flex conduit rework and repair effective tbd draft web viewlum-ffa-mnt-0022 flex conduit rework and...

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Subject: Flex Conduit Rework and Repair

Revision Number and Date: Rev. 0; TBD Procedure No.: LUM-FFA-MNT-0022

Use: Reference Use

Effective Date: TBD

Prepared by: Jerry Wayne Date: ____________________

Reviewed by: ___________________________________________________ Date: ____________________

Approved by: ___________________________________________________ Date: ____________________

Required review frequency: TBD

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Table of Contents1. Purpose and Scope........................................................................................................................................ 42. Acceptance Criteria...................................................................................................................................... 43. Special Tools and Materials....................................................................................................................... 4

3.1 Special Tools.............................................................................................................................................................43.2 Materials..................................................................................................................................................................... 4

4. Precautions, Limitations, and Notes.......................................................................................................44.1 Precautions................................................................................................................................................................54.2 Limitations.................................................................................................................................................................54.3 Notes.............................................................................................................................................................................5

5. Prerequisites.................................................................................................................................................. 55.1 Planner........................................................................................................................................................................ 55.2 Electricians................................................................................................................................................................ 5

6. Definitions and Acronyms....................................................................................................................... 767. Instructions.................................................................................................................................................. 87

7.1 Reinserting the Flex Conduit...........................................................................................................................877.2 Repair Flex Conduit Jacket............................................................................................................................1087.3 Remove and Rework Flex Conduit.............................................................................................................1197.4 Rebuild and Reassemble Flex Conduit..................................................................................................13117.5 Terminate Cable and Conductor..............................................................................................................1614

8. References................................................................................................................................................ 17158.1 Development References............................................................................................................................17158.2 Performance References.............................................................................................................................1715

9. Attachments............................................................................................................................................ 1715

Attachment A: Bend Radii Chart.................................................................................................................................1816Attachment B: Torque Value Chart............................................................................................................................1917Attachment C: Verification Sheet...............................................................................................................................2018

List of FiguresFigure 1 Flex Grounding Clamps and Wire.............................................................................................................1513

List of TablesTable 1 Signature Box ...............................................................................................................................................................6Table 2 Test Equipment Used...............................................................................................................................................6

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ReviewsWriter completes this section and deletes from final version after approval. Review comments are stored in <type location where comments are stored.>.

< In the Name column, list the names of reviewers you plan to review your document.>

Internal ReviewName Position Date<type name of program owner>

<type title, organization> <m/d/yy>

Gwen Holladay Technical Writer, DCD 3/1/11

Stakeholder ReviewName Position Date<type name of organization manager>

<type title, organization> <m/d/yy>

<type name of reviewer> <type title, organization> <x/x/xx>

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1. Purpose and ScopeThe purpose of this procedure is to provide instructions and guidance in the rework/replacement and repair of liquid tight type flexible conduit (flex) equal to four inches in diameter or less.

2. Acceptance CriteriaThis procedure contains in-process inspections. The acceptance criteria are the satisfactory completion of all applicable instructions for the procedures you perform.

3. Special Tools and MaterialsUse the following special tools and materials to perform this procedure.

3.1 Special ToolsThe following special tools are required:

Torque wrench Digital multi-meter (DMM) Weidmueller screwdriver

3.2 MaterialsThe following materials are required:

Electrical tape (Scotch 33 or 88) Glass Cloth Tape (Scotch 69) Fish tape Pull rope Polywater lubricant Aluminum oxide cloth or fine grade sandpaper

Gwen Holladay, 03/02/11,

“in reworking, replacing, and repairing”


From page 10


Weidmuller. Their website lists different models. Will reader need a specific type or size?


It might make sense to introduce the abbreviation here.


Can we leave this word out? I don’t think it adds meaning.

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4. Precautions, Limitations, and NotesBefore performing the procedure, ensure you understand the following precautions, limitations, and notes.

4.1 Precautions The following precautions shall be followed:

Obtain a LOTOV clearance if you must de-terminateion of the conductors is necessary to isolate the cables or conductors within the flex being reworked.

If it is not possible to obtain a LOTOV clearance on all conductors, then work should be done using good electrical work practices. Insulate or isolate.

Establish and maintain an adequate level of cleanliness to prevent the entrance ofintroducing foreign material (debris) into the flex.

