAN & PERLENGKAPAN PESERTA
Test Project For Skills Refrigeration and Air Conditioning
National Vocational Students Skills Competition - 2017
Page 42
Peralatan yang disiapkan peserta
Peralatan berikut merupakan peralatan minimum yang dibawa oleh setiap peserta lomba
dan yang akan digunakan selama lomba berlangsung, peserta diperbolehkan membawa
peralatan lain yang dianggap perlu dan membantu dalam proses mengerjakan soal lomba.
Competitor Supply
Measuring, Preparatory pahse
Writing equipment, including, pencils,
coloured
pens,
paper, highlighters
Tape measure: 5 m
Centre punch
Pipe reamer
Scribe
Set of drills: 1-10 mm
Spirit level
Tong-ammeter
Metal Rule: 300 mm
Knife
Hammer
Hacksaw
Screw drivers
Try-square
Set squares
Long nose pliers
Mechanical tasks
Tube cutter, up to 22 mm
Files: flat, half round and round
Pipe Bending Machine 6 mm
Pipe Bending Machine 10 mm
Pipe Bending Machine 12 mm
Mechanical tube benders,
Set of spanners up to 25 mm
Shifting spanners
Side cutting pliers
Steel wool
Oil can
Refrigeration
Set of gauges R-134a and R410A
Gauge manifold set R134a and R410A
Vacuum gauge, down to 50 Pascal
Scale digital balanced
Ratchet key
Schrader valve key
Allen keys – imperial and metric
Vacuum pump
Digital Thermometers with at least 2 sensors
Electronic Leak Detector
Leak detection solution
Small mirror
Electrical Work
Wire Strippers
Electrician’s pliers
Multigrips
Electrical Crimping Tools
Megohmmeter
Multi-meter
Safety
Clothing, long sleeves, long work trousers
Emergency cloth
Safety shoes
Clear Safety glasses
Gloves
Test Project For Skills Refrigeration and Air Conditioning
National Vocational Students Skills Competition - 2017
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LKS2017_TPRA.doc Bagian F
BAGIAN F
SKEMATIK PENILAIAN
Test Project For Skills Refrigeration and Air Conditioning
National Vocational Students Skills Competition - 2017
Page 44
SKEMATIK PENILAIAN
Berikut ini adalah Rangkuman skala penilaian untuk bidang Refrigerasi & Air Conditioning yang
harus dipersiapkan oleh seluruh peserta sesuai bahasa masing-masing pada bagian Informasi,
dilakukan sebelum pelaksanaan lomba.
Gambaran teknis untuk Refrigerasi & Air Conditioning pada bagian F merupakan daftar
keterampilan yang harus dipenuhi oleh peserta lomba dan kriteria penilaian akan di berikan untuk
semua modul berikut:
Kriteria Keterampilan (Skill)
Nilai Maksimum
A
Component fabrication
12.00
B
Component and System Installation
20.00
C
Electrical Installation
12.00
D
Commissioning and Adjustment
24.00
E
Mechanical Fault Finding & Repair
10.00
F
Refrigerant Recovery & Emission Control
13.00
G
Health and Safety
Total
Test Project For Skills Refrigeration and Air Conditioning
National Vocational Students Skills Competition - 2017
9.00
100.00
Page 45
National Vocational Students Skills Competition - 2017
Test Project For Skills Refrigeration and Air Conditioning
National Vocational Students Skills Competition - 2017
Page 1
DAFTAR ISI
Dokumen-dokumen dalam lembar soal berikut meliputi beberapa
bagian diantaranya adalah :
1. LKS2017_TPRA.doc Bagian A : Kisi-Kisi Lomba
2. LKS2017_TPRA.doc Bagian B : Petunjuk Lomba
3. LKS2017_TPRA.doc Bagian C : Soal – Soal Lomba
4. LKS2017_TPRA.doc Bagian D : Gambar / Drawing
5. LKS2017_TPRA.doc Bagian E : Peralatanan Perlengkapan
6. LKS2017_TPRA.doc Bagian F : Skematik Penilaian
Test Project For Skills Refrigeration and Air Conditioning
National Vocational Students Skills Competition - 2017
Page 2
LKS2017_TPRA.doc Bagian A
BAGIAN A
KISI-KISI LOMBA
Test Project For Skills Refrigeration and Air Conditioning
National Vocational Students Skills Competition - 2017
Page 3
INFORMASI LOMBA
DESKRIPSI TEKNIK
A.
Nama dan Deskripsi Kompetensi
1. Nama kompetensi adalah Teknik Pendingin dan Tata Udara
2. Jenis yang dikompetensikan pada Teknik Pendingin dan Tata Udara adalah perakitan
dan pengelasan, sistem pemipaan refrigerasi dan pemasangan sisten AC split
3. Peserta Lomba dipilih oleh propinsinya masing-masing.
4. Syarat peserta adalah siswa SMK yang sesuai dengan jurusan Teknik Pendingin dan
Tata Udara
5. Kompetisi dilakukan secara individual. Jumlah peserta dalam 1 team mewakili 1 SMK
dan 1 team terdiri dari 1 orang.
