Carryout - Substation Inspections

State Training Services

Carry out substation inspections (UETTDRSB02A) Certificate IV in ESI Substation Resources (UET40206) Learner Guide

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Carry out substation inspections Learner Guide - 3 - NSW DET 2009

TABLE OF CONTENTS Using this Learner Resource..........................................................................................4

Use as Refresher Training .......................................................................................4 Mapping to Training Package........................................................................................4

Essential Knowledge and Associated Skills ..........................................................5 Learning Outcomes....................................................................................................5

Pre-Requisite Knowledge ......................................................................................6 Assessment.................................................................................................................6 Recognition of Prior Learning/Current Competence.................................................7

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

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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. 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: .. .. .. 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.SA

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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. Equipment to be inspected (Some general principles when conducting the inspection :) 1. (!!) Advise the System Operator that you are on site and about to commence

inspection activities. 2. (!!) Confirm that the DC battery volts is correct. This will ensure that

protection equipment will operate correctly if required during the inspection. 3. (!!) 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.

4. 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.)

5. 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.

6. 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.

7. 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.

8. 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.

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Fire Pump (if applicable) Fire pump is checked to ensure that it operates correctly from its electric motor

and alternate motor (e.g. fuel motor) if supplied. Fuel and water level of pump is checked. (Usually there will be an indicator line

showing the correct level.) Spare fuel supply is checked. Fuel is stored correctly, and there is an adequate

amount. Domestic pump operation is checked (where applicable). Any defects which cannot be dealt with during the inspection must be reported for repair or replacement. Fire Protection Equipment Fire extinguisher tags are checked to confirm currency. Fire protection systems are checked for currency of inspection tags. Fire fighting equipment is checked for good condition. Fire protection systems are checked as per summary sheets or local workplace

instructions. Fire protection equipment can only be serviced by licensed providers. Any defects must be reported for repair or replacement. Safety Equipment and Spares Inspect and note the condition of: Area marker tape stands Access/authority permit holders Area maker tape Locks Warning and Danger signs Spare danger and warning tags, including quantity on hand. Any damaged or missing equipment must be reported so that it can be replaced. Portable and Trailing Earth Equipment Inspect all sticks for fractures or other damage. Check leads (earthing conductor) for damage. Any damaged or missing equipment must be reported so that it can be replaced. H.V. Operating Rods The condition of the rods should be inspected, as well as the number of

extensions. The date of the last HV test on the rod should be recorded and any further testing

needed should be identified and recorded on the inspection report. (Operating rods are to be tested by HV tests annually. Each set of rods should be

checked.)

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Any damaged or missing equipment must be reported so that it can be replaced. HV Testing Device HV testing device meter operation should be checked and batteries replaced if

necessary. Lighting All lighting is checked and lamps/tubes replaced where necessary. Lumitrols and contactor operation checked (where fitted). Emergency lighting checked. Most defective lighting (including lumitrols and alarm lamps) can be rectified during the inspection using spares held on-site. Some external lighting may be at heights requiring working-at-heights that may be particularly hazardous in the substation environment. In these cases the defect should be report for repair through a Works Order. Spares Equipment spares are inspected and checked for serviceable condition. Quantities of lamps, fuses and panel equipment spares are checked to ensure

sufficient stocks are available on site. General Appearance The Auxiliary Services Building, substation yard and surrounds are inspected.

Maintenance work required (e.g. weed poisoning, grass slashing) is noted. Cleaning of building and polishing floors, disposal of rubbish, weeding substation

yards and mowing of grass should be done where possible. Security Fencing and Gates The perimeter fencing and gates need to be checked for overall condition. Security locks are in place. Fencing is undamaged. Gate hinges secure. Failures in the security fencing or gates are very serious as it can allow entry into the hazardous substation environment by members of the public, for example, children. Any defects should be escalated for immediate attention. Oil Leaks Any oil leaks are identified with reference to the location and number of the piece

of equipment. Leaks are identified as requiring urgent attention or not.