4.2 LimitationsNone

4.3 NotesThe following information may be used while performing the procedure, but is not required:

Use Attachment C:Attachment C: Verification Sheet Verification Sheet to record wiring terminations "as found." Use Have a second person as a verifyier the information.

5. PrerequisitesThe following prerequisites must be met before performing this procedure.

5.1 PlannerThe planner must enter the following information:

Work Order No.: __________________________________ Component Tag No.: ______________________________

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Unit No.: ____________________________________________ Conduit No.: ________________________________________

5.2 ElectriciansPersonnel performing this procedure shall review all instructions, precautions, notes, and safety requirements prior to performing this procedure.

Each person performing work using this procedure is required to record their name, signature, and initials in the following signature box. If a worker does not have a RACF ID, then include their contact phone number.

Print Name Sign Name Initials RACF ID

Table 1 Signature Box

Test Equipment ID Number Cal Due Date

Table 2 Test Equipment Used

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[6.] Definitions and AcronymsThe following definitions and acronyms appear throughout this procedure. The first occurrence of each term and acronym appears in italics.

DMM—Digital Multi-Meter

Flex—Liquid-Tight or Seal-Tight brands of flexible conduit

Snug Tight—Fastener tightness attained by using the propera tool to tighten a connection that cannot be loosened tightened by hand.

Term Tight—Mating surfaces of terminations in full contact with each other with no visible gap or space and the wire or lug does not move with awhen slight pressure is applied.

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[7.] InstructionsThe procedures below contain instructions for the following tasks:

Reinserting the flex conduit Repair flex conduit jacket Remove and rework flex conduit Rebuild and reassemble flex conduit Terminate cable and conductors

[7.1] Reinserting the Flex Conduit

Use this section to repair the flex conduit by reinserting the flex jacket into the ferrule and tightening the compression nut.

1. If the flex conduit has pulled out of the compression fitting, perform the following:

a. Loosen and remove the compression nut from the fitting.

[b.] Inspect the cable and conductors for damage to the extent practical. The following conditions are acceptable:

jacket cuts, scrapes, gouges, or bruises that extend 20 percent% or less into the jacket wall thickness

indentations to shielded power cable jacket less than 20 percent% of jacket thickness are acceptable provided that no further damage can be expected due to physical orientation once cable is in permanent location

insulation cuts, scrapes, gouges, or bruises that extend 10 percent% or less into the insulation wall thickness, provided the damage is located inside equipment enclosures, junction boxes, or cabinets

indentations in conductor insulation no greater than 30 percent% of insulation

[c.] If the conditions of the cable or conductors exceed is worse than the acceptable conditions listed above, record damage below and inform your supervisor.

Comments:_______________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________


What does this mean?

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2.[1.] Inspect the flex conduit for the following damage:

tears, splits, or deformations of the grounding ferrule tears, splits, or cuts in the outer jacket that exposes the metal core tears or ruptures of the metal core deformation of the metal core that reduces the inside diameter

3.[2.] If flex requires repair, record damage below and inform your supervisor.

Comments: ____________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________

4.[3.] Re-insert flex into the fitting. If the flex conduit jacket cannot be maintained within the compression nut after the compression nut has been tightened snug tight, then repair as described in 7.2: Repair Flex Conduit Jacket.

[4.] If the metal core and grounding ferrule are not damaged, Satisfactory ____ Unsatisfactory ____

[5.] Tighten compression nut snug tight.


Section needs to be completed.


Suggest “If the compression nut will not hold the flex conduit jacket …”

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5.3[7.2] Repair Flex Conduit Jacket Use this section to is for inspection and repair of flex conduit jacket.

1. Inspect damaged area of flex to determine if the metal core is damaged (e.g., metal core is torn, ruptured, or deformed). Record damage found in comments. No damage ____

Comments:________________________________________________________________________________________ _______________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________

2. If the metal core is not damaged and taping the conduit jacket is the chosen repair method, complete the following:

[a.] Roughen the surface of the jacket in the area to be taped using aluminum oxide cloth or fine grade sand paper. Clean the area to be taped with a clean, lint lint-free cloth and approved cable cleaner.

b. Apply three half-lapped layers of Scotch 69 Glass Tape with minimum tension necessary so that it conforms evenly to the contour of the jacket and extends a minimum of one inch to either side of the damaged area.

c. If the damaged area is less than one inch from the flex conduit connector, the tape should extend onto the connector body and completely cover the compression nut.

d. If the repair is being made on flex conduit whose jacket has been pulled out of the connector, the tape should completely cover the compression nut to a minimum of two inches past the area where the jacket has pulled out of the connector.

e. ________/_________________ Initial and date for completion of flex jacket repair.

