Refrigeration Training :: Courses
Course: CG 2079 F GAS Cat 1 SKILLSCAN

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CG 2079 LEVEL 2 AWARD in F-GAS & ODS REGS

INDIVIDUAL SKILLSCAN

Name: Date:

Company:

This skillscan is aimed at identifying your strengths and weaknesses in line with the qualification requirements.
It will enable an INDIVIDUAL training & assessment plan to be devised-
FOR YOU!

Please identify your skill or knowledge level next to the appropriate topic item to indicate:

  • COMPETENT - lots of experience & knowledge- no training required

  • NOT YET COMPETENT – some experience & some knowledge: would benefit from some specialist training/updating 
  • X INCOMPETENT- definitely no experience & no knowledge Requires training

Note: you must understand that there are 4 categories as follows:

There are 4 Categories of qualification:

  • Category 1: For those working on systems with above 3kg of refrigerant charge:

  • Category 11: For those working on systems with below 3kg of refrigerant charge:

  • Category 111: For those that are involved in REFRIGERANT RECOVERY ONLY

  • Category 1V: For those that are involved in LEAKAGE TEST ONLY

 

Category 1 : SYSTEMS with ABOVE 3kg of refrigerant

Practical Tasks

Assessment: The following tasks will be undertaken on a designated assessment rig and have to be completed within 4 hours.

  • Carry out risk assessment

Understands why a risk assessment has to be done

Understands what must be contained in a risk assessment

Can carry out a risk assessment

Knows what happens to the risk assessment

  • Recover Refrigerant from system

Select correct PPE

identify the type of refrigerant within system

locate where to fit the service gauge manifold

check position/settings of relevant valves

fit service gauge manifold to system

correctly purge service manifold

correctly attach recovery equipment

select correct recovery cylinder

obtain TARE weight of cylinder

check weight of cylinder to identify capacity

carry out pre-recovery checks on system & equipment

carry out recovery from system

confirm system charge fully recovered

remove recovery equipment with NO/minimal loss of refrigerant

Prepare system to enable work to be carried out

Blanking off parts of system/ re-setting valve positions

Prepare recovery cylinder for return to supplier

  • Complete waste transfer documentation & F-GAS LOGSHEET

Complete waste transfer documentation

Is aware of Company Premises Code

Is aware of the processing of the Waste Transfer Note

Complete F-GAS Log sheet

  • Produce a brazed joint in suction line of system

Removes part of suction line

Produces a replacement piece of pipework

Makes flares

Makes a swaged joint

Ensures HOT WORK PERMIT is in place

Ensures fire extinguisher is in place

Sets up brazing equipment

Sets up OFN purge

Carries out brazing of joint

Visually inspects brazed & flared joints

Fits test piece onto assessment rig

  • Carry out pressure test to BS EN 378 Standards

Visually inspects system for pressure testing procedures

Ensures safety notice/s are in place

Selects Pressure testing equipment

Calculates the required Strength Test/Tightness pressure

Introduces OFN into system in stages up to correct pressure

Identifies & repairs any leaks

Completes any records

  • Carry out leak test to BS EN 378 Standards

Obtains correct pressure for leak pressure testing

Reduces to correct pressure

Carries out leak detection procedures using appropriate test equipment

Repairs any leaks

Leaves system on Standing Pressure test for appropriate period

  • Carry out evacuation to BS EN 378 Standards

Checks that system pressure test is PASSED

Releases OFN

Obtains correct evacuation pressure

Selects correct evacuation equipment

Carries out checks on vacuum pump & vacuum test gauge

Correctly connects evacuation equipment to system

Monitors the evacuation process

Checks integrity of vacuum by ‘isolation & rise’ test

Confirms suitable pressure is achieved

Isolates evacuation equipment & prepares for charging.

