Issue date: June 2016

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H P O S I 5 0 1 -

SUBSTATION INSTALLATIONS MAINTENANCE

HPOSI 501

Maintain substation installations

REQF Level: 5

Learning hours

Credits: 5

50 Sector: energy

Sub-sector:

All

Issue date:

June 2016

Purpose statement

This module describes the skills, knowledge and attitude required to maintain pneumatic and hydraulic systems in different areas such as industries, vehicle systems and in laboratory boards. The learner will be able to plan and execute preventive maintenance of HV switching and protecting devices, rectify HV switching and protecting devices, clean the working area and manage waste materials.

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Learning assumed to be in place

Basic welding

Basics of electricity Mathematics

Low voltage installations Maintenance Low voltage electrical circuits Installation Substation installations

Elements of competence and performance criteria

Learning units describe the essential outcomes of a competence.

Performance criteria describe the required performance needed to demonstrate achievement

of the learning unit.

By the end of the module, the trainee will be able to

Elements of competence Performance criteria

1. Prepare preliminary activities 1.1 Proper Planning of preventive maintenance for

substation installation according to the manufacturer information

1.2 Appropriate identification of tools and measurement instruments according to the work to be done

1.3 Proper identification of PPE (Personal Protective Equipment) according to the work to be done

2. Execute preventive maintenance 2.1 Proper identification of planned activities according to

the planned maintenance activities

2.2 Accurate testing of substation installations according to the types of faults Appropriate Cleaning/ Replacing/ Lubrication/ Adjusting of required devices according to the type of faults

2.3 Convenient completing maintenance report according to report format

3. Rectify faults in substation installations

3.1 Appropriate identification of faults according to troubleshoot procedures

3.2 Correct rectification of detected faults according to the types of faults

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format

4. Clean the workplace 4.1 Proper collection of tools and equipment according to

their types and collecting methods

4.2 Proper arrangement of non-used materials according to their types

4.3 Appropriate cleaning of tools and working area according to the cleaning techniques

4.4 Convenient management of waste materials according to their types

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LU 1: Prepare preliminary activities

1

Learning Outcomes:

1. Plan preventive maintenance for HV switching and protection devices

2. Identify tools and measurement instruments used to maintain substation installations

3. Identify PPE (Personal Protective Equipment) according to their types

5 Hours

Learning Outcome 1.1 :

Plan preventive maintenance for HV switching and protection devices

 Recommended Practice for Maintaining different equipment of a substation  Daily activities

 Weekly activities  Monthly activities  Annual activities

 Elaboration of convenient maintenance schedule/plan

o Brainstorming on

recommended practices for equipment of a substation o Group discussion on

recommended practices for equipment of a substation o Documentary Research - Books - Internet - Manual - User’s and service manuals - Handout notes

Formative Assessment 1.1

Assessor may collect among the following evidences and make judgements on whether the performance criterion has been achieved.

Performance criterion

Plan preventive maintenance for substation installations

Resources

Learning activities

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Types of evidence Portfolio assessment tools

W Written evidence

 Written evidence

 oral evidence

 True or false questions  Ticking questions  Open questions  Expose  Interview  Presentation Checklist Score Yes No Identification of recommended practice for substation installations

‘maintenance

Elaboration of convenient maintenance schedule

Observation

Learning Outcome 1.2:

Identify tools and measurement instruments used to maintain

substation installations

 Types of HV measurement instruments used in substation installations

 High voltage Insulation tester  High voltage insulation resistance

tester

 Circuit breaker tester  Protection relay tester  Megohmmeter  High voltage detector

 High voltage multimeter tester

 Types of tools used in (electromechanical toolkit)

o Brainstorming on tools and measurement instruments o Group discussion on tools

and measurement instruments

o Physical demonstration of tools and measurement instruments

o Practical exercises on identification of tools and measurement instruments o Documentary Research

-

Books

-

Manual

-

Multi-meter

-

High voltage Insulation tester

-

High voltage insulation resistance tester

-

Circuit breaker tester

-

Protection relay tester

-

Megohmmeter

-

High voltage detector

-

High voltage multimeter tester

-

Electromechanical tool kit

Resources

Learning activities

Content

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Formative Assessment 1.2

 True or false questions  Ticking questions  Open questions  Expose  Interview  Presentation Checklist Score Yes No Identification of different types of measuring instruments

Identification of different types of leads Identification of different types of tools

Observation

Learning Outcome 1.3 :

Identify PPE (Personal Protective Equipment) according to their

types

 Types of PPE used in maintenance of pneumatic and hydraulic systems

 Overcoat and overall  Gloves  Safety shoes  Helmet  Earmuff o Brainstorming on Safety equipment

o Group discussion on Safety equipment

o Physical demonstration of Safety equipment o Practical exercises on the

- Books - Internet - Overcoat and overall - Gloves - Safety shoes - Helmet

Resources

Learning activities

Content

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 Goggles

 Nose protection mask

use of Safety equipment o Documentary Research - Earmuff - Goggles - Nose protection mask

