diesel power plant operation and maintenance nc iii

7/29/2019 Diesel Power Plant Operation and Maintenance NC III

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COMPETENCY-BASED

CURRICULUM

Sector:

UTILITIESQualification:

Diesel Power Plant Operationand Maintenance NC III

TECHNICAL EDUCATIONAND SKILLS DEVELOPMENTAUTHORITYEast Service Road, South Superhighway, Taguig City, Metro Manila


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TABLE OF CONTENTS

Page

A...COURSE DESIGN...................................................................................1-7

B. MODULES OF INSTRUCTION.............................................................8-75

Basic Competencies.................................................................................8

o Lead workplace communication......................................9-12

o Lead small team.............................................................13-17

o

Develop and practice negotiation skills.........................18-21o Solve problem-related to work activities........................22-25

o Use mathematical concepts and techniques.................26-29

o Use relevant technologies.............................................30-33

Common Competencies.........................................................................34

o Reading, interpreting and applying specification and manual

35-38

o Performing shop maintenance.......................................39-43

o Performing mensuration and calculation.......................44-47

o Performing basic benchwork ........................................48-51

o Performing basic electrical works..................................52-54

Core Competencies................................................................................55

o Overhauling diesel engine.............................................56-64

o Diagnosing and repairing diesel engine........................65-68

o Diagnosing and repairing electrical system...................69-75


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COURSE DESIGN

COURSE TITLE : DIESEL POWER PLANT OPERATION ANDMAINTENANCE NC III

NOMINAL DURATION : 302 hours

COURSE DESCRIPTION :

This course is designed to enhance the knowledge, skills and attitudes of atrainee/student in tending diesel engine operation, operating diesel power plant, maintainingand repairing diesel engine and servicing alternator or generator.

This course also participating in workplace communication, working in a teamenvironment, practicing career professionalism, practicing occupational health and safetyprocedures, applying appropriate sealant and adhesive, reading, interpreting and applying

specification and manual and using lubricants.

ENTRY REQUIREMENTS:

Trainees or students should possess the following requirements:

can communicate both oral and written in English;

physically and mentally fit;

with good moral character; and

can perform basic mathematical computation

This list does not include specific institutional requirements such as educationalattainment and others that may be required from the trainees by the training schooldelivering the TVET program.

Diesel Power Plant Operation and Maintenance NC III - 1 -


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COURSE STRUCTURE:

BASIC COMPETENCIES(56 hours)

Units ofCompetency

Module Title Learning OutcomesNominalDuration

1. Leadworkplacecommunication

1.1Leadingworkplacecommunication

1.1.1 Communicate informationabout workplaceprocesses.

1.1.2 Lead workplacediscussions.

1.1.3 Identify and communicateissues arising in theworkplace

10 hours

2. Lead smallteam

2.1 Leading smallteam

2.1.1 Provide team leadership.

2.1.2 Assign responsibilities among

members.2.1.3 Set performance expectation

for team members2.1.4 Supervise team performance

10 hours

3. Developand practicenegotiationskills

3.1 Developing andpracticingnegotiationskills

3.1.1 Identify relevant informationin planning negotiations

3.1.2 Participate in negotiations3.1.3 Document areas for

agreement

8 hours

4. Solve

problem relatedto workactivities

4.1 Identifying/

determiningfundamentalcause ofproblem

4.1.1 Explain the analytical

techniques.4.1.2 Identify the problem.4.1.3 Determine the possible

cause/s of the problem.

10 hours

5. Usemathematicalconcepts andtechniques

5.1 Usingmathematicalconcepts andtechniques

5.1.1 Identify mathematical toolsand techniques to solveproblem

5.1.2 Apply mathematicalprocedures/solution

5.1.3 Analyze results

8 hours

6. Userelevanttechnologies

6.1 Using relevanttechnologies

6.1.1 Study/ select appropriatetechnology

6.1.2 Apply relevant technology6.1.3 Maintain/enhance relevant

technology

10 hours



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COMMON COMPETENCIES(80 hours)

Units ofCompetency


1. Read, interpretand applyspecificationand manual

1.1Reading,

interpreting andapplyingspecificationand manual

1.1.1. Identify/accessed manualsand interpret data andspecification.

1.1.2. Apply information accessedin manual.

1.1.3. Store manual

16 hours

2. Perform shopmaintenance

2.1Performing

shopmaintenance

4.1.1. Inspect and clean tools,equipment and the workarea.

4.1.2. Store/arrange tools andshop equipment.

4.1.3. Dispose waste and usedlubricants.

4.1.4. Report damaged tools andequipment

8 hours

3. Performmensurationand calculation

3.1Performing

mensurationand calculation

3.1.1. Select measuringinstruments

3.1.2. Carry out measurement andcalculation

3.1.3. Maintain measuringinstruments

16 hours

4. Perform basicbenchwork 4.1Performingbasicbenchwork

4.1.1. Prepare supplies, materials,tools, and equipment4.1.2. Layout necessary

dimensions4.1.3. Perform grinding, cutting,

filing, drilling and boring

24 hours

5. Perform basicelectrical works

5.1Performing

basic electricalworks

5.1.1. Test power supply andelectrical components

5.1.2. Perform basic repairs andinstallation

16 hours



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CORE COMPETENCIES(166 hours)

Units ofCompetency


1. Overhaul dieselengine

1.1.Overhaulingdiesel engine

1.1.1. Disassemble the engine1.1.2. Assess and repair engine

Block, parts and sub-assembly

1.1.3. Re-assemble engine1.1.4. Test run the engine

56 hours

2. Diagnose andrepair dieselengine

2.1.Diagnosing andrepair dieselengine

2.1.1. Plan and prepare fortroubleshooting and repair

2.1.2. Perform troubleshootingand repair

54 hours

3. Diagnose and

repair electricalsystem

3.1.Diagnose and

repair electricalsystem

3.1.1. Plan and prepare for

troubleshooting and repair3.1.2. Perform trouble shooting

and repair ofalternator/generator

3.1.3. Perform troubleshootingand repair of control andprotection system

56 hours

ASSESSMENT METHODS:

Written test Practical test

Direct observation

Interview

COURSE DELIVERY:

Lecture/discussion

Demonstration

Viewing multimedia

Hands-on practice Project making/ laboratory exercises

Distance learning

RESOURCES:

