DIESEL POWER PLANT MAINTENANCE NC III – TESDA COURSE MODULE

TESDA TRAINING REGULATIONS FOR MACHINING NC III COURSE

The TESDA Course in DIESEL POWER PLANT MAINTENANCE NC III consists of competencies that a person must achieve to enhance the knowledge, skills and attitudes of a trainee/student in diagnosing, repairing and overhauling diesel engine as well as servicing alternator and diagnosing & repairing electrical system of a diesel power plant.

A student who has achieved this TESDA Course in DIESEL POWER PLANT MAINTENANCE NC III is competent to be:

• Diesel power plant senior operation maintenance technician

TRAINEE ENTRY REQUIREMENTS

Trainees or students should possess the following requirements:

• can communicate both oral and written;
• with good moral character; and
• can perform basic mathematical computation.
• must have completed training in all the units of competency in Diesel Power Plant Operation and Maintenance NC II

This list does not include specific institutional requirements such as educational attainment, appropriate work experience, and others that may be required of the trainees by the school or training center delivering the TVET program.

DIESEL POWER PLANT MAINTENANCE NC III COURSE MODULE

Course Title: DIESEL POWER PLANT MAINTENANCE
Level: NC III

TOTAL DURATION: 352 Hours

This qualification is designed to develop knowledge, desirable attitudes and skills of Machinist NC III.
It covers the competencies required to Turn Workpiece ( Advanced ) and Mill Workpiece ( Advanced ).

COMPETENCIES REQUIRED DIESEL POWER PLANT MAINTENANCE NC III

This units of competency comprising this qualification include Basic, Common and Core Competencies.

To obtain this TESDA Course in DIESEL POWER PLANT MAINTENANCE NC III, all units prescribed below for this qualification must be achieved.

These units of competency comprising this qualification include the following:

UNIT CODE	CORE COMPETENCIES (216  hours)
UTL723209	Overhaul Diesel Engine
UTL723210	Diagnose and Repair Diesel Engine
UTL723211	Service Alternator/Generator
UTL723212	Diagnose and Repair Electrical System
UNIT CODE	COMMON COMPETENCIES (80 hours)
UTL311202	Perform Mensuration and Calculation
UTL723203	Read, Interpret and Apply Specifications and Manuals
UTL723205	Perform Shop Maintenance
UTL713202	Perform Basic Bench Works
UTL724201	Perform Basic Electrical Works
UNIT CODE	BASIC COMPETENCIES (56 hours)
500311109	Lead Workplace Communication
500311110	Lead Small Teams
500311111	Develop and Practice Negotiation skills
500311112	Solve Problems Related to Work Activities
500311113	Use Mathematical Concepts and Techniques
500311114	Use Relevant Technologies

These guidelines are set to provide the Technical Vocational Education and Training (TVET) providers with information and other important requirements to consider when designing training programs for DIESEL POWER PLANT MAINTENANCE NC III.

CORE COMPETENCIES

UNIT OF COMPETENCY : OVERHAUL DIESEL ENGINE
UNIT CODE : UTL723209

This unit identifies the competence required to disassemble, inspect, evaluate and determine preferred repair action for engine block and sub-assemblies as part of a regular preventive-maintenance schedule and covering top, intermediate and major overhauling procedures.

1. Disassemble engine block and sub-assemblies
   • Engine block and sub-assemblies are disassembled without causing damage to any component or system and in accordance with manufacturers manual.
   • Components or system are ensured to be free of dirt, grease, rust and other foreign materials in preparation for the inspection and testing.
   • Disassembled components are marked and arranged according to prescribed arrangements.
   • All disassembling and cleaning activities are carried out according to industry regulations or guidelines and occupational health and safety procedures.
2. Assess engine block and sub-assembly components
   • Components and systems are tested and measured using prescribed method and without causing damage to any component or system.
   • Fuel injector is serviced and calibrated in accordance with the manufacturer’s instruction manual.
   • Result of testing and measurement are assessed using manufacturer specifications.
   • Repair or replacement requirements are identified and reported according to enterprise policy and procedure.
   • Pre-repair inspection report is completed and dealt with relevant to the assessment outcome.
   • Required component repair or replacements are carried out in accordance with manufacturer’s recommendations
3. Re-assemble engine blocks and sub-assemblies
   • Component measurements are checked in accordance with manufacturer’s specification
   • Faults in measurements are rectified in accordance with manufacture’s specification.
   • Engine block and sub assemblies are assembled following manufacturers manual and without damage to the components or workplace property.
4. Carry out test procedure
   • Pre-testing activities are performed following system normal operating procedure
   • Engines performance is checked for normal operation using different testing methods in accordance with manufacturer’s manual and without causing damage to the workplace property.
   • Faults in engine operation are remedied following manufacturer’s manual.
   • Overhaul report is prepared according enterprise policy.

