Cable Accessory Failure Analysis · 2010-10-27 · ICC Education Session Cable Accessory Failure...
Transcript of Cable Accessory Failure Analysis · 2010-10-27 · ICC Education Session Cable Accessory Failure...
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1Fall 2010 ICC Education Session
ICC Education Session
Cable Accessory Failure Analysis
F. Dean Williams
Fall 2010 Meeting
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2Fall 2010 ICC Education Session
Outline
• Background • Overall Process for an Effective Forensic Program• Primary Modes of Failure• Benefits of a Forensic Program• Summary
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3Fall 2010 ICC Education Session
Background – Significance of Problem
OldMiddle AgedNew
80
70
60
50
40
30
20
10
0OldMiddle AgedNew
Accessories
Age Description
Perc
enta
ge o
f Se
rvic
e In
teru
ptio
ns (
%)
Cable•Cable accessories have a significant Infant mortality rate
•Newly installed accessories account for 20% of accessory related service interruptions
•Workmanship is the Number 1 cause of failure representing nearly 50% of the total failures
•The number of unknown cause of failure is high (about 20%) showing the need for more thorough forensic evaluations
•Manufacturing defects represent 15% of the total failures
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4Fall 2010 ICC Education Session
Analysis of Collated Data – Cable Accessories -Cause of Failure
Fault Type
05
10152025303540
Poor w
orkman
ship
Manufa
cturin
g prob
lemCorr
osion
Mecha
nical
Damag
eEve
ntAgin
gOve
rload
Unkno
wnMois
ture
Other
Dielec
tric br
eakd
own
Contam
inatio
nOve
rheat
Incorr
ect re
cord
Mainten
ance
failu
re%
of T
otal
Cas
es
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5Fall 2010 ICC Education Session
Analysis of Collated Data – Failures by Accessory Vintage
Accessory Vintages - All Utilities
05
10152025303540
1970
-1975
1975
-1980
1980
-1985
1985
-1990
1990
-1995
1995
-2000
2000
-2005
>2005
Vintage
% o
f Tot
al F
ailu
res
Joints Terminations Junctions
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6Fall 2010 ICC Education Session
Analysis of Collated Data – Cause of Failure
Summary by Failure Type ‐ All Utilities
Overheat4%
Dielectric breakdown
10%
Aging6%
Corrosion4%
Moisture4%
Event3%
Manufacturing problem14%
Overload2%
Maintenance fai lure2%
Mechanical Damage1% Contamination
1%
Poor workmanship
49%
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7Fall 2010 ICC Education Session
Overall Process for an Effective Forensic Program
• Preservation of sample integrity• Importance of sister components• Collection of background information• Obtain installation instructions• Choose the right evaluation technique/document all findings• Identify all installation errors/determine most probable root cause of
failure • Clearly and accurately report all findings/forward to the appropriate
personnel• Track results of examinations
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8Fall 2010 ICC Education Session
Preservation of Sample Integrity
• Remove sufficient cable length on either side of failed component
• Label sample to clearly identify location of failure• Seal cable ends and wrap component to protect from
environment• Keep associated components together• Store in a dry location prior to performing analysis
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9Fall 2010 ICC Education Session
Preservation of Sample Integrity
• If you do not know what you are doing Do Not attempt your own analysis
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10Fall 2010 ICC Education Session
Importance of Sister Components
• Sister components are those installed at the same time of the failed component, likely by the same installer
• Significant damage to failed component may prevent determining most probable root cause of failure
• Sister components allow for easy detection of installation/workmanship errors if installed by the same personnel
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11Fall 2010 ICC Education Session
Sister Units
Jacket Cutback
Constant Force Spring
Ground Strap
Copper Tape Shield
Jacket Cutback
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12Fall 2010 ICC Education Session
Sister Units
Cut in Cable Insulation at Jacket Cutback
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13Fall 2010 ICC Education Session
Sister Units
Cut in Tape Shield at Jacket Cutback
Copper Tape Shield intact
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14Fall 2010 ICC Education Session
Collection of Background Information
• Events leading up to failure (weather, switching events, previous failures, etc.)
