Learning Objectives

Upon successful completion of this course, participants will be able to:

1. Fundamentals of Electrical Component Replacement

• Understand the types and functions of electrical components.
• Identify common reasons for component failure (wear, overheating, mechanical damage).
• Recognize signs of faulty electrical components before replacement.

2. Safety Procedures for Electrical Component Removal and Replacement

• Follow electrical safety standards (NFPA 70E, OSHA, IEC 60204-1, NEC).
• Implement Lockout/Tagout (LOTO) procedures before replacing components.
• Use personal protective equipment (PPE) and arc flash protection.
• Identify hazards such as shock risks, short circuits, and fire hazards.

3. Common Electrical Components and Their Replacement Procedures

• Circuit Breakers & Fuses
• Identify overloaded, shorted, or faulty breakers and fuses.
• Properly remove and install new components with correct ratings.
• Contactors & Relays
• Recognize signs of wear such as pitted or burned contacts.
• Correctly wire new relays and test coil activation.
• Motors & Starters
• Safely disconnect motors and replace starters.
• Verify correct phase connections and torque settings.
• Transformers & Power Supplies
• Replace small control transformers and power converters.
• Ensure proper grounding and insulation checks.
• Switches, Sensors, and Indicators
• Diagnose faulty switches and limit sensors.
• Replace worn-out pushbuttons and selector switches.

4. Tools and Techniques for Component Removal & Installation

• Use multimeters, clamp meters, and insulation testers for diagnostics.
• Apply torque settings and proper fasteners for secure connections.
• Properly strip and crimp wires to prevent loose or unsafe terminations.
• Follow correct cable management practices for safety and efficiency.

5. Testing and Verification After Replacement

• Perform continuity, insulation resistance, and function testing.
• Verify correct voltage, current, and load conditions.
• Check for proper grounding and bonding after installation.

6. Documentation and Compliance

• Maintain replacement logs and maintenance records.
• Ensure compliance with electrical codes and manufacturer specifications.
• Follow procedures for re-certification and testing approvals.

7. Troubleshooting and Failure Analysis

• Identify root causes of recurring failures.
• Analyze environmental factors, power surges, and operational stresses affecting component lifespan.
• Implement preventive maintenance to reduce future failures.

8. Case Studies and Practical Applications

• Participate in hands-on component replacement exercises.
• Analyze real-world case studies of electrical failures and solutions.
• Develop a replacement plan for a facility or industrial system.

Target Audience

• Electrical maintenance technicians
• Industrial electricians
• Facility and plant operators
• Electrical engineers and supervisors
• Safety and compliance officers