Lesson 1Essential Hand and Power Tools for Rotating Machines and TransformersDescribes key hand and power tools for rotating machines and transformers, including how to choose, use properly, and maintain pullers, drivers, spanners, drills, grinders, and torque tools to prevent damage and ensure solid repairs in Nigerian workshops.
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, covering isolation spots, lock kinds, tagging rules, group lockout, verification processes, and removal guidelines to stop sudden power-up in busy repair shops.
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 PressDetails 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 to avoid mishaps during repairs.
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 weight guesses, sling and shackle choices, gravity center control, and using hoists, jacks, and skates in tight Nigerian 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 kits, and phase rotation testers on motors and transformers in local contexts.
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 isolating, discharging, and grounding motor and transformer circuits, detailing switch sequences, stored energy risks, discharge tools, temporary grounds, and confirming de-energized state before touching in Nigerian repair environments.
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 jobs, covering arc-rated clothes, gloves, face shields, breathing protection, and oil-proof gear, plus choosing based on task and energy risks in local workshops.
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 measures for transformer oil, including fire types, extinguishers, bunding, absorbents, emergency steps, and reporting for leaks during maintenance and testing in Nigerian facilities.
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, addressing ventilation, temperature checks, spill prevention, labeling, and waste management to safeguard workers, gear, and surroundings during repairs in local shops.
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, verifying, and safely using test instruments, including traceability, function checks, insulation tester verification, hipot safety locks, and recording calibration status before key measurements in workshops.
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-offs to ensure trackable, auditable maintenance in Nigerian operations.
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
