CABLE SPLICING AND TERMINATION TRAINING SYSTEM ......Cable Splicing and Termination (IRI-EM19) Page...

CABLE SPLICING AND TERMINATION

TRAINING SYSTEM EQUIPMENT MAINTENANCE DESCRIPTION (IRI-EM19)

INDUSTRIAL RESOURCES, INC.

A TRAINING SERVICES COMPANY

©This document is the property of Industrial Resources, Inc. Copies and distribution of this document is prohibited

unless written authorization is granted by Industrial Resources, Inc.

Cable Splicing and Termination

(IRI-EM19)

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PREFACE

This Training Equipment Maintenance Description (EMD) has been designed to assist you in

meeting the requirements of Module IRI-EM19 of the Electrical Distribution Training Program. It

contains information about the Power Plant, Cable Splicing and Termination. This includes

function, quantity of parts, location of parts, description of the physical construction of the part, and

description of the operation of the part, equipment preventive and corrective maintenance, and

references.

You should review each chapter objective. In doing so you will be better prepared to learn the

required information. You should also inspect the equipment identifying the components and

controls. Should you have additional questions about the equipment, ask your supervisor.

A separate document, Cable Splicing and Termination Equipment Maintenance Procedure (IRI-

EM19-EMP), covers detailed maintenance of the Cable Splicing and Termination.


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TRAINING EQUIPMENT MAINTENANCE DESCRIPTION

TABLE OF CONTENTS

1.0 Introduction ......................................................................................................................... 5

1.1 Equipment Function ............................................................................................................ 5

1.2 Equipment Description ....................................................................................................... 5

1.3 Equipment Connections and Interface ................................................................................ 6

2.0 Equipment Major Parts ....................................................................................................... 7

2.1 Cable Splicing and Termination Equipment ....................................................................... 7

2.2 Preparing the Cable for Termination .................................................................................. 9

2.3 Attaching the Cable Lug ................................................................................................... 14

2.4 Cleaning the Cable ............................................................................................................ 15

2.5 Applying Stress Relief Material to the Cable ................................................................... 16

2.6 Positioning and Shrinking the Stress Relief Tube on the Cable ....................................... 16

2.7 Grounding the Cable Shield .............................................................................................. 18

2.8 Applying Sealant to the Cable .......................................................................................... 20

2.9 Placing and Shrinking the HV Tube on the Cable ............................................................ 21

2.10 Completing Outdoor Termination of the Cable ................................................................ 22

3.0 Equipment Preventive and Corrective Maintenance ......................................................... 25

3.1 Cable Splicing and Termination Preventive Maintenance................................................ 25

3.2 Cable Splicing and Termination Corrective Maintenance ................................................ 25

4.0 References .......................................................................... Error! Bookmark not defined.

Appendix 1 - Cable Splicing and Termination Kits..................................................................... 26


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List of Figures:

Figure 1 – Determining the Required Amount of Insulation Cutback

Figure 2 – Insulation Cutback for Cable Shielded with Copper Tape

Figure 3 – Installing Ground Braid on Cable Shielded with Copper Tape

Figure 4 – Insulation Cutback for Cable Shielded with Wire

Figure 5 – Installing the Lug on Wire Shielded Cable

Figure 6 – Insulation Cutback for Cable with UniShield

Figure 7 – Installing Lug for Cable with UniShield

Figure 8 – Insulation Cutback for Cable with Lead Sheath

Figure 9 – Soldering the Ground Braid for Cable With Lead Sheath

Figure 10 – Positioning the Ground Braid for Cable with Lead Sheath

Figure 11 – Applying Red Sealant to Lug Barrel

Figure 12 – Installing the Shim Tube

Figure 13 – Abrading and Cleaning the Cable

Figure 14 – Applying Stress Relief Material to Cable

Figure 15 – Positioning and Shrinking Stress Relief Tube

Figure 16 – Preparing to Ground Cable with Copper Tape or Lead Sheath

Figure 17 – Applying Red Sealant to Cable

Figure 18 – Applying More Red Sealant to Cable

Figure 19 – Preparing to Ground Wire Shield or UniShield

Figure 20 – Cleaning the Jacket for Wire Shield or UniShield

Figure 21 – Continue Wrapping Red Sealant for Wire Shield or UniShield

Figure 22 – Applying Sealant to Cable at Lug

Figure 23 – Applying Sealant to Cable with No Lug

Figure 24 – Placing and Shrinking HV Tube on Cable

Figure 25 – Trimming the HV Tube on Cable

Figure 26 – Positioning Skirt on Cable

Figure 27 – Positioning Skirt for Top Feed Termination

Figure 28 – Adding Extra Skirts on Cable


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Figure 29 – Adding Extra Skirts for Top Feed Termination


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1.0 Introduction

Chapter Objectives:

Describe the functions of the Cable Splicing and Termination equipment.

1. State, from memory, the functions of the Cable Splicing and Termination equipment.

2. Draw a simplified arrangement of the Cable Splicing and Termination equipment.

3. Describe the flow path and how the Cable Splicing and Termination equipment is

operated and maintained.

3. List the normal Cable Splicing and Termination operating parameters.

1.1 Equipment Function

The function of Cable Splicing and Termination is to properly connect electrical cables to other

electrical equipment.

1.2 Equipment Description

A cable must be properly terminated to safely carry current, with no arcing, grounding, or other

problems that could cause an electrical fault in an electrical distribution system. The insulation of

the cable must also be replaced in the spliced/terminated area to protect both equipment and

personnel. The type of cable determines the exact procedure required to properly splice/terminate

that cable.

The proper cable termination kit must be used for the particular cable being spliced/terminated. A

list of cable types and the appropriate kit to use are listed in Appendix 1 of this System Description.

When using any termination procedure and kit, several steps are necessary. These steps are:

1. Gathering the required tools for termination of the specific cable

2. Determining the amount of insulation cutback required

3. Installing the lug, if used

4. Abrading and cleaning the end of the cable

5. Applying stress relief material (SRM) to the cable

6. Grounding the cable insulation


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7. Applying sealant to the end of the cable

8. Positioning and shrinking the HV tube

9. Trimming the HV tube

10. Applying skirt(s) for outdoor termination

Proper performance of these steps is described in detail in section 2.0 of this system description.

