ML20136B491
| ML20136B491 | |
| Person / Time | |
|---|---|
| Site: | Comanche Peak  |
| Issue date: | 06/08/1984 |
| From: | Bielfeldt L TEXAS UTILITIES ELECTRIC CO. (TU ELECTRIC) |
| To: | |
| Shared Package | |
| ML20136A539 | List:
|
| References | |
| FOIA-85-59 QI-QP-11.3-28, NUDOCS 8601020626 | |
| Download: ML20136B491 (33) | |
Text
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UT1UTIES GENERA 7tNG CO.
h6ER REVISION eREEE PAGE r
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1.0 REFERENCES
j 1-A CP-QP-11.3, " Electrical Inspection Activities" 1-B QI-QP-11.3-26, " Electrical Cable Installation Inspection" 1-C FSI-10B f
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1-0 CP-QP-16.0, "Nonconfomances" l
1-E CP-QP-15.0, " Tagging System" 1-F CP-QP-18.0, " Inspection Report" l
1-G i
QI-QP-11.3-41, " Veri fy Soldering Electrical Connections" 1-H QI-QP-11.3-43, "Ve ri fy Tes ting and Installa tion of NIS l
l Triaxial Cable Connectors"
- I CP-CPM-7.1, " Package Flow Co' ntrol" 2.0 PURPOSE AND SCOPE 2.1 The punose of Reference 1-A and to verify the adequacy of Class IE Cablet and associated cable Electric Station.
tenninations at Comanche Peak Steam 3.0 INSTRUCTION l
3.1 INSPECTION FREQUENCY The frequency of inspection efforts, as a minimum, shall be established within this Instruction.
Tne QC Supervisor or his designee may direct inspection to a stiould circumstances greater frequency warrant t51s act.a.
the following are required ninimum inspections.and voltage I
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INS CTION I
REVISION PAGE TEXAS UTILITIES GENERATING CO.
CPSES QI-QP '.1.3-28 21 2 of 31
,JUN 8 584 a.
All Class 1E and associated 8kV cable teminations shall be witnessed.
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b.
All Class 1E and associated MOV power cable temina-I tions shall be verified.
c.
All Class 1E and associated control wi re and instru-mentation tenninations shall be verified.
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Aii uass IE and anactated cable splices and temina-tions that utilize solice connectors shall be witnessed.
e.
All Class IE and associated snodi fied prefabrication cable pin / plug orientation shall be verified.
f.
A weekly in-process inspection is required for above
/
activities not being wi tnessed, excluding Item "e".
g.
All tenninations wi tnessed or veri fied shall~ be inspected in accordance with separation criteria.
h.
All Class 1E and associated solder connections shall be witnessed and inspected in accordance with the criteria as delineated in Referernce 1-G.
1.
Al'1 NIS Triaxial connector installations shall be witnessed and inspected in accordance with the criteria as delineated in Reference 1-H.
s 3.2 INSPECTION CRITERIA 3.2.1 Verify Flexible Conduit Flexible ~ conduit shall be inspected in accordance with the latest approved Engineering drawing.
Unless shown otherwise on drawings "Sealtite" or " Liquid-Tite" flexible conduit shall be used in all areas except
- the Containment.
l Stainless steel flexible conduit as shown on material list shall be used in the Containment.
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PROCEDURE NUMBER REVISION ISSUE TEXAS UTIUTIES GENERATING CO.
DATE PAGE i
QI-Q P-11.3-28, 21 y g ggg4 3 of 31 The installat' ion of flex conduit at all instruments (wall, support or rack munted) shall be in accordance with Reference 1-C.
It is the responsibility of the QC Inspector to verify the spare conduit connection has been plugged in accordance with Reference 1-C.
The QC Inspector 'is reminded that construction requirements may prevent the final installation of flex conduit until the final cable is installed.
This instruction charges QC Inspectors making tennination inspections wi th. the resoonsibility of determining if the cable he is inspecting represents final processing.
If no further cables are to be installed, the QC Inspector shall inspect flex conduit ins tal la tions, and upon acceptance, affix a QC Acceptance sticker and enter the conduit number in the " Remarks" Section of the Inspection Report.