Formative Assessment 1.3

 True or false questions  Ticking questions  Open questions  Expose  Interview  Presentation Checklist Score Yes No PPE usage Identification of PPE Observation Performance criterion

Proper identification of PPE (Personal Protective Equipment) according to the work to be done

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LU 2: Execute preventive maintenance

2

Learning Outcomes:

1. Identify planned activities according to the preventive maintenance schedule

2. Test different equipment of a substation

3. Clean/Replace/ Lubricate/Adjust required devices according to their types

4. Complete maintenance report according to report format 20 Hours

Learning Outcome 2.1:

Identify planned activities according to the preventive maintenance

schedule

 Recommended maintenance activities for the different substation equipment  Daily activities

 Weekly activities  Monthly activities  Annual activities

 Interpretation of the maintenance records history

 Maintenance steps for the different substation equipment

 Bus-bar

 Single-break isolating switch  Double-break isolating switch  On load isolating switch

 Isolating switch with earth Blade  Current transformer

 Potential transformer

 Capacitive voltage transformer  Oil circuit breaker

 Air circuit breaker with over-current tripping device  Air blast circuit breaker  Lightning arrester (active gap)

o Brainstorming on the interpretation of the maintenance records o Group discussion on recommended maintenance activities o Group discussion on maintenance steps o Documentary Research - Books - Internet - Service manuals - Maintenance records - Handout notes

Resources

Learning activities

Content

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 Lightning arrester (valve type)  Arcing horn

 Three-phase Power transformer  Over current relay

 Earth fault relay

Formative Assessment 2.1

 True or false questions  Ticking questions  Open questions  Expose  Interview  Presentation Checklist Score Yes No Identification of recommended maintenance activities

Interpretation of maintenance record

Identification of maintenance steps for different parts of a substation

Observation

Proper identification of planned activities according to the planned maintenance activities

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Learning Outcome 2.2 :

Test different equipment of a substation

General faults that occurs in substation installations

 Switching equipments faults  Protection equipments faults  Insulating materials faults  Conductors faults

 Power transformers faults

o Brainstorming on general faults that occur in PH systems

o Group discussion on general faults that occur in PH systems o Documentary Research - Books - Internet - Service manuals - Handout notes

Formative Assessment 2.2

 Performance evidence

 True or false questions  Ticking questions  Open questions  Expose

 Interview  Presentation

 Task: Test any given equipment of a substation

Checklist Score

Yes No Power transformer testing

Measuring transformer testing Circuit breaker testing

Fuses testing Bus bar testing Switchgears testing Protective relay testing

Applications of testing techniques Use of testing instruments

Accurate testing of substation equipment according to the types of faults

Resources

Learning activities

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Learning Outcome 2.3:

Clean/Replace/ Lubricate/Adjust required devices according to their

types

 Cleaning techniques of different parts of substation equipments

 Assembling and disassembling techniques of different parts of substation equipment

 Different equipment of a

substation that need lubricating

 Lubricating procedures of mechanical parts

 Types of lubricating oils  Parts needing lubrication

 Adjustment/replacement of defective parts

o Brainstorming on the cleaning techniques

o Group discussion on the faults detection and repairs

o Physical demonstration of lubricating oils

o Practical exercises on the repair works

o Documentary Research

- Books - Internet

- Service and user manuals - Journals - PPE - Electrician toolbox - Handout notes - Fuses - Circuit breakers - Switchgears - Protective relay - Bus bar - Power transformer

Formative Assessment 2.3

Observation

Appropriate Cleaning/ Replacing/ Lubrication/ Adjusting of required devices according to the type of faults

Resources

Learning activities

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 Task: Lubricate mechanical parts of any given substation equipment

Yes No Identification of different substation equipment that need lubricating

Application of cleaning techniques

Application of assembling and disassembling techniques Appropriate lubricating oil

Application of lubricating techniques

Observation

Learning Outcome 2.4:

Complete maintenance report according to report format

 Preparation of the maintenance report

 Maintenance report format (Company/institution name, technician name, Date of maintenance, planned

activities planned date for next maintenance, Equipment specifications, Checklist table, recommendation)

 Keeping records of maintenance activities

 Analysis of the maintenance report

o Brainstorming on how to prepare the maintenance report

o Group discussion on taking records

o Practical exercises on filling the maintenance report

o Group discussion on analysis of the maintenance report o Documentary Research - Books - Internet - Service manuals - Maintenance report

Formative Assessment 2.4

Convenient completion of maintenance report according to report format

Resources

Learning activities

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 True or false questions  Ticking questions  Open questions  Expose  Interview  Presentation Checklist Score Yes No Maintenance report format

