ML20199E163

Rev 2 to Prerequisite Test Instruction XCP-EE-20, Continuity & Termination Verification. Related Documentation Encl

ML20199E163
Person / Time
Site:	Comanche Peak
Issue date:	09/02/1985
From:	London D TEXAS UTILITIES ELECTRIC CO. (TU ELECTRIC)
To:
Shared Package
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References
FOIA-86-36 NUDOCS 8606230209
Download: ML20199E163 (90)

Text

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i CPSES 6

PREREQUISITE TEST INSTRUCTION

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XCP-EE-20 CONTINUITY AND TERMINATION VERIFICATION I

Revision:

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j Prepared By:

D. Arthur London Z

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1 K3 Reviewed By:

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' cup / Turnover Surveillance Lead

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Reviewed By:

Title:

Reviewed By:

Title:

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Approved By:

Neo Of. '

Dates dea. S 1988 l.

Manager, CPSES Startup li l

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0606230209 860609 SAP-7-1 PDR FOIA GARDE 86-36 PDR

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Continuity and Termination Verification ij 1.0 Purpose The purpose of this instruction is to ensure that continuity and termination verification tests are performed in a complete and consist manner and to provide a means to document these tests.

2.0 Acceptance Criteria 2.1 Cable Continuity Each conductor of power, control and instrumentation cables shal.

exhibit electrical continisity from origin to destination.

2.2 Cable Termination Each conductor of power, control and instrumentation cables shall terminated in accordance with applicable connection drawings that reflect cable terminations at the time of verification.

b 2.3 Vendor Internal Wiring i

Terminations and continuity of vendor internal wiring shall be in j

accordance with the latest applicable vendor drawing and/or desig changes.

I 3.0 References Custody Transfer of Station Components 3.1 CP-SAP-3 Safety Tagging Procedt$re 3.2 CP-SAP-5 3.3 CP-SAP Review Approval and Retention of Test Results b

O 3.4 CP-SAP Temporary System Modifications l

Megger/Hi Pot Testing 3.5 XCP-EE-1 Control Circuit Functional Testing 3.6 XCP-EE-8 Clearance and Safety Tagging

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3.7 STA-605 i

4.0 Prerequisites

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l 4.1 Cables or equipment to be tested shall have b'een released to artup custody in accordance with CP-SAP-3.

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XCP-EE-20 Rsvision 2 Page 3 of 9 iI 4.2 The latest revision of cable origin and destination connection drawings are available with applicable design changes. Use of " Office j

and Engineering Use" drawings is permissible. The drawings shall be j

stamped with the XCP-EE-20 stamp as shown in Figure 1.

j 4.3 Prior to continuity / termination verification, the cable connection I

drawings should be reviewed against the applicable schematic /oneline to ensure correlation between connection and schematic drawings.

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Note When actual cable termination i

status is not reflected on the latest drawing revisions due to unimplemented design changes,

.i it is permissible to test the I

cables to superseded revisions I

that reflect actual cable ter-minations.

If this is required, the STE shall make an entry on the MDB stating that the design change or the latest drawing revisions have not been imple-mented in the field equipment.

Reference specific DCAs, drawing l

revisions, etc., with the cable that is not terminated per latest design.

4 4.4 The responsible STE shall record system designation, system number, reference schematic / revision and cables to be tested t

I origin and destination connection drawings / revisions on Data Sheet 1.

4.5 The responsible STE shall review cables to be continuity /

termination verified with test support personnel prior to j

commencing verification activities.

>l Note

.Z It is recommended that con-F j

struction termination docu-I mentation be verified as o

complete and current prior to commencing test activities.

f 4.6 The latest revision of vendor internal wiring drawings and/or applicable design changes have been stamped with the XCP-EZ-20 and the " Test Record Drawing" stamps as'shown by Figures ' and 2. b q

Use of " Office and Engineering Use" drawings is permissible.

