Industrial Electrician
Level 3
Industrial Electrician
C1 Electrical Code III
Unit:
Three
Level:
Duration: 80 hours
Theory:
Practical:
80 hours
0 hours
Overview:
This unit of instruction is designed to provide the Electrician apprentice with knowledge and understanding of the
Canadian Electrical Code. On satisfactory completion, the apprentice-learner will be able to describe and
calculate protection and wiring methods for feeders and branch circuits supplying motors, transformers,
capacitors, arc welders, batteries and lighting circuits. They will also be able to describe specific requirements in
high voltage installations, Class 1 and 2 circuits and hazardous locations. In addition they will be able to
understand the precautions to follow when working on live electrical circuits.
Percent of
Unit Mark (%)
Objectives and Content:
1.
Describe and calculate for feeder and branch circuit conductors in cables,
raceways, free air and underground.
a. Continuous and non-continuous loading
b. Tap conductors
c. Voltage drop
d. Parallel conductors
9%
2.
Describe busways.
a. Application
b. Types
c. Rationings and ampacities 6 hours
d. Components and connections
e. Metallurgical considerations (e.g. Copper to aluminum connections)
f.
Support systems
g. Torque specifications
7%
3.
Describe raceway systems.
a. Cable trough
b. Surface raceways
5%
4.
Describe busways.
a. Motors
b. Arc welders
c. Capacitors
d. Transformers
12%
1
Rev. September 2008
e.
f.
Batteries
Lighting circuits
5.
Describe and calculate the size and type of over current protection required for
conductors supplying:
a. Motors
b. Arc welders
c. Capacitors
d. Transformers
e. Batteries
6.
Describe and calculate the size and type of overload protection required for
motors.
a. Thermal, magnetic, electronic
b. Service factor
3%
7.
Describe installation methods required in hazardous locations.
a. Classification
b. Wiring methods
c. Grounding and bonding
7%
8.
Describe wiring methods for Class 1 and Class 2 signal and remote control
circuits.
a. Extra low voltage power circuits
b. Low energy power circuit
5%
9.
Describe lighting systems.
a. Wiring methods
b. Over current protection
c. Types of fixtures
d. Control
7%
10.
Describe arc flash protection.
a.
Personal protective grounds
b.
Hazard analyses
c.
Limited approach boundary limitations
d.
Energized electrical work permits
e.
P.P.E.
f.
National codes
9%
11.
Describe high voltage installations.
a. Bonding and grounding methods
b. Lightning protection
c. Touch and step voltages
5%
12.
Describe type, typical applications and interrupting means of circuit breakers.
a. High and low voltage types
b. Moulded case and switchgear
c. Interrupting capacity and ratings
d. Interpret breaker time – current curves for typical breakers
4%
13.
Describe arc extingusing means for circuit breakers.
4%
2
11%
Rev. September 2008
a.
b.
c.
d.
e.
Air
Air/magnetic
Oil
Vacuum
Gas
14.
Describe type, typical applications and interrupting means of fuses.
a. High and low voltage types
b. Interrupting capacity and ratings
c. Interpret fuse time – current curves for typical fuse types
d. Describe arc extinguishing means for fuses
5%
15.
Describe type, typical applications and isolating means of disconnects.
a. High and low voltage types
b. Equipment withstand ratings
3%
16.
Describe system overcurrent co-ordination.
a. High and low voltage systems
3%
***
3
Rev. September 2008
Industrial Electrician
C2 Three Phase Theory and Transformers
Unit:
Three
Level:
Duration: 80 hours
Theory:
Practical:
60 hours
20 hours
Overview:
Upon successful completion of this course, the apprentice will have the knowledge of the three-phase systems
including wye circuits, delta circuits, power factor correction, methods of three-phase power measurement The
apprentice will also gain a knowledge of transformers including operating principals, ratings and ratios, polarities,
cooling methods, PCB hazards, tap setting, single phase transformer connection, % impedance, paralleling, three
phase transformer connections, troubleshooting and protection, and current transformers and potential as well as
power quality, power factor correction, filtering and surge suppression devices.
Percent of
Unit Mark (%)
Objectives and Content:
1.
Describe three phase theory.
a. Review DC and single phase theory.
b. Describe by the use of a phasor diagram the relationship between phase voltage and
line voltage in a wye connected source.
c. Describe by the use of phasor diagram the relationship between phase voltage and
line voltage in a delta connected source.
d. Describe and verify by connection, the relationship between phase and line for a wye
system.
e. Describe and verify by connection, the relationship between phase and line for a
delta system (balanced).
f.
