Report of practical work No.

1. Draw the scheme of the refrigeration unit and describe the procedure for
filling refrigerant systems with the name of the valves.

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The refrigeration system requires some means of connecting the basic major
components - evaporator, compressor, condenser, and metering device -
just as roads connect communities. Tubing or "lines" make the system
complete so that the refrigerant will not leak out into the atmosphere. The
suction line connects the evaporator or cooling coil to the compressor, the
hot gas or discharge line connects the compressor to the condenser, and the
liquid line is the connecting tubing between the condenser and the metering
device (Thermal expansion valve). Some systems will have a receiver
immediately after the condenser and before the metering device, where the
refrigerant is stored until it is needed for heat removal in the evaporator.

There are many different kinds and variations of the refrigeration cycle
components. For example, there are at least a half dozen different types of
compressor, from the reciprocating, piston through a screw, scroll and
centrifugal impeller design, but the function is the same in all cases - that of
compressing the heat laden vapor into a high-temperature vapor.

The same can be said of the condenser and evaporator surfaces. They can
be bare pipes, or they can be finned condensers and evaporators with
electrically driven fans to pass the air through tem, or with a condenser
pump to pump the water through a water-cooled condenser.
2. Safety measures when working with refrigerants, list
measures and personal protective equipment.
-Before using or handling any refrigerant, personnel should be
familiar with safety concerns for the specific product with which
they are working. This is particularly important for some of the
new replacement refrigerants. Specific product safety information
is available from the manufacturer.

Health hazards
Although the toxicity of the fluorocarbon refrigerants is low, the
possibility of injury or death exists in unusual situations, or if they
are deliberately misused. The vapors are several times heavier than
air. Good ventilation must be provided in areas where high
concentrations of the heavy vapors might accumulate and exclude
oxygen.

Inhalation of concentrated refrigerant vapor is dangerous and can

be fatal. Exposure to levels of fluorocarbons above recommended
exposure levels can result in loss of concentration and drowsiness.
There have been reported cases of fatal cardiac arrhythmia in
humans accidentally exposed to high levels. Skin or eye contact
can result in irritation and frostbite.
 Personal protective -:

-Always read the product label and the product Material Safety
Data Sheet (MSDS);

-Always use with adequate ventilation. Most fatal accidents

involving refrigerant are due to oxygen deprivation;

-Never expose refrigerants to flames, sparks or hot surfaces;

-Never trap liquid refrigerants between valves where there is no

pressure relief device. A dirty pressure relief device must be
replaced;

3. Describe the procedure for removing air from their

refrigeration unit.

There are low pressure and high pressure areas in a

refrigeration system. Air can enter in the refrigeration
plant when any part of the system pressure drops
below atmospheric pressure. If the low pressure (LP)
cut off in the plant is malfunctioning or adjusted
improperly, there is a chance that the refrigeration
compressor keep running even if suction pressure is
low and sucking the refrigeration gas into the system.
In such conditions, air may enter the system when
 pressure in the plant is lower than surrounding air
pressure.

4. List the main malfunctions of the refrigeration unit

and the steps to eliminate them.
Malfunction of refrigeration
- Defective fridge MCB:- If your fridge does not start it is always
recommended to check the MCB (miniature circuit breaker).
Problem with MCB can be a leading cause of refrigerator
breakdown. In such case call a refrigerator repair professional.

-Insufficient current- A leading reason behind refrigerator not

working is insufficient current or voltage to the unit. Check the
current and voltage of the outlet with a multi-meter and voltage
tester device.

-Faulty motor:- A defective motor is a leading reason behind

refrigerator not working problem. In many cases, the refrigerator
unit will shut down immediately or won’t start at all if the motor
is defective. Motors usually have to be replaced when they get
broken. In such case, call a fridge repair professional.

Coolant shortage:- If the fridge doesn’t have enough coolant, it

may not turn on or may not operate correctly. The coolant
circulates through the evaporator coils and cools the air flowing
over it and eventually sends cold air in the food section. So when
the level of this refrigerant becomes insufficient, the refrigerator
may not work properly. We recommend you to consult a
refrigerator repair professional to refill the coolant.

Faulty start capacitor:- When the fridge is switched ON, the

thermostat sends a signal to the start capacitor to trigger the
compressor and start the refrigeration cycle of fridge. But when
the capacitor goes bad, it fails to trigger refrigeration cycle and in
some case the refrigerator does not even start.

Report of practical work No. 5

1 Indicate the safety rules for the maintenance and repair

of ship boilers.