Records keeping

Analysis of maintenance report

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LU 3: Rectify faults in HV switching and protecting

devices

3

Learning Outcomes:

1. Identify faults according to troubleshoot procedures 2. Rectify detected fault according to the types of faults 3. Complete the repair report according to the format

20 Hours

Learning Outcome 3.1:

Identify faults according to troubleshoot procedures

 Substation installation troubleshooting procedures and techniques

 Visual inspection  Testing

 Assumptions (possible cause)

 Troubleshoot different equipment of a substation

 Troubleshoot power transformer  Troubleshoot switchgears

 Troubleshoot fuses

 Troubleshoot protective relay  Troubleshoot measuring

transformer

 Troubleshoot bus bar

 Troubleshoot- circuit breakers

o Brainstorming on troubleshooting procedures and techniques o Group discussion on troubleshooting procedures and techniques o Practical exercises on troubleshooting procedures and techniques o Physical demonstration on troubleshooting procedures and techniques o Documentary Research

-

Books

-

Manual

-

Multi-meter

-

Megohmmeter

-

High voltage detector

-

High voltage multimeter tester

-

Electromechanical tool kit

Resources

Learning activities

Content

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Formative Assessment 3.1

Types of evidence Portfolio assessment tools  Written evidence

 Task: Troubleshoot a transformer

Yes No Identification of substation installations troubleshooting procedures

Troubleshooting circuit breaker Troubleshooting fuses

Troubleshooting power transformer Troubleshooting measuring transformer Troubleshooting power conductors Troubleshooting bus bars

Troubleshoot switchgears Troubleshoot protective relay

Observation

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Learning Outcome 3.2:

Rectify detected fault according to the types of faults

 Procedures for fault rectifications

 Circuit breaker faults rectification techniques

 Switchgears faults rectification techniques

 Fuse faults rectification techniques

 Protective relay faults rectification techniques

 Bus bar fault rectification

 Power transformer fault rectification

 Measuring transformer fault rectification

 After-repair Testing

o Brainstorming on the rectification of faults o Group discussion on the

rectification of faults o Practical exercises on faults

correction o Documentary Research

-

Books

-

Manual

-

Multi-meter

-

Megohmmeter

-

Bus bar

Formative Assessment 3.2

 Interview

 Task: Rectify any fault in a given PH system

Yes No Application of repair procedures

Rectification of faults in fuses

Rectification of faults in circuit breaker

Correct rectification of detected faults according to the types of faults

Resources

Learning activities

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Rectification of faults in switch gears Rectification of faults in bus bar

Rectification of faults in measuring transformer Rectification of faults in power conductors Rectification of faults in protective relay Testing after repair

Observation

Learning Outcome 3.3:

Complete the repair report according to the format

 Preparation of the repair report  Repair report format

(Company/institution name, technician name, Date of repair, Equipment specifications, Fault description, repair work description)

 Keeping records of repair activities

 Analysis of the repair report

 Billing of repair work

o Brainstorming on how to prepare the repair report o Group discussion on taking

records

o Practical exercises on filling the repair report

o Practical exercises on billing the repair work

o Group discussion on

analysis of the repair report o Documentary Research - Books - Internet - Service manuals - Repair report templates - Handout notes

Formative Assessment 3.3

Convenient completion of repair report according the format

Resources

Learning activities

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Yes No Format of the report

Content of the report

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LU 4: Clean the workplace

4

Learning Outcomes:

1. Collect tools and equipment

2. Arrange non-used materials(consumables) 3. Clean tools and working area

4. Manage waste materials 5 Hours

Learning Outcome 4.1:

Collect tools and equipment

 Identification of different

tools/equipment used for cleaning:  Brushes for cleaning sharp edges  Lubricants

 Blower machines  Sponge

 Method of collecting tools and equipment used in hydraulic and pneumatic systems

 Arrangement of tools/equipment according to their use

o Brainstorming on different tools/equipment used for cleaning

o Group discussion on different

tools/equipment used for cleaning

o Physical demonstration on tools and equipment used for cleaning o Documentary Research - Books - Internet - Manual - Brushes - Lubricants - Blower machine - Sponge - Electromechanical tool kit

- Plumber tool kit - Hoses

Formative Assessment 4.1

Proper collection of tools and equipment

Resources

Learning activities

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 Interview

 Task: Rectify any fault in a given PH system

Yes No Identification of types of tools and equipment

Applications of methods of tools and equipment collection Arrangement of tools and equipment

Observation

Learning Outcome 4.2:

Arrange non-used materials(consumables)