3.2.1.1 Rework of Flex Conduit Containing Cables The QC Inspector shall verify or monitor at the inspector's discretion rework of flex conduit or unique flex conduit to ensure the following:
a.
Minimum ben radius is not violated (Reference 1-B, ) when flex conduit is reinstal 2d.
b.
No damage to cable jacket or insulation during reinstallation of flex conduit.
Flexible conduit is installed according to Rc,uirenents
.c.
i of Paragraph 3.2.1 of this instruction.
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l 3.2.2 Verify Proper Cable Being Installed The QC Inspector shall visually inspect 'the cable to. be tenninated to verify consistency with the Cable Connection Diagrams.
The Cable Connection Diagram supercedes the Cable Connect Card when there are any inconsistencies in the termination process.
Field jumpers shall be installed as shown on approved engineering design drawings.
3.2.3 Verify Cable Continuity-Check performed The QC Ins pector shall verify that craft personnel have completed cable continuity portion of the Cable Connect Card, indicating that continuity checks were satisfactorily perfonned.
The QC Inspector shall ensure that continuity tests are i
performed for each Class 1E electrical / associated cable pr.ior to its final tennination at an electrical penetration.
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PROCEDURE NUMBER REVISION ISSUE DATE PAGE TEXAS UTILITIES GENERATING CO.
CPSES QI-QP-11.3-28 21 ggy S TM 4 of 31, 3.2.4 Verify Cable Jacket / Insulation Removal The QC Inspector shall inspect cable jacket / insulation renoval in accordance with the applicable cable tennination kit manufacturer's recommendations and/or the following criteria:
Verify outer jacket renoval - multi-conductor cables; a.
the QC Inspector shall visually ensure that cable jackets are renoved without damage to internal shielding, conductors or conductor insulation.
b.
Verify renoval of single conductor insulation; conductor insulation shall be squarely cut and contiguous with connector barrel.
Unless specifically' recommended by the connector manufacturer, 1/4" length between the connector barrel and cable insulation is an acceptable installation. Any nicking or indentat'an of conductors shall be subject to Owner's inspection and approval.
The QC Inspector shall ensure that oxidation or foreign c.
materials are renoved fra bare conductor surfaces.
3.2.5 Verify Proper Tools The 'following criteria applies:
l a.
All crimping and compre sion tools shall be of the ct.librated type;-
b.
The QC Inspector shall verify cunpression tool calibration.
c.
Verify proper. tool was used to make the crimp on lugs and pins.
~See attached Table 1 and " Verify Prefabricated Cable Crimping" for this infonna tion.
3.2.6 Verify Cable Shielding 8kV Shielded Cable Particular care shall be us, in tenninating and grounding of cable ~ shielding. The shic of single conductor shielded cable shall be tenninated at each end.
- 8kV electrical per.etration shield shall not be grounded.
If shielding is tenninated and grour.ded after cable passes i
through a ground sensor current transformer, the shielding lead shall be carried back through the ground sensor before grounding.
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INSTRUCTION TIDCAS UTILITIES GENERATING CO.
NUMBER REVISION ISSUE DATE PAGE QI-QP-11.3-28 5 of 31 21 gg Instrument and Signal Cibles Terminations and shielded connections for instrtsnent itnd signal cables shall be as shown on wiring diagrams. Shield grounds shall be applied only at points ' indicated on latest approved Engineering drawings.
3.2.7 Verify Proper 1.ug or Connector / Connection, Type and Size The QC Inspector shall vi sually inspect or witness (as required) Class 1E cable tenninations in accordance with standard work practices and the applicable temination manufacturer's recommendations and the following criteria:
a.
Teminal lugs and connectors shall be compression solderless tin plated copper by equipment manufscturer. '
type, unless supplied b.
All cables / wires shall be tenninated in accordance with Engineering approved drawings and/or vendor drawings.
Multipin connectors shall be assembled and verified in c.
accordar.ce with the manufacturer's instruction (see
" Verify Prefabricated Cable Crimping").
600 Volt Tenninations (Fower and Control)
The crite 'a is as follows:
a.
For t OV power and control cable sizes #8AWG and smaller, tenninal lugs shall be insulated. For insulated terminals two (2) crimps, one shall be an the conductor and one on the insulation, per manufac-turer's recommendations.
b.
