318

Maintain HV power system transformers
& instrument transformers (UETTRDSB05A)
SA
M
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Certificate IV in ESI Substation Resources (UET40206)

Learner Guide
State Training Services
TABLE OF CONTENTS
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Using this Learner Resource..........................................................................................5

Use as Refresher Training .......................................................................................5
Mapping to Training Package....................................................................................5
Learning Outcomes....................................................................................................6
Assessment.................................................................................................................7
Recognition of Prior Learning/Current Competence.................................................7
References..................................................................................................................8
Introduction....................................................................................................................9
Types of Devices Covered in this Module.................................................................9
Types of Maintenance Testing Covered in this Module............................................9
Importance of this Learning Module .........................................................................9
Transformer Theory A Review.................................................................................11
Why use Transformers.............................................................................................11
Construction of Transformers ..................................................................................12
Transformer Theory .................................................................................................12
Three Phase Transformers .......................................................................................28
Parallel Operation of Three-Phase Transformers ....................................................33
Transformer Cooling................................................................................................34
Gas Pressure Relay (Buchholz Relay) .....................................................................38
Explosion Vent.........................................................................................................39
Bushings...................................................................................................................40
Autotransformer.......................................................................................................41
Substation Auxiliary Transformer ...........................................................................41
Reactors....................................................................................................................42
Instrument Transformers..............................................................................................43
Voltage (Potential) Transformers ............................................................................43
Current Transformers...............................................................................................44
Tapchangers .............................................................................................................46
Risk Assessment ..........................................................................................................49
Transformer Oil Testing ..............................................................................................49
Oil Sampling ............................................................................................................49
Dealing with Contaminated Oil ...............................................................................57
Transformer Testing.....................................................................................................59
Cleaning Prior to Testing .........................................................................................59
Insulation Failure .....................................................................................................59
Insulation Resistance Tests ......................................................................................61
Winding Resistance Measurement...........................................................................65
Dielectric Dissipation Factor Tests..........................................................................68
Turns Ratio Checks..................................................................................................71
Frequency Response Analysis .................................................................................72
Recovery Voltage Measurement..............................................................................74
Low Voltage Excitation Check................................................................................77
Conclusion ...................................................................................................................78
Appendix One: Example of a Substation Maintenance Instruction for Power
Transformers. ...............................................................................................................79
Appendix Two: Glossary of Transformer Terms.........................................................99
Appendix Three: Temperature Correction Tables .....................................................103
Appendix Four: Three-phase Transformer Connections ...........................................104
Maintain HV power system transformers Learner Guide
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Self Assessment Questions ........................................................................................106

Learning Tasks and Practical Exercises.....................................................................110
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NSW DET 2009
Introduction
One of the most important and expensive items of capital equipment in a substation is
a power transformer. If maintained correctly they will give very long service life. It
is not uncommon to encounter units which have been in service for greater than 40
years. They are used to transform voltages either up or down as required for
distribution between substations and customers.
Apart from power transformers there are instrument transformers used in the
substation environment. These devices are used to monitor the power levels, or are
used for protection purposes to trigger circuit breakers and other current breaking
devices.
There are also other inductive coil devices that resemble transformers called
reactors. These are used to limit surge currents, and have maintenance regimes
similar to transformers.
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This module will review the theory of transformers, especially as used in high voltage
power applications. It will then explain the maintenance and testing requirements for
these devices.
Types of Devices Covered in this Module
The following high voltage devices are described and their maintenance requirements
reviewed:
Power transformers
Voltage (potential) transformers
Current transformers
Reactors (series and shunt)
Auxiliary Transformers
Types of Maintenance Testing Covered in this Module

Insulation resistance tests
Dielectric dissipation factor tests
Low voltage excitation tests
Frequency response analysis
Recovery voltage measurements
Ratio checks
Winding resistance checks
Oil sampling
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Importance of this Learning Module

Transformers are probably the single most valuable asset located in a transformer
substation. When maintained correctly they will remain serviceable for many
decades. It is the job of a substation operator to understand the working principles of
power and instrument transformers and the subsequent maintenance and testing
procedures that are required to keep them serviceable. Poorly maintained power
transformers can result in catastrophic failure of the unit, with the potential to cause
major damage to other substation plant equipment and network outages.
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NSW DET 2009
Typical Tasks Required

Included in the Appendix of this Learner Guide is a Maintenance Instruction from an
electrical supply utility. This lists the typical types of tasks that substation operators
are required to perform when maintaining power transformers. (This document
should be regarded as indicative only as all electrical supply utilities will have their
own version of this Work Procedure as applicable to that organisation. The
highlights in the text have no significance and can be disregarded.)
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Student Exercise
Obtain a listing of the types of maintenance tasks (work procedures) performed
upon power and instrument transformers in your organisation.
Obtain copies of a number of these work procedures and review the steps involved
to perform the task.
Attach copies to this Learner Guide of some of the appropriate organisational
work procedures in your organisation.
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NSW DET 2009
Transformer Theory A Review

Transformers provide a simple means of changing an alternating voltage (AC) from
one value to another. (Note: A transformer cannot transform direct current voltages.
Where you may see examples that appear to do this it is actually achieved by
converting the DC voltage to an AC waveform first, and then applying it to the
primary side of a transformer. It may then be rectified back to a DC voltage if
required.)
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A transformer may receive energy at a lower voltage and deliver it at higher voltage
(step up transformer) or it may receive energy at higher voltage and deliver it at a
lower voltage (step down transformer). Any transformer may operate as a step-up or
step-down transformer depending on the requirements of the system, the supply
voltage available and the desired output voltage.
High
Voltage
Low
Voltage
Low
Voltage
High
Voltage
Figure 1: Transformers can transform voltages up or down.
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(Safety Note: This ability of a transformer to operate in either direction is a critical

safety hazard when servicing power transformers. If an out-of-service power
transformer is accidentally energised on the secondary then the full transformed
voltage will appear on the primary. This can result in electrocution of any person
working on the unit.)
Why use Transformers
Transformers are very efficient machines, often operating at close to 99%. (They
are generally regarded as the most efficient machines invented so far.)
They are reliable when correctly maintained.
To overcome the I2R losses of long transmission lines between generating power
stations to population regions, very high voltages such as 330kV and above are
used. (Without the use of transformers most of the energy from the power station
generators would be lost as heat in the transmission lines, or the transmission line
would need to be increased in diameter enormously, making them impractical or
too expensive to use.)
Transformers are used to reduce the high voltages used for transmission to lower
voltages suitable for distribution to consumers.
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NSW DET 2009
Figure 2: Transformers are used in the distribution and supply chain to transform voltages up
and down so as minimise energy losses due to power line resistance losses.
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Construction of Transformers
The transformers you will encounter in a substation, whether they are power
transformers or instrument transformers, are constructed of the same basic
components.
The core (which is made of an iron alloy)

Windings which are wound onto the core
A tank to contain the windings and core, and
A means of insulating the windings from the tank and from other windings.
Core
(hidden by the windings)
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Tank
(cutaway to show interior
of transformer)
Windings
(wound onto the core)
Insulation, typically
Cellulose paper
Wood
Mineral oil
Figure 3: Interior view of a relatively small power transformer.
Transformer Theory
All transformers use the same basic principle, and only the finer points ever change.
A transformer works on the principle of magnetic coupling to transfer the energy from
one side (winding) to the other. The construction and physical appearance of a power
transformer in a substation may look very different from a transformer used for radio
frequency (RF) applications in a radio transmitter, yet the theory remains the same.
Transformers are a passive device there are no active components such as
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NSW DET 2009

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Trainer Guide
TABLE OF CONTENTS
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Using this Trainer Resource...........................................................................................4

Modifying the Training Resources ............................................................................4
Training Learners in Specific Tasks ..........................................................................5
Practical Tasks ...........................................................................................................5
References..................................................................................................................7
Introduction....................................................................................................................8
Topics Covered in this Module..................................................................................8
Types of Devices Covered in this Module.................................................................9
Types of Maintenance Testing Covered in this Module............................................9
Importance of this Learning Module .......................................................................10
Transformer Theory A Review.................................................................................10
Why use Transformers.............................................................................................11
Construction of Transformers ..................................................................................11
Transformer Theory .................................................................................................12
Three Phase Transformers .......................................................................................26
Parallel Operation of Three-Phase Transformers ....................................................30
Transformer Cooling................................................................................................31
Gas Pressure Relay (Buchholz Relay) .....................................................................36
Explosion Vent.........................................................................................................36
Bushings...................................................................................................................37
Autotransformer.......................................................................................................37
Substation Auxiliary Transformer ...........................................................................38
Reactors....................................................................................................................38
Instrument Transformers..............................................................................................39
Voltage (Potential) Transformers ............................................................................40
Current Transformers...............................................................................................41
Tapchangers .............................................................................................................42
Risk Assessment ..........................................................................................................46
Transformer Oil Testing ..............................................................................................46
Oil Sampling ............................................................................................................47
Dealing with Contaminated Oil ...............................................................................56
Transformer Testing.....................................................................................................59
Cleaning Prior to Testing .........................................................................................59
Insulation Failure .....................................................................................................59
Insulation Resistance Tests ......................................................................................62
Winding Resistance Measurement...........................................................................67
Dielectric Dissipation Factor (DDF) Tests ..............................................................70
Turns Ratio Checks..................................................................................................73
Frequency Response Analysis .................................................................................74
Recovery Voltage Measurement..............................................................................76
Low Voltage Excitation Check................................................................................78
Conclusion ...................................................................................................................79
Maintain HV power system transformers Trainer Guide
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NSW DET 2009
Instructional Content
Notes to Trainer
Introduction
Display Slide 1
Timing
One of the most important and expensive items of capital equipment in a substation is a power
transformer. If maintained correctly they will give very long service life. It is not uncommon to
encounter units which have been in service for greater than 40 years. They are used to transform
voltages either up or down as required for distribution between substations and customers.
PL
Apart from power transformers there are instrument transformers used in the substation
environment. These devices are used to monitor the power levels, or are used for protection
purposes to trigger circuit breakers and other current breaking devices.
There are also other inductive coil devices that resemble transformers called reactors. These are
used to limit surge currents, and have maintenance regimes similar to transformers.
This module will review the theory of transformers, especially as used in high voltage power
applications. It will then explain the maintenance and testing requirements for these devices.
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Learning Outcomes
Display Slide 2, 3, 4
(As per those listed on page 6 of this Trainer Guide.)
Display Slide 5
Topics Covered in this Module
Transformer theory
Three-phase transformer theory
Transformer cooling
Supplemental power transformer components
Autotransformers, auxiliary transformers, and reactors
Instrument transformers
Oil sampling and testing
Transformer tests
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NSW DET 2009
Display Slide 6
Types of Devices Covered in this Module
Power transformers
Voltage (potential) transformers
Current transformers
Reactors (series and shunt)
Auxiliary Transformers
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The following high voltage devices are described and their maintenance requirements reviewed:
Types of Maintenance Testing Covered in this Module

Low voltage excitation tests
Ratio checks
Oil sampling
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Display Slide 7
NSW DET 2009
Importance of this Learning Module
Typical Tasks Required
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Transformers are probably the single most valuable asset located in a transformer substation.
When maintained correctly they will remain serviceable for many decades. It is the job of a
substation operator to understand the working principles of power and instrument transformers
and the subsequent maintenance and testing procedures that are required to keep them serviceable.
Poorly maintained power transformers can result in catastrophic failure of the unit, with the
potential to cause major damage to other substation plant equipment and network outages.
Included in the Appendix of the Learner Guide is a Maintenance Instruction from an electrical
supply utility. This lists the typical types of tasks that substation operators are required to perform
when maintaining power transformers. (This document should be regarded as indicative only as
all electrical supply utilities will have their own version of this Work Procedure as applicable to
that organisation.)
Trainer Note:
Transformer Theory A Review
Much of the content of this

section on Transformer Theory
will have already been learnt in
previous theoretical instruction.
Special emphasis has been
placed in the notes where the
theory references transformers
used in high voltage applications.
Trainers may choose to reduce
the time spent on this section at
their discretion.
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Student Exercise
Obtain a listing of the types of maintenance tasks (work procedures) performed upon power and
instrument transformers in your organisation.
Obtain copies of a number of these work procedures and review the steps involved to perform the
task.
Transformers provide a simple means of changing an alternating voltage (AC) from one value to
another. (Note: A transformer cannot transform direct current voltages. Where you may see
examples that appear to do this it is actually achieved by converting the DC voltage to an AC
waveform first, and then applying it to the primary side of a transformer. It may then be rectified
back to a DC voltage if required.)
A transformer may receive energy at a lower voltage and deliver it at higher voltage (step up
transformer) or it may receive energy at higher voltage and deliver it at a lower voltage (step down
transformer). Any transformer may operate as a step-up or step-down transformer depending on
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You may need to assist trainees

to access your workplace
procedures, which will often be
held in an electronic file format. If
so, demonstrate the process for
how to retrieve these files.
NSW DET 2009