Describe the phase relationship between phase currents and phase voltages in a
wye connected system at unity, and other than unity power factor (balanced and
unbalanced) by the use of a phasor diagram.
g. Describe the importance of neutral conductor on an unbalanced wye system.
h. Describe the phase relationship between phase currents and phase voltages in a
delta connected system at unity and other than unity power factor (balanced or
unbalanced) by the use of a phasor diagram.
i.
Calculate three-phase true power, apparent power and reactive power in balanced
and unbalanced systems.
j.
Describe overall “power factor” as it applies to three phase systems.
k. Describe how capacitors should be connected to a three-phase system.
l.
Perform power factor correction calculations and verify.
m Calculate and verify power measurement:
• Single phase
• Two wattmeter method
• Three wattmeter method
n.
Verify three-phase power, apparent power and reactive power.
4
31%
Rev. September 2008
2.
Describe transformers.
a. Describe the purposes of a transformer.
b. Describe the basic components of a transformer and the nameplate information
(conservator, bushings, pressure relief device, breather [types-activated alumina,
silica gel, drycol condenser], gas relay, gauges and sensors).
c. Describe primary and secondary of a transformer.
d. Describe the difference between a step-up and a step-down transformer.
e. Describe the difference between subtractive and additive terminal markings.
f.
Describe the standard terminal and winding identification.
g. Describe transformer action.
h. Describe the operation of a transformer as load is added.
i.
Describe the losses that occur in a transformer.
j.
Calculate the efficiency of transformers.
k. Describe the operation and demonstrate connections for auto transformers.
l.
Describe how transformers are rated and sized.
m Describe and solve problems involving transformers in terms of voltage, turns and
current ratios.
n. Describe the reason why transformers are rated in voltage and volt-amps.
o. Describe the possible effects of operating a transformer at above its rated voltage.
p. Describe the difference between the high voltage and the low voltage windings of a
transformer.
q. Calculate the rated primary and secondary currents of a transformer from nameplate
data.
r. Describe a properly rated transformer for a specified load.
s. Describe the various methods of cooling for distribution and Power transformers and
the liquids used (air, water, oil, forced and natural).
t.
Describe the hazards of PCBs as related to transformers.
u. Describe out of step condition when runing tap changers in parallel.
v. Describe the purpose of % impedance stated on the nameplate for parallel
operation.
w. Describe the conditions to be met before operating two transformers in parallel.
x. Describe the expected secondary voltage by the use of a phasor diagram.
y. Describe the connections required, given the nameplate information, for supply
voltage, and required load voltage for single and three phase transformers.
z. Draw schematics and wiring diagrams for single and three phase transformer
connections.
aa Measure and compare primary and secondary voltages.
bb Describe the purposes of instrument transformers.
cc Describe the primary and secondary circuit connections for current transformers
(CTs) and potential transformers (PTs).
dd Describe why a shorting device must be provided for the secondary of a current
transformer.
ee Describe and give examples of commonly used ratings of instrument transformers.
ff
Describe the connection of instrument transformers and how to put it into a circuit to
determine the voltage and the current.
gg Describe the operation of two transformers in parallel with respect to load sharing.
ii
Connect the windings of a transformer for series or parallel operation.
jj
Connect a single phase transformer for single and dual voltages.
kk Connect three phase transformer banks.
ll
Describe how to set a tap changer to increase and decrease secondary voltage
levels (auto and manual).
m
Describe tap changers and 3 phase regulators and their applications (on load in
m
separate compartment, off load in main tank.
nn Describe the maximum fault current from transformer nameplate data.
5
50%
Rev. September 2008
3.
Describe Power Quality.
b. Identify the characteristics of voltage sag, voltage swell, over and under voltage
condition, voltage fluctuation and voltage transient.
c. Describe the operation of different types of UPS (uninterruptible power supplies)
systems.
• Standby Generator
• Battery Charger/Battery Bank
• Electronic Converters
d. Describe surge suppression and how it is applied to transmission lines, primary
distribution centers and secondary circuits.
e. Describe the effects of linear and non-linear loads on the electrical distribution
system.
f.
List the frequency of different order harmonics.
g. Identify the electrical effects that are caused by negative, positive and zero
sequence harmonics to transformers, circuit breakers and neutral conductors.
h. Describe the effects of harmonic currents on motors, capacitors and sensitive
electronic equipment.
i.
