ENGINEER POWER GENERATION (THERMAL)€¦ · impurities in water and steam. • Discuss the various...

Engineer Power Generation (Thermal) i

Model Curriculum

ENGINEER POWER GENERATION

(THERMAL)

SECTOR:

SUB-SECTOR:

OCCUPATION:

REF ID:

NSQF LEVEL:

POWER

GENERATION

ENGINEER-GENERATION

PSS/Q1007, V1.0

6

Engineer Power Generation (Thermal) ii

Engineer Power Generation (Thermal) iii

TABLE OF CONTENTS

1. Curriculum 01

2. Trainer Prerequisites 12

3. Annexure: Assessment Criteria 13

Engineer Power Generation (Thermal) 1

Engineer Power Generation (Thermal) CURRICULUM / SYLLABUS

This program is aimed at training candidates for the job of a “Engineer Power Generation (Thermal)”,

in the “Power” Sector/Industry and aims at building the following key competencies amongst the

learner

Program Name Engineer Power Generation (Thermal)

Qualification Pack Name

& Reference ID. Engineer Power Generation (thermal) PSS/Q1007

Version No. 1.0 Version Update Date 17-05-2021

Pre-requisites to Training B.Tech/BE (Electrical/ Mechanical/Electronics & Communication

(Instrumentation)

Training Outcomes After completing this programme, participants will be able to:

• Gain familiarity with Power system: overview especially

Generation Sector. Understand basics of electricity terms used

while carrying activities related to testing, repair and

maintenance

• Perform Erection and Commissioning activities in thermal

power plant: Understand the erection and commissioning of

Power Generation Plants. In addition of the above the candidate

also able to perform material management, resource

mobilization, BOQ etc..

• Perform Operation and Maintenance activities in

thermal power plant: Understand operation and

maintenance of all the power plant equipment –BTG &

auxiliaries system and BoP ensuring healthy operation of all

system equipment.

• Use basic health and safety practices for power related

work: Understand procedure & practices to follow to

maintain healthy, safe & secure work environment covering

safety of self, others, assets, and the environment

• Work Effectively with others: Understand basic etiquette and

competencies to demonstrate in their behaviour and interaction

with others at workplace


This course encompasses 4 out of 4 National Occupational Standards (NOS) of “Engineer Power

Generation (Thermal)” Qualification Pack issued by “Power Sector Skill Council”.

Sr.

No. Module Key Learning Outcomes

Equipment

Required

1 Introduction Theory Duration

(hh:mm)

04:00

Practical Duration

(hh:mm)

00:00

Corresponding NOS Code

PSS/N1007

• Explain about Power sector

scenario including generation,

transmission, and distribution

scenario of India.

• Discuss elements of power

systems, transmission,

distribution and generations

• Discuss functions of Power

Generation Companies

• Discuss about generation from

generator to switchyard

2 Organizational context Theory Duration (hh:mm) 04:00 Practical Duration (hh:mm) 00:00 Corresponding NOS Code PSS/N1007

• Explain organization structure

and reporting levels in

Generation Company

• Discuss duties and

responsibilities of Engineer-

Power Generation

• Discuss relevant Legislation,

Electricity act 2003, CERC,SERC

• Interpret CEA Regulations 2010

3 Basics Of Electricity Theory Duration

(hh:mm)

08:00

Practical Duration

(hh:mm)

08:00


PSS/N1007

• Explain basic fundamentals of

Electricity, Mechanics and C & I

• Explain the basic key

concepts of Voltage,

Current, Capacitance,

Resistance, KVA, KWh.

• Discuss Circuit connections,

voltage and current

relationship in star & delta

configuration

• Explain 3 phase and 1 phase

supply

Voltmeter,

Ammeter,

Wattmeter, basic

components,

Energy Meter (

single phase and

three phase),

Register,

Inductor,

Capacitor etc.

4 Constructional Features of Power Plant Theory Duration

(hh:mm)

64:00

Practical Duration

(hh:mm)

40:00


• Describe the Boiler and

Turbine cycle as operational in

thermal power plant.

• Explain the difference of sub-

critical and super-critical boiler

installed in power plant and

their selection criteria.

• Discuss the steam generation

process and its utilisation in

turbine to generate power.


Sr.