  • Refrigerant charge system to correct levels

Carries out pre-charge checks

Ascertains correct amount of refrigerant charge required

Obtains correct refrigerant cylinder

Calculates amount of refrigerant within cylinder

Attaches refrigerant charging equipment to system

Carries out purging and adjusts valves

Liquid charges system to correct level

  • Correctly commission system, Establish correct function & test of system

Ensures system correctly charged

Knows how to read service gauge manifold

Knows how to read refrigerant comparitor

Checks sightglass ;empty, bubbles, full & moisture indication

Checks System pressures

Checks System temperatures

Identifies system components and pipework

Suction line location & state of refrigerant

Discharge line & state of refrigerant

Liquid line and state of refrigerant

Compressor : brief function and state of refrigerant

Condenser: brief function and state of refrigerant

TEV: brief function and state of refrigerant

Evaporator: brief function and state of refrigerant

Obtain amount of suction superheat

Obtain amount of discharge superheat

Obtain amount of liquid sub-cooling

Obtains compressor amps

Confirms system is correctly charged and working efficiently

Checks for leaks

Removes charging equipment

  • Complete commissioning logs

Correctly completes commissioning sheet & data log

  • Complete F-GAS logsheet

Correctly completes F-GAS LOG SHEET

Completes Plant details, engineers details, refrigerant charge amount & reason for charge

  • Handover system to assessor

System & documents handed over to assessor

  • Drain oil from a compressor ( this is from a DIFFERENT COMPRESSOR )

Selects correct PPE

Selects correct vessel for oil drainage

Drains oil

Correctly identifies condition of refrigerant oil

Completes waste transfer documents

Theoretical Assessment & Topic Areas

  • Basic thermodynamics of refrigeration & air conditioning systems

SI metric units of measurement pressure, temperature, density, enthalpy. Conversion scales for pressure & temp. Pascals /bars.

Simple vapour compression refrigeration cycle. Superheat, saturation & subcooling. Sensible & Latent heat.

  • Compressor function & potential leakage risks

Different types of compressors: semi-hermetic, hermetic & open.

Scroll, reciprocating-piston, screw.

Effects of high running temps/high superheat & high pressures

  • Condensers (air-cooled, water-cooled & evaporative) function

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Various types of condensers & functions. Methods of operation. Latent heat removal. Effects of external blockage. Effects of internal blockage.Effects of under condensing & over condensing.

Typical temperature differences between refrigerant & cooling medium

  • Evaporator( DX & flooded) function & potential leakage risks

Various types of evaporators & functions. Methods of operation. Latent heat addition. Effects of external blockage. Effects of internal blockage. Effects of low superheat & high superheat

Typical temperature differences between evaporating refrigerant & product/space temp. Understanding of defrosting techniques: electric, hot gas.

  • TEV & capillary tube function & potential leakage risks

Internally & externally equalised TEVs-operations & functions. Typical superheat settings for TEVs and effects of low & high superheat.

Effects of wrong-sized orifice-TOO SMALL & TOO BIG.

Capillary tube function.

  • Pressure-enthalpy diagrams; plotting systems & obtaining refrigeration effect, heat of compression, condensing effect, COPr & COPhp.

Understands a P-h Chart & function. Plots a simple refrigeration cycle on P-h Chart. Identifies refrigeration cycle and components/pipelines on P-h Chart.
Compression, condensing, expansion & evaporation processes. Suction superheat, discharge superheat & liquid subcooling. Obtains & recognises Refrigeration
effect, heat of compression, condensing effect/heat rejection. Obtains COEFFICIENT OF PERFORMANCE ( COPr & COPhp)

Effects of increasing and/or decreasing suction pressure & discharge pressure and effects on energy consumption

  • Environmental impact of refrigerants and corresponding environmental regulations; ODPs, GWPs , EPA, F-GAS, ODS , Montreal & Kyoto Protocols.

Understands Montreal Protocol relates to ODS

Understands Kyoto Protocol relates to GWP. Understands Direct & Indirect GWP

Understands F-Gas regs = EC 842/2006:Requirements for systems containing less than 3kg, more than 3kg, more than 30kg & more than 300kg

Understands Ozone Regs = EC 2037/2000

Understands requirements of F-GAS regs.