UNIT OF COMPETENCY : DIAGNOSE AND REPAIR DIESEL ENGINE
UNIT CODE : UTL723210

The unit identifies the competence required to troubleshoot and repair diesel engine. This involves planning, preparing and performing troubleshooting and repair as well as

1. Plan and prepare for troubleshooting and repair
   • Work requirements are identified from relevant personnel and documentation.
   • Service prerequisites are carried out in accordance with enterprise policy.
   • Required resources are identified and prepared based on enterprise policy and on-site validation report.
   • 5s and safety practices are implemented in accordance with the enterprise policy
2. Perform troubleshooting and repair
   • Engine defects or defective components are identified through systematic and logical method of isolation and testing without causing damage to the engine and other workplace property
   • Root cause analysis is performed using data gathered and without causing damage to engine and other workplace property
   • Repair or replacement of defective components are carried out in accordance with the result of troubleshooting and root cause analysis and manufacturers instruction.
3. Carry out test procedure
   • Pre-testing activities are performed following system normal operating procedure
   • Test run is carried out while monitoring the condition of the engine in accordance with manufacturer’s manual and without causing damage to components or workplace property.
   • Faults in engine operation are corrected following manufacturer’s manual.
   • Service report is prepared according enterprise policy.

UNIT OF COMPETENCY : SERVICE ALTERNATOR/GENERATOR
UNIT CODE : UTL723211

The unit identifies the competence required to disassemble, inspect, evaluate and determine preferred repair action for alternator/generator.

1. Disassemble alternator/generator
   • Main circuit breaker is locked open and tagged-out as per enterprise policy.
   • Terminals are disconnected and properly marked without damaging other components.
   • Alternator is decoupled without damaging other components
   • Baseline data are taken using prescribed methods.
   • Components are cleaned and freed of dust, grease and other foreign materials in preparation for the inspection and testing.
   • All disassembling and cleaning activities are carried out according to manufacturers recommendations and occupational health and safety procedures
   • Service report is prepared in accordance with enterprise policy.
2. Assess and repair alternator components
   • Components are tested and assessed using prescribed methods and without causing damage to any component.
   • Repair / replacement requirements are identified and reported according to enterprise policy and procedure.
   • Required component repair or replacements are carried out in accordance with manufacturer’s recommendations and specification.
   • Repaired or replaced component’s data are recorded in accordance with enterprise policy
3. Re-assemble and re-terminate alternators
   • Alternator are assembled following manufacturers manual and without damage to the components or workplace property
   • Alternator is coupled to the engine according to manufacturer’s instruction.
   • Alignment of the alternator to the diesel engine is performed following manufacturer’s instruction.
4. Carry-out test procedure
   • Testing methods are carried out in accordance with manufacturer’s manual and without causing damage to components or workplace property.
   • Faults in alternator operation are remedied following manufacturer’s manual.
   • Service report is finalized according enterprise policy.

UNIT OF COMPETENCY : DIAGNOSE AND REPAIR ELECTRICAL SYSTEM
UNIT CODE : UTL723212

The unit identifies the competence required to troubleshoot and repair electrical system.

