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Simulated workplace
Scenario · Mechanical Maintenance

Isolate multiple energy sources and repair a cooling tower fan gearbox

You are a Mechanical Fitter on the day crew at Newport West.

Intermediate3 to 4 hours7 tasks
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Home/Scenarios/Isolate multiple energy sources and repair a cooling tower fan gearbox
The situation

What has happened

The oil sample from cooling tower fan CT-3 shows elevated iron and copper and the gearbox has been noisy for a week. Permit PTW-26-1191 shows the motor control centre racked out and the fan blade restrained, and work order WO-26-5134 asks for an inspection and bearing replacement. The fan sits on top of the cooling tower cell, so the work involves working at height and the blade carries stored energy from wind. The condenser vacuum on the steam turbine depends on the tower, so the control room wants the fan back before the weekend. Mei Ling Chua is your leading hand and will check your alignment.

Your brief. Verify the isolation covers every energy source, complete the permit walk down, carry out the inspection and bearing replacement, record alignment and clearances on the work order, and restore the fan under the permit rules.
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Tasks

Deliverables

  • Energy source list and permit walk down findings
  • Completed permit request
  • Work order with alignment and clearance records
  • Hazard report if applicable

Documents to use

Systems to use

Permit and Isolation Register

Records every permit to work and its isolations from request through issue, work, restoration and close out.

Maintenance Work Orders and Defects

Holds every defect raised and every planned and corrective maintenance work order across the three sites with priority, crew and completion records.

HSE Incident Register

Records every injury, near miss, plant event, environmental incident and hazard with investigation status and corrective actions.

For trainers and assessors

Units of competency

Current on training.gov.au for the Electricity Supply Industry - Generation Sector Training Package as at 10 September 2026.

UEPOPS011Conduct multiple energy source isolation procedures for permit to work
UEPMNT305Maintain industrial fans
UEPMNT402Conduct complex levelling and alignment
UEPMNT317Diagnose and repair faults in mechanical equipment
UEPOPS003Apply quality systems to work

Qualifications

UEP40522Certificate IV in ESI Generation Maintenance (Mechanical)
UEP30322Certificate III in ESI Generation
Assessor notes

What to look for

Evidence guide

Check that the student identifies stored energy in the blade and the gearbox oil as energy sources, walks the isolation before accepting the permit, records alignment and backlash figures with units on the work order, and describes restoration that ends with control room release. Quality records must be complete enough for a later fitter to trust. The hazard report, if raised, must be specific.

The student's evidence summary lists every record they created or changed in the systems named above, their notes and the tasks they ticked. Verify it against the deliverables and your own assessment tool.