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Where equipment is leaking the oil level of that piece of equipment must be checked and confirmed as acceptable.

Major Substation Inspection Battery Checks (if applicable) Electrolyte levels in batteries checked and topped up if necessary. Charger turned off and battery placed under load. Cell voltages are checked.

Note any cells that differ significantly from the rest of the cells. Cell interconnecting links are visually checked for deterioration and all cell

connections for continuity and tightness. Operation of ventilation system and general condition is checked. Fan operates

freely and grill is clear of an obstructions. (Further specific detail on this subject is included in the Learning Module: UETTDRSB03A Install and maintain substation DC systems.) HV Equipment Overall Condition The following HV equipment checks are performed visually. Be aware that generally this equipment is in-service and operating at high voltages. Maintain HV clearance distances at all times. HV equipment includes line traps, air cored reactors, transformer tanks and

support structures. Look for evidence of flashovers, pollution, excessive corona, evidence of

overheating, or any abnormalities. Check alignment and condition of disconnectors. Check appearance of earth mat connections and condition of equipment of

equipment in marshalling kiosks. Check general condition of all HV equipment, looking for corrosion, painting and

general condition. Check the equipment's H.V. operating nameplate. Circuit Breakers Record Cyclometer/pump start readings Record oil levels Check for and record oil/air/gas leaks Check the weatherproofing of cubicles Check anti-condensation heaters and general condition. The operating mechanism of the circuit breakers is visually inspected. The operation counter reading is recorded in the log book. It may also be

necessary to report this information in organisation-specific reporting tools e.g. monthly reports.

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Circuit breakers should be operated once a year to exercise the mechanism. Usually performed during annual maintenance, or when performing reclose and intertrip checks.

Transformers (including out-of-service transformers) Oil levels are checked. Breathers are checked. If colour change indicates significant moisture absorption

they should be replaced. All fans and pumps are checked for correct operation. This will require switching

to manual to be able to operate and perform the checks. Bushing oil levels are check if possible. Checks for oil leaks. Readings are to be taken of oil and winding temperature, the operation counter,

tap changer position and operating range. Reset range indicators on temperature gauges. Explosion membranes are confirmed as being intact, and any pressure release

devices have not tripped. Tapchangers Record cyclo counter reading. Inspect gear box oil and general condition. Oil colour is acceptable; no excessive

sludge. Procedure for checking Tap Changer Operation, Voltage Control and Parallel Operation In-service transformers are selected to non-auto voltage control and raised two

taps by push button control. When the selector is returned to auto voltage control the tap changer should return the output voltage to normal.

This is to be done in both raise and lower directions. Both transformers in turn are operated as master (where parallel operation is

provided) and the follower transformer is confirmed as following the master in each case.

Tapchangers are run through their tapping range if they have not gone through the reversing position in the last 12 months.

o This must be done with the transformer out-of-service to prevent extreme voltage conditions.

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Control Rooms Emergency lighting. Operates correctly when 240VAC mains power removed, or Operates when test button pushed (on some models) ELV lamps operational. Replace any defective globes.

415 V change-over. Test that change-over occurs and then switch back. Local and remote operation of alarms. (Advise System Operator and any other

staff present that test is being performed). Fire protection system and alarm panel. (Advise System Operator, Fire Protection

Company and any other staff present that test is being performed). Operating rods and earths. (As per earlier comments on this topic.) Revenue metering supplies. (Paper recorder paper is adequate, etc) Air conditioners. Operating as expected. Diesel Alternators or Pumps (if applicable) Checks are made of: Fuel level. Fuel is full or at the appropriate level. Oil level. Sump level is correct. Operation. Starts and runs without signs of problems. Leaks. No leaks should be observed, especially from fuel system and oil seals and

sump. Battery/charger and heaters. Starter battery is correctly connected to trickle

charger and maintaining correct voltage level. Check specific gravity of battery as an indication of correct charge level.