• Circuit diagram• Number of re-closures on circuit after initial failure• Available fault current• Typical loading conditions• Type of load being served• Any additional information that may be helpful in
determining the root cause of failure
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15Fall 2010 ICC Education Session
Obtain Installation Instructions
• Obtain installation instructions for vintage of component to be evaluated
• A proper analysis of most failed components is the exact reverse of the installation instructions
• Check for function, not for detailed compliance• A perfectly installed accessory may fail by means
outside the installers control
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16Fall 2010 ICC Education Session
Outside the Installers ControlTermite Damage
UV Aging
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17Fall 2010 ICC Education Session
Outside the Installers Control
12 Inches
Over ¾ inch Total Insulation
Shrinkback
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18Fall 2010 ICC Education Session
• Think before you cut• Document all findings/observations
through photographs• Preserve failure site, Do Not make
cuts directly through failure site• Cuts should be made at locations 90
degrees on either side of failure site• Cuts through failure site should only
be made, if necessary, and once a detailed examination of the various mating interfaces has been made
Choose the Right Evaluation Technique
Failure Site
Cut through Failure Site
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19Fall 2010 ICC Education Session
X-Ray
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20Fall 2010 ICC Education Session
Identify all Installation Errors/Determine Most Probable Root Cause of Failure
• Identification of all installation errors should be documented to enhance training efforts
• Multiple errors may have contributed to the failure• Determine most probable cause by process of elimination through a
detailed analysis of the available evidence
“When you have eliminated the impossible, whatever remains, however improbable, must be the truth”
Sherlock Holmes – In the Sign of the Four
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21Fall 2010 ICC Education Session
Clearly and Accurately Report all Findings
• Report should indentify most probable cause of failure and all installation errors observed
• Share report with all parties to reduce or prevent future occurrences
• Discuss product defects with manufacturer to improve processes
• Discuss installation errors with training personnel or installers to eliminate installation errors
• If installation errors are the result of unclear installation instructions revise instructions As-Built of termination used in report
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22Fall 2010 ICC Education Session
Track Examination Results
• Results of examinations should be tracked in a database• A database will help responsible personnel to observe and
take appropriate action when trends in installation errors or manufacturing defects are evident
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23Fall 2010 ICC Education Session
Common Failure Modes
• Workmanship• Manufacturing Defects• Design Issues
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24Fall 2010 ICC Education Session
Workmanship
Cut in Cable Insulation
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25Fall 2010 ICC Education Session
Workmanship
Nicks in Conductor Strands
Cuts in Conductor Strands
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26Fall 2010 ICC Education Session
Workmanship
Lower Cold Shrink Tube Incorrectly Installed at Upper End of Termination
Black Stress Control Tube
Electrical Activity off Insulation Shield Cutback
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27Fall 2010 ICC Education Session
Workmanship
Incomplete Shrink Down of Dual Layer Tube Leading to Failure
Puncture
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28Fall 2010 ICC Education Session
Workmanship
Discharge between Inner Stress Control Tube and
Cable Insulation Caused by Incomplete Shrink Down
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29Fall 2010 ICC Education Session
Workmanship
Discharge between Inner Stress Control Tube and Dual Layer Tube Caused by Incomplete Shrink Down and Failure to Keep Stress Control Tube Hot
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30Fall 2010 ICC Education Session
Workmanship
Corrosion Deposits
Lack of Bond between Mastic and Jacket
Water Migrated Past End
Seal
No Mastic between Solder Blocks
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31Fall 2010 ICC Education Session
Workmanship
Discharge between Stress Control
Tube and Insulation Shield
Puncture at Knife Cut in Cable
Insulation
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32Fall 2010 ICC Education Session
Workmanship
Interface Tracking from Surface
Contamination
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33Fall 2010 ICC Education Session
Workmanship
Water