ITEM DESCRIPTION QTY UNIT

Equipment

o Generating set with control panel, 160 KW 1 unit

o PPE 1 set

o Dummy load 1 seto Hydraulic jack 10 tons 2 set

o Air compressor with spray gun 1 set



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o AC Clamp ammeter 1 unit

o Insulation tester 1 set

o Multi tester 1 set

o Chain Block at least 3 tons 2 units

o Personal Computer 10 units

Materials

o Assorted abrasive paper 40 pc

o Automotive wire #14 2 m


o Automotive wire, no. 12 AWG 10 m

o Bearing 1 pc

o Brush 2, 3, 4 9 pc

o Cable ties Assorted 2 box

o Carbon remover 1 pail

o Contact cleaner 16oz 3 can

o Coolant 40 ltrs

o Cotton tapes 3 roll

o Degreaser 1 Gal

o Descaler 1 pail

o Diesel fuel 124 ltr

o Dye penetrant and developer 4 set

o Electrical enamel 8 ltr

o Electrical tapes 16 roll

o

Foam 1 rollo Gasket 6 sheet

o Grease and degreasers 4 pack

o Grinding compound(fine and coarse) 3 set

o Grinding sticks 15 pc

o Hi temp grease 2 kg

o Insulating varnish 20 ltr

o Log sheet/ Log book and writing tools 1 set

o Forms and writing materials 1 set

o Lube oil 124 ltr

o Manuals, Drawings and Diagrams 1 Seto Metal marker 1 pc

o Nylon Rope or sling 2 mtrs

o O-rings 1 kit

o Penetrating oil 3 can

o Plastic gauge 1 set

o Rags 40 kg

o Replacement components (assorted) 1 lot

o Rubber tapes 10 roll

o Rust converter 1 pail

o Safety Solvent 20 ltr

o Scrubbing pad 2 pc

o Silicon gasket maker 5 pc



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o Soldering lead 1 roll

o Spaghetti tube, 10 mm 5 m

o Steel brush 5 pc

o System diagrams and service manuals 1 set

o Terminal lugs assorted 2 box

o Terminal lugs, dia, 20 Pco Thread sealant 2 tubes

o Repair kits for 1 set

Turbo charger

Water pump

Primary fuel filter

o Wire marker 1 kit

o Wiring diagrams and service manuals 1 set

o Brochures/Catalogs 1 lot

o Reference materials 1 lot

Tools

o A frame 1 set

o Allen wrench 1 set

o Bearing heater 1 unit

o Bearing Puller 1 unit

o Bench vise 1 unit

o Caliper 150 mm 1 pc

o Combination wrench (8-32) 1 Set

o Crimping tool 1 set

o

Electric hand drill with bits 1 seto Empty drum 210 L 1 unit

o Eye bolts and shackles 2 set

o Feeler gauge 1 set

o Flashlight 1 unit

o Grinder 1 unit

o Hacksaw 1 set

o Heater 2 Sets

o Magnetic dial gauge 1 unit

o Mechanical tools (i.e. wrenches, pliers, screw

drivers, etc.)

1 set

o micrometer 150mm (inside and outside) 1 set


o Nozzle tester 1 unit

o Panelboard key 1 pc

o Pliers and screw driver 1 set

o Pressure washer 1 unit

o Sling and shackles for 5 tons 4 sets

o Socket wrench (8-32) 1 Set

o Soldering set 2 set

o Torque wrench 0-1000Nm 1 Unit


o Wooden blocks 2 set



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QUALIFICATIONS OF INSTRUCTORS/TRAINERS:

Must be a holder of Diesel Power Plant Operation and Maintenance NC III or itsequivalent

Must have undergone training on Training Methodology II (TM II)

Must be computer literate

Must be physically and mentally fit *Must have at least 2 years job/industry experience related to Diesel Power Plant

Operation and Maintenance specifically in generating set servicing

Must be a civil service eligible (for government position or appropriate professionallicense issued by the Professional Regulatory Commission)

* Optional. Only when required by the hiring institution.



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MODULES OF INSTRUCTION

BASIC COMPETENCIES

DIESEL POWER PLANT OPERATION AND MAINTENANCE NC III


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BASIC COMPETENCY : COMMUNICATIONS

UNIT OF COMPETENCY : LEAD WORKPLACE COMMUNICATION

MODULE TITLE : LEADING WORKPLACE COMMUNICATION

MODULE DESCRIPTOR : This module covers the knowledge, skills and attitudesrequired to prepare different reports required in theworkplace.

SUGGESTED DURATION : 10 hours

SUMMARY OF LEARNING OUTCOMES:

Upon completion of this module the students/trainees will be able to:

LO1. Communicate information about workplace processes.

LO2. Lead workplace discussions.

LO3. Identify and communicate issues arising in the workplace.



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LO1. COMMUNICATE INFORMATION ABOUT WORKPLACE PROCESSES

ASSESSMENT CRITERIA:

1. Appropriate communication method is selected.2. Multiple operations involving several topic areas are communicated.3. Questions are used to gain extra information.4. Correct sources of information are identified.5. Information is selected and sequenced correctly when required.6. Verbal and written reporting is maintained in both familiar and unfamiliar

situations.

CONTENTS:

Method of communication

Communication skills

Communication tools

Questioning techniques

CONDITIONS:

The students/trainees must be provided with the following:

Simulated workplace environment

Communication tools

Variety of informations

METHODOLOGIES:

Discussion

Role play

Brainstorming

ASSESSMENT METHODS:

Direct observation

Interview



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LO2. LEAD WORKPLACE DISCUSSIONS


1. Responses to workplace issues are sought.2. Response to workplace issues are provided when sought.3. Constructive contributions are made to workplace discussion on such issues as

production, quality and safety.4. Goals and aims of actions under taken in the workplace are communicated.

CONTENTS:

Method/techniques of discussion

How to lead discussion

How to solicit responseCONDITIONS:



Communication tools


METHODOLOGIES:

Discussion

Role play

Brainstorming

ASSESSMENT METHODS:

Direct observation

Interview



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LO3. IDENTIFY AND COMMUNICATE ISSUES ARISING IN THE WORKPLACE


1. Issues and problems are identified as they arise.2. Information regarding problems and issues are organized coherently to ensure

clear and effective communication.3. Dialog is initiated with appropriate personnel.4. Communication problems and issues are addressed as they arise.

CONTENTS:

Identify problems and issues

Organizing information on problem and issues

Relating problems and issues

Communication barriers affecting workplace discussions.

CONDITIONS:



Communication tools


METHODOLOGIES:

Discussion

Role play

Brainstorming

ASSESSMENT METHODS:

Direct observation

Interview



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BASIC COMPETENCY : TEAM WORK

UNIT OF COMPETENCY : LEAD SMALL TEAM

MODULE TITLE : LEADING SMALL TEAM

MODULE DESCRIPTOR : This module covers the knowledge, skills and attitudesrequired to lead small team including setting and maintainingteam and individual performance standard.




LO1. Provide team leadership.

LO2. Assign responsibilities among members.

LO3. Set performance expectation for team members.

LO4. Supervise team performance.



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LO1. PROVIDE TEAM LEADERSHIP


1. Work requirements are identified and prescribed to members.2. Reasons for instructions and requirements are properly disseminated to teammembers.3. Team members questions, problems, concerns are recognized, discussedand dealt accordingly.

CONTENTS:

Communication skills required for leading small team

Skills and techniques in promoting team building

Negotiating skills

Up to date dissemination of instruction and requirements to members.

