By the end of this chapter, you will be able to:
Mastering these skills ensures you can work confidently and safely on electrical machines, which is essential for quality and reliability in the electrical trade.
Type: Individual
| Tools & Equipment | Materials |
|---|---|
| Electrician Toolkit (Screwdrivers, Pliers, Adjustable Spanner, Hammer) | 3-phase Induction Motor (415 V, 50 Hz) |
| Set of Allen Keys (Metric) | Lint-free Cleaning Cloth |
| Bearing Puller | Waste Bin |
| Insulation Resistance Tester (Megger) | Personal Protective Equipment (Safety boots, Overalls, Gloves, Safety goggles) |
| Cleaning Brush | |
| Tool Storage Tray |
| S/N | Item | Quantity |
|---|---|---|
| 1 | 3-phase Induction Motor (415 V, 50 Hz) | 1 Pc per Candidate |
| 2 | Electrician Toolkit (Screwdrivers, Pliers, Adjustable Spanner, Hammer) | 1 Set per Candidate |
| 3 | Set of Allen Keys (Metric) | 1 Set per Candidate |
| 4 | Bearing Puller | 1 Pc per Candidate |
| 5 | Insulation Resistance Tester (Megger) | 1 Pc per Candidate |
| 6 | Cleaning Brush | 1 Pc per Candidate |
| 7 | Lint-free Cleaning Cloth | 2 Pcs per Candidate |
| 8 | Tool Storage Tray | 1 Pc per Candidate |
| 9 | Waste Bin | 1 Pc per 2 Candidates |
| 10 | Personal Protective Equipment (Safety boots, Overalls, Gloves, Safety goggles) | 1 Set per Candidate |
| Items to be Evaluated | Marks Available | Marks Obtained | Comments |
|---|---|---|---|
| TASK 1: Workspace Preparation and Tool Selection | |||
| Wore all appropriate personal protective equipment (safety boots, overalls, gloves, goggles) before commencing work (Award 2 marks for full compliance; 0 for any missing item) | 2 | ||
| Ensured the working area was clean and free from oil, debris, and unnecessary materials prior to tool arrangement (Award 2 marks if area is properly cleaned; 0 if not) | 2 | ||
| Arranged all required tools on the tool storage tray in an orderly, accessible manner (Award 2 marks for correct and neat arrangement; 0 if disorganized or incomplete) | 2 | ||
| Checked the physical condition and functionality of each tool (including insulation tester, bearing puller, and hand tools) (Award 2 marks if all tools are checked and in good condition; 0 if any tool is unchecked or defective) | 2 | ||
| Placed the waste bin within reach and prepared lint-free cloths and cleaning brush for use (Award 1 mark if both items are ready; 0 if either is missing) | 1 | ||
| Identified and selected the correct size of Allen keys and spanners for motor fasteners (Award 2 marks for correct selection; 0 for incorrect or missing selection) | 2 | ||
| Verified that the insulation resistance tester is functioning and set to appropriate range for 415V equipment (Award 2 marks for correct verification and setting; 0 if not done or incorrect) | 2 | ||
| Demonstrated safe handling of all tools and equipment during preparation (no dropping or unsafe placement) (Award 2 marks for safe handling throughout; 0 if unsafe practices observed) | 2 | ||
| Sub-Total | 15 | ||
| TASK 2: Cleanliness and Tool Storage Post-Preparation | |||
| Cleaned tools with lint-free cloth after checks and before storage (Award 2 marks if all tools are cleaned; 0 if any tool is left dirty) | 2 | ||
| Returned all tools to the tool storage tray after use (Award 1 mark if all tools are returned; 0 if any tool is missing) | 1 | ||
| Disposed of any waste (cloth, debris) into the waste bin after preparation (Award 1 mark for proper disposal; 0 if not done) | 1 | ||
| Left the working area clean and organized upon completion of preparation (Award 1 mark if area is clean; 0 if not) | 1 | ||
| Sub-Total | 5 | ||
| PRODUCT CHECKLIST | |||
| All required tools and materials for disassembly of a 3-phase induction motor (frame length 400mm, diameter 250mm) are present, clean, and in good working order as verified by the assessor (Award 5 marks if all items are correct and functional; 0 if any are missing or defective) | 5 | ||
| Workspace is free from clutter and all tools are stored neatly in the tool tray (Award 2 marks if workspace is completely neat and organized; 0 if not) | 2 | ||