[3.]


Is this an item the reader would have or should it be on the supply list?

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[7.3] Remove and Rework Flex Conduit

Use this section for to removeal and rework of the flex to be replaced.

5.3.1[7.3.1] De-terminate Conductors

1. Remove the cover from junction box or device of that contains the wiring termination points.

[4.] Use a digital multi-meter (DMM) to measure the voltage potential on all affected conductors to be lifted. (A Tic-Tracer will show AC volts only.) _______/_____________ Initial and date for completion of voltage check.

Warning Possible Electrical Shock Hazard on the Leads or Terminals.

2.[5.] Use approved wire markers to identify all conductors to be lifted and their respective termination points.

3.[6.] Use Attachment C: Verification Sheet to record all conductors that will be de-terminated. Have a second person verify the accuracy of the record.

[7.] Disconnect affected leads from the junction box terminals or device. Disconnect wires one-at-a-timeone at a time, then use electrical tape to insulate terminal lugs or ends of wire.

4.[8.] Sign for leads lifted on Attachment C: Verification Sheet. Have second person verify and sign.

[7.3.2] Pullback Cable Pullback

1. Connect a pull rope to the cable and tape cable ends using electrical tape.

2. Lubricate cables with Polywater lubricant for pull lengths of more than 5 feet.

[3.] Be careful not to scrape, cut, or abrade the cable or conductors when pulling conductors out of junction boxes or the devices.

3.[4.] If installed, loosen the ground clamps from the affected ends of the conduit and disconnect the ground wire from the flex conduit.


Or “Pull Back” or just “Pull”?


??

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[5.] Mark the ground clamp(s) for proper orientation prior to loosening or disassembling the ground clamp(s). Document ground wire lifting on Attachment C: Verification Sheet. ________/_________________ Initial and date for marking clamps..

[6.] If installed, loosen the flex conduit positioning clamp and make note of its location.

[7.] If angled flex fittings are installed, mark them for proper orientation prior to removal. Orientation of angled fittings marked. _______/____________________ Initial and date for marking orientation of angled fittings.

[7.3.3] Remove Flex Removal

[1.] Disconnect flex conduit and associated applicableits fittings.

4.[2.] If the conduit is to be shortened, determine the length of flex conduit that must be removed. Record that amount _______.

[3.] Shorten the flex conduit the required amount using a saw or snips.saw/snips/etc.

5.[4.] If the conduit is to be replaced, then record the following for the removed flex:

final length ______ diameter ______ conduit identification number of the removed flex ___________________________.

6.[5.] If applicable, remove the ID tag from the flex conduit and save for reuse later. Comments:________________________________________________________________________________________ _______________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________

7.[6.] _______/_____________ Initial and date for completion of flex conduit removal and rework.


What would make this applicable? Should we specify it? What is the comments section for?


To account for possibly shortening it.


“their” ??

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5.4[7.4] Rebuild and Reassemble Flex Conduit Use this section to rebuild or reassemble the flex, then install the flex.

5.4.1[7.4.1] Rebuild Flex

[1.] Gather reworked or replacement flex and associated fittings. for inspection and reassembly.

[2.] Verify that the conduit fittings, and ferrules are free of damage and that replacement flex is an approved type, length, and diameter. Record the following for the replacement flex:

type _______ length _______ diameter ________of the replacement flex.

[3.] Install compression nut and, then ferrule onto flex.

[4.] Inspect the cable and conductors for damage to the extent practical. The following conditions are acceptable:

jacket cuts, scrapes, gouges, or bruises that extend 20 percent% or less into the jacket wall thickness

indentations to shielded power cable jacket less than 20 percent% of jacket thickness are acceptable provided that no further damage can be expected due to physical orientation once cable is in permanent location

insulation cuts, scrapes, gouges, or bruises that extend 10 percent% or less into the insulation wall thickness, provided the damage is located inside equipment enclosures, junction boxes, or cabinets

indentations in conductor insulation no greater than 30 percent% of insulation

[5.] If the conditions of the cable or conductors exceedis worse than the acceptable conditions listed above, record damage below and inform your supervisor.