Art of listening and treating individual team members concern

CONDITIONS:


Learning materials- team building manual- catalogs- brochures

Simulated team

METHODOLOGIES:

Traditional /lecture

Demonstration

Case studies



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LO2. ASSIGN RESPONSIBILITIES AMONG MEMBERS


1. Duties and responsibilities are allocated in respect to the skills, knowledgeand attitudes of every team member.2. Duties are allocated having regard to individual preference, domestic andpersonal considerations.3. Duties and responsibilities of each member are properly identified anddefined.

CONTENTS:

Duties and responsibilities of each team member

Skills in identifying individual skills ,knowledge and attitude as basis for allocatingresponsibilities

Knowledge in identifying each team member duties and responsibilities

CONDITIONS:


Learning materials- relevant legal requirements- manuals

METHODOLOGIES:


Demonstration



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LO3. SET PERFORMANCE EXPECTATION FOR TEAM MEMBERS


1. Performance expectations are established based on client needs andaccording to assigned requirements.2. Performance expectations are based on individual team members duties andresponsibilities.3. Performance expectations are discussed and disseminated to individual teammember.

CONTENTS:

Knowledge and skills in setting individual performance target/expectation

Team members duties and responsibilities

Employee policies and procedures

Defining performance expectations criteria

CONDITIONS:


Performance expectation worksheet

Relevant legal requirementsMETHODOLOGIES:


Demonstration

Case studies



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LO4. SUPERVISE TEAM PERFORMANCE


1. Team members performance is monitored in respect to the definedperformance criteria.2. Team members are provided with feedback, positive support and advice onstrategies to overcome any difficulties.3. Team members are informed of any changes in the priority allocated toassignment or task.4. Communication follow-up is provided on all issues affecting the team.

CONTENTS:

Knowledge and skills in monitoring team member performance

Monitoring team operation to ensure client needs and satisfaction

Methods of monitoring performance

Informal/formal counseling skills

CONDITIONS:


Performance expectation worksheet

Relevant legal requirementsMETHODOLOGIES:


Demonstration

Modular

ASSESSMENT METHOD:

Written examination

Direct observation



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UNIT OF COMPETENCY : DEVELOP AND PRACTICE NEGOTIATION SKILLS

MODULE TITLE : DEVELOPING AND PRACTICING NEGOTIATION SKILLSMODULE DESCRIPTOR : This module covers the skills, knowledge and attitudes

required to collect information in order to plan and participatein the negotiation.



Upon completion of this module the students/ trainees will be able to:

LO1. IDENTIFY RELEVANT INFORMATION IN PLANNING NEGOTIATIONS

LO2. Participate in negotiations

LO3. Document areas for agreement



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LO1. IDENTIFY RELEVANT INFORMATION IN PLANNING NEGOTIATIONS


1. Information in preparation for negotiation is identified and included in the plan.2. Information on creating non verbal environments for positive negotiations is

identified and included in the plan.3. Information on different questioning techniques is identified and included in the

plan.

CONTENTS:

Background information on other parties to the negotiation

Observing differences between content and process

Identifying bargaining information

Applying strategies to manage process

Applying steps in negotiating process

Strategies to manage conflict Steps in negotiating process

CONDITIONS:

The students/ trainees must be provided with the following:

Pertinent documents

Simulated workplace

Paper and pencil

Calculator

Hands out

METHODOLOGIES:

Lecturette

Role playing

practical exercises



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LO2. PARTICIPATE IN NEGOTIATIONS


1. Criteria for successful outcome are agreed upon by all parties.2. Desired outcome of all parties are considered.3. Appropriate language is used throughout the negotiation.

CONTENTS:

Decision making and conflict resolution strategies procedures

Problem solving strategies on how to deal with unexpected questions andattitudes during negotiation

Background information on other parties to the negotiation

Observing differences between content and process

CONDITIONS:


Pertinent documents

Simulated workplace

Supplies

Paper and pencil

Calculator

Hands out

METHODOLOGIES:

Lecturette

Role playing

practical exercises

ASSESSMENT METHODS:

Written test/ questioning

Demonstration



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LO3. DOCUMENT AREAS FOR AGREEMENT


1. The issues and processes are documented and agreed upon by all parties.2. Possible solutions are discussed and their viability assessed.3. Areas for agreement are confirmed and recorded.4. Follow-up action is agreed upon by all parties.

CONTENTS:

Procedure in documenting negotiations

Managing information

Filing documents

CONDITIONS:


Pertinent documents

Simulated workplace

Supplies

Paper and pencil

Calculator

Hands out

METHODOLOGIES:

Lecturette

Role playing

practical exercises

ASSESSMENT METHODS:

Written test/ questioning

Demonstration



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BASIC COMPETENCY : PROBLEM SOLVING

UNIT OF COMPETENCY : SOLVE PROBLEMS RELATEDTO WORK ACTIVITIES

MODULE TITLE : IDENTIFYING / DETERMININGFUNDAMENTAL CAUSE OF PROBLEM

MODULE DESCRIPTOR : This module expresses the competency required to apply

problem solving techniques to identify/determinefundamental cause problem.




LO1. Explain the analytical techniques.

LO2. Identify the problem.

LO3. Determine the possible cause /s of the problem.



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LO1. EXPLAIN THE ANALYTICAL TECHNIQUES


1. Importance and application of analytical techniques are explained.2. Analytical techniques such as brainstorming, cause and effects diagrams,PARETO analysis, SWOT analysis, GANT chart, PERT CPM & graphs, andscatter grams are defined.

CONTENTS:

Observation, investigation & analytical techniques

Brainstorming

Cause and effect diagrams

PARETO analysis

SWOT analysis

GANT chart

PERT CPM & graph SCATTERGRAMS

CONDITIONS:


Coursewares

Learning materials/guides

Computer

OHP

METHODOLOGIES:

Direct observation

Simulation /role playing

Case studies

ASSESSMENT METHODS:

Written

Practical/performance test



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LO2. IDENTIFY THE PROBLEM


1. Variances are identified from normal operating parameters and productquality.2. Extent, cause, and nature of the problem are defined based on observation,investigation and analytical techniques.3. Problems are clearly stated and specified.

CONTENTS:

Normal operating parameters & product quality

Identifying & clarifying the nature of problem

Application of analytical techniques

CONDITIONS:


Coursewares


Computer

OHP

METHODOLOGIES:

Direct observation

Simulation /role playing

Case studies

ASSESSMENT METHODS:

Written




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LO3. DETERMINE THE POSSIBLE CAUSE/S OF THE PROBLEM


1. Possible causes of problems are identified based on experience & the use ofproblem solving tools/analytical techniques.

2. Possible cause statements are developed.3. Fundamental causes are explained.

CONTENTS:

Non-routine process and quality problems

Teamwork and work allocation problem

Safety and emergency situations and incidentsCONDITIONS:


Coursewares


Computer

OHP

METHODOLOGIES:

Direct observation

Simulation /role playing Case studies

ASSESSMENT METHOD:

Written




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UNIT OF COMPETENCY : USE MATHEMATICAL CONCEPTS AND TECHNIQUES

MODULE TITLE : USING MATHEMATICAL CONCEPTS ANDTECHNIQUES

MODULE DESCRIPTOR : This unit covers the knowledge, skills and attitudes requiredin the application of mathematical concepts and techniques.



