TVET Training on Commercial HVAC Systems.pptx

Commercial HVAC Training

1. COMPETENCY STANDARDS for HEATING VENTILATION, AIR-CONDITIONING AND REFRIGERATION (HVACR) Prepared By: Omer Iqbal

2. Key Points Carry Out Fabrication for HVAC Work Duct Designing Duct Materials / Selection Duct Joints Duct Installation Insolation Type Pipe Designing Pipe Materials / Selection Pipe Joints Pipe Installation System Designing Cooling Load Calculation Equipment Selection Building Modification

3. Key Points Install Central Air Conditioning System Package Type Unit Installation Installation of VRF / VRV System Installation of Water Chiller System Carry Out Commissioning

4. Key Points Repair / Service Central Air Conditioning System Diagnose Fault in Central Air Conditioning System Repairing of Chillers / Air Handling Unit (AHU) / Fan Coil Unit (FCU) Repair Pumps and Cooling Tower Repair Control System

5. Competency Units Performance Criteria Fabricate Ducts Select tools, machines, equipment, sheet materials and related accessories according to requirements and standards Take measurements, mark proper location and select Duct fittings as specified in the layout plan/ diagram Prepare different types of Edges / Joints / Seams / Bends and Notches used to join Sheet Metal work Prepare flexible connections between Duct sections and unit fittings (Air Handling Units / Fan Coil Units) Prepare duct in required size, shape and pieces and connect with each other according to Duct route drawing Seal Duct joints with good mastic material, to avoid air leakage, according to SMACNA /ASHRAE standards Fabricate cladding to protect insulation Carry Out Fabrication for HVAC Work

6. Competency Units Performance Criteria Fabricate Pipes Select tools, machines, equipment, pipe materials and related accessories according to requirements and standards Prepare joints (Elbow / Reducer / Tees / Offset / Couplings / Flanges etc.) for jointing of Pipes as per layout plan / requirements Prepare and clean Pipe joints for smooth Welding / Threading work according to layout plan / diagram Carry out Jointing using Welding or Threading methods to ensure proper fitting according to international standards Carry Out Fabrication for HVAC Work

7. Competency Units Performance Criteria Install Ducts and Piping Follow International standards of ASHRAE or SMACNA while installing ducts and piping Select tools, equipment, Pipe materials and related accessories according to requirements and standards Mark location for Duct and Pipes installations according to drawing specifications Mount Hangers, Angle rails, threaded rods / Studs and Straps according to standards Install the Ducts and Pipes on angle rails and ensure the straps are fabricated into one unit according to layout plan / diagram Seal all the joints with good mastic material to avoid leakage according to standards Install Grills / Diffusers / Dampers and Flexible Duct according to drawing / layout plan Install the valves in pipes as per drawing Perform leak testing of piping and duct system as per standards Carry Out Fabrication for HVAC Work

8. Competency Units Performance Criteria Insulate Ducts and Piping Select tools, equipment, pipe materials and related accessories according to requirements and standards Prepare insulation material / Sound liner according to manufacturer specifications Insulate water / steam pipes with specified insulation according to ASHRAE or SMACNA standards Apply vapor barrier paper, cotton cloth wrapping and sheet metal cladding firmly on the ducts / pipes according to manufacturer specifications Carry Out Fabrication for HVAC Work

9. Carry Out Fabrication for HVAC Work Duct Designing Duct Materials / Selection Galvanized Steel Aluminum Fabric PVC Duct Joints S Type Drive Type

10. Duct Designing Duct Installation Duct Type (Shapes) Metal Cutting Pieces Joining Insulation Type Fiber Glass Poly Styrene Mineral Wool Cellulose Carry Out Fabrication for HVAC Work

11. Duct Hanging & Support

12. Duct Hanging & Support

13. Pipe Designing Pipe Materials / Selection Brass Cast iron G/S Steel Copper Pipe Joints Threaded Welded Flanged Grooved Pipe Installation Carry Out Fabrication for HVAC Work

14. System Designing Cooling Load Calculation Transmission Load 10 – 15% Product Load 55 – 75% Internal Load 10 – 20% Equipment Load 01 – 10% Infiltration Load 01 – 10% Equipment Selection Air Cooled chiller Water cooled chiller Building Modification According to requirement Carry Out Fabrication for HVAC Work

15. Knowledge and Understanding The candidate must be able to demonstrate underpinning knowledge and understanding required to carry out tasks covered in this competency standard. This includes the knowledge of: Knowledge of Sheet Metal & Air Conditioning Contractors’ National Association (SMACNA) Knowledge of American Society Of Heating, Refrigeration, And Air Conditioning Engineers (ASHRAE) Layout plans, drawing and manufacturer specifications, and HVAC symbols etc. Working at heights and platforms Use and transport of Ladders / Scaffolds safely Type of Ducts, Duct fittings and their applications

16. Knowledge and Understanding Type of Pipes, Pipe fittings and their applications Methods of Duct Cutting / Bending / Jointing / Fixing and Sealing Methods of Pipe Cutting / Bending / Jointing / Fixing and Sealing Preparation of hanging supportive structures for Ducts and Piping Types and techniques of welding Types of Insulation and their application Techniques for installation of Ducts and Pipes by using specified test instruments Procedures of pressure testing of Pipes by using specified test instruments Procedures of leakage testing in Ducts by using light source Record keeping and reporting

17. Competency Units Performance Criteria Install Package Unit Select tools, equipment and related accessories according to job requirements Mark the location and area according to layout plan and manufacturer specifications Prepare foundation as per drawing, place, adjust and level the Package unit by giving attention to safety precautions Connect Package unit with supply, return and fresh air duct through flexible connection as per drawing / unit specification Insulate duct where required Remove all packaging material from work place Connect the power supply and control wire Switch on the supply and check the performance according to manufacturer instructions and standards Install Central Air Conditioning System

18. Competency Units Performance Criteria Install Variable Refrigerant Flow (VRF) / Variable Refrigerant Volume (VRV) System Select tools, equipment and related accessories according to job requirements Prepare foundation as per drawing, place, adjust and level the outdoor unit by giving attention to safety precautions Prepare piping, weld / braze them according to unit specifications and layout drawings Install indoor units according to layout diagrams, client requirements and manufacturer instruction manual Fix Shut-off valves with service ports on every indoor unit Check leaks by applying pressure method before the joints insulation; repair leaks, if any Insulate the copper pipe joints according to manufacturer instructions and standards Evacuate the system and charge the refrigerant as per requirement Connect the power supply and control wires attached with central control / Building Management (BMS) system Switch on the system and check performance Install Central Air Conditioning System

19. Competency Units Performance Criteria Install Water Chiller System Select tools, equipment and related accessories according to job requirements Mark the location and area according to layout plan Prepare foundation as per drawing, place, adjust and level the chiller by giving attention to safety precautions Install Air Handling Units (AHU) / Fan Coil Unit (FCU) at different locations inside the building according to drawing Install high pressure MS Pipe from chiller to Air Handling Units/ Fan Coil Unit inside the building Fabricate and install G.I sheet ducting inside the building as per drawing Install Cooling Tower and water pumps (Only for water cooling condenser) Establish the electric power supply system for the chiller and air handling units and cooling tower as per Requirements and Standards Install Central Air Conditioning System

20. Competency Units Performance Criteria Carry out Commissioning Select tools, equipment and related accessories according to job requirements Start the condenser and chilled water pump for water circulation in the system Start the chiller and take reading of all parameters regarding temperature / pressure and electric power, check unusual vibrations / noises etc., if any Perform Air Balancing and water balancing to check the air / water distribution according to design requirements Check the system performance as per design criteria Install Central Air Conditioning System

21. Vapor Compression Refrigeration Cycle Vapor Absorption Cycle Centrifugal Refrigeration Cycle Air Washer System Types of HVACR System According to Cycle

22. Vapor Compression Refrigeration Cycle Compressor Condenser Refrigerant Control Evaporator Types of HVACR System According to Cycle

