Issue 10 – 24 September 2009


Two new padlocks, an NK6 padlock and an NMK2 padlock, were recently returned
from the field after a defect was noticed.
1) Missing Screw - The returned NK6 padlock’s cylinder was found to dislodge from
the padlock’s body (Figure 1) due to a missing cylinder retaining screw, which holds
the padlock assembly together (Figure 2).
2) Hole not countersunk – The shackle of the NMK2 padlock was able to be pulled
out when the padlock was in the locked position (Figure 3). The problem was found
to have been caused by a missing countersink hole for the cylinder retaining screw.
The missing countersink hole caused the screw to sit higher in the shackle chamber              Figure 1 - The defective NK6 unit's          Figure 2 – Cylinder retaining screw is
                                                                                              cylinder was found to dislodge from its          absent from a defective unit (Left
thereby preventing the shackle from fully engaging the locking ball when closed.              body. The defect can easily be checked         padlock) but present in a normal unit
                                                                                                by striking the side of the padlock                     (Right padlock)
ACTIONS TAKEN: A number of padlocks were inspected at WP stores to determine
                                                                                                   against the palm of your hand
the magnitude of the problem. No padlock during the inspection was found to have
any of the quality issues listed above. No previous or further reports of this problem
have been reported.
The supplier has not had any reports of this issue from other customers.
Nevertheless the supplier has been notified of these issues and preventative quality
steps have been put in place to prevent a recurrence of these issues.
Since these issues are the first and only ones to be reported and inspection of
stocks did not reveal any problems, these issues are an isolated “one-off” case and
not widespread.
NOTE - personnel must always check for signs of the aforementioned defects
subsequent to locking any padlock. Once the padlock is locked, pull the body
to ensure it is securely locked.                                                          Figure 3 – The shackle of the returned MK unit was
                                                                                         able to be pulled out when the padlock is in a locked
                                                                                          position. This condition can be checked by giving
                                                                                            the shackle a tug once a unit has been locked.

DMS#5164583                                                                                                                                              Page 1 of 14
                                                                                                                                     Issue 10 – 24 September 2009

There is an inconsistency with the assignment of stock codes and
identification of MPS and non-MPS transformers as shown below. Some               1) Supply efficiency since tanks are all pre-painted and stenciled by tank
transformers are identified by the stenciled stock code on the tank (eg,             manufacturer and labels added by ABB when confirmed orders received.
XA2170 or XA2190) and others by the nametag (eg XA2176) attached to the           2) Transformer identification by Logistics for picking made easier
lifting eye of the tank.
                                                                                  3) Asset data recorded in Asset Management system is more consistent – using
An MPS padmount transformer consists of 3 major components being the                 stock code on Bushing cabinet
Tank, Bushing cabinet, and LV cabinet. A Non-MPS transformer consists of
the Tank and Bushing cabinet only.                                                4) Technically more logical to have each component have a unique Id ie, tank,
                                                                                     Bushing cabinet, LV cabinet.
A change has been implemented to the marking of stock codes on the
transformers. All Tanks will have stenciled on them a Tank Only stock code
(eg. XA2170). All Non-MPS transformers will have the non-MPS stock code           KEY POINTS:
stenciled on the Bushing cabinet. All MPS transformers will also have its MPS
stock code stenciled on the Bushing cabinet. All transformer nameplates               •   The stock code to record on data sheets (ie DFIS, DFMS) is the number
however, will list stock codes of all 3 variations (eg TX, Non-MPS and MPS).              stenciled on the bushing cabinet.
All transformer tanks (replacement tanks) will be stenciled with its stock code
                                                                                      •   The stock code number marked on the transformer tank will continue to be
and will have attached a weatherproof bag with the corresponding MPS
                                                                                          stenciled to reflect the tank number, but is not to be entered on data
transformer stock code label for placement over the bushing cabinet stenciled
                                                                                          sheets and any asset management system.
stock code when a transformer tank is replaced.
From now on, the stock codes stenciled to the side of the Bushing cabinet             •   When a MPS transformer is upgraded, a replacement label is supplied
shall be used to identify MPS and non-MPS transformers and shall be the                   with the transformer tank which must be fitted to the bushing cabinet,
stock codes recorded in asset management systems, and equipment                           covering the existing cabinet stenciling.
commissioning sheets. The stock code on the transformer tank will be the
stock code for tank replacement only if required in the future.
There are no changes to stock codes already assigned to MPS and non-MPS
transformers, but only the way they are marked on the transformers for better