Compressed Air Systems (if applicable) Checks are made of: Compressor operation, (Bleed off some air and check compressor operation) Cyclo readings, Oil leaks and air leaks. No audible air leaks are apparent. Dryers are drained and wiped out. Oilers are topped up to fill-line. General condition of equipment Switchyard Checks are made of: General condition of switchyard. Condition of pavement surfaces, gravel

surfaces, condition of buildings, masonry structures. Metalwork structures and surfaces. Look for signs of corrosion, especially at

ground level where DC electrolysis can cause problems. Condition of HV cages and switchyard external fence.

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Operation and condition of all switchyard lighting. (See earlier comments on this subject.)

Cables General condition of cables and busbars is visually checked. Isolators (disconnectors) are visually checked for full and tight closing.

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Carry out substation inspections (UETTDRSB02A) Certificate IV in ESI Substation Resources (UET40206) Trainer Guide

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Carry out substation inspections Trainer Guide - 3 - NSW DET 2009

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

Modifying the Training Resources ............................................................................4 Training Learners in Specific Tasks ..........................................................................5 Use as Refresher Training .......................................................................................5 Mapping to Training Package....................................................................................5

Essential Knowledge and Associated Skills ..........................................................5 Learning Outcomes....................................................................................................6

Pre-Requisite Knowledge ......................................................................................7 Introduction: The Need for Substation Inspections .......................................................8

Learning Outcomes....................................................................................................8 Topics Covered in this Module..................................................................................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

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Timing Instructional Content Notes to Trainer

Introduction: 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.

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.

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 organisation-specific aspects.

Learning Outcomes (As per those listed on Page 5 of this Guide.)

Display Slide 2, 3 & 4

Topics Covered in this Module Frequency of Substation Inspections Safety equipment and spares Visual checks DC Systems HV Equipment

Display Slide 5

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Control rooms and ancillary plant Environmental inspections Oil containment systems Ancillary Slides

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General Substation Inspections Display Slide 6

Categories of Substation Inspection Inspections are split up into three distinct categories:

General Substation Inspection Substation Security Inspection Substation Environmental Inspection

Frequency of Substation Inspections Inspections are carried out by a competent substation operator/fitter on two time scales.

Minor Substation Inspection Every month a minor Substation inspection will be carried out and this inspection 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.

Display Slide 7 (N.B. Trainer to confirm currency of this schedule and applicability to organisation. Update notes as required.)

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Minor Substation, Environmental and Safety Inspection Before commencing an inspection, you must advise the System Operator that you are on-site and about to commence inspection and checking tasks.

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.

Trainers should advise trainees to refresh their knowledge on these topics by referring to Learning Modules on the topic of safe working in substations.

Equipment to be inspected It is good practice to use a checklist when conducting inspections. The following equipment listed in this section can form the basis of such a checklist.

Some organisations have management systems that generate inspection checklists automatically. If this is the case in your organisation, then you should refer to this and consider modifying the instructional design accordingly.

(Some general principles when conducting the inspection :) 1. (!!) Advise the System Operator that you are on site and about to commence

inspection activities.

2. (!!) Confirm that the DC battery volts is correct. This will ensure that protection equipment will operate correctly if required during the inspection.

3. (!!) 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.

4. Switch alarms to local, switch on the indicating lamps (if fitted) and leave on

The trainer should add any organisation/regional/local additions to this list of principles for conducting inspections as appropriate. The (!!) symbol indicates that these points should be emphasised. SA

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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.)

5. 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.

6. 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.

7. 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.

8. 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.

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Fire Pump (if applicable)

Fire pump is checked to ensure that it operates correctly from its electric motor and alternate motor (e.g. fuel motor) if supplied.

Fuel and water level of pump is checked. (Usually there will be an indicator line showing the correct level.)

Spare fuel supply is checked. Fuel is stored correctly, and there is an adequate amount.