 Selection of area for storing non-consumable and non-used materials

 Prioritize tools/materials and equipment according to their nature

 Discard unused tools and equipment

 Disposal of waste materials:  Sharp pieces of materials  Lubricants

o Brainstorming on waste management of materials used in pneumatic and hydraulic systems

o Group discussion on waste management of materials used in pneumatic and hydraulic systems o Physical demonstration

waste management of materials used in pneumatic and hydraulic systems o Practical exercises on waste

management of materials used in pneumatic and hydraulic systems o Documentary Research - Books - Internet - Manual - Brushes - Lubricants - Blower machine - Sponge - Electromechanical tool kit

- Plumber tool kit - Hoses

- Recycle bin

Resources

Learning activities

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Formative Assessment 4.2

 Task: Arrange non-used materials after a given work

Yes No Area for storing non-used and non-consumable materials

Prioritization of tools, materials and equipment Discard of unused tools and materials

Disposal of waste materials

Observation

Learning Outcome 4.3:

Clean tools and working area

 Different methods of cleaning tools and equipment used in pneumatic/hydraulic installation:

 Air blowing  Water

 Different detergents

 Different methods of cleaning the working area in pneumatic/hydraulic

o Brainstorming on different methods of cleaning tools and equipment used in pneumatic/hydraulic installation

o Group discussion on Different methods of cleaning tools and

- Books - Internet - Manual - Lubricating oil - Cooling water/ coolant - Electromechanical tool kit

Resources

Learning activities

Content

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installation:

 Air blowing  Lubricating oil  Water

 Different detergents

 Disposal of waste materials according to their nature equipment used in pneumatic/hydraulic installation o Physical demonstration on Different methods of cleaning tools and equipment used in pneumatic/hydraulic installation

o Practical exercises (in workshops) on cleaning of tools/ equipment and working area o Documentary Research - Overcoat and overall - Gloves/ Helmet - Safety shoes - Earmuff/Goggles - Nose protection mask - Cleaning cloth / Brush

Formative Assessment 4.3

 Interview

 Task: Clean the tools and the working area

Yes No Application of tools/equipment cleaning methods

Application of working area cleaning techniques Disposal of waste materials

Observation

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Learning Outcome 4.4:

Manage waste materials

 Arrangement of waste materials according to their nature

 Disposal of waste materials

o Brainstorming on different ways of waste management o Group discussion on

different ways of waste management

o Physical demonstration on different ways of waste management o Documentary Research - Books - Internet - Overcoat and overall - Gloves - Safety shoes - Helmet, Earmuff - Goggles - Nose protection mask - Cleaning cloth / brush - Recycle bin

Formative Assessment 4.4

 True or false questions  Ticking questions  Open questions  Expose  Interview  Presentation Checklist Score Yes No Arrangement of waste materials

Disposal of waste materials

Observation

Convenient management of waste materials according to their types

Resources

Learning activities

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Summative Assessment

Integrated situation

Resources

Ten years ago Rwanda Energy Group (REG) decided to separate the ULK campus’ electrical consumption from the surrounding residential consumption due to its increasing energy consumption by giving to the campus its own transformer substation. As one of REG’s substation technicians you are requested to maintain and plan for preventive maintenance of the HV switching/protecting devices that are associated to this transformer substation within 3hours.

Assesment Criterion 1: Quality of Process

Yes No Indicator: Types of maintenance were properly identified

Required maintenance

Indicator: Maintenance activities and requirements were properly planned Maintenance schedule format

Activities to be done meet the manufacturer’s information

Indicator: Tools and measurement instruments to be used are well identified Tools

Measuring instruments

Indicator: To Safety precautions were applied according to the type of equipment Appropriate personal protective equipment are used

Safe work practices

Indicator: Drawing are properly interpreted Substation installations’ symbols are identified Types of drawing identified

Indicator: Tools and equipment are properly used Measuring instruments

Testing tools

Indicator: System testing is well done Testing procedures are applied Testing techniques are applied Faults are identified

Indicator: Repaired parts are appropriately tested Use of measurement and testing instruments

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Assesment Criterion 2: Quality of product

Yes No Indicator: The faults detected are conveniently rectified

The equipment is operating properly The fault is rectified

Tightness Fitness

Indicator: Maintenance plan is well done Format

Contents Schedule

Observation

Assesment Criterion 3: Relevance

Yes No Indicator: Work done within required time

Time respect

Indicator: Materials and equipment are well used No waste material

No damaged equipment

Observation

Testing the different parts of substation installation’s equipment Indicator: The workplace is properly cleaned

Right cleaning material

Appearance of different components Appearance of work place

Indicator: Convenient completing of repair report is conveniently completed Report format

Report content

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Perfection

Checklist Score Yes No Indicator: Innovation Creativity Observation

Reference books:

1. Principles of power system, V.K MEHTA , ROHIT MEHTA, S.CHAND &COMPANY, NEW DELHI 2004 2. http://www.ebay.com/bhp/high-voltage-tester