DMS#5164583                                                                                                                                  Page 2 of 14
                                                                                              Issue 10 – 24 September 2009

CURRENT STANDARD (21/9/09)                       Bushing                         LV Cabinet

       TX Only                                             XA2176
                                      NON-MPS                           MPS

         XA2170                       XA2190                   XA2170

NEW STANDARD (01/10/09)

      TX Only
                           XA2176    NON-MPS

                                                XA2190                        XA2176
        XA2170                        XA2170                    XA2170

                                                                                                  RECORD ON
                                                                                                  DATA SHEET
                 Nameplate with 3
                 stock codes and
                 transformer mass

DMS#5164583                                                                                          Page 3 of 14
                                                                                                  Issue 10 – 24 September 2009


We have found that installation steps are not being followed in the sequence
prescribed in the installation instructions when terminating 185-400mm2, 22kV cable
on the Ring Main Units (RMUs).

This leads to over tightening of the insulated plug on the termination elbows and
could possibly lead to damage of the bushings on the Ring Main Units (RMUs).

The installation instruction requires that the clamping screw (stud) and insulating
plug should be installed as follows:
       A) Insert clamping screw into the threaded hole of the bushing. Use
          torque wrench with a 22mm socket and tighten exerting 50Nm of
          torque. Clean and lubricate the basic insulating plug and plug
       B) Insert the plug in the connector; engage the threads and hand tighten.
          Tighten assembly: use torque wrench with 24mm socket and tighten
          exerting 50Nm.

It is very important to use a torque wrench to avoid over or under
tightening and potential damage to the bushing ie carry out steps
                        A and B in sequence.

DMS#5164583                                                                                              Page 4 of 14
                                                                                                          Issue 10 – 24 September 2009


We have found locations where jointers have not fixed the stainless steel ID tag
when installing a joint or termination. ID tags must have the jointers ID stamped on
the tags.

The stainless steel ID tag is supplied with joint and termination kits (refer Figure 4)
and must be fixed to the cable or associated earthed apparatus.

Where tags have not been fitted, the equipment will not be energised or handed

 Installations will be checked to ensure ID tags are fitted prior to

                                                                                          Figure 4 – ID tags correctly installed
                                                                                              with joints and terminations

DMS#5164583                                                                                                         Page 5 of 14
                                                                                                                                 Issue 10 – 24 September 2009

                                                                                                         KITS CONTAINING POLYURETHANE COMPOUND
JOINTS                                                                                                   FJ0218            120-240 SQMM BREECH JOINT

                                                                                                         FJ0219              240 SQMM BREECH JOINT
Imperfections were noted in random samples of primary filler used in the LV jointing
kits. It was identified that in the primary fillers “lumps” had settled which requires                   FJ0228           120 SQMM STRAIGHT THROUGH
additional “kneading” to break up the filler prior to the mixing process. The “lumps”
were due to inconsistencies in the manufacturing process which has since then been                       FJ0230         185-240 SQMM STRAIGHT THROUGH
                                                                                                         FJ0245   SERVICE TEE (2X25 SQMM OFF 120-185 SQMM MAIN)

                                                                                                         FJ0246    SERVICE TEE (2X25 SQMM OFF 240 SQMM MAIN)
ACTIONS TAKEN: A number of resin pouches were inspected to determine the
implications of the problem. The supplier confirmed that the compound is still “fit for
purpose” and does not affect the rest of the compound if dispersed.
In cases where the primary filler is not fully dispersed, the volume of resin produced
from each 4.2 litre kit may be reduced by up to 0.5 litres. If this is the case boxes
should be topped up with additional resin. The supplier will supply additional resin
needed to fill up joint boxes. Jointers must check pouches to determine the extent of
“lumps” before commencing a job. If the primary filler cannot be substantially
dispersed then the supplier will replace the resin.

Batches with expiry dates of Jan/2010 up to and including August/2010 on the labels
have been identified to possibly have defective compound. Checks at Western
Power Stores have been undertaken and most of the product has been issued.
Batches dated September/2010 and beyond are unaffected.
                                                                                                                                                 Figure 5 – Primary
                                                                                                                                                  Filler with lumps
                                                                                          LUMPS FORMED                                          formed and batches
NOTE: Any issues with compound found outside of these dates should be                       IN PRIMARY                                                 identified
reported to Distribution Underground Standards, Policy and Data Quality.                       FILLER

DMS#5164583                                                                                                                              Page 6 of 14
                                                                                                   Issue 10 – 24 September 2009