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XCP-EE-20

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R2violon 2 Page 4 of 9 Design changes affecting ven-dor internal wiring may be

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drawn on the vendor drawing utilizing RED for additions, d

GREEN for deletions. Alter-I nately, the design change may be attached to the vendor f

drawing and utilized for test-ing.

Ij 5.0 Test Equipment I

Fluke Model 8020B digital volt ohm meter or equivalent 5.1 5.2 Simpson Model 260 analog volt ohm meter or equivalent 5.3 Battery powered telephone handsets with test leads

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5.4 Series battery / bell combination with test leads Note Items 5.3 and 5.4 are qualita-tive versus quantitative equipment and as such are not controlled under the M&TE calibration program.

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6 5.

5.7 James G. Biddle - Motor and Phase Rotation Indicator i

Cat. #560060 or equivalent 6.0 Precautions I

6.1 Conductors should be electrically isolated to be continuity tested If determination is required for isolation, the conductors cust be p===

I promptly reterminated upon conclusion of test activities.

Note Lifted conductors that are left unattended or will remain lifted beyond the end of the shift shall be identified and logged l

as Temporary Modifications per CP-SAP-13.

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XCP-EE-20 Rsvision 2 Page 5 of 9 I

6.2 Ensure conductors are isolated from instruments, electronic equipment or other solid state devices prior to applying battery powered

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telephones or battery / bell test equipment. This must be done to preclude damage to the equipment.

6.3 Circuits containing cables to be continuity tested shall be b

l de-energized and safety tagged, if required.

l 6.4 Ensure an Inspection Removal Notice (IRN) is initiated prior to determinating Class IE bolted bue power conductors or conductors f -

Westinghouse AR re: lays which require torquing.

6.5 Use caution not to overtorque terminal screws en Westinghouse AR h

I Auxiliary Relays as this can deform the stationary contact assenb:

If determination or change of contact configuration / terminal wir.:

required, the terminal screws shall be torqued to 9.5 0.5 inch pounds per memo TBX-M-513 dated August 11, 1980.

7.0 Instructions 7.1 Cable Continuity and Termination Verification 7.1.1 Verify that applicable prerequisites of paragraph 4.0 a d

complete.

7.1.2 Ensure the cable to be tested is de-energized.

-l 7.1.3 Determinate the origin and destination of the cable to i

continuity tested.

(1)

It is permissi e to determinate i

each conductor of multiconductor

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cables one at a time for con-tinuity testing.

l (2) Determination of power feeds q{

terminated with Ray Chem heat shrink is not required.

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I (3) Determination of power leads e

d at the source is not required as long as isolation is pro-vided by an open molded case or racked out air circuit breaker.

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1 XCP-EE-20 R2 vision 2 Page 6 of 9 7.1.4 Verify continuity of each conductor utilizing phones.

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battery / bell tester or volt ohm meter.

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Note l

I The continuity of motor feeders terminated with RayChem heat j

shrink can be verified by moni-l toring the deflection of a phase rotation indicator con-I nected at the source while hand i

rotating the motor at the cables destination. Refer to the j

manufacturer's instructions for test connections.

s 7.1.5 Record results of continuity testing on Data Sheet 1.

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Note Megger each cable conductor in accordance with XCP-EE-1 if megger testing is to be performed.

7.1.6 Reterminate the cable per the applicable connection dra b

if the cable was determinated in Step 7.1.3.

Ensure te minal screws are tight.

For cables that require torqui ensure Quality Control is present to witness torquing operations. Record the torque wrench or screwdriver M6 number on Data Sheet 1.

Record applicable QC inspectio report numbers in the remarks section of Data Sheet 1.

Steps 7.1.7 and 7.1.8 may be d

performed concurrently.

7.1.7 Compare each conductor color, tag number and terminatior b

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point to applicable origin and destination connection drawings to verify correct cable termination.

i 7.1.8 Highlight the cable number on each conductor identificat

.c tag or sleeve located near the termination with a permat

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j yellow marker. Use caution to prevent smearing of the <

4 numbers.