B.
Ruang Lingkup Kompetensi :
1. Peserta harus mampu :
a. Membaca gambar kerja pemipaan dan kelistrikan sistem refrigerasi dan tata udara
b. Membentuk berbagai macam pola sambungan pemipaan dan penggunaan peralatan
mekanik guna mendukung sistem refrigerasi dan tata udara.
c. Memasang AC split pada papan panel dan menguji coba hasil rakitannya,
d. Memasang sistem pemipaan refrigerasi pada display dan menguji coba hasil
rakitannya
e. Menemukan dan menganalisa kesalahan sistem kelistrikan dan sistem refrigerasi.
2. Proyek dilaksanakan dalam 3 hari dimulai pukul 08.00 sampai pukul 17.00
C.
Kerja Praktik :
1. Desain: proyek akan didesain dengan menggunakan komponen industri sesungguhnya
yaitu AC split, kompresor,evaporator, kondenser, dan alat ekspansi
2. Pemasangan: refrigerasi dan tata udara dipasang pada papan panel peraga sesuai
dengan gambar rancangan,
3. Komisioning: rancangan harus dapat difungsikan sesuai dengan instruksi/dokumentasi.
4. Tidak ada kesalahan yang disengaja dilakukan oleh peserta.
5. Troubleshooting: mencari kesalahan pada rangkaian yang kesalahannya dibuat oleh juri.
D.
Pengetahuan Teori :
1. Desain rangkaian: peserta harus mengetahui fungsi komponen-komponen utama sistem
tata udara dan refrigerasi, elektrik dan aksesories lainya serta dapat menjelaskan fungsi
rangkaian.
2. Analisa teknik: peserta harus mampu menganalisa rangkaian untuk menemukan
kesalahan-kesalahan yang terjadi pada rangkaian kontrol.
E.
Material :
Disediakan oleh panitia lomba :
1. AC Split set
2. Condensing Unit
3. Recovery unit
4. Sumber listrik 220 VAC
5. Bahan Utama sistem pendingin
Test Project For Skills Refrigeration and Air Conditioning
National Vocational Students Skills Competition - 2017
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Test Project For Skills Refrigeration and Air Conditioning
National Vocational Students Skills Competition - 2017
Page 5
Disediakan oleh peserta :
1. Diperbolehkan membawa multi meter sendiri
2. Diperbolehkan membawa manifold gauge sendiri
3. Membawa peralatan tulis.
4. Peralatan yang diperlukan untuk perakitan dan pengelasan pipa, pemasangan air
conditioner, dan pemasangan sistem refrigerasi pada refrigerator dan display case.
F.
Ruangan :
Minimal ruangan adalah 18 x 21 m dan dilengkapi dengan meja dan kursi untuk peserta,
meja untuk peralatan komponen, meja untuk juri/panitia, dan dilengkapi dengan sumber
listrik 220V
G.
Kriteria Penilaian :
1. Ketepatan ukuran dan kerapihan hasil kerja para peserta
2. Peralatan yang dirancang dapat bekerja sesuai dengan lembar kerja yang diberikan ,
3. Tidak melebihi waktu yang diberikan dalam merakit, realisasi, dan mencari kesalahan
(troubleshooting),
4. Waktu yang dinilai adalah waktu sebelum waktu maksimum dengan hasil pekerjaan
benar.
5. Kebenaran rangkaian setelah proses trouble-shooting.
GAMBARAN UMUM SOAL LOMBA
A. Bentuk Soal
Soal yang dikompetensikan adalah perakitan sistem refrigerasi dan tata udara, bentuk detail
soal dalam bahasa Inggris.
B. Soal
1. Fabrikasi Komponen
a. Membentuk pipa sesuai dengan tuntutan gambar kerja dan mengelasnya sehingga
membentuk sambungan yang kokoh dan tidak bocor.
b. Melakukan proses perakitan.
2. Perakitan Sisten Refrigerasi
a. Merakit sistem refigerasi dan sistem kelistrikan sesuai gambar dan melakukan
pengaturansuhu sesuai menu yang ada pada sistem kontrol alat tersebut.
b. Menjalankan sistem refrigerasi dan control
c. Melakukan pressure test, evaluasi dan charging with refrigerant
d. Melakukan komisioning sistem refrigerasi
3. Pemasangan sistem tata udara (unit AC) pada papan peraga :
Memasang (instalasi) unit AC sesuai dengan spesifikasi produk yang telah dibuat oleh
manufakturing, detail berupa :
a. Membangun sistem pemipaan untuk AC Split
b. Merakit sistem kelistrikan AC Split pada papan peraga sesuai gambar yang ditentukan.