Understands requirements & implications of Environmental Protection Act

Understands HCFCs, HFCs & HCs. Knows ODPs & GWPs of various refrigerants: R22,R134a,R410a,R407c,R404A,R744,R600a,R1290, R717 Understands
azeotropic & zeotropic blends. Understands blend separation; temperature glide & slide:dew & bubble temps.

Knows how to obtain superheat & subcooling with zeotropic blends.

  • Refrigerant hazards: asphyxiation, burns, cardiac sensitization , Central Nervous System & thermal decomposition.

Knows the hazards associated with refrigerants: cold burns, frostbite, asphyxiation. Symptoms of each, coughing, choking & retching.

Knows critical temperature, ignition & flash points of refrigerants.

Thermal decomposition of refrigerants & effects

  • Handling, storage, transportation & disposal of refrigerant and oil

Correct handling, storage and transportation of refrigerants & oils

COSHH, HASAWA, Transporting/ Carriage of Dangerous Substances-Road TRAFFIC Regs

Waste Transfer Regs

  • Correct procedures for pressure testing, evacuation, leak testing & refrigerant charging

Knows requirements of each to EN 378:2008 Regs & PED. Saturation temperatures used to obtain high side & low side pressures for pressure testing: 32C & 55C

Strength & leak test procedures. Knows that 41/8” & 21/8” copper pipes may not withstand strength test to EN378

Evacuation procedures

Refrigerant charging- liquid charging blends

  • Correct procedures for brazing , flaring & swaging copper pipe

Oxy- acetylene brazing equipment: Setting Up & usage; correct pressures & types of flame- neutral, caburising & oxidising

Mapp Gas & turbo-torch equipment.

Copper to copper brazing, Copper to brass brazing Types of brazing rod & fluxes. Hazards with fluxes.

Knows how to flare & swage; reasons for annealing, how to anneal.

  • Correct procedures for refrigerant recovery techniques

Knows how to obtain TARE WEIGHT of recovery cylinder

Knows how to obtain amount of refrigerant within cylinder

Indentifies correct filling weight.

Knows refrigerant recovery techniques-liquid ,vapour & push pull

Knows how to complete waste transfer documentation

  • Correct procedures for refrigerant charging

Knows how to obtain correct filling charge-labels

Knows how to liquid charge

Knows how to vapour charge

Identifies that system is correctly charged: weight, full sightglass, temps & pressures, running conditions

  • Checks for leakage; direct & indirect methods

Knows various types of direct leak detection methods: electronic, fluid, dye & spray

Knows various indirect leak detection: confirms that system has lost some refrigerant-effect on system performance: sightglass, loss of pressure/temp.
Effect on energy consumption

  • Energy efficiency; effects of lowering/increasing suction & discharge pressure, undercharge/overcharge on system performance & EER.

Knows symptoms of undercharge/overcharge & impact on energy consumption/system performance.

Knows implications of low suction pressure/low discharge pressure.

Knows implications of high suction & high discharge pressure

Understands principle of ENERGY EFFICIENCY RATIO ( EER )

Knows how to obtain/calculate EER for systems

  • Temperature differences between evaporating temperature & product temperature, condensing temperature and ambient temperatures.

Knows that low temperature differences are preferred for high energy efficiency

Approx 10K TD for evaporators & 16K TD for condensers

Knows that for every 1C rise in evaporating temperature, cooling capacity increases by 3% and energy consumption decreases by 3

  • Appropriate records/logs: F-GAS log, Commissioning logs & Waste transfer logs

Knows the various logs & records that need to be completed.

Risk Assessments, permits to work

Commissioning logs

F-Gas logs & requirements

Waste transfer documents & requirements

Many thanks for taking your time in completing this very detailed skillscan. This has enabled us to capture your current skills and knowledge and will allow us to devise a
specific training and assessment plan dedicated to you.

Signature of engineer                                                                                                                                                    Signature of Assessor

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After 40 plus years in the refrigeration industry with very little training in the early days (working on site with a more experienced engineer and picking up information along the way), not a bad way to learn gradually I learned the job.
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