Instructions to Assessors

Assessment Guide
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This Assessment Guide is part of a suite of resources that have been developed to
support 8 core units of competency from the Certificate IV in ESI Substation
(UET40206) as follows:
UETTDRIS05A
UETTDRIS22A
UETTDRIS23A
UETTDRSB01A
UETTDRSB02A
UETTDRIS03A
UETTDRIS04A
UETTDRIS05A
Perform substation switching operation to a given schedule

Implement and monitor the organisational OHS policies,
procedures and programs
Implement and monitor environmental and sustainable energy
management policies and procedures
Diagnose and rectify faults in power systems substation
environment
Carry out substation inspections
Install and maintain substation DC systems
Maintain HV power system circuit breakers
Maintain HV power system transformers and instruments
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This Assessment Guide together with a Trainer Guide and a Learner Guide are
designed for UETTDRSB05A - Maintain HV power system transformers and
instrument transformers. This guide is intended to provide some direction to assessors
who are determining competence of students who have completed the theoretical and
practical instruction in this learning module. Assessors are expected to use their own
judgement in designing appropriate assessment questions and tasks and putting them
into context for the assessment candidate. At all times the evidence requirements as
set out in the unit and the principles of assessment, that is, validity, reliability,
flexibility and fairness must be complied with.
Use these guidelines to assist in preparing your own assessment instruments and tools.
The checklist should be treated as a starting point. You may choose to add more
checkpoints to highlight particular aspects of knowledge and skill that you want to see
evidence of. This could be through practical tasks or problem-based questions.
Evidence Required
Evidence for competence in this unit shall be considered holistically. Each element
and associated Performance Criteria shall be demonstrated on at least two occasions in
accordance with the Assessment Guidelines UET06. Evidence must also reflect
the critical aspects of evidence which includes the following:
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A representative body of performance criteria demonstrated within the timeframes

typically expected of the discipline, work function and industrial environment. In
particular this must incorporate evidence that shows a candidate is able to:
Implement Occupational Health and Safety workplace procedures and practices
including the use of risk control measures as specified in the Performance Criteria
and Range Statement.
Apply sustainable energy principles and practices as specified in the Performance
Criteria and Range Statement
Demonstrate an understanding of the essential knowledge and associated skills as
described in this unit to such an extent that the learners performance outcome is
reported in accordance with the preferred approach; namely a percentile graded
result, where required by the regulated environment.
Demonstrate an appropriate level of skills enabling employment.
Conduct work observing the relevant Anti Discrimination legislation, regulations,
polices and workplace procedures.
To be deemed as competent in this Unit, the candidate must provide sufficient

evidence of being able to confidently and competently conduct a number of
transformer tests on a range of equipment. Where summative (or final) assessment is
used it is to include the application of the competency in the normal work
environment or, at a minimum, the application of the competency in a realistically
simulated work environment. In some circumstances, assessment in part or full can
occur outside the workplace. However, it must be in accordance with industry and
regulatory policy. (For more detail on assessment practices you are advised to refer
to the Training Package and the Evidence Guide for this Unit of Competence,
especially where longitudinal competency development and Profiling has been used).
This assessment guide covers all tasks and equipment included in the section of the
Unit: Critical aspects for assessment and evidence required to demonstrate
competency in this unit, as shown in the table below.
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The minimum number of items

on which skill is to be
demonstrated.
At least
following:
At least
following:
At least
following:
one
of
two
of
two
of
the
the
the
Item List
Power transformer
High voltage reactor (series or parallel)
Auxiliary transformer
Current transformer
Voltage transformer
Low voltage excitation checks
Ratio checks
Oil sampling
Maintain HV power system transformers Assessment Guide
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Perform substation switching operation to

given schedule (UETTDRIS05A)
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Learner Guide
TABLE OF CONTENTS
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Mapping to Training Package........................................................................................5
Essential Knowledge and Associated Skills ..........................................................6
Assessment.................................................................................................................6
Introduction....................................................................................................................8
Health and Safety Considerations..................................................................................8
Safe Working Distances.............................................................................................8
Personal Protective Equipment (PPE) .......................................................................8
Standard Abbreviations..................................................................................................9
Overview of Network Switching .................................................................................10
Operational Objectives.............................................................................................10
Substation Switching Principles ..............................................................................11
Disconnection Procedure .....................................................................................11
Reconnection Procedure ......................................................................................11
Re-arrangement of System.......................................................................................11
Load Transfer...........................................................................................................12
Isolation of Equipment to be Worked On ................................................................12
Testing to Prove De-energised.................................................................................12
Earthing of Equipment to be Worked On ................................................................13
Setting Out the Work Area ......................................................................................13
Issue of Access Authorities for Work or Test..........................................................13
Surrender of Access Authority for Work or Test.....................................................13
Removal of Work Area............................................................................................14
Removal of Earths....................................................................................................14
Reconnection of Equipment.....................................................................................14
Switching Instructions (Disconnect and Reconnect) ...................................................15
The Switching Instruction (D&R) Paperwork .........................................................16
Switching Steps....................................................................................................17
Communication with Area System Controller.....................................................22
Preparation ...................................................................................................................22
Job Safety Analysis..................................................................................................22
Check the Job...........................................................................................................23
Danger Tags .............................................................................................................23
Access Authorities for Work or Test .......................................................................23
Tape Stands and Tape ..............................................................................................23
Earth Cables .............................................................................................................23
Isolation Switching ......................................................................................................23
Circuit Breaker Operation........................................................................................23
Circuit Breaker Controls ......................................................................................24
Operating Aids .....................................................................................................25
Operating Practices for Opening a Circuit Breaker .............................................25
Operating Practices for Closing a Circuit Breaker ..............................................26
Isolator Operations.......................................................................................................27
Operating Substation Isolators.................................................................................27
Proving De-Energised..................................................................................................28
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General Description of HV Detectors......................................................................28

Proving HV Apparatus De-Energised......................................................................28
Method of Operation of HV Detectors ....................................................................28
General Description of Operating Rods...............................................................29
Earthing HV Electrical Apparatus ...........................................................................29
Confirm Earthing Equipment is Serviceable .......................................................30
Using Earthing Equipment...................................................................................30
Operating Earth Switches ....................................................................................31
Self Assessment Questions ..........................................................................................32
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NSW DET 2009
Introduction
Substation switching operations may be required for a number of purposes. These
include:
Taking a high voltage feeder out of service.

Performing maintenance or replacement of equipment such as transformers.
Isolation of other substation equipment including circuit breakers, busbars,
capacitor banks, frequency injection equipment, and singular items of HV
apparatus such as isolators, earth switches, cable potheads, surge arrestors, current
transformers and voltage transformers.
Making temporary or permanent reconfiguration of the substation.
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The most common substation switching activity is associated with feeders and
transformers, and this learning module will focus upon these activities as examples.
The same principles are utilised for switching and isolation of other substation
equipment.
The procedure for performing the substation switching operation will be provided to
you by the System Operator (or equivalent) in the form of a Switching Instruction
(also known as a Disconnection and Reconnection Instruction). It is possible to be
lulled into a false sense of security through the use of these instructions. Switching
operators must have the knowledge and skill to recognise mistakes or omissions in the
Switching Instruction, which can occur because of local substation variations and
conditions which the System Operator, who is located elsewhere, may be unaware of.
Health and Safety Considerations
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Incorrect substation switching can cause catastrophic failure of equipment, extreme

electrical arcing, and explosions, all of which have the potential to cause serious
injury or death. These training resources provide the theory and methodology for you
to work safely when performing switching operations within the substation
environment. There should be no departure from these principles unless your
organisation has produced a more up-to-date procedure which has been approved by a
qualified senior electrical engineer.
Safe Working Distances

All safe working distances must be maintained. Ensure you know the current
standards for safe working distance that apply in your organisation.
Personal Protective Equipment (PPE)

The standard PPE for entering and working in a substation is:
Protective headwear, usually incorporating sun protection for the neck
Eye protection
Safety shoes
High visibility clothing, including long sleeved shirt
Gloves
Sunscreen
Some organisations may have other PPE requirements, and these should be checked
and confirmed before commencing work.
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NSW DET 2009
Dehydration can be a problem for outdoor workers in Australia. Before commencing

work ensure that adequate supplies of drinking water are available, and make sure that
your water hydration is maintained while working outdoors.
Condition of Tools and Equipment

You will use a range of tools and equipment to perform substation switching. Before
commencing work this should all be checked for currency of operational certificates
or tags, and visually inspected to ensure that it is in safe usable condition. This
especially applies to high voltage testers and earth cables.
Standard Abbreviations
People working in substation environments and performing substation switching often
abbreviate technical terminology or use acronyms. The following is a list of those
which may be encountered, and which may be used in these learning resources.
ABBREVIATION
AA / AAs
ABS
ACB
A/R
ATW
AS/by
AUX
BUS
CVT
CAP
CO
CB
CT
DT
D&R
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ITEM
Access Authority(s)
Air Break Switch
Air Circuit Breaker
Auto Reclose
Approval to Work
Auto Standby
Auxiliary
Busbar
Capacitive Voltage Transformer
Capacitor
Changeover
Circuit Breaker
Current Transformer
Danger Tag
Disconnection and Reconnection
Instruction
Drop-out Fuse or Expulsion Drop-out
Earth Switch
Feeder
Ganged Tripping Drop-out Fuse
Gas Circuit Breaker
Group
Hazemeyer
High Voltage
Hours
Independent
Joint Use
Lightning Arrester
Line Drop Compensation
Live Line Clamp (or Connection)
Low Voltage
Low Voltage Link
Maintenance
Minutes
Non-auto
DOF / EDO
ESW
FDR
GDO / DDO
GCB
GRP
HAZ
HV
HRS
INDEP
JU
LA
LDC
LLC
LV
LVL
MAINT
MINS
NA
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NSW DET 2009
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Normally Open
N/O
Normally Closed
N/C
No-volt
NV
Number
No
Numbers
Nos
Oil Circuit Breaker
OCB
Oil Fuse Switch
OFS
Open Circuit
OC
Open, Locked and Danger Tagged
OLDT
Operating Agreement
OA
Operations
OPS
Overhead
O/H
Overground Box (Pillar Box)
OG Box
Out of Service
O/S
Parallel
//
Permanent
PERM
Primary
PRIM / PRI
Protection
PROTN / PTN
Reclosing Circuit Breaker
RecCB
Ring Main Isolator
RMI
Supervisory Control And Data
SCADA
Acquisition
Secondary
Sec
Seconds
SECS
Section
SECT
Sectionaliser
SEC SW/AS
Sensitive Earth Fault
SEF
Short Circuit
SC
Single Pole Switch
SP SW
Standby
S/BY
Switch
SW
Switchgear
SWGR
Tap Changer
TC
Temporary
TEMP
Transformer
TRANSF / TX / TXR
Underground
UG
Underground to Overhead Termination
UGOH
Underslung Link
USL
Unserviceable
US
Voltage Regulator (or Voltage
VR
Regulation)
Voltage Transformer
VT
Table 1: Common Abbreviations in the Substation Environment
Overview of Network Switching