c. Mencari dan menganalisa gangguan sistem kelistrikan dan mekanik yang ada pada
Split Air Conditioner
d. Melakukan proses recovery refrigeran pada unit air conditioning
Test Project For Skills Refrigeration and Air Conditioning
National Vocational Students Skills Competition - 2017
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Test Project For Skills Refrigeration and Air Conditioning
National Vocational Students Skills Competition - 2017
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5. Kriteria Soal Lomba, Nilai dan Waktu
Soal Lomba
a. Component Fabrication
b. Refrigeration System Installation & Commissioning
c. Air-Conditioning System Installation & Commissioning
Nilai
15poin
55 poin
30poin
Waktu
4.0 jam
8.0jam
6.0jam
C. Jadual Kegiatan :
1. Hari ke 1 :
• Familiarisasi peralatan,
• Pembukaan
2. Hari ke 2 :
• Test Project 1: Component Fabrication
3. Hari ke 3 :
• Test Project 2: Refrigeration system installation & commisioning
4. Hari ke 4 :
• Test Project 3: Air conditioning Installing & Commissioning
5. Hari ke 5 :
Penutupan
Test Project For Skills Refrigeration and Air Conditioning
National Vocational Students Skills Competition - 2017
Page 8
LKS2017_TPRA.doc Bagian B
BAGIAN B
PETUNJUK LOMBA
Test Project For Skills Refrigeration and Air Conditioning
National Vocational Students Skills Competition - 2017
Page 9
PETUNJUK UNTUK PESERTA LOMBA
Soal LKS ini dibuat untuk menguji peserta Lomba dalam memasang atau merakit peralatan sistem
refrigerasi dan Tata Udara (split air conditioner), termasuk melakukan proses perbaikan pada
peralatan tersebut.
A. Soal Lomba
Ada Lima (3) soal lomba yang akan diujikan dengan total waktu adalah 18 jam.
1. Component Fabrication
2. Refrigeration System Installation & Commissioning
3. Air-Conditioning System Installation & Commissioning
15 poin
55poin
30poin
4.0 jam
8.0jam
6.0jam
B. Informasi Tambahan
Beberapa informasi tambahan berkenaan dengan lomba akan diberikan pada saat kompetisi
diantaranya adalah :
- Jadwal detail lomba.
- Persyaratan yang berhubungan dengan keselamatan dan kesehatan kerja (K3)
- Kategori peraturan dan prosedur lomba
- Dan beberapa informasi lain yang dianggap perlu untuk disampaikan
C. Alokasi Waktu Penyelesaian Soal
Setiap peserta lomba diwajibkan untuk dapat menyelesaikan soal sesuai dengan waktu yang
telah ditetapkan dan tidak diberikan penambahan nilai pada saat peserta dapat menyelesaikan
soal lebih cepat daripada waktu yang telah ditetapkan. Penambahan waktu tidak akan diberikan
kepada seluruh peserta.
Pada saat peserta telah menyelesaikan pemipaan peserta harus meminta juri menilai
pekerjaannya dengan melakukan test kebocoran kurang lebih 15 menit sebelum melanjutkan
pada tahap berikutnya, dan juga 10 menit untuk menilai hasil proses pemvakuman yang
dilakukan oleh peserta.
D. Poin Pengecekan
Hal penting dalam lomba ini adalah adanya prosedur yang menghendaki setiap peserta untuk
meminta kepada juri untuk mengobservasi setiap langkah kerja yang dilakukannya. Sebagai
contoh pada saat peserta telah menyelesaikan proses pemvakuman unit, maka peserta meminta
salah seorang juri untuk melakukan observasi hasil pekerjaannya dan meminta juri untuk
menandatangani kotak proses vakum yang tersedia dalam soal. Silahkan lihat pada contoh
berikut :
Proses Pemvakuman Sistem
Juri:
Test Project For Skills Refrigeration and Air Conditioning
National Vocational Students Skills Competition - 2017
Page 10
Informasi Keselamatan (Safety)
Selama Lomba, seluruh peserta diwajibkan mengikuti dan melaksanakan aturan keselamatan yang
telah ditetapkan, yaitu :
1.
Sepatu Kerja :
Diwajibkan untuk menggunakan sepatu keselamatan (Safety Shoes).
2.
Pakaian Kerja :
• Menggunakan baju kerja dengan bagian tangan dan kaki sepenuhnya terlindungi (trousers
or overalls).
• Tubuh bagian atas selalu tertutup.
• Lengan harus tertutup dengan menggunakan pakaian lengan panjang pada saat
pengelasan dan penanganan Refrigerant.
3.
Pelindung Mata
• Wajib mengenakan pelindung mata (Kaca Mata) putih atau Clear Glasses.
• Terutama untuk pekerjaan brazing, soldering, filing, reaming, hack-sawing, drilling, grinding
dan penanganan refrigerant, dry nitrogent dan udara bertekanan., termasuk ketika sedang
mengerjakan pekerjaan kelistrikan.
