This unit involves the skills and knowledge required to design complex industrial refrigeration systems and select equipment.

It includes applying system processes and methods of industrial refrigeration systems, safety and relevant industry standards; developing alternative design schemes based on a design brief and customer requirements; and documenting system designs.

The skills and knowledge described in this unit may, in some jurisdictions, require a licence or permit to practice in the workplace subject to regulations for undertaking refrigeration and air conditioning work. Practice in the workplace and during training is also subject to work health and safety (WHS)/occupational health and safety (OHS) regulations.

No other licensing, legislative or certification requirements apply to this unit at the time of publication.

ELEMENTS

PERFORMANCE CRITERIA

Elements describe the essential outcomes.

Performance criteria describe the performance needed to demonstrate achievement of the element.

1

Prepare to design complex industrial refrigeration system

1.1

WHS/OHS requirements and workplace procedures for a given work area are identified, obtained and applied

1.2

WHS/OHS risk control measures and workplace procedures are followed in preparation for the work

1.3

Scope of the refrigeration system is determined from the design brief and/or consultations with relevant person/s

1.4

Design development work is planned in accordance with workplace procedures for timelines in consultation with others involved

2

Design complex industrial refrigeration system

2.1

Relevant industrial refrigeration system processes and methods are applied to the design

2.2

Alternative concepts for design are evaluated in accordance with the design brief

2.3

Safety, functionality and budgetary considerations are incorporated in the design specifications

2.4

System design draft is checked for compliance in accordance with the design brief and relevant industry standards

2.5

System design is documented and submitted to relevant person/s for approval in accordance with workplace procedures

2.6

Unplanned events are dealt with in accordance with problem-solving techniques and workplace procedures

3

Obtain approval for complex industrial refrigeration system design

3.1

System design is presented to customer and/or relevant person/s in accordance with workplace procedures

3.2

Requests for alterations to the design are negotiated with relevant person/s in accordance with workplace procedures

3.3

Final design is documented and approval obtained from relevant person/s in accordance with workplace procedures

3.4

Quality of work is monitored in accordance with workplace procedures and relevant industry standards

Evidence required to demonstrate competence in this unit must be relevant to and satisfy all of the requirements of the elements, performance criteria and range of conditions on at least one occasion and include:

developing outlines of alternative designs

developing the design within the safety, regulatory, functional requirements and budget limitations

documenting and presenting design effectively

negotiating design alteration requests successfully

obtaining approval for final design

dealing with unplanned events

applying relevant industrial refrigeration system processes and methods

applying relevant work health and safety (WHS)/occupational health and safety (WHS/OHS) requirements, including using rick control measures

designing complex commercial refrigeration system

preparing to design complex industrial refrigeration system.

Evidence required to demonstrate competence in this unit must be relevant to and satisfy all of the requirements of the elements and performance criteria and include knowledge of:

complex industrial refrigeration system design, safe working practices and relevant standards, codes and regulations including:

AS/NZS 1677 Refrigerating systems SAA refrigeration code

ANSI/IIAR standards

ANSI/ASHRAE standards

IIAR bulletins

moderate and low temperature industrial refrigeration systems:

direct, flooded and pumped liquid recirculation systems

evaporators

multi-staged compression

direct staging

cascade staging

compound compressors

de-superheaters and liquid injection

direct expansion intercoolers

open and closed intercoolers

basic designs of accumulators/intercooler vessels

oil cooling methods

oil stabilisation, return and oil recovery in flooded systems

multiple evaporators and multiple compressors:

parallel evaporators

multiple temperature systems

evaporator pressure regulators

temperature control methods

parallel compressors

pipe work layout

methods of establishing pressure drop in dry and wet suction lines

indirect refrigeration systems:

classification according to AS/NZS 1677 Refrigerating systems SAA refrigeration code

applications

evaporators

heat exchangers, types, construction and selection

secondary refrigerants

brines

antifreeze solutions

flooded systems:

applications

equipment

accumulators

level controls

liquid recirculation pumps

liquid pressure relief valve

cryogenic systems:

applications and equipment

system components

refrigerants

design safety

economics

cascade systems

basic control sequences:

maintaining evaporator conditions

staging and suction pressure control

maintaining condenser conditions

control of intermediate pressure, methods of industrial refrigeration compressor capacity control

system design:

required cooling capacity per day

running time and required system cooling capacity

system capacity control for peak and low load

refrigeration system diagrams

refrigerant, equipment, major component, controls, piping and accessory selection

problem-solving techniques

relevant job safety assessments or risk mitigation processes

relevant manufacturer specifications

relevant WHS/OHS legislated requirements

relevant workplace budget, quality, policies and procedures

relevant workplace documentation.

Assessors must hold credentials specified within the Standards for Registered Training Organisations current at the time of assessment.

Assessment must satisfy the Principles of Assessment and Rules of Evidence and all regulatory requirements included within the Standards for Registered Training Organisations current at the time of assessment.

Assessment must occur in suitable workplace operational situations where it is appropriate to do so; where this is not appropriate, assessment must occur in simulated suitable workplace operational situations that replicate workplace conditions.

Assessment processes and techniques must be appropriate to the language, literacy and numeracy requirements of the work being performed and the needs of the candidate.

Resources for assessment must include access to:

a range of relevant exercises, case studies and/or simulations

relevant and appropriate materials, tools, facilities and equipment currently used in industry

applicable documentation, including workplace procedures, equipment specifications, regulations, codes of practice and operation manuals.

Foundation skills essential to performance are explicit in the performance criteria of this unit of competency.

Range is restricted to essential operating conditions and any other variables essential to the work environment.

Non-essential conditions may be found in the UEE Electrotechnology Training Package Companion Volume Implementation Guide.

Designing a complex industrial refrigeration system must include at least the following:

one multiple major component, including:

compressors

condenser

evaporators

circuits and/or systems

associated components and controls

Electrotechnology

Refrigeration and air-conditioning