Operational Objectives
When performing substation switching we have priorities or objectives to personnel,
the owner of the infrastructure and to customers. These can be summarised as
follows:
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Trainer Guide
TABLE OF CONTENTS
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Practical Task.............................................................................................................5
Introduction....................................................................................................................7
Network Overview.........................................................................................................9
Overview of Substation Switching ..............................................................................10
Operational Objectives.............................................................................................10
Substation Switching Principles ..............................................................................10
Re-arrangement of System.......................................................................................11
Load Transfer...........................................................................................................11
Isolation of Equipment to be Worked On ................................................................12
Testing to Prove De-energised.................................................................................13
Earthing of Equipment to be Worked On ................................................................13
Setting Out the Work Area ......................................................................................13
Issue of Access Authorities for Work or Test..........................................................14
Surrender of Access Authority for Work or Test.....................................................15
Removal of Work Area............................................................................................15
Removal of Earths....................................................................................................15
Reconnection of Equipment.....................................................................................16
Switching Instructions (Disconnect and Reconnect) ...................................................16
Initial Request ..........................................................................................................16
The Switching Instruction (D&R) Paperwork .........................................................17
Preparation ...................................................................................................................21
Job Safety Analysis..................................................................................................21
Check the Job...........................................................................................................21
Danger Tags .............................................................................................................22
Access Authorities for Work or Test .......................................................................22
Tape Stands and Tape ..............................................................................................22
Earth Cables .............................................................................................................22
Isolation Switching ......................................................................................................23
Circuit Breaker Operation........................................................................................23
Isolator Operations.......................................................................................................29
Operating Substation Isolators.................................................................................29
Proving De-Energised..................................................................................................31
General Description of HV Detectors......................................................................31
Proving HV Apparatus De-Energised......................................................................31
Method of Operation of HV Detectors ....................................................................32
Proving the HV Detector .........................................................................................32
Operating Sticks or Rods .........................................................................................32
Earthing HV Electrical Apparatus ...........................................................................33
Example of Typical Switching Operation................................................................36
Perform substation switching operation Trainer Guide
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NSW DET 2009
Notes to Trainer
Timing
Introduction
Substation switching operations may be required for a number of purposes. These

include:
Taking a high voltage feeder out of service.
Performing maintenance or replacement of equipment such as transformers.
Isolation of other substation equipment including circuit breakers, busbars, capacitor

banks, frequency injection equipment, and singular items of HV apparatus such as
isolators, earth switches, cable potheads, surge arrestors, current transformers and
voltage transformers.
Making temporary or permanent reconfiguration of the substation.
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Display Slide 2
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The most common substation switching activity is associated with feeders and
transformers, and this learning module will focus upon these activities as examples. The
same principles are utilised for switching and isolation of other substation equipment.
The procedure for performing the substation switching operation will be provided to you
by the System Operator (or equivalent) in the form of a Switching Instruction (also
known as a Disconnection and Reconnection Instruction). It is possible to be lulled
into a false sense of security through the use of these instructions. Switching operators
must have the knowledge and skill to recognise mistakes or omissions in the Switching
Instruction, which can occur because of local substation variations and conditions which
the System Operator, who is located elsewhere, may be unaware of.
Learning Outcomes
Display Slide 3
Display Slide 4 & 5
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NSW DET 2009
E
Display Slide 6

Overview of substation switching
Setting out the work area
Access Authority
Switching Instruction
Communication with the System Controller
Preparation
Steps to perform switching
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NSW DET 2009
Network Overview
Display Slide 8
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Substation switching is applicable to either transmission or zone substations. Figure 1

provides an overview of the typical electrical supply and distribution network.
Figure 1: Typical supply distribution network, indicating substations where switching occurs.
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NSW DET 2009


Assessment Guide
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UETTDRIS05A
UETTDRIS22A
UETTDRIS23A
UETTDRSB01A
UETTDRSB02A
UETTDRIS03A
UETTDRIS04A
UETTDRIS05A

environment
SA
designed for UETTDRIS05A Perform substation switching operation to a given
schedule. This guide is intended to provide some direction to assessors who are
determining competence of students who have completed the theoretical and practical
instruction in this learning module. Assessors are expected to use their own
judgement in designing appropriate assessment questions and tasks and putting them
into context for the assessment candidate. At all times the principles of assessment,
that is, validity, reliability, flexibility and fairness must be complied with.
Evidence Required
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evidence of being able to confidently and competently conduct HV switching within
an electrical substation. Where summative (or final) assessment is used it is to
include the application of the competency in the normal work environment or, at a
minimum, the application of the competency in a realistically simulated work
environment. In some circumstances, assessment in part or full can occur outside the
workplace. However, it must be in accordance with industry and regulatory policy.
(For more detail on assessment practices you are advised to refer to the Training
Package and the Evidence Guide for this Unit of Competence, especially where
longitudinal competency development and Profiling has been used).
SA

demonstrated.
All of the following:

Any one of the following:
Any two of the following:
Item List
Approvals/clearances
Access permits
Operating sticks
Operating earths
Voltage detectors
Phasing equipment
Ground equipment isolating handles and earths
Links
Air break switches
Fuses
Reclosers
Ring main units
Circuit breakers
Perform substation switching operation Assessment Guide
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NSW DET 2009
Implement and monitor the organisational

OHS policies and programs (UETTDRIS22A)
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Learner Guide
Education and Training. The NSW Department of Education and Training do not give warranty or
accept any liability in relation to the content of this work.
TABLE OF CONTENTS
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Assessment.................................................................................................................7
Occupational Health and Safety Legislation..................................................................8
NSW Occupational Health and Safety Act 2000.......................................................9
Penalties ...................................................................................................................11
Inspection powers ....................................................................................................11
Implementing the OH&S Act ..................................................................................12
Workplace obligations .............................................................................................12
Meeting OH&S obligations .....................................................................................13
OH&S Notices .........................................................................................................16
Consultation and Employee Involvement................................................................18
Responsibility and Accountability...........................................................................22
Legal Responsibilities..............................................................................................22
Sources of information.............................................................................................22
Further Information..................................................................................................23
Application of Workplace Health and Safety Practices...............................................24
Continuous Improvement.........................................................................................26
OH&S Checklist ......................................................................................................27
Training....................................................................................................................28
Glossary of OH&S Definitions and Terms..............................................................30
Risk Assessment and Management..............................................................................35
Introduction..............................................................................................................35
Risk Management ....................................................................................................36
Risk Management Process .......................................................................................37
Development of Safe Work Methods ......................................................................38
Example of a Risk Management System .....................................................................47
Risk Management on-the-job.......................................................................................51
Introduction..............................................................................................................51
Hazard Identification ...............................................................................................51
Hazards what to look for.......................................................................................54
Risk Rating...............................................................................................................58
Hazard Control.........................................................................................................58
Continually Monitor.................................................................................................60
Reporting..................................................................................................................61
Control and Quality Improvement ...........................................................................62
Procedural Health and Safety Systems Applicable to Substations ..............................64
Work Permits and Clearances..................................................................................64
Area Marking Tapes ................................................................................................68
Tags..........................................................................................................................68
Hazards within Electrical Substations .........................................................................70
General Hazards.......................................................................................................70
Implement and monitor the organisational OHS policies Learner Guide
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NSW DET 2009
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Exposed Electrical Conductors ................................................................................70

Voltage Gradients ....................................................................................................73
Safe Approach Distances .........................................................................................74
Transferred Earthed Potential (Transfer Voltages)..................................................75
Electrical Induction..................................................................................................76
Working at Heights ..................................................................................................77
Confined Spaces.......................................................................................................77
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NSW DET 2009
Occupational Health and Safety Legislation

The first pieces of legislation introduced into Australia that related to Occupational
Health and Safety (OH&S) were on an as needed basis, and closely followed (if not
copied) British OH&S Legislation. In 1873 the first Act was passed in Victoria which
specified penalties applying to breaches of the Act and allowed for government
inspection and enforcement. It took approximately another 25 years for the other
States (then separate colonies) to introduce similar legislation.
Many workers had no protection at all due to gaps in the coverage of the laws.
The number of laws and regulations often made their enforcement difficult, and if
many types applied to one workplace, there was often much confusion for both the
employers and employees.
Standards laid down by these laws were the bare minimum, often leaving workers
grossly under protected.
There was no systematic review of the laws.
There were major problems in monitoring and enforcement. This was mainly due
to insufficient inspectors, a reluctance to prosecute due to lack of resources, and
the intricacies and ambiguities of the numerous Acts and Regulations.
There was no scope for employee or union involvement.
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This pattern of developing legislation for each specific problem or issue continued
until the 1970s, resulting in numerous Acts and Regulations. Unfortunately, and
partly due to the ad hoc approach, the legislation was significantly flawed, in that:
In 1972 the Robens Report was published in Britain, recommending much needed
reforms for OH&S laws. The South Australian Parliament passed an Act based on the
Robens Report that year, and all other jurisdictions (States) have followed suit. The
major recommendation made by this report was to have OH&S legislation that was:
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unified and streamlined

a single piece of legislation to impose duties of care on those concerned
to incorporate standards that would protect anyone in or near the work area
administered by a single regulatory body
made it a requirement for the employer to have an OH&S Policy
a replacement of the inspection system with self-regulatory alternatives
inclusive of joint involvement by workers/employer in formulating and
implementing OH&S in the workplace.
The new Australian OH&S legislation took the form of an umbrella Act requiring
employers to discharge a general duty of care. Hazard identification and correction
became the responsibility of management with government acting primarily as an
advisor. In dealing with this new approach to OH&S both the government and
industry have struggled, and a proliferation of legislation in the form of regulations
and Approved Codes of Practices has resulted.
In the end, employers are responsible for establishing a system of work, or adopting a
system of work from an industry code, that will ensure the health, safety, and welfare
of their employees. The government will no longer prescriptively tell the employer
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NSW DET 2009
how to achieve this end but rather will monitor employers to ensure that the objectives
and aims of the legislation are being achieved.
The objectives of the Act are to:
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secure and promote the health, safety and welfare of people at work.
protect people at a place of work against risk to health or safety arising out of the
activities of persons at work.
promote a safe and healthy work environment for people at work that protects
them from injury and illness and is adapted to their physiological and
psychological needs.
provide for consultation and cooperation between employers and employees in
achieving the objects of the Act.
ensure that risks to health and safety at a place of work are identified, assessed and
eliminated or controlled.
develop and promote community awareness of occupational health & safety
issues.
provide a legislative framework that allows for progressively higher standards of
occupational health and safety to take account of changes in technology and work
practices.
protect people (whether or not at a place of work) against risks to health and
safety arising from the use of plant that affects public safety.
The aim of Occupational Health and Safety Acts is to prevent anyone being killed,
injured, or contracting an illness due to a workplace, workplace activities, or specified
high risk plant. This is achieved by preventing or minimising exposure to risk.
NSW Occupational Health and Safety Act 2000
SA
The NSW Occupational Health and Safety Act 2000 replaces the 1983 Act and
contains new provisions that require employers to consult with employees on health,
safety and welfare matters. The Act has been written in plain-English and lays down
general requirements for health, safety and welfare, which must be met at all places of
work in New South Wales. The Act covers self-employed people as well as
employees and employers. It therefore applies to you if you are:
an employer
a worker, employee
a self-employed person
a person in control of workplaces
a principal contractor
a designer, manufacturer, importer or supplier of plant
a manufacturer, importer or supplier of substances
an owner of specified high risk plant
a visitor to a workplace: for example, customer or a sales representative.
The Act places an obligation on every person associated with a workplace in any way
to ensure his or her own workplace health and safety and the workplace health and
safety.
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Trainer Guide
TABLE OF CONTENTS
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Introduction....................................................................................................................9
Learning Outcomes........................................................................................................9
Topics Covered in the Module.......................................................................................9
Occupational Health and Safety Legislation................................................................10
NSW Occupational Health and Safety Act 2000.....................................................12
Penalties ...................................................................................................................14
Inspection powers ....................................................................................................15
Implementing the OH&S Act ..................................................................................16
Workplace obligations .............................................................................................17
Meeting OH&S obligations .....................................................................................18
OH&S Notices .........................................................................................................20
Consultation and Employee Involvement................................................................21
Responsibility and Accountability...........................................................................24
Legal Responsibilities..............................................................................................24
Sources of information.............................................................................................25
Further Information..................................................................................................26
Application of Workplace Health and Safety Practices...............................................27
Continuous Improvement.........................................................................................28
OH&S Checklist ......................................................................................................30
Training....................................................................................................................30
Glossary of OH&S Definitions and Terms..............................................................32
Risk Assessment and Management..............................................................................39
Introduction..............................................................................................................39
Risk Management ....................................................................................................40
Risk Management Process .......................................................................................41
Development of Safe Work Methods ......................................................................42
Example of an Organisations Risk Management System.......................................51
Risk Management on-the-job.......................................................................................51
Introduction..............................................................................................................51
Hazard Identification ...............................................................................................52
Hazards what to look for.......................................................................................53
Risk Rating...............................................................................................................54
Hazard Control.........................................................................................................55
Workteam Briefing ..................................................................................................56
Continually Monitor.................................................................................................57
Reporting..................................................................................................................58
Control and Quality Improvement ...........................................................................58
Procedural Health and Safety Systems Applicable to Substations ..............................60
Work Permits and Clearances..................................................................................60
Area Marking Tapes ................................................................................................62
Tags..........................................................................................................................63
Hazards within Electrical Substations .........................................................................64
Implement and monitor the organisational OHS policies Trainer Guide
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NSW DET 2009
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General Hazards.......................................................................................................64
Exposed Electrical Conductors ................................................................................64
Voltage Gradients ....................................................................................................67
Safe Approach Distances .........................................................................................68
Transferred Earthed Potential ..................................................................................68
Electrical Induction..................................................................................................70
Working at Heights ..................................................................................................70
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NSW DET 2009
Notes to Trainer
Timing
Introduction
Display Slide 1
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This Unit, Implement and monitor the organisational OHS policies, procedures and
programs, covers a range of topics that apply to the everyday tasks when working around a
substation. It includes the identification, assessment and control (or minimisation) of health
and safety risks that may occur from substation operations and maintenance. It also includes
some revision material on significant workplace hazards in substations that arise from the high
voltage and extra high voltages that are present.
Because of the high voltages present and the amount of energy flowing through substations
they have the potential to be extremely hazardous environments. Policies and procedures have
been implemented by electricity distributors to control the risks presented by these hazards,
but it is important that you, in your role as a team leader, supervisor or senior operator have an
understanding of hazard prevention and management strategies as applied in electrical
substations.
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As this learning module is aligned to a CIV Unit of Competence there is an expectation that
you will be proactive in your attitude to OH&S matters. This means being actively involved in
the process of ensuring that your organisations work procedures are continually improved
upon and standardised so as to protect the health and safety of workers.
Display Slide 2
Learning Outcomes
[Refer to the Learning Outcomes at the beginning of this Learning Module.]