7.1.9 The individuals that performed the origin and destination termination verification shall signify satisfactory completion by signing the terminacion verification.'anks next to the cable number and the recorded by blank on Data Sheet 1.

If the cable is terminated per a design change against the applicable drawings, note the design change

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number in the remarks section of Data Sheet 1.

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XCP-EE-20 Rsvision 2 Page 7 of 9 1

7.1.10 The responsible STE shall review Data Sheet 1 for completion]

l and adequacy and signify that review in the space provided.

7.2 Vendor Internal Wiring Termination and Continuity Verification 7.2.1 Verify that applicable prerequisites or paragraph 4.0 are complete.

I 7.2.2 Utilizing vendor wiring drawings and design changes, ir applicable, perform point-to-point continuity and

.j termination verifications. Highlight the vendor drawing 2

vendor conductor identification tags as the verificatior f

are completed.

7.2.3 Signify completion of the continuity and termination

.i verifications by signature of the " Test Record Drawing' stamp on the vendor wiring drawing and/or design change Note Review and retention of test results is as specified by CP-SAP-11.

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XCP-EE-20 Rsvision 2 Page 8 of 9 l

TEST RECORD DRAW 1NG j

System Number Applicable Prereqs. of Section 4.0 Ard Comp.

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DATA SHEET 1 XCP-EE-20 I

Revision 2 CABLE CONTINUITY & TERMINATION VERIFICATION Page 9 of 9 f

Applicable Prerequisite of Paragraph 4.0 are Complete:

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Nam 3:

Date:

1, Syctem Designation:

Syst.em No.

i R:forence Schematic / Revision i

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l Destination Continuity Termination Verific 3

.i Origin Conn.

Conn.

Satisfactory Signatures Cable No.

Drawing /Rev.

Drawing /Rev.

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Origin Dest'i

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-I Test Equipment:

Type S

L Identification Number Calibration Due Date

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Rsmarks:

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Date:

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Witnessed By:

Date:

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MSC:

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i SUPPLEMENTAL INSPECTION PROCEDURE j

POPULATION DESCRIPTION /NUl1BER

. POPULATION INSPECTION PROCEDURE

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EQUIPMENT MARX / TAG NO.

EQUIP / SAMPLE DESCRIPTION VERIFICATION PKG. NO.

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r-E-cA st 0 30 ESBI LIGH TINCr CASLE pAGE OF ATTRIBUTE:

INSTRUCTIONS AND ACCEPT / REJECT CRITERI A

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1. I si ructio n F.I of-QI-O I 4., Rev. O is not AppUtable,

j Verify he following.'

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a. Wire for branc.h circuib is f/c # 12 AWC,,

j copper, unless o%eedse note l. on drawings.

.b. wire for ciccurb within fixtuces. is Vc *sz, Goov stednded copper u4ess o%uwise, noted on drawings (This scludos fixture stems and finible conduit to reces3 cJ Gtuces).

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c. N eubl condabes are sigle, condu. dor of the same sge.

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and in sul ation a.3 phase conduc tors.

d. wi<e ts color coded Orage Cec Trak "h" a~a keen

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Sc. Verih &f Me jaChet of w;ees is p/ &d 'slach." a r-Phase A, ' Ref fe e Noe 8, "61ue" b Phase C

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COMANCHE PEAR RES?OMSE

.01 SU?PLDiENTAL INS?IC'" ION INSTRUCTION POPULATION DESCRIPTION QUALITY INSTRUCTION i

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Ft NUMBER SUPPLEMENTAL INFORMATION AND JUSTIFICATION 5

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A. Seismic Restraints (Kestraints Anchors, Cuides, etc.)

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(2 I pipe vall chickness* + 2 inches) from drawing location for Unit 2.

Unit 1 and Common shall be : 2 inches.

• Nominal pipe vall thickness, t as supplied by

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5.6.6 Cracks, Lack of Fusion

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A. Verify no lack of fusion or cracks are visible and that there are not any linear indications in excess of 1/16 inch.