Comments:_______________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________


??


Is this a duplicate section or might the reader come directly to this section?


Should we add “, in that order.” ?


Suggest “necessary” instead of “associated.”

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[6.] If you performed cable pullback through rigid conduit was performed, then pull swab through rigid conduit.

8.[7.] Verify rigid conduit is free of material or conditions that could damage cable jackets.

[8.] Verify that cable and or conductors to beare free from oil and grease.

[9.] _______/____________________ Initial and date for to indicate good conduit and cable condition.

5.4.2[7.4.2] Reassemble flex to rigid conduit

1. Tape cable ends using electrical tape and use pull rope that was attached during pullback.

2. Attach the flex connector to the rigid conduit. Tighten so it cannot be turned by hand. If attaching an angled flex connector, ensure proper connector orientation. _______/____________________ Initial and date for connector orientation.

3. Attach new flex to the connector on rigid conduit.

4. Apply Polywater lubricant for pull lengths of five feet or more.

[5.] Use one man to pPull cables from rigid conduit, through flex. and eEnsure minimum bend radius is not violated. Minimum bend radii are given in Attachment A: Bend Radii Chart.

5.[6.] _______/____________________ Initial and date for completion of cable pull and acceptable minimum bend radii.

6.[7.] Attach another flex connector to junction box or device. If attaching an angled flex connector, ensure proper connector orientation.

[8.] Feed leads from the flex through the flex connector into junction box or device. Be careful not to exceed minimum bend radius, or scrape, or abrade conductors.

7.[9.] Tighten flex compression nut snug tight. _______/____________________ Initial and date for tightening of flex compression nut.


Does this need to be a separate step? Previous signoffs have been part of the step just completed.


“Attach” or “Reattach” ?


Does this need to be a separate step? Previous signoffs have been part of the step just completed.


Should this be on the materials list or would the reader have it?

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8. Install the ground clamp and ground wire to the flex conduit if previously removed. Ensure the clamp is properly orientated. See Figure 1 Flex Grounding Clamps and Wire. _______/____________________ Initial and date for installing and orienting ground clamp.

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Figure 1 Flex Grounding Clamps and Wire

9.[10.] _______/_____________ Initial and date for ground wire installation.

[11.] Install flex positioning clamp if one wasyou removed one (it?).

[12.] Re-install the conduit ID tag if one wasyou removed one (it?) earlier.

[13.] If conduit did not have an ID tag was installed, use a permanent marker to label flex with the conduit number. Conduit numbers should be 1/3 to 1/2 the size of conduit’s outside diameter.

10.[14.] Use Ty-Wraps to hold ground wire close to flex.

11.[15.] _______/_____________ Initial and date for flex conduit rebuild/reassembly completion.


Should this be on the materials list or would the reader have it?


Does this need to be a separate step? Previous signoffs have been part of the step just completed. Also, should it be with the step on the previous page?

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5.5[7.5] Terminate Cable and Conductor

Use this section for to terminateion of cables and conductors.

1. Check LOTOV to be certain protection boundaries have not changed. Be aware that some of these conductors may be energized. Work as though all conductors were energized.

2. Remove pull rope from cable and wipe any remaining Polywater lubricant from cables or conductors.

5.5.1[7.5.1] Re-Terminate Leads to Terminal Blocks

[1.] Verify and re-terminate the leads lifted from terminal blocks and /terminal strips in accordance with the Attachment C: Verification Sheet.

[2.] Have a second person verify that re-termination is correct.Use co-worker as a second verifier. Sign and date after each wire is terminated.

3. Term tighten or torque each conductor in accordance with Attachment B: Torque ValueChart.

[4.] Ensure terminations on both sides of terminal block are tight by applying a pulling slightly pull.

[7.5.2] Re-Terminate Conductors to Weidmuller Terminal Blocks

Caution The common tapered blade screwdriver will cause terminal block fracture. Use a screwdriver with parallel sides made for this application.

[1.] Use the Attachment C: Verification Sheet to re-terminate conductors to the terminal block.

