Industrial Electrics & Control Fundamentals Part 1

Duration:

5 days

Prerequisites:

Basic engineering background & awareness of electrically controlled & automated machinery.

Aims:

This course is primarily intended for mechanically biased maintenance personnel who need to Up-Skill so they can work alongside their electrical colleagues in the modern industrial workplace. Multi-skilled maintenance people can then work more safely around electrically operated systems & machinery, to support their electrical colleagues & to begin to take on & undertake specified electrical tasks without direct supervision.

Many modern industrial components are discussed along with the principle of operation & how to easily check for fault status. Safe Working Practices are covered along with 1st stage Proof of Competency in Safe Isolation Lock Off & Tag Out (LOTO) plus Resetting Trips & Overloads. To get full benefit from this training, the Part 2 should ideally be completed within 3-4 months.

Content MODULE 1 Hazards & Effects of Electricity The Effects of Voltage & Current, Shock, Burns, Arcing, Explosion & Fire What the Law says Regulations H&S at Work Act (HASAWA:1974) Management of H&S of Work (MHSW:1999) Provision & Use of Work Equipment Regulations (PUWER:1998) Electricity at Work Regulations (EAW:1989) Approved Codes of Practice (ACOPS) IEE Wiring Regulations 17th Edition (BS 7671: 2008) Electrical Equipment of Machines (BS EN60204-1:2006) H&S Executive Guidance Notes (GS38 & HSG 85) etc. H&S Executive Information Sheets

Risk Assessment The Five Steps Identifying the hazards Deciding who might be harmed & how Evaluating the risks & deciding on precautions Record your findings & implement them Reviewing your assessment & updating Importance of Personal Risk Assessment

Personal Protective Equipment (PPE) Eye protection Insulated Gloves Rubber Mats Footwear Anti-flash Clothing Signage & Barriers Insulated screening

Tools & Test Equipment Regulations & Standards Correct Tool for the Job Voltage Testers & Proving Units Multi-meters, Megger/ Insulation testing & Current Clamps Safe Isolation Lock Off & Tag Out (LOTO) Isolating, Locking Off & Checking for Dead Importance & Implications of this Responsibility Hazards & Safety Considerations Importance of Site Electrical H&S procedures

Industrial Electrics & Control Fundamentals Part 1

Industrial Electrics & Control Fundamentals Part 1

Ingress Protection (IP) (BS EN 60529) Typical examples of IP codes Hazards & Effects of Electricity Shock, Basic First aid Burns, how they are caused & can be avoided Fire, Type of extinguishers Dos & Don’ts of fire extinguishers Arcing/Flash & suitable PPE Protective clothing Explosions MODULE 2 Fundamentals of Electricity What is electricity & how it is used AC Theory AC Measurements DC Theory DC Measurements Practical exercises including 3 phase voltage & current measurements Electrical Distribution Relationship between Voltage, Current, Power & Resistance

Site Procedures & Permits to Work Sample Safe Working Practices Example Procedures Example Permits to Work

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Electrical Measurement How to safely use a typical Test instrument Resistance, Voltage, Current A series of practical exercises Continuity testing Safety of Test Leads Safety Fuses CAT ratings & importance RMS, Peak Current Clamps, AC & DC types Voltage Indicators & Proving Units Other useful test tools MODULE 3 Industrial Electrics The industrial Control Cabinet The importance of an electrical earth point Protective & Function earth Importance of good solid electrical connections Cable sizes & methods of connection Cable colour coding Common Electrical Components What are they, how do they function, how they fail, how to test?

Switches of various types & function, key features & how to test Emergency switch Stop Switch Safety Switch Isolator Switch Relay/ Timing Relays Safety Relays & Solid State Relays Contactors RCD & RCBO (Residual Current Devices) Fuses MCB (Miniature Circuit Breaker) MPCB (Motor Protective Circuit Breaker) Resetting Trips & Overloads Heaters, single & 3 phase types Compact Starters, combined contactor with Motor Protective Circuit Breaker etc Power Supplies AC & DC Transformers

The importance of Electrical Diagrams How to navigate electrical diagrams Circuit diagrams Wiring diagrams Wiring schedules Block diagrams Parts list Circuit symbols/ standards Some typical circuit elements (latching & control switching etc) MODULE 4 Industrial Motors An overview of AC, DC, Servo & in particular 3 phase motors How motors work, how they fail & how to test?

DC motors AC motors Servo motors Single & 3 phase motors Soft starts Direct On-line Starters (DOL) Exercises using the simulator Start-up current Run current Fault current Use of current clamp to safely monitor motor currents Megger/ Insulation testing Typical faults Forward & reverse switching of motors MODULE 5 Practical Building a basic motor control system & troubleshooting basics Handling motor control components Making good connections Using the correct tools Reading & interpreting the wiring diagram Matching components to the electrical diagram/ symbols Building & understanding the important circuit functions Testing the finished unit build Overview of Logical Troubleshooting Troubleshooting on Motor Simulator with group exercises The importance of gathering the facts of the fault symptom The importance of an accurate electrical diagram Practice Locking Off & Testing for DEAD Discussion of safer testing methods Types of test equipment Troubleshooting some basic motor control faults