4.
Sarung Tangan
• Harus digunakan pada saat Brazing dan penanganan refrigerants
• Wajib digunakan pada saat melakukan pekerjaan kelistrikan termasuk pengujian kelistrikan.
5.
Kelistrikan
Seluruh peserta wajib untuk meminta izin dari Juri pada saat ingin mengoperasikan semua
peralatan listrik kecuali peralatan kerja seperti Bor dan hand power tools lainnya.
Setiap peserta yang terindikasi tidak menggunakan peralatan keselamatan yang telah ditentukan
dapat diberhentikan aktivitasnya oleh Juri sampai peserta tersebut memenuhi persyaratan
keselamatan yang dimaksud.
LKS2017_TPRA.doc Bagian C
Test Project For Skills Refrigeration and Air Conditioning
National Vocational Students Skills Competition - 2017
Page 11
BAGIAN C
SOAL – SOAL LOMBA
Test Project For Skills Refrigeration and Air Conditioning
National Vocational Students Skills Competition - 2017
Page 12
Competition Details - Module 1
Component Fabrication
Maximum Time Allowed – 4 hours
15 Marks
SCOPE
The Competitors are required to fabricate a copper tubing circuit for the secondary refrigerant circuit
that will form the ice rink surface, this coil will be incorporated into the design of the system at a later
stage. The coil is constructed using 13 lengths of 1/2” copper tubing, fed by a 7/8” copper header as
per supplied drawing. This entire unit will sit in the bottom of a tank and form the secondary
refrigerant coil for the ice rink being installed in Module B.
TIMING
Competitors are to all complete the ice rink piping at the same time in the morning of C1, this will
allow for marking to take place in the afternoon, any Competitors that do not finish Module A in the
allocated time will be required to submit the unfinished project for assessment. Competitors will
receive additional points for completing this module in less than the allocated time (as defined in the
marking summary) providing that the fabricated component does not leak when pressure tested.
ASSESSMENT
Competitors will be assessed as per technical description, the marking scale will reflect dimensions
and tolerances for assessment in addition to the quality of brazed joints. Fabricated component will
be tested for leaks by pressure testing with dry nitrogen to ensure no leaks are present. Any
Competitor who does not complete Module A in the required time (4 hours) will be allowed to
complete it after it is assessed and handed back to them during Module B – no additional time will
be allowed for either Module A or Module B for those who do not complete the fabrication in the
allotted time.
DRAWINGS
R.001 Ice Ring Coil
Test Project For Skills Refrigeration and Air Conditioning
National Vocational Students Skills Competition - 2017
Page 13
Competition Details - Module 2
Refrigeration System Installation and Commissioning
Maximum Time Allowed – 8 hours
55 Marks
SCOPE
Competitors are to install a refrigeration system to refrigerate a small scale ice rink, the system uses
a secondary refrigerant to remove heat from the ice rink and mimics a small industrial plant
commonly used to carry out a much larger duty.
The Competitors are required to use the supplied components along with the coil fabricated in
Module A to form a low pressure flooded system that utilizes a brazed plate heat exchanger to
refrigerate propylene glycol to remove heat from water to form the ice rink. A small condensing unit
is used to draw vapour off the top of the vessel and compress and condense the refrigerant, an
electric expansion valve is used to meter the refrigerant into the vessel. Two level switches are used
to control the liquid level inside the vessel, a capacity control valve is used to ensure suction
pressure does not drop below design. Refrigerant is R134a.
Secondary refrigerant circuit for ice rink is to be constructed using copper pipe, copper pipe will be
used to form the secondary refrigerant pipe circuit joining heat exchanger, ice rink coil and glycol
tank with a flexible hose connection used to connect the copper pipe to the circulating pump.
Competitors are required to connect all components to a prewired electrical panel
TIMING
Competitors are to all complete the installation over C1, C2 and C3. The secondary refrigerant
circuit (glycol) pipework must be completed by the end of C2 for assessment overnight, the entire
installation will be completed by the end of C3 for assessment. The completed project with ice rink
frozen may be left running and displayed on C4.
ASSESSMENT
Competitors will be assessed as per technical description with particular weighting on the
commissioning and operation of the project.
DRAWINGS
R.002 Primary refrigerant flow circuit
R.003 Tube in tube heat exchanger
R.004 Ice ring & glycol tank
R.005 Refrigeration Installation Bay Frame
R.006 Refrigeration Installation
R.007 Electrical Control Diagram
R.008 Electrical Control Panel
Test Project For Skills Refrigeration and Air Conditioning
National Vocational Students Skills Competition - 2017
Page 14
COMPONENTS
Basic air cooled condensing unit with liquid receiver
Expansion valve (Danfoss AKV)
Tube in tube heat exchanger (Danfoss)
Circulating pump (submersible type)
Ice ring coil
Electrical switchboard
Temperature controller (Danfoss)
SYSTEM DESIGN SPECIFICATIONS
The following system design specifications for the installation should be used for commissioning and
control setting and are as follows:
SPESIFICATION DESIGN SYSTEM
Primary refrigerant = R134a
Secondary refrigerant = Propylene Glycol (40% by volume)
Maximum ambient temperature = 35°C Db, 28°C Wb
Design saturated suction temperature = -15 °C
Suction line pressure drop = 1 K
Design Glycol temperature = -10°C supply to ice rink
CONTROL AND SAFETY SETTING
Low Pressure Controller cut off 5K lower than design saturated suction temperature (SST).