Equipment

Required

PSS/N1007 • Describe the working principle

of major components of


• Explain about the specific uses

of various components

installed for power generation.

• Discuss with shape and size of

major parts of power plant.

• Describe the major equipment

other than Turbine and Boiler

needed for power generation.

• Discuss about the various

types of equipment available

and their selection and

contribution in power

generation and dispatch to the

grid.

• Explain about various systems

and equipment as support and

stand-by for safety of the

power plant for all known

sources of disturbances

• Discuss the stand alone

systems essential for power

generation but nor required to

run continuously or

simultaneous with boiler and

turbine.

• Explain about the various

components of the systems,

their location and effect on the

system.

• Describe about the

functioning of systems and

contribution in keeping the

plant in operation

continuously.

• Describe the overall plant

configuration and location of

various balance of plant

systems in thermal power

plant.


Sr.


Equipment

Required

• Discuss the purchase function

in power plant.

• Discuss about the

procurement process for

component/consumables in

power station.

• Discuss about contracting

process for outsourcing the

job/package.

• Discuss about the activities of

stores in preserving and

issuance of materials.

• Discuss the building

configuration for smooth flow

of parts/consumables in

power plant stores.

5 Erection of Thermal Power Plant Theory Duration

(hh:mm)

40:00

Practical Duration

(hh:mm)

40:00


PSS/N1007

• Discuss how the selection was

made for the site.

• Discuss the various tools and

tackles deployed for erection

and familiarise their use.

• Explain the process of

preparing schedule for the

project and methods to

monitor the progress.

• Describe the quantum of work

involved in erection of power

plant equipment.

• Explain civil work associated

with Main Package like Boiler,

Turbine Generator, Power

House structure etc.

• Explain civil work related to

ASP, CHP and Ash Pond.

• Discuss Misc civil works

associated with BOP (Balance of

Plants).

• Describe Switch yard with

associated civil foundations

• Explain the critical component

erection process and safety

associated with them.

• Describe the pre-requisite for

erection process.


Sr.


Equipment

Required

• Explain the essentiality of close

monitoring of work and

precautions to be observed

during working at site.

• Discuss the scheduling of

activity to match with parts and

space availability for particular

erection work.

• Describe sequence of activities

for various components of

power plant.

• Discuss the erection procedure

of Turbine in power plant.

• Discuss various measurement

tools specific to turbine

erection.

• Explain the criticality of lifting

arrangement of heavy items

with precision.

• Discuss the erection procedure

of Generator and its auxiliaries.

• Explain about various parts of

Generator and sequence of

activities in erection.

• Discuss about the criticality in

insertion of Rotor in the Stator

shell and precautions needed

during insertion of rotor.

• Describe the erection sequence

of various auxiliaries of turbine

in power plant.


auxiliary systems of turbine.

• Discuss about the safety aspect

and handling of materials

during erection.

• Discuss about the precautions

needed during erecting various

components.

• Discuss about the

interconnection of various

systems with Turbine.

• Explain the working principle of

various components of the coal

handling plant


Sr.


Equipment

Required


and various components of ash

handling system


and various components of

switchyard

6 Commissioning Activities

in Power Plant

Theory Duration

(hh:mm)

40:00

Practical Duration

(hh:mm)

40:00


PSS/N1007

• Explain the activities to be

checked for completion prior to

commissioning.

• Describe the sequence of

checking activities for giving

clearance before start-up.

• Describe the PERT chart of the

project and its monitoring for

timely completion.

• Explain the process and

equipment involved in the test.

• Discuss the method of checking

and identifying leakages during

the test.

• Check the readiness of

equipment/system for

commissioning.

• Discuss about the safety aspect

and precautions needed during

boiler commissioning.

• Discuss about the precautions

needed during trial run after

installation.

• Describe the sequence of

checking interlock and

protection before start-up.

• Discuss the safety aspect

required during

commissioning.

• Explain various electrical

systems provided in the power

plant.

• Discuss the various safety

precautions required

before/during commissioning.

• Discuss the sequence of

checking electrical systems to

make them available for use.

• Discuss the requirement of the

process in cleaning main steam

lines.


Sr.


Equipment

Required

• Explain the completion criteria

of each stage of steam blowing.

