Refrigerant Piping Installation And Joining Techniques Training

Objectives:
• Identify common refrigerants and their properties
• Explain the purpose and components of a refrigeration system
• Describe relevant South African safety regulations (SANS 10147)
• Recognise personal protective equipment (PPE) requirements
• List environmental considerations for refrigerant handling

Topics:
• Overview of refrigeration cycle principles
• Types of refrigerants: CFCs, HCFCs, HFCs, and natural refrigerants
• Introduction to the Pressure-Enthalpy diagram
• South African legislative framework: OHS Act and SANS standards
• Hazards associated with refrigerants: toxicity, flammability, pressure
• Environmental impact and responsible handling practices
• Introduction to system components: compressor, condenser, evaporator, expansion device
• Basic system schematics and symbols

Objectives:
• Select appropriate piping materials for different refrigerants and applications
• Interpret piping specifications and sizing charts
• Demonstrate correct measurement, cutting, and deburring techniques
• Identify and mitigate common material defects
• Prepare pipe ends for joining according to manufacturer specifications

Topics:
• Copper piping types: ACR, soft, hard-drawn; sizes and wall thicknesses
• Steel and aluminium piping applications
• Pipe sizing calculations and pressure drop considerations
• Proper use of measuring tapes, tube cutters, and reamers
• Deburring techniques and inspection for imperfections
• Cleaning procedures: brushes, solvents, and nitrogen purging
• Storage and handling best practices to prevent contamination
• Introduction to piping supports, hangers, and expansion loops

Objectives:
• Differentiate between brazing and soldering processes
• Set up and safely operate oxy-acetylene or air-acetylene equipment
• Execute correct joint preparation and flux application
• Perform horizontal and vertical brazing/soldering joints
• Inspect completed joints for defects and integrity

Topics:
• Theory of capillary action and joint design
• Filler metals: phosphor-copper and silver-based alloys
• Flux types, application, and post-join cleaning
• Oxy-acetylene safety: cylinder handling, regulators, hoses, and flashback arrestors
• Flame adjustment: neutral, oxidizing, and carburizing
• Heating techniques and temperature control
• Step-by-step brazing procedure on practice coupons
• Visual inspection criteria: fillet shape, penetration, and discoloration

Objectives:
• Assemble and tighten flare and compression fittings correctly
• Select appropriate gaskets, O-rings, and sealants
• Perform pipe flaring using manual and hydraulic tools
• Pressure test mechanical joints for leaks
• Troubleshoot common leakage issues in mechanical connections

Topics:
• Types of mechanical fittings: flare, compression, and bite-type
• Flare fitting standards: SAE 45-degree vs. JIC 37-degree
• Proper use of flaring tools: single, double, and bubble flares
• Torque specifications and sequential tightening patterns
• Gasket and O-ring material compatibility with refrigerants
• Application of thread sealants and lubricants
• Hands-on practice: creating and assembling mechanical joints
• Leak testing methods: soap bubble and electronic detector

Objectives:
• Plan and execute a piping installation following design drawings
• Connect system components: compressor, heat exchangers, valves
• Perform deep vacuum evacuation to remove moisture and non-condensables
• Calculate and add correct refrigerant charge
• Document installation procedures and commissioning data

Topics:
• Reading and interpreting piping and instrumentation diagrams (P&IDs)
• Component installation: filter-driers, sight glasses, solenoid valves
• Proper routing: slopes, traps, and vibration isolation
• Vacuum pump operation and micron gauge use
• Vacuum decay test and triple evacuation method
• Charging methods: vapour, liquid, and weigh-in
• Use of manifold gauges and temperature-pressure charts
• Commissioning checklist and log sheet completion

Objectives:
• Install piping for complex systems: multi-circuit and heat recovery
• Diagnose and rectify common piping and jointing faults
• Apply leak detection and repair procedures
• Complete a practical installation assessment
• Review course content and prepare for workplace application

Topics:
• Parallel compressor rack piping and oil management
• Heat reclaim system piping configurations
• Troubleshooting scenarios: vibration fractures, corrosion, thermal stress
• Advanced leak detection: ultrasonic, infrared, and dye methods
• Repair techniques: section replacement and epoxy sealing
• Final integrated practical project: install, evacuate, and charge a circuit
• Theory and practical summative assessment
• Course recap, Q&A, and resource handover