Domestic pump operation is checked (where applicable). Any defects which cannot be dealt with during the inspection must be reported for repair or replacement.

Display Slide 8

Fire Protection Equipment

Fire extinguisher tags are checked to confirm currency. Fire protection systems are checked for currency of inspection tags. Fire fighting equipment is checked for good condition. Hoses are in good

serviceable condition. Fire blankets are

Fire protection systems are checked as per summary sheets or local workplace instructions.

Fire protection equipment can only be serviced by licensed providers. Any defects must be reported for repair or replacement.

Display Slide 9, 10 & 11

Safety Equipment and Spares

Inspect and note the condition of:

Area Marker Tape Stand Access authority holders Yellow tape

The AS/NZ Standard now specifies yellow tape. Some may previously know this as white tape. Display Slide 12 & 13 SA

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Locks Warning and Danger signs Spare danger and warning tags, including quantity on hand. Any damaged or missing equipment must be reported so that it can be replaced.

Portable and Trailing Earth Equipment

Inspect all sticks and heads for fractures or other damage. Check leads (earthing conductor) for damage. Check earths for currency of test dates. Any damaged or missing equipment must be reported so that it can be replaced.

Display Slide 14 & 15

H.V. Operating Rods

The condition of the rods should be inspected, as well as the number of extensions.

The date of the last HV test on the rod should be recorded and any further testing needed should be identified and recorded on the inspection report.

(Operating rods are to be tested by HV tests annually. Each set of rods should be checked.)

Any damaged or missing equipment must be reported so that it can be replaced.


HV Tester (Proving De-energised Meter) HV testing device meter operation should be checked and batteries replaced if

necessary.


Lighting All lighting is checked and lamps/tubes replaced where necessary. Lumitrols and contactor operation checked (where fitted). Emergency lighting checked.

Display Slide 20 SA

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Most defective lighting (including lumitrols and alarm lamps) can be rectified during the inspection using spares held on-site. Some external lighting may be at heights requiring working-at-heights that may be particularly hazardous in the substation environment. In these cases the defect should be report for repair through a Works Order.

Spares Equipment spares are inspected and checked for serviceable condition. Quantities of lamps, fuses and panel equipment spares are checked to ensure

sufficient stocks are available on site. (If applicable.)

Display Slide 21

General Appearance The Auxiliary Services Building, substation yard and surrounds are inspected.

Maintenance work required (e.g. weed poisoning, grass slashing) is noted. Cleaning of building and polishing floors, disposal of rubbish, weeding

substation yards and mowing of grass should be done where possible.


Security Fencing and Gates The perimeter fencing and gates need to be checked for overall condition. Security locks are in place. Fencing is undamaged. Gate hinges secure. Failures in the security fencing or gates are very serious as it can allow entry into the hazardous substation environment by members of the public, for example, children. Any defects should be escalated for immediate attention.


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Instructions to Assessors 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 Perform substation switching operation to a given schedule UETTDRIS22A Implement and monitor the organisational OHS policies,

procedures and programs UETTDRIS23A Implement and monitor environmental and sustainable energy

management policies and procedures UETTDRSB01A Diagnose and rectify faults in power systems substation

environment UETTDRSB02A Carry out substation inspections UETTDRIS03A Install and maintain substation DC systems UETTDRIS04A Maintain HV power system circuit breakers UETTDRIS05A Maintain HV power system transformers and instruments This Assessment Guide together with a Trainer Guide and a Learner Guide are 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.

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:

Carry out substation inspections (UETTDRSB02A) Certificate IV in ESI Substation Resources (UET40206) Assessment Guide

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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 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). 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. The minimum number of items

on which skill is to be demonstrated.

Item List

At least one of the following:

Transmission substation Distribution substation Traction substation

All of the following: Substation plant and equipment Substation environmental systems Substation security systems

Carry out substation inspections Assessment Guide - 2 - NSW DET 2009

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Carryout - Substation Inspections

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