Display Slide 3
Topics Covered in the Module
Legislation and other regulatory issues

Responsibilities of management and workers with regards to health and safety
Implementing and applying health and safety policy and procedures
Principle of risk management
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NSWDET 2009
Development of health and safety work procedures

Undertaking on-the-job risk management
Work permits and clearances
Particular hazards to be aware of in the electrical substation.
Occupational Health and Safety Legislation
PL
The first pieces of legislation introduced into Australia that related to Occupational Health and Display Slide 4
Safety (OH&S) were on an as needed basis, and closely followed (if not copied) British
OH&S Legislation. In 1873 the first Act was passed in Victoria which specified penalties
applying to breaches of the Act and allowed for government inspection and enforcement. It
took approximately another 25 years for the other States (then separate colonies) to introduce
similar legislation.
This pattern of developing legislation for each specific problem or issue continued until the
1970s, resulting in numerous Acts and Regulations. Unfortunately, and partly due to the ad
hoc approach, the legislation was significantly flawed, in that:
Many workers had no protection at all due to gaps in the coverage of the laws.
The number of laws and regulations often made their enforcement difficult, and if many
types applied to one workplace, there was often much confusion for both the employers
and employees.
Standards laid down by these laws were the bare minimum, often leaving workers grossly
under protected.
There was no systematic review of the laws.
There were major problems in monitoring and enforcement. This was mainly due to
insufficient inspectors, a reluctance to prosecute due to lack of resources, and the
intricacies and ambiguities of the numerous Acts and Regulations.
There was no scope for employee or union involvement.
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In 1972 the Robens Report was published in Britain, recommending much needed reforms for
OH&S laws. The South Australian Parliament passed an Act based on the Robens Report that
year, and all other jurisdictions (States) have followed suit. The major recommendation made
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NSWDET 2009


Assessment Guide
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UETTDRIS05A
UETTDRIS22A
UETTDRIS23A
UETTDRSB01A
UETTDRSB02A
UETTDRIS03A
UETTDRIS04A
UETTDRIS05A

environment
SA
designed for UETTDRIS22A - Implement and monitor the organisational OHS
policies, procedures and programs. This guide is intended to provide some direction to
assessors who are determining competence of students who have completed the
theoretical and practical instruction in this learning module. Assessors are expected to
use their own judgement in designing appropriate assessment questions and tasks and
putting them into context for the assessment candidate. At all times the evidence
requirements as set out in the unit and the principles of assessment, that is, validity,
reliability, flexibility and fairness must be complied with.
Evidence Required
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evidence of being able to identify, assesses and control health and safety hazards that
may occur in substations according to the appropriate legislation, guidelines,
standards and organisational policies and procedures. Where summative (or final)
assessment is used it is to include the application of the competency in the normal
work environment or, at a minimum, the application of the competency in a
realistically simulated work environment. In some circumstances, assessment in part
or full can occur outside the workplace. However, it must be in accordance with
industry and regulatory policy. (For more detail on assessment practices you are
advised to refer to the Training Package and the Evidence Guide for this Unit of
Competence, especially where longitudinal competency development and Profiling
has been used).
SA
Implement and monitor the organisational OHS policies Assessment Guide
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NSW DET 2009
Diagnose and rectify faults in power

systems substation environment
(UETTDRSB01A)
SA
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Trainer Guide
Education and Training. The NSW Department of Education and Training do not give warranty or
accept any liability in relation to the content of this work.
TABLE OF CONTENTS
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References..................................................................................................................6
Introduction....................................................................................................................7
Fault Finding Documentation ........................................................................................8
Identification and Coding of Equipment and Plant........................................................8
Introduction to Electrical Fault Finding.......................................................................10
Understanding Drawings and Terminology.............................................................10
AC Distribution Systems .........................................................................................14
Circuit Breaker Control Panel..................................................................................15
Transformer Control Panel ......................................................................................18
Substation Alarm Systems .......................................................................................22
Programmable Logic Controllers (PLCs) ................................................................22
Test Tools and Instruments..........................................................................................23
Fault Finding Techniques ............................................................................................24
Diagnose and rectify faults in power systems substation environment Trainer Guide
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NSW DET 2009
Notes to Trainer
Timing
Introduction
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This learning module encompasses the application of the full range of knowledge and skills
from the other learning modules associated with Substation Maintenance. It requires the
application of recognised fault finding techniques, combined with the use of test equipment, to
diagnose and rectify faults in power system substations. Diagnosis of faults also requires the
ability to read and interpret enterprise technical documentation such as schematic diagrams
associated with control panels. Tracing and testing of substation wiring and cabling requires
knowledge of enterprise coding systems.
Fault finding also requires a recognition that the initial fault indication may in fact be a
symptom, rather than the actual fault. For example, a circuit breaker trip failure may not in
fact be the circuit breaker but rather a control panel relay failure or a low voltage wiring fault
caused by a rodent.
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Much of the content of this learning module is enterprise-specific. Trainees need to clearly
understand that whilst the principles are transferable to other ESI organisations, many of the
standards used (e.g. wiring identification codes) are potentially unique to that enterprise and
are not necessarily transferable.
Risk Assessment
Emphasise the importance of conducting a risk assessment before commencing fault finding
activity. This is especially important when performing fault finding. The pressure to resolve
faults quickly can potentially lead operators/fitters to take short cuts. However the very fact
that a fault has occurred suggests that new hazards may have been introduced into the
substation that need to be taken into consideration.
If necessary, refer trainees back to the material in the learning module: Implement and
monitor the organisational OHS policies, procedures and programs.
Learning Outcomes
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NSW DET 2009
Fault Finding Documentation
Trainers should develop a session which incorporates the range of enterprise documentation
that operators/fitters are expected to be able to access in order to perform fault finding activity.
These will likely include:
Service Instructions or Work Method Statements
Local or Regional Instructions
Manufacturers manuals
Schematic diagrams
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Detail should also be provided about where and how these documents can be accessed.
Identification and Coding of Equipment and Plant
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Whilst Australian Standards do exist, they are not always followed, or enterprises have found
it necessary to modify or depart from the Standards to take account of organisation-specific
requirements. Furthermore, often within the one enterprise a range of coding systems may be
in use due to historical factors.
Trainers need to develop content on the topic of coding and identification of wiring, cabling,
bays and equipment/plant for their enterprise. Topics may include:
Single Line Diagrams
Voltage Identification (Coding)
Definition of a Bay and how it is identified
Symbols used in Operating Diagrams
Wiring Codes (refer to AS2067 and local adaptations)
Wiring colour codes
Cable Identification
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NSW DET 2009
Diagnose and rectify faults in power

systems substation environment
(UETTDRSB01A)

Assessment Guide
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UETTDRIS05A
UETTDRIS22A
UETTDRIS23A
UETTDRSB01A
UETTDRSB02A
UETTDRIS03A
UETTDRIS04A
UETTDRIS05A

environment
SA
This guide is intended to provide some direction to assessors who are determining
competence of students who have completed the theoretical and practical instruction
in this learning module. Assessors are expected to use their own judgement in
designing appropriate assessment questions and tasks and putting them into context
for the assessment candidate. At all times the evidence requirements as set out in the
unit and the principles of assessment, that is, validity, reliability, flexibility and
fairness must be complied with.
Evidence Required
and associated Performance Criteria shall be demonstrated on at least two occasions
in accordance with the Assessment Guidelines UET06. Evidence must also
reflect the critical aspects of evidence which includes the following:
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evidence of being able to confidently and competently conduct a number of fault
finding exercises upon power systems in substation environments. Where summative
(or final) assessment is used it is to include the application of the competency in the
normal work environment or, at a minimum, the application of the competency in a
has been used).
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demonstrated.
At least two of the following
At least three of the

following:
Item List
AC circuit breaker fault

Transformer system fault
DC supply systems fault
DC switchgear and equipment fault
Multimeters
Tong testers (current clamp meter)
Insulation resistance/continuity tester
Ductor tester (micro-ohm meter)
Overload injection tester
Specialist test equipment
Diagnose and rectify faults in power systems substation environment Assessment Guide - 2 -
NSW DET 2009

(UETTDRSB02A)
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Learner Guide
TABLE OF CONTENTS
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Pre-Requisite Knowledge ......................................................................................6
Assessment.................................................................................................................6
General Substation Inspections......................................................................................8
The Need for Substation Inspections .........................................................................8
Categories of Substation Inspection...........................................................................8
Frequency of Substation Inspections .........................................................................8
Health and Safety...................................................................................................9
Equipment to be inspected .....................................................................................9
Major Substation Inspection ....................................................................................12
Environmental Inspection ........................................................................................16
Documentation and Record Keeping ...........................................................................19
Carry out substation inspections Learner Guide
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NSW DET 2009
General Substation Inspections

The Need for Substation Inspections
Substations are unmanned installations, therefore they require regular inspection to

ensure uninterrupted supply to customers.
During the substation inspection the condition of:
equipment
buildings
surroundings
fencing and gates
are checked to confirm that they are in operational condition, safe and secure.
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Data collected during routine inspections is fed back into operational planning so that
equipment can be repaired or replaced before it fails. It is therefore crucial that you
note and record all data about what was observed and done during the inspection, and
that this information is provided to the appropriate person or input into organisational
systems such as databases.
Categories of Substation Inspection
Inspections are split up into three distinct categories. These are:
..
..
..
Frequency of Substation Inspections
The frequency of substation inspections for our organisation/region/location is:
..
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..
..
Equipment, security, and environmental inspections are typically conducted

sequentially using a pre-prepared organisation checklist. It will normally take a few
hours to conduct a major inspection (depending upon the size of the substation and the
amount of equipment and plant to be inspected).
Substation inspections should also include the rectification and repair of minor defects
during the inspection.
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NSW DET 2009
Minor Substation, Environmental and Safety Inspection

What important step must you take before commencing any inspection and checking
activities?
Health and Safety

