reqf level: 5 learning hours credits: 5 sector: energy all · 2018-10-31 · correct insertion of...
TRANSCRIPT
H P O R M 5 0 1 -
ELECTRICAL ROTATING MACHINES WINDING / REWINDING
HPORM 501 Winds / Rewind Electrical Rotating Machines
REQF Level: 5 Learning hours
Credits: 5 50
Sector: Energy
Sub-sector: All
Issue date: June, 2016
Purpose statement
This particular module describes the skills, knowledge and attitude required to wind electrical rotating
machines. The electrician will be able to mount/ dismount a rotating machine, prepare the winding
diagram and wind accordingly. It applies to electricians working in maintenance.
Learning assumed to be in place
Mathematics
Basics of electricity
Electrical motors maintenance
Electrical generators maintenance
Elements of competence and performance criteria
Learning units describe the essential outcomes of a competence.
Performance criteria describe the required performance needed to demonstrate achievement
of the learning unit.
By the end of the module, the trainee will be able to:
Elements of competence Performance criteria
1. Collect data related to the machine to be wound /rewound.
1.1. Proper interpretation of the machine’s nameplate 1.2. Proper interpretation of electrical drawing of the
machine 1.3. Adequate calculations of machine parameters 1.4. Proper determination of winding configurations
2. Select tools, equipment and materials
2.1. Appropriate identification of tools, equipment and materials
2.2. Proper arrangement of tools, equipment and materials at working area
2.3. Proper identification of Personal Protective Equipment (PPE)
3. Wind / Rewind Electrical Rotating Machines
3.1. Proper dismantling of the machine 3.2. Proper preparation of winding diagram 3.3. Adequate lining of the slots with required type of
insulating materials 3.4. Accurate winding of the coil 3.5. Correct insertion of the coil in the slots 3.6. Proper insulation for windings 3.7. Proper reassembling of the machine
4. Test the wound / rewound machine
4.1. Proper testing of the machine faults 4.2. Proper checking of the machine characteristics on
load/no load 4.3. Proper reporting the work done
LU : Collect data related to the machine to be wound/rewound
1
Learning Outcomes:
1. Interpret machine’s nameplate 2. Interpret electrical drawing of the rotating machine 3. Calculate rotating machine parameters 4. Determine winding configurations
10 Hours
Learning Outcome1.1 : Interpret machine’s nameplate
Rotating machine nameplate elements Model and serial number Insulation Class Duty Cycle Rotating machine weight Input frequency Voltage rating KW ratings /HP rating Rated load current Power factor Speed (rpm) Type of connection Efficiency Operating voltage Number of phases IP indication Number of cycles Operating temperature
Interpretation of the rotating machine nameplate/ manual indication
o Brainstorming on the rotating machine’s nameplate indications
o Group discussion on the interpretation of the nameplate
o Physical demonstration of the nameplate’s data
o Practical exercises on the interpretation of the nameplate
o Documentary Research
- Books - Internet - Equipment
manuals - DC Rotating
machines - AC rotating
machines - Manuals
Resources Learning activities Content
Formative Assessment 1.1
Assessor may collect among the following evidences and make judgements on whether the
performance criterion has been achieved.
Types of evidence Portfolio assessment tools
Written evidence
Oral evidence
Multiple choice Open questions Ticking Interview
1.
Checklist Score
Yes No
Type of rotating machine
Speed
Frequency
Power factor
Power rating
Efficiency
Connection type
IP indication
Observation
Learning Outcome 1.2: Interpret electrical drawing of the rotating machine
Construction of the machines Single phase machine Three phase machine
Draw and interpret schematic diagram of rotating machine depending on
o Brainstorming on rotating machine diagrams and rotating machine winding diagrams
o Group discussion on
- Books - Internet - Manual - Hand-out
Resources Learning activities Content
Performance criterion
Proper interpretation of the machine’s nameplate
Number of slots Poles Pitches Speed Frequency
Draw and interpret winding diagrams of rotating machine: Lap winding Wave winding
rotating machine diagrams and rotating machine winding diagrams
o Physical demonstration of on rotating machine diagrams and rotating machine winding diagrams
o Practical exercises on rotating machine diagrams and rotating machine winding diagrams
o Documentary Research
Formative Assessment 1.2
Assessor may collect among the following evidences and make judgements on whether the
performance criterion has been achieved.