Following changes made to the UMS (Unmetered Supply) Policy recently, it was necessary to make
minor changes to the relevant CUs (Compatible Units) in DQM, Part 5 (Low Voltage Underground –
U23) in the DCSH (Distribution Construction Standards Handbook) and Unmetered Supply part in
the DDC (Distribution Design Catalogue). Refer to the Un-metered Supply Guideline for more
information at the following link:

Changes made to CUs in DQM:
       10A fuse (stock code GF2101) replaced with 20A fuse (stock code GF2102) to allow up to
       20A unmetered supply.
       30A fuse (stock code GF2103) removed from CUs (Compatible Units) as this is not
       necessary, giving both WP and the customer a single point of isolation.
       Unmetered Supply Warning Label (stock code CZ0307) added to CUs (Compatible Units).
       New UM4 CU has been created for CBD only which is a pit connection where the criteria for
       installation of pits can be satisfied.

The following changes were made within the kit contained in the CUs, stock code FE0110:
       The Western Power isolating point label and the Customer isolating point label were
       One (1) Floodseal fuse holder removed from the kit.
       Two (2) Red heat shrink tubing’s, 500mm length removed and replaced by one (1) Red heat
       shrink tubing, 750mm length.

DMS#5164583                                                                                               Page 7 of 14
                                                                                                                                            Issue 10 – 24 September 2009

                                                                                           Danger labels, DBYD are fitted on both sides of the marker. There are two depth
ABOVE GROUND MARKERS                                                                       marker holes in the marker, 1000mm and 1200mm respectively from the top of the
Introduction:                                                                              marker.

The existing above ground cable marker is prone to damage and permanent                    The depth marker hole 1000mm from the top of the marker indicates the depth to
deformation when hit by vehicles or machinery. Also due to the design of the               which the marker must be installed for the purpose of warning for underground
existing cable marker, it suffers severe corrosion when the paintwork is damaged           cables in the vicinity (Figure 7 part B). The depth marker hole 1200mm from the top
(Refer to Figure 8).                                                                       of the marker indicates the depth to which the marker must be installed for the
                                                                                           purpose of equipment protection (Figure 7 part C), e.g. in front of a pillar on a
New Flexible Above Ground Markers:                                                         building site.
The new flexible above ground markers are manufactured from spring steel, metallic,
fully flexible and capable of withstanding impacts from vehicles, machinery and               B
livestock. The markers are hot dip galvanized and pre-treated with zinc phosphate
prior to being powder coated, delivering superior corrosion resistance.
The markers are supplied in a box with 10 markers and installation instructions are
included in each box. A manual driver is used for installation of the above ground
markers. The installation tool (stock code - CR0328) will need to be sourced from
Western Power Stores and used repeatedly for installation of markers.


           Figure 6 – Manual Driver for Installation of Flexible Above Ground Marker

The marker has a double retention barb system (Figure 7 part A), making it resistant
to removal by persons other than authorised personnel using a removal tool.
                                                                                                               Figure 7 – Flexible Above Ground Marker

DMS#5164583                                                                                                                                         Page 8 of 14
                                                                                                                              Issue 10 – 24 September 2009

Western Power has been purchasing above ground markers that consist of three   The DCSH (Distribution Construction Standards Handbook) has been updated to
parts; CB2011, CR0325, and CR0326 (Figure 8).                                  include a new drawing R40 showing the installation of the cable marker.
From now on only a single Stock Code CR0327 will be necessary.

           Existing Stock Codes          Replacement Stock Codes


                   CR0325                              CR0327





                   Figure 8 – Three part Above Ground Cable Marker

DMS#5164583                                                                                                                          Page 9 of 14
                                                                                                                                 Issue 10 – 24 September 2009

                                                                                The reason for the change is to allow an easy upgrade of a 25kVA with 2 (outgoing
The existing 50kVA SPUD Transformer XA2210 with one (1) outgoing bushing (SW    bushings to a 50kVA..
OUT1) will be replaced by XA2209 to have two (2) outgoing bushings (SW OUT 1
and SW OUT 2) to allow looping in and out.                                      NOTE: XA2209 shall only be used to upgrade an EXISTING XA2210.

Figure 9 shows the change from 1 outgoing bushing to 2 outgoing bushings. CUs
have been updated to replace XA2210 with XA2209.
NOTE: If the 50kVA transformer XA2209 is not going to be looped out, a dead
end (CU and STOCK Code) must be fitted to SW OUT 2.