Low Pressure Controller cut in at -10 °C saturated suction temperature
Capacity control valve to maintain -15 °C saturated suction temperature
High Pressure cut out the system when the Condensing temperature reaches 55 °C
Temperature controller cut out at -15 °C
Temperature controller cut in at -10 °C
Temperature sensor to be submerged in glycol tank
SYSTEM OPERATION
Low level liquid level sensor to cycle on electric expansion valve
High level liquid level sensor to cycle off electric expansion valve
Test Project For Skills Refrigeration and Air Conditioning
National Vocational Students Skills Competition - 2017
Page 15
Temperature controller to cycle off expansion valve if glycol tank temperature falls below -15
°C
Temperature controller to cycle on expansion valve if glycol tank temperature rises above
-10 °C
Capacity control valve set to maintain -15 °C saturated suction temperature and limit
temperature cycling to safety only (unit should run continually and not cycle on and off)
Test Project For Skills Refrigeration and Air Conditioning
National Vocational Students Skills Competition - 2017
Page 16
INSTALL AND COMMISSION REFRIGERATION SYSTEM
1.
INSTALL REFRIGERATION SYSTEM
All Competitors will supplied with all necessary equipment and materials to complete the installation
of the refrigeration system in accordance with test project drawings and WorldSkills International
Standard for Refrigeration and Air Conditioning.
Refer to the following project drawings to assist to complete this task
R.002 Primary refrigerant flow circuit
R.003 Tube in tube heat exchanger
R.004 Ice ring & glycol tank
R.005 Refrigeration Installation Bay Frame
R.006 Refrigeration Installation
2.
INSTALL ELECTRICAL SYSTEM
All Competitors will supplied with all necessary equipment and materials to complete the installation
of the refrigeration system in accordance with test project drawings and WorldSkills International
Standard for Refrigeration and Air Conditioning.
All cabling to be installed in double insulated, flexible cable or single insulated cable protected by
conduit, no single insulated cable is to be left without additional protection.
All temperature probe cables to be protected by conduit.
Refer to the following project drawings to assist to complete this task
R.007 Electrical Control Diagram
R.008 Electrical Control Panel
3.
PRESSURE TEST SYSTEM
Carry out a staged pressure test of the primary refrigeration system (R134a) to a value of 9.5 bar
gauge (950kpa). The pressure test point should not drop from the starting point in the fifteen (15)
minutes after the pressure test is isolated from the Nitrogen cylinder. If the pressure test has not
been achieved, the Competitor can continue to fix the leak and achieve the pressure test, however
the full mark for Pressure Test will be lost. The pressure test will be monitored remotely via a data
logging process to ensure all Competitors achieve the required pressure and standing time.
Test Project For Skills Refrigeration and Air Conditioning
National Vocational Students Skills Competition - 2017
Page 17
To be filled in by COMPETITORS
PRESSURE TEST ATTEMPT #1
Starting test pressure
:
Starting Time
:
Test pressure after standing time
:
Finishing Time
:
PRESSURE TEST ATTEMPT #2
Starting test pressure
:
Finishing Time
:
Test pressure after standing time
:
Finishing Time
:
Test Project For Skills Refrigeration and Air Conditioning
National Vocational Students Skills Competition - 2017
□ kPa □ psi
□ kPa □ psi
□ kPa □ psi
□ kPa □ psi
Page 18
4.
EVACUATION
Evacuate the primary refrigeration system (R134a) in accordance with manufacturer’s instructions
and WorldSkills standards using the Deep Vacuum Method to hold a vacuum of at least 1000
microns (130Pa absolute) of mercury. The evacuation point should not rise to a value greater than
1000 microns in the Ten (10) minutes after the vacuum pump is isolated from the system under test.
To be filled in by EXPERTS ONLY
EVACUATION TEST ATTEMPT #1
Starting evacuation level
:
Starting Time
:
Evacuation level after standing time
:
Finishing Time
:
□ Microns
□ Microns
EVACUATION TEST ATTEMPT #2
Starting evacuation level
:
Starting Time
:
Evacuation level after standing time
:
Finishing Time
:
□ Microns
□ Microns
Comments :
Refrigeration Evacuation Test
Expert 1 Initials :
Expert 2 Initials :
Expert 3 Initials :
Test Project For Skills Refrigeration and Air Conditioning
National Vocational Students Skills Competition - 2017
Page 19
5.