1.3 Equipment Connections and Interface

Cable Splicing and Termination does not require the use of instrumentation.


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2.0 Equipment Major Parts

Chapter Objectives:

Describe how the equipment parts perform their function:

1. Draw from memory a diagram of the equipment showing major parts

2. State from memory, the names and functions of the major parts

3. Describe the location of the major parts

2.1 Cable Splicing and Termination Equipment

In order to properly splice and terminate cables, the proper installation equipment must be used.

Installation equipment includes:

1. Termination kit

2. Cable preparation tools

3. Cable preparation kit or approved solvent

4. Clean, lint-free cloths

5. Non-conducting abrasive cloth (120 grit or finer)

6. Electrician’s tape

7. Connector(s) and installation tools

8. Approved Torch

The specific equipment in a termination kit depends upon the size and application of the cable

being terminated. A typical termination kit contains:

1. One (1) non-tracking tube (red)

2. One (1) stress control tube (black)

3. Two (2) mastic strips (red)

4. One (1) angle-cut mastic strip (yellow)

5. One (1) ground clamp spring

6. One (1) solder-blocked braid

7. One (1) copper-backed tape strip

8. One (1) short shim tube (25 & 35 kV only) (red)

9. Heat shrinkable skirts


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a. One (1) for 8 kV

b. Two (2) for 15 kV

c. Three (3) for 25 kV

d. Four (4) for 35 kV

10. One (1) set of installation instructions

Torch must be “clean-burning”, meaning that the torch does not deposit conductive contaminants

on the cable. Examples of clean-burning torches are Raychem FH-2629 (using refillable propane

cylinders) and Raychem FH-2616A1 (using disposable propane cylinders).

Adjust the torch when preparing the cable and terminating it by doing the following:

1. Adjust regulator and torch as required to provide an overall flame that is 12-inches long

and “bushy”.

2. Raychem FH-2629 will have a blue flame.

3. All other torches will have a yellow tip that is 3 to 4 inches long.

4. Use the yellow tip for shrinking.

5. Regulator pressure for Raychem FH-2629 is 15 psig and for Raychem FH-2616A1 is full

pressure.

To properly use the torch on the cable, do the following:

1. Use the 3-inch to 4-inch torch flame tip in a rapid brushing motion.

2. Keep the flame moving to avoid scorching.

3. Unless otherwise instructed, start shrinking the tube at its center, working the flame along

all sides of the tube in order to apply heat uniformly.

4. When installing multiple tubes, make sure that the surface of the last tube is still warm

before positioning and shrinking the next tube. If the installed tube has cooled, reheat the

entire surface.


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To determine if a tube has fully recovered from shrinking, check the following, especially on the

back and underside of the tube:

1. Uniform wall thickness

2. Conformance to substrate

3. No flat spots

4. No chill marks

5. Visible sealant flow (if the tube is coated)

2.2 Preparing the Cable for Termination

Use Table 1 (Appendix 1) to determine which termination kit should be used.

To prepare the cable, select the cable type to determine the amount of insulation cutback required

on the cable to properly prepare it. Use Figure 1 to determine the jacket cutback.

Figure 1 Determining the Required Amount of Jacket Cutback

Then use A + Z to determine the exact amount of cutback required. The “A” values to use with a

cable on which a lug is be used for termination are:

1. If 5 kV or 8 kV, use A of 6.50 inches.

2. If 15 kV, use A of 11 inches.

3. If 25 kV, use A of 22 inches.

4. If 35 kV, use A or 29 inches.

If no lug is used, choose Z as 2 inches.

Then determine what type of cable shielding is used. The types include:


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1. Cable shielded with copper tape

2. Cable shielded with wire

3. Cable has UniShield

4. Cable shielded with lead

The exact method used to prepare the cable depends upon the type.

Copper Tape Shield

If the cable is shielded with copper tape, use the following diagram to cut back the insulation:

Figure 2 Insulation Cutback for Cable Shielded with Copper Tape

Install the ground braid by doing the following, as shown in Figure 3:


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Figure 3 Installing Ground Braid on Cable Shielded with Copper Tape

1. Flare the moisture-blocked end of the ground braid and place it onto the metallic tape

butted up to the cable jacket.

2. Attach the braid to the shield by placing two wraps of the field clamp over the braid.

3. Fold the braid back over the spring clamp wraps.

Wire Shield

If the cable is shielded with wire, use the following diagram to cut back the insulation:

Figure 4 Insulation Cutback for Cable Shielded with Wire

If a lug is to be used, install the lug and then clean and deburr the lug as shown in Figure 5.


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Figure 5 Installing the Lug on Wire Shielded Cable

If the step between the lug barrel and the insulation is greater than 1/8-inch (3 mm), taper

(chamfer) the insulation to meet the lug barrel. Conventional penciling is not required.

UniShield

If the cable has a UniShield, use the following diagram to cut back the insulation

Figure 6 Insulation Cutback for Cable with UniShield

If a lug is to be used, install the lug and then clean and deburr the lug as shown in Figure 7.


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Figure 7 Installing Lug for Cable with UniShield

If the step between the lug barrel and the insulation is greater than 1/8-inch (3 mm), taper

(chamfer) the insulation to meet the lug barrel. Conventional penciling is not required.

Lead Sheath

If the cable has a lead sheath, use the following diagram to cut back the insulation:

Figure 8 Insulation Cutback for Cable with Lead Sheath

Butt the end of the braid up against the cable jacket as shown in Figure 9 and solder to the lead

sheath.


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Figure 9 Soldering the Ground Braid for Cable With Lead Sheath

Bend the braid back over the cable jacket so that the braid solder block is positioned as shown.

Figure 10 Positioning the Ground Braid for Cable with Lead Sheath

2.3 Attaching the Cable Lug

If voltage is 25 kV or 35 kv, this step is required. For lower voltage, the following requirements

are not necessary.

Apply red sealant on lug barrel. Using light tension, wrap two layers of red sealant around the

lug barrel.

