Lesson 1Essential Hand and Power Tools for Rotating Machines and TransformersDescribes key hand and power tools for rotating machines and transformers, covering choice, proper use, and maintenance of pullers, drivers, wrenches, drills, grinders, and torque tools to prevent damage and ensure dependable repairs in local 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 EquipmentExplains lockout/tagout procedures for electrical and mechanical equipment, including isolation points, lock types, tagging rules, group lockout, verification steps, and removal protocols to prevent unexpected energisation in Zambian facilities.
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 used on machines, including micrometers, dial indicators, bore gauges, bearing pullers, and hydraulic presses, with focus on accuracy, alignment, and safe force application in practical Zambian 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 estimation, sling and shackle selection, centre-of-gravity control, and use of hoists, jacks, and skates in confined Zambian workshops.
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 TesterIntroduces key electrical test instruments used in machine repair, explaining functions, ranges, limitations, and safe application of multimeters, clamp meters, insulation testers, hipot sets, and phase rotation testers on motors and transformers in Zambia.
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 isolation, discharge, and grounding of motor and transformer circuits, detailing switching sequences, stored energy hazards, discharge tools, temporary grounds, and verification of de-energised status before any contact work in local setups.
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 equipment for electrical and oil-filled transformer work, covering arc-rated clothing, gloves, face shields, respiratory protection, and oil-resistant gear, plus selection based on task and incident energy in Zambian conditions.
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 precautions for transformer oil, including fire classes, extinguishers, bunding, absorbents, emergency response steps, and reporting requirements for leaks during maintenance and testing in Zambian sites.
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, labelling, and waste handling to protect personnel, equipment, and the environment during repair operations in Zambia.
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 InstrumentsFocuses on calibration, verification, and safe use of test instruments, including traceability, functional checks, insulation tester verification, hipot safety interlocks, and documentation of calibration status before critical measurements in local workshops.
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 TestsCovers documentation, tagging, and work permit procedures for repairs and tests, including job plans, risk assessments, isolation tags, test records, and sign-off requirements to ensure traceable, auditable maintenance activities in Zambian 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
