BAGIAN A
KISI-KISI LOMBA
DESKRIPSI TEKNIK
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
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.
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.
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
BAGIAN B
PETUNJUK 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 15 poin 4.0 jam
2. Refrigeration System Installation & Commissioning 55 poin 8.0 jam
3. Air-Conditioning System Installation & Commissioning 30 poin 6.0 jam
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
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 :
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.
BAGIAN C
SOAL – SOAL LOMBA
Component Fabrication
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
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.
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 12
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)
The following system design specifications for the installation should be used for commissioning and
control setting and are as follows:
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
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 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.
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.
Starting Time :
Finishing Time :
Finishing Time :
Finishing Time :
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.
Starting Time :
Finishing Time :
Starting Time :
Finishing Time :
Comments :
Expert 2 Initials :
Expert 3 Initials :
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.
Comments :
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.
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 :
Comments :
Expert 2 Initials :
Expert 3 Initials :
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
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.
_______________________________________________________________________________
_______________________________________________________________________________
__________________________________________________________
Please indicate what repairs need to be done to the system to return it to normal operation
_______________________________________________________________________________
_______________________________________________________________________________
_______________________________________________________________________________
_______________________________________________________________________________
________
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.
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.
Evacuation Test
Starting Time :
Finishing Time :
Comments :
Expert 2 Initials :
Expert 3 Initials :
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.
Refrigerant Charging
Comments :
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.
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.
BAGIAN D
GAMBAR / DRAWING
BAGIAN E
PERALATAN & PERLENGKAPAN 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 Refrigeration
Writing equipment, including, pencils, Set of gauges R-134a and R410A
coloured
pens, paper, highlighters Gauge manifold set R134a and R410A
Tape measure: 5 m Vacuum gauge, down to 50 Pascal
Centre punch Scale digital balanced
Pipe reamer Ratchet key
Scribe Schrader valve key
Set of drills: 1-10 mm Allen keys – imperial and metric
Spirit level Vacuum pump
Tong-ammeter Digital Thermometers with at least 2 sensors
Metal Rule: 300 mm Electronic Leak Detector
Knife Leak detection solution
Hammer Small mirror
Hacksaw
Screw drivers Electrical Work
Try-square Wire Strippers
Set squares Electrician’s pliers
Long nose pliers Multigrips
Electrical Crimping Tools
Mechanical tasks Megohmmeter
Tube cutter, up to 22 mm Multi-meter
Files: flat, half round and round
Pipe Bending Machine 6 mm Safety
Pipe Bending Machine 10 mm Clothing, long sleeves, long work trousers
Pipe Bending Machine 12 mm Emergency cloth
Mechanical tube benders, Safety shoes
Set of spanners up to 25 mm Clear Safety glasses
Shifting spanners Gloves
Side cutting pliers
Steel wool
Oil can
BAGIAN F
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: