Lesson 1Essential Hand and Power Tools for Rotating Machines and TransformersOutlines key hand and power tools for rotating machines and transformers, including how to choose, use properly, and maintain pullers, drivers, wrenches, drills, grinders, and torque tools to prevent damage and ensure solid repairs.
Screwdrivers, spanners, and torque wrenchesBearing pullers and fitting toolsElectric and pneumatic impact toolsDrills, taps, and thread repair kitsGrinders, sanders, and surface prep toolsTool storage, inspection, and maintenanceLesson 2Lockout/Tagout Procedures for Electrical and Mechanical EquipmentCovers lockout/tagout steps for electrical and mechanical gear, including isolation spots, lock kinds, tagging guidelines, group lockout, verification processes, and removal steps to stop unexpected power-ups.
Identifying isolation points and boundariesPersonal locks, hasps, and group boxesTag information and language requirementsVerification of zero energy stateShift change and group lock managementRestoring equipment to service safelyLesson 3Mechanical Measuring and Removal Tools: Micrometer, Dial Indicator, Bore Gauge, Bearing Puller, Hydraulic PressExplains mechanical measuring and removal tools for machines, like micrometers, dial indicators, bore gauges, bearing pullers, and hydraulic presses, focusing on precision, alignment, and safe force use.
Using micrometers and vernier calipersDial indicators for runout and alignmentBore gauges for housing and sleeve checksBearing puller selection and setupHydraulic press safety and load limitsRecording fits, clearances, and tolerancesLesson 4Lifting, Rigging and Handling Equipment for 7.5 kW Motors and 25 kVA TransformersDiscusses safe lifting, rigging, and handling of 7.5 kW motors and 25 kVA transformers, covering weight estimates, sling and shackle choices, gravity center control, and using hoists, jacks, and skates in tight workshops.
Estimating motor and transformer weightsSelecting slings, shackles, and eyeboltsCenter of gravity and balance controlUsing chain blocks, hoists, and jacksMoving loads with rollers, skates, and pry barsRigging inspection and rejection criteriaLesson 5Electrical Test Instruments: Multimeter, Clamp Meter, Insulation Tester, Hipot, Phase Rotation TesterIntroduces main electrical test tools for machine repair, explaining their functions, ranges, limits, and safe use of multimeters, clamp meters, insulation testers, hipot sets, and phase rotation testers on motors and transformers.
Multimeter functions and measurement rangesClamp meter use for load and inrush currentInsulation resistance tester test voltagesHipot tester purpose and risk controlsPhase rotation tester use on motor feedersInstrument category ratings and fusingLesson 6Isolation, Discharge and Grounding of Motor and Transformer CircuitsDetails isolation, discharge, and grounding of motor and transformer circuits, including switching orders, stored energy risks, discharge tools, temporary grounds, and confirming de-energized state before touching work.
Identifying all energy sources and feedersProving dead with approved testersCapacitor and winding discharge methodsApplying and removing temporary groundsGrounding of transformer tanks and coresSignage and barriers around isolated gearLesson 7Personal Protective Equipment for Electrical and Oil-Filled Transformer WorkDefines personal protective gear for electrical and oil-filled transformer tasks, including arc-rated clothes, gloves, face shields, breathing protection, and oil-resistant kit, plus selection by task and energy incident.
Arc-rated clothing categories and limitsInsulating gloves and leather protectorsFace shields, goggles, and hearing protectionRespirators for fumes and oil mistsOil-resistant footwear and apronsPPE inspection, testing, and replacementLesson 8Fire, Spill and Spill-Containment Precautions for Transformer OilOutlines fire, spill, and containment measures for transformer oil, covering fire types, extinguishers, bunding, absorbents, emergency steps, and reporting for leaks during upkeep and testing.
Fire classes and suitable extinguishersOil storage, bunds, and drip traysSpill kits, absorbents, and neutralizersImmediate actions for small and large spillsReporting, documentation, and cleanup recordsPreventive inspection of tanks and hosesLesson 9Personal and Environmental Controls for Varnish, Solvents and Insulating OilExplains safe handling of varnish, solvents, and insulating oil, covering ventilation, temperature management, spill prevention, labeling, and waste disposal to safeguard people, gear, and surroundings in repair work.
Ventilation and fume extraction setupFlash point, ignition sources, and hot workSolvent-compatible gloves and PPEStorage, labeling, and segregation rulesWaste collection and disposal proceduresMonitoring exposure and health symptomsLesson 10Calibration, Verification and Safe Use of Test InstrumentsEmphasizes calibration, verification, and safe handling of test instruments, including traceability, function checks, insulation tester verification, hipot safety locks, and recording calibration status before key measurements.
Calibration intervals and traceabilityField verification with check sourcesLabeling calibration status and due datesHandling damaged or suspect instrumentsSafe test lead selection and inspectionRecording measurement uncertainty notesLesson 11Documentation, Tagging, and Work Permit Procedures for Repairs and TestsCovers documentation, tagging, and work permit steps for repairs and tests, including job plans, risk checks, isolation tags, test logs, and sign-off needs for traceable, checkable maintenance tasks.
Job cards, repair orders, and scope definitionRisk assessments and method statementsTagging of removed parts and connectionsTest reports and measurement traceabilityPermit-to-work types and approvalsShift handover and record retention
