R&AC (FOUNDATION LEVEL) PPT 2018

1. REFRIGERATION
&
AIR CONDITIONING
{ FOUNDATION LEVEL}

2. ATMOSPHERE:
• ENVIRONMENT, HEALTH AND SAFETY:
• Almost all the corporate companies in Indian and abroad have A written policy on EHS. The policy
is percolated down the line and is monitored at regular interval of time for its proper execution.
The policy is revised based on the requirement.
• Voltas,GMR and Andhra bank are no different and all of them have written policy on EHS.
• The subject covers the policy broadly and is mandatory for al the students to follow the same
during the training and thereafter.

3. ENVIRONMENT:
EARTH IS SURROUNDED BY
• Oxygen ( O2 ) around21%,
• Nitrogen around ( N2 ) 78%,
• Other gases around 1%

4. Oxygen
required by
Human Beings Animals & birds
Aqua
Creatures

5. We are
increasing CO2
level by using
Industrial Gases Automobiles De-Forestation
Chemicals &
Effluents
Releasing CO2 & CO Releasing CO2 & CO Cutting O2 source Releasing Acids

6. ENVIRONMENT:
All The CO2 released in the
Atmosphere is forming a carbon
layer around the earth

7. EARTH’S ENERGY:
During the day the earth absorbs heat from the sun,
70 % of the heat is radiated back out into space.
The balance 30 % reflected from earth’s surface.
These gases are called greenhouse gases because
they effectively make the blanket around our globe

8. Effect of
Global
Warming
Drought
Breathing Problem
Melting of Ice
Temperature Rise
Floods

9. We are releasing Cl2 in the
atmosphere by use of
Paints Refrigerant gases Furniture
Releasing Cl2 Releasing VOC’sReleasing Cl2

10. ENVIRONMENT:
Acid Rain
Ozone
Depletion
Global
Warming
Plastics

11. SAFETY:
Types of safety
General safety Tool safety Electrical safety

12. GENERAL SAFETY:
• 5S is a workplace organization technique
• It is a way to involve associates in the ownership of their workspace
• It helps create and maintain the efficiency and effectiveness of a work area
What is it?

13. BASIC SAFETY RULES
• Perform regular maintenance
• Use right tool for the job
• Inspect all tools before use
• Use the right personal protective equipment (PPE)
• Report to your supervisor any unsafe tool.

14. THE FIVE S’S
• Sorting – separating the needed from the not-needed
• Simplifying – a place for everything and everything in its place, clean and ready to use
• Systematic cleaning or sweeping – cleaning for inspection
• Standardizing – developing common methods for consistency
• Sustaining – holding the gains and improving

15. WHAT’S IT FOR?
• IT IS A WAY TO CREATE:
• Cleaner work areas
• More organization
• Safer working conditions
• Less wasted time
• Efficient work processes and practices
• More available space

16. PLANNING
• Assemble a 5S lead team
• Define the work area 5S boundaries
• Assign work group members to their 5S areas
• Install a 5S communication board
• Determine 5S targets, activities, and schedule
• Review/finalize plans with work group and site leadership

17. PREPARING FOR IMPLEMENTATION
• Obtain existing standards for color-coding and signage
• Decide on 5S color-coding and signage standards
• Prepare for sorting
• Prepare for simplifying
• Prepare for systematic cleaning
• Prepare for standardizing
• Prepare for sustaining

18. SUMMARY: IMPLEMENTING FIVE S’S
• Share 5S overview
• Choose work area implementation group
• Determine implementation targets, activities, and schedules
• Document current situation
• Apply 5s’s
• Document improvements
• Determine new improvement goals and action steps

19. ISSUES AND CONCERNS
• Communicating across shifts
• Disposing of, or moving, personal items
• Making time available
• Following agreements consistently
• Maintaining the gains
• Giving rewards and recognition
• Integrating 5S with other improvement activities

20. WHAT’S AN EXAMPLE?

21. ELECTRICAL SAFETY:
CAUSES:
• UNSAFE CONDITIONS
o Faulty insulation
o Improper grounding
o Loose connections
o Defective parts
o Ground faults in equipment
o Unguarded live parts
o Underrated equipment
o Work environment
Prevailing Mind Set
“It Won’t Happen To Me”
(Famous Last Words)
ELECTRICAL HAZARDS:

22. How Electricity Acts:
• Power Source – The Power Generating Station
• Transport Method – Electric Current Travels Through Conductors,
Normally In The Form Of Wires
• Force – The Pressure To Make Electricity Flow, Measured In Volts, Is
Provided By A Generator
Behind Turning On An Electric Switch There
Must Be:

23. ENERGIZED (electrically): electricity is flowing into and powering A piece
of equipment in order for it to perform its function, i.e., The equipment is
“live” or “hot”
Only QUALIFIED PERSONS May Work
On Energized Electric Circuit Parts Or
Equipment
• Trained To Avoid The Electrical
Hazards Of Working On Or Near
Exposed Energized Parts

24. BODY PATH RESISTANCE CURRENT
Ear to Ear 100 1,100 mA
Head to Foot 500 220 mA
Dry Skin 350,000 0.3 mA
Wet Skin 1,000 110 mA
SHOCK HAZARD :
Conductors - Offer Little Resistance To The Flow
Of Electric Current
• Metals, Water
Insulators - Have High Resistance to the flow of
electric current
• Porcelain, Pottery, Dry Wood
Low Resistance High Current
High Resistance Low Current
Dry Skin Has A Fairly High Resistance To
Electric Current; But When Moist There Is A
Drastic Drop In Resistance.
Dry Your Hands Before Inserting/ Removing
A Power Plug.
Effects On Human Body:

25. INSULATION:
Material located between points of different
potential to prevent the flow of electricity
• Most common causes of failure - heat, dirt,
chemicals, moisture, sunlight & physical
damage
SHOCK HAZARD:
120 And 240 Volt Wire Color Codes
• Phase 1 - Black
• Phase 2 - Red
• Phase 3 - Blue
• Neutral - White Or Three White Stripes
• Ground - Green Or Green Striped
277 And 480 Volt Wire Color Codes
• Phase 1 - Brown
• Phase 2 - Orange
• Phase 3 - Yellow
• Neutral - Gray Or With 2 White Stripes
• Ground - Green With Yellow Stripe
Protective Measures:

26. GUARDING
• > 50 V requires
o Enclosed room
o Permanent partitions
o > 8’ above floor
o Platform / balcony / gallery
• > 600 v requires
o Metal-enclosed equipment
o Enclosed vault controlled by a lock
o Marked with caution signs

27. GROUNDING:
Non-current-carrying metallic system components, such as
equipment cabinets, enclosures, and structural steel, need to be
electrically interconnected so voltage potential cannot exist between
them then A low-resistance path to the earth is provided
• Service / system ground
o White / gray wire is grounded at the generator /
transformer & at the service entrance of the building
o Protects machines, tools & insulation against damage
• Equipment ground
o Additional ground path from machine / tool to the ground
o Protects equipment operator
NOT a Guarantee Against Shock

28. Circuit Breakers Fuses GFCIs
CIRCUIT PROTECTION DEVICES
Protects worker from overcurrent & short circuits by automatically shutting off the electricity
• Overcurrent caused by: malfunction, overheating, too much on A circuit, power surge,
damaged insulation

29. CIRCUIT BREAKERS
Over-current devices designed to trip open the circuit by
electromechanical means when set current value is exceeded

30. GROUND-FAULT CIRCUIT INTERRUPTER (GFCI)
Designed to shutoff electricity within 1/40th of a second
• Compares current going into and out of equipment
o Interrupts power if differs more than 6 ma
• Prevents electrocution
• Used in high-risk areas
o Wet locations
o Construction sites
Receptacle GFCI
Portable GFCIs

31. REPLACE / RESET CIRCUIT PROTECTION
• Random power surge: replace fuse or reset breaker
o Use exact duplicate fuse
 Higher rated fuse can damage equipment / start A fire
 Lower rated fuse could explode
• Circuit breaks again or if there is smoke, heat or unusual odor
o Immediately de-energize
o Do not keep resetting breaker - find the problem
• Never bypass, bridge or disable

32. Type of FR clothing required for work on or
near systems rated at:
• 240 volts & below (low-energy work)
o Natural-fiber / non-synthetic clothing is
adequate for many tasks
o Some higher risk tasks require flame
resistant (FR) clothing
• 241 - 559 volts
Requires at least one layer of FR clothing
worn over natural-fiber clothing
PERSONAL PROTECTIVE EQUIPMENT(PPE)
FLAME RESISTANT (FR) CLOTHING:

33. • Type 1 – Reduce Impact Force From Blow To Top Of Head
• Type 2 - Reduce Impact Force From Blow To Top Or Sides Of Head
• Class G (General) – Reduce Danger Of Contact With Low Voltage
(Tested At 2,200 Volts Phase To Ground)
• Class E (Electrical) - Reduce Danger Of Contact With Higher
Voltages (Tested At 20,000 Volts Phase To Ground)
• Class C (Conductive) – Not Intended To Protect Against Electrical
Hazards
Hard Hat Ratings:
ANSI Head Protection Standard Z89.1

34. Dielectric Mats
And Use Protective Equipment/Insulated Tools
Rubber / Composition Gloves / Sleeves
• Personally Assigned
• Inspect & Air Test At Start Of Each Day
• To Be Regularly Lab Tested Every 6 Months

35. TOOL SAFETY:
• Loss of eye/vision
• Using striking tools without eye protection.
• Puncture wounds
• Using a screwdriver with a loose handle which causes the hand to slip.
• Severed fingers, tendons and arteries
• Using a dull knife requires so much force that your hand may slip down the blade.
• Broken bones
• Using the wrong hammer for the job and smashing a finger.
• Contusions
• Using a small wrench for a big job and bruising a knuckle.
TOOL HAZARDS

36. • Do not use defective tools
• Use tied-off containers to keep tools from falling off of molds or work platforms.
• Keep all cutting tools sharp.
• Carry all sharp tools in a sheath or holster.
• Return tools to their storage places after use.

37. • Watch your hands and fingers.
• Keep your mind on your work.
• Grip tools firmly.
• Operate according to the manufacturer's instructions.
• Never carry a tool by the cord or hose.
• Never yank the cord or the hose to disconnect it from the receptacle.
• Disconnect tools when not in use, before servicing, and when changing accessories such as
blades, bits and cutters.

38. TYPES OF FIRE EXTINGUISHERS

39. THREE WAYS TO EXTINGUISH A FIRE
• Starvation - removal of fuel
• Smothering - removal of oxygen
• Cooling - removal of heat
• Remove any one of the three components and fire cannot start or be
sustained

40. FIRE CLASSIFICATION:
• Class A: SOLIDS such as paper, wood, plastic etc
• Class B: FLAMMABLE LIQUIDS such as paraffin, petrol, oil etc
• Class C: FLAMMABLE GASES such as propane, butane, methane etc
• Class D:METALS such as aluminium, magnesium, titanium etc
• Class f:cooking OIL & FAT etc

41. TYPES OF FIRE EXTINGUISHERS:
WATER
• 6 or9 liter size
• Suitable for class A fires
• Not for use on flammable liquids
• Not to be used near to live
electrical apparatus
• Discharge time, approximately 60
seconds
• Weighs approximately 15 kilOS

42. FOAM
• Multi-purpose foam spray
• 9 liters, 6 liters or 2 liters
• Ideal for burning solids and
hydrocarbon liquids
• Can be rated for use on live
electrical equipment

43. DRY POWDER
• 1kg, 2kg, 3kg, 6kg, and 9kg capacities
• ABC powder for burning solids, burning liquids
and if specially trained, burning gases
• Could be harmful in a confined space, and will
contaminate prepared foods, and delicate
electronic equipment
• Little cooling effect

44. SPECIAL FIRE EXTINGUISHERS
• ‘Fry fighter’
• For class F fires (overheated
cooking oils/ fats)
• ‘Unique’ wet chemical’
formulation to saponification
the burning fat

45. CARBON DIOXIDE (CO2)
• Clean non conductive agent
• Ideal for fires involving live
electrical apparatus
• Noisy in operation
• Some parts of the extinguisher
will become very cold
• Little to no cooling effect

46. OTHER FIRE FIGHTING EQUIPMENT
• HOSE - REELS
• FIRE BLANKETS

48. INTRODUCTION
TO
ELECTRICITY

49. ELECTRICITY:
Electricity is the set of physical phenomena associated with the presence and motion of electric
charge. The presence of an electric charge, which can be either positive or negative, produces an
electric field. The movement of electric charges is an electric current and produces a magnetic field.

50. EFFECTS OF ELECTRIC CURRENT:
• THREE EFFECTS OF AN ELECTRIC CURRENT:
• Heating effect : Generally a battery or cell is used as a source of electrical energy. If an electric
circuit is purely resistive (only resistors are connected to a battery), the energy from the source
continually gets dissipated totally in the form of heat.
• Magnetic effect: The magnetic effect of electric current is known as electromagnetic effect . it is
observed that when a compass is brought near a current carrying conductor the needle of compass
gets deflected because of flow of electricity. This shows that electric current produces a magnetic
effect.
• Chemical effect : The passage of an electric current through a conducting liquid
causes chemical reactions. The resulting effects are called chemical effects of currents. The
process of depositing a layer of any desired metal on another material, by means of electricity, is
called electroplating.