Substations can be dangerous environments to work in if you do not keep yourself
aware of the hazards that are present. When you conduct an inspection you must:
Maintain clearance distances from HV equipment, busbars and cables.
Practise the principles of confined entry, such as awareness of areas where
asphyxiate gases can collect.
Practise the principles of working at heights, such as correct use of ladders.
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Equipment to be inspected
(Some general principles when conducting the inspection :)
1.
2.
3.
4.
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5.
(!!) Advise the System Operator that you are on site and about to commence
inspection activities.
(!!) Confirm that the DC battery volts is correct. This will ensure that
protection equipment will operate correctly if required during the inspection.
(!!) Check and confirm that all exits are operational and clear of obstructions.
This will ensure that the substation can be exited quickly if an emergency
situation should arise.
Switch alarms to local, switch on the indicating lamps (if fitted) and leave on
for the duration of the visit. This applies even if only a brief visit is made, the
purpose being to ensure that a Substation Maintainer can promptly advise the
System Operator of any irregularity which may occur. (Ensure they are
switched back at the completion of the inspection.)
All equipment is to be inspected whether it is in service or not. Even
equipment standing in the substation partially or completely erected but
disconnected from the system should be examined for correct oil level and
breather condition, and any leaks. This requirement is necessary because
electrical equipment will normally deteriorate more quickly when out of
service.
Similarly all readings on transformers, circuit breakers and capacitors are to be
taken irrespective of whether they are in service or not, even if it is known that
they have not been in service since the last reading. All cyclo readings are
entered in equipment log book.
Attention must be paid to items such as broken relay or annunciator glasses
and similar minor defects. These should be serviced or repaired at the time, if
possible, otherwise reported. Correctness and completeness of equipment
labelling should also be constantly checked.
For all relevant matters in the main reports and for all readings taken it is
important that approximately correct times be given. This information may be
particularly valuable in the analysis of a fault but it is required in any case in
the preparation of reliable statistics.
6.
7.
8.
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(UETTDRSB02A)
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Trainer Guide
TABLE OF CONTENTS
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Introduction: The Need for Substation Inspections .......................................................8
General Substation Inspections....................................................................................10
Categories of Substation Inspection.........................................................................10
Frequency of Substation Inspections .......................................................................10
Minor Substation Inspection ................................................................................10
Major Substation Inspection ................................................................................10
Minor Substation, Environmental and Safety Inspection ........................................11
Health and Safety.................................................................................................11
Equipment to be inspected ...................................................................................11
Major Substation Inspection ....................................................................................17
Environmental Inspection ........................................................................................22
Environmental inspections and assessments include:..........................................22
Inspecting the local environment .........................................................................22
Inspecting outside the perimeter fence ................................................................23
Inspecting the substation......................................................................................24
Ancillary Slides........................................................................................................28
Documentation and Record Keeping .......................................................................28
Carry out substation inspections Trainer Guide
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NSW DET 2009
Notes to Trainer
Introduction: The Need for Substation Inspections
Timing
Substations are unmanned installations, therefore they require regular inspection

to ensure uninterrupted supply to customers.
equipment
buildings
surroundings
fencing and gates
PL
During the substation inspection the condition of:
These notes have been prepared as an

amalgam of practices from a range of
electrical supply organisations. Not all
aspects are therefore applicable to the
organisation in which training is being
conducted. Furthermore, the trainer may
wish to add further detail at various points
in the training to emphasise organisationspecific aspects.
are checked to confirm that they are in operational condition, safe and secure.
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Data collected during routine inspections is fed back into operational planning so
that equipment can be repaired or replaced before it fails. It is therefore crucial
that you note and record all data about what was observed and done during the
inspection, and that this information is provided to the appropriate person or
input into organisational systems such as databases.
Learning Outcomes
Display Slide 2, 3 & 4
(As per those listed on Page 5 of this Guide.)
Safety equipment and spares
Visual checks
DC Systems
HV Equipment
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Display Slide 5
NSW DET 2009
Control rooms and ancillary plant
Environmental inspections
Oil containment systems
Ancillary Slides
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NSW DET 2009
E
Display Slide 6
General Substation Inspections

Categories of Substation Inspection
Inspections are split up into three distinct categories:
General Substation Inspection
Substation Security Inspection
Substation Environmental Inspection
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Inspections are carried out by a competent substation operator/fitter on two time

scales.
Minor Substation Inspection
Display Slide 7
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(N.B. Trainer to confirm currency of this

Every month a minor Substation inspection will be carried out and this inspection schedule and applicability to organisation.
Update notes as required.)
will be co-ordinated with a minor monthly environmental check.
Major Substation Inspection
The major Substation Inspection is carried out every three months, and each
second major inspection is aligned with a six monthly environmental inspection
and Security inspections.
Equipment, security, and environmental inspections are typically conducted
sequentially using a pre-prepared organisation checklist. It will normally take a
few hours to conduct a major inspection (depending upon the size of the
substation and the amount of equipment and plant to be inspected).
Substation inspections should also include the rectification and repair of minor
defects during the inspection.
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NSW DET 2009

(UETTDRSB02A)

Assessment Guide
M
PL
UETTDRIS05A
UETTDRIS22A
UETTDRIS23A
UETTDRSB01A
UETTDRSB02A
UETTDRIS03A
UETTDRIS04A
UETTDRIS05A

environment
SA
designed for UETTDRSB02A Carry out Substation Inspections. This guide is
intended to provide some direction to assessors who are determining competence of
students who have completed the theoretical and practical instruction in this learning
module. Assessors are expected to use their own judgement in designing appropriate
assessment questions and tasks and putting them into context for the assessment
candidate. At all times the evidence requirements as set out in the unit and the
principles of assessment, that is, validity, reliability, flexibility and fairness must be
complied with.
Evidence Required
and associated Performance Criteria shall be demonstrated on at least two occasions
in accordance with the Assessment Guidelines UET06. Evidence must also
reflect the critical aspects of evidence which includes the following:
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evidence of being able to confidently and competently conduct all aspects of
substation inspections. Where summative (or final) assessment is used it is to include
the application of the competency in the normal work environment or, at a minimum,
the application of the competency in a realistically simulated work environment. In
some circumstances, assessment in part or full can occur outside the workplace.
However, it must be in accordance with industry and regulatory policy. (For more
detail on assessment practices you are advised to refer to the Training Package and
the Evidence Guide for this Unit of Competence, especially where longitudinal
competency development and Profiling has been used).
SA

demonstrated.
At least
following:
one
of
the
Item List
Transmission substation
Distribution substation
Traction substation
Substation plant and equipment
Substation environmental systems
Substation security systems
Carry out substation inspections Assessment Guide
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NSW DET 2009
Maintain HV power system circuit

breakers (UETTRDSB04A)
SA
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Learner Guide
TABLE OF CONTENTS
SA
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Essential Knowledge and Associated Skills (EK&S)............................................6
Assessment.................................................................................................................7
References..................................................................................................................7
Introduction....................................................................................................................9
Basic Circuit Breaker Design.........................................................................................9
Preface........................................................................................................................9
Summary of functions of Circuit Breakers ............................................................9
Categories of Circuit Breakers.............................................................................10
Circuit Breaker Rating .........................................................................................10
Arcing in the Circuit Breaker...................................................................................11
Arc Formation......................................................................................................11
Arc Extinguishing ................................................................................................12
Oil Circuit Breakers (OCB) .....................................................................................12
Bulk Oil Circuit Breakers ....................................................................................13
Minimum Oil Circuit Breaker..............................................................................14
Air Blast Circuit Breaker .....................................................................................15
SF6 Circuit Breakers............................................................................................16
Vacuum Circuit Breaker ......................................................................................18
Circuit Breaker Contacts..........................................................................................19
Contact Design.....................................................................................................20
Mechanical Functionality Operating Mechanism.................................................22
Pneumatic Drive...................................................................................................22
Hydraulic Drive ...................................................................................................23
Spring-loaded Drive.............................................................................................23
Solenoid Drive .....................................................................................................24
Maintenance of Circuit Breakers .................................................................................25
Maintenance Program ..............................................................................................25
Routine Inspection ...............................................................................................25
Minor Maintenance..............................................................................................25
Major Maintenance ..............................................................................................26
Environmental and Operational Considerations ..................................................26
Maintenance Tasks...................................................................................................26
Isolation................................................................................................................26
Discharge of Energy Storage Mechanism............................................................26
Visual Inspection .................................................................................................27
Arc Chutes Cleaned .............................................................................................27
Contacts Cleaned .................................................................................................27
Mechanism Inspection and Adjustment...............................................................27
(For oil circuit breakers) Check or Replace Oil...................................................28
SF6 Pressure Levels and Gas Quality..................................................................28
Testing......................................................................................................................28
Contact Resistance Measurement ........................................................................28
Dynamic Contact Resistance ...............................................................................29
Maintain HV power system circuit breakers Learner Guide
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NSW DET 2009
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Insulation (Megger) Testing ................................................................................31

Timing Tests (Motion Analysis)..........................................................................31
Vibration Analysis Testing ..................................................................................32
Oil Sampling ........................................................................................................34
SF6 Sampling .......................................................................................................35
SF6 Filtering and Replacement............................................................................36
SF6 Leak Testing .................................................................................................37
Functional Operational Tests ...............................................................................37
Infra-Red Thermal Monitoring/Testing ...............................................................38
Learning Tasks and Practical Exercises.......................................................................42
Appendix: Example of a Circuit Breaker Work Method .............................................44
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NSW DET 2009
Introduction
High voltage circuit breakers form a critical component of the HV switching network.
They ensure that network operation can continue by automatically disconnecting
faulty branches of the distribution network. They are also the primary means used to
off-load the supply, in conjunction with isolators, to isolate the supply so that
maintenance can be performed on the transmission lines and other switching gear.
Because of the high voltages and currents that the circuit breakers are required to
switch, the circuit breakers can be subjected to routine wear of the contacts and arc
chutes, and in cases of extreme fault switching, the circuit breaker may be physically
damaged. Routine maintenance performed at regular intervals is used to detect and
repair wear and damage of circuit breakers.
This learning module will review the principles of operation of the major categories
of HV circuit breakers. The common types of maintenance procedures used will then
be covered.
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Because of the wide range of types and models of circuit breakers this learning
module cannot cover all specific cases. You will need to refer to manufacturers data
and local work procedures to gain a full appreciation of how to maintain particular
models of circuit breakers.
Basic Circuit Breaker Design

Preface
The interruption of electric power circuits has always been an essential function,
especially in cases of overloads or short circuits when immediate interruption of the
current flow becomes necessary as a protective measure.
In earliest times, circuits could be broken only by separation of contacts in air
followed by drawing the resulting electric arc out to such a length that it can no longer
be maintained. This means of interruption soon became inadequate and special
devices called circuit breakers had to be developed.
SA
The basic problem has been to control and quench or extinguish the high power arc,
which necessarily occurs at the separating contacts of a breaker when opening high
current circuits. The problem of arc extinction is worsened when the power factor is
low, that is, when the voltage and current are significantly out-of-phase. Since arcs
generate a great deal of heat energy, most often destructive for the breaker's contacts,
technology had to find ways to limit the arc duration and develop contacts that can
withstand the arc effect time after time.
Summary of functions of Circuit Breakers

The following is a list of functions that circuit breakers must be able to adequately
perform:
CLOSE onto and maintain full load current for long periods.
Automatically disconnect the full load current.
Interrupt and disconnect fault currents from the system.
Withstand full rated voltage across it when OPEN.
CLOSE onto a fault and immediately re-open to clear that fault.
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NSW DET 2009
Carry short circuit fault current for a period of time.
Withstand the effects of arcing at the contact surfaces.
HV circuit breakers contain the contacts within a sealed enclosure, with an insulating
dielectric surrounding the contacts and other ancillary parts of the circuit breaker.
Despite the range of types of circuit breakers available they all share common
principles; they all have to provide two main functionalities which are inter-related:
Electrical functionality (Interrupter, or contacts)
Mechanical functionality (Mechanism for tripping and closing the breaker)
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The difference between these two functions is shown in the graphic (Figure 1) which
illustrates these two aspects of the circuit breaker.
Figure 1: The electrical interrupter functionality and the mechanical

functionality of circuit breakers.
Categories of Circuit Breakers
SA
High voltage circuit breakers generally fall into one of four categories (defined by the
type of dielectric used), each often having its own sub-categories. These are:
Oil (Bulk oil and Minimum Oil)
Compressed Air
SF6
Vacuum
SF6 is increasingly being used as an insulating medium in switching gear. Some

modern designs of circuit breaker use combinations such as vacuum and SF6.
Circuit Breaker Rating