Figure 11 Applying Red Sealant to Lug Barrel


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To install the shim, place the shim tube over the end of the red sealant, butted against the

insulation. Use Figure 12. Shrink into place. Apply heat in a smooth, brushing motion.

Figure 12 Installing the Shim Tube

2.4 Cleaning the Cable

Abrade the insulation, if necessary, to remove imbedded semi-con.

Figure 13 Abrading and Cleaning the Cable

Using an oil-free solvent, clean the cable. (A copper-tape cable is shown in figure as an

example. Any cable can be used.)


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2.5 Applying Stress Relief Material to the Cable

Apply stress relief material (SRM) at the semi-con cutback. Begin by removing backings from

the short angle-cut piece of SRM.

Figure 14 Applying Stress Relief Material to Cable

Place the tip of the SRM at the semi-con cutback and stretch to one-half of its original width.

Tightly wrap 3 to 4 layers to fill the semi-con step. Overlap semi-con and insulation. Taper the

SRM down to meet insulation. If using UniShield cable, apply the SRM as shown to fill the

conductive jacket step.

2.6 Positioning and Shrinking the Stress Relief Tube on the Cable

Position black stress control tube and shrink into place by doing the following on the cable.

Position the black stress control tube 1 inch (25 mm) from the jacket cutback (or wire whipback).


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Figure 15 Positioning and Shrinking Stress Relief Tube

Begin shrinking at the ground end and work the torch with a smooth brushing motion around the

tube toward the lug end.


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2.7 Grounding the Cable Shield

Complete grounding for the type of cable being terminated. If the cable has a copper tape shield

or a lead shield, prepare for grounding by doing the following as shown in Figure 16:

Figure 16 Preparing to Ground Cable with Copper Tape or Lead Sheath

Lift the ground braid away from the cable jacket. Using an oil-free solvent, clean the jacket for

2-1/2 inches (60 mm) below the jacket cutback point.

Figure 17 Applying Red Sealant to Cable

Remove the backing from the red sealant. Using light tension, wrap two layers of red sealant

onto the jacket under the braid.

Figure 18 Applying More Red Sealant to Cable


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Lay the braid back over the jacket and press the moisture blocked section of braid into the red

sealant. Using light tension, wrap two more layers of red sealant over the braid and first two

layers of sealant.

If the cable has a wire shield or is a UniShield cable, use the method shown in Figure 19 to

prepare to ground the shield.

Figure 19 Preparing to Ground Wire Shield or UniShield

Lift the drain wires away from the cable jacket. Using an oil-free solvent, clean the jacket as

shown in Figue 20.

Figure 20 Cleaning the Jacket for Wire Shield or UniShield

Remove the backing from the red sealant. Using light tension, wrap two layers of red sealant

onto the jacket under the drain wires.

Figure 21 Continue Wrapping Red Sealant for Wire Shield or UniShield


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Lay the drain wires evenly back over the jacket and press them into the red sealant. Using light

tension, wrap two more layers of red sealant over the braid and the first two layers of sealant.

Discard the spring clamp, braid, and foil tape.

2.8 Applying Sealant to the Cable

Apply red sealant to the Cable. If there is a lug (or lug and shim) on the end of the cable, using

light tension, wrap red sealant on the lug barrel (or over the shim). Build up the lug diameter to

the cable insulation and overlay the insulation by ½-inch (10 mm).

Figure 22 Applying Sealant to Cable at Lug

If there is no lug on the cable, wrap two layers of red sealant onto the cable insulation. Note: the

sealant will not prevent water ingress between the strands.

Figure 23 Applying Sealant to Cable with No Lug


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2.9 Placing and Shrinking the HV Tube on the Cable

Position the red HV tube and shrink into place. Position the HV tube at the bottom edge of the

red sealant on the jacket. Begin shrinking at the ground end and work toward the lug.

Figure 24 Placing and Shrinking HV Tube on Cable

If the cable has a wire shield or is a UniShield cable, twist the drain wires to make a ground lead.

Then trim the HV tube. Allow the tube to cool enough to touch before proceeding.

Figure 25 Trimming the HV Tube on Cable

If necessary, trim excess tubing from the lug area as shown.

Inspect the installation. Reheat any flat spots or wrinkles.

Is the termination is indoors, termination is complete.


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2.10 Completing Outdoor Termination of the Cable

If the termination is outdoors, position the skirt and shrink into place, as shown in Figures 26 and

27.

Figure 26 Positioning Skirt on Cable

Position the first skirt as shown in Figure 26 and shrink into place. Hold the edge of the skirt

lightly with pliers. Brush the flame tip around the outside of the skirt collar. Only the collar will

shrink.

Figure 27 Positioning Skirt for Top Feed Termination

If the termination is outdoors, position additional skirts, if needed. For 5 kV and 8 kV, only one

skirt is needed. If the termination is for 15 kV, two (2) skirts are required. If the termination is

for 25 kV, three (3) skirts are required. If the termination is for 35 kV, four (4) skirts are

required.


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Figure 28 Adding Extra Skirts on Cable

Position the remaining skirts, facing the skirts in the same direction as the first skirt.

Shrink the skirt(s) into place.

Figure 29 Adding Extra Skirts for Top Feed Termination

Figure 532

Check that the skirts have been evenly shrunk and appear symmetrical, with no tilt or sag.


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3.0 Equipment Preventive and Corrective Maintenance

3.1 Cable Splicing and Termination Preventive Maintenance

Preventive maintenance on the cables is limited to visual inspection.

3.2 Cable Splicing and Termination Corrective Maintenance

Corrective maintenance is not performed except through specific procedures, preferably with the

advice and assistance of the relay manufacturer.