Upon completion of the module, the learner/students must be able to:

LO1. Identify mathematical tools and techniques to solve problems.

LO2. Apply mathematical procedure/solution.

LO3. Analyze results.



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LO1. IDENTIFY MATHEMATICAL TOOLS AND TECHNIQUES TO SOLVE PROBLEMS


1. Problem areas based on given condition are identified.2. Mathematical techniques based on the given problem are selected.

CONTENTS:

Four Fundamental Operations

Steps in solving a problem

Standard formulas

Conversion

Measurement

CONDITION:

The students/learners must be provided with the following:

Manuals

Hand-outs

Problem set

Conversion table

Table of formulas

Measuring tools

METHODOLOGIES:

Lecturette

Self-paced instruction

Group discussion

ASSESSMENT METHODS:

Written

Demonstration



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LO2. APPLY MATHEMATICAL PROCEDURE/SOLUTION


1. Mathematical techniques based on the problem identified are applied.2. Mathematical computations are performed to the level of accuracy required for

the problem.3. Results of mathematical computation based on job requirements is determined

and verified.

CONTENTS:

Problem-based questions

Estimation

Use of mathematical tools and standard formulas

Mathematical techniques

CONDITION:


Manuals

Hand-outs

Calculator

Measuring tools/devices

Case problems

METHODOLOGIES:

Lecturette


Group discussion

Practical Work Approach

ASSESSMENT METHODS:

Written

Oral Interview



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LO3. ANALYZE RESULTS


1. Results of application based on expected and required specifications andoutcome is reviewed.2. Appropriate action in case of error is applied.

CONTENTS:

Four fundamental operations

Steps in solving a problem

Standard formulas

Conversion

Measurement

CONDITION:


Manuals

Hand-outs

Problem set

Conversion table

Table of formulas

Measuring tools

METHODOLOGIES:

Lecturette


Group discussion

Research study

ASSESSMENT METHODS:

Written

Oral



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UNIT OF COMPETENCY : USE RELEVANT TECHNOLOGIES

MODULE TITLE : USING RELEVANT TECHNOLOGIES

MODULE DESCRIPTOR : This unit covers the knowledge, skills and attitudes requiredin selecting, sourcing and applying appropriate andaffordable technologies in the workplace.



Upon completion of the module, the learner/students must be able to:

LO1. Study/ select appropriate technology

LO2. Apply relevant technology.

LO3. Maintain/ enhance relevant technology



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LO1. STUDY/ SELECT APPROPRIATE TECHNOLOGY


1. Appropriate technologies are studied based on work requirements.2. Appropriate technologies are identified and selected based on work

requirements.

CONTENTS:

Machineries/ equipment and their application

Software/ programs

CONDITION:


Manuals Hand-outs

Multimedia

Video tape

Brochures

CDs

Internet access

Computer

METHODOLOGIES:

Lecturette


Group discussion

Film showing

ASSESSMENT METHODS:

Written

Interview



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LO2. APPLY RELEVANT TECHNOLOGY


1. Relevant technology is used in carrying out function based on work requirements.2. Applicable software and hardware is used as per job requirement.3. Management concepts are observed as per established industry practices.

CONTENTS:

Office technology

Industrial technology

System technology

Information technology

Training technology

Different software / Hardware

5S (Proper House Keeping)

CONDITION:


Manuals

Hand-outs

Multimedia

Video tape

Brochures

CDs Internet access

Computer

METHODOLOGIES:

Lecturette


Group discussion

Film showing

ASSESSMENT METHODS:

Written

Interview



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LO3. MAINTAIN / ENHANCE RELEVANT TECHNOLOGY


1. Maintenance of technology is applied in accordance with the industrystandard operating procedure, manufacturers operating guidelines andoccupational health and safety procedure2. Updating of technology is maintained through continuing education or trainingin accordance with job requirement.3. Appropriate action for technology failure/defect is immediately reported to theconcerned/ responsible person or section.

CONTENTS:

Corrective and preventive maintenance

Upgrading of technology

Communication Skills

Organizational set-up / work flow

CONDITION:


Manuals

Hand-outs

Multimedia

Video tape

Brochures CDs

Internet access

Computer

METHODOLOGIES:

Lecturette


Group discussion

Film showing

ASSESSMENT METHODS:

Written

Interview



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COMMON COMPETENCIES



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UNIT OF COMPETENCY : READ, INTERPRET AND APPLY SPECIFICATION ANDMANUAL

MODULE TITLE : READING, INTERPRETING AND APPLYINGSPECIFICATION AND MANUAL

MODULE DESCRIPTION : This module deals with identifying, interpreting and applyingservice manuals, maintenance procedures manuals, repairmanuals and periodical maintenance manual.



Upon completion of the module, the trainees/ students should be able to:

LO1. Identify/accessed manuals and interpret data and specification.

LO2. Apply information accessed in manual.

LO3. Store manual



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LO1. IDENTIFY/ACCESS MANUALS AND INTERPRET DATA AND SPECIFICATION


1. Appropriate manuals are identified and accessed as per job requirements.2. Information and procedures in the manual are interpreted in accordance with

industry practices.3. Relevant sections, chapter of manuals/specifications are located in relation to the

work to be performed.

CONTENTS:

Identifying appropriate manuals.

Procedure / techniques in interpreting data and specifications.

Knowledge and techniques in accessing data and specifications as per jobrequirements.

Types of manuals used in automotive industry.

Identification of symbols used in the manuals. Identification of units of measurements.

CONDITIONS:

Students/trainees must be provided with the following:

Supplies and materials:o manufacturing specifications

o repair manual

o

maintenance manualo periodic maintenance manual

Instructional materialso reference books

o professional emergency

o learning guides

o modules

o CDs, VHS tapes, transparencies

METHODOLOGIES:

Lecture/demonstration

Dualized training

Distance learning

ASSESSMENT METHODS:

Written/oral examinations

Direct observation

Project method

Interview



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LO2. APPLY INFORMATION ACCESSED IN THE MANUAL


1. Data and specification are interpreted according to job requirement.2. Work steps are correctly identified in accordance with manufacturer

specifications.3. Manual data is applied according to the given task.4. All correct sequence and adjustment are interpreted in accordance with

information contained on the manual or specification.

CONTENTS:

Interpreting appropriate data and specifications.

Applying data and specification accessed from the manuals as required in thegiven task.

CONDITIONS:


Supplies and materialso manufacturing specifications

o repair manual

o maintenance manual

o periodic maintenance manual


o learning guides

o modules


METHODOLOGIES:


Dualized training

Distance learning

ASSESSMENT METHODS:


Direct observation

Project method

Interview



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LO3. STORE MANUAL


1. Manuals are stored appropriately to insure prevention of damage.2. Manuals are stored properly for easy accessed and ready for updating of

information required in the given task.

CONTENTS:

Techniques in storing manuals.

Procedures in maintaining manuals.