Dirt Deposits and Lack of
Bond
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34Fall 2010 ICC Education Session
Workmanship
Contamination between Insulating Tube and Stress Control Tube
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35Fall 2010 ICC Education Session
Workmanship
Stress Relief Mastic Across Entire Cable Interface
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36Fall 2010 ICC Education Session
WorkmanshipBrown Discoloration of TRXLPE caused
by Overheating Compression
Connector
No Wire Brush Marks on Conductor in Area of Crimp Down
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37Fall 2010 ICC Education Session
WorkmanshipDeformation of
Insulation
Transition of Insulation Color Away from Connector
Thermal Damage to Joint Body
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38Fall 2010 ICC Education Session
Workmanship
No Wire Brush Marks on Conductor
Wire Brush Marks on Conductor
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39Fall 2010 ICC Education Session
WorkmanshipBrown Discoloration of
TRXLPE caused by Overheating Compression
Connector
Thermal Damage
Tool Cuts in Conductor
Strands
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40Fall 2010 ICC Education Session
WorkmanshipAluminum Oxides
Area of Crimpdownin Connector Body
Arc Pit in Connector Body
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41Fall 2010 ICC Education Session
Workmanship
Bent Probe
Melting of Arc Quenching Probe
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42Fall 2010 ICC Education Session
Workmanship
Surface Tracking
Surface Contamination
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43Fall 2010 ICC Education Session
Workmanship
Corrosion Deposits
Ground Strap
Soldier Block Located over Dual Layer Tube
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44Fall 2010 ICC Education Session
Workmanship
Cut in Cable Insulation
DielectricPuncture
Start of Penciling on Cable Insulation
Thin Area of Insulation Wall In Line With Failure
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45Fall 2010 ICC Education Session
WorkmanshipNote that Cut Aligns with Centerline of Puncture
Electrical Treeing
Fault Channel
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46Fall 2010 ICC Education Session
WorkmanshipFailure Site
Open Neutrals Arcing to Bracket
Bracket Cutting into Cable
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47Fall 2010 ICC Education Session
Workmanship
Compression Lug Vaporized
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48Fall 2010 ICC Education Session
Workmanship/Manufacturing
Knife Cuts Created During removal of Joint Body
Sanding Marks
Folds/Wrinkles in Copper Tape
White Bedding Tape
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49Fall 2010 ICC Education Session
Manufacturing Defect
Puncture Site
Area of Discoloration
Puncture Site
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50Fall 2010 ICC Education Session
Manufacturing Defect
Insulation
Conductor Shield
Puncture in Conductor
Shield
Void in Insulation
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51Fall 2010 ICC Education Session
Manufacturing DefectFault
Channel in Joint
InsulationMetal Contaminant
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52Fall 2010 ICC Education Session
Design Issues
Surface Tracking on Cable
Insulation
Erosion of Stress Control Tube
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53Fall 2010 ICC Education Session
Design Issues
Corrosion on Conductor
Path of MoistureMoisture Entry Point
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54Fall 2010 ICC Education Session
Design Issue
Dielectric Puncture
Cable Training
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55Fall 2010 ICC Education Session
Design IssueComplete Break in Sheath
Stress Cracking
Failure Site
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56Fall 2010 ICC Education Session
Design Issue - UV AgingSurface Tracking and
Erosion
Stress Cracking
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57Fall 2010 ICC Education Session
Benefits of a Failure Analysis Program
• Improve Training• Reduce outages• Increase in revenue• Reduce need for expensive diagnostic testing
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58Fall 2010 ICC Education Session
Summary
• Surveys and data analysis show cable accessory failures make up a large percentage of in-service outages
• About 20% of accessory failures have no known cause, indicating a need for more detailed forensic analysis
• About 15% of accessory failures can be attributed to manufacturing defects, indicating a need for tighter control of manufacturing processes
• Surveys and data analysis show the need for improved training of cable accessory installers
Unknown1.1%Terminations
5.6%
Splices37.1% Cable
56.2%
Utility Survey Showing System Failure Causes
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59Fall 2010 ICC Education Session
Summary
All evidence points to improved TRAINING
as the single most cost effective
means of improving system reliability