Describe displacement power factor, THD (total harmonic distortion) and
transformer.
• Rating
j.
Troubleshoot AC circuits for power quality problems.
19%
***
6
Rev. September 2008
Industrial Electrician
C3
Unit:
Electronic Concepts II
Three
Level:
Duration: 40 hours
Theory:
Practical:
20 hours
20 hours
Overview:
This unit of instruction is designed to provide the Electrician apprentice with additional knowledge and
understanding of electronic devices and there applications in control and detection systems.
Percent of
Unit Mark (%)
Objectives and Content:
1.
Review Basic Semiconductor Devices.
a. Describe the operation of a P-N junction diode, zener diode, SCR and triac in AC
and DC circuits.
b. Draw and label the terminals of the schematic symbols for a P-N junction diode,
zener diode, SCR and triac
c. Describe and discuss the following terms as they apply to P-N junction diodes, zener
diodes, SCR’s and triacs:
• Forward bias
• Reverse bias
• Peak inverse voltage
• Avalanche current/voltage
• Gate current
d. Test a P-N junction diode, zener diode, SCR and triac individually and in an electric
circuit for proper operation.
e. Describe the operation of the half wave, full wave and bridge rectifier in a single
phase AC circuit.
f.
Describe and calculate the peak, RMS and average current and voltage for a half
wave, full wave and bridge rectifier in a single phase AC circuit.
g. Describe the operation of the half wave and bridge rectifier in three phase AC circuits
h. Describe and calculate the peak, RMS and average current and voltage for a half
wave, full wave and bridge rectifier in a three phase AC circuit.
i.
Describe and calculate the output frequency of the rectifiers above
j.
Describe the purpose of a rectifier filter circuit
k. Describe the operation of a capacitor, inductor and resistor in a filter circuit with
respect to:
• Percent ripple.
• Voltage and current regulation.
• Bullet number three.
l.
Describe the following terms as they apply to SCR’s
7
70%
Rev. September 2008
•
Phase shifting
Conduction angle
• Commutation
Describe the operation of a SCR in AC and DC circuits
Test an SCR for proper operation individually and in AC and DC circuits
Describe the operation of a zener diode in a DC circuit
Discuss the purpose of a surge resistor in zener diode circuits
Test a zener diode’s operation in a DC circuit
Describe the effects of heat on the conductivity of seminconductor devices
Describe the proper use of heat sinks with respect to size, material, orientation and
use of thermal compounds
•
m
n.
o.
p.
q.
r.
s.
2.
Describe transistors.
a. Describe the operating characteristics of common transistors
b. Label common terminal designations on common transistor symbols
c. Describe transistor operation in digital applications
d. Describe transistor operation in analog applications
e. Describe Pulse Width Modulation (PWM)
30%
***
8
Rev. September 2008
Industrial Electrician
C4
Unit:
Industrial Control Systems
Three
Level:
Duration: 90 hours
Theory:
Practical:
50 hours
40 hours
Overview:
This unit of instruction is designed to provide the Industrial Electrician apprentice with complex knowledge and
understanding of microprocessor-based control and monitoring systems (PLCs). The unit is intended to
supplement the information taught in print reading, electrical code and electrical concepts.
.
Percent of
Unit Mark (%)
Objectives and Content:
1.
Describe Control Systems.
a. Describe the function and operation and application of motor control with use of pilot
devices
• Push buttons
• Float switches
• Temp switches
• Flow switches
• Pressure switches
• Limit switches
• Selector switches
b. Describe, design and demonstrate motor control schematic diagrams with all
applicable pilot devices.
c. Describe, design and demonstrate motor control circuits and application by use of
sensing devices:
• Proximity detectors (e.g., inductive, capacitive, and magnetic)
• Photo detectors.
d. Describe and design methods of reduced voltage starting methods:
• Explain the difference between across the line and reduced voltage starting
methods
• Explain the various methods (Resistive starts, Wye-start, Delta-run, Part winding
starts, Auto transformer, wound rotor motors. )
• Explain the reasons for reduced voltage starting.
e. Describe manual and automatic control for synchronous motors. (4 hours)
f.
Describe variable frequency drive and soft start controllers. (10 hours)
50%
2.
Describe Basic Programmable Logic Controllers.
a. Identify the basic components of fixed and modular Programmable Logic Controllers.