• Discuss the safety aspect and

precautions needed during

steam blowing activities.

• Explain the necessity of

following OEM's

recommendation for steam

blowing activities.

• Perform oil flushing of oil lines

prior to supplying oil to

bearings.

• Discuss the process of setting

governing system as per OEM's

chart.

• Describe the method of setting

governing system components

after oil flushing.

• Explain the interlock and

protection of Coal and Ash

handling plant.

• Discuss the sequence of start-

up/stopping of the coal and ash

handling plant

7 Operation of Power Plant

Theory Duration

(hh:mm)

40:00

Practical Duration

(hh:mm)

64:00


PSS/N1008

• Discuss about the work permit

system of the power plant.

• Discuss about the safety

requirement during plant

operation.

• Discuss about indenting and

receiving consumables for

plant operation.

• Discuss about the requirement

at the time of unit start-up.

• Discuss about the process of

start-up of major equipment of

power plant.

• Discuss about the sequence of

activities during plant start-up.

• Explain the interlock and

protections checking before

starting any

equipment/system.


Sr.


Equipment

Required

• Discuss about shut down and

cooling down of turbine and

boiler and their precautions.

• Describe important

parameters/conditions of

various equipment/system

during operation

of the unit.

• Describe the activities done

during shift and at the end of

shift.

• Explain the criticality of

chemical parameters of water

and steam used in thermal

power plant.

• Discuss about methods to

control the rise in steam and

water parameters.

• Describe blow down methods

and process to control

impurities in water and steam.

• Discuss the various impurities,

their effect and treatment

methods.

• Describe the various systems

associated with turbine that

must be started before rolling

of turbine.

• Discuss the operating

conditions and settings for

each system of the turbine.

• Perform the cold, warm and

hot start-up and their methods

and precautions.

• Discuss rate of loading of

turbine as per temperature

chart provided by OEM.

• Explain shutting down

procedure and cooling curves

supplied by OEM

• Describe the interlocks and

protections and sequence of

start-up of coal plant.

• Perform various checks during

operation of coal handling

plant.


Sr.


Equipment

Required

• Describe the actions for each

emergency condition during

operation in power plant.


possible abnormalities in

different systems/equipment in


• Explain the process of

identifying the fault condition

and remedial actions

envisaged for particular fault in

equipment/system.

8 Maintenance in Power Plant Theory Duration

(hh:mm)

35:00

Practical Duration

(hh:mm)

43:00


PSS/N1008

• Explain the various

maintenance techniques being

followed in power plant.

• Discuss the meaning of

maintenance and its execution

policy.

• Discuss about the requirement

of maintenance and its

advantage in power plant.

• Explain applicability of

different tools in different

materials/conditions.

• Discuss the mechanism

causing failure of component/

equipment.

• Explain the boiler tube failure

reasons and method/

observation to pinpoint the

reason of failure to suitably

attend it.

• Discuss the resultant damage

of any mechanism and ways to

prevent repeat failures of

similar nature.

• Explain the process of studying

and confirming the reason of

every failure in the plant and

attending suitably for long

continuous operation of the

plant.

• Discuss precautions and safety

aspect to be followed during

maintenance.


Sr.


Equipment

Required

• Describe the repair

requirement in boiler to avoid

costly replacement.

• Discuss about various welding

processes to join/repair tubes

in the boiler.

• Discuss about various welding

defects noticed during repair

process.

• Describe possible locations of

faults and remedial measures.

• Discuss about different types

of maintenance undertaken in

turbine.

• Discuss about the procedure

and sequence of activities

during turbine maintenance.

• Perform the maintenance

requirement of balance of

plants due their handling of

corrosive/erosive materials.

• Discuss about the specialised

use of technique/material to

avoid frequent failures of

components/equipment in

these systems.

• Discuss about preventive

maintenance and breakdown

maintenance as these mostly

have standbys and not needed

for round the clock operation

9 Use basic Health & Safety practices for power related work Theory Duration

(hh:mm)

24:00

Practical Duration

(hh:mm)

24:00


PSS/N 2001

• Discuss general health issues

and precautions at workplace

• Discuss the clauses of CEA

Gazette Notification

• Explain legislature, provision,

rules and guidelines for

ensuring safety in power sector

• Mention the hazards

associated with erection and

commissioning of power plant

equipment

• Mention hazards associated

with operation and

maintenance of power plant

equipment

Helmet, Gloves,

rubber mat,

ladder, neon

tester, Personal

Protective

Equipment


Sr.