1. Plan and prepare for troubleshooting and repair
   • Work requirements are identified from relevant personnel and documentation.
   • Service prerequisites are carried out in accordance with enterprise policy.
   • Required resources are identified and prepared based on enterprise policy and on-site validation report.
   • 5s and safety practices are implemented in accordance with the enterprise policy
2. Perform troubleshooting and repair
   • Electrical system defects or defective components are identified through systematic and logical method of isolation and testing without causing damage to the electrical system and other workplace property.
   • Root cause analysis is performed using data gathered and without causing damage to electrical components and other workplace property.
   • Repair or replacement of defective components are carried out in accordance with the result of troubleshooting and root cause analysis and manufacturers instruction.
   • Repairs requiring outside services are identified and reported in accordance with enterprise policy.
3. Carry out test procedure
   • Pre-testing activities are performed following system normal operating procedure.
   • Testing methods are carried out in accordance with manufacturer’s manual and without causing damage to components or workplace property.
   • Faults in electrical system operation are corrected following manufacturer’s manual.
   • Service report is prepared according enterprise policy

COMMON COMPETENCIES

UNIT OF COMPETENCY : PERFORM MENSURATION AND CALCULATION
UNIT CODE : UTL311202

This unit covers the knowledge, skills and attitudes in measuring and calculating using tools and measuring instruments. It also covers care and handling of measuring instruments.

1. Select measuring instruments
   • Object or component to be measured is identified
   • Correct specifications are obtained from relevant source
   • Appropriate measuring instrument is selected according to job requirements
2. Carry out measurements and calculation
   • Measuring tools are selected in line with job requirements
   • Accurate measurements are obtained to job
   • Calculation needed to complete work tasks are performed using the four fundamental operation of addition (+), subtraction (-), multiplication (x) and division (/).
   • Calculations involving fractions, percentages and mixed numbers are used to complete workplace tasks.
   • Numerical computation is self-checked and corrected for accuracy
   • Instruments are read to the limit of accuracy of the tool.
3. Maintain measuring instruments
   • Measuring instruments are kept free from corrosion
   • Measuring instruments are not dropped to avoid damage
   • Measuring instruments are cleaned before and after using.

UNIT OF COMPETENCY : READ, INTERPRET AND APPLY SPECIFICATION AND MANUALS.
UNIT CODE : UTL723203

This unit deals with identifying, interpreting and applying service specification manuals, maintenance procedure manuals and periodic maintenance manual.

1. Identify and access manual/specification
   • Appropriate manuals are identified and accessed as per job requirements.
   • Version and date of manual is checked to ensure correct specification and procedure are identified.
2. Interpret manuals
   • Relevant sections, chapters of manuals/specifications are located in relations to the work to be conducted
   • Information and procedure in the manual are interpreted in accordance to industry practices
3. Apply information in manual
   • Manual is interpreted according to job requirements
   • Work steps are correctly identified in accordance with manufacturer specification
   • Manual data is applied according to the given task
   • All correct sequencing and adjustments are interpreted in accordance with information contained on the manual or specifications
4. Store manuals
   • Manual or specification are stored appropriately to ensure prevention of damage, ready access and updating of information when required in accordance with company requirements

UNIT OF COMPETENCY : PERFORM SHOP MAINTENANCE
UNIT CODE : UTL723205

This unit deals with inspecting and cleaning of work area including tools, equipment and facilities. Storage and checking of tools/ equipment and disposal of used materials are also incorporated in this competency.

1. Inspect/clean tools and work area
   • Cleaning solvent used as per workshop/tools cleaning requirement
   • Work area is checked and cleaned
   • Wet surface/spot in work area is wiped and dried
2. Store/arrange tools and shop equipment
   • Tools/equipment are checked and stored in their respective shelves/location
   • Corresponding labels are posted and visible
   • Tools are safely secured and logged in the records
3. Dispose wastes/used lubricants
   • Containers for used lubricants are visibly labeled
   • Wastes/used lubricants are disposed as per workshop SOP
4. Report damaged tools/equipment
   • Complete inventory of tools/equipment is maintained
   • Damaged tools/equipment/facilities are identified and repair recommendation is given
   • Reports prepared has no error/discrepancy

UNIT OF COMPETENCY : PERFORM BASIC BENCHWORK
UNIT CODE : UTL713202

This unit covers the knowledge, skills and attitudes in preparing materials, tools and equipment, lay-outing dimensions and performing basic benchwork based on the required performance standards.