4.0 References

Raychem HVT Series Terminations 5-35kV Class


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Appendix 1 - Cable Splicing and Termination Kits

Kit

Voltage

Conductor

Size

Max./Min. Insulation

Diameter

Max. Jacket

Diameter

(inches) (mm) (inches) (mm)

HVT-80-G(SG) 5 kV #4-#1 AWG 0.35 – 0.60 9 - 15 0.95 24

HVT-81-G(SG) 1/0-250 kcmil 0.60 – 0.95 15 - 24 1.20 30

HVT-82-G(SG) 300-500 kcmil 0.80 – 1.25 20 - 32 1.50 38

HVT-83-G(SG) 600-1750 kcmil 1.10 – 1.75 28 - 44 2.10 53

HVT-84-G(SG) 1500-2500 kcmil 1.60 – 2.45 41 - 62 2.75 70

HVT-80-G(SG) 8 kV #6-#2 AWG 0.35 – 0.60 9 - 15 0.95 24

HVT-81-G(SG) #1-4/0 AWG 0.60 – 0.95 15 - 24 1.20 30

HVT-82-G(SG) 250-500 kcmil 0.80 – 1.25 20 - 32 1.50 38

HVT-83-G(SG) 600-1750 kcmil 1.10 – 1.75 28 - 44 2.10 53

HVT-84-G(SG) 2000-2500 kcmil 1.60 – 2.45 41 - 62 2.75 70

HVT-151-G(SG) 15 kV #4-1/0 AWG 0.60 – 0.95 15 - 24 1.20 30

HVT-152-G(SG) 2/0-350 kcmil 0.80 – 1.25 20 - 32 1.50 38

HVT-153-G(SG) 400-1000 kcmil 1.10 – 1.65 28 - 42 2.10 53

HVT-154-G(SG) 1250-2500 kcmil 1.60 – 2.45 41 - 62 2.75 70

HVT-252-G(SG) 25 kV #2-250 AWG 0.80 – 1.25 20 - 32 1.50 38

HVT-253-G(SG) 300-750 kcmil 1.10 – 1.65 28 - 42 2.10 53

HVT-254-G(SG) 1000-1750 kcmil 1.60 – 2.45 41 - 62 2.75 70

HVT-255-G(SG) 2000-2500 kcmil 2.05 – 3.30 52 - 84 3.45 88

HVT-352-G(SG) 35 kV #1-1/0 AWG 0.80 – 1.25 20 - 32 1.50 38

HVT-353-G(SG) 2/0-500 kcmil 1.10 – 1.65 28 - 42 2.10 53

HVT-354-G(SG) 750-1750 kcmil 1.60 – 2.45 41 - 62 2.75 70

HVT-355-G(SG) 2000-2500 kcmil 2.05 – 3.30 52 - 84 3.45 88


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TRAINING EQUIPMENT MAINTENANCE PROCEDURE (IRI-EM19)






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PREFACE

This Training Equipment Maintenance Training Procedure (EMP) has been designed to assist you

in meeting the requirements of Module IRI-EM19 of the Electrical Distribution Training Program.

It contains information pertaining to maintenance of the Power Plant, Cable Splicing and

Termination. This includes purpose, precautions, limits and setpoints, procedures and references for

maintaining equipment.

You should also inspect the equipment, identifying its components and controls. Should you have

additional question about the equipment maintenance, ask your supervisor.


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TRAINING EQUIPMENT MAINTENANCE PROCEDURE

TABLE OF CONTENTS

I. Purpose .................................................................................................................................... 0

II. Precautions, Limitations, and Setpoints .............................................................................. 0

III. Procedure ............................................................................................................................ 0

A. Preparing to Splice or Terminate Cable .............................................................................. 0

B. Applying Stress Relief Material (SRM) to Calbe ............................................................... 2

C. Complete Grounding of Cable Shielding ............................................................................ 3

D. Placing the HV Tube on the Cable ..................................................................................... 3

E. Outdoor Cable Termination ................................................................................................ 4

F. Cable Splicing Preventive Maintenance ............................................................................. 5

G. Transformer Corrective Maintenance ................................................................................. 5

I. Purpose

This procedure provides information and guidance for the correct and safe splicing and

termination of cables.

II. Precautions, Limitations, and Setpoints

A. When installing electrical power system accessories, failure to follow applicable

personal safety replacements and written installation instructions could result in fire

or explosion and serious or fatal injuries.

B. To avoid risk of accidental fire or explosion when using gas torches, always check all

connections for leaks before igniting the torch and follow the torch manufacturer’s

safety instructions.

C. To minimize any effect of fumes produced during installation, always provide good

ventilation of confined workspaces.

D. The torch used for cable splicing and termination must be “clean-burning”,

meaning that the torch does not deposit conductive contaminants on the cable.

III. Procedure

1. The following procedures provide detailed instructions for splicing and

terminating high voltage cables.

A. Preparing to Splice or Terminate Cable

__1. Determine the exact size and type of cable.

__2. Select the proper termination kit for the cable.

__3. Verify that all required contents of the kit are in the kit.

__4. Verify that the following equipment is available:

a. Cable preparation tools

b. Cable preparation kit or approved solvent

c. Clean, lint-free cloths


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d. Non-conducting abrasive cloth (120 grit or finer)

e. Electrician’s tape

f. Connector(s) and installation tools

g. Approved Torch

__5. Determine the exact amount of insulation cutback required for the type of

cable being spliced or terminated.

__6. If the cable is shielded with copper tape, do the following to prepare the

cable:

a. Cut back the required amount of insulation.

b. Flare the moisture blocked end of the ground braid.

c. Place the braid onto the metallic tape butted up to the cable jacket.

d. Attach the braid to the shield by placing two wraps of the field clamp

over the braid.

e. Fold the braid back over the spring clamp wraps.

__7. If the cable is shielded with copper tape, do the following to prepare the

cable:


b. If a lug is to be used, install the lug and then clean and deburr the lug.

c. If the step between the lug barrel and the insulation is greater than 1/8-

inch (3 mm), taper (chamfer) the insulation to meet the lug barrel.

Conventional penciling is not required.

__8. If the cable is a UniShield cable, do the following to prepare the cable:


b. If a lug is to be used, install the lug and then clean and deburr the lug.

c. If the step between the lug barrel and the insulation is greater than 1/8-

inch (3 mm), taper (chamfer) the insulation to meet the lug barrel.

Conventional penciling is not required.

__9. If the cable is shielded with lead, do the following to prepare the cable:



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b. Butt the end of the braid up against the cable jacket.

c. Solder the braid to the lead sheath.

d. Bend the braid back over the cable jacket.