1 5.6.7 Welder ID Symbol C '1.

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POP h TION SIZI SAMPLI SIZI t

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SE / OF 3 NO.

l C9 D _v M STICS(s) AND INFORMATION RIO.UIRED l QUANTI!!

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l IDENTlFl CATION l

WAS TH6 NON.TNTEGRAL PORT l0W 0F THE SUPPORT O A.

I IOGNTlFiED ? IF NO, ENTER / UNDER QUANT lTY (INDICATING QUE REJECT). IF YES, ENTER O (IND CAT NG NO REJECTS).

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NO.

Of INTEGRAL ATTACH NG MEMBERS O

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No. OF INTEGRAL ATTACH lNG MEMEERS WITH

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2. -

LOCATION AND CRlENTATl0N A.

WAS LOCATIOM ACCEPTABLE ? IF YES, ENTER Ci

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IF N0, ENTER I

B.

WAS SUPPORT ORlENTATl CAL ACCEPTA6LE.7 JF YES, O

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ENTER 0 3 IF HD, ENTER 1.

3.

CONF GURAT OM A.

No. Of 17 CMS IN Bit.L OF MATER AL CN DWG/ CMC.

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5. No. OF 1TEMS INCORREC.TLY LlSTED IN 5l1.

OF

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WAS SUPPORT.WhH M.DINENSkNAL TOLERANCES.7 O

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OF BAS &PLA TES O

E. NO.

CF BAS & PLATE 5 WITH GACUTING ';

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of BASE?!.A TES THAT ARE UN XCEPTABLE A

i BOLTING (OTHER ~}RAAl Hl5.i

'8CLTS) k A. No. OF RICHMcMD INSERT 5 Q

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8. No. cf u-8017s c)

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No. CF grout-IN ANCHORS O

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E. 20. OF RICHMOND INSERTS FCUND UNACCEPTABLE O

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R No. OF U-80LTS /DUNO UNACCEPTABLE O

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NO. CF GROUT-IN ANCHcRS FOUND UNACcEPTAELE O

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No. OF GTHER 80L.TS F44.IND UNACCEPTABLE O

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1 VERIFICATION FKG NO.

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NO.

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• TSTICS(s) AND INFORP.ATION' REQUIRED 1

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5.

PlP NG WELOS

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S. NO. OF WELDS INSPECTED 0

B. No. OF WELDS LOCA TED INCD&R ECTLY 0

,k C. NO. OF WELDS UNDERSl ZED O

O. No. OF WELDS OF INSUFFICIENT LENGTH

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G. NO. OF WELDS FOUND UNACCEPTA ELE D

G.

SUPPORT WELDS A. No. OF WELDS INSPECTED.

A 8.

NC. OF WELDS LOCA TED INCo?JECTLY 0

C.

N O.

OF WELDS UNDERSIZED O

D.

NO. OF WELDS OF INSUFF CIENT LENG TH

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C5 RfEL.OS FDUND UMPCCEPTAELE~ ~

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7.

HlLT BOLTS A. N o. O F BOLT 5 0

5. No. OF BCLT.S WITH NO LENGTH IDENTIFI CA TIDM 0

STAMPED 'CM TCP CF THE SCLT C

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No. OF SCLTS FCUMD UMAcc e?fAELs O

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COMPCHENT SUPPORT CATA LCG ITEMS

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OF' ST;:LUT5 O

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VERIFICATION PKG NO.

POPULATION SIZE SAMPLE SIZE SH 3 0F 3 I Lbst. -ot9_.. _

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NO.

CHARACTERISTICS (s) AND INFORMATION REQUIRED QUANTITY 9.

OTHER SPECiF!C CHARACTERiS TICS A. PIPE CLAMP HAl.VES PARALLEL /SM t

1.

No.

OF PIPE CLAMPS O

2.

No.

OF UNA CCEPTABLE P/PE CLAbfPS Q

8. SPHERICAL.

BEAR /h/G GAP l.