                                                                                             Figure 9 – SPUD Transformer 50kVA

DMS#5164583                                                                                                                             Page 10 of 14
                                                                                                                                   Issue 10 – 24 September 2009

House Service Clamp Supply Arrangement                                             Future House Service Clamp Supply Arrangement
The existing house service clamp, stock number CC0111, is currently supplied       Western Power was approached by the supplier requesting the elimination of
with a rubber band tying the wedge and the body together and packed in a plastic   packaging.
bag, as shown in Figure 10.
                                                                                   The same supplier renders this product to the Eastern State utilities that have
                                                                                   opted to go with the provision of the unit to them without the rubber band and
                                                                                   plastic bag.
                                                                                   The unit is designed such that the wedges and body cannot become separated
                                                                                   and thus will not be issued with the rubber band or the plastic bag packaging.
                                                                                   Figure 11 shows the clamp without rubber band and packaging.

                                    Figure 10
                                                                                                                    Figure 11

DMS#5164583                                                                                                                                Page 11 of 14
                                                                                                                                         Issue 10 – 24 September 2009

Current LV bonding method                                                                Bonding kit CE7544 shown in Figure 13 has been created for LV wood cross-arm
                                                                                         applications and must be applied as follows:
Bonding kit CE7552 shown in Figure 12 was used for application on low voltage
wood cross-arms to bond the neutral insulator pin to a dispersion plate. Unfortunately
this bonding method was not durable and it was found that the connectors on the
dispersion plate become disconnected.

                                                                                                                        Figure 13 CE7544

                                 Figure 12 CE7552
New LV bonding method
In the past there has been evidence of electrical tracking towards the neutral
conductor on the LV wood cross-arm. To eliminate the possibility of pole top
fires/damage to the LV wood cross-arm the Insulator pin of the neutral conductor
must be electrically bonded to the cross-arm bracket, from where the leakage                               Figure 14                     Figure 15
currents will be dispersed via the dispersion plates into the wood pole.                 Figure 14 shows how the two dispersion plates and pole bolts must be fitted to the
                                                                                         cross arm bracket. Figure 15 shows how the dispersion plates must be secured
                                                                                         using a roofing nail on each end of the dispersion plate. The coil spring washer
                                                                                         helps maintain the electrical connection to the pole.

DMS#5164583                                                                                                                                      Page 12 of 14
                                                                                                                                            Issue 10 – 24 September 2009

Fit one of the 17mm diam. bonding clips, with the 7/1.6mm diam. galv. wire inserted     Retrofit LV Bonding
through the “U” section, onto the bottom end of the neutral Insulator pin as shown in
Figure 16 and secure it with a nut.                                                     For retro fit bonding remove the existing nut at the “T” bracket bolt and neutral LV pin
                                                                                        stud and place a 17mm diam. bonding clip with the 7/1.6 galv. wire passed through
                                                                                        the “U” section directly onto the coil spring then secure with the nut. Should this not
                                                                                        be possible then place a 17mm diam. bonding clip with the 7/1.6 galv. wire passed
                                                                                        through the “U” section directly onto the existing nut and secure in place with the
                                                                                        M12 and M16 nuts supplied in bonding kit CE7544.

                                     Figure 16
In Figure 17 the red circled section shows the coil washer side of the bolt which
secures the cross-arm to the “T” bracket, undo the nut remove round washer and
place a 17mm diam. bonding clip with the 7/1.6 galv. wire passed through the “U”
section directly onto the coil spring then secure in place with the washer and nut of
the bolt. The bonding wire must be kept at leats 10mm away from the other phase
Insulator pins, as shown in Figure 17.

                                     Figure 17

DMS#5164583                                                                                                                                         Page 13 of 14
                                                                                                                                       Issue 10 – 24 September 2009

Mains Connection Box (MCB)                                                             To allow individual issue a stock number has been created for the shroud and a
Background                                                                             separate stock number for the MCB
The MCB and shroud have one stock number. However, sometimes only one of the
components is required but there is no facility to be able to issue these components   The single phase and three phase MCB’s will have the following stock code numbers
separately.                                                                            respectively HZ0115 and HZ0116. The single phase and three phase shrouds will
                                                                                       have the following stock code numbers respectively HZ0117 & HZ0118.

                                                                                          1ph MCB stock code HZ0115         1ph Shroud stock code HZ0117

         Stock code HZ0115                    Stock code HZ0116

                                                                                         3ph MCB stock code HZ0116          3ph Shroud stock code HZ0118

DMS#5164583                                                                                                                                   Page 14 of 14

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