Types of evidence Portfolio assessment tools
Written evidence
Oral evidence
Multiple choice questions Open questions Ticking Expose
2.
Checklist Score
Yes No
Electrical symbols identification
Types of diagrams identification
Description of electrical drawings
Observation
Performance criterion
Proper interpretation of electrical drawing of the machine
Learning Outcome 1.3 : Calculate rotating machine parameters
Compute and analyse rotating machine parameters: Speed Emf Number of conductors Size of conductors Number of turns Number of slots Number of poles Number of coils Number of coils per phase Number of slots per pole Angle between slots Coil span Length of coil Electrical angle Winding pitch Frequency Voltage rating KW ratings Rated load current Power factor Efficiency Operating voltage Number of phases Number of cycles Winding pitch Mechanical and Electrical degree
o Brainstorming on rotating machine parameters
o Group discussion on rotating machine parameters
o Practical exercise on Determining rotating machine parameters
o Documentary Research
- Books - Internet - Manual - Hand-out
Formative Assessment 1.3
Assessor may collect among the following evidences and make judgements on whether the
performance criterion has been achieved.
Performance criterion
Adequate calculations of machine parameters
Resources Learning activities Content
Types of evidence Portfolio assessment tools
Written evidence
Oral evidence
Multiple choice questions Open questions Interview
3. 4.
Checklist Score
Yes No
Speed
Emf
Number of conductors
Size of conductors
Number of turns
Number of slots
Number of poles
Number of coils
Number of coils per phase
Number of slots per pole
Angle between slots
Coil span
Length of coil
Electrical angle
Winding pitch
Observation
Learning Outcome 1.4: Determine winding configurations
Armature winding for AC machines: Single phase winding Lap winding Wave winding Concentric winding Three phase winding Single layer winding Double layer winding
Armature winding for DC machines: Double layer simplex Lap winding
o Brainstorming on winding configurations of rotating machines
o Group discussion on winding configurations of rotating machines
o Physical demonstration of winding configuration
o Practical exercise on machine’s winding
- Books - Internet - Manual - Hand-out
Resources Learning activities Content
Double layer duplex Lap winding Double layer simplex wave winding
configurations o Documentary Research
Formative Assessment 1.4
Assessor may collect among the following evidences and make judgements on whether the
performance criterion has been achieved.
Types of evidence Portfolio assessment tools
Written evidence
Multiple choice questions Open questions Case study
Checklist Score
Yes No
Identification of armature winding for AC machines
Identification of armature winding for DC machines
Observation
Performance criterion
Proper determination of winding configurations
LU 2: Select tools, equipment and materials
2
Learning Outcomes:
1. Identify tools, equipment and materials 2. Arrange tools, equipment and materials 3. Identify personal protective equipment (PPE)
5 Hours
Learning Outcome 2.1: Identify tools, equipment and materials
Types of tools and equipment: Screw drivers Electrician’s knives Hammers Coil tamping tools Mallet Wire brushes Wire strippers Slotting files Connectors Cutting pliers Neon tester Crimping tool Multimeter Wattmeter Energy meter Nose Pliers Line tester Soldering iron Standard wire gauge Motorized coil winding machine Hand operated coil winding machine Bench work Soldering iron
o Brainstorming on types of tools, equipment and materials
o Group discussion on types of tools, equipment and materials
o Physical demonstration of types of tools, equipment and materials
o Practical exercises on selection of tools equipment and materials
o Documentary Research
- Books - Internet - Screw drivers - Electrician’s
knives - Hammers - Coil tamping tools - Mallet - Wire brushes - Wire strippers - Slotting files - Connectors - Cutting pliers - Neon tester - Crimping tool - Multimeter - Wattmeter - Energy meter - Nose Pliers - Vernier calliper - Line tester - Soldering iron - Standard wire
gauge
Resources Learning activities Content
Vernier calliper Electromechanical tool kit
Types of materials: Conductors Tin Insulation materials (varnish,
insulating papers)
- Motorized coil winding machine
- Hand operated coil winding machine
- Bench work - Soldering iron - Conductors - Tin - Insulation
materials - Electromechanical
tool kit
Formative Assessment 2.1
Assessor may collect among the following evidences and make judgements on whether the
performance criterion has been achieved.