Equipment

Required

• Differentiate between hazards

and risk and their prevention

at worksite

• Describe factors causing

accidents and prevention of

accidents at workplace

• Explain causes of Electric

shocks

• Mention the effects of current

on human body

• Discuss the procedure to be

followed for reporting

accidents

• Describe the importance of

work permit system and

creation of safety zone

• Discuss best practices for

working safely in power

transmission network

• Explain the importance of

using PPE

• Name safety equipment used

at heights

• Discuss safety measures to be

taken while working with

electrical equipment

• Discuss electric and fire safety

at workplace

• Mention various types of fire

extinguisher

• Execute correct selection and

use of fire extinguisher

• Describe Basic Rules of First

Aid

• Discuss first aid and its impact

for saving lives in case of

Electrocution

• Discuss handling and storage

of oils, greases and paints

• Discuss ways to store material

and equipment

10 Work effectively with others Theory Duration

(hh:mm)

16:00

• Work effectively in a team.

• Demonstrate good

interpersonal

relation, discipline

behaviour, developing a


Sr.


Equipment

Required

Practical Duration

(hh:mm)

16:00

Corresponding NOS Code PSS/N 1336

positive attitude and building

self-confidence.

• Receive information and

instruction from supervisor and

fellow workers, pass on

information

• Assist others to maximize

effectiveness

• Escalation of problem

• Demonstrate responsible,

disciplined behaviour at

workplace

• Display appropriate

communication etiquette while

working

• Discuss basic Computer

application

Total Duration

Theory Duration

275:00

Practical Duration

275:00

Unique Equipment Required:

Thermo Vision Camera, Transformer Oil test Kit, Megger, Tan

∂ test Kit, Ratio Tester, first aid kit etc.

Grand Total Course Duration: 550Hours, 0 Minutes

(This syllabus/ curriculum has been approved by POWER SECTOR SKILL COUNCIL)


Trainer Prerequisites for Job role: “Engineer- Power Generation (Thermal)” mapped to

Qualification Pack: “PSSC/Q1007, v1.0”

Sr.

No. Area Details

1 Description To deliver accredited training service, mapping to the curriculum detailed

above, in accordance with the Qualification Pack “PSS/Q1007”

2 Personal

Attributes

Aptitude for conducting training, with relevant work experience. So, that

competent candidate is produced at end of the training who are employable.

Strong communication skills, interpersonal skills, ability to work as part of a

team, a passion for quality and for developing others; well-organised and

focused, eager to learn and keep oneself updated with the latest in the

mentioned field.

3 Minimum

Educational

Qualifications

B.Tech/BE in Electrical/ Mechanical/Electronics & Communication

Instrumentation Engineering

4a Domain

Certification

Certified for Job Role: “Engineer Power Generation (Thermal)” mapped to QP:

“PSS/Q1007 v1.0”., Minimum accepted score as per PSSC guidelines- 80% for

Trainer and 90% for Master Trainer

4b Platform

Certification

Recommended that the Trainer is certified for the Job Role: “Trainer”,

mapped to the Qualification Pack: “MEP/Q2601”. Minimum accepted score

as per SSC guidelines – 80% for Trainer and 90% for Master Trainer

5 Experience Engineer B.Tech/BE in Electrical/ Mechanical/Electronics & Communication

Instrumentation Engineering with at least 2-year relevant experience in

power Generation either in the Power Generation utility or with the

turnkey /EPC contractors of the power generation companies carrying out

the work of erection of power generation stations etc.


Annexure: Assessment Criteria

Assessment Criteria

Job Role Engineer Power Generation (Thermal)

Qualification Pack PSSC/Q1007, v1.0

Sector Skill Council Power

Guidelines for Assessment 1. Criteria for assessment for each Qualification Pack will be created by the Sector Skill Council. Each Performance Criteria (PC) will be assigned marks proportional to its importance in NOS. SSC will also lay down proportion of marks for Theory and Skills Practical for each PC. 2. The assessment for the theory part will be based on knowledge bank of questions created by the SSC. 3. Assessment will be conducted for all compulsory NOS, and where applicable, on the selected elective/option NOS/set of NOS. 4. Individual assessment agencies will create unique question papers for theory part for each candidate at each examination/training center (as per assessment criteria below). 5. Individual assessment agencies will create unique evaluations for skill practical for every student at each examination/training center based on this criterion. 6. To pass the Qualification Pack, every trainee should score a minimum of 70% of aggregate marks to successfully clear the assessment. 7. In case of unsuccessful completion, the trainee may seek reassessment on the Qualification Pack.