4.[2.] Insert wires into terminal block to full depth one at a time. Tighten screws term tight.

[3.] Verify wires landed to terminal point as described on Attachment C: the Verification Sheet. Sign and date after each wire is landed.

[4.] Have a second person Use co-worker to verify and sign for each wire landed.


Suggest “Re-terminate conductors to terminal block using Attachment C: Verification Sheet.”

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[5.] Ensure terminations on both sides of terminal block are tight by applying a pulling slightly pull.

5.[6.] Check completed terminations and ensure the following:

Terminal Block block and accessories have not been damaged. Bare wire does not extend out of terminal block entry port.

6.[7.] Install the junction box cover and device cover. Tighten cover bolts snug tight or torque in accordance with Attachment B: Torque Value Chart.

7.[8.] _______/_____________ Initial and date for completion of conductor termination.

6.[8.] ReferencesDevelopment references are documents used to develop the procedure. Performance references are documents referenced within the procedure.

6.1[8.1] Development References[1] MSG-1055 Flexible Conduit Rework and Repair (from Comanche Peak NPP)

6.2[8.2] Performance References[1] Generation Safety Handbook[2] LUM-FFA-REL-0014 Standard of Human Performance Improvement[3] STA-124 Electrical Safe Work Practices (from Comanche Peak NPP)

7.[9.] Attachments The following attachments are appended to this procedure.

Attachment A: Bend Radii Chart

Attachment B: Torque Value Chart

Attachment C: Verification Sheet

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Attachment A: Bend Radii ChartUse this chart to prevent stress on cables and conductors within the flex.

Minimum Bend Radius for Cables/Conductors Inside Flex FittingsFlex Fitting Size

(Inch)

Radius of Inside Bend (Inch)

90 degrees 45 degrees

½ 0.34 inch (0.028 ft.) 0.73 inch (0.06 ft.)

¾ 0.45 inch (0.037 ft.) 0.64 inch (0.053 ft.)

1 0.50 inch (0.041 ft.) 0.52 inch (0.043 ft.)

1½ 0.72 inch (0.06 ft.) 0.73 inch (0.06 ft.)

2 0.94 inch (0.078 ft.) 0.66 inch (0.055 ft.)

3 5.89 inch (0.49 ft.) 5.89 inch (0.49 ft.)

4 7.75 inch (0.645 ft.) 7.75 inch (0.645 ft.)

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Attachment B: Torque Value ChartUse this chart to add values not given in the Work Order.

Bolt Material Torque in Foot / Pounds for Bolt Size 1/4 - 20 5/16 - 18 3/8 - 16 1/2 - 13 5/8 - 11

Silicone Bronze 5 10 15 40 55

Stainless Steel 3.5 7 13 30 60

Aluminum _ _ _ 25 40

All Other Materials 3.5 7 13 25 40

Use the torque values listed in this table unless the torque value for a specific device is given or the torque value is given in the Work Order.

Torque tolerance is plus or minus 10%. Connections using hardware smaller than 1/4 inch shall be term tight. Use the specific torque value on a device if given. Terminations made by compressing a wire /or cable strand with a bolt /or screw shall be

term tight.If torque values are not given in Work Order use torque values listed in this table.

LUM-FFA-MNT-0022 Flex Conduit Rework and Repair Draft R0 of 24

Attachment C: Verification SheetEquipment / Module /Device

Term / Wire Unique ID

Term / Wire Unique ID

Action Code

Performer Date Verifier Date

Action Codes

DL = Determ Lead IF = Install Jumper RO = Remove Old RD = Remove Device RC = Remove Card O = other(explain)

RL = Reland Lead RJ = Remove Jumper IN = Install New ID = Install Device IC = Install Card

OB = Open Breaker OV = Open Valve OS = Open Switch RF = Remove Fuse IT = Install Tubing

CB = Close Breaker CV = Close valve CS = Close Switch IF = Install Fuse RT = Remove Tubing

Remarks: __________________________________________________________________________________________________________________________________________________

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Subject: <Type name of procedure>

Revision Number and Date: <Type revision number and date (e.g., R0; 9/4/10)>

Procedure No.: <Type procedure number>

Use: <Type Information, In-Hand, or Reference>

Revision HistoryRevision Number Approval Date Name ChangesRev. 0 TBD Jerry Wayne Initial release

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