CONDITIONS:


Supplies/materialso manufacturing specifications

o repair manual

o maintenance manual

o periodic maintenance manual


o learning guides

o modules


METHODOLOGIES:


Dualized training

Distance learning

ASSESSMENT METHODS:


Direct observation

Project method

Interview



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UNIT OF COMPETENCY : PERFORM SHOPMAINTENANCE

MODULE TITLE : PERFORMING SHOP MAINTENANCE

MODULE DESCRIPTION : This module covers inspecting, cleaning, arranging andstoring tools and shop equipment, including disposal ofwaste and used lubricant and reporting of damaged toolsand equipment in the shop.



Upon completion of this module, the trainee/student must be able to:

LO1. Inspect and clean tools, equipment and the work area.

LO2. Store/arrange tools and shop equipment.

LO3. Dispose waste and used lubricants.

LO4. Report damaged tools and equipment



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LO1. INSPECT AND CLEAN TOOLS, EQUIPMENT AND WORK AREA


1. Tools, equipment and work area is inspected and cleaned, free from dust, greaseand other substances.

2. Cleaning solvent is used as per workshop cleaning requirements is observed.3. Work area is checked and cleaned.4. Wet surface or spot in the work area is kept dry.

CONTENTS:

Workshop policies.

Types and usage of cleaning chemicals.

Safe handling of equipment and tools.

Service procedures.

Equipment maintenance standards.

CONDITIONS:


Open workshop/garage

Well ventilated enclosed work and office area

Wash area and mess hall

Cleaning chemicals

Inventory of equipment and tools

Rugs

Containers for used oils

Vehicle

Oiler

METHODOLOGIES:

Lecture

Demonstration


Dual training

ASSESSMENT METHODS:

Direct Observation

Practical

Interview

Written examination



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LO2. STORE/ARRANGE TOOLS AND SHOP EQUIPMENT


1. Tools and equipment are arranged and stored in their respective shelves/location.

2. Corresponding labels are posted and visible.3. Tools are secured and logged in the record book.

CONTENTS:

Storage and disposal of hazardous/flammable tools/materials.

Personal safety procedures.

Relevant technical information

Labeling procedures

Principles of total quality management (TQM) and 5S

CONDITIONS:


Tool cabinet

Appropriate tools and equipment

Tool room

Fire extinguishers

Tool kit

Log/record book

Labeling materials

METHODOLOGIES:

Interactive lecture

Dual training


Simulation

ASSESSMENT METHODS:

Practical

Direct observation

Interview

Written examination



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LO3. DISPOSE WASTE AND USED LUBRICANTS


1. Waste and used lubricants are disposed in accordance with the standardoperational procedures and environmental regulations.

2. Containers for waste and used lubricants are properly labeled.3. Personal safety in disposing waste and used lubricants is evident.

CONTENTS:

Effects of automotive wastes to men and its environment.

Waste management and disposal

Cleaning chemicals for grease and lubricants

Labeling procedures and technique

CONDITIONS:


Waste disposal area

Oiler

Handouts for waste management and disposal

Cleaning chemicals for grease and lubricants

Containers for waste and used lubricants

METHODOLOGIES:

Interactive lecture

Dual training


Simulation

Demonstration

ASSESSMENT METHODS:

Direct observation

Simulation

Written examination

Interview



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LO4. REPORT DAMAGED TOOLS AND EQUIPMENT


1. Complete inventory of tools and equipment is maintained.2. Damaged tools/equipment are identified with repair recommendation.3. Reports prepared on damaged tools/equipment have no error/discrepancy.

CONTENTS:

Conducting inventory and preparing records

Maintenance and safe handling of tools and equipment

Maintenance and updating of records and reports

CONDITIONS:


Records and inventory of tools and equipment

Record books

Checklist

Waste disposal reports

Racks for tools

METHODOLOGIES:

Interactive lecture

Dual Training Self-paced instruction

Simulation

ASSESSMENT METHODS:

Interview

Written examination

Demonstration

Direct observation



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UNIT OF COMPETENCY : PERFORM MENSURATION AND CALCULATIONS

MODULE TITLE : PERFORMING MENSURATION AND CALCULATIONS

MODULE DESCRIPTION : This unit covers the knowledge, skills and attitudes inidentifying and measuring objects based on the requiredperformance standard.



Upon completion of the module, the trainees/students should be able to:

LO1. Select measuring instruments

LO2. Carry out measurements and calculations

LO3. Maintain measuring instrument



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LO1. SELECT MEASURING INSTRUMENTS

ASSESSMENT CRITERIA

1. Object or component to be measured is identified, classified and interpreted tothe appropriate regular geometric shape.

2. Measuring tools are selected/identified as per object to be measured or jobrequirements.

3. Correct specifications are obtained from relevant sources.4. Appropriate measuring instruments are selected according to job requirements.5. Alternative measuring tools are used without sacrificing cost and quality of work.

CONTENTS:

Linear measurements

Testing measurements

Four fundamental operations

Dimensions Units of conversion

Ratio and proportion

Trigonometric functions

Algebraic equations

CONDITIONS:


Tools Supplies and Materials

Micrometer

Protractor

Round

VernierCaliper

Combination Gauge

Square

DialGauge with MagnitudeStandard

SteelRule

Rectangular

StraightEdge

Voltmeter

Triangle

Thickne

ss Gauge

Amm

eter

Sp

here TorqueGauge

MegaOhmmeter

Conical

SmallHole Gauge

KWHMeter

Telescopic Gauge

Gauges

Try-square

Thermometer

METHODOLOGIES:


Film viewing



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Group discussion

ASSESSMENT METHODS:

Interview

Written examination

Observation with questioning



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LO2. CARRY OUT MEASUREMENTS AND CALCULATIONS

ASSESSMENT CRITERIA:1. Accurate measurements are obtained according to job requirements.2. Alternative measuring tools are used without sacrificing cost and quality work.3. Calculation needed to complete work tasks are performed using the four

fundamental operations (addition, subtraction, multiplication and division)including but not limited to trigonometric function and algebraic computations.

4. Calculations involving fractions, percentages and mixed numbers are used tocomplete workplace tasks.

5. Numerical computation is self- checked and corrected for accuracy.6. Instruments are read to the limit of accuracy of the tool.7. Systems of measurement are identified and converted according to job

requirements/ISO.8. Workpieces are measured according to job requirements.

CONTENTS:

Linear measurements Four fundamental operations

Dimensions

Units of conversion

Ratio and proportion

Trigonometric functions

Algebraic equations

CONDITIONS: Students/trainees must be provided with the following:

Tools

Micrometer

Torque Gauge

Voltmeter

VernierCaliper

SmallHole Gauge

Ammeter

DialGauge with MagnitudeStandard

Telescopic Gauge

Mega Ohmmeter

Protractor

Try-square

KWH Meter

Straight

Edge

Comb

ination Gauge

Ga

uges Thickness Gauge

SteelRule

Thermometer

Suppliesand Materials

Round Triangle

Square Sphere

Rectang

ular

Conic

al

METHODOLOGIES:




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Film viewing

Group discussion

E-learning

ASSESSMENT METHODS:

Actual demonstration

Direct observation

Written test/questioning



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LO3. MAINTAIN MEASURING INSTRUMENT


1. Measuring instruments are cleaned before and after using.2. Measuring instruments are kept in safe dry place.3. Proper techniques in using precise instrument according to manufacturers

standards.4. Proper handlings of measuring instruments are observed in accordance with

industry standards.