23. Vapor Absorption Cycle Generator/Concentrator Condenser Evaporator Absorber Heat Exchanger Water 77% (Gravity 1.0) Lithium Bromide 23% (Gravity 1.5) Types of HVACR System According to Cycle

24. Centrifugal Refrigeration Cycle All Components are same as vapor compression cycle due to using of centrifugal compressor it is known as centrifugal refrigeration cycle. This cycle can be use for places which required 50-500 Tons of refrigeration Types of HVACR System According to Cycle

25. Air Washer System Water Pumps Fan Motors Water Spray nozzles Water sump Types of HVACR System According to Cycle

26. Air Cooled Chiller Water Cooled chiller Evaporative Condensers chiller Sub Categories Reciprocating Screw Scroll Centrifugal Types of Air Conditioning Systems According to Working

27. Air Cooled Chillers It Removes condenser heat through Forced air, that’s the reason we known it as air cooled chiller. Types of Air Conditioning Systems According to Working

28. Water Cooled Chillers It Removes condenser heat through water, that’s the reason we called it water cooled chiller Types of Air Conditioning Systems According to Working

29. Types of Air Conditioning Systems According to Working

30. Types of Air Conditioning Systems According to Working Centrifugal Comp. Scroll Comp. Screw Comp. Reciprocating Comp. Sub Categories of Chiller (According to their Compressor)

31. Single Stage Compression System Multi Stages Compression System Multi Evaporator/Temperature Refrigeration System Cascade Refrigeration System Types of Chillers according to Temperature Requirement

32. It is a basic refrigeration cycle Single Stage Compression System

33. It uses more then one compressors to increase the pressure of the refrigerant then single stage compression cycle. Multi Stages Compression System

34. Sometimes in a refrigerator several loads are varied. Refrigerators used to function at different loads operated under different condition of temperatures and pressures. There may be arrangements possible for multi evaporators on the basis of single or multi compressors. If refrigerant from each evaporator compressed in the same single compressor then it is called as Multi-evaporator single-compressor system. Multi Evaporator Refrigeration System

35. Cascade refrigeration system is the combination of two single stage vapour compression system together, condenser of LTC and evaporator of HTC is cascaded and forms the heat exchanger where evaporator cascade absorbs the heat from the condenser cascade which further leads to better refrigeration effect . Cascade Refrigeration System

36. Constant-Volume System Variable Air Volume (VAV) System Package Type Air Conditioning System Commercial Air Conditioning System

37. Constant Supply Air quantity Variable Supply Air Temperature Constant-Volume System

38. Variable Supply Air quantity Constant Supply Air Temperature Variable Air Volume (VAV) System

39. A  package  unit is the all-in-one heating and cooling system for homes that don't have a lot of room indoors for either a furnace and coil, or an air handler. Package units will contain all of their parts in one outdoor unit that sits on either the roof or to the side of a building. Package Type Air Conditioning System

40. Package Type Unit Installation Install Central Air Conditioning System

41. Package Type Unit Installation Safety Precautions Complete Knowledge about Product Ducts Hanging & Supporting Fixing Ducts Installation Duct Leakage Checking Ducts Insolation Out Door Unit Placement Electrical Wiring & Connections and paneling Testing Install Central Air Conditioning System

42. Installation of VRF / VRV System Install Central Air Conditioning System

43. Installation of VRF / VRV System Safety Precautions Complete Knowledge about Product Ducts, Pipes and Wires Hanging & Supporting Fixing Ducts & Pipes Installation Duct and pipes Leakage Checking Ducts and Pipes Insolation Energy Recovery Ventilation (ERV) Installation Copper Pipe Installation Copper Pipes Joints Leakage Testing Copper pipe Insolation Install Central Air Conditioning System

44. Installation of VRF / VRV System Drain pipe installation Out Door Unit Placement Ceiling / Indoor Unit Installation Electrical Wiring & Connections and paneling Nitrogen Pressure Testing of all refrigerant pipes (Up to 500 Psi) Vacuum all refrigerant Pipes Gas Charging Indoor Capacity Setting Debugging Testing Install Central Air Conditioning System