__10. If the cable is to be used in 25 kV or 35 kV application, attach the lug by

doing the following:

a. Apply red sealant on lug barrel. Using light tension, wrap two layers

of red sealant around the lug barrel.

b. Place the shim tube over the end of the red sealant, butted against the

insulation.

c. Shrink into place. Apply heat in a smooth, brushing motion.

__11. Abrade the cable insulation, if necessary, to remove imbedded semi-con.

__12. Using an oil-free solvent, clean the cable.

B. Applying Stress Relief Material (SRM) to Cable

__1. Apply stress relief material (SRM) at semi-con cutback.

a. Remove backings from the short angle-cut piece of SRM.

b. Place the tip of the SRM at the semi-con cutback and stretch to one-

half of its original width.

c. Tightly wrap 3 to 4 layers to fill the semi-con step.

d. Overlap semi-con and insulation.

e. Taper the SRM down to meet insulation.

f. If using UniShield cable, apply the SRM to fill the conductive jacket

step.

__2. Position black stress control tube and shrink into place.

a. Position the black stress control tube 1 inch (25 mm) from the jacket

cutback (or wire whipback).

b. Begin shrinking at the ground end and work the torch with a smooth

brushing motion around the tube toward the lug end.


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C. Complete Grounding of Cable Shielding

__1. If the cable has a copper tape shield or a lead shield, do the following:

a. Lift the ground braid away from the cable jacket.

b. Using an oil-free solvent, clean the jacket for 2-1/2 inches (60 mm)

below the jacket cutback point.

c. Remove the backing from the red sealant.

d. Using light tension, wrap two layers of red sealant onto the jacket

under the braid.

e. Lay the braid back over the jacket and press the moisture blocked

section of braid into the red sealant.

f. Using light tension, wrap two more layers of red sealant over the braid

and first two layers of sealant.

__2. If the cable has a wire shield or is a UniShield cable, do the following:

a. Lift the drain wires away from the cable jacket.

b. Using an oil-free solvent, clean the jacket.

c. Remove the backing from the red sealant.

d. Using light tension, wrap two layers of red sealant onto the jacket

under the drain wires.

e. Lay the drain wires evenly back over the jacket and press them into the

red sealant.

f. Using light tension, wrap two more layers of red sealant over the braid

and the first two layers of sealant.

g. Discard the spring clamp, braid, and foil tape.

D. Placing the HV Tube on the Cable

__1. Apply red sealant to the cable by doing the following:

a. If there is a lug (or lug and shim) on the end of the cable, using light

tension, wrap red sealant on the lug barrel (or over the shim).


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b. Build up the lug diameter to the cable insulation and overlay the

insulation by ½-inch (10 mm).

c. If there is no lug on the cable, wrap two layers of red sealant onto the

cable insulation.

Note: the sealant will not prevent water ingress between the strands.

__2. Position the red HV tube and shrink into place:

a. Position the HV tube at the bottom edge of the red sealant on the

jacket.

b. Begin shrinking at the ground end and work toward the lug.

c. If the cable has a wire shield or is a UniShield cable, twist the drain

wires to make a ground lead.

__3. Trim the HV tube, after allowing the tube to cool enough to touch:

a. If necessary, trim excess tubing from the lug area.

b. Inspect the installation.

c. Reheat any flat spots or wrinkles.

d. If the termination is indoors, termination is complete.

E. Outdoor Cable Termination

__1. Position the skirt and shrink into place:

a. Place the first skirt in the proper position on the cable.

b. Hold the edge of the skirt lightly with pliers.

c. Brush the flame tip around the outside of the skirt collar. Only the

collar will shrink.

__2. Position additional skirts, if needed:

a. For 5 kV and 8 kV, only one skirt is needed.

b. If the termination is for 15 kV, two (2) skirts are required.

c. If the termination is for 25 kV, three (3) skirts are required.

d. If the termination is for 35 kV, four (4) skirts are required.


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e. Position the remaining skirts, facing the skirts in the same direction as

the first skirt.

f. Shrink the skirt(s) into place.

g. Check that the skirts have been evenly shrunk and appear symmetrical,

with no tilt or sag.

F. Cable Splicing Preventive Maintenance

__1. Except for periodic inspection, no preventive maintenance is required for

cable splicing and termination.

G. Transformer Corrective Maintenance

No corrective maintenance is required for cable splicing and termination.


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TRAINING SYSTEM JOB PERFORMANCE MEASURE (IRI-EM19)






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Electrical Technician (IRI-EM19-JPM)

Performance Measure: Cable Splicing and Termination

Name: __________________________________

All Parts Satisfactorily Completed:

________________________________________ ____________________

(Supervisor’s Signature) (Date)

Supervisor’s Comments: __________________________________________________

_______________________________________________________________________

_______________________________________________________________________

_______________________________________________________________________

References:

Training Module IRI-EM19

Materials Needed:

Pencil and Clipboard

Equipment Maintenance Description – Cable Splicing and Termination (IRI-EM19-EMD)

Equipment Maintenance Procedure – Cable Splicing and Termination (IRI-EM19-EMP)

Associated Maintenance Checklist, Charts, Parts List, Technical Manuals

Safety/Environmental:

Wear hard hats, safety glasses, safety toe shoe, and ear plugs as required.

Discuss environmental hazards associated with performing maintenance of the equipment.

Discuss any safety precaution that must be observed while performing the procedure.

Note: Always observe all plant safety rules in accordance with Services Safety and Health

Procedures and all Federal, State and/or Local TOSHA Standards.


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Part A: Locate Equipment

Locate and identify the following equipment and major components.

1. Types of cables used in distribution 2. Contents of a termination kit 3. Equipment used for cable termination 4. Types of torches that may be used

Satisfactorily Completed ____________________________

Part B: Controls/Breakers

Locate and identify the following cable termination devices.

1. Types of cable insulation 2. Grounding braid 3. Cable lugs 4. Cable HV tubes 5. Cable skirts

Satisfactorily Completed _________________________


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Part C: Preparation for Maintenance

This is to be performed under direction of the Shop Supervisor.