50%
9
Rev. September 2008
•
Processor unit
I / O section (Fixed and remote)
• Power supplies
• Programming devices
Describe the function(s) of the main components of a PLC.
• Processor unit
• I / O section
• Power supplies
• Programming devices
Program basic ladder logic using discrete inputs and outputs.
• Interpret basic ladder logic (Examine on and examine off contacts, Internal and
external outputs, Time on and time off timers, Count up and count down counters)
• Field and internal addressing
• Contact nesting
Describe troubleshooting methods for PLC controlled systems.
• LED indicators
• Search functions
• Forcing functions
• Voltmeter testing (Power supplies, I / O modules)
Describe safe programming and wiring practices for PLC controlled systems
• Master control relays
• Emergency stop stations
• Over current protection
• Bonding and shielding
• Processor security (e.g., key lock and software)
• Proper procedures for using force functions
• Program documentation
• Processor scan time
• Describe the functions and use of specialty Modules. (Analog input and output
modules, Communication modules, Numerical modules)
Describe the use of binary, BCD, octal and hexadecimal numbering systems with
respect to computerized equipment.
Describe memory storage systems, CPU and its main components as it pertains to
PLC's.
Apply basic principles/functions of programmable logic, including discrete
inputs/outputs, and counters and timers for control systems.
•
b.
c.
d.
e.
f.
g.
h.
***
10
Rev. September 2008
Industrial Electrician
C5
Unit:
Industrial Control Systems
Three
Level:
Duration: 30 hours
Theory:
Practical:
20 hours
10 hours
Overview:
This unit of instruction is designed to provide the Industrial Electrician apprentice with knowledge and
understanding of Industrial AC motors and generators.
Percent of
Unit Mark (%)
Objectives and Content:
1.
Describe three phase motors.
a. Squirrel cage induction motors
b. Wound rotor induction motors
c. Three phase synchronous motors
• Basic construction
• Terminal markings
• Reversing
• Applications
20%
2.
Describe operating characteristics of three phase.
a. Speed control
b. Speed regulation.
20%
3.
Describe single phase AC motors.
a. Split phase induction motors
b. Alternating current series motors
c. Shaded pole motors (Basic construction, Terminal markings, Reversing,
Applications)
40%
4.
Describe alternating current generators.
a. Types and construction details
b. Operating characteristics and losses
c. Paralleling requirements.
20%
***
11
Rev. September 2008
Industrial Electrician
C6 Preventive and Predictive Maintenance
Unit:
Three
Level:
Duration: 30 hours
Theory:
Practical:
20 hours
10 hours
Overview:
This unit of instruction is designed to provide the Industrial Electrician apprentice with knowledge and
understanding of preventive and predictive maintenance procedures. The Electrician apprentice will learn to
interpret, from test data and inspection, the mechanical and electrical condition of distribution feeder and branch
circuit conductors, motors and generators, transformers and batteries.
Percent of
Unit Mark (%)
Objectives and Content:
1.
Describe Insulation Testing.
b. Describe the proper testing procedures for making a megohmmeter test.
• Lockout / tag out procedures
• Equipment and personal protective grounding
• Maximum test voltages
• Meter lead connections
c. Discuss methods of trending the condition of insulating materials using a
meggohmmeter.
• Sixty second test
• Step voltage test
• Dielectric absorption test
• Polarization Indexing
• Temperature correction
d. Describe the minimum resistance IEEE standard for electrical systems and
apparatus.
• Low voltage wiring systems
• Motors and generators
• Transformers
• HV cables and equipment
e. Describe methods of testing and cleaning insulating liquids.
f.
Discuss the hazards associated with high potential testing methods.
g. Perform insulation tests on electrical systems and apparatus.
34%
2.
Maintenance and troubleshooting of stationary and rotating equipment.
a. Describe transformer maintenance.
33%
12
Rev. September 2008
•
Insulation Testing
Polarity Test
• Ratio Test
• Core loss Test
• Impedance Test
Describe testing and maintenance for AC and DC motors and:
• DC motors and generators
• AC motors and generators
• Rotors and stators
• Commutator and slip rings
• Brushes and brush rigging
• Bearings
•
c.
3.
Describe predictive maintenance practices.
a. Describe Advanced Maintenance Technologies
• Infrared Scanning
• Vibration Analysis
• Ultrasonic Analysis.
• Harmonic Analyzers
• Computer Managed Maintenance Systems (CMMS)
33%
***
13
Rev. September 2008