Compulsory NOS Total Marks: 400

Marks Allocation

Assessment Outcomes Assessment Criteria for Outcomes Total

Marks Out Of Theory

Skills Practical

1. PSS/N1007 Conduct Thermal power plant – Erection and commissioning

PC1. get familiarize with overall thermal power plant working principle

100

9 3 6

PC2. Illustrate concept of thermal power plant location /site selection, plant layout & single line diagram etc.

9 3 6

PC3. plan, monitor and progress of erection and commissioning of BTG & and auxiliaries, coal handling, water treatment, fuel & ash handling etc.

9 3 6

PC4. apply the concept of modern technologies of thermal power plant operation- super critical & sub critical plants

6 2 4

PC5. plan, monitor and progress of erection and commissioning of switchyard, transformer, O/H line, U/G cables etc.

PC6.

8 2 6

PC7. differentiate various types of motor, valves and pumps, bearings, pulverization systems etc.

6 3 3

PC8. plan, monitor and progress of proper protection and earthing of equipment for healthy operation

8 2 6

PC9. review installation of protection devices- earth fault, surge protection, over/under voltage protection etc. to all the critical system

6 3 3

PC10. coordinate and manage all logistics, material planning and handling related issues

8 2 6

PC11. undertake installation of temporary construction power supply 8 2 6

PC12. undertake testing or inspection on pre & post commissioning of all the system

8 2 6

PC13. possess operational familiarity with tools and tackles 5 1 4

PC14. take responsibility for mobilizing resources 5 1 4

PC15. undertake co-ordinating with management and also monitoring individual worker/helper

5 1 4

Total 100 30 70


2. PSS/N1008 Conduct operation and maintenance activities in thermal power plant

PC1. get familiarize with overall plant system and control room

100

4 2 2

PC2. oversee all sub systems of the thermal power plant

4 2 2

PC3. undertake regular inspection of boiler, turbine and alternator and other critical equipment for proper operation & maintenance

4 2 2

PC4. review operation process of various critical equipments 6 2 4

PC5. carry out overhauling process of boiler 6 2 4

PC6. perform starting and shut down process of thermal plant

6 2 4

PC7. ensure maintenance of auxiliary system as and when required 6 2 4

PC8. review fault detection and correction of running plant system 4 1 3

PC9. check all the intersections & joints(termination) in the line or cable

4 1 3

PC10. monitor running parameter of BTG and auxiliaries system as per design standard

4 1 3

PC11. monitor working condition of power transformer (overloading/ underloading)

4 1 3

PC12. undertake performance monitoring of critical system such as BTG and BOP systems

4 1 3

PC13. carry out preventive, breakdown, routine maintenance and overhauling

4 1 3

PC14. manage manpower for maintenance 4 1 3

PC15. test the system parameter to know abnormal condition of the system 4 1 3

PC16. test the healthiness of connected equipment 4 1 3

PC17. maintain log of system condition( parameters) 4 1 3

PC18. undertake software upgradation and testing 4 1 3

PC19. carry out repair and replacement of faulty/ unhealthy equipment 4 1 3

PC20. troubleshoot faulty system 4 1 3


PC21. upgrade or modify the existing unhealthy equipment/system 4 1 3

PC22. carry out general routine repair work 4 1 3

PC23. implement technical changes in

equipment/system 4 1 3

Total 100 30 70

3. PSS/N2001 Use basic health and safety practices for power related work

PC1. use protective clothing/equipment for specific tasks and work conditions.