A circuit breaker will have a number of specification ratings, and these will usually
appear on the nameplate of the unit. The interpretation of these ratings is as follows:
Maximum kV Rating
The specified upper limit of voltage for which the circuit breaker is expected to
operate e.g.145kV.
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NSW DET 2009

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Trainer Guide
TABLE OF CONTENTS
SA
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Practical Task.............................................................................................................5
Essential Knowledge and Associated Skills ..............................................................6
References..................................................................................................................7
Introduction....................................................................................................................8
Topics Covered in this Learning Module ..................................................................8
Basic Circuit Breaker Design.........................................................................................9
Preface........................................................................................................................9
Circuit Breaker Rating .............................................................................................10
Arcing in the Circuit Breaker...................................................................................11
Oil Circuit Breakers (OCB) .....................................................................................13
Air Blast Circuit Breaker .........................................................................................15
SF6 Circuit Breakers................................................................................................16
Vacuum Circuit Breaker ..........................................................................................18
Circuit Breaker Contacts..........................................................................................18
Mechanical Functionality Operating Mechanism.................................................20
Maintenance of Circuit Breakers .................................................................................23
Maintenance Program ..............................................................................................23
Maintenance Tasks...................................................................................................25
Testing......................................................................................................................27
Practical Instruction .....................................................................................................36
Maintain HV power system circuit breakers Trainer Guide
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NSW DET 2009
Timing
Notes to Trainer
Introduction
PL
Display Slide 2
High voltage circuit breakers form a critical component of the HV switching network. They
ensure that network operation can continue by automatically disconnecting faulty branches of the
distribution network. They are also the primary means used to off-load the supply, in conjunction
with isolators, to isolate the supply so that maintenance can be performed on the transmission lines
and other switching gear.
Because of the high voltages and currents that the circuit breakers are required to switch, the
circuit breakers can be subjected to routine wear of the contacts and arc chutes, and in cases of
extreme fault switching, the circuit breaker may be physically damaged. Routine maintenance
performed at regular intervals is used to detect and repair wear and damage of circuit breakers.
This learning module will review the principles of operation of the major categories of HV circuit
breakers. The common types of maintenance procedures used will then be covered.
SA
M
Because of the wide range of types and models of circuit breakers this learning module cannot
cover all specific cases. Learners will need to refer to manufacturers data and local work
procedures to gain a full appreciation of how to maintain particular models of circuit breakers.
Learning Outcomes
Display Slide 3 & 4
(As per those shown on Page 6 of this Learning Guide.)
Topics Covered in this Learning Module
Categories of HV circuit breakers
Circuit breaker contacts
Mechanical functionality
Maintenance program
Circuit breaker testing
-8-
Display Slide 5
NSW DET 2009
Basic Circuit Breaker Design

Preface
PL
The interruption of electric power circuits has always been an essential function, especially in
cases of overloads or short circuits when immediate interruption of the current flow becomes
necessary as a protective measure.
In earliest times, circuits could be broken only by separation of contacts in air followed by
drawing the resulting electric arc out to such a length that it can no longer be maintained. This
means of interruption soon became inadequate and special devices called circuit breakers had to
be developed.
SA
M
The basic problem has been to control and quench or extinguish the high power arc, which
necessarily occurs at the separating contacts of a breaker when opening high current circuits. The
problem of arc extinction is worsened when the power factor is low, that is, when the voltage and
current are significantly out-of-phase. Since arcs generate a great deal of heat energy, most often
destructive for the breaker's contacts, technology had to find ways to limit the arc duration and
develop contacts that can withstand the arc effect time after time.
Summary of functions of Circuit Breakers
CLOSE onto and maintain full load current for long periods.
Automatically disconnect the full load current.
Interrupt and disconnect fault currents from the system.
Withstand full rated voltage across it when OPEN.
CLOSE onto a fault and immediately re-open to clear that fault.
Carry short circuit fault current for a period of time.
Withstand the effects of arcing at the contact surfaces.
Display Slide 6
HV circuit breakers contain the contacts within a sealed enclosure, with an insulating dielectric
surrounding the contacts and other ancillary parts of the circuit breaker. Despite the range of types
of circuit breakers available they all share common principles; they all have to provide two main
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NSW DET 2009


Assessment Guide
M
PL
UETTDRIS05A
UETTDRIS22A
UETTDRIS23A
UETTDRSB01A
UETTDRSB02A
UETTDRIS03A
UETTDRIS04A
UETTDRIS05A

environment
SA
designed for UETTDRSB04A Maintain HV power system circuit breakers. This
guide is intended to provide some direction to assessors who are determining
for the assessment candidate. At all times the principles of assessment, that is,
validity, reliability, flexibility and fairness must be complied with.
Evidence Required
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evidence of being able to confidently and competently conduct testing, maintenance
and repair of HV circuit breakers. Where summative (or final) assessment is used it is
to include the application of the competency in the normal work environment or, at a
minimum, the application of the competency in a realistically simulated work
environment. In some circumstances, assessment in part or full can occur outside the
workplace. However, it must be in accordance with industry and regulatory policy.
(For more detail on assessment practices you are advised to refer to the Training
Package and the Evidence Guide for this Unit of Competence, especially where
longitudinal competency development and Profiling has been used).
SA

demonstrated.
At least
following:
two
of
At least
following:
two
of
the
the
Item List
Oil circuit breakers

Small oil volume circuit breakers
Air blast circuit breakers
Vacuum circuit breakers
GIS (SF6) circuit breakers
Gas circuit breakers
Spring operated mechanism
Solenoid operated mechanism
Hydraulic operated mechanism
Pneumatic operated mechanism
Maintain HV power system circuit breakers Assessment Guide
NSW DET 2009
Install and maintain substation DC

systems (UETTRDSB03A)
SA
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Learner Guide
TABLE OF CONTENTS
SA
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Assessment.................................................................................................................7
Introduction....................................................................................................................8
Hazards Associated with DC Systems...........................................................................8
Environmental Considerations.......................................................................................9
Performance Characteristics of DC Systems .................................................................9
Storage Battery Principles..............................................................................................9
Primary Cells .............................................................................................................9
Secondary Cells .......................................................................................................10
Lead Acid Batteries..................................................................................................10
Sulphation ............................................................................................................11
Terminal Corrosion..............................................................................................11
Sealed Lead Acid (SLA) Batteries...........................................................................12
Nickel Iron/ Nickel Alkaline....................................................................................12
Nickel Cadmium Cells.............................................................................................12
Identification of Battery Type..................................................................................13
Student Activity: Comparing Cell Type, Physical Size and Capacity.................13
Internal Resistance ...................................................................................................13
Battery Capacity.......................................................................................................14
Voltage Curves.........................................................................................................15
Lead Acid Discharge Curve.................................................................................15
Nickel Cadmium Discharge Curve ......................................................................15
Specific Gravity of Lead Acid Batteries..................................................................16
Specific Gravity Testing ..........................................................................................17
Student Activity: Using a Hydrometer ................................................................17
Batteries and Cells ...................................................................................................18
Student Activity: Constructing a Battery Bank ...................................................19
Battery Maintenance ................................................................................................20
Lead Acid Battery Maintenance ..........................................................................20
Alkaline (Nickel Cadmium / Nickel Iron) Batteries ............................................20
Student Activity: Battery Maintenance................................................................20
Replacing Defective Cells........................................................................................21
Student Activity: Replacing Defective Cells .......................................................21
Battery Charging......................................................................................................21
Lead Acid Charging.............................................................................................21
Nickel Cadmium / Nickel Iron Charging.............................................................22
Stratification of battery cells................................................................................22
Discharge Testing ....................................................................................................23
Quick Discharge Test...............................................................................................23
High Current Discharge Test ...................................................................................24
Capacity Testing ......................................................................................................24
Impedance Testing ...................................................................................................25
Install and maintain substation DC systems Learner Guide
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NSW DET 2009
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Principle of Impedance Testing ...........................................................................25

Student Activity: Discharge and Impedance Testing...........................................26
Recycling Secondary Battery Cells .............................................................................26
DC Testing ...............................................................................................................27
Student Activity: DC Testing...............................................................................27
DC Lighting Systems...................................................................................................27
First Aid ...................................................................................................................28
DRABC................................................................................................................28
Electric Shock ......................................................................................................29
Acid and Alkali Spills..........................................................................................29
Muscle Strain .......................................................................................................30
Learning Tasks and Practical Exercises.......................................................................31
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NSW DET 2009
Introduction
DC systems are installed in substations to supply power for control, protection,
alarms, communications, and other critical auxiliary circuits where maximum
reliability of supply is essential.
AC supplies can be unreliable, whether it is obtained from the local supply or from
on-site alternator sets. In the event of AC supply failure, DC electricity is stored in
batteries with sufficient capacity to provide enough power until the AC supply
becomes available again.
Different DC voltages are used within substations depending upon equipment

requirements. Common voltages are 50, 120 and 400.
The storage batteries may be of a few main types: lead-acid, alkaline, and nickelcadmium; each type with its own characteristics.
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Substation staff need to have an understanding of how batteries are maintained, the
principles of charging and discharging of batteries, how to recognise and diagnose
battery faults, and how to diagnose faults which may occur in the DC distribution
network. Installation in the context of this Learning Module refers to replacement
of defective units. (Installation and commissioning of battery banks will be generally
performed by contractors from the supplier.)
The principles contained within this module are also appropriate to other electrical
and electronic fields that use DC storage systems, including telecommunications,
security, computer and renewable energy.
Hazards Associated with DC Systems
There are a number of hazards that may be present when working with DC systems in
electrical substations. These include:
Electrical shock DC voltages and large currents may be high enough to cause
severe burns or electrocution.
Acids and alkalis Can burn skin and eyes.
Large mass batteries and cells are very heavy and can cause injury if not lifted
and transferred using appropriate techniques.
Confined spaces gases from battery cells can build up and require ventilation
before battery rooms can be entered.
SA
This list is not definitive. A risk assessment should always be performed before
commencing any activity. The work method statement for your organisation can also
provide guidance about how to work safely.
Treatment of these injuries is covered in the section on First Aid later in this
Learning Guide.
For more detail on working safely in electrical substations refer to Learning Module:
UETTDRIS22A - Implement and monitor the organisational OHS policies,
procedures and programs.
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NSW DET 2009
Environmental Considerations
As you will learn, battery cells may be constructed using the heavy metals of lead or
cadmium. Both of these metals are known to be detrimental to the environment, and
if absorbed by the human body they can be very detrimental to health. If nickel
cadmium cells are carelessly disposed of in landfills the cadmium eventually
dissolves and the toxic substance can seep into the water supply, causing serious
health problems.
Cells which have reached the end of their life or are faulty are returned to the
manufacturer on an exchange basis for replacement new cells, or are sent to specialist
recycling facilities where the metals are recovered and reused.
Battery rooms must be kept clean. Liquid spills or leaking electrolyte must be
cleaned up.
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Battery rooms should be bunded to prevent harmful chemicals entering the

environment. Bunding is a method of sealing the flooring and walls so that liquids
cannot escape into the environment. Any signs of damage to the proofing membrane
(cracking, flaking etc) should be reported.
All waste associated with DC Systems should be disposed of correctly, in accordance

with your organisational guidelines.
Further detail on environmental management can be found in the Learning Module:
UETTDRIS23A - Implement and monitor environmental and sustainable energy
management policies and procedures.
Performance Characteristics of DC Systems
SA
The battery is required to supply the electrical requirements of the system substation
when there is no output from the battery charger. This may be due to a loss of the
A.C. supply to the substation or a fault in the battery charger or its supply. Under
these conditions the battery is required to supply the loads it is connected to for a
period of 10 hours.
The battery should be able to be recharged from its design end-of-discharge voltage to
full charge in 5 hours.
Storage Battery Principles