Demonstrate the following preparation for use of the Cable Splicing and Termination equipment:

1. Follow all standard IRI safety practices while performing the task at hand. 2. Wear adequate (proper) personnel protective equipment for the task at hand. 3. Torch should be filled or spare containers of gas available. 4. Determine the type of cable being terminated. 5. Select the proper termination kit for the cable. 6. Gather the tools needed to perform termination.

Satisfactorily Completed __________________________


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Part D: Operating Procedure

This is to be performed under direction of the Shop Supervisor.

Demonstrate the following operational steps for the safe and efficient operation of the Cable

Splicing and Termination equipment.

Preparing the Cable for Termination

__13. Determine the amount of insulation cutback necessary for the cable being terminated. __14. Properly cut back the insulation to the required dimensions. __15. Install the lug, if a lug is to be used. __16. Apply stress relief material properly, including proper use of the torch to shrink the SRM. __17. Abrade the insulation, as necessary. __18. Properly clean the end of the cable, including the lug.

Complete Grounding of the Cable Shield

i. Demonstrate how to properly ground the shield on the cable being terminated. ii. Describe the proper way to ground the shield on other types of cables.

Placing the HV Tube on the Cable

1. Properly apply red sealant to the end of the cable. 2. Position the HV tube and shrink into place. 3. Describe how the torch should be used to properly shrink the HV tube. 4. Trim the HV tube. 5. Inspect the cable, describing what you are looking for and why.

Outdoor Cable Termination

1. Install the first skirt to the end of the cable for outdoor use. 2. Discuss how many skirts are required for different voltages. 3. Describe how multiple skirts are positioned, including the proper spacing. 4. Describe how to inspect for proper position and condition of skirts.

Satisfactorily Completed __________________________________


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Part E: Preventive Maintenance

Except for visual inspection, no preventive maintenance is required

Part F: Corrective Maintenance

No corrective maintenance is associate with this equipment.

Part G: Personnel and Equipment Safety

Performed all aspects of the JPM using safe operating practices and following plant safety and

environmental procedures.

Satisfactorily Completed __________________________


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TRAINING SYSTEM FACILITATOR’S GUIDE (IRI-EM19-FG)






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1.0 Introduction

This Facilitator’s Guide is designed to assist you in coordinating the Training for Module

(IRI-EM19) of the Power Plant Mechanical Distribution Section Training Program. It

contains information about conducting training for the Power Plant Electrical Distribution

Equipment.

Each Trainee is required to successfully complete all four (4) elements of the module to be

certified on the Training Progress Monitoring Card (TPMC) as completed. Each of the

following four (4) elements are included in each system training module to ensure the trainee

has knowledge of each system and can perform the required tasks.

Formal System Training provides the trainee with a structured training session that teaches

and tests the knowledge required to understand the operation of the system and related

equipment. The instructional method can be Facilitator Led Classroom, Video Program,

Computer Based Training, Self-Study, or any combination of acceptable methods that

provides quality instruction that meets the lesson objectives.

Equipment Maintenance Procedure (EMP) Formal Training provides a formal process for

instructing the trainee on the understanding and proper execution of all Equipment

Maintenance Procedures.

On-The-Job Training will be designed to include 1) equipment preventive maintenance, and

2) corrective maintenance. OJT will also include how to properly perform all equipment

checks, the frequency of each check, and any equipment adjustments that are made to bring

the checked parameter within limits.

Equipment Checkout involves formal instruction on how to properly perform all equipment

maintenance and checks. This includes 1) how to perform preventive maintenance, 2) make


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routine equipment adjustments 3) perform corrective maintenance 4) proper use of checklists

while performing routine system inspections and equipment checks.

Both knowledge tests and Job Performance Measures will be used to test trainees on both

knowledge and performance to measure competency.

This training program may utilize the self-study method of training. Training materials and

assistance will be provided to the trainee as needed to complete the module. However, trainee

progress will depend on their willingness to gain the required knowledge and skills.

As the trainees gain the knowledge and skills listed for each module they will be required to

demonstrate actual work proficiency before they can be signed off on that module.

Preparing to complete each module will require preparatory work, such as reading, studying,

observation, or practical experience. The trainee should ask questions if they are unsure about

any items. It is the trainee’s responsibility to take the initiative to request training or help in

learning a knowledge or skill.

The training requirements for each module are listed in the module outline. They have been

designed to include the knowledge and skills needed to satisfactorily perform the job. The

Facilitator is responsible for observing the trainee’s safety habits, work procedures, and

completion time. As the trainee demonstrates skills, the Facilitator will initial and date the

space next to the knowledge or skill demonstrated on the TPMC.

The module requirements as listed in the TPMC do not have to be completed in their order of

appearance except that one (1) level must be completed before the next can be started. The

order in which the trainee performs the demonstration of these skills depends on their

experience and preparation. It also depends on their current work schedule.


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The Facilitator will consider safety habits when judging whether or not to approve a skills

demonstration. An unsafe act may invalidate an otherwise approved performance.

Remember that safety is a crucial part of any Mechanical Distribution Mechanic’s work and

of every task performed.

Your Facilitator, or someone designated by the Facilitator, must approve skill demonstrations.

The company-approved safety procedures will be used to determine the quality of a

demonstration. In some cases, the Facilitator may use a team to approve a demonstration.

The Facilitator will date and initial or sign all approvals on the TPMC.

2.0 Equipment Maintenance Facilitator’s Guide

The Equipment Maintenance Training Module is designed as part of the Power Plant

Maintenance Distribution Training Program. This module is designed to aid mechanics in

upgrading their knowledge and understanding of the equipment.

Reference Materials: Power Plant Mechanical Distribution Technical Manuals, and Charts or

Diagrams used in performing the maintenance.

2.1 Formal Training

The format of the Module formal training materials (Equipment Maintenance

Description Document) is suited for either formal classroom instruction, self-study or for

refresher training.

Unless a waiver is granted, the trainee must have completed the prerequisite basic

knowledge modules (IRI Web Based Training, Videos or CD Rom Programs) and safety

modules before starting training on the next module. If the training is presented as

classroom instruction the following applies.