CONTENTS:

Handling and caring of measuring instruments.

Calibrating measuring instrument.

Safe handling and procedures in using measuring instruments.

Storing of measuring instruments.

CONDITIONS:


Equipment/tools/instrumento Computer

o VHS player

o OHP

o Vernier calipers, micrometer, bore gauge, feeler gauge

o

Steel rule, push ruleo Supplies/materials

o Paper

o Pencil

o Engine parts

Instructional materialso Reference books

o Learning guides

o Modules

o CDs VHS tapes, Transparencies

METHODOLOGIES:

Lecture

Demonstration

Simulation

ASSESSMENT METHODS:

Written examination

Direct observation

Oral examination



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UNIT OF COMPETENCY : PERFORM BASIC BENCHWORK

MODULE TITLE : PERFORMING BASIC BENCHWORK

MODULE DESCRIPTION : This module covers the knowledge, skills and attitudesrequired in performing basic bench work.




LO1. Prepare supplies, materials, tools, and equipment

LO2. Layout necessary dimensions

LO3. Perform grinding, cutting, filing, drilling and boring



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LO1. PREPARE SUPPLIES, MATERIALS, TOOLS, AND EQUIPMENT


1. Supplies, materials, tools, and equipment are identified according to jobrequirements.

2. Supplies, materials, tools, and equipment are prepared according to jobrequirements.

3. Supplies, materials, tools, and equipment are checked according to jobrequirements.

4. Tools and equipment condition are checked following SOP.

CONTENTS:


Materials, tools and equipment uses and specifications

CONDITIONS:

Students / trainees must be provided with the following:

Blueprint

Catalogue

List of tools and equipment

Forms (request & bill of materials)METHODOLOGIES:


Film viewing

Direct laboratory experience

Group discussion

Industry Immersion

ASSESSMENT METHODS:

Interview

Written examination

Observation with questioning Demonstration with questioning



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LO2. LAYOUT NECESSARY DIMENSIONS


1. Layout dimensions are in accordance with job requirements.2. Dimensions are laid out within the required tolerance.3. Dimensions are checked within the actual work plan.4. Proper usage of measuring instrument is observed.

CONTENTS:

Measuring tools functions and usage


Trade mathematics

Mensuration

Calculation

Conversion

Plan Specifications

CONDITIONS:


Measuring Tools

Drawing Instruments

Work Plan

Markers

Calculator

METHODOLOGIES:


Film viewing


Group discussion

Industry Immersion

ASSESSMENT METHODS:

Interview

Written examination


Demonstration with questioning



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LO3. PERFORM GRINDING, CUTTING, FILING, DRILLING AND BORING


1. Workpieces are cut according to required measurement.2. Workpieces are free from bores and sharp edge.3. Welded joints are free from weld defects.4. Appropriate Personal Protective Equipment (PPE) is applied.5. Safety work habits are observed.6. Worksite is cleaned and cleared of debris and left in safe state according to

occupational health and safety (OH & S)

CONTENTS:

Tools and equipment usage and specifications

Grinding, cutting, drilling, filing techniques

Basic welding principles and application

Applied occupational health and safety (OH & S)

CONDITIONS:


Personal Protective Equipment (PPE)

Tools and equipment

Measuring instruments

Work plan

required supplies and materials Worksite

METHODOLOGIES:


Film viewing


Group discussion

ASSESSMENT METHODS:

Interview

Written examination





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UNIT OF COMPETENCY : PERFORM BASIC ELECTRICAL WORKS

MODULE TITLE : PERFORMING BASIC ELECTRICAL WORKS

MODULE DESCRIPTION : This module covers the knowledge, skills and attitudesrequired in performing basic electrical works.




LO1. Test power supply and electrical components

LO2. Perform basic repairs and installation



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LO1. TEST POWER SUPPLY AND ELECTRICAL COMPONENTS


1. Required materials, tools and equipment are prepared in line with workrequirements

2. Required procedure in using testing instrument are applied3. Power supply and electrical components are checked with the manufacturers

specification4. Identified defects of power supply and electrical components are recorded5. Safe working habits are observed

CONTENTS:

Functions and uses of testing instruments

Basic electricity

Electrical safety and hazards

Testing procedures

CONDITIONS:


Tools and testing instruments

Required electrical components

Personal protective equipment

Worksite

Trainer / workshop Courseware

METHODOLOGIES:


Film viewing

Group discussion

ASSESSMENT METHODS:

Interview

Written examination





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LO2. PERFORM BASIC REPAIRS AND INSTALLATION


1. Electrical fixtures are fixed in line with standard operating procedures (SOP).2. Defective electrical components are replaced with the same specifications.3. Testing of units after repair is performed.4. Work instructions are followed to ensure safety at work.5. Workplace is cleaned and cleared of debris and in a safe state of condition and in

line with occupational health and safety (OH & S) regulations.

CONTENTS:

Types of electrical fixtures

Testing procedures

Electrical safety and hazards

Applied occupational health & safety (OH & S)

CONDITIONS:


Workplace

Required electrical fixtures and components

Tools and testing instruments

Trainer / mock ups

Personal protective equipment(PPE)

Trainer/ mock ups Courseware

METHODOLOGIES:


Film viewing


Industry immersion

E-learning

ASSESSMENT METHODS:

Interview

Written examination





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CORE COMPETENCIES



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UNIT OF COMPETENCY : OVERHAUL DIESEL ENGINE

MODULE TITLE : OVERHAULING DIESEL ENGINE

MODULE DESCRIPTION : This module covers the required performance in executingthe overhauling of diesel engine.


PRE-REQUISITE : A trainee who wants to take this module must be familiar withthe diesel engine systems, reading & interpreting mechanicaldiagrams, usage and handling of tools and precisionmeasuring instruments.

SUMMARY OF LEARNING OUTCOMES


LO1. Disassemble the engine

LO2. Assess and repair engine block, parts and sub-assembly

LO3. Re-assemble engine

LO4. Test run the engine



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LO1. DISASSEMBLE THE ENGINE


1. Engine is disassembled in accordance with manufacturers manual2. Parts and components are cleaned in accordance to industry regulation and

occupational health and safety procedure3. Parts and components are properly arranged and marked during disassembly

CONTENT:

Parts and components of diesel engine.

DC System.

Cooling System.

Aspiration System.

Speed Regulating System.

Fuel System.

Lube-oil System. Diesel Engine Assembly.

