DIESEL POWER PLANT OPERATION AND MAINTENANCE NC II – TESDA COURSE MODULE

TESDA TRAINING REGULATIONS FOR DIESEL POWER PLANT OPERATION AND MAINTENANCE NC II COURSE

The TESDA Course in DIESEL POWER PLANT OPERATION AND MAINTENANCE NC II consists of competencies that a person must achieve to enhance the knowledge, skills and attitudes of a trainee/student in tending diesel engine operation as well as maintaining and repairing diesel engine.

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

• Diesel power plant operator
• Diesel power plant maintenance technician

TRAINEE ENTRY REQUIREMENTS

Trainees or students should possess the following requirements:

• can communicate both oral and written;
• physically and mentally fit;
• with good moral character; and
• can perform basic mathematical computation.

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 OPERATION AND MAINTENANCE NC II COURSE MODULE

Course Title: DIESEL POWER PLANT OPERATION AND MAINTENANCE
Level: NC II

TOTAL DURATION: 262 Hours

This course is designed to enhance the knowledge, skills and attitudes of a trainee/student in tending diesel engine operation and maintaining and repairing diesel engine.

This course also includes participating in workplace communication, working in a team environment, practicing career professionalism, practicing occupational health and safety procedures and reading manuals.

COMPETENCIES REQUIRED DIESEL POWER PLANT OPERATION AND MAINTENANCE NC II

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

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

These units of competency comprising this qualification include the following:

UNIT CODE	CORE COMPETENCIES (126 hours)
UTL723206	Tend Diesel Engine
UTL723208	Maintain and Repair Diesel Engine Systems and Alternator
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)
500311105	Participate in Workplace Communication
500311106	Work in Team Environment
500311107	Practice Career Professionalism
500311108	Practice Occupational Health and Safety Procedures

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 OPERATION AND MAINTENANCE NC II.

CORE COMPETENCIES

UNIT OF COMPETENCY : TEND DIESEL ENGINE
UNIT CODE : UTL723206

This unit covers the required performance in executing the preparation and tending of diesel engine and its auxiliary equipment.

1. Perform pre-operation check of diesel engine and auxiliary equipment
   • Walk around check of plant system is performed in accordance with enterprise procedure.
   • Fluid deficiencies are refilled/ topped–up in accordance with enterprise procedures
   • Non-fluid deficiencies are identified and corrected in accordance with enterprise procedures.
   • Result of walk around check are recorded and reported to shift in charge.
2. Perform operation check
   • Engine running condition is monitored for normal operation based on indicating parameters.
   • Routine check is performed during operation in accordance with equipment checklist.
   • Unit abnormalities are recorded and reported to shift in charge.
3. Perform post-operation procedure
   • Shutdown procedure is coordinated with the control operator in accordance with enterprise policy.
   • Emergency stop push button is engaged in accordance with the operations manual.
   • Daily operation is recorded and reported in accordance with the enterprise policy.

UNIT OF COMPETENCY : MAINTAIN AND REPAIR DIESEL ENGINE SYSTEMS AND ALTERNATOR
UNIT CODE : UTL723208

This unit identifies the competence required to maintain and service the diesel engine systems and alternator. This includes servicing aspiration system, lube oil system, cooling system, fuel system as well as performing minor servicing of alternator unit.

1. Service Aspiration (intake and exhaust) System
   • Turbocharger is maintained based on PMS
   • Cleaning or replacement of air filter is done as indicated by air restriction indicator
   • Air filter casing is cleaned and freed of dust or foreign particles as cleaning or replacement of filter occurs.
2. Service Lube Oil System
   • Oil cooler assembly is uninstalled and installed in accordance with the manufacturer’s instruction
   • Oil cooler assembly are disassembled and assembled without causing damage to the fins, oil cooler tubes and
     oil seals (o-rings) and in accordance with manufacturer’s instruction.
   • Oil cooler tubes are cleaned and freed of scale or restrictions.
   • Change oil is performed according to SOP
3. Service of Cooling System
   • Cooling System is checked for leaks visually.
   • Radiator is serviced following enterprise policy
   • Thermostat is checked in accordance with its operating temperature.
   • Replace or repair system components based on test result.
   • Coolant is refilled in accordance to the manufacturer’s instruction.
   • Maintain coolant pump in accordance with PMS
4. Service Fuel System
   • Fuel filter is replaced in accordance with manufacturer’s instruction and PMS.
   • Fuel oil/water separator is drained to ensure that the system is free from foreign elements.
   • Servicing and calibration of fuel injector is recommended in accordance with enterprise policy
5. Check condition of alternator
   • Loose connections are remedied and restored to normal conditions in accordance with manufacturer’s instructions.
   • Insulation and winding resistance are checked in accordance with manufacturer’s manual.
   • Revolving diodes and bridge rectifiers are checked in accordance with manufacturer’s manual.
   • AVR functionality is tested based on enterprise policy.
   • Air gap clearances are checked in accordance with manufacturer’s manual.
   • Service report is prepared and submitted in accordance with 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 : PARTICIPATE IN WORKPLACE COMMUNICATION
UNIT CODE : 500311105

This unit covers the knowledge, skills and attitudes required to gather, interpret and convey information in response to workplace requirements.

1. Obtain and convey workplace information
   • Specific and relevant information is accessed from appropriate sources
   • Effective questioning, active listening and speaking skills are used together and convey information
   • Appropriate medium is used to transfer information and ideas
   • Appropriate non- verbal communication is used
   • Appropriate lines of communication with supervisors and colleagues are identified and followed
   • Defined workplace procedures for the location and storage of information are used
   • Personal interaction is carried out clearly and concisely
2. Participate in workplace meetings and discussions
   • Team meetings are at ended on time
   • Own opinions are clear expressed and those of others are listened to without interruption
   • Meeting inputs are consistent with the meeting purpose and established protocols
   • Workplace interactions are conducted in a courteous manner
   • Questions about simple routine workplace procedures and matters concerning working conditions of employment are asked and responded to.
   • Meetings outcomes are interpreted and implemented
3. Complete relevant work related documents
   • Range of forms relating to conditions of employment are completed accurately and legibly
   • Workplace data is recorded on standard workplace forms and documents
   • Basic mathematical processes are used for routine calculations
   • Errors in recording information on forms/documents are identified and properly acted upon
   • Reporting requirements to supervisor are completed according to organizational guidelines

UNIT OF COMPETENCY : WORK IN TEAM ENVIRONMENT
UNIT CODE : 500311106

This unit covers the skills, knowledge and attitudes to identify role and responsibility as a member of a team.

1. Describe team role and scope
   • The role and objective of the team is identified from available sources of information
   • Team parameters, reporting relationships and responsibilities are identified from team discussions and appropriate external sources.
2. Identify own role and responsibility within team
   • Individual role and responsibilities within the team environment are identified.
   • Roles and responsibility of other team members are identified and recognized.
   • Reporting relationships within team and external to team are identified.
3. Work as a team member
   • Effective and appropriate forms of communications used and interactions undertaken with team members who contribute to known team activities and objectives.
   • Effective and appropriate contributions made to complement team activities and objectives, based on individual skills and competencies and workplace context.
   • Observed protocols in reporting using standard operating procedures.
   • Contribute to the development of team work plans based on an understanding of team’s role and objectives and individual competencies of the members.

UNIT OF COMPETENCY : PRACTICE CAREER PROFESSIONALISM
UNIT CODE : 500311107

This unit covers the knowledge, skills and attitudes in promoting career growth and advancement.

1. Integrate personal objectives with organizational goals
   • Personal growth and work plans are pursued towards improving the qualifications set for the profession
   • Intra- and interpersonal relationships is are maintained in the course of managing oneself based on performance evaluation
   • Commitment to the organization and its goal is demonstrated in the performance of duties
2. Set and meet work priorities
   • Competing demands are prioritized to achieve personal, team and organizational goals and objectives.
   • Resources are utilized efficiently and effectively to manage work priorities and commitments
   • Practices along economic use and maintenance of equipment and facilities are followed as per established procedures
3. Maintain professional growth and development
   • Trainings and career opportunities are identified and availed of based on job requirements
   • Recognitions are sought/received and demonstrated as proof of career advancement
   • Licenses and/or certifications relevant to job and career are obtained and renewed

UNIT OF COMPETENCY : PRACTICE  OCCUPATIONAL HEALTH AND SAFETY PROCEDURES
UNIT CODE : 500311108

This unit covers the outcomes required to comply with regulatory and organizational requirements for occupational health and safety.

1. Identify hazards and risks
   • Safety regulations and workplace safety and hazard control practices and procedures are clarified and explained based on organization procedures
   • Hazards/risks in the workplace and their corresponding indicators are identified to minimize or eliminate risk to co-workers, workplace and environment in accordance with organization procedures
   • Contingency measures during workplace accidents, fire and other emergencies are recognized and established in accordance with organization procedures
2. Evaluate hazards and risks
   • Terms of maximum tolerable limits which when exceeded will result in harm or damage are identified based on threshold limit values (TLV)
   • Effects of the hazards are determined
   • OHS issues and/or concerns and identified safety hazards are reported to designated personnel in accordance with workplace requirements and relevant workplace OHS legislation
3. Control hazards and risks
   • Occupational Health and Safety (OHS) procedures for controlling hazards/risks in workplace are consistently
     followed
   • Procedures for dealing with workplace accidents, fire and emergencies are followed in accordance with organization OHS policies
   • Personal protective equipment (PPE) is correctly used in accordance with organization OHS procedures and practices
   • Appropriate assistance is provided in the event of a workplace emergency in accordance with established organization protocol
4. Maintain OHS awareness
   • Emergency-related drills and trainings are participated in as per established organization guidelines and procedures
   • OHS personal records are completed and updated in accordance with workplace requirements