Types of evidence Portfolio assessment tools
Written evidence
Oral evidence
Interview/ exposing Multiple choice questions Open questions
5.
Checklist Score
Yes No
Identification of tools
Identification of equipment
Identification of materials
Observation
Performance criterion
Appropriate identification of tools, equipment and materials
Learning Outcome 2.2: Arrange tools, equipment and materials
Selection of tools, equipment and materials needed for rotating machine winding/rewinding
Disposition of tools, equipment and materials according to their nature
o Brainstorming on arrangement of tools, equipment and materials into the working area
o Group discussion on arrangement of tools, equipment and materials into the working area
o Physical demonstration on disposition of tools, equipment and materials according to their nature
o Practical exercises on selection of tools, equipment and materials needed for winding/rewinding of rotating machines
o Documentary Research
- Books - Internet - Screw drivers - Electrician’s knives - Hammers - Coil tamping tools - Mallet - Wire brushes - Wire strippers - Slotting files - Connectors - Cutting pliers - Neon tester - Crimping tool - Multimeter - Wattmeter - Energy meter - Nose Pliers - Line tester - Soldering iron - Standard wire
gauge - Motorized coil
winding machine - Hand operated coil
winding machine - Bench work - Soldering iron - Conductors - Tin - Insulation
materials - Electromechanical
tool kit
Formative Assessment 2.2
Performance criterion
Proper arrangement of tools, equipment and materials into the working area
Resources Learning activities Content
Assessor may collect among the following evidences and make judgements on whether the
performance criterion has been achieved.
Types of evidence Portfolio assessment tools
Performance evidence
Oral evidence
Expose
Task: Select, arrange tools, equipment and materials according to
their properties or use
Observation checklist
Checklist Score
Yes No
Identification of tools, equipment and materials used in winding
Handling precautions of tools, equipment and materials
Tools, equipment and materials arrangement techniques
Observation
Learning Outcome 2.3: Identify personal protective equipment (PPE)
Safety equipment used for rotating machines winding/rewinding Overcoat and overall Gloves Safety shoes Helmet Goggles Nose protection mask
o Brainstorming on Safety equipment
o Group discussion on Safety equipment
o Physical demonstration of Safety equipment
o Practical exercises on the use of Safety equipment
o Documentary Research
- Books - Internet - Overcoat - Gloves - Safety shoes - Helmet - Goggles - Nose protection
mask
Formative Assessment 2.3
Performance criterion
Proper identification of personal protective equipment (PPE)
Resources Learning activities Content
Assessor may collect among the following evidences and make judgements on whether the
performance criterion has been achieved.
Types of evidence Portfolio assessment tools
Written evidence
Oral evidence
Performance evidence
Multiple choice questions Open questions Interview/exposing Task: Select PPE according the working environment Observation checklist
Checklist Score
Yes No
Overcoat and overall
Gloves
Safety shoes
Helmet
Goggles
Nose protection mask
Handling of PPE
Observation
LU 3: Wind / Rewind Electrical Rotating Machines
3
Learning Outcomes:
6. Dismantle the machine 7. Prepare winding/rewinding diagram 8. Execute the work
9.