Procedure in disassembly of diesel engine

Procedures in undertaking proper cleaning activities

CONDITION: Students / trainees must be provided with the following:


Equipment

o Diesel engine, 160kW 1 unit

o PPE 1 set Materials

o Rags 5 kg


o Diesel fuel 60 ltr



o Steel brush 5 pc



o Plastic gauge 1 set

o Grease and degreasers 1 pack

o Lube oil 60 ltr

o Dye penetrant and developer 2 set


o Gasket 2 sheet

o Nylon Rope or sling 2 mtrs

o Metal marker 1 pc

o Foam 1 roll

o

Paint Brush, asstd. sizes 6 pco Descaler 1 pail

o Carbon remover 1 pail

o Rust converter 1 pail



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Tools

o Mechanical tools (i.e. wrenches, pliers, screw drivers,

etc.)

1 set

o Compressor 1 set

o Grinder 1 unito Pressure washer 1 unit

o Chain Block 1 unit

o Hydraulic jack 1 unit

o Sling and shackles 1 set

o A frame 1 set

o Wood blocks 1 set

o Empty drum 210 L 1 unit

METHODOLOGIES:

Lecture

Discussion

Demonstration

Practicum

ASSESSMENT METHODS:

Written

Demonstration with oral questioning



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LO2. ASSESS AND REPAIR ENGINE BLOCK, PARTS AND SUB-ASSEMBLY


1. Parts and components are tested and measured in accordance with prescribedmethods.

2. Components are assessed based on test results and measurements.3. Repairable components are repaired in accordance to manufacturers

recommendation4. Data and results of assessment are recorded using prescribed forms.

CONTENT:

Engine parts and components limits and tolerances

Testing and measurement of parts

Repairing procedure of the ff:

water pump

turbo charger fuel injectors

cylinder head

oil cooler

starter

charge alternator

primary fuel filter

Service report



Equipment

o Diesel engine, 160kW 1 unit

o PPE 1 set

Materials


o Water pump

o Turbo charger

o Primary fuel filtero Rags 5 kg




o Grease 1 pack

o Lube oil 60 ltr


o Gasket 2 sheet

o Electrical Tape 1 roll

o Log book and writing tools 1 set

o Diesel Fuel 1 L

o Paper 1 sheet



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Tools


etc.)

1 set

o Compressor 1 set

o Hydraulic jack 10 tons 1 unit

o Caliper 150 mm 1 pco micrometer 150mm (inside and outside) 1 set


o Bench vise 1 unit



METHODOLOGIES:

Lecture

Discussion Demonstration

Practicum

ASSESSMENT METHODS:

Written




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LO3. RE-ASSEMBLE ENGINE


1. Clearances are checked and/or corrected according to manufacturersspecification during assembly

2. Re-assembly of engine is performed accordance with first-out last-in sequence3. Tightening of bolts and nuts are done in accordance with manufacturers

recommendation

CONTENT:

Diesel Engine re-assembly procedure

Test and measurement during assembly

Torque table



Equipment

o Diesel engine 160 KW 1 unit

o PPE 1 set

Materials

o Rags 5 kg


o Diesel fuel 1 L

o Assorted abrasive paper 5 pcso Plastic gauge 1 set

o Grease 1 pack

o Lube oil 2 L

o Silicon gasket maker 2 pcs

o Gasket 2 sheets

o Electrical Tape 2 rolls

Tools


etc.)

1 set

o Compressor 1 set

o Chain Block at least 3 tons 2 units

o Hydraulic jack 10 tons 2 units

o Sling and shackles for 5 tons 4 sets

o A frame 1 set









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METHODOLOGIES:

Lecture

Discussion

Demonstration Practicum

ASSESSMENT METHODS:

Written




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LO4. TEST RUN THE ENGINE


1. Pre-testing activities are performed in accordance with prescribed procedure2. Testing of the assembled engine is performed using different methods3. Functional failures before and during testing are corrected following

manufacturers manual4. Testing and Overhaul/service report is prepared using prescribed forms

CONTENT:

Pre-testing activitiesa. Re-coupling of generatorb. Barring the enginec. Re-connection of cables

Preparation of the following system:

a. dc systemb. cooling systemc. lube oil systemd. fuel systeme. aspiration systemf. speed regulating system

Engine performance testo Calibration of governor

o Temperature and pressure monitoring

o Vibration and sound inspection

o Leakage detection

o Exhaust gas monitoring

o Load test

Protection simulation testing



Equipment

o Diesel generating set 160 KW 1 unit

o PPE 1 set

o Dummy load 1 set

Materials

o Rags 5 kg


o Lube oil 60 ltrs

o Coolant 40 ltrs

o Diesel fuel 60 ltrs

Tools


etc.)

1 set

o Tachometer 1 set



70/83

METHODOLOGIES:

Lecture

Discussion

Demonstration

Practicum

ASSESSMENT METHODS:

Written




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UNIT OF COMPETENCY : DIAGNOSE AND REPAIR DIESEL ENGINE

MODULE TITLE : DIAGNOSING AND REPAIRING DIESEL ENGINE

MODULE DESCRIPTION `: This unit covers the required performance in diagnosing andrepairing of diesel engine.


PRE-REQUISITE : A trainee who wants to takes this module must haveknowledge and experience in overhauling diesel engine.



LO1. Plan and prepare for troubleshooting and repair

LO2. Perform troubleshooting and repair



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LO1. PLAN AND PREPARE FOR TROUBLESHOOTING AND REPAIR


1. Identification of work requirements, trouble and defects is performed.2. Identifying of required resources as service prerequisite based on enterprise

policy.3. Observance to Safety practices in accordance with the enterprise policy.

CONTENT:

Diesel engine normal operating systems

Possible defects and its cause

Standard safety practices


ITEM DESCRIPTION QTY UNIT Equipment

o Diesel generating set 160 KW 1 unit

o PPE 1 set

Materials

o Rags 5 kg

o Dye penetrant and developer 2 sets

o Papers and Writing Materials 1 set

o Tools

o Manuals, Drawings and Diagrams 1 Set

METHODOLOGIES:

Lecture

Discussion

Demonstration

ASSESSMENT METHODS

Written




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LO2. PERFORM TROUBLESHOOTING AND REPAIR


1. Reference data is gathered using manufacturers maintenance manual2. Defective device or components are identified through systematic and logical

method of isolation and testing without causing damage to the engine and otherworkplace property

3. Root cause analysis is performed using result of based on data gathered andwithout causing damage to engine and other workplace property

4. Repair or replacement of defective components are carried out in accordancewith the result of troubleshooting and root cause analysis and manufacturersinstruction.

CONTENT:

Troubleshooting and repair Cooling system

Troubleshooting and repair Fuel system

Troubleshooting and repair Lube oil system

Troubleshooting and repair Aspiration system

Troubleshooting and repair Speed regulating system

Standard safety practices.



Equipment

o

Diesel engine, 160kW 1 unito PPE 1 set

Materials


Water pump

Turbo charger

Primary fuel filter

o Rags 5 kg


o Grease 1 pack

o Lube oil 2 ltr o Silicon gasket maker 2 pc

o Gasket 2 sheet

o Log book and writing tools 1 set

o Diesel Fuel 1 L

o Paper 1 sheet

o O-rings 1 kit


o Degreaser 1 Gal

o Thread sealant 2 tubes

Tools

o Mechanical tools (i.e. wrenches, pliers, screw

drivers, etc.)