No.

Of SPHER l CAL BEAR lNGS O-2.

NO.

DF UNACCEPTABLE SfMEA/ CAL BEAKING O

GAPS C. SNt/88ER ADAPTER. PLATE BOLT THREAD ENGAGEMENT LENGTH

1. No. OF SNUBBER ADAPTCR PLATE BOLTS

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?. N0. OF BOLTS W5TH lilSUFFIClENT THREAD

• • M ENGAGEMENT.

D. LOCKlil6 DEVICES FOR LDAD PlAIS AND LOAD BOLTS

l. No. OF LOAD PINS ANO LDAD Bol TS (coMatHED).

O LOAD PINS AND LCAD BOLTS ARE THE PINS AND BOLTS USED FOR BRACK.ETS AND CLAMPS. TNERE lS ONLY ONE LOAD BCLT FOR EACH CCNNECT/0H TO A CLAMP.

2. No. OF UNACCEPTABLE LOAD PINS AND LOAD D__

BOLTS (COM8IntED).

6. LOCKI'NG DEVICES FOR THREADED FASTENERS 1.- N0.:0f. 8CLTS; STUDS AND 7t/ READ &D FASTENERS OTHER 7HAAI 0

SA-IB BCLTS, SA-325 BOL7S,' HlLTi BOLTS, LDAD PINS AAID

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LDAD DOLTS.

2. No. OF BOL7S, STUCS AND THREADED FASTENERS OTHER 7HAN D

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d LOAD. BOLTS THAT ARE. UNACCEPTABLE, i.e. w/TH I

LOCKING DEVICES missing F Hli.Ti BOLT MINIMUM EMBEDMEMT LENGTM l

1. Mo. OF HiLTi FOLTS WITH UNA<.CEPTABLE

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EMOEDMEMT LENGTH.

PREPARED BY COMPLETED BY O $..-

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INSP'CTION TOOLS USED

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ATTRI3UTE TOOL CODE (s)

SER. #/CALI3. DUE DATE 1.

Identification VT g/

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Location & Orientation ST VT 3.

Configuration 1/ T ST I

A.

Components l/I ST B.

Estarials 3 7' l/ 7" C.

Installation S7 V T D.

Clearance

1. 4 V 7' i

E.

Baseplates A////

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Bolting I

A.

Engagement A//g B.

Surface Contact A//4

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Richmond Insert A//M C.

i Locking Devices A/.4 D.

E.

U-Bolts A//4 F.

Torque AMM

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Edge Distance h/lA H.

Grout-In Anchors M[4 ll J

5.

Piping Welds i

A.

Location N//f e

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B.

Size N/AP C.

Profile A///9 D.

Rainforcement N/M E.

Undercut N//9 A/4 F.

Surface Condition ~

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The following support services are requircd for reinspection of this item:

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QA/QC INSPECTION SUPERVISOR

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Attached is the minimum acceptable termination criteria for use in the i

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f This criteria is not intended to modify workmanship criteria in owners or 1

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. contact. Tin being a soft metal has little recistance i

to abrasion. Tightening of the screws, nuts, and washers on i

the lugs may cause surface scratches at the top of the lug which may uncover copper. However, the bottom of the lug f

which provides the surface contact for electrical conductivity h

is not prone to these damages.

1, sj Therefore, tin plating damage caused by scratches at the top of the lug which may uncover the copper surface is acceptable.

3 However, the bottom surface should be free of scratches causing i

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uncovering of copper.

i Twisted / bent lugs O

k'.

Lugs provide a means of transferring current from the conductor r

to a terminal and are selected based on the conductor si:e.

