ELECTRICAL MAINTENANCE SKILLS FOR INSTRUMENTATION PERSONNEL TRAINING COURSE

COURSE 120: 7 DAYS: Max 8 Candidates

The end objectives are identical to those of the Electrical maintenance skills (Course 110) but this course starts from the assumption of prior electrical knowledge associated with instrumentation engineers, or candidates who have gained a basic understanding of the relevant electrical principles from another source. It is designed to provide basic electrical skills to those who wish to perform first-line electrical maintenance tasks – including the safe isolation, replacement and testing of a range of common electrical devices (motors, sensors, heating elements, solenoids, etc.) – in a safe and effective manner. Importantly, the format of the course is specifically designed so that, when combined with suitable on-site consolidation of training (see section ‘Consolidation of training’), it will assist the maintenance manager in meeting the legal requirements for employee competency in electrical work.

PARTICIPANTS

The content of the course is aimed specifically at those who currently fulfil an instrumentation role. Since prior electrical knowledge is assumed it is important to note that basic electrical theory is not covered on this course.

COURSE PRESENTATION

The course has an extensive ‘hands-on’ component, placing emphasis on safe working practice and on the development of useful, practical skills. Comprehensive course notes are provided.

COURSE OBJECTIVES

On completion of the course, participants will be able to

Successful completion of the course leads to the award of the Technical Training Solutions competence certificate 120: Electrical maintenance skills for instrumentation personnel.

What do candidates on the electrical maintenance skills for instrumentation personnel course actually do?

The candidates begin by learning about electrical dangers and protection methods; the principles of earthing, how the effects of electric shock are reduced, fuses, circuit breakers, RCDs and other related issues. They also learn about the Electricity at Work (EAW) Regulations and how these might affect their future work - exploring issues like live-working, competency, etc. The following are example pages from this part of the course notes for the electrical maintenance skills course, describing the various types of fuses available, how insulation resistance testers should be used and how electrical systems should be isolated (getting the candidates to think through the various stages necessary):

This is page 2 of the electrical maintenance skills training course notes, describing the various types of fuses available This is page 12 of the electrical maintenance skills training course notes, describing insulation and continuity testing This is page 16 of the electrical maintenance skills training course notes, describing isolation procedures

Page 2 of the electrical maintenance skills training course notes, describing the various types of fuses available

Page 12 of the electrical maintenance skills training course notes, describing insulation and continuity testing

Page 16 of the electrical maintenance skills training course notes, describing isolation procedures

We explore the skills of faultfinding by discussing the most common fault conditions e.g. Open Circuit, Short Circuit and Insulation Breakdown. The candidates are provided with course notes that explain how these faults can be found in real industrial electrical systems.

This is page 18 of the course notes for the electrical faultfinding part of the course This is page 21 of the course notes for the electrical faultfinding part of the course This is page 27 of the course notes for the electrical faultfinding part of the course

Page 18 of the course notes for the electrical faultfinding part of the course

Page 21 of the course notes for the electrical faultfinding part of the course

Page 27 of the course notes for the electrical faultfinding part of the course

The candidates are then given fault simulation rigs and test equipment. The simulation rigs present the candidates with industrial sensors, relays and switches that provide a baffling array of faults and symptoms. In some cases the candidates may not immediately be aware of any faults as the equipment appears to be working correctly.

However, by using logical faultfinding methods and the equipment provided, candidates are able to successfully diagnose faults that impact upon safety as well as functionality alone. This builds confidence and enables the candidate to suggest the necessary actions to effect a suitable repair.

The simulated faults range from welded switch contacts and burnt out relay coils to faulty proximity sensors. All testing is carried out in complete safety because the fault rigs (which have both control and load circuits) operate from 24v dc and 24v ac.

The faultfinding simulation rig used by candidates on the electrical maintenance skills training course

The fault-finding simulation rig used by candidates on the electrical maintenance skills training course

We teach the candidates the right way to prepare and terminate cables into plugs and sockets and how to use professional crimp tools to crimp conductors properly.