1 set



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o Compressor 1 set

o Hydraulic jack 10 tons 1 unit




o Bench vise 1 unito Magnetic dial gauge 1 unit


METHODOLOGIES:

Lecture

Discussion

Demonstration

Practicum

ASSESSMENT METHODS:

Written




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UNIT OF COMPETENCY : DIAGNOSE AND REPAIR ELECTRICAL SYSTEM

MODULE TITLE : DIAGNOSING AND REPAIRING ELECTRICAL SYSTEM

MODULE DESCRIPTION : This module covers the required performance in diagnosingand repairing defects in the power plants electrical system


PRE-REQUISITE : A trainee who wants to take this module must be familiar withthe alternator/generator operation and can read and interpretdiesel power plant circuit diagram.



LO1. Plan and prepare for troubleshooting and repair

LO2. Perform trouble shooting and repair of alternator/generator

LO3. Perform troubleshooting and repair of control and protection system



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LO1. PLAN AND PREPARE FOR TROUBLESHOOTING AND REPAIR


1. Work requirements are gathered from Spot Report.2. Service pre-requisites are complied with in accordance with enterprise policy3. Required resources are prepared based on on-site validation report4. Safety and environmental practices are observed in accordance with enterprise

policy

CONTENT:

Interpretation, validation and analysis of work requirements

Preparation of on-site validation report or spot report

Warehouse Requisition Slip preparation

5S and Good Housekeeping



Equipment

o Generating set, 160 KW 1 unit

o PPE 1 set



Materials

o Contact cleaner 1 can

o Brush 2 1 pco Rags 1 Kg

o Forms and writing materials 1 set

o System diagrams and service manuals 1 set

Tools

o Flashlight 1 unit


o Socket wrench (8-32) 1 Set

o Allen wrench 1 set


o Panelboard key 1 pc

METHODOLOGIES:

Lecture

Discussion

Demonstration

Practicum

METHOD OF ASSESSMENT

Written




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LO2. PERFORM TROUBLE SHOOTING AND REPAIR OFALTERNATOR/GENERATOR


1. Conditions of exciter rotor, exciter stator, main rotor, main stator windings andpower cables are assessed using prescribed methods.2. Conditions of compounding transformer, PTs, CTs, and Diodes are testedand assessed using prescribed methods.3. Component repair or replacements are performed in accordance with theprescribed methods.

CONTENT:

Procedure in testing of exciter rotor and stator

Procedure in testing of main rotor and stator

Procedure in testing power cables

Procedure in testing Compounding Transformer Procedure in testing Current and Potential Transformer

Procedure in testing Diodes

Common defects and remedies

Procedure in re-insulating windings



Equipment

o Alternator/generator, 160 KW 1 unito PPE 1 set

o Hydraulic jack 3 tons 2 set

o Air compressor with spray gun 1 set



Materials

o Safety Solvent 20 ltr

o Bearing 1 pc

o Insulating varnish 20 ltr

o Electrical enamel 8 ltr o Brush 2, 3, 4 9 pc

o Terminal lugs, dia, 20 Pc

o Cotton tapes 3 roll

o Rags 10 Kg

o Automotive wire, no. 12 AWG 10 m

o Hi temp grease 2 kg



o Spaghetti tube, 10 mm 5 m

o Wire marker 1 kit

o Scrubbing pad 2 pc

o Cable ties 6 24 pc



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o Wiring diagrams and service manuals 1 set

Tools

o Heater 2 Sets

o Bearing Puller 1 unit

o Bearing heater 1 unito Chain block 1 pc



o A-frames 1 Set

o Hacksaw 1 set

o Electric hand drill with bits 1 set

o Slings 2 set

o Eye bolts and shackles 2 set

o Wooden blocks 2 set



METHODOLOGIES:

Lecture

Discussion

Demonstration

Practicum

ASSESSMENT METHODS

Written




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LO3. PERFORM TROUBLESHOOTING AND REPAIR OF CONTROL ANDPROTECTION SYSTEM


1. Defective circuit is isolated based on panel indicator display2. Cause of trouble is identified by tracing diagrams and testing components3. Remedy is applied in accordance with enterprise policy

CONTENT:

Troubleshooting and repair voltage regulation circuit

Troubleshooting and repair speed regulation circuit

Troubleshooting and repair reverse power circuit

Troubleshooting and repair earth-fault circuit

Troubleshoot and repair low-oil pressure and high engine temperatureprotection circuit

Troubleshooting and repair breaker control circuit Troubleshooting and repair synchronization circuit

Troubleshooting and repair re-closer circuit

CONDITION:


Equipment


o PPE 1 set

o Multi tester 1 seto AC Clamp ammeter 1 unit

o Insulation Tester 500V 1 unit

Materials

o Rags 2 Kg




o Wire marker 1 kit




o Paint brush 1 pc




Tools


etc.)

1 set





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METHODOLOGIES:

Lecture

Discussion

Demonstration

Practicum

ASSESSMENT METHODS:

Written




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LO4. PERFORM TROUBLESHOOTING AND REPAIR OF DC SYSTEM


1. Defective circuit is isolated based on panel indicator and engine performancesymptoms2. Cause of trouble is identified by tracing diagrams and testing components3. Remedy is applied in accordance with enterprise policy

CONTENT:

Troubleshooting and repair of starter motor

Troubleshooting and repair of charge alternator

Troubleshooting and repair of panel board auxiliary charger

Troubleshooting and repair of ignition circuit


ITEM DESCRIPTION QTY UNIT Equipment


o PPE 1 set


Materials

o Rags 2 Kg




o Wire marker 1 kit




o Paint brush 1 pc




Tools

o

Mechanical tools (i.e. wrenches, pliers, screw drivers,etc.) 1 set



METHODOLOGIES:

Lecture

Discussion

Demonstration

Practicum

ASSESSMENT METHODS:



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Written




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WHAT IS COMPETENCY-BASED CURRICULUM (CBC)

A competency-based curriculum is a framework or guide for thesubsequent detailed development of competencies, associatedmethodologies, training and assessment resources.

The CBC specifies the outcomes which are consistent with therequirements of the workplace as agreed through the industry orcommunity consultations.

CBC can be developed immediately when competency standardsexist.

When competency standards do not exist, curriculum developersneed to clearly define the learning outcomes to be attained. Thestandard of performance required must be appropriate to industryand occupational needs through the industry/enterprise orspecified client group consultations.

These materials are available in both printed and electronic copies.

For more information please contact:Technical Education and Skills Development Authority(TESDA)Telephone Nos.: 893-8281, 817-4076 to 82 loc. 611 to 630, 631 and635 or visit our website: www.tesda.gov.phor the TESDA Regional or Provincial Office nearest you.
http://www.tesda.gov.ph/http://www.tesda.gov.ph/

diesel power plant operation and maintenance nc iii

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