CHARGING WITH REFRIGERANT – PRIMARY CIRCUIT
Charge the primary refrigeration system (R134a) with the required weight of refrigerant to ensure
operation according to specification above, and in accordance with acceptable trade and
environmental practices.
To be filled in by EXPERTS ONLY
Bottle weight prior to charging
:
□ Kg □ Lb
Bottle weight at completion of charging
:
□ Kg □ Lb
Comments :
6.
CHARGING WITH REFRIGERANT – SECONDARY CIRCUIT
Charge the secondary refrigeration system (propylene glycol) with the required quantity of glycol
and water to ensure operation according to specification above, and in accordance with acceptable
trade and environmental practices.
To be filled in by EXPERTS ONLY
Bottle volume prior to charging
:
□ L □ fl oz
Bottle volume at completion of charging
:
□ L □ fl oz
Comments :
7.
ELECTRICAL TESTING
Under the supervision of an Expert, perform all necessary safety checks to ensure the Test Project
is safe to energize.
Competitor Name
:
All wiring inspected by Expert prior to energizing
: □ Yes
Electrical safety checks performed prior to energizing
: □ Yes
Comments :
Refrigeration Evacuation Test
Expert 1 Initials :
Expert 2 Initials :
Test Project For Skills Refrigeration and Air Conditioning
National Vocational Students Skills Competition - 2017
Page 20
Expert 3 Initials :
8. COMMISSION THE SYSTEM
Competitors are to commission the system for operation in accordance with the design
specifications supplied. Please fill out the following commissioning document with the system fully
operational and as close to operating temperatures as possible. Please indicate units by checking
appropriate boxes.
Ambient Temperature
: _____________ □ Celsius □ Fahrenheit
Refrigerant Type
: _____________ □
Mass of Refrigerant Charge
: _____________ □ grams □ pounds
Suction Pressure
: _____________ □ kPa □ psi
Discharge Pressure
: _____________ □ kPa □ psi
Condenser Subcooling
: _____________ □ Kelvin □ Fahrenheit Degrees
Total System Superheat
: _____________ □ Kelvin □ Fahrenheit Degrees
LP Control Cut In
: _____________ □ kPa □ psi
LP Control Cut Out
: _____________ □ kPa □ psi
HP Control Cut Out
: _____________ □ kPa □ psi
HP Control Cut In
: _____________ □ kPa □ psi
Capacity regulator setting
: _____________ □ Celsius □ Fahrenheit
Glycol supply to ice rink temp
: _____________ □ Celcius □ Fahrenheit
Glycol return from ice rink temp
: _____________ □ Celsius □ Fahrenheit
Condensing Unit Operating Current
: _____________ □ Amps
Glycol Pump Operating Current
: _____________ □ Amps
Test Project For Skills Refrigeration and Air Conditioning
National Vocational Students Skills Competition - 2017
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Test Project For Skills Refrigeration and Air Conditioning
National Vocational Students Skills Competition - 2017
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Competition Details - Module 3
Air Conditioning System Installation, Fault Finding,
Repair and Commissioning
Maximum Time Allowed – 6 hours
30Marks
SCOPE
Competitors will be provided with an air conditioning system that has been leak tested and verified
to have no leaks, pressure testing of the system is not required at any point in time. Competitors will
be required to identify 1x electrical fault and 1x refrigeration system fault on the supplied air
conditioning systems, once faults have been identified the Competitors will be required to repair the
faults including full refrigerant recovery and recharging of refrigerant charge to manufacturer’s
specifications. Competitors will then be required to commission the system and plot operating
conditions on a psychometric chart.
TIMING
Competitors will be assessed as per technical description with particular weighting on the fault
finding and commissioning of the project.
ASSESSMENT
Competitors will be assessed as per technical description with particular weighting on the fault
finding and commissioning of the project.
DRAWINGS
R.009 Air Conditioning Installation Bay Frame
R.010 Air Conditioning Installation
R.011 Psychometric chart (SI units)
R.012 Psychometric chart (IP units)
1.
FAULT FINDING
All Competitors are required to identify 1 x electrical fault and 1 x refrigeration system fault with the
operation of the unit, the root cause must be found and repaired. Once the fault is identified
Competitors are to fill in this sheet of paper identifying what they believe to be the fault with the
equipment. An Expert then needs to sign this sheet of paper.
All fault finding MUST be done with all relevant safety rules adhered to.
Once faults are found and recorded the Competitor is free to continue by running the unit and
progressing to the next stage of the Module.
ELECTRICAL SYSTEM FAULT
Please write down what the fault with the equipment is and any supporting information that indicates
what the fault was.