For 600V cable sizes #6AWG and larger, tenninal lugs shall be uninsulated, tongue type having either two (2) bolt hole lugs or one (1) bolt hole lugs. One bolt hole lugs may be utilized wher.
supolied by equipment vendor or whenever equi pment has -ovisions for lugs with only one bolt hole.
c.
For 20V cables sizas #6AWG through 500 MCM, compression type terminal lugs shall be either short barrel lugs wi th single cable compression indent or long barrel i
type having two (2) cable compression indents.
TUGCO oA
INSTRUCTION REVISION ISSUE TkXAS UTluTIES GENERATING CO.
PAGE i
CMES QI-QP-11.3-28 21 6 of M g 8 Sg4 d.
For 600V cable sizes 750 MCM and larger the compression type teminal lugs shall be the long barrel type having two (2) cable compression indents.
Instrument Cable and Thermocouple Wire Teminations Compression type tenninals shall not be used on themo -
couple wi re.
Connections at instrument and reference junctions shall be made in acco dance with the instrument manufacturer's recommendations.
Wires will be loope.d under screws in a clockwise direction.
8kV Terminations and Motor Connections The criteria is as follows:
a.
Connectors used on all 8kV teminations and motor connections will be those approved for use on 600V applications (see "600 Volt Tenninations").
b.
8kV tenninations shall be installed with RAYCHEM "N-HVT" tenninations kits in accordance with the manufacturer's recommendations and detailed instructions.
c.
For 8kV power cable - (4/0 AWG and larger), one bolt hole lugs may be utilized when supplied by equipment ver. dor or whenever equipment has provisions for lugs with only one bolt hole.
.2.8 Verify Final Crimo The QC Inspector shall visually inspect final crimps for attributes consistent with a quality installation.
Care-fui attention should be focused on the following:
a.
No conductor strands outside of Connector Barrel; b.
No " Splitting" evident on the Connect 3r Barrel; i
Conductor should be visible from the Inspection Hole c.
when lug has an inspection hole provided; d.
Actual Crimps are located correctly; Excess material, indicating improper' lug size; e.
f.
No evidence of Connector insulation damage.
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INSTRUCTION ISSUE REVISION TEXAS UTILITIES GENERATING CO.
DATE PAGE CPSES QI-QP-11.3-28 21 7 of 31
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I' 3.2.9 Verify Preparation of Surfaces and Bolted Connections Bare copper contact surfaces shall be cleaned ~and wire brushed.
Copper or alumintan contact surfaces which are i
tinned shall not be wire brushed or otherwise abraded.
Bare aluminum contact surfaces shall be liberally coated i
l with suitable joint cunpound and wire brushed through the I
compound.. Excess compound shall not be wiped from aluminum contact surfaces before bolting.
Joint compound shall be applied to all mating contact surfaces where one of the connecting pads is aluminum.
Lugs which have the designa-tion "AL-CU" requi re no.oint compound when terminatin.3 copper conductors.
Bolted cable joints utilizing
" and larger bolts shall be made with standard, course thread, hex head bolts and nuts.
Bolted cable joints utilizing bolts smaller than k" shall be made with stand 1rd machine screws and hex nuts. Threads may be either fine or coarse.
NOTE:
Machine screws may be varied configurations ;
i.e., round head, slotted, hex head, etc.
Bolted cable shall use flat washers under the head and nuts and lockwashars under the turning member. Belleville spring washers shall be used in lieu of lockwashers if either mating surface is aluminum.
Bolts, nuts and washers shall be # ASTM A-307, as indicated in NEMA standard CCl-1975.
It is acceptable to substitute higher.
strength carbon steel (ASTM-A325, A449), stainless steel or silicone bronze hardware for copper to copper connections.
For copper to copper connections below
, brass may be used if other material is not available. Carbon steel bolts shall be electro galvanized.
Where bolting hardware is supplied by Vendor, substitutions may not be made without prior approval from site Engineering.
Bolting lengths shall be determined by the minimum length providing full nut engagement.
Note:
Stock bolts may be shortened to meet speci fic requirements providing they are cut square, threads are dressed to ensure elimination of burrs and sharp edges, and the end of plated bolts shall be coated with zinc rich paint.