1. Prepare materials, tools and equipment
   • Work plan is interpreted to determine job requirements
   • Materials, tools and equipment are identified and prepared according to job requirements
   • Materials are checked according to the required specifications
   • Tools and equipment conditions are checked following the standard operating procedures (SOPs)
2. Lay-out and mark dimensions/features on workplace
   • Metallic and non-metallic materials are selected according to the requirements specified in the blueprint
   • Dimensions/features are laid-out/marked according to job specifications/blueprint and within the required tolerance
   • Dimensions are checked against the actual work plan
3. Perform required benchworks
   • Work instructions are followed to ensure work safety
   • Benchworks are performed applying knowledge on safety procedures and according to job requirements
   • Workpieces are clamped in workholding device to avoid damage and accidents
   • Work pieces are cut, chipped or filed according to required measurements, tolerance specified in the blueprint and free from burrs and sharp edges
   • Drilling is performed according to recommended sequence and specifications
   • Proper usage of materials, tools and equipment is observed
   • Appropriate PPE and safety procedures are applied
   • Worksite is cleaned and cleared of all debris and left in safe state in accordance with OHS regulations

UNIT OF COMPETENCY: PERFORM BASIC ELECTRICAL WORKS
UNIT CODE : UTL724201

This unit covers the knowledge, skills and attitudes in preparing materials, tools and equipment, testing electrical components and basic repairing in electricity based on the required performance standards.

1. Prepare electrical tools and test instruments
   • Work plan is interpreted to determine job requirements
   • Electrical tools and instruments are identified and prepared according to job requirements
   • Electrical tools and instruments are checked for conditions and calibrated as required
2. Test power supply and electrical components
   • Instruments are tested in accordance with PEC
   • Power supply and electrical components are checked in accordance with manufacturer’s specifications/PEC
   • Defects of power supply and electrical components are identified and recorded
   • Safe working habits is observed
3. Perform basic electrical repair
   • Work instructions are followed to ensure safety work
   • Loose connections are tightened in accordance with PEC
   • Defective electrical components are replaced and tested in accordance with PEC
   • Work place is cleaned and in safe state in line with OHSA regulations

BASIC COMPETENCIES

The BASIC COMPETENCIES refer to non-technical skills (knowledge, skills and attitudes) that everybody will need in order to perform satisfactorily at work and in society and are considered portable and transferable irrespective of jobs and industrial settings.

UNIT OF COMPETENCY : LEAD WORKPLACE COMMUNICATION
UNIT CODE : 500311109

This unit covers the knowledge, skills and attitudes required to lead in the dissemination and discussion of ideas, information and issues in the workplace.

1. Communicate information about workplace processes
   • Appropriate communication method is selected
   • Multiple operations involving several topics areas are communicated accordingly
   • Questions are used to gain extra information
   • Correct sources of information are identified
   • Information is selected and organized correctly
   • Verbal and written reporting is undertaken when required
   • Communication skills are maintained in all situations
2. Lead workplace discussions
   • Response to workplace issues are sought
   • Response to workplace issues are provided immediately
   • Constructive contributions are made to workplace discussions on such issues as production, quality and safety
   • Goals/objectives and action plan undertaken in the workplace are communicated
3. Identify and communicate issues arising in the workplace
   • Issues and problems are identified as they arise
   • Information regarding problems and issues are organized coherently to ensure clear and effective communication
   • Dialogue is initiated with appropriate personnel
   • Communication problems and issues are raised as they arise

UNIT OF COMPETENCY : LEAD SMALL TEAMS
UNIT CODE : 500311110

This unit covers the knowledge, skills and attitudes to lead small teams including setting and maintaining team and individual performance standards.

1. Provide team leadership
   • Work requirements are identified and presented to team members
   • Reasons for instructions and requirements are communicated to team members
   • Team members’ queries and concerns are recognized, discussed and dealt with
2. Assign responsibilities
   • Duties, and responsibilities are allocated having regard to the skills, knowledge and aptitude required to properly undertake the assigned task and according to company policy
   • Duties are allocated having regard to individual preference, domestic and personal considerations, whenever possible
3. Set performance expectations for team members
   • Performance expectations are established based on client needs and according to assignment requirements
   • Performance expectations are based on individual team members duties and area of responsibility
   • Performance expectations are discussed and disseminated to individual team members
4. Supervised team performance
   • Monitoring of performance takes place against defined performance criteria and/or assignment instructions and corrective action taken if required
   • Team members are provided with feedback, positive support and advice on strategies to overcome any deficiencies
   • Performance issues which cannot be rectified or addressed within the team are referenced to appropriate personnel according to employer policy
   • Team members are kept informed of any changes in the priority allocated to assignments or tasks which might impact on client/customer needs and satisfaction
   • Team operations are monitored to ensure that employer/client needs and requirements are met
   • Follow-up communication is provided on all issues affecting the team
   • All relevant documentation is completed in accordance with company procedures

