TECHNICAL EDUCATION AND SKILLS DEVELOPMENT AUTHORITY

HEATING AND VENTILATING AIR-CONDITIONING/REFRIGERATION

(HVAC/R)
TRADE NUMBER 38

TEST PACKAGE

November 17-20, 2015

 PHILIPPINE NATIONAL SKILLS COMPETITION
I. TECHNICAL DESCRIPTION
1. INTRODUCTION
1.1 Name and Description of Skill
The Name of Skill is Refrigeration and Airconditioning
1.1.1 Description of skill
The refrigeration (HVAC/R) technician deals with the Refrigeration
System Installation & Commissioning, Airconditioning System
Installation and Commissioning, Component Fabrication & Brazing
and Mechanical Component Replacement.
The technician will operate the equipment using HFC refrigerant 404a
and 410a.

2. COMPETENCY AND SCOPE OF WORK

The competition is a demonstration and assessment of the competencies
associated with the skill. The Test Project is consists of practical works only.
2.1 Competency Specification
The competitors must be able to carry out the following task with their working skills:
• Installation of refrigerant piping
• Installation and setting of controls and regulating devices
• Installation and commissioning of completed systems
• Charging, recovering and transferring refrigerants
• Electrically connecting the components and testing the circuits
• Troubleshooting and repairing systems
• Replacing components
• Measuring and recording system operating parameters
• Interpreting manufacturers operating manuals, piping diagrams and
electrical diagrams
• Completing material list from system specifications and drawings

2.2 Practical Work

The Test Project is designed to test the skills of Competitors in the following areas:
• Refrigeration pipe work
• Electrical wiring
• Component and system installation
• Commissioning and adjustment
• Fault finding
• Repair and part replacement
 • Refrigerant recovery and control
• Work practices and safety

3. TEST PROJECT

3.1 Structure of the Test Project

The Test Project is a series of standalone modules.

The Test Project may include the following standalone modules designed to test the
skills of the Competitors:
• Module 1: Refrigeration System Installation & Commissioning
• Module 2: Air Conditioning System Installation & Commissioning
• Module 3: Fabrication and Brazing
• Module 4: Mechanical Component Replacement

3.2 Test Project Design/Schedule

Date Time Activity Marks Time

Allotted
8:15 AM – 12:00 AM Refrigeration System Installation & 4 Hrs.
Commissioning 40
Day 1 Nov 18, 2015 12:00NN - 01:00PM Lunch Break Marks 1 Hrs.
01:00PM – 05:15PM Continuation 4 Hrs.
8:30 AM to 11:30 Airconditioning System Installation 3 Hrs.
AM and Commissioning 25
Day 2 Nov 19, 2015 12:00NN-01:00PM Break Time Marks 1 hr
1:00 PM to 3:00PM Fabrication and Brazing 15 2 Hrs.
Marks
Day 3 Nov 20, 2015 8:15 AM to 11:15 Mechanical Component 20 3 Hrs.
AM Replacement Marks

4. ASSESSMENT
This section describes how the Experts will assess the Test Project/Modules. It also
specifies the assessment specifications and procedures and requirements for marking.
4.1 Assessment Criteria
This section defines the assessment criteria and the number of marks awarded.
The total number of marks for all assessment criteria must be 100.
Section Criterion Marks
Subjective Objective Total
 A Refrigeration Pipework - 40 40
B Electrical Wiring - 14 14
C Component and System Positioning - 10 10
D Commissioning and Adjustment - 10 10
E Repair and Replacement - 5 5
F Refrigerant Recovery and Emission Control - 13 13
G Safety - 8 8
Total - 100 100

4.2 Skill Assessment Specification

Section Criterion Modules
1 2 3 4 Total
A Refrigeration Pipe work 18 9 13 - 40
B Electrical Wiring 10 4 - - 14
C Component and System Positioning 5 5 - - 10
D Commissioning and Adjustment 5 5 - - 10
E Repair and Replacement - - - 5 5
F Refrigerant Recovery and Emission Control - - - 13 13
G Safety 2 2 2 2 8
Total 40 25 15 20 100

A – Refrigeration Pipe Work

• Pipe branch
• Dimension accuracy
• Flare and swage joint quality
• Silver brazing
• Strength pressure and leak test
• Brazing alloy penetration
• Suction and liquid lines to standards
• TX and Solenoid Valves assembly & position
B – Electrical Wiring
• Connection of electrical circuit
• Test the electrical circuit
• Component layout

C – Component and System Positioning

• Material list
• Condensing unit position
• Fan coil units position
• Installation of electrical control and safety devices
 • Installation of condensate drain
D – Commissioning and Adjustment
• Pressure and leak test
• Evacuation and dehydration test
• Set pressure controls
• Set defrost/temperature for freezer and/or cooler
• Set defrost/temperature for Beverage Cabinet
• Measure Freezer and Cooler TXV Superheat
• Commissioning and Refrigerant Weight Report

E – Repair and Part Replacement

• Correct removal and installation

F – Refrigerant Recovery & Emission Control

• Refrigerant Recovery/handling
• Emission control
• Refrigerant charging
• Maintain records

G – Safety
• Safe working practice

4.3 Skill Assessment Procedures

There is to be a majority agreement from experts on the acceptedCompetition marking
scale.
The Experts will decide on the marking criteria and the dimensional tolerances of the
Objective Marking Form and the Marking Summary.
The Chief Expert will then divide the Experts into teams for the purpose of marking
andsetting up the marking schedule in accordance with the requirements of subsection 4.2
Everyteam will mark a similar percentage of marks. Each team will be assigned to a
workstation ona rotation basis by the Designated Chief Expert (DCE).
All teams will be on the floor at once providing assistance tothe Competitors where
required and observing for illegal actions or unsafe actions byCompetitors.
The Experts must sign the written hard copy assessment sheet daily of their own
competitor and use it to verify with the final copy from CIS system in the last day.
The Chief Expert will not judge competitor's work but will be responsible for clarifying
disputesor inconsistencies in the final marking.
 5. SKILL-SPECIFIC SAFETY REQUIREMENTS

Refer to Host Region Health and Safety Regulation.