- Boiler water is to be kept within the upper and lower limits at all times. If
the water level disappears from either the top or the bottom of the glass
and does not return immediately, then all burners are to be shut off until
the water level has been restored in the gauge glass. Any such loss of
water must be recorded in the Engine Log Book and reported to the Chief
Engineer.

- All boiler controls, regulators, alarms and trips must be tested regularly
in accordance with the applicable Planned Maintenance System and
maker’s recommendations. Each test is to be recorded with the signature
of the Engineer Officer who conducted the test.
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Marine Boilers Repair
- Our company produces tube bundles, coil-pipes, tube sheets and
collectors for marine auxiliary boilers and marine heat recovery boilers.
- Our specialists can perform re-tubing of the boiler, replacement of
collectors or tube sheets onboard anywhere in the world. All of our
specialists hold certificates of corresponding maritime class societies that
confirm their qualification.
 2. Indicate the cleaning requirements for the inoperative boiler.

-General Maintenance of Boilers

Always look for leaks in steam, water, and fuel connections

Washing Out the Boiler

After the first three months of operation, new boilers should be shut down, drained,
opened up, flushed out with a tube high-pressure hose, and inspected. 

Cleaning the Fires

Inspect the fireside of the tubes the first time the boiler is washed out.

Lubrication in Boilers

Pump and fan motors may be equipped with either prelubricated bearings, sealed
bearings, or standard ball bearings.

Refractory Maintenance

Inspect the refractory each time the boiler is opened for cleaning.

3. How often do intermediate inspections of the boiler take place?

- Intermediate boiler inspection should be done every three month.

4 Indicate the carried-out jobs during the intermediate inspections of ship's

boilers.
-REMOVAL OF THE OLD TRFRACTORY.
MAY BE ACCOMLPISHED WITH A HAMMER AND CHISEL OR A
LIGHT PNEUMATIC HAMMER..

-THE INNER AND OUTER CASINGS ARE CON-STRUCTED OF

 RAINFORCED, SPOT-WELDED STEEL PANELS.

-OVERHAULING BOILER CASINGS TO MAKE THEM TIGHT IS

TEDIOUS AND DIFFICULT WORK..

-A COMPLETE INSPECTION OF HALL FIRESIDE SURFACES

MUST BE MADE DURING EACH BOILER OVERHAUL AND
CLEANING PERIOD.

5. Indicate the carried-out jobs during the annual inspections of ship's boilers.

-For seagoing ships, annual surveys are to be conducted for the hull and the
machinery, including the electrical plant, and, where applicable, for special
equipment classed, at intervals of 12 months, as from the date of commencement
of the class period indicated in the certificate .
- Survey period (time window): The survey has to be carried out within ± 3
months, counted from the day at which the current class period will complete one
year of validity.
- For ships with accommodations for more than 12 passengers, the annual
survey has to be carried out by no later than the due date entered

6. What is the purpose of hydraulic testing of boilers?

-Hydrostatic test is the last of the test to ensure completion ,

compliance and safety before the boiler produces steam. –
The test consists of filling the Boiler with water and pressurizing the
water to at least one and half times the maximum operating pressure for a
short time.

7. Indicate the rules for the replacement and repair of boiler furnace
refractory.

HEATING AND COOLING
SYSTEM REPAIRS AND ... Replace/modify boilers Clean heat exchanger,
adjust burner air shutter(s), ... Protection from flame contact with conversion
burners by refractory shield.

8. What is the frequency of checking the main isolating and safety valves of
boilers?

- Boiler Safety Valve Rules and Regulations: Nameplate ... must meet

regulatory specifications and require ongoing maintenance and
periodic testing. ... Proper sizing and correct installation are
the primary concerns for boiler safety valves. ... Avoid isolating safety
valves from the system, such as by installing 

9. Describe procedure of boiler safety valves adjustment?

- Safety valve pressure setting can be done from high to low pressure or vice
versa.

- Take necessary personal safety precaution and arrange tools i.e. gagging tool
and master gauges.

- Slowly raise the boiler pressure and blow off the safety valves manually few
times for thermal expansion and to reduce the thermal stress on the valves.

- Then screw down all the safety valves higher than the setting pressure at
which you are going to set.

- Raise the boiler steam pressure 2-3 % more than the designed pressure of
the boiler, then stop firing and unscrew the first valve slowly, when it blows
off at 2-3 % more than the designed pressure then note this opening and
closing pressure of the valve and finally gag it.

- The loose pin is provided to secure valve lid and allow thermal expansion.