UNIT OF COMPETENCY : DEVELOP AND PRACTICE NEGOTIATION SKILLS
UNIT CODE : 500311111

This unit covers the skills, knowledge and attitudes required to collect information in order to negotiate to a desired outcome and participate in the negotiation.

1. Plan negotiations
   • Information on preparing for negotiation is identified and included in the plan
   • Information on creating non verbal environments for positive negotiating is identified and included in the plan
   • Information on active listening is identified and included in the plan
   • Information on different questioning techniques is identified and included in the plan
   • Information is checked to ensure it is correct and up-to- date
2. Participate in negotiations
   • Criteria for successful outcome are agreed upon by all parties
   • Desired outcome of all parties are considered
   • Appropriate language is used throughout the negotiation
   • A variety of questioning techniques are used
   • The issues and processes are documented and agreed upon by all parties
   • Possible solutions are discussed and their viability assessed
   • Areas for agreement are confirmed and recorded
   • Follow-up action is agreed upon by all parties

UNIT OF COMPETENCY : SOLVE PROBLEMS RELATED TO WORK ACTIVITIES
UNIT CODE : 500311112

This unit of covers the knowledge, skills and attitudes required to solve problems in the workplace including the application of problem solving techniques and to determine and resolve the root cause of problems.

1. Identify the problem
   • Variances are identified from normal operating parameters; and product quality
   • Extent, cause and nature are of the problem are defined through observation, investigation and analytical techniques
   • Problems are clearly stated and specified
2. Determine fundamental causes of the problem
   • Possible causes are identified based on experience and the use of problem solving tools / analytical techniques.
   • Possible cause statements are developed based on findings
   • Fundamental causes are identified per results of investigation conducted
3. Determine corrective action
   • All possible options are considered for resolution of the problem
   • Strengths and weaknesses of possible options are considered
   • Corrective actions are determined to resolve the problem and possible future causes
   • Action plans are developed identifying measurable objectives, resource needs and timelines in accordance with safety and operating procedures
4. Provide recommendation/s to manager
   • Report on recommendations are prepared
   • Recommendations are presented to appropriate personnel.
   • Recommendations are followed-up, if required

UNIT OF COMPETENCY : USE MATHEMATICAL CONCEPTS AND TECHNIQUES
UNIT CODE : 500311113

This unit covers the knowledge, skills and attitudes required in the application of mathematical concepts and techniques.

1. Identify mathematical tools and techniques to solve problem
   • Problem areas are identified based on given condition
   • Mathematical techniques are selected based on the given problem
2. Apply mathematical procedure/solution
   • Mathematical techniques are applied based on the problem identified
   • Mathematical computations are performed to the level of accuracy required for the problem
   • Results of mathematical computation is determined and verified based on job requirements
3. Analyze results
   • Result of application is reviewed based on expected and required specifications and outcome
   • Appropriate action is applied in case of error

UNIT OF COMPETENCY : USE RELEVANT TECHNOLOGIES
UNIT CODE : 500311114

This unit of competency covers the knowledge, skills, and attitude required in selecting, sourcing and applying appropriate and affordable technologies in the workplace.

1. Study/select appropriate technology
   • Usage of different technologies is determined based on job requirements
   • Appropriate technology is selected as per work specification
2. Apply relevant technology
   • Relevant technology is effectively used in carrying out function
   • Applicable software and hardware are used as per task requirement
   • Management concepts are observed and practiced as per established industry practices
3. Maintain/enhance relevant technology
   • Maintenance of technology is applied in accordance with the industry standard operating procedure, manufacturer’s operating guidelines and occupational health and safety procedure to ensure its operative ability
   • Updating of technology is maintained through continuing education or training in accordance with job requirement
   • Technology failure/ defect is immediately reported to the concern/responsible person or section for appropriate action