All competitors must use safety glasses when using any hand, power or machine tools or
equipment likely to cause or create chips or fragments that may injure the eyes.
Experts will use the appropriate PPE when inspecting, checking or working with
competitor’s project.

5.1 ADDITIONAL INFORMATION CONCERNING SAFETY REQUIREMENTS

During the competition all competitors MUST follow the safety rules listed along with
Health safety requirements of the Host Region.

SHOES
• Fully enclosed work shoes or boots must be worn at all times.

CLOTHING
• Legs must be covered at all times, by either long work trousers or coverall.
• Upper body must be covered at all times
• Arms must be covered with long sleeves, when brazing and using refrigerant.

CLEAR SAFETY GLASSES

• Must be worn when necessary to protect your eyes.
• Must be worn when brazing, soldering, filing, reaming, hack-sawing, drilling and using
refrigerant, dry nitrogen and compressed air.

GLOVES
• Must be worn when brazing and using refrigerant
• All electrical work involving live testing will require wearing of approved gloves.

FACE MASK
• Must be worn when working with refrigerants.
• Must be worn when brazing/soldering

ELECTRICAL
 • Competitors MUST NOT SWITCH ON (apply power) any electrical equipment
(Refrigeration and Airconditioning unit) until they receive permission from an expert,
except for power tools.

Any competitor that is identified for not wearing the PPE or is engaging in any unsafe practice
will be stopped and advised on the correct safety practice by an expert.

Furthermore, if unsafe working practice is repeated the expert may STOP the competitor and
report the issue to the Chief Expert. The competitor may not be allowed to continue until the
safety issue is resolved. The competitor will lose associated safety marks.

If the competitor continues to ignore the safe working practice they may be removed from the
competition area for a safety briefing for 10 mins. By the Host Region Health and Safety
Representative.

6. MATERIALS/SUPPLIES AND EQUIPMENT

A. To be provided by the Host Region
A.1 EQUIPMENT
Qty. Unit Equipment Description Estimated Total Qty on
Unit Price site
Recovery Machine for HFC P90,000.00
540,000.00 none
Refrigerants (410a, 404a), 220V,
6 Units 60Hz, 200grms recovery rate in
vapour and 400grms recovery rate in
liquid form.
Refrigeration Freezer, 220V. 60Hz, P135,000.00 P810,000.00 None
6 Units 3/4HP, R404a, Single door, L=45cm,
W=60cm, H=240cm. Danfoss
Control Panel with complete none
accessories (Digital thermostat, P10,000.00 P60,000.00
6 Pcs
Magnetic contactor, Rotary switch
“on” and “off”, 3 Indicating lamp)
Inverter ACU, 220V, 60Hz, R410a, P35,000.00 P240,000.00 1 unit
6 Units
1HP
TOTAL 1,650.000

A.2 SUPPLIES/MATERIALS
Qty Unit Supplies Description Estimated Total Qty on
Unit Price site
2 cyl R410a (13.6kg/cyl) P10,200.00 P20,400.00 none
2 cyl R404a (13.6kg/cyl) P10,200.00 P20,400.00 none
2 rolls 2.0mm2 THHN wire/black. P3200.00 P6,400.00 none
12 Pcs. 3 pin/ C.O. combination of P300.00 P3,600.00 12 pcs
horizontal & vertical
50 Mtr. 5.5mm2 /3wires royal cord P150.00 P7,500.00 none
12 Pcs. Circuit bkr. /20 AT/1Ph With P500.00 P6,000.00 6pcs
enclosure
5 kg Wood nail/2 inch L P75.00 P375.00 ok
500 Pcs. Metal screw/ 1.5”L x ¼” dia. P5.00 P2,500.00 none
6 rolls ½” Copper pipe for inverter ACU P4,500.00 27, 000.00 none
50’/roll
6 rolls ¼” copper pipe for inverter ACU P2,500.00 15,000.00 none
50’/roll
15 pcs Rubber insulation 3/8” x 3/8” x 8’ 45.00 675.00 none
15 pcs Rubber insulation ¼” x 3/8” x 8’ 40.00 600.00 none
6 rolls Insulation tape 150.00 900.00 none
18 set Flare fittings 12.7mm, brass (union 400.00 7200.00 none
and nuts)
6 set Flare fittings 6.35mm, brass, (union 250 1500 none
and nuts)
6 pcs Copper elbow 12.7mm 150.00 900.00 none
6 pcs Copper T joint 12.7mm 80.00 480.00 none
6 pcs Copper reducing socket 12.7mm x 80.00 480.00 none
6.35mm
6 pcs PVC conduit ¾” Neltex 200.00 1,200.00 ok
20 Gal. white paint/boysen QDE P650..00 P13,000.00 none
10 Gal. Paint thinner P300.00 P3000.00 none
3 Pcs. Roller brush P200.00 P600.00 ok
6 Cyl Nitrogen Tank /REFILL P1,000.00 P6,000.00 none
6 cyl Oxygen Tank /REFILL P1000.00 P6,000.00 none
6 cyl Acetylene tank /REFILL P1,000.00 P6,000.00 none
50 pcs Plywood 4’ x 8’ x ¾” Marine P1,500.00 P75,000.00 none
12 pcs Square Tube B.I. 2mm x 2” x 20 ‘ P1500.00 P18,000.00 none
TOTAL P251,710.00