_______________________________________________________________________________
_______________________________________________________________________________
__________________________________________________________
Test Project For Skills Refrigeration and Air Conditioning
National Vocational Students Skills Competition - 2017
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_______________________________________________________________________________
_____________________________
Please indicate what repairs need to be done to the system to return it to normal operation
_______________________________________________________________________________
_______________________________________________________________________________
_______________________________________________________________________________
_______________________________________________________________________________
________
REFRIGERATION SYSTEM FAULT
Please write down what the fault with the equipment is and any supporting information that indicates
what the fault was.
_______________________________________________________________________________
_______________________________________________________________________________
_______________________________________________________________________________
_______________________________________________________________________________
________
Please indicate what repairs need to be done to the system to return it to normal operation
_______________________________________________________________________________
_______________________________________________________________________________
_______________________________________________________________________________
_______________________________________________________________________________
________
2.
REPAIR SYSTEM
All Competitors are required to repair the faults they have identified on the unit, refrigerant must be
removed from the system to repair the refrigeration fault. All necessary materials will be provided to
repair the equipment and return it to an operating state
All repairs MUST be done with all relevant safety rules adhered to.
3.
RECLAIM SISTEM
All Competitors are required to repair the fault they have identified on the unit, the refrigerant will
need to be removed from the system to complete the repair then the system pressure tested,
evacuated and recharged with refrigerant. All necessary materials will be provided to repair the
equipment and return it to an operating state.
All repairs MUST be done with all relevant safety rules adhered to.
Test Project For Skills Refrigeration and Air Conditioning
National Vocational Students Skills Competition - 2017
Page 24
To be filled in by EXPERTS ONLY
Reclaim system
Reclaim bottle weight prior to reclaim
:
Reclaim bottle weight at completion of reclaim :
Test Project For Skills Refrigeration and Air Conditioning
National Vocational Students Skills Competition - 2017
□ Kg □ Lb
□ Kg □ Lb
Page 25
4.
EVACUATION
Evacuate the refrigeration system in accordance with manufacturer’s instructions and WorldSkills
standards using the Deep Vacuum Method to hold a vacuum of at least 1000 microns (130Pa
absolute) of mercury. The evacuation point should not rise to a value greater than 1000 microns in
the Ten (10) minutes after the vacuum pump is isolated from the system under test.
To be filled in by EXPERTS ONLY
Evacuation Test
Starting evacuation level
:
Starting Time
:
Evacuation level after standing time
:
Finishing Time
:
□ Microns
□ Microns
Comments :
Refrigeration Evacuation Test
Expert 1 Initials :
Expert 2 Initials :
Expert 3 Initials :
5.
CHARGING WITH REFRIGERANT
Charge the refrigeration system with the required weight of refrigerant to ensure operation
according to specification above, and in accordance with acceptable trade and environmental
practices.
To be filled in by EXPERTS ONLY
Refrigerant Charging
Bottle weight prior to charging
:
□ Kg □ Lb
Bottle weight at completion of charging
:
□ Kg □ Lb
Comments :
Test Project For Skills Refrigeration and Air Conditioning
National Vocational Students Skills Competition - 2017
Page 26
6.
COMMISSION THE SYSTEM
Competitors are to commission the system for operation in accordance with the manufacturers
specifications supplied. Please fill out the following commissioning document with the system fully
operational, on “Cooling” mode, indoor fan on highest speed and as close to operating temperatures
as possible. Please indicate units by checking appropriate boxes.
Ambient Temperature
:
_____________ □ Celsius □ Fahrenheit
Return Air Dry Bulb Temperature
:
_____________ □ Celsius □ Fahrenheit
Return Air Wet Bulb Temperature
:
_____________ □ Celsius □ Fahrenheit
Supply Air Dry Bulb Temperature
:
_____________ □ Celsius □ Fahrenheit
Supply Air Wet Bulb Temperature
:
_____________ □ Celsius □ Fahrenheit
Air Velocity of indoor unit
:
_____________ □ m/sec □ ft/sec
Air Volume of indoor unit
:
_____________ □ m3/sec □ cfm
Indoor Fan Speed
: □ High □ Medium □ Low
Mode of Operation
: □ Cooling □ Heating
Refrigerant Type
:
_____________ □
Mass of Refrigerant Charge
:
_____________ □ grams □ pounds
Suction Pressure
:
_____________ □ kPa □ psi
Discharge Pressure
:
_____________ □ kPa □ psi
Condenser Subcooling
:
_____________ □ Kelvin □ Fahrenheit Degrees
Total System Superheat
:
_____________ □ Kelvin □ Fahrenheit Degrees
Compressor Operating Current
:
_____________ □ Amps
Indoor Fan Operating Current
:
_____________ □ Amps
Test Project For Skills Refrigeration and Air Conditioning
National Vocational Students Skills Competition - 2017
Page 27
7.
COOLING PROCESS
Plot the supply and return air conditions as specified in your commissioning report on the
psychrometric chart supplied. Join the supply and return conditions with a line as per below
example.