Candidates also learn why and how insulation and continuity testers are used, for which we have developed simulation units so that once they are able to use the testers properly to check cables, accessories and current-using equipment, they then apply their skills to finding open circuits, short circuits and insulation breakdowns within specially constructed test circuits. This allows them to gain some basic electrical faultfinding skills, developing their skills and understanding of the fundamentals further.

We also explain the effects of overload, short circuit and earth faults in electrical systems, showing how the various protective devices like fuses, circuit breakers and RCDs operate. We have a specially-constructed training rig for this also, so that candidates can explore these important issues.

The following are examples of the fault-finding training rigs (where candidates diagnose faults in the control and load circuits of industrial electrical circuits), the tools that the candidates use on the course for terminating cables, the training rig used for exploring the effects of short circuits, overloads and earth faults, the rig used for the cable termination exercise, one of the insulation resistance testers used and examples of some of the leads that candidates build on the course:

The faultfinding test board used on the electrical maintenance skills for instrument personnel training course We provide the candidates with all the necessary tools during the electrical maintenance skills for instrument personnel training course The electrical fault board used on the electrical maintenance skills for instrument personnel training course - this is used to explain what happens when short circuits, earth faults and overloads occur

The fault-finding test board used on the electrical maintenance skills training course

We provide the candidates with all the necessary tools during the electrical maintenance skills training course

The electrical fault board used on the electrical maintenance skills training course - this is used to explain what happens when short circuits, earth faults and overloads occur



This is the cable termination rig used on the electrical maintenance skills for instrument personnel training course We use professional insulation resistance / continuity testers on the electrical maintenance skills for instrument personnel training course Examples of some of the leads that candidates construct on the electrical maintenance skills for instrument personnel training course

This is the cable termination rig used on the electrical maintenance skills training course

We use professional insulation resistance / continuity testers on the electrical maintenance skills training course

Examples of some of the leads that candidates construct on the electrical maintenance skills training course

We then teach the candidates about three-phase motors: how they work, identification features, terminal configuration, testing, etc, whilst using their knowledge of voltage, current and resistance to understand the principles of induction.

This is page 65 of the electrical maintenance skills for instrument personnel training course notes, describing the key features of cage induction motors This is page 69 of the electrical maintenance skills for instrument personnel training course notes, describing the information found on the nameplates of industrial motors This is page 73 of the electrical maintenance skills for instrument personnel training course notes, describing the configuration of the terminals of a delta-linked motor

Page 65 of the electrical maintenance skills training course notes, describing the key features of cage induction motors

Page 69 of the electrical maintenance skills training course notes, describing the information found on the nameplates of industrial motors

Page 73 of the electrical maintenance skills training course notes, describing the configuration of the terminals of a delta-linked motor

We go on to explain the various standards of symbols used on industrial circuit diagrams and look at the function of the most common components found in control panels - contactors, overload relays, etc. The following are example pages from this part of the course, describing electrical symbols, contactors and overload relays:

This is page 17 of part 2 of the course notes for the course, describing the various electrical symbols used on drawings for a range of common Standards This is page 20 of part 2 of the course notes for the course, describing how contactors are used This is page 23 of part 2 of the course notes for the course, describing how overload relays are used

Page 17 of part 2 of the course notes for the electrical maintenance skills training course, describing the various electrical symbols used on drawings for a range of common Standards

Page 20 of part 2 of the course notes for the electrical maintenance skills training course, describing how contactors are used

Page 23 of part 2 of the course notes for the electrical maintenance skills training course, describing how overload relays are used

We then introduce industrial control panels with DIN-rail mounted components like circuit breakers, fuses, contactors, overload relays, timers, switches and lamps. The candidates build some basic industrial electrical circuits - for example from simple DOL to star/delta motor starters - giving them the experience of recognising each of the components, their markings and terminal identifications, the differences between the load and control circuits etc, in an engaging way that they really enjoy. The following are the three-phase 40V motors we use, the empty control panel (before candidates have assembled their circuits) and the components that they use to build the circuits:

This is one of the specially-wound 40 volt three-phase motors used on the course We have designed a special training rig so that the candidates actually build the circuits that we give them, using real industrial components, following the circuit diagrams provided in week 2 of the course Candidates are provided with a range of industrial circuit breakers, contactors, timers and overload relays with which to build the circuits that we give them in week 2 of the course

This is one of the specially-wound 40 volt three-phase motors used on the electrical maintenance skills training course

We have designed a special training rig so that the candidates actually build the circuits that we give them, using real industrial components, following the circuit diagrams provided in the electrical maintenance skills training course

Candidates are provided with a range of industrial circuit breakers, contactors, timers and overload relays with which to build the circuits that we give them on the electrical maintenance skills training course

Reading circuit diagrams and translating them to real components is a key objective of the course. The best method for learning about this is to engage the candidates in an enjoyable way and therefore we provide the candidates with (amongst others) the following example circuits which they build into the panels shown above:

This is page 34 of part 2 of the course notes for the course, describing how DOL starters work - candidates build this circuit in the panels shown above This is page 45 of part 2 of the course notes for the course, describing star/delta starters - candidates build this circuit in the panels shown above This is page 46 of part 2 of the course notes for the course, describing a complex control circuit diagram - candidates build this circuit in the panels shown above

Page 34 of part 2 of the course notes for the electrical maintenance skills training course, describing how DOL starters work - candidates build this circuit in the panels shown above

Page 45 of part 2 of the course notes for the electrical maintenance skills training course, describing star/delta starters - candidates build this circuit in the panels shown above

Page 46 of part 2 of the course notes for the electrical maintenance skills training course, describing a complex control circuit diagram - candidates build this circuit in the panels shown above

The candidates can then (before connecting these circuits to our custom-manufactured 3-phase 40 Volt motors) inspect and test their prepared units, ensuring that the circuits have been interpreted correctly. We have developed a three phase 40-volt ac supply to power these systems so that all this can be done safely. The following are examples of our 40 volt three-phase supply units, one of the control panels assembled and ready for the candidates to wire up, and our testing for dead instruments:

This is our specially-designed three-pase 40 Volt ac supply: It generates its output from a single-phase mains supply, so that we can provide the course without needing a three-phase supply for the course One of the control panels, ready for wiring by the candidates on the course Candidates use professional voltage testers and proving units on the course

This is our specially-designed three-phase 40 Volt ac supply: It generates its output from a single-phase mains supply, so that we can provide the course without needing a three-phase supply for the electrical maintenance skills training course

One of the control panels, ready for wiring by the candidates on the electrical maintenance skills training course

Candidates use professional voltage testers and proving units on the electrical maintenance skills training course

The above units can then be powered-up to check for their correct functionality. Any faults need to be rectified and candidates gain valuable experience of faultfinding in real industrial control panels during this exercise.

Once the systems are working correctly we can then explore various scenarios in which candidates work out how a safe isolation should be performed on their systems. We can simulate a variety of scenarios, including situations in which the system has local and remote start/stop and local and remote isolators. Candidates give their written explanation (a method statement of work) for how they intend to do this and once they have written it correctly we ask them to perform it for real on the systems that they constructed earlier.

The above exercise is one of the focal points of the course as it brings together not only the candidate's ability to perform an electrical isolation but also their use of voltage testers, recognition of the various components, an understanding of the system etc.

We then replace some of the components in the candidates' functional systems with faulty components like burned out contactors, faulty overload relays, incorrect contactor coil voltages, faulty auxiliary contacts etc. Candidates then fault-find the systems to diagnose the faults.

To be absolutely sure that the candidates have understood the key teaching points of the course we then administer a multiple choice assessment paper.

Part of the assessment paper for the Industrial Electrical Maintenance Skills course Part of the assessment paper for the Industrial Electrical Maintenance Skills course Part of the assessment paper for the Industrial Electrical Maintenance Skills course

Part of the Assessment Paper for the Industrial Electrical Maintenance Skills Course


If you would like to see some of the equipment used on the electrical maintenance skills for instrumentation personnel course for yourself, then please call us to arrange a visit to our offices in Kent. Alternatively, we can visit you anywhere in the British Isles.

 

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