B. To be brought by the competitor

Qty Unit Description

1 unit Multi-tester
6 unit Vacuum pump 1/3 HP. 220V, 60Hz. 2 stage, Robinaire
6 pcs Nitrogen Regulator
6 sets Oxy-acetylene welding outfit
1 sets Gauge Manifold for R410a
1 sets Gauge Manifold for R404a
1 unit Vacuum pump 1/3 HP. 220V, 60Hz. 2 stage, Robinaire
1 pcs Nitrogen Regulator
1 sets Oxy-acetylene welding outfit
1 set Gauge Manifold for R410a
1 set Gauge Manifold for R404a
1 unit Clamp-on ammeter
1 unit Electronic leak detector
1 unit Digital Thermometer with dual sensor
1 unit Electric Drill 220V, 60Hz
1 set Hole saw
1 set Flaring Tools
1 set Pipe bender180®, up to 16mm
1 pc Hammer
1 Pc. ea Files, Flat, Half round and Round
1 pc Metal Ruler
1 pc Hacksaw
1 set Drill bits metal
1 pc Long nose plier
1 pc Diagonal Cutting Plier
1 pc Combination Plier
1 pc Splicer
1 set Philips Screw driver
1 set Flat Screw driver
1 pc Spirit lever
1 pc Scriber
1 pc Crimping Plier
1 pc Pull push rule/steel tape 5M
1 pc Center Punch
Tri and set square
Writing Equipment (pencil, color pens, paper, highlighter)
set Allen wrench
1 pc Pipe reamer
PPE ( Goggle, coverall, air respirator, hand gloves, safety shoes, )
1 set Swaging Tools
Rags
Tube Cutter Big and small
1 pc Refrigerant Cylinder empty, 5kg
2 pcs Fixing Bracket (angle bar, 1.25mm x 1.25mm x 3mm 250 mm length
Assorted tie wire
4 pcs Saddle band
8 pcs Cross recessed round head screw 4mm length
8 pcs Plain washer (small round)
Silver rod
1 pc Loop forming jig PVC conduit 38mm O.D. 150mm length
II. LAY-OUT
REFRIGERATION LAY-OUT
AIRCONDITION LAY-OUT
III- MARKING SCHEME

Below is the Marking Scale Summary for Trade Refrigeration and Air Conditioning, which must
be provided to all Competitors at the Information Session, conducted prior to the start of the
competition.

The Criteria Marks to be awarded for all four modules are listed below.
Skill Criteria Maximum Points

A Refrigeration Pipe work 40

B Electrical Wiring 14
C Component and System Positioning 10
D Commissioning and Adjustment 10
E Repair and Replacement 5
F Refrigerant Recovery and Emission Control 13
G Safety 8

The above skills criteria are spread over Four (4) Modules listed below:

TIME ALLOWED FOR EACH MODULE

Module 1 - Refrigeration System Installation & Commissioning 40 Marks 10 hours

Module 2 - Air Conditioning System Installation & Commissioning 25 Marks 3 hours
Module 3 - Fabrication and Brazing 15 Marks 2 hours
Module 4 - Mechanical Component Replacement 20 Marks 3 hours
Competitor Name: ____________________________
Region : ____________________________
Trade Name : ____________________________
Section Criterion Marks Points Earned
Objective Total Day 1 Day 2 Day 3
A Refrigeration Pipe work 40 40
B Electrical Wiring 14 14
C Component and System Positioning 10 10
D Commissioning and Adjustment 10 10
E Repair and Replacement 5 5
F Refrigerant Recovery and Emission Control 13 13
G Safety 8 8
Total 100 100

Skills Assessment Specification

Section Criterion Modules

1 2 3 4 Total
A Refrigeration Pipe work 18 9 13 - 40
B Electrical Wiring 10 4 - - 14
C Component and System Positioning 5 5 - - 10
D Commissioning and Adjustment 5 5 - - 10
E Repair and Replacement - - - 5 5
F Refrigerant Recovery and Emission Control - - - 13 13
G Safety 2 2 2 2 8
Total 40 25 15 20 100
• Module 1: Refrigeration System Installation & Commissioning
• Module 2: Air Conditioning System Installation & Commissioning
• Module 3: Fabrication and Brazing
• Module 4: Mechanical Component Replacement

______________________________ _ __________
Expert’s Signature Over-Printed Name Date
 Module 1 Module 2 Module 3 Module 4 Total
Section Criterion Sub-criterion
18 pts. 9 pts. 13 pts. -- 40 pts.
A Refrigeration Pipe work 13
• Pipe branch 4 1.5
• Dimension accuracy 2 0.5
• Flare and swage joint quality 2 1
• Silver brazing 2 1
• Strength pressure and leak test 4 2
• Brazing alloy penetration 2 1.5
• Suction and liquid lines to standards 2 1.5
Total 18 9 13 40

Module 1 Module 2 Module 3 Module 4 Total

Section Criterion Sub-criterion
10 pts. 4 pts. -- -- 14 pts.
B Electrical Wiring
• Connection of electrical circuit 3.5 1.25
• Test the electrical circuit 3.5 1.25
• Component layout 3 1.5
Total 10 4 14

Module 1 Module 2 Module 3 Module 4 Total

Section Criterion Sub-criterion
5 pts. 5 pts. -- -- 10 pts.
Component and System
C
Positioning
• Material list 0.25 0.25
• Condensing unit position 1 1
• Fan coil unit’s position 1 1
• Piping lay-out 1 1.5
• Installation of electrical control 1.5 1
and safety devices
• Installation of condensate drain 0.25 0.25
Total 5 5 10
 Module 1 Module 2 Module 3 Module 4 Total
Section Criterion Sub-criterion
5 pts. 5 pts. -- -- 10 pts.
Commissioning and
D
Adjustment
• Pressure and leak test 1 1.5
• Evacuation and dehydration test 1 1.5
• Set pressure controls 1 0
• Set defrost/temperature for
1 0
Freezer Cabinet
• Measure Suction Line Superheat 0.5 0.5
• Commissioning and Refrigerant
0.5 1
Weight Report
• Measure Air temperature onto
0 0.5
and off evaporator
Total 5 5 10

Module 1 Module 2 Module 3 Module 4 Total

Section Criterion Sub-criterion
-- -- -- 5 pts 5 pts.
E Repair and Part
Replacement
• Correct removal and installation 5
Total 5 5

Module 1 Module 2 Module 3 Module 4 Total

Section Criterion Sub-criterion
-- -- -- 13 pts 13 pts.
F Refrigerant Recovery &
Emission Control
• Refrigerant Recovery/handling 5
• Emission control 1.5
• Recommissioning (Recharging, 5.5
Pressure Testing, Evacuation)
 • Maintain records 1
Total 13 13