30 Hours
Learning Outcome 3.1: Dismantle the machine
Major machine’s parts: Electrical parts Mechanical parts
Assembling and disassembling of the machine Tools Procedures
o Brainstorming on major parts of the rotating machine, assembling and disassembling of rotating electrical machines
o Group discussion on major parts of the rotating machine, assembling and disassembling of rotating machines
o Physical demonstration of major parts of the rotating machine, assembling and disassembling of rotating machines
o Practical exercises on assembling and disassembling of rotating machines
o Documentary Research o Video show
- Books - Internet - Screw drivers - Electrician’s
knives - Hammers - Coil tamping tools - Mallet - Wire brushes - Wire strippers - Slotting files - Connectors - Cutting pliers - Neon tester - Crimping tool - Multimeter - Wattmeter - Energy meter - Nose Pliers - Line tester - Soldering iron - Standard wire
gauge - Motorized coil
Resources Learning activities Content
winding machine - Hand operated
coil winding machine
- Bench work - Soldering iron - Conductors - Rotor - Tin - Lamination paper - Insulation
materials - Electromechanical
tool kit
Formative Assessment 3.1
Assessor may collect among the following evidences and make judgements on whether the
performance criterion has been achieved.
Types of evidence Portfolio assessment tools
Written evidence
Oral evidence
Performance evidence
Multiple choice questions Open questions Interview/exposing Task: Disassembling the machine Assembling the machine Observation checklist
Checklist Score
Yes No
Identification of electrical parts of the machine
Identification of mechanical parts of the machine
Tools to be used for assembling/disassembling the machine
Procedures for disassembling and reassembling the machines
Observation
Performance criterion
Proper dismantling of the machine
Learning Outcome 3.2: Prepare winding/rewinding diagram
Procedure for development of winding diagram of rotating machines
Draw the wiring diagram
Interpret the winding scheme of the machine to be rewound
o Brainstorming on winding/rewinding diagram of rotating machines
o Group discussion on winding/rewinding diagram of rotating machines
o Physical demonstration of winding/rewinding diagram of rotating machines
o Practical exercises on winding/rewinding diagram of rotating machines
o Documentary Research
- Books - Internet - Manual - Winding diagram
Formative Assessment 3.2
Assessor may collect among the following evidences and make judgements on whether the
performance criterion has been achieved.
Types of evidence Portfolio assessment tools
Written evidence
Oral evidence
Performance evidence
Product evidence
Multiple choice questions Open questions Interview/exposing Task: Draw the winding diagram for a given machine Observation checklist
Checklist Score
Yes No
Identification of Winding scheme used
Identification of Pole pitch
Identification of coil pitch
Performance criterion
Proper preparation of winding/rewinding diagram
Resources Learning activities Content
Indication of the direction of poles
Interpretation of the winding diagram of the machine to be rewound
Appearance of drawing
Observation
Learning Outcome 3.3: Execute the work
Winding methods Hand winding Formed coil winding
Steps for winding/rewinding of rotating machines: Line the slots with the required type
of insulating material Winding the coil according to the
winding diagram Insert the coils to the slots Insulate the winding Reassemble the machine
o Brainstorming on winding steps and methods of rotating machines
o Group discussion on winding steps and methods of rotating machines
o Physical demonstration of winding steps and methods of rotating machines
o Practical exercises on winding steps and methods of rotating machines
o Documentary Research o Video show
- Books - Internet - Manual - Rotating machine - Windings - Hand-out notes
Formative Assessment 3.3
Assessor may collect among the following evidences and make judgements on whether the
performance criterion has been achieved.
Types of evidence Portfolio assessment tools
Written evidence
Oral evidence
Performance evidence
Product evidence
Multiple choice questions Open questions Interview/exposing Task: Wind/rewind the machine Observation checklist
Performance criterion
Proper winding/rewinding the rotating machine
Resources Learning activities Content
10.
