AC Plant Operator Syllabus – Kerala PSC Exam

Detailed syllabus for the Post of Ac Plant Operator.

Module-1

Fitting, Sheet metal & Welding

Safety 2 Marks

1. Safety precautions
2. First Aids
3. Personal Protective Equipments (PPE)
4. Fire fittings equipments
5. Electrical safety

Fitting 3 Marks

1. Different types of fitting hand tools, power tools
2. Functions, constructions, specifications & application of hand tools and power tools
3. Care and maintenance of hand tool & power tools
4. Machineries and equipments like drilling machines, grinding machines etc
5. Function, construction, specification, application, care & maintenance of machineries & equipments
6. Precision measuring instruments like verniercalliper, micrometers, vernier height gauge etc
7. Functions, constructions, specifications & application of precision instruments
8. Care and maintenance of precision instruments

Sheet metal 2 Marks

1. Sheet metal tools, instruments, equipments
2. Construction, working, use, application and specification
3. Care and maintenance of sheet metal tools, instruments& equipments
4. Types of sheet metal joints
5. Rivets & riveting, their types and uses

Welding 2 Marks

1. Welding tools and equipments, types specifications and use
2. Oxy-Acetylene welding equipments & accessories
3. Gas welding hand tools and safety apparels
4. Arc welding accessories
5. Classification of welding process
6. Methods of gas welding
7. Use of Oxy Acetylene, Oxy LPG, Air LPG and two stage regulator
8. Types of weld

Module-2

Electrical

Electrical 3 Marks

1. Electrical terms such as AC and DC supply, voltage, current, capacitors, resistors, power, energy, frequency etc
2. Conductors and insulators
3. Series circuits, parallel circuits, open circuits, short circuits
4. Material used as conductors
5. Joints in conductors
6. Measuring instruments such as voltmeter, ammeter, ohmmeter, energy meter, frequency meter etc
7. Earthing and its importance
8. Earth resistance, insulation, and continuity testing

AC Motors 3 Marks

1. Single phase and three phase motors
2. Construction and working principle of Capacitor start Capacitor run induction motor (CSR), Split phase induction motor (RSIR), Capacitor start induction
3. motor (CSIR),Permanent Capacitor or capacitor run induction motor (PSC), Resistance start capacitor run induction motor (RSCR), Shaded pole motor etc
4. Centrifugal switch
5. Methods of changing the direction of rotation
6. Construction and working principle of squirrel cage induction motor, slip ring induction motor
7. Common faults, causes and remedies in single phase and three phase motors

Motor starters 2 Marks

Construction and working of Single phase and three phase motor starters such as DOL starter, Star delta starter, Auto transformer starter, Rotor resistance starter
Common faults, causes and remedies in single phase and three phase motor starters

Module-3

Electronics

Electronic components 2 Marks

1. Active and passive components
2. Resistor, Capacitors, Semiconductors, Diodes, Transistors etc
3. Rectifiers (Half wave, Full wave, Bridge rectifier etc )
4. Zener diodes, voltage regulator, Amplification
5. Transistors-CB,CE,CC Configuration
6. Photo diodes, Photo transistors, Multi vibrator, SCRs, UJTs, ICs etc.

Module-4

Basic refrigeration

Refrigeration tools, instruments ,and equipments 4 Marks

1. Refrigeration tools, instruments, and equipments|
2. Construction, working, use, application and specification
3. Care and maintenance of refrigeration tools, instruments& equipments

Fundamentals of refrigeration 5 Marks

1. Fundamentals of refrigeration
2. Science related to refrigeration such as units, mass, weight, work, power, energy, force, pressure, heat, temperature, sensible heat, latent heat, super heating, sub cooling, saturation temperature, boiling point , freezing point, etc
3. Laws of thermodynamic, Laws of perfect gases