Module 1 Module 2 Module 3 Module 4 Total

Section Criterion Sub-criterion
2 pts 2 pts 2 pts 2 pts 8 pts.
G Safety
• Safe working practice 2 2 2 2
Total 2 2 2 2 8
A – Refrigeration Pipe Work
• Pipe branch
• Dimension accuracy
• Flare and swage joint quality
• Silver brazing
• Strength pressure and leak test
• Brazing alloy penetration
• Suction and liquid lines to standards
B – Electrical Wiring
• Connection of electrical circuit
• Test the electrical circuit
• Component layout
C – Component and System Positioning
• Material list
• Condensing unit position
• Fan coil units position
• Piping lay-out
• Installation of electrical control and safety devices
• Installation of condensate drain
D – Commissioning and Adjustment
• Pressure and leak test
• Evacuation and dehydration test
• Set pressure controls
• Set defrost/temperature for Freezer Cabinet
• Measure Suction Line Superheat
• Commissioning and Refrigerant Weight Report
E – Repair and Part Replacement
• Correct removal and installation
F – Refrigerant Recovery & Emission Control
• Refrigerant Recovery/handling
• Emission control
• Recommissioning (Recharging, Pressure Testing, Evacuation)
• Maintain records
G – Safety
• Safe working practice
 COMPETITION DETAILS - MODULE 1

Refrigeration System Installation and Commissioning

Maximum Time Allowed – 10 hours 40 Marks

The competitor is required to position the supplied No-Frost Refrigeration Equipment according to the
schematic pipe work diagram that will be supplied.

Components will include the following:

• Condensing Unit with Liquid Receiver
• System Components
❖ Filter drier
❖ Sight Glass
❖ Solenoid Valve
❖ Thermostatic Expansion Valve (Internally Equalized)
❖ Service Valve
❖ Schrader Valve
• Suction Line Accumulator
• Evaporator
• Refrigeration Quality Pipe Work
• Electrical Protection
❖ Automatic Circuit Breaker 15AT, Surface mounting
• Electrical Components
❖ Convenient Outlet3 pin
❖ Safety Pressure Switches
❖ Temperature and Defrost Controller
• Refrigerant 404a

The competitor is required to commission the system within the time limit. When you have finished
commissioning the system, you are required to record the operational setting on a System Data Sheet
that will be provided to each competitor.
The competitor must ask an Expert to check their own commissioning records and obtain an Expert
signature in the space provided in the commissioning sheet.
The Specifications for the Freezer Cabinet are:

1. Freezer Cabinet Specification

Refrigerant
Ambient Temperature
Condensing temperature difference
Cabinet temperature
Evaporation temperature difference
Suction line Pressure Drop
= R404a/R134A
= 30 ®C Db
= 12 K
= 5®C - 10®C
= 7K
= 1K

2. Control and Safety Setting

a. Low Pressure Controller Cut-off the system 10 K lower than design Saturated Suction
Temperature (SST) and cut-in (Start) the system when SST reaches -8®C.
b. High Pressure Cut-out the system when the condensing temperature reaches 10 K above the
design condensing pressure.
c. Temperature Controller cut-off the solenoid valves and must maintain the average room
temperature at return air within 1 K.
d. Defrost controller cuts off the system every 6 hours a day with 30 minute of defrost duration.
e. Defrost termination temperature at 10®C with 5 min fan delay for water draining.
REGION :

Commissioning the Refrigeration System

The Competitor must ask an Expert to check their refrigeration unit and initial the box after the
following items occur;

1. Pressure Test

Under the supervision of an Expert, carry out a staged pressure test of the refrigeration system in
accordance to manufacturer’s equipment instructions.
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.

Pressure Test Observed: Expert’s Initials:

Pressure Test Achieved Within 15 Minutes: Competitor’s Initials:

Expert’s Initials:

2. Evacuation

• Under the supervision of an Expert, evacuate the refrigeration system in accordance with
manufacturer’s instructions using the Deep Vacuum Methodto hold a vacuum of at least 1000
microns (29.88 In. Hg) of mercury.

The evacuation point should not rise more than 20% of the starting point in the Ten (10) minutes after
the vacuum pump is isolated from the system under test.

If the evacuation below 1000 microns of mercury has not been reached within 1/2 hour, the competitor
can continue to achieve the evacuation; however the full mark for Evacuation will be lost.

Evacuation Achieved in 1/2 Hour: Expert’s Initials

Region:

Or
Evacuation Achieved Outside ½ Hour: Competitor’s Initials:

Expert’s Initials:
3. Determine and Adjust the Cut-in & Cut-out Temperature

• Determine the settings of the controller to comply with the system specification.

Show all working out for your settings below.

 Cut-in Temperature  ®C  ®F =

 Cut-out Temperature  ®C  ®F =

• Under the supervision of an Expert, adjust the control switch settings, in accordance with
acceptable trade practices.

Control Settings Observed: Expert’s Initials

Region:

4. Determine and Adjust the Pressure Controls and Safety Devices

• Determine the settings for the Dual Pressure Control to ensure its safe and effective operation.
Show all pressure settings below.

LOW PRESSURE CONTROL

 Cut-in Setting  Bar  psi =

 Differential setting Bar  psi =

HIGH PRESSURE SWITCH

 Cut-out setting Bar  psi =

• Under the supervision of an expert, adjust the Pressure Control settings, in accordance with
acceptable trade practices.
 5. Charge the System with Refrigerant

• Under the supervision of an Expert, Charge the refrigeration system with the required weight of
refrigerant to ensure operation according to beverage cabinet specification above, and in
accordance with acceptable trade & environment practices.

Refrigerant Charging Observed: Expert’s Initials

Region:

6. Check Thermostatic Expansion Valve Adjustment

• Under the supervision of an Expert, check and adjust if necessary, the Thermostatic Expansion
Valve superheat setting, to ensure the system’s efficient and effective operation.
• Temperature TXV Superheat K  ®C =

TXV Superheat Adjustment Observed Expert’s Initials

Region:

REFRIGERATION SYSTEM COMMISSIONING REPORT

When you have completed commissioning the system so that it operates efficiently and
effectively, under the supervision of an Expert record the operating conditions listed below.
Show all working out.