Primary Cells
The simplest form of battery is non-rechargeable. These are known as primary

cells.
Without getting overly complicated, a battery is formed when two different metals
have an electrolyte (a solution that an electrical current can pass through) placed
between them. A potential difference (voltage) is developed between the two metals.
If the circuit is closed by placing a wire between the two metals then a chemical
reaction begins as electrons and ions circulate. In a primary cell a non-reversible
reaction occurs whereby the two metals are permanently changed. (This us
technically called a redox reaction, which means reduction-oxidisation, of which
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NSW DET 2009
common metal rusting is a type.) The common zinc-carbon dry cell and alkaline dry
cell is an example of this type of battery. A typical voltage of such a primary cell is
1.5 volts. Lithium dry cells may have voltages higher to 3 volts due to the higher
electrochemical potential of this metal and its compounds. The name dry cell is
given because the electrolyte is in a paste-form rather than liquid form.
Primary cells must not be recharged as they may explode.
Secondary Cells
Also called storage or accumulator cells, these battery cells can be recharged because
the chemical reaction that occurs during discharge can be reversed by applying a
reverse current into the cell. The cell can be discharged and recharged many times
(often many thousand times) before it is degraded to the point where it can no longer
provide reliable service.
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Lead Acid Batteries
This is perhaps the most common type of rechargeable battery,

especially in substation environments. It is also called a wet-cell
or flooded-cell battery because the electrolyte is in a liquid form.
They are vented batteries because the charging process can
produce gasses of hydrogen and oxygen which needs to be able to
escape from the confines of the battery case.
In its charged state the cathode (positive plates) are lead peroxide,
the anode (negative plates) are lead, and the electrolyte is dilute
sulphuric acid. As the cell is discharged the plates are converted to
lead sulphate and the electrolyte becomes water. The chemical
reaction looks like this:
SA
Figure 1
Cell charged
+ve plate -ve plate
A lead acid rechargeable

cell.
Cell discharged
+ve plate
-ve plate
PbO2
+ Pb
+ 2H2SO4
PbSO4
+ PbSO4
+ 2H2O
(lead
peroxide)
(lead)
(sulphuric
acid)
(lead
sulphate)
(lead
sulphate)
(Water
peroxide)
The open circuit voltage of a fully charged lead acid cell is between 2.3 volts and 2.4
volts. Under load the voltage will typically be between 2.0 volts and 2.2 volts.
Lead acid batteries have reduced life expectancy if they are left in a discharged
condition. Ordinarily they do not deal well with deep discharge cycles, although
recent advances in design have produced lead acid batteries more suitable to such
tasks.
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NSW DET 2009

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Trainer Guide
TABLE OF CONTENTS
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Further Reference Materials ......................................................................................6
Introduction....................................................................................................................9
Learning Outcomes......................................................................................................10
Topics Covered in this Learning Module ....................................................................10
Hazards Associated with DC Systems.........................................................................11
Environmental Considerations.....................................................................................11
Performance Characteristics of DC Systems ...............................................................13
Storage Battery Principles............................................................................................13
Primary Cells ...........................................................................................................13
Secondary Cells .......................................................................................................14
Lead Acid Batteries..................................................................................................14
Sealed Lead Acid (SLA) Batteries...........................................................................15
Nickel Iron/ Nickel Alkaline....................................................................................16
Nickel Cadmium Cells.............................................................................................16
Identification of Battery Type..................................................................................17
Internal Resistance ...................................................................................................18
Battery Capacity.......................................................................................................19
Voltage Curves.........................................................................................................21
Specific Gravity of Lead Acid Batteries..................................................................22
Specific Gravity Testing ..........................................................................................24
Batteries and Cells ...................................................................................................25
Battery Maintenance ................................................................................................27
Replacing Defective Cells........................................................................................28
Battery Charging......................................................................................................30
Discharge Testing ....................................................................................................33
Quick Discharge Test...............................................................................................33
High Current Discharge Test ...................................................................................34
Capacity Testing ......................................................................................................35
Impedance Testing ...................................................................................................37
Recycling Secondary Battery Cells .............................................................................38
DC Testing ...................................................................................................................39
DC Lighting Systems...................................................................................................40
First Aid .......................................................................................................................41
Install and maintain substation DC systems Trainer Guide
-3-
NSW DET 2009
Notes to Trainer
Timing
Introduction
Display Slide 2 & 3
PL
DC systems are installed in substations to supply power for control, protection,

alarms, communications, emergency lighting, and other critical auxiliary circuits
where maximum reliability of supply is essential.
AC supplies can be unreliable, whether it is obtained from the local supply or from
on-site alternator sets. In the event of AC supply failure DC electricity is stored in
batteries with sufficient capacity to provide enough power until the AC supply
becomes available again.
While the battery provides the reserve of stored energy, this is only normally used
in an emergency, or for supplying the short time heavy current drain of circuit
breaker closing solenoids. Under normal conditions the station load and the small
current required to maintain the battery in a fully charged state is supplied by the
battery charger.
SA
M
Different DC voltages are used within substations depending upon equipment

requirements. Common voltages are 50, 120 and 400.
The storage batteries may be of a few main types: lead-acid, alkaline, and nickelcadmium; each type with its own characteristics.
Substation staff need to have an understanding of how batteries are maintained, the
principles of charging and discharging of batteries, how to recognise and diagnose
battery faults, and how to diagnose faults which may occur in the DC distribution
network. Installation in the context of this Learning Module refers to
replacement of defective units. (Installation and commissioning of battery banks
will be generally performed by contractors from the supplier.)
Some ESI organisations may use other

voltages such as 20VDC and 30VDC.
Furthermore, there may be some
tolerance around the actual voltage
descriptor; 50VDC may also be known as
48VDC, 120VDC may also be know as
110VDC depending upon the particular
ESI organisation.
400VDC is commonly used to supply
Uninterruptible Power Supplies (UPS)
systems: inverters generating 240VAC for
critical mains powered equipment such as
computers.
The principles contained within this module are also appropriate to other electrical
and electronic fields that use DC storage systems, including telecommunications,
security, computer and renewable energy.
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NSW DET 2009
Display Slide 4
Learning Outcomes
(As per those listed on Page 5 of this Trainer Guide.)
Display Slide 5
DC Equipment in Substations
Primary and secondary cells
Lead-acid cells
Alkaline cells
Cell capacity
Battery maintenance
Battery testing
Earth fault detection
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Topics Covered in this Learning Module
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NSW DET 2009
E
Display Slide 6
Hazards Associated with DC Systems
There are a number of hazards that may be present when working with DC
systems in electrical substations. These include:
Electrical shock DC voltages and large currents may be high enough to cause
severe burns or electrocution.
Acids and alkalis Can burn skin and eyes.
Large mass batteries and cells are very heavy and can cause injury if not
lifted and transferred using appropriate techniques.
Confined spaces gases from battery cells can build up and require ventilation
before battery rooms can be entered.
PL
SA
M
This list is not definitive. A risk assessment should always be performed before
commencing any activity. The work method statement for your organisation can
also provide guidance about how to work safely.
Treatment of these injuries is covered in the section on First Aid later in this
Learning Guide.
For more detail on working safely in electrical substations refer to Learning
Module: UETTDRIS22A - Implement and monitor the organisational OHS
policies, procedures and programs.
Environmental Considerations
Display Slide 7
As you will learn, battery cells may be constructed using the heavy metals of lead
or cadmium. Both of these metals are known to be detrimental to the environment,
and if absorbed by the human body they can be very detrimental to health. If
nickel cadmium cells are carelessly disposed of in landfills the cadmium
eventually dissolves and the toxic substance can seep into the water supply,
causing serious health problems.
Cells which have reached the end of their life or are faulty are returned to the
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NSW DET 2009


Assessment Guide
M
PL
UETTDRIS05A
UETTDRIS22A
UETTDRIS23A
UETTDRSB01A
UETTDRSB02A
UETTDRIS03A
UETTDRIS04A
UETTDRIS05A

environment
SA
designed for UETTDRSB03A Install and maintain substation DC systems. This
guide is intended to provide some direction to assessors who are determining
for the assessment candidate. At all times the evidence requirements as set out in the
unit and the principles of assessment, that is, validity, reliability, flexibility and
fairness must be complied with.
Evidence Required
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evidence of being able to maintain and repair the range of DC systems within the
electrical substation.
Where summative (or final) assessment is used it is to include the application of the
competency in the normal work environment or, at a minimum, the application of the
competency in a realistically simulated work environment. In some circumstances,
assessment in part or full can occur outside the workplace. However, it must be in
accordance with industry and regulatory policy. (For more detail on assessment
practices you are advised to refer to the Training Package and the Evidence Guide
for this Unit of Competence, especially where longitudinal competency development
and Profiling has been used).
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demonstrated.
At least
following:
At least
following:
one
of
one
of

At least
following:
two
of
the
the
the
Item List
Nickel cadmium batteries

Sealed/unsealed lead acid batteries
Main batteries
Communication batteries
Pilot isolation batteries
Battery chargers
DC control circuits
Cell voltage test
Hydrometer/specific gravity test
Battery discharge and capacity tests
Impedance testing
Install and maintain substation DC systems Assessment Guide
NSW DET 2009
Implement and monitor environmental

and sustainable energy management
policies and procedures (UETTDRIS23A)
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Learner Guide
TABLE OF CONTENTS
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Assessment.................................................................................................................7
Introduction....................................................................................................................8
Definitions Used in this Module ................................................................................8
The Environment .......................................................................................................9
Common Environmental Hazards from Substations..................................................9
Environmental Management Systems..........................................................................10
Role of Team Leaders and Supervisors in Environmental Management ....................12
Environmental Legislation and Compliance................................................................13
Specific Environmental Legislation.............................................................................13
Department of Environment and Climate Change (DECC) ....................................14
Environment Protection Offences............................................................................14
Instituting Proceedings.............................................................................................15
Organisational Environmental Standards ................................................................16
Summary of Environmental Requirements..............................................................16
Pollution and Pollution Control ...................................................................................17
Soil Erosion and Sediment Control..........................................................................17
Acid sulphate Soils ..................................................................................................22
Stormwater and waterways ......................................................................................24
Liquid Handling and Storage ...................................................................................25
Storage of Oil-filled Containers and Equipment .....................................................26
Noise Management ..................................................................................................30
Air pollution and Dust Suppression.........................................................................31
Greenhouse Gas Emissions......................................................................................32
Handling Sulphur Hexafluoride (SF6) .....................................................................33
Historical Contamination .........................................................................................33
Heritage Items..............................................................................................................34
Vegetation Control.......................................................................................................36
Weeds.......................................................................................................................37
Pesticides and Herbicides ........................................................................................37
Bushfire Management..............................................................................................38
Waste Management......................................................................................................39
Legislation................................................................................................................39
Waste Classification.................................................................................................39
Licensing Requirements...........................................................................................41
Responsibilities ........................................................................................................41
Minimum Waste Management Standards................................................................42
Commonly Generated Wastes..................................................................................43
Vegetation ................................................................................................................45
Soil, Rock and Fill ...................................................................................................45
Poles, Towers and Columns.....................................................................................48
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Inert Wastes .............................................................................................................52