4 TUGCO CA
INSTRUCTION REVISION ISSUE NUMBER DATE PAGE TEXAS UTILITIES GENERATING CO.
CPSES QI-QP-11.3-28 21 jg S 1984 8 of 31 Bolted joints shall be toqued to values defined herein, unless otherwise recommended by the manufacturer:
I Bolted Material Torque in Foot-Pounds for Bolt Size 1/4-20 5/16-18 3/8-16 1/2-13 5/8-11 Carbon Steel (A-325) 8 17 20 50 95 Carbon Steel (A-307) 5 12 15 40
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65 Silicone Bronze 5
10 15 40 55 Stainless Steel 5
12 15 40 70 NOTE:
1.
Torque tolerance is 10%.
2.
. Bolted cable joint screws smaller than " shall be snug tight.
3.
The QC Inspector is cautioned to inspect for torquing requirements prior to the application of heat shrinkable tubing, when the shrink tubing will cover the bolted connections.
4.
The QC Inspector shall apply torque sealing conpound to bolts after the satisfactory witnessing of torque requirenents.
3.2.10 Verify Minimum 8end Radius and Inner Cabinet Routing Inner cabinet training and routing shall be arranged a.
in a neat and orderly fashion and be consistent with good construction practices.
b.
The QC Inspector shall assure that the radius of the finally " trained" cable does not violate the minimum bend radius criteria contained in Reference
'l-B, l
Attachment l'.
1 I
c.
Routing of fi eld installed jumpers shall not violate l
separation requirement, l
TUGCC CA
I CTION REVISION PAGE TEXAS UTIUTIES GENERATING CO.
QI-QP-11.3-28 21 9 of 31 g g tog 4 d.
The QC Inspector shall verify the Bend Radius requirenents of NIS Triaxial Cable as delineated in Reference 1-B.
3.2.11 Verify Cable Secure Cable shall be verified as secure as fo' lows:
a.
Securing the cable inside cabinets shall be accanpli shed with Engineering approved materials and shall be consistent with good construction practices.
b.
The QC Inspector shall assure that no cable camage occurs during cable tie installation, The QC Inspector shall assure that the exposed ends of c.
cutoff cable ties do not present hazards to personnel.
d.
When cat les are bundled together the cut off ends of cable ties should not be buried in the interior of cable bundles.
3.2.12 Verify Tenninations The following criteria applies:
a.
The QC Inspector shall verify that conductors are tenninated to the. proper place and shall be in accordance with the latest applicable Eng-iering drawings or Vendor drawings.
b.
No more than two (2) lugs will be allowed under a single tenninal block screw, unless otherwise shown on approved Engineering drawings.
c.
Conductor tenninations should be arranged in a neat and orderly fashion, and secured with tyraps or approved equivalents.
d.
Upon Engineering approval cables will be teminated teraporarily and ~ tagged as such.
The Insp-tor is directed to perform the necessary inspections 6 er the pemanent connection is completed.
TUGCC CA 1-
INSTRUCTION NUMBER REVISION I
ThXAS UTILITIES GENERATING CO.
o PAGE CPSES QI-QP-11.3-28 21 10 of 31 JUN 8 1984
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3.2.13 Verify Cable Identification The QC Inspector shall visually inspect the cable iden-tif.ications to ensure that identifications are consistent with the Cable Tennination Card, Cable and Raceway Sche-dule (El-1700), applicable Engineering drawings and the following criteria:
Cable shall be identified with cable numbers as shown a.
on design drawings and Cable and _ Raceway Schedule.
Wires in multi-conductor cable and single cable /grou'p six feet or less do not have to be identified.
b.
The cable markers shall be placed as follows:
1.
Cables shall be identified at each end; 2.
All cables shall be identified
- temination poi nts..
c.
All wires shall be tenninated to teminal blocks and equipment components according to the identification nunbers and color coding shown on the drawings with the exception of phasing.
Identificatfors of wires of multi-conductor cables b.
tagging is not requi red unless the cable does not have color coded w;res.
Cable for safety-related a ' associated circuits will be color coded by the cab manufacturers.
If field color coding