Refrigerant Type =

Mass of the Refrigerant Charge  Grams  Pound =

Ambient Temperature  ®C  ®F =

Discharge Pressure  Bar  psi = _______________

Condensing Saturation Temperature  ®C  ®F = ________________

Liquid Subcooling Value  ®C  ®F = _________________

 Suction Pressure KPa  psig  Bar =

Evaporation Saturation Temperature  ®C  ®F =

TXV Bulb Temperature  ®C  ®F = ________________

TXV Superheat Setting K  ®R = ________________

Cabinet Space Temperature  ®C  ®F =

Commissioning settings Observed: Expert’s Initial

Region:

The Final Beverage Cabinet Temperature when the Competitor hands over the test project

• Final Beverage Cabinet temperature  ®C  ®F =

Final Cabinet temperature Observed: Expert’s Initials

Region:
 COMPETITION DETAILS – MODULE 2

Air Conditioning System Installation and Commissioning

Maximum Time Allowed – 3 25 Marks

The competitor will be issued with a split type inverter air conditioning system that includes
R410a refrigerant charge. The competitor will be required to position, install and commission the Indoor
unit and Outdoor unit, pipe work and associated wiring onto a supplied framework. The installation of a
Condensate drain is also required.
The test module requires the installed pipe work to be Pressure tested and Evacuation tested
within the time limit. You are then to commission the system according to the specifications provided.

Components will include the following

• Condensing unit (outdoor unit)
• Fan Coil unit (indoor unit)
• Refrigeration pipe work
• Electrical wiring

The competitor is required to commission the system within the time limit.
When you have finished commissioning the system; you are required to record the operational settings
on a System Data Sheet that will be supplied to you.
The competitor must ask an expert to check their own commissioning records and obtain an
expert signature in the space provided on the commissioning sheet.

The specifications for the Air Conditioning unit are:

Cooling Mode
Room temperature setting at = +21 Degree C
Fan speed setting at = High Speed
Louver Setting = Fixed Open

Evacuation Reached within 30 mins. Expert’s Initial

Region:

Air Conditioning System Set Up Observed: Expert’s Initials

Region:
REGION : ________________________________________________________

AC SYSTEM COMMISSIONING REPORT

The Competitor must ask an Expert to observe their air conditioning unit operation and set up and
obtain an Expert initial in the box provided.

Show all working out.

 Refrigerant Type =

 Mass of the Refrigerant Charge  Grams  Ounces =

 Ambient Temperature  ®C  ®F =

 Suction Pressure kPa  psig  Bar =

 Suction Superheat Value K R =

 Air Temperature onto Evaporator  ®C  ®F =

 Air Temperature off Evaporator  ®C  ®F =

Air Conditioning System Commissioning Expert’s Initials

Observed Region:
 COMPETITION DETAILS – MODULE 3

Component Fabrication and Brazing

Maximum Time Allowed – 2 hours 15 Marks

This module involves the marking out, cutting, flaring, swaging and silver brazing to a high standard and
cleaning the finished job.

Fabricate a copper component for a refrigeration system per drawing given.

The component will be pressure tested and the silver brazed joints and flare joints will be inspected and
marked according to the marking scale.

Pressure Test

Under the supervision of an Expert, pressure test the components to 1,050kpa (150 psig) in accordance
with manufacturer’s instruction and skill standards.

The system must hold this pressure for 15 minutes.

Flare Checked Expert’s Initials

Region:

Completed Expert’s Initials

Region:
 COMPETITION DETAILS – MODULE 4

Mechanical Component Replacement

Maximum Time Allowed – 3 hours 20 Marks

Using specialized and selected refrigeration tools, the Competitor is required to remove and replace a
component and re-commission the system.

The component could be on either the refrigeration or air conditioning system.

The system must be returned to correct operation within the 3 hour time limit.

There will be any number of component replacement tasks available and each individual task will be
kept secret in its own envelope until the time of this competition module.

The task Description will be announced at the start of the module test by the Chief Expert or the
delegated representative.

The module is designated to test the Competitors ability to recover refrigerant in an environmentally
safe way.
REGION:

AIR CONDITIONING SYSTEM MECHANICAL FAULT FIND AND REPAIR

Refrigerant Recovery Observed Expert’s Initials:

Pressure Test Observed Expert’s Initials:

Evacuation Test Observed Expert’s Initials:

Recommissioning Observed (Recharging, Expert’s Initials:

Pressure Testing, Evacuation)
1.PIPE WORK INSTALLATION STANDARD
This section is to ensure standardization of all pipe work installed and to provide objective
marking of all installation work performed by competitors. The standard for flame brazing is
covered in section 3.
1.1. Pipe Work Bend Radius
1.1.1. Minimum radius
The minimum radius of copper pipe should be no less than the specified pipe bending tool
can produce.
The radius will ensure the formed pipe work is not kinked, flattened or reduces the internal
diameter of the formed pipe work.
1.1.2. Maximum radius
The maximum radius of copper pipe should be a radius that ensures free flow of refrigerant
through the formed pipe work. Therefore the maximum radius accepted in this standard
should be not more than 10 times the diameter of the pipe being bent.
E.g.: 6mm pipe = 60mm, 9mm pipe = 90mm, 12mm pipe = 120mm
1.2. Pipe work quality
For the purpose of this standard acceptable pipe work will be regarded as follows for:
1.2.1. Pipe work acceptable
All vertical and horizontal pipe work is to be directly vertical or horizontal when measured by
spirit level.
Where diagonal pipe work is installed it must be straight and without deviation across the
entire length.
All horizontal pipe work in the suction line is to have a 20mm in 4m (1:200) pitch (+/-2mm)
towards the compressor to allow for oil return.
1.2.2. Pipe work unacceptable
For the purpose of this standard unacceptable pipe work will be that which has kinks or
bends that arenot as described in 1.1 above.
In addition, pipe work that is not contained within the boundaries of the equipment
enclosure or prevent access to equipment that requires service or adjustment such as
isolation/control valves and pressure switches.
1.3. Pipe work connections
To promote the reduction of refrigerant leaks, all flare pipe connections must have an
application of oil prior to final assembly.
Flared copper must be no more than 100% and no less than 50% of the flare fitting surface.