Test Project For Skills Refrigeration and Air Conditioning
National Vocational Students Skills Competition - 2017
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LKS2017_TPRA.doc Bagian D
BAGIAN D
GAMBAR / DRAWING
Test Project For Skills Refrigeration and Air Conditioning
National Vocational Students Skills Competition - 2017
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DrawingR.001
Test Project For Skills Refrigeration and Air Conditioning
National Vocational Students Skills Competition - 2017
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Drawing R.002
Test Project For Skills Refrigeration and Air Conditioning
National Vocational Students Skills Competition - 2017
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Drawing R.003
Test Project For Skills Refrigeration and Air Conditioning
National Vocational Students Skills Competition - 2017
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Drawing R.004
Test Project For Skills Refrigeration and Air Conditioning
National Vocational Students Skills Competition - 2017
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Drawing R.005
Test Project For Skills Refrigeration and Air Conditioning
National Vocational Students Skills Competition - 2017
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DrawingR.006
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National Vocational Students Skills Competition - 2017
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DrawingR.007
Test Project For Skills Refrigeration and Air Conditioning
National Vocational Students Skills Competition - 2017
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DrawingR.008
Test Project For Skills Refrigeration and Air Conditioning
National Vocational Students Skills Competition - 2017
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DrawingR.009
Test Project For Skills Refrigeration and Air Conditioning
National Vocational Students Skills Competition - 2017
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DrawingR.010
Test Project For Skills Refrigeration and Air Conditioning
National Vocational Students Skills Competition - 2017
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Test Project For Skills Refrigeration and Air Conditioning
National Vocational Students Skills Competition - 2017
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Test Project For Skills Refrigeration and Air Conditioning
National Vocational Students Skills Competition - 2017
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LKS2017_TPRA.doc Bagian E
BAGIAN E
PERALATAN & PERLENGKAPAN PESERTA
Test Project For Skills Refrigeration and Air Conditioning
National Vocational Students Skills Competition - 2017
Page 42
Peralatan yang disiapkan peserta
Peralatan berikut merupakan peralatan minimum yang dibawa oleh setiap peserta lomba
dan yang akan digunakan selama lomba berlangsung, peserta diperbolehkan membawa
peralatan lain yang dianggap perlu dan membantu dalam proses mengerjakan soal lomba.
Competitor Supply
Measuring, Preparatory pahse
Writing equipment, including, pencils,
coloured
pens,
paper, highlighters
Tape measure: 5 m
Centre punch
Pipe reamer
Scribe
Set of drills: 1-10 mm
Spirit level
Tong-ammeter
Metal Rule: 300 mm
Knife
Hammer
Hacksaw
Screw drivers
Try-square
Set squares
Long nose pliers
Mechanical tasks
Tube cutter, up to 22 mm
Files: flat, half round and round
Pipe Bending Machine 6 mm
Pipe Bending Machine 10 mm
Pipe Bending Machine 12 mm
Mechanical tube benders,
Set of spanners up to 25 mm
Shifting spanners
Side cutting pliers
Steel wool
Oil can
Refrigeration
Set of gauges R-134a and R410A
Gauge manifold set R134a and R410A
Vacuum gauge, down to 50 Pascal
Scale digital balanced
Ratchet key
Schrader valve key
Allen keys – imperial and metric
Vacuum pump
Digital Thermometers with at least 2 sensors
Electronic Leak Detector
Leak detection solution
Small mirror
Electrical Work
Wire Strippers
Electrician’s pliers
Multigrips
Electrical Crimping Tools
Megohmmeter
Multi-meter
Safety
Clothing, long sleeves, long work trousers
Emergency cloth
Safety shoes
Clear Safety glasses
Gloves
Test Project For Skills Refrigeration and Air Conditioning
National Vocational Students Skills Competition - 2017
Page 43
LKS2017_TPRA.doc Bagian F
BAGIAN F
SKEMATIK PENILAIAN
Test Project For Skills Refrigeration and Air Conditioning
National Vocational Students Skills Competition - 2017
Page 44
SKEMATIK PENILAIAN
Berikut ini adalah Rangkuman skala penilaian untuk bidang Refrigerasi & Air Conditioning yang
harus dipersiapkan oleh seluruh peserta sesuai bahasa masing-masing pada bagian Informasi,
dilakukan sebelum pelaksanaan lomba.
Gambaran teknis untuk Refrigerasi & Air Conditioning pada bagian F merupakan daftar
keterampilan yang harus dipenuhi oleh peserta lomba dan kriteria penilaian akan di berikan untuk
semua modul berikut:
Kriteria Keterampilan (Skill)
Nilai Maksimum
A
Component fabrication
12.00
B
Component and System Installation
20.00
C
Electrical Installation
12.00
D
Commissioning and Adjustment
24.00
E
Mechanical Fault Finding & Repair
10.00
F
Refrigerant Recovery & Emission Control
13.00
G
Health and Safety
Total
Test Project For Skills Refrigeration and Air Conditioning
National Vocational Students Skills Competition - 2017
9.00
100.00
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