ICC Fall 2010 ICC Education Session

ICC Education Session
Cable Accessory Failure Analysis

F. Dean Williams
Fall 2010 Meeting

1
Fall 2010 ICC Education Session
Outline
Background
Overall Process for an Effective Forensic Program
Primary Modes of Failure
Benefits of a Forensic Program
Summary
2
Cable accessories have a significant

Infant mortality rate
Newly installed accessories account
for 20% of accessory related service
interruptions
Workmanship is the Number 1 cause
of failure representing nearly 50% of
the total failures
The number of unknown cause of
failure is high (about 20%) showing the
need for more thorough forensic
evaluations
Percentage of Service Interuptions (%)
Background Significance of Problem

Accessories
80
Cable
70
60
50
40
30
20
10
0
New
Middle Aged
Old
New
Age Description
Middle Aged
Old
Manufacturing defects represent 15%

of the total failures
3
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ai r rec eat
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% of Total Cases
Analysis of Collated Data Cable Accessories Cause of Failure
Fault Type
40
35
30
25
20
15
10
5
0
Analysis of Collated Data Failures by Accessory

Vintage
Accessory Vintages - All Utilities

% of Total Failures
40
35
30
25
20
15
10
5
>2
00
5
20
00
-2
00
5
19
95
-2
00
0
19
90
-1
99
5
19
85
-1
99
0
19
80
-1
98
5
19
75
-1
98
0
19
70
-1
97
5
Vintage
Joints
Terminations
Junctions
5
Analysis of Collated Data Cause of Failure

SummarybyFailureTypeAllUtilities
Event
3%
Moisture
4%
Maintenancefailure
2%
Overload
MechanicalDamage
2%
1%
Contamination
1%
Corrosion
4%
Poor
workmanship
49%
Overheat
4%
Aging
6%
Dielectric
breakdown
10%
Manufacturing
problem
14%
6
Overall Process for an Effective

Forensic Program
Preservation of sample integrity

Importance of sister components
Collection of background information
Obtain installation instructions
Choose the right evaluation technique/document all findings
Identify all installation errors/determine most probable root cause of
failure
Clearly and accurately report all findings/forward to the appropriate
personnel
Track results of examinations
7
Preservation of Sample Integrity

Remove sufficient cable length on either side of failed
component
Label sample to clearly identify location of failure
Seal cable ends and wrap component to protect from
environment
Keep associated components together
Store in a dry location prior to performing analysis
8
Preservation of Sample Integrity

If you do not know what you are doing Do Not attempt
your own analysis
9
Importance of Sister Components
Sister components are those installed at

the same time of the failed component,
likely by the same installer
Significant damage to failed component
may prevent determining most probable
root cause of failure
Sister components allow for easy
detection of installation/workmanship
errors if installed by the same personnel
10
Sister Units
Jacket
Cutback
Jacket
Cutback
Copper Tape
Shield
Ground Strap
Constant Force Spring
11
Sister Units
Cut in Cable Insulation at
Jacket Cutback
12
Sister Units
Cut in Tape Shield

at Jacket Cutback
Copper Tape
Shield intact
13
Collection of Background Information

Events leading up to failure (weather, switching events,
previous failures, etc.)
Circuit diagram
Number of re-closures on circuit after initial failure
Available fault current
Typical loading conditions
Type of load being served
Any additional information that may be helpful in
determining the root cause of failure
14
Obtain Installation Instructions

Obtain installation instructions for vintage of
component to be evaluated
A proper analysis of most failed components is the
exact reverse of the installation instructions
Check for function, not for detailed compliance
A perfectly installed accessory may fail by means
outside the installers control
15
Outside the Installers Control

Termite
Damage
UV Aging
16
Outside the Installers Control

Over inch
Total Insulation
Shrinkback
12 Inches
17
Choose the Right Evaluation

Technique
Think before you cut

Document all findings/observations
through photographs
Preserve failure site, Do Not make
cuts directly through failure site
Cuts should be made at locations 90
degrees on either side of failure site
Cuts through failure site should only
be made, if necessary, and once a
detailed examination of the various
mating interfaces has been made
Cut through Failure
Site
Failure Site
18
X-Ray
19
Identify all Installation Errors/Determine

Most Probable Root Cause of Failure
Identification of all installation errors should be documented to

enhance training efforts
Multiple errors may have contributed to the failure
Determine most probable cause by process of elimination through a
detailed analysis of the available evidence
When you have eliminated the impossible, whatever remains, however
improbable, must be the truth
Sherlock Holmes In the Sign of the Four
20
Clearly and Accurately Report all

Findings
Report should indentify most

probable cause of failure and all
installation errors observed
Share report with all parties to reduce
or prevent future occurrences
Discuss product defects with
manufacturer to improve processes
Discuss installation errors with
training personnel or installers to
eliminate installation errors
If installation errors are the result of
unclear installation instructions revise
instructions
As-Built of termination used in report
21
Track Examination Results

Results of examinations should be tracked in a database
A database will help responsible personnel to observe and
take appropriate action when trends in installation errors
or manufacturing defects are evident
22
Common Failure Modes

Workmanship
Manufacturing Defects
Design Issues
23
Workmanship
Cut in Cable
Insulation
24
Workmanship
Nicks in Conductor
Strands
Cuts in Conductor
Strands
25
Workmanship
Lower Cold Shrink Tube Incorrectly
Installed at Upper End of Termination
Black Stress
Control Tube
Electrical Activity off

Insulation Shield Cutback
26
Workmanship
Puncture
Incomplete Shrink Down of Dual

Layer Tube Leading to Failure
27
Workmanship
Discharge between Inner

Stress Control Tube and
Cable Insulation Caused by
Incomplete Shrink Down
28
Workmanship
Discharge between Inner Stress Control