Different types of refrigeration system 3 Marks

1. Construction and working of ice refrigeration
2. Construction and working of Dry ice refrigeration
3. Construction and working of Water vapour refrigeration
4. Construction and working of Liquid gas refrigeration
5. Construction and working of Evaporative refrigeration
6. Construction and working of Steam jet refrigeration
7. Construction and working of Thermo electronic refrigeration
8. Construction and working of Vapour absorption refrigeration cycle
9. Construction and working of Vapour compression cycle, fundamental operations, Sub cooling and super heating
10. Application of vapour compression cycle
11. COP, Ton of Refrigeration
12. Study of Ph, Ts, Pv diagram

Compressor 5 Marks

1. Construction, working, types and application of different compressors such as Reciprocating, Rotary, Scroll, Screw, Centrifugal, Swash plate etc
2. Volumetric efficiency, capacity control, factors influencing volumetric efficiency, piston displacement, compression ratio etc
3. Compressor lubrication oil, properties, types and lubrication methods
4. oil separator
5. Advantage and disadvantage of different types of compressors
6. Common faults, care and remedies in compressor

Module-5

Refrigeration equipments

Condenser 3 Marks

1. condenser capacity
2. Advantage and disadvantage of different types of condensers
3. De-scaling, methods of descaling, fouling factor etc
4. Liquid receiver
5. Drier, types and application
6. Description of desiccants

Cooling tower 3 Marks

1. Construction and working principles of different types of cooling towers
2. Types of cooling towers
3. Capacity of cooling towers, factors affecting the cooling tower capacity
4. Advantage and disadvantage of different types of cooling towers
5. Cooling tower approach, range, efficiency etc
6. Water treatment, water softening plant

Expansion valve 3 Marks

1. Construction and working principles of different types of expansion valves such as Thermostatic expansion valves (TXV), Automatic expansion valves (AXV), Float valve, Electronic expansion valves, Level master control (LMC),Capillary tubes etc
2. Selection of expansion valves

Evaporator 2 Marks

1. Construction and working principles of different types of evaporators
2. Capacity of an evaporator, factors affecting the capacity of an evaporator
3. Types of evaporators such as Natural convention, forced convention, flooded evaporator, Dry expansion evaporator, Bare tube coil evaporator, Finned tube evaporator, Plate evaporator, Shell and tube, Shell and coil, Tube in tube evaporator, frosting evaporator, non frosting evaporator etc
4. Methods of defrosting such as Manual defrosting, Pressure control defrosting, Temperature control defrosting, Water defrosting, Reverse cycle defrosting, Simple hot gas defrosting, Automatic defrosting, Electric defrosting etc
5. Accumulator
6. Heat exchanger, their function, construction, application & advantage

Module-6

Refrigerant

Refrigerant 5 Marks

1. Properties of refrigerant
2. Classification of refrigerants
3. Alternative refrigerants
4. Climatic impact of refrigerants
5. Ozone depletion potential (ODP)
6. Green house effect- global warming (GWP)
7. ODP & GWP of various Refrigerants
8. Numbering of refrigerants
9. Refrigerant cylinders, Cylinder colour coding
10. Handling of refrigerant cylinders & Flammable refrigerant
11. Refrigerant leak detection methods
12. Flushing, leak testing, Evacuation, Gas charging in different system
13. Retrofitting

Module-7

Refrigeration system

Refrigerator (direct cool) 3 Marks

1. Construction and working principles of single door direct cool refrigerator
2. Study the electrical and mechanical components
3. Testing of electrical and mechanical components
4. Door gasket
5. Heat insulation materials, types & properties
6. Trouble shooting of refrigerator
7. Installation method
8. Care and maintenance of refrigerator
9. Leak testing, Evacuation, Gas charging
10. Electrical circuit diagram

Frost free refrigerator 2 Marks

1. Construction and working principles of frost free refrigerator (2 or 3 door)
2. Study the electrical and mechanical components
3. Testing of electrical and mechanical components
4. Trouble shooting of frost free refrigerator
5. Care and maintenance of frost free refrigerator
6. Installation method
7. Leak testing, Evacuation, Gas charging
8. Electrical circuit diagram