51. →CONTROLS ALWAYS CONNECTED IN SERIES.
→LOADS ALWAYS CONNECTED IN PARALLEL.

52. CAPACITOR:
A capacitor is a passive two-terminal electrical component that stores potential energy in an
electric field. The effect of a capacitor is known as capacitance.
TYPES OF CAPACITORS:
1.STARTING CAPACITOR:
A motor capacitor, such as a start capacitor or run capacitor
is an electrical capacitor that alters the current to one or more
windings of a single phase AC induction motor to create a rotating magnetic field.
2.RUNNING CAPACITOR:
Capacitors are small cylindrical objects that store energy. They either send a
jolt to start a motor or send jolts to keep a motor running. They work with the
compressor, the blower motor, and the outside fan in your air conditioner.

53. RELAYS:
• Relays are switches that open and close circuits electromechanically or
electronically. Relays control one electrical circuit by opening and closing contacts in another
circuit. When a relay contact is normally closed (NC), there is a closed contact when the relay is
not energized.

54. TYPES OF RELAYS:
1. OVER LOAD RELAY:
A relay that opens a circuit when the load in the circuit exceeds
a present value, in order to provide overload protection;
usually responds to excessive current, but may
respond to excessive values of power, temperature, or other quantities.
Also known as overload release.
2.BOX RELAY:
Box relay is a new workflow tool that allows anyone to
easily create custom workflows. Box relay helps you and
your team get work done faster.

55. GENERAL TOOLS:
• Screwdrivers.
• Hammer.
• Tape measure.
• Pliers.
• Knife and blades.
• Adjustable wrenches.
• Combination plier.
• Centre punch.
• Adjustable spanner.
• Double ended spanner.
• Tube cutter .
• Ball pin hammer.
• Steel rule .
• Hack saw frame with blade.
• Scissor
• Cutting pliers
• Wooden mallet

56. REFRIGERATION & AIR CONDITIONING TOOLS:
1. Tube cut
2. Swaging tool.
3. Flaring tool.
4. Brazing tool.
5. Bending tool.
6. Adjustable wrench.
7. Manifold gauge.
8. Thermometers.
9. Sling psychrometer
10. Electrical clamp
meter.
11. Vacuum tube.

57. INTRODUCTION:
• Air conditioning is the process of removing heat and moisture from the interior of an occupied
space, to improve the comfort of occupants.
• Refrigeration is a process of removing heat from a low-temperature reservoir and transferring it
to a high-temperature reservoir. The work of heat transfer is traditionally driven by mechanical
means, but can also be driven by heat, magnetism, electricity, laser, or other means.

58. TYPES OF REFRIGERATION:
• Top freezer type refrigerators.
• Bottom freezer type refrigerator.
• Side by side refrigerator.
• Single door refrigerator.
• Compact refrigerator.

59. TYPES OF AIR CONDITIONING:
• 1.Residential air conditioner.
→Window ac.
→Portable ac.
→Split ac.
• 2.Commercial air conditioner.
→Ductable ac.
→Central plant ac.

60. REFRIGERATION SYSTEMS FOR INDUSTRIAL PROCESSES:
• Small capacity modular units of direct expansion type (50 tons of refrigeration)
• Centralized chilled water plants with chilled water as a secondary coolant (50 – 250 TR)
• Brine plants with brines as lower temperature, secondary coolant (>250 TR)

61. REFRIGERATION SYSTEMS:
• Vapour compression refrigeration (VCR): uses mechanical energy
• Vapour absorption refrigeration (VAR): uses thermal energy

62. VAPOUR COMPRESSION REFRIGERATION:
REFRIGERATION CYCLE:

63. ADVANTAGES & DISADVANTAGES OF AIR CONDITIONING SYSTEM:
• Advantages
• Prevents dehydration and heat strokes.
• Improves the quality of air.
• Helps to reduce asthma and allergies.
• Skin dryness.
• Aggravation of respiratory problems.
• Respiratory tract infections and allergies.
• Disadvantages of air conditioner on health
• Unexpected changes in humidity & temperature affects individual's respiratory system.
• Regular usage of air conditioner dries skin & mucous membranes.
• Its ambient noise, leads to noise pollution.
• Air circulation even transmits infectious respiratory diseases.
• Airborne dust & fungi cause allergic reactions.

64. THANK YOU