The current carrying capacity of the lug is directly proportional to the cross-sectional area of the lug. A bend or a tvist at the collar which does not cause mechanical fatigue-crack vill not 1

1 affect the cross-sectional area of the lug and the current j

carrying ability of the lug. Lugs can be tvisted or bent at the j

collar to any degree provided they show no signs of cracking due to a,

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fatigue. This position is supported by the Vendor's Workmanship ni Standard, as well as the multi-axial vibration tests

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cenducted by the lug manufacturer. However, a bend in the lug tongue which vill not flatten even after tightening of the screv/ nut is net 4j acceptable because it vill reduce the contact ares between the tenrue and the terminal.

j Excessive strip length extruding from lug barrel Excessive strand lengths protruding beyond the end of wire barrel are acceptable provided they do not form an obstruction to tightening of the nuts or screws.

If the strands extend to undesirable lengths, they could be cut back up to the end of the wire barrel.

Construction procedure eel-8, Rev. 5, requires vire strands to be flush with or extead slightly beyond the end of the wire barrel, i

d Vendor's Workmanship Standard, calls for minimum flush to maximum i

1/16". These requirements provide for neatness in their connection, and are not essential for the functionality of the circuit.

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TSG-12271 Page 2 of 3 Conductors are not flush with or protruding past the wire barrel it is not necessary for the conductors to be flush with or protrude past the wire barrel.

As long as the conductors protrude past the crimp point as determined by a visible check from the end of the wire barrel, the termination vill hold for rigidity as well as j

conductivity.

L h-Strands bunched at the barrel entry

, Bunched strands at the barrel entry may result in loss of ampacity 3

for the conductor due to reduction of the cross-sectional area cf conductor at that junction. This reduction of cross-sectional area should not cause a concern because the cable at that point is not I

covered by insulation which is a limiting condition for allowable

)

cable ampacity and therefore it will not cause localized hot j

spot. However, if excessive strands are lef t out of the barrel j

a loose crimp connection may result, in which case it would require rework.

4 out of the 1

Therefore, lugs with approximately 151 of the strands left l

barrel are acceptable for the ampacity requirements.

.)

Lugs crimped off-center i

Crimp centering, although desirable for neat workmanship, is not j

essential for the lugs from the conductivity standpoint.

Full l

impression of the crimp must however, be on the wire barrel. An off-set is acceptable provided the conductor extends beyond the cr1cp point'and is visible in the wire barrel.

i i

insulation over-stripted i

d Over-stripped insulation vill cause exposure of the conducter ij beyond the barrel.

It is preferable that the exposed conductor does not show-up beycnd the insulation barrel.

Probability of grounding er

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shorting does not exist because of the external insulation barrel j

provided in the crimp.

In the case of uninsulated lugs, the short length, approximately k", of uninsulated wire at the E

barrel end is not a concern because the termination design of the lugs excludes any possibility of grounding or shorting.

i insulation / Mylar under wire barrel it it is probable sometimes, that the insulation or mylar or any such type of conductor covering gets trapped under the wire barrel during crimping process. This becomes a barrier between the conductor and the lug barrel. The Vendor's own Q.C. inspection program would i

normally detect this condition at the factory and the crimp would l

be re-worked before shipping.

In the event field inspection finds that some lugs are crimped with insulation under the wire barrel, h

the following reject criterion can be applied:

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TSG-12275

• 6y Pcge 3 of 3 The total length of the stripped conductor should not be less than the length of toe wire barrel and

• j I

- The conductors should not protrudt beycnd 1/16 inch from the end of the wire barrel.

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j

-Insulated lugs not required 2

i This criterion takes the position that lugs inside the control panels

.need not be insulated although customarily specified for the Vendor furnished equipments.

Insulated lugs are usually equipped with nylon, vinyl, and teflon sleeves; the purpose of which is to prevent

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wire to wire contact, to eliminate moisture and to provide additional s

circumferential insulation support. Insulated lugs are, however.

l needed in equipments subjected to vibration during normal operation.

such as motors. For equipments such as the MCC's and switchgears,

?

which are stable under normal operating conditions, insulated lugs are not required. Uninsulated lugs, i.e. lugs without the insulation barrels or sleeves are acceptable for switchboard / control boarc viring as long as they are properly trained for separation and rigidly tightened in position on their respective terminals.

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