Recyclables ..............................................................................................................53
Liquid Wastes ..........................................................................................................53
Containers ................................................................................................................58
Oils and Oil-Filled Equipment.................................................................................59
Electrical and Electronic Equipment .......................................................................63
Asbestos-based Materials.........................................................................................65
Gases ........................................................................................................................67
Radioactive Wastes..................................................................................................68
Other Wastes............................................................................................................68
Environmental Incidents ..............................................................................................68
Causes of Environmental Incidents .........................................................................69
Typical Locations where Environmental Incidents Occur.......................................69
Appendix One: Case Study of Pollution of a Waterway. ............................................71
Appendix Two: Case Study of Desecration of Indigenous Heritage Item...................74
Further Student Exercises ............................................................................................79
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NSW DET 2009
Introduction
This Unit, Implement and monitor environmental and sustainable energy
management policies and procedures, covers a range of topics that apply to the
everyday tasks when working around a substation. It includes the identification,
assessment and control (or minimisation) of environmental risks that may occur from
substation operations and maintenance. It also covers aspects such as dealing with
waste products of various types, recycling, and responding to an environmental
incident.
As this learning module is aligned to a CIV Unit of Competence there is an

expectation that you will be proactive in your attitude to environmental matters. This
means being actively involved in the process of ensuring that your organisations
work procedures are continually improved upon and standardised so as to protect the
environment.
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When you have completed this unit, you should be able to apply relevant
environmental and sustainable energy procedures to specific projects or sites,
including incorporating energy conservation principles and recycling procedures.
Definitions Used in this Module
Sites include buildings, plant, construction and maintenance sites, workshops,

laboratories, catchments, flood plains, irrigation sites, wetlands, drainage sites,
waste disposal sites, easements.
Environmental risks include impact of mismanagement of chemicals or biological

agents, detrimental impact on limited water resources, spillage, waste disposal,
detrimental impact on water catchment areas (urban and non-urban), detrimental
impact on rivers, waterways and channels, unsatisfactory trade waste treatment
and disposal processes, poor construction processes, planning efficiencies, neglect
of sustainable energy principles.
Environmental legislation includes relevant Federal and State/Territory

legislation, local government by-laws, government or quasi government policies
and regulations, community planning and development agreements (eg, land care
agreements)
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Incidents of environmental impact may involve implementing emergency

responses. Incidents include emissions to air, releases of water, releases to land or
water, vibration and noise, disposal of waste, contamination of land, impact on
communities, destruction of habitat, use of energy sources, waste generation
processes and technologies, impact on culturally significant sites.
Environmental management documentation includes information on applicable

environmental laws or other requirements, complaint records, training records,
process information, process operational log books, inspection, maintenance and
calibration records, relevant contractor and supplier information, incident reports,
information on emergency preparedness and response, records of significant
environmental impacts, chain of custody and compliance records, audit results and
management reviews.
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NSW DET 2009
The Environment
The substations that are owned and operated by electrical supply organisations operate
in an environment that includes:
Land
Water
Air
Flora and fauna
Natural resources, and
Humans and their interactions, including the built-environment.
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Environmental management is therefore an essential part of an electricity distributors

operations. There is considerable pressure on all to operate in an environmentally
friendly way, for reasons such as:
Legislation and compliance enforcement
Stakeholder pressure from shareholders, employees, environmental interest

groups, consumers, and the general public.
Reputation and corporate image.
There are economically sound reasons to do so (e.g reducing waste increases

profitability).
Common Environmental Hazards from Substations
The operation and maintenance of substations has the potential to result in a range of
environmental problems. Some of these are:
Historical contamination (such as oil or chemical contamination caused by past
industrial activities)
Generation of waste and appropriate disposal of waste
Oil management and spills
SA
Visual impacts
Greenhouse gas emissions
Asbestos (handling and removal)
Air emissions (toxic and greenhouse gases)
Noise and vibration
Dust generation
PCB (polychlorinated biphenyls) management
Radiation (electric and magnetic fields EMF)
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Student Exercise
List other types of environmental hazards that you may be aware of existing (or
potentially existing) in and around substations.
Environmental Management Systems
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All electricity distribution organisations today will have an Environmental

Management System, (EMS) the purpose of which it to put into place policies and
procedures for identifying, controlling and managing environmental hazards. (This
may exist as a subset of another management system such as Quality or Health,
Safety and Environment.)
Figure 1: A graphic illustration on Environmental

Management System. (Courtesy of Integral Energy)
The diagram in Figure 1 shows a typical graphic of an EMS. Whilst the graphic
representing the EMS may look different in your organisation, the EMS will still have
the following characteristics:
There is a Planning Phase where hazards are identified and the risks they pose
are assessed.
Suitable control measures are determined and selected.
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NSW DET 2009

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Trainer Guide
TABLE OF CONTENTS
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Introduction....................................................................................................................8
Learning Outcomes........................................................................................................8
Topics Covered in the Module.......................................................................................8
Definitions Used in this Module ................................................................................9
The Environment .....................................................................................................10
Common Environmental Hazards from Substations................................................10
Environmental Management Systems..........................................................................11
Role of Team Leaders and Supervisors in Environmental Management ....................12
Environmental Legislation and Compliance................................................................13
Specific Environmental Legislation.........................................................................13
Department of Environment and Climate Change (DECC) ....................................14
Environment Protection Offences............................................................................15
Instituting Proceedings.............................................................................................16
Organisational Environmental Standards ................................................................17
Summary of Environmental Requirements..............................................................17
Pollution and Pollution Control ...................................................................................18
Soil Erosion and Sediment Control..........................................................................19
Acid sulphate Soils ..................................................................................................23
Stormwater and waterways ......................................................................................25
Liquid Handling and Storage ...................................................................................25
Liquids commonly found at substations include: ....................................................25
Storage of Oil-filled Containers and Equipment .....................................................26
Noise Management ..................................................................................................29
Air pollution and Dust Suppression.........................................................................31
Greenhouse Gas Emissions......................................................................................31
Handling Sulphur Hexafluoride (SF6) .....................................................................32
Historical Contamination .........................................................................................33
Heritage Items..............................................................................................................33
Vegetation Control.......................................................................................................35
Weeds.......................................................................................................................36
Pesticides and Herbicides ........................................................................................37
Bushfire Management..............................................................................................38
Waste Management......................................................................................................38
Legislation................................................................................................................38
Waste Classification.................................................................................................39
Licensing Requirements...........................................................................................40
Minimum Waste Management Standards................................................................42
Commonly Generated Wastes..................................................................................44
Vegetation ................................................................................................................46
Soil, Rock and Fill ...................................................................................................46
Poles, Towers and Columns.....................................................................................50
Environmental and sustainable energy management policies Trainer Guide
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NSW DET 2009
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Inert Wastes .............................................................................................................57

Recyclables ..............................................................................................................58
Liquid Wastes ..........................................................................................................58
Containers ................................................................................................................65
Oils and Oil-Filled Equipment.................................................................................67
Electrical and Electronic Equipment .......................................................................72
Asbestos-based Materials.........................................................................................75
Gases ........................................................................................................................76
Radioactive Wastes..................................................................................................77
Other Wastes............................................................................................................78
Environmental Incidents ..............................................................................................78
Causes of Environmental Incidents .........................................................................79
Typical Locations where Environmental Incidents Occur.......................................80
Further Student Exercises ............................................................................................81
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NSW DET 2009
Notes to Trainer
Timing
Introduction
Display Slide 1
PL
This Unit, Implement and monitor environmental and sustainable energy management
policies and procedures, covers a range of topics that apply to the everyday tasks when
working around a substation. It includes the identification, assessment and control (or
minimisation) of environmental risks that may occur from substation operations and
maintenance. It also covers aspects such as dealing with waste products of various types,
recycling, and responding to an environmental incident.
As this learning module is aligned to a CIV Unit of Competence there is an expectation that
you will be proactive in your attitude to environmental matters. This means being actively
involved in the process of ensuring that your organisations work procedures are continually
improved upon and standardised so as to protect the environment.
SA
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When you have completed this unit, you should be able to apply relevant environmental and
sustainable energy procedures to specific projects or sites, including incorporating energy
conservation principles and recycling procedures.
Display Slide 2 & 3
Learning Outcomes
[Refer to the Learning Outcomes at the beginning of this Learning Module.]

Display Slide 4 & 5
Topics Covered in the Module
Introduction: Why undertake environmental management?

Legislation and Regulation
Pollution
Soil erosion
Liquid handling and storage
Oil storage and handling
Noise pollution
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NSW DET 2009
Dust suppression
Greenhouse gas pollution
Heritage items
Vegetation control
Waste management
Non-liquid waste
Liquid waste
Waste poles, towers and columns
Recycling
Asbestos
Environmental incidents
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Definitions Used in this Module
Sites include buildings, plant, construction and maintenance sites, workshops, laboratories,
catchments, flood plains, irrigation sites, wetlands, drainage sites, waste disposal sites,
easements.
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Environmental risks include impact of mismanagement of chemicals or biological agents,

detrimental impact on limited water resources, spillage, waste disposal, detrimental impact
on water catchment areas (urban and non-urban), detrimental impact on rivers, waterways
and channels, unsatisfactory trade waste treatment and disposal processes, poor
construction processes, planning efficiencies, neglect of sustainable energy principles.
Environmental legislation includes relevant Federal and State/Territory legislation, local

government by-laws, government or quasi government policies and regulations,
community planning and development agreements (eg, land care agreements)
Incidents of environmental impact may involve implementing emergency responses.

Incidents include emissions to air, releases of water, releases to land or water, vibration
and noise, disposal of waste, contamination of land, impact on communities, destruction of
habitat, use of energy sources, waste generation processes and technologies, impact on
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NSW DET 2009


Trainer Guide
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UETTDRIS05A
UETTDRIS22A
UETTDRIS23A
UETTDRSB01A
UETTDRSB02A
UETTDRIS03A
UETTDRIS04A
UETTDRIS05A

environment
SA
designed for UETTDRIS23A - Implement and monitor environmental and sustainable
energy management policies and procedures. This guide is intended to provide some
direction to assessors who are determining competence of students who have
completed the theoretical and practical instruction in this learning module. Assessors
are expected to use their own judgement in designing appropriate assessment
questions and tasks and putting them into context for the assessment candidate. At all
times the evidence requirements as set out in the unit and the principles of assessment,
that is, validity, reliability, flexibility and fairness must be complied with.
Evidence Required
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evidence of being able to identify, assesses and control environmental hazards that
may occur in substations according to the appropriate legislation, guidelines,
standards and organisational policies and procedures. Where summative (or final)
assessment is used it is to include the application of the competency in the normal
work environment or, at a minimum, the application of the competency in a
has been used).
SA
demonstrated.
Item List
Gather environmental management information.

Implement and monitor environmental and
sustainable energy policies and procedures.
Identify environmental impacts and assess risks.
Implement and monitor the procedures for
quantifying environmental impacts and controlling
risks.
Implement and monitor procedures for dealing
with environmental incidents.
Maintain environmental records, reports and plans.
Environmental and sustainable energy management policies Assessment Guide
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NSW DET 2009

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Maintain HV power system transformers

& instrument transformers (UETTRDSB05A)

Certificate IV in ESI Substation Resources (UET40206)

State Training Services

Using this Learner Resource..........................................................................................5

Maintain HV power system transformers Learner Guide

NSW DET 2009

Self Assessment Questions ........................................................................................106

Maintain HV power system transformers Learner Guide

NSW DET 2009

Types of Devices Covered in this Module

Types of Maintenance Testing Covered in this Module

Importance of this Learning Module

Maintain HV power system transformers Learner Guide

NSW DET 2009

Typical Tasks Required

Maintain HV power system transformers Learner Guide

NSW DET 2009

Transformer Theory A Review

Figure 1: Transformers can transform voltages up or down.

(Safety Note: This ability of a transformer to operate in either direction is a critical

Why use Transformers

Maintain HV power system transformers Learner Guide

NSW DET 2009

The core (which is made of an iron alloy)

Figure 3: Interior view of a relatively small power transformer.

NSW DET 2009

Maintain HV power system transformers

Certificate IV in ESI Substation Resources (UET40206)

State Training Services

Using this Trainer Resource...........................................................................................4

Maintain HV power system transformers Trainer Guide

NSW DET 2009

(As per those listed on page 6 of this Trainer Guide.)

Topics Covered in this Module

Maintain HV power system transformers Trainer Guide

NSW DET 2009

Types of Devices Covered in this Module

Voltage (potential) transformers

Reactors (series and shunt)

Types of Maintenance Testing Covered in this Module

Dielectric dissipation factor tests

Low voltage excitation tests

Frequency response analysis

Recovery voltage measurements

Winding resistance checks

Maintain HV power system transformers Trainer Guide

NSW DET 2009

Importance of this Learning Module

Typical Tasks Required

Transformer Theory A Review

Much of the content of this

Maintain HV power system transformers Trainer Guide

You may need to assist trainees

NSW DET 2009

Maintain HV power system transformers

Certificate IV in ESI Substation Resources (UET40206)

Perform substation switching operation to a given schedule

State Training Services

A representative body of performance criteria demonstrated within the timeframes

To be deemed as competent in this Unit, the candidate must provide sufficient

The minimum number of items

Maintain HV power system transformers Assessment Guide

NSW DET 2009