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2.2 Equipment Maintenance Description (EMD) - Facilitated Training

The following guide is used to formally instruct the trainee in a structured training

environment. If the training is presented as classroom instruction, the following applies:

2.2.1 Suggested training aids and materials:

Overhead Projector

Chalkboard/Whiteboard

Flipchart

PC and Monitor

Pencils

Notebook paper

Hi-liters

2.2.2 Facilitator Preparations

Review Equipment Maintenance Description text.

Prepare copies of Equipment Maintenance Description for trainee handouts.

Print EMD drawings as overhead slides.

Review the Job Performance Measure

Prepare copies of JPM.

Display or Review Reference Materials: Power Plant Mechanical

Distribution Technical Manuals, and Charts or Diagrams used in performing

the maintenance.

2.2.3 Classroom Presentation

Describe the module and how the material is to be presented.

Hand out copies of student text.

Present each chapter objective.

Review the contents of each chapter with the students using student text and

drawings.


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Allow for discussion at the end of each chapter. Encourage the students

draw on their past experiences with regard to the lesson.

Summarize each chapter.

Inspect the equipment with the trainee and instruct them to describe the flow

path, identify the equipment components and describe the function of each

component.

At completion of lecture and discussion, administer the written test.

2.2.4 Module Equipment Maintenance Description (EMD) Overall Training

Objectives

The objective of this lesson is to present the material relating to the equipment.

Upon completion of the training the Maintenance Mechanic should be able to:

Describe the function of the equipment.

List the components that make up the equipment.

Describe the flow path through the equipment.

Describe the function of each component of the equipment.

Identify equipment under the maintenance jurisdiction of the Power Plant

Mechanical Distribution Mechanic.

2.2.5 Module Equipment Maintenance System Description Chapter 1.0 - Training

Objectives:

This section describes the function of the equipment. It provides a simplified

description of the equipment; introducing the equipment major parts, and flow

path. Components are described as they apply to Power Plant.

Upon completion of this chapter, each student should be able to:

State from memory the function of the equipment.

Draw a simplified diagram of the equipment, including internal parts.

Describe the equipment connections and interaction with other systems.

List the equipment operating parameters.


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2.2.6 Module Equipment Maintenance Description Chapter 2.0 - Training

Objectives:

This segment addresses each Equipment Major Part. The major parts are

described as to their function and type. Upon completion of the chapter, each

student should be able to:

Draw from memory a diagram of the equipment showing major parts.

State from memory the names and functions of major parts.

Describe the location of the major parts.

2.2.7 Module Equipment Maintenance Description Chapter 3.0 - Training

Objectives

This section describes the Equipment Preventive and Corrective Maintenance as

it applies to Power Plant Maintenance Mechanics. Upon completion of this

section, each student should be able to describe:

Routine Preventive Maintenance (equipment not taken out of service).

Preventive and Corrective Maintenance (requiring the equipment to be taken

out of service for inspection and repair.)

Reassembly and Testing after Preventive or Corrective Maintenance that

requires the equipment to be taken out of serve.

At the end of the training session a written test will be administered. A score of

75 percent

must be obtained to satisfactorily complete this part of the training.

2.3 Equipment Maintenance Description (EMD) - Self-Directed Learning

The following guide is used to provide direction to the trainee to self-study the module

training materials. If a self-directed approach is used, then the following applies:


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2.3.1 Trainee Preparation for Self-Study

Provide the trainee with the following tools and training materials:

Pencil

Notebook

Hi-liter

Equipment Maintenance Description

Plant reference materials such as: Power Plant Mechanical Distribution

Technical Manuals, and Charts or Diagrams used in performing the

maintenance.

Discuss the self-directed learning strategy with the trainee:

Read each chapter of the Equipment Maintenance Description (EMD) and

be able to complete each of the chapter objectives.

Review the Power Plant Mechanical Distribution Technical Manuals, and

Charts or Diagrams used in performing the maintenance.

Inspect the equipment and refer to the training materials to help you

understand the function of each component, the location of each

component, the flow path and maintenance parameters.

Interact with more experienced Maintenance Distribution Mechanics and

your assigned facilitator. They are responsible for answering questions,

providing you with On-The-Job Training and conducting oral quizzes to

determine your progress and competency level.

When the facilitator agrees you are ready then you will be given the

written test. A mastery level of 75 percent is required to demonstrate

knowledge.


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2.4 Equipment Maintenance Procedure (EMP) - Facilitated Training

The following guide is used to formally instruct the trainee to understand and perform

all maintenance tasks described in the Equipment Maintenance Procedure.

2.4.1 Suggested Training Aids

Overhead Projector

Chalkboard/Whiteboard

Flipchart

PC and Monitor

2.4.2 Suggested Student Materials

Pencils

Notebook paper

Hi-liters

2.4.3 Classroom Preparation

Review Equipment Maintenance Procedure Text.

Prepare copies of Equipment Maintenance Procedure Text for student

handouts.

Prepare copies of the written test.

Prepare the Equipment Maintenance Checklist as overhead slides.

Display Reference Materials: Power Plant Mechanical Distribution

Technical Manuals, and Charts or Diagrams used in performing the

maintenance.


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2.4.4 Classroom Presentation

Describe the EMP and discuss how the material is to be presented.

Hand out copies of the EMP.

Present each section objective.

Review the contents of each section of the EMP with the students using

drawings to illustrate locations of components and equipment.

Allow for discussion at the end of each section. Encourage the students to

draw on their past experiences with regard to the lesson.

Summarize each section.

When complete with the classroom instruction, thoroughly inspect the

equipment with the trainee and discuss/demonstrate how to perform all steps

of the equipment maintenance procedure.

At completion of lecture and discussion, administer the written test.

2.4.5 Module Equipment Maintenance Procedures (EMP) Objectives

This section describes the maintenance of the equipment. Upon completion of

this training the trainee should be able to:

List the safety requirements associated with the equipment.

Describe any environmental impacts or concerns involved with the

equipment maintenance.

Discuss training and responsibilities required for maintenance of the

equipment.