100

3 0 3

PC2. state the name and location of people responsible for health and safety in the workplace

2 0 2

PC3. state the names and location of documents that refer to health and safety in the workplace

2 0 2

PC4. identify job-site hazardous work and state possible causes of risk or accident in the workplace

3 1 2

PC5. follow electrical safe working procedures such as Tag out/Lock out and display PTW (Permit To Work),

3 1 2

PC6. follow warning signs (danger, out of service, etc.) while working with electrical systems

3 1 2

PC7. use standard safe working practices when working at heights, confined areas and trenches

3 1 2

PC8. test any electrical equipment and system using insulated testing devices before touching them

3 1 2

PC9. ensure positive isolation of electrical equipment & system as per given standards

3 1 2

PC10. recognize any abnormalities in electrical equipment or system installed alarm annunciation and/or noticing parameters from gauge/ indicator installed

3 1 2

PC11. carry out safe working practices while dealing with hazards to ensure the safety of self and others

3 1 2

PC12. state methods of accident prevention in the work environment of the job role

2 0 2

PC13. state location of general health and safety equipment in the workplace 2 0 2

PC14. inspect for faults, set up and safely use of scaffolds and elevated platforms and ladder

2 0 2


PC15. lift, carry and transport heavy objects & tools safely using correct procedures from storage to workplace and vice versa

2 1 1

PC16. inspect Grid station and its equipment routinely for any signs of oil and water leakage

2 0 2

PC17. store flammable materials and machine lubricating oil safely and correctly

2 0 2

PC18. check that the emission and pollution control devices are working properly in line with environmental policy standards

3 1 2

PC19. apply good housekeeping practices at all times 3 1 2

PC20. identify common hazard signs displayed in various areas 2 0 2

PC21. retrieve and/or point out documents that refer to health and safety in the workplace

2 0 2

PC22. inform relevant authorities about any abnormal situation/behavior of any equipment/system promptly

3 0 3

PC23. use the various appropriate fire extinguishers on different types of fires correctly

2 1 1

PC24. distinguish types of fire 3 1 2

PC25. demonstrate rescue techniques applied during fire hazard 3 1 2

PC26. demonstrate good housekeeping in order to prevent fire hazards 3 1 2

PC27. demonstrate the correct use of a fire extinguisher 3 1 2

PC28. demonstrate how to free a person from electrocution 3 1 2

PC29. administer appropriate first aid to victims where required e.g. in case of bleeding, burns, choking, electric shock, poisoning etc.

3 0 3

PC30. demonstrate basic techniques of bandaging 3 1 2

PC31. respond promptly and appropriately to an accident situation or medical emergency in real or simulated environments

3 1 2

PC32. perform and organize loss minimization or rescue activity 3 1 2


during an accident in real or simulated environments

PC33. administer first aid to victims in case of a heart attack or cardiac arrest due to electric shock, before the arrival of emergency services in real or simulated cases

3 1 2

PC34. demonstrate the artificial respiration and the CPR Process 3 1 2

PC35. participate in emergency procedures Emergency procedures: raising alarm, safe/efficient, evacuation, correct means of escape, correct assembly point, roll call, correct return to work

3 1 2

PC36. complete a written accident/incident report or dictate a report to another person, and send report to person responsible

3 1 2

PC37. demonstrate correct method to move injured people and others during an emergency

3 1 2

Total 100 24 76

4. PSS/N1336 Work effectively with others

PC1. accurately receive information and instructions from the supervisor and fellow workers, getting clarification where required

100

10 3 7

PC2. accurately pass on information to authorized persons who require it and within agreed timescale and confirm its receipt

10 3 7

PC3. give information to others clearly, at a pace and in a manner that helps them to understand

10 3 7

PC4. display helpful behavior by assisting others in performing tasks in a positive manner, where required and possible

10 3 7

PC5. consult with and assist others to maximize effectiveness and efficiency in carrying out tasks

10 3 7

PC6. display appropriate communication etiquette while working 10 3 7

PC7. display active listening skills while interacting with others at work 10 3 7

PC8. use appropriate tone, pitch and language to convey politeness, assertiveness, care and professionalism

10 3 7


PC9. demonstrate responsible and disciplined behaviors at the workplace

10 3 7

PC10. escalate grievances and problems to appropriate authority as per procedure to resolve them and avoid conflict

10 3 7

Total 100 30 70

ENGINEER POWER GENERATION (THERMAL)€¦ · impurities in water and steam. • Discuss the various...

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