Course Duration: 4–6 weeks (customizable)
Mode: Classroom + Hands-on Lab + Field Visits
Module 1: Introduction to Power Systems & Substations
Duration: 1 day
Objective: Understand the basics of power systems, substation role, and components.
Topics:
Overview of Power Systems (Generation, Transmission, Distribution)
Types of Substations: Indoor, Outdoor, GIS, AIS
Substation Components: Transformers, Busbars, Circuit Breakers, Disconnectors, Relays
Introduction to Protection & Control
Safety Procedures & PPE
Hands-on / Exercises:
Identify substation components on site or lab mock-up
Reading single line diagrams (SLD)
Module 2: Substation Equipment & Their Functions
Duration: 2 days
Objective: Deep dive into individual substation equipment.
Topics:
Transformers (types, ratings, oil, cooling)
Switchgear: Circuit Breakers (Vacuum, SF6, Oil), Disconnectors
Protection Relays: Overcurrent, Earth Fault, Differential
Instrument Transformers: CT, PT, Capacitor Voltage Transformers (CVT)
Earthing Systems & Lightning Arresters
Hands-on / Exercises:
Measuring insulation resistance of transformers
Checking relay settings
Transformer and CT/PT ratio calculation exercises
Module 3: Substation Design & Layout
Duration: 2 days
Objective: Learn to design substation layout for efficiency and safety.
Topics:
Single Line Diagram (SLD) Design
Busbar Arrangements: Single, Double, Ring, Breaker & Half
Cable Sizing & Routing
Earthing & Grounding Design Principles
Substation Layout Drawing & Site Planning
Hands-on / Exercises:
Draw a sample substation layout on AutoCAD / Visio
Busbar and feeder arrangement exercises
Earthing pit & conductor sizing calculations
Module 4: Substation Operation & Maintenance
Duration: 2 days
Objective: Practical knowledge for operating and maintaining substations.
Topics:
Switchgear Operation Procedures
Routine Maintenance of Transformers, Breakers, Relays
Fault Diagnosis & Troubleshooting
SCADA / Remote Monitoring Overview
Safety Procedures & Emergency Response
Hands-on / Exercises:
Perform mock breaker operation
Relay testing and fault simulation
Transformer oil & temperature check exercises
Module 5: Power Factor Improvement (PFI)
Duration: 2 days
Objective: Learn techniques to improve plant power factor and efficiency.
Topics:
Basics of Power Factor: Leading, Lagging, Unity
Causes of Low Power Factor
Capacitor Bank Types & Installation
Automatic Power Factor Correction (APFC) Panels
Power Factor Calculations & Billing Impact
Harmonics and Power Quality Issues
Hands-on / Exercises:
Power factor measurement using meters
Capacitor sizing and connection calculation
APFC panel operation demo
Module 6: Protection, Testing & Commissioning
Duration: 2 days
Objective: Learn protection philosophy, testing, and commissioning procedures.
Topics:
Protection Coordination & Settings
Relay Testing & Calibration
Circuit Breaker Testing
Substation Commissioning Procedures
Record Keeping & Reporting
Hands-on / Exercises:
Relay and breaker testing using secondary injection
Commissioning checklist exercises
Fault simulation exercises
Module 7: Field Visit & Practical Exposure
Duration: 1–2 days
Objective: Real-world exposure to substations and PFI systems.
Activities:
Visit a local 11kV/33kV/132kV substation
Observe transformer, breaker, relay operations
Apply PFI concepts to real loads
Module 8: Capstone Project / Assessment
Duration: 1–2 days
Objective: Test understanding of theory and practical skills.
Activities:
Design a mini substation (SLD, layout, PFI plan)
Simulate a fault and propose protection scheme
Final written and practical assessment
Additional Notes:
Total Duration: ~4–6 weeks (can be condensed)
Class Size: 10–15 engineers/technicians for hands-on efficiency
Prerequisites: Basic electrical engineering knowledge