Lesson 1Essential Hand and Power Tools for Rotating Machines and TransformersThis lesson details essential hand and power tools for rotating machines and transformers, including selection, safe operation, and maintenance of pullers, drivers, spanners, drills, grinders, and torque tools to prevent damage and ensure quality repairs in workshop settings.
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 EquipmentThis lesson outlines lockout/tagout procedures for electrical and mechanical equipment, covering isolation points, lock types, tagging requirements, group lockout, verification processes, and removal steps to prevent accidental energisation during repairs.
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 PressThis lesson examines mechanical measuring and removal tools for machines, including micrometers, dial indicators, bore gauges, bearing pullers, and hydraulic presses. It stresses accuracy, alignment checks, and safe application of force to maintain precision in 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 TransformersThis lesson addresses safe lifting, rigging, and handling of 7.5 kW motors and 25 kVA transformers, including weight estimation, sling and shackle choices, centre-of-gravity management, and use of hoists, jacks, and skates in tight workshop spaces.
Estimating motor and transformer weightsSelecting slings, shackles, and eyeboltsCentre 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 TesterThis lesson introduces key electrical test instruments for machine repair, detailing functions, ranges, limitations, 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 CircuitsThis lesson explains isolation, discharge, and grounding for motor and transformer circuits, including switching sequences, stored energy risks, discharge tools, temporary grounds, and confirming de-energised status before handling.
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 WorkThis lesson defines personal protective equipment for electrical and oil-filled transformer tasks, including arc-rated clothing, gloves, face shields, respiratory gear, and oil-resistant items, selected based on task risks and incident energy levels.
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 OilThis lesson covers fire, spill, and containment measures for transformer oil, including fire classes, extinguishers, bunding, absorbents, emergency responses, and reporting for leaks during maintenance and testing in workshops.
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 OilThis lesson discusses safe handling of varnish, solvents, and insulating oil, focusing on ventilation, temperature management, spill prevention, labelling, and waste disposal to safeguard workers, equipment, and the environment during repairs.
Ventilation and fume extraction setupFlash point, ignition sources, and hot workSolvent-compatible gloves and PPEStorage, labelling, and segregation rulesWaste collection and disposal proceduresMonitoring exposure and health symptomsLesson 10Calibration, Verification, and Safe Use of Test InstrumentsThis lesson focuses on calibrating, verifying, and safely using test instruments, covering traceability, functional tests, insulation tester checks, hipot interlocks, and recording calibration status for accurate measurements.
Calibration intervals and traceabilityField verification with check sourcesLabelling 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 TestsThis lesson reviews documentation, tagging, and work permit processes for repairs and tests, including job plans, risk assessments, isolation tags, test records, and sign-offs for traceable and compliant 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
