Lesson 1Essential hand and power tools for rotating machines and transformersTalks about key hand and power tools for rotating machines and transformers, covering picking them, right use, and care for pullers, drivers, wrenches, drills, grinders, and torque tools to stop damage and make sure repairs last.
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 equipmentExplains lockout/tagout steps for electrical and mechanical gear, including cut-off points, lock kinds, tagging rules, group lockout, check steps, and removal ways to stop sudden power coming back.
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 pressGoes into mechanical measuring and removal tools used on machines, like micrometers, dial indicators, bore gauges, bearing pullers, and hydraulic presses, stressing accuracy, lining up, 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 transformersCovers safe lifting, rigging, and handling of 7.5 kW motors and 25 kVA transformers, including guessing weight, picking slings and shackles, center-of-gravity 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 used in machine repair, explaining what they do, 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 circuitsExplains cutting off, discharging, and grounding of motor and transformer circuits, detailing switch sequences, stored energy dangers, discharge tools, temporary grounds, and checking 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 work, covering arc-rated clothes, gloves, face shields, breathing protection, and oil-resistant gear, plus picking based on task and incident energy.
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 oilDetails fire, spill, and containment steps for transformer oil, including fire types, extinguishers, bunding, absorbents, emergency response steps, and reporting for leaks during maintenance 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 use of varnish, solvents, and insulating oil, addressing ventilation, temperature control, spill prevention, labeling, and waste handling to protect people, gear, and the environment during 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 instrumentsFocuses on calibrating, checking, and safe use of test tools, including traceability, functional 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 records, and sign-off needs to ensure traceable, checkable maintenance activities.
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