List the Precautions, Limitations and Setpoints relating to maintenance of the

equipment.

Perform equipment preventive maintenance.

Perform the checks, isolations and tagouts required when performing

corrective maintenance of the equipment.

Perform corrective maintenance.

Test the equipment after completion of corrective maintenance.

Use the Equipment Maintenance Checklist to restore it to service.


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2.5 Equipment Maintenance Procedure – Self-Directed Learning

To ensure the trainee fully understands all aspects of the Equipment Maintenance

Procedure, it is required that he/she is provided with facilitated instruction. However, to

minimize Facilitator time, the trainee can do the following self-study so he/she is better

prepared prior to the formal training session:

2.5.1 Provide the trainee with the following tools and training materials:

Pencil

Notebook

The Equipment Maintenance Procedure.

Power Plant Mechanical Distribution Technical Manuals, and Charts or

Diagrams used in performing the maintenance.

Equipment Maintenance charts and diagrams.

Provide a handout of the Procedure Objectives listed in section 2.4.5

2.5.2 Instruct the trainee to do the following self-study:

Discuss the Procedure Objectives with the trainee and instruct him/her to use

the objectives to direct the outcome of the self-study session.

Read the Equipment Maintenance Procedure.

Inspect the equipment, following each step of the maintenance procedure,

and mentally simulate how to perform the required actions.

Make note of any questions that you may have concerning the procedure so

they can be discussed with your facilitator.


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2.5.3 Once the trainee has completed the self-study, the facilitator will conduct a

facilitated training session that includes the following:

Conduct an oral review to assess the trainee’s understanding and answer the

questions that were noted during the self-study.

Inspect the equipment with the trainee and have them discuss or demonstrate

how to perform each step of the procedure.

Explain and demonstrate any aspects of the procedure that the trainee doesn’t

fully understand.

At the end of the training session administer the written test. A score of 75

percent must be obtained to satisfactorily complete this part of the training.

3.0 On-The-Job Training

The purpose of On-The-Job Training is to demonstrate to the trainee how to perform the

various maintenance procedures associated with the equipment. Trainees are to be given

copies of the JPM. The OJT Training Process is performed as follows:

Step 1 The Facilitator discusses the performance of the JPM

Facilitator gives an overview of the maintenance procedure associated with the equipment.

Shows location of the major parts of the equipment.

Describes the preparations needed for maintenance of the equipment.

Step 2 Facilitator describes or performs the JPM

Facilitator describes or performs each step that is needed to isolate the equipment.

Facilitator describes or performs each step that is needed during preventive and corrective

maintenance of the equipment.

Facilitator describes or performs each step that is needed to isolate in readiness to perform

corrective maintenance of the equipment.


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Facilitator describes or performs system corrective maintenance. This includes how to

properly perform the maintenance task, the, any routine adjustments that may be required,

and how to properly use and record information on the maintenance checklist.

4.0 Equipment Checkout

Equipment Checkout involves having the trainee properly perform all system preventive and

corrective maintenance. The trainee will use the JPM, the Equipment Maintenance Procedure,

and Equipment Maintenance Checklist to perform the System Checkout using the following

process:

Step 1 Trainee discusses the System Checkout with the Facilitator

Trainee gives an overview of the procedure or process that is to be performed.

Trainee will show location of Equipment and the major parts.

Step 2 Trainee performs the System Checkout and is evaluated by the Facilitator

Trainee describes or performs the preparations needed for Maintenance of the equipment

using the Equipment Maintenance Procedure and associated Checklists as needed.

Trainee describes or performs each step that is needed to perform preventive and

corrective maintenance on the equipment.

Trainee describes or performs each step that is needed during preventive and corrective

maintenance of the equipment.

Trainee describes or performs each step that is needed to test the equipment after

corrective maintenance.

Trainee performs complete equipment inspection and checks after returning the equipment

to service.


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5.0 Module Requirements Sign Off

When all the elements of the Equipment Maintenance Training Module have been completed,

the Supervisor or designated Subject Matter Expert will sign off the associated documents in

the trainee’s TPMC.


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TRAINING SYSTEM TEST QUESTONS (IRI-EM19)






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1. (IRI-EM19-EI) For outdoor cable termination, __________ protective skirts must be installed

for 25 kV terminations.

A. one (1)

B. two (2)

C. three (3)

D. four (4)

2. (IRI-EM19-EI) In cable termination, a torch is used to shrink ____________.

A. lugs

B. HV tubes

C. conductors

D. shielding

3. (IRI-EM19-EI) A torch used in cable termination must be “clean-burning”, which means

_________________.

A. the torch does not deposit contaminants on the cable

B. has a short, compact flame

C. could make use of oil as a fuel

D. the flame is green throughout

4. (IRI-EM19-EI) When using a torch to shrink during cable termination, the portion of the flame

used is ___________.

A. the base of the flame only

B. any part of the flame

C. the tip of the flame only

D. no part of the flame

5. (IRI-EM19-EI) To determine if a cable has properly recovered from shrinking during

termination, the wall thickness should be ___________.

A. narrower than before termination

B. thicker than before termination

C. uneven

D. uniform


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6. (IRI-EM19-EI) When terminating a cable with copper tape, the ground braid should be

___________.

A. pointed away from the lug

B. pointing toward the lug

C. soldered to the tape

D. cut off at the terminal

7. (IRI-EM19-EI) When terminating a cable with a lead shield, the ground braid should be

________.

A. soldered to the lead sheath

B. cut off at the terminal

C. taped to the lead shield

D. separated from the lead sheath

8. (IRI-EM19-EI) When shrinking an HV tube to a cable being terminated, the torch flame

should be ____________.

A. held still near the lug

B. held away from the lug

C. moved in a smooth, brushing manner

D. moved in a quick, jerking manner

9. (IRI-EM19-EI) When terminating a cable, the HV tube should be ____________ .

A. bolted to the cable

B. shrunk to the cable

C. crimped

D. separated from the cable

10. (IRI-EM19-EI) Skirts must be attached to the end of the cable being terminated for

____________.

A. indoor use only

B. indoor or outdoor use

C. low voltage equipment

D. outdoor use only

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