1.4 Oil return and oil pipe traps

Suction line pipe work oil traps are required on box type evaporators where the compressor
is installed above the evaporator. Wedge type evaporators will not require oil trap.
1.5. Pipe supports/clamps/hangers
Any pipe work supports/hangers provided must be installed to offer support for the pipe
work and to limit the transfer of vibration. The spacing of pipe supports will be of equal
lengths no more than 400mmm apart, ensuring at least one pipe support is located in each
parallel, vertical or diagonal plane when pipe length is less than 400mm. Pipe clamps must
not be positioned over a brazed pipe fitting.
1.6. Pipe Insulation
1.6.1 Refrigeration Systems
Suction pipe work must be fully covered by the insulation. The insulation surface must not be
damaged in any way. Where insulation has been cut and wrapped around pipe work, or
where insulation sections join together the insulation must be sealed using appropriate
adhesive.

Pipe supports must be fitted with some form of protection to the insulation so as not
tocompress or deform the insulation. Where pipe temperatures operate below zero
Centigrade insulation must be vapour sealed to the pipe work using appropriate adhesive.

1.6.2. Air Conditioning Systems

Both Suction and Liquid lines are to be insulated and follow the pipe insulation
standard1.6.1
1.6.3. Unacceptable insulation
Insulation that has only been sealed by using electrical PVC tape or Insulation tape.
1.7. Condensate Drain Piping
1.7.1 Refrigeration Systems
A ‘U’ trap must be installed in all refrigeration condensate drains to prevent the possibility of
fumes or vermin from entering the refrigerated space. This trap will constructed to provide a
vapour barrier between refrigerated space and the outside space.

1.7.2 Split type air conditioners

Condensate drains for air conditioning systems are to be installed strictly as per the
manufacturer’s recommendations.

1.8 Pipe work connection onto refrigeration evaporator

The location of the suction line should be in a position such that it receives the warmest part
of the fluid passing over the last stage of the evaporator coil to ensure maximum efficiency of
the evaporator.

2. COMPONENT LOCATIONS STANDARD

This section is to ensure standardisation of all component positions and to provide objective
marking of all components installed by competitors.
2.1 Expansion Valve
The expansion valve must be installed according to manufacturer’s instructions. Typically
meaning; in the liquid line as close to the evaporator coil inlet.

2.1.1 Thermostatic Expansion Valve

The sensing bulb is to be fastened to the suction line as close to the evaporator pipe
workoutlet as is possible. The expansion valve may be installed within the evaporator
housing orwithin the refrigerated space adjacent to the evaporator. Externally equalised
expansion valvesmust have the pressure equalising line connected to the suction line
immediately after thebulb. The bulb is to be located on a horizontal section of the suction line
immediately after theevaporator, in a position corresponding to between 12 o’clock and 8 or 4
o’clock positions.

2.2 Solenoid Valves

Solenoid valves are to be installed according to manufacturer’s instructions. Typically
solenoid valvesmust be installed in the direction of flow of the refrigerant. Liquid line solenoid
valves should be installedbefore expansion valves. To avoid moisture damage to the electric
coil the valve must be installedoutside of the evaporator casing.
2.3 Filter Drier
The filter drier must be installed with the flow arrow in the direction of refrigerant flow
to the evaporator. The filter drier can have any orientation. It must be installed in the
liquid line directly after the receiver and before any solenoid valve, sight glass and the
expansion valve.

2.2. Sight glass

The sight glass with moisture indicator must be installed in the liquid line after the filter
drierand as per manufacturer’s instructions.

2.3. Suction Line Heat exchangers

Where suction line heat exchangers are fitted, they must be installed immediately
following the evaporator and outside of the refrigerated compartment.

2.4. Suction Accumulators

Suction accumulators must be installed in the correct orientation as per the
manufacturer’s instructions in the suction return line to the compressor. On capillary
systems they can be located at the outlet of the evaporator.

2.5. Pressure Control Switches

Pressure control devices must be fitted within the equipment boundaries and ensure that
service access is provided for testing and calibration.
2.6. Pressure control monitoring location & Schrader fitting points
For the purpose of this standard all pressure control monitoring points will be at the
compressor.

To ensure compliance with health & safety and reduction of emissions, the high pressure
sensing point must be installed to ensure the pressure sensing point cannot be isolated.
Schrader fittings cannot be used to connect high pressure switches.

The high pressure sensing point may either be at the compressor discharge or in the high
pressure liquid line. Where no service fittings are present, the sensing point must be located
in the discharge line between the compressor and the condenser.

The low pressure sensing point must be made at the compressor suction service valve or
crankcase pressure fitting. Where suction service valves are not available; the low pressure
sensing point must be made by flame brazing a ¼’’ (6mm) Shrader fitting into the suction
pipe work entering the compressor.
 Schrader copper pipe fittings must not be cut down. The maximum inserted pipe depth to be
no more than 5mm into the pipe work.

3. FLAME BRAZING STANDARD

At all times the competitors and experts must be vigilant to ensure the risk of fire is
prevented.Competitors and experts must follow the risk assessment control measures for
the refrigeration skillcompetition.

3.1. Equipment and clothing

All flame brazing equipment must be fit for purpose and have been tested for safe operation
prior to the competition starting. The following safety clothing must be worn throughout any
flame brazing activity:
Long sleeve fire retardant clothing / coveralls
Gloves specifically designed for flame brazing
Safety glasses that include wrap around protection or goggles
3.2. Quality of joints
Copper to copper or dissimilar metals will require an applicable solder to withstand the same
tensilestrength as the parent metals.