45. Installation of Water Chiller System Safety Precautions Complete Knowledge about Product Ducts, Pipes and Wires Hanging & Supporting Fixing Ducts & Pipes Installation Duct and pipes Leakage Checking Ducts and Pipes Insolation Duct and piping installation Install Central Air Conditioning System

46. Installation of Water Chiller System Ducts and piping insolation Water Pumps installation Chiller installation AHU installation Cooling Tower Installation Electrical Wiring & Connections and paneling Nitrogen Pressure Testing of all refrigerant pipes (Up to 500 Psi) Vacuum all refrigerant Pipes Gas Charging Testing Install Central Air Conditioning System

47. Carry Out Commissioning Unit Running/Testing Duct Checking Pipes Checking Pumps Running Temperature Checking Final Report Preparation Install Central Air Conditioning System

48. The candidate must be able to demonstrate underpinning knowledge and understanding required to carry out tasks covered in this competency standard. This includes the knowledge of: Knowledge of American Society Of Heating, Refrigeration, And Air Conditioning Engineers (ASHRAE) Ozone Protection and Synthetic Greenhouse Gas Management Act 1989 Fundamental knowledge of HVACR, Electric and Electronics Techniques for installation of central Air conditioners Fundamental and Technical Operations of VRF / VRV system Electrical / HVAC layout plans/wiring diagrams Types of electrical control wires, cables, including underground cables, their ratings and its applications Knowledge & Understanding

49. Methods of Copper Tube Cutting / Bending / Swaging / Flaring / Brazing / Y-Jointing / Fixing Basic Masonry and Carpentry applications Welding types and techniques Types of Insulation and their applications Types of AHU, FCU, Chillers and Cooling Towers, Compressor, Condenser and pump types and their applications Types of Refrigerant, its properties, recovery and reclaiming Procedure regarding commissioning the central HVAC systems Record keeping and reporting Knowledge & Understanding

50. Competency Units Performance Criteria Diagnose Fault in Central Air Conditioning System Check for obvious problem to determine which component or system is causing the problem Select tools, equipment and related accessories according to requirements and standards Arrange drawings and manuals of the equipment to be attended for diagnosing the fault Check the power supply, electric wiring, electric / electronic components and refrigerant pressure to determine the exact problem and record the results Start the air conditioning unit and recheck as specified in the manufacturer manual and record the results Repair/Service Central Air Conditioning System

51. Competency Units Performance Criteria 2. Repairing of Chillers / Air Handling Unit (AHU) / Fan Coil Unit (FCU) Select tools, equipment and related accessories according to job requirements System shut down and follow the instructions manual for rectification Rectify the diagnosed faults; repair / replace the components, as necessary Switch on the system to check the performance of electrical / mechanical components as specified in the manufacturer manual and record the results Repair/Service Central Air Conditioning System

52. Competency Units Performance Criteria 3. Repair Pumps and Cooling Tower Select tools, equipment and related accessories according to job requirements System shut down and follow the instructions manual for rectification Check water level of cooling tower Check the fan assembly, to check the bearings and motor abnormalities according to manufacturer specifications and HVAC standards Check the float valves and strainers to maintain water level Perform chemical treatment to prevent the sludge / scaling problems according to manufacturer specifications and HVAC standards Condenser / chilled water pumps start and check their performance according to their specifications; service / repair, if necessary Clean the sprinkler assembly water pan from leaves, mud, and scale, if any Rectify the fault and restart the cooling tower and pumps Repair/Service Central Air Conditioning System

53. Competency Units Performance Criteria 4. Repair Control System Select tools, equipment and related accessories according to job requirements System shut down and follow the instructions manual for rectification Arrange drawings and manuals of the equipment to be attended for diagnosing the fault Check the details of fault / errors on computer screen to rectify the same Eliminate the causes of the problem according to the manufacturer manual and standards Isolate and recheck the causes of the problem and correct the fault Start the air conditioning unit and recheck as specified in the manufacturer manual and record the results Repair/Service Central Air Conditioning System