Refrigerator (inverter technology) 1 Marks

1. Construction and working principles of refrigerator
2. Refrigeration cycle & Air cycle
3. Study the electrical and mechanical components
4. Testing of electrical and mechanical components
5. Trouble shooting of refrigerator
6. Care and maintenance of refrigerator
7. Leak testing, Evacuation, Gas charging
8. Electrical circuit diagram

Water cooler & Water dispenser 2 Marks

1. Construction and working principles of water cooler & water dispenser
2. Types of water cooler & water dispenser
3. Refrigeration cycle of water cooler & water dispenser
4. Study the electrical and mechanical components
5. Testing of electrical and mechanical components
6. Trouble shooting of water cooler & water dispenser
7. Care and maintenance of Water cooler & Water dispenser
8. Leak testing, Evacuation, Gas charging
9. Electrical circuit diagram
10. Insulation materials

Visible cooler & Bottle cooler 1 Marks

1. Description, Construction and working principles
2. Study the electrical and mechanical components
3. Testing of electrical and mechanical components
4. Trouble shooting of visible cooler & bottle cooler
5. Care and maintenance of visible cooler & bottle cooler
6. Leak testing, Evacuation, Gas charging
7. Electrical circuit diagram

Deep freezer/Display carbine 2 Marks

1. Description, Construction and working principles
2. Study the electrical and mechanical components
3. Testing of electrical and mechanical components
4. Trouble shooting
5. Care and maintenance
6. Leak testing, Evacuation, Gas charging
7. Electrical circuit diagram
8. Installation method

Ice cube machine/Softy machine 1 Marks

1. Description, construction, working
2. Study the electrical and mechanical components
3. Testing of electrical and mechanical components
4. Trouble shooting
5. Care and maintenance
6. Leak testing, Evacuation, Gas charging
7. Electrical circuit diagram
8. installation method

Window Air Conditioner 5 Marks

1. Construction and working principles
2. Study the electrical and mechanical components
3. Testing of electrical and mechanical components
4. Trouble shooting and servicing
5. Installation method
6. Care and maintenance of refrigerator
7. Leak testing, Evacuation, Gas charging
8. Electrical circuit diagram
9. Energy Efficiency Ratio(EER)
10. Energy Efficiency labeling on Air-Conditioning system
11. Construction and working principles
12. Study the electrical and mechanical components

Module-8

Air conditioning system

Split AirConditioner (Wall Mounted, Floor, Ceiling/Cassette mounted, Duct able)  2 Marks

1. Testing of electrical and mechanical components
2. Trouble shooting and servicing
3. Installation method
4. Care and maintenance of refrigerator
5. Leak testing, Evacuation, Gas charging
6. Electrical circuit diagram
7. Energy Efficiency Ratio(EER)
8. Energy Efficiency labeling on Air-Conditioning system

Multi split AirConditioner  2 Marks

1. Construction and working principles
2. Study the electrical and mechanical components
3. Testing of electrical and mechanical components
4. Trouble shooting and servicing
5. Installation method
6. Care and maintenance of refrigerator
7. Leak testing, Evacuation, Gas charging
8. Electrical circuit diagram

Inverter Split Air Conditioner   2 Marks

1. Construction and working principles
2. Study the electrical and mechanical components
3. Testing of electrical and mechanical components
4. Trouble shooting and servicing
5. Installation method
6. Care and maintenance of refrigerator
7. Leak testing, Evacuation, Gas charging
8. Electrical circuit diagram

Module-9

Commercial Refrigeration and air conditioning system

Walk in cooler & reach in cabinet   1 Marks

1. Capacity & types
2. Trouble shooting and servicing
3. Installation method
4. Care and maintenance of refrigerator
5. Leak testing, Evacuation, Gas charging

Cold storage 3 Marks

1. Function, construction, Working principle
2. Controls & Circuit diagram
3. Capacity & types of cold storage and its details
4. Trouble shooting and servicing
5. Installation method
6. Care and maintenance of refrigerator
7. Methods of Leak testing, Evacuation, Gas charging
8. Food preservation
9. Maintaining temperature in different places
10. Properties of commonly used refrigerants like ammonia and its safe handling
11. use of vibration eliminator and shock absorber
12. Mobile refrigeration in transport vehicle
13. Deep freezing, Freezing tunnel, Blast freezing