3.2.1. Acceptable joint

The flame brazing activity aims to test the competitor’s efficient use of flame brazing
equipment and materials when joining two metals together. Components should not suffer
excessive heat or scorching.

The standard of joint must be completely filled all around and have no raised marks or
depressions around the circumference.

3.2.2. Use of Nitrogen during flame brazing

Nitrogen must be purged through the pipe work during flame brazing.
The competitor is to indicate where a pipe outlet is uncapped to allow Nitrogen exhaust.

3.2.3. Unacceptable joints

Where a joint leaks refrigerant or oil
Where a brazing drip is observed greater than 2mm.
Where a brazed joint is marked or pitted due to excessive heat

4. PRESSURE TESTING STANDARDS

This standard has been developed for the sole purpose of ensuring both safe working
practice and system integrity (avoid system rupture) during the Regional Skills refrigeration
and air conditioning test project competition.

This standard covers testing of high side and low side equipment and includes fabricated
pipe workassemblies that have been insulated but before the joints and ends are sealed.

4.1. Procedures

All pressure relief devices are to be isolated during pressure testing.

Pressure testing must not exceed the maximum test pressure of the nameplate on the
manufactured equipment.

High and low side test pressures may require isolation of certain components.
Competitor must ensure all valves are open for the pipe work section under test.

Oxygen Free Nitrogen (OFN) is connected to the pipe work assembly using test
 hoses suitable to handle the maximum regulator pressure plus 20%.

A calibrated Nitrogen pressure regulator must be used to measure the pressure of

the Nitrogen in the system.

The Nitrogen pressure test must be carried out according to the temperatures that
are equivalent to the standard air temperature reference for the pipe work section
under pressure e.g.

• For the low side pressure test it will be 32°C

• For high side water cooled pressure test it will be 43°C
• For high side air cooled system pressure test it will be capped at 45°C

The system test pressure as indicated on the regulator will be recorded by the competitor.

The competition area is not expected to suffer a difference in temperature. Therefore the
pressure test will be regarded as failed if the test pressure drops over a 15 minute time
period.

If pressure does not hold, it is the responsibility of the competitor to solve the problem
without the assistance from an expert.

On completion of the test, the Nitrogen must be released in a slow and controlled manner so
that it does not endanger themselves, spectators, experts or others in the area.

The Nitrogen cylinder and regulator must be disconnected from the system after the test.

5. EVACUATION STANDARDS

Evacuation of the refrigeration system will be required after pressure testing is performed to
the standard. The purpose of evacuation is to ensure the complete removal of any moisture
and any other non condensable fluids that may affect efficient and reliable system
operation.

The Test Project will only require the deep evacuation method described as follows:

5.1. Deep evacuation method

Using a suitable vacuum pump, the system pressure will be reduced to a vacuum of 130 Pascal
Absolute (1,000 microns of mercury) and left to stand isolated from the vacuum pump for a
period of ten minutes. A vacuum gauge must be fitted to a remote part of the system to
ensure the complete system vacuum is achieved.
 The system evacuation will not be accepted if the vacuum has raised more than 20% of the
starting vacuum position. For example: a 1000micron vacuum test that rises to above 1200
microns will fail the test.

6. L EAK TESTING METHODS

To ensure the refrigeration system integrity, and minimise the risk of environmental damage
from emission of Fluorinated gases, the following two methods will be the accepted
standard for leak testing.

6.1. Fluid Solution leak detection

When the appropriate test pressure for the device being tested is achieved, the competitor
must use an industry approved leak detection solution. Where soap and water solution is
used the competitor must prove the solution mixture will ‘bubble up’ at the maximum test
pressure.

6.2. Electronic leak detection

Electronic leak detectors must be used to test for refrigerant leaks during charging
process and when the system is operating at design conditions. In addition, the
refrigeration system must be leak tested when the complete system is switched off and
system pressures have equalised. Electronic leak detectors must be suitable to measure
at least 5 grams of Refrigerant gas per year.

7. REFRIGERANT HANDLING

7.1. Charging systems

HFC pure or blended refrigerants must be liquid charged and weighed into the system being
charged. A record of the type and weight of refrigerant added and/or removed from the
system must be attached to the refrigeration system.

7.2. Deliberate venting of refrigerants

Deliberate venting of refrigerants is damaging to our environment and must be prevented at

all times. Refrigerant must be recovered using suitable refrigerant recovery system to the
appropriate container. Unavoidable loss of refrigerant is detailed in section 7.3. The
following situations will not be allowed:

7.2.1 The venting of surplus refrigerant from a system to atmosphere during

decommissioning or repair/replacement of a component.
 7.2.2 Venting of refrigerant charge to atmosphere when purging non condensable gas from a
refrigeration system.

7.2.3 Using refrigerant as a fluid for cleaning or for pressure testing.

7.2.4 Adding refrigerant to a system that has a recognised refrigerant leak, before examining
and repairing the refrigerant leak.

7.3 Unavoidable loss of refrigerants

The loss of refrigerant to atmosphere must be kept to a minimum. The following examples
describe where unavoidable losses may occur:

7.3.1 Loss of refrigerant from leaking seals, joints, gaskets and cracked pipes. The leak(s)
must be located and completely eliminated.

7.3.2 Loss of refrigerant from relief valves, bursting discs and fusible plugs discharging to the
atmosphere to protect against dangerous pressure levels. Where possible these safety
devices should be vented back into the system or to another working system.

7.3.3 Loss of refrigerant dissolved in oil, this should be minimised during the normal process
ofrefrigerant recovery.

7.3.4 Loss of small quantities of refrigerant from charging hoses and pipes which occurs in
the normal process of connecting and disconnecting. Charging hoses and pipes should be
sealed at each end when not in use.

7.4. Safe Handling of refrigerants

The primary objective is to ensure the safety of competitors, technical experts and others
involved in the refrigeration Test Project, plus visitors in the vicinity and close proximity of
the test area.

Safety clothing must be worn when handling refrigerant fluids. The Host may request specific
work wear or materials in addition to the following list of work wear.

• Long sleeve shirt Long pants or coveralls

• Gloves that will resist low temperatures of -80 ®C
• Safety glasses that include wrap around protection or goggles
8. CARE OF OILS

Sustainability is one of the competition values. The purpose of this standard is to ensure that
wherever possible and practical to do so, competitors take care of the quality of the oils they
are using.

Refrigeration and Vacuum pump oil containers must remain sealed when not in use.

9. ELECTRICAL SAFETY
There must be no working on live (energised) equipment. For example using an insulated
screw driver to tighten a live electrical terminal is not allowed.

Electrical safety gloves must be worn at all times when testing live (energised) electrical
components. The gloves must meet the Host safety standards.

All connections will be terminated securely and with the use of ferrule terminals. No bare
conductors can be on show when viewed from ninety degree (90o) angle to the terminal.

The installed electrical system must be checked by an expert prior to the competitor
performing the electrical installation tests.
The competitor must ensure the test instrument is tested and set correctly prior to electrical
testing of the system.

Experts are responsible for the supervision of electrical testing and must sign the appropriate
test box on the competitor’s work sheet.

9.1. Earth continuity test

This test aims to ensure the installation has continuous earth bonding of all components.
The competitor must perform an earth continuity test in the presence of the technical expert
(judge) before applying the voltage power supply to the system.

There must be a continuous circuit measured.

9.2. Polarity test

Polarity test ensures live and neutral are not crossed in the circuit.
Safety switches must be in the made position to enable this test.

9.3. Insulation resistance test

This test ensures the power cables are not conductive to earth.
 Care must be taken to ensure the system is not in vacuum state, and electronic components
are isolated before the test can be performed by the competitor.

Test result must not be less than 1megaohm.

Where any test fails to pass the standard, the competitor is required to solve the problem
without guidance from an expert.

10. COMMISSIONING AND SET UP

The Test Project will be selected to use a refrigerant that ensures positive pressure for all
operational controls.

10.1 High Pressure Cut-out

The high pressure cut-out safety switch setting of air conditioning is to be determined and set
at 0.9 x maximum allowable pressure (MAP).

10.2 Low Pressure cut-out

The setting of Air conditioning system must be at 30 psig cut-out with 40 psig pressure
difference to cut-in.

10.3. Where a Low Pressure cut-out switch is used as a safety device.

To prevent harm to the compressor system from loss of refrigerant or to achieve a suitable
pump down, the switch should be set to stop the compressor above 0 Barg but no more than
0.1 Barg.

11. GENERAL SAFETY & EQUIPMENT

Compliance with local health and safety standards must prevail at all times.

A risk management assessment must be carried out each day prior to the start of competition.
Any hazards identified during these risk assessments must be isolated and rectified
immediately.

There must be an evacuation procedure, along with the host institution’s health & safety
requirements posted within easy access of each work area.
 The nominated safety officer along with first aid station and first aid equipment should be
clearly defined.

Fire extinguishers suitable for the type of risks must be clearly identified and located.
Any injuries sustained by either experts or candidates must be recorded in the first aid register
regardless of the degree of injury.

Competitors must use the appropriate personal protective equipment (PPE) as and when
required.

IV. INFRASTRUCTURE LIST

The host country experts and assigned workshop supervisors will prepare all the setup on
thematerials and equipments referring the test project requirements.

1. Equipment

Qty. Unit Equipment Description

Recovery Machine for HFC Refrigerants (410a, 404a), 220V, 60Hz, 200grms
6 Units
recovery rate in vapour and 400grms recovery rate in liquid form.
Refrigeration Freezer, 220V. 60Hz, 3/4HP, R404a, Single door, L=45cm, W=60cm,
6 Units
H=240cm. Danfoss
Control Panel with complete accessories (Digital thermostat, Magnetic contactor,
6 Pcs
Rotary switch “on” and “off”, 3 Indicating lamp)
6 Units Inverter ACU, 220V, 60Hz, R410a, 1HP
50 pcs Plywood 4’ x 8’ x ¾” Marine
12 pcs Square Tube B.I. 2mm x 2” x 20 ‘
6 unit Vacuum pump 1/3 HP. 220V, 60Hz. 2 stage, Robinaire
6 pcs Nitrogen Regulator
6 sets Oxy-acetylene welding outfit
6 sets Gauge Manifold for R410a
6 sets Gauge Manifold for R404a

2. Supplies/Materials
Qty Unit Supplies Description
6 cyl R410a (13.6kg/cyl)
 6 cyl R404a (13.6kg/cyl)
2 rolls 2.0mm2 THHN wire/black.
12 Pcs. 3 pin/ C.O.combination of horizontal & vertical
50 Mtr. 5.5mm2 /3wires royal cord
12 Pcs. Circuit bkr. /20 AT/1Ph With enclosure
5 kg Wood nail/2 inch L
1 Gal. Red oxide Primer paint
1 Gal. White paint/Automotive enamel
1 gal Lacquer thinner
15 Pcs. #220 sand paper
500 Pcs. Metal screw/ 1.5”L x ¼” dia.
6 rolls ½” Copper pipe for inverter ACU 50’/roll
6 rolls ¼” copper pipe for inverter ACU 50’/roll
15 pcs Rubber insulation 3/8” x 3/8” x 8’
15 pcs Rubber insulation ¼” x 3/8” x 8’
6 rolls Insulation tape
18 set Flare fittings 12.7mm, brass (union and nuts)
6 set Flare fittings 6.35mm, brass, (union and nuts)
6 pcs Copper elbow 12.7mm
6 pcs Copper T joint 12.7mm
6 pcs Copper reducing socket 12.7mm x 6.35mm
6 pcs PVC conduit ¾” Neltex
6 Cyl Nitrogen Tank /REFILL
6 cyl Oxygen Tank /REFILL
6 cyl Acetylene tank /REFILL
20 Gal. white paint/boysen QDE
10 Gal. Paint thinner
3 Pcs. Roller brush

3. Venue

TESDA REGIONAL TRAINING SAN JOSE, PILI CAMARINES SUR

4. TABLES AND CHAIRS