Tube and Dual Layer Tube Caused by
Incomplete Shrink Down and Failure to
Keep Stress Control Tube Hot
29
Workmanship
Corrosion
Deposits
No Mastic between
Solder Blocks
Lack of Bond between

Mastic and Jacket
Water
Migrated
Past End
Seal 30
Workmanship
Puncture at Knife
Cut in Cable
Insulation
Discharge between
Stress Control
Tube and Insulation
Shield
31
Workmanship
Interface Tracking
from Surface
Contamination
32
Workmanship
Water
Dirt Deposits
and Lack of
Bond
33
Workmanship
Contamination between Insulating

Tube and Stress Control Tube
34
Workmanship
Stress Relief Mastic Across

Entire Cable Interface
35
Workmanship
Brown Discoloration
of TRXLPE caused
by Overheating
Compression
Connector
No Wire Brush Marks on Conductor

in Area of Crimp Down
36
Workmanship
Deformation of
Insulation
Thermal
Damage to
Joint Body
Transition of Insulation Color

Away from Connector
37
Workmanship
No Wire Brush
Marks on Conductor
Wire Brush Marks on

Conductor
38
Workmanship
Brown Discoloration of
TRXLPE caused by
Overheating Compression
Connector
Thermal
Damage
Tool Cuts in
Conductor
Strands
39
Workmanship
Aluminum
Oxides
Arc Pit in
Connector
Body
Area of Crimpdown
in Connector Body
40
Workmanship
Bent
Probe
Melting of Arc
Quenching
Probe
41
Workmanship
Surface
Contamination
Surface
Tracking
42
Workmanship
Ground
Strap
Corrosion
Deposits
Soldier Block Located over Dual

Layer Tube
43
Workmanship
Start of Penciling on Cable Insulation
Cut in Cable
Insulation
Dielectric
Puncture
Thin Area of Insulation Wall In Line

With Failure
44
Workmanship
Note that Cut Aligns with
Centerline of Puncture
Fault
Channel
Electrical
Treeing
45
Workmanship
Failure
Site
Bracket Cutting into
Cable
Open Neutrals Arcing

to Bracket
46
Workmanship
Compression Lug
Vaporized
47
Workmanship/Manufacturing
Knife Cuts Created During
removal of Joint Body
White
Bedding Tape
Sanding
Marks
Folds/Wrinkles in
Copper Tape
48
Manufacturing Defect
Area of
Discoloration
Puncture Site
Puncture Site
49
Void in
Insulation
Insulation
Conductor
Shield
Puncture in
Conductor
Shield
50
Fault
Channel in
Joint
Insulation
Metal
Contaminant
51
Design Issues
Surface Tracking
on Cable
Insulation
Erosion of Stress
Control Tube
52
Design Issues
Corrosion on
Conductor
Moisture Entry
Point
Path of Moisture
53
Design Issue
Dielectric
Puncture
Cable
Training
54
Design Issue
Complete Break in
Sheath
Failure Site
Stress Cracking
55
Design Issue - UV Aging

Surface Tracking and
Erosion
Stress
Cracking
56
Benefits of a Failure Analysis Program
Improve Training
Reduce outages
Increase in revenue
Reduce need for expensive diagnostic testing
57
Summary
Surveys and data analysis show

cable accessory failures make up a
large percentage of in-service
outages
About 20% of accessory failures
have no known cause, indicating a
need for more detailed forensic
analysis
About 15% of accessory failures
can be attributed to manufacturing
defects, indicating a need for
tighter control of manufacturing
processes
Surveys and data analysis show
the need for improved training of
cable accessory installers
Terminations
5.6%
Splices
37.1%
Unknown
1.1%
Cable
56.2%
Utility Survey Showing System Failure Causes
58
Summary
All evidence points to
improved TRAINING
as the single most
cost effective
means of improving
system reliability
59

ICC Fall 2010 ICC Education Session

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ICC Fall 2010 ICC Education Session

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Verfügbare Formate

ICC Education Session

Cable Accessory Failure Analysis

Fall 2010 Meeting

Cable accessories have a significant

Percentage of Service Interuptions (%)

Background Significance of Problem

Manufacturing defects represent 15%

Analysis of Collated Data Cable Accessories Cause of Failure

Fall 2010 ICC Education Session

Analysis of Collated Data Failures by Accessory

Accessory Vintages - All Utilities

Analysis of Collated Data Cause of Failure

Overall Process for an Effective

Preservation of sample integrity

Preservation of Sample Integrity

Preservation of Sample Integrity

Importance of Sister Components

Sister components are those installed at

Cut in Tape Shield

Collection of Background Information

Obtain Installation Instructions

Outside the Installers Control

Outside the Installers Control

Choose the Right Evaluation

Think before you cut

Fall 2010 ICC Education Session

Identify all Installation Errors/Determine

Identification of all installation errors should be documented to

Clearly and Accurately Report all

Report should indentify most

As-Built of termination used in report

Track Examination Results

Common Failure Modes

Electrical Activity off

Incomplete Shrink Down of Dual

Discharge between Inner

Discharge between Inner Stress Control

Lack of Bond between

Fall 2010 ICC Education Session

Contamination between Insulating

Stress Relief Mastic Across

No Wire Brush Marks on Conductor

Transition of Insulation Color

Wire Brush Marks on

Fall 2010 ICC Education Session

Soldier Block Located over Dual

Thin Area of Insulation Wall In Line

Open Neutrals Arcing

Design Issue - UV Aging

Benefits of a Failure Analysis Program

Surveys and data analysis show

Utility Survey Showing System Failure Causes

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