Module-9

Commercial Refrigeration and air conditioning system

Psychrometry  4 Marks

1. Requirement of comfort Air-Conditioning
2. Study of psychrometric terms-DBI, WBT, RH, enthalpy, dew point, specific humidity etc
3. Study of psychrometric chart-Dry bulb temperature line, Wet bulb temperature line, Specific humidity or moisture content line, Dew point temperature line, Enthalpy (total heat) line, Vapour pressure line, Relative humidity line etc
4. Study of psychrometric process-Sensible heating, Sensible cooling, Humidification & Dehumidification, Cooling and adiabatic humidification, Cooling and humidification by water injunction, Heating and humidification, Humidification by steam injection, Adiabatic chemical dehumidification etc
5. Heat load calculation for commercial and industrial buildings

Central AirConditioning system/HVAC plant 3 Marks

1. Introduction to HVAC
2. Fundamentals of central Air-Conditioning/ HVAC plant
3. Types of central Air-Conditioning (direct & indirect)
4. Construction & Working
5. Components, Fault, Care & Maintenance
6. Temperature & pressure control used in AC plant
7. Construction and working of safety devices in AC plant
8. Cooling tower, Pipe lines
9. Preventive maintenance schedule of central Air Conditioning plant
10. Maintain log book for daily operation
11. Modulating valve for temperature control
12. Package chiller, Screw chiller, Reciprocating chiller
13. Humidity control
14. Humidifier
15. Dehumidifier
16. Air washer
17. AHU, FCU
18. Chilled water system

Package AirConditioner (Air cooled, Water cooled condenser)  1 Marks

1. Construction & working principles
2. Types, application
3. Installation methods
4. Trouble shooting
5. Care and maintenance
6. Temperature & pressure control
7. Construction and working of safety devices

Split package  1 Marks

1. Construction & working principles
2. Types, application
3. Study of various electrical & mechanical components
4. Installation methods
5. Trouble shooting
6. Care and maintenance
7. Temperature & pressure control
8. Construction and working of safety devices
9. VRV/VRF system
10. Details of piping
11. Common reason for error code
12. Types of ODU & IDU

Duct  4 Marks

1. Function, types
2. Classification of ducts
3. Materials used for ducting
4. Duct designing
5. Pressure in ducts
6. Duct insulations
7. Properties of insulation materials
8. K-factors
9. Acoustic insulation
10. Air distribution methods
11. Air flow
12. Fan and blower
13. Function, types, classification of fan & blower
14. Static & Velocity pressure measurements

Air Filter  3 Marks

1. Construction, Function of air filters
2. Types of air filters
3. Care & maintenance of air filter
4. Effect of chocked air filter
5. Clean room

Module-10

Automobile air Conditioning

Car Air Conditioner  2 Marks

1. Construction, working
2. Study various electrical & mechanical components
3. Testing components
4. Electrical circuit diagram
5. Fault detection
6. Leak testing, evacuation, gas charging
7. Installation
8. Trouble shooting
9. Magnetic clutch operation
10. Free wheeling
11. Care and maintenance

Mobile AirConditioner (Bus, Train) 1 Marks

1. Study the refrigeration cycle in automobile AC
2. Construction and working of bus AC
3. Magnetic clutch operation, free wheeling
4. Refrigerant used HCFC-22, HFC_134a, HFOs, Blends of
5. HFCs, and HFOs
6. Construction and working of train AC
7. Trouble shooting of Bus AC & Train AC
8. Planning for Preventive maintenance and scheduling
9. Maintenance actives in large AC and Refrigeration plant

NOTE: – It may be noted that apart from the topics detailed above, questions from other topics prescribed for the educational qualification of the post may also appear in the question paper. There is no undertaking that all the topics above may be covered in the question paper