Checklist Score
Yes No
Coil winding
Coil insertion into the slot
Insulation of the windings
Use of Machine assemble/ reassemble techniques
Observation
LU 4: Test the wound / rewound machine
4
Learning Outcomes:
1. Test the machine
2. Report the work done
5 Hours
Learning Outcome 4.1: Test the machine
General faults in rotating machine
Testing the machine’s electrical parts Winding states (short-circuit, open-
circuit) Brush wearing, springs tension,
excitation)
Testing the machine’s mechanical parts Bearings wear Load coupling on Shaft
Belt and conveyors alignment
Test machine characteristics on load/no load
o Brainstorming on general faults occurring in rotating machine
o Group discussion on how to test machines conditions
o Physical demonstration on testing of the machine faults
o Practical exercises on testing of the machine faults
o Documentary Research o Video show
- Books - Internet - Service manuals - Hand-out notes - Motors - Multimeters - Tachometer - Electromechanical
toolbox
Formative Assessment 4.1
Performance criterion
Proper testing of the machine
Resources Learning activities Content
Assessor may collect among the following evidences and make judgements on whether the
performance criterion has been achieved.
Types of evidence Portfolio assessment tools
Written evidence
Oral evidence
Performance evidence
Multiple choice questions Open questions Interview/exposing Recording Task: Perform the test Observation checklist
Checklist Score
Yes No
Use of measurement instrument
Testing the machine on load
Testing the machine on no load
Testing of windings continuity
Testing of the Brush wearing
Observation
Learning Outcome 4.2: Report the work done
Elaborate the work report Report format Cost estimation
Keeping records of current machine state
o Brainstorming on how to prepare the report
o Group discussion on taking records
o Practical exercises on billing the work
o Documentary Research
- Books - Internet - Service manuals - Hand-out notes
Formative Assessment 4.2
Performance criterion
Proper reporting of the work
Resources Learning activities Content
Assessor may collect among the following evidences and make judgements on whether the
performance criterion has been achieved.
Types of evidence Portfolio assessment tools
Written evidence
Multiple choice questions
Open questions
Checklist Score
Yes No
Use of the report format
Observation
Summative Assessment
Integrated situation Resources
A Technician of Bralirwa Ltd located in RUBAVU district, NYAMYUMBA sector, started a 3 phase induction motor. After few minutes, its windings burnt because of overload. As an electrician in Bralirwa, you are required to rewind that induction motor within 6 hours. Information related to the motor are on the nameplate.
Assesment Criterion 1: Quality of Process
Checklist Score
Yes No
Indicator: Motor’s nameplate is correctly interpreted
Insulating class
Input frequency
Voltage rating
Type of connection
Power rating
Speed
Number of phases
Operating temperature
Indicator: Tools, equipment and materials are well identified Opening tools
Cutting tools
Measurement instruments
Indicator: Tools, equipment and materials are well arranged into the working area
Disposition according to the type
Disposition according to the use
Indicator: Personal protective equipment (PPE) are well identified
Overcoat
Gloves
Safety shoes
Nose protection mask
Indicator: The motor is correctly dismantled
Procedures for disassembling the motor
Indicator: Winding configurations are well determined Identification of Type of winding
Indicator: Machine parameters are well determined Speed
Length of coil
Number of poles
Number of turns
Number of slots
Number of conductors
Winding pitch
Indicator: Electrical drawing of the motor is correctly prepared
Winding diagram
Indicator: The motor is correctly rewound
The slots are lined with the required type of insulating material
The coil is wound
The coil is inserted in the slots
Windings are connected
Windings are insulated
Motor is reassembled
Indicator: The wound motor is correctly tested
Use of measurement instrument
Testing of windings continuity
Testing of the Brush wearing
No load characteristics of the machine are tested
Load characteristics of the machine are tested
Indicator: The work is correctly reported
Format
Report content
Observation
Assesment Criterion 2: Quality of product
Checklist Score
Yes No
Indicator: The motor is well running
Rated power
Rated speed
No overheating
No abnormal noise
Indicator: The condition of the motor is preserved
No scratch
No damaged parts
Indicator: Motor is well fixed
Steadiness
Fitness
Tightness
Observation
Assesment Criterion 3: Relevance
Checklist Score
Yes No
Indicator: Time is respected
Work done within required time (6h)
Indicator: Materials and equipment are well used
No wasted material
Observation
Perfection
Checklist Score
Yes No
Indicator: Innovation
Creativity
Observation
Reference books:
1. Electrical machines by S K Bhattacharya
2. Electrical machines and appliances theory by Tamil Nadu Textbook Corporation