| Sub-Total | 7 | ||
| GRAND TOTAL | 27 | ||
Type: Individual
| Tools & Equipment | Materials |
|---|---|
| Open-end spanner set | 3-phase Induction Motor |
| Socket set | Dust coat/overall |
| Screwdriver set | Safety boots |
| Soft-faced hammer | Safety goggles |
| Bearing puller | Hand gloves |
| Long nose pliers | |
| Circlip pliers | |
| Marker pen | |
| Clean rags | |
| Drip tray |
| S/N | Item | Quantity |
|---|---|---|
| 1 | 3-phase Induction Motor (Frame size 132M, 415V, 50Hz, 7.5kW) | 1 Pc per Candidate |
| 2 | Open-end spanner set (8mm-19mm) | 1 Set per Candidate |
| 3 | Socket set (8mm-19mm) | 1 Set per Candidate |
| 4 | Screwdriver set (flat and Phillips) | 1 Set per Candidate |
| 5 | Soft-faced hammer | 1 Pc per Candidate |
| 6 | Bearing puller (2-jaw, 100mm) | 1 Pc per Candidate |
| 7 | Long nose pliers | 1 Pc per Candidate |
| 8 | Circlip pliers | 1 Pc per Candidate |
| 9 | Marker pen | 1 Pc per Candidate |
| 10 | Clean rags | 2 Pcs per Candidate |
| 11 | Drip tray | 1 Pc per Candidate |
| 12 | Dust coat/overall | 1 Pc per Candidate |
| 13 | Safety boots | 1 Pair per Candidate |
| 14 | Safety goggles | 1 Pc per Candidate |
| 15 | Hand gloves | 1 Pair per Candidate |
| Items to be Evaluated | Marks Available | Marks Obtained | Comments |
|---|---|---|---|
| TASK 1: Disassembly Process | |||
| Wore complete personal protective equipment (dust coat/overall, safety boots, gloves, goggles) (Award 2 marks for all correct PPE worn, 0 if incomplete) | 2 | ||
| Ensured clean and organized working area before starting (Award 2 marks for clean and organized area, 0 if not) | 2 | ||
| Correctly identified and assembled all required tools and materials (Award 2 marks for correct identification and assembly, 0 if not) | 2 | ||
| Isolated motor from power supply and confirmed safe to work (Award 2 marks for proper isolation and confirmation, 0 if not) | 2 | ||
| Marked orientation of end shields and terminal box with marker for proper reassembly (Award 2 marks for correct and visible marking, 0 if not) | 2 | ||
| Removed terminal box cover and disconnected motor leads correctly (Award 2 marks for correct removal and disconnection, 0 if not) | 2 | ||
| Loosened and removed all fastening bolts using correct tools (Award 2 marks for correct use of tools and method, 0 if not) | 2 | ||
| Removed end shields with care using soft-faced hammer and bearing puller as appropriate (Award 2 marks for careful removal without damage, 0 if not) | 2 | ||
| Extracted rotor from stator without damaging windings (Award 2 marks for correct extraction, 0 if windings are damaged) | 2 | ||
| Removed bearings and circlips using bearing puller and circlip pliers (Award 2 marks for correct and safe removal, 0 if not) | 2 | ||
| Placed all removed parts (stator, rotor, end shields, bearings, fasteners) in drip tray and wiped clean with rags (Award 2 marks for all parts cleaned and organized, 0 if not) | 2 | ||
| Maintained good housekeeping throughout the process (Award 2 marks for tidy workspace throughout, 0 if not) | 2 | ||
| Sub-Total | 24 | ||
| PRODUCT CHECKLIST | |||
| All motor parts (stator, rotor, both end shields, bearings, fasteners, terminal box) present and undamaged (Award 4 marks if all parts present and undamaged, 0 if any missing/damaged) | 4 | ||
| Parts arranged in logical order as per disassembly sheet (Award 2 marks for correct arrangement, 0 if not) | 2 | ||
| No visible damage to stator and rotor laminations or windings (Award 2 marks if no damage, 0 if any damage present) | 2 | ||
| All fasteners and small parts accounted for and grouped (Award 2 marks if all accounted for, 0 if any missing) | 2 | ||
| Work area left clean and free of debris (Award 2 marks for clean area, 0 if not) | 2 | ||
| Sub-Total | 12 | ||
| GRAND TOTAL | 36 | ||
At the start of this chapter we promised you would be able to:
Tick each one you can genuinely do.
So, are you there yet?
You're competent when you can confidently do 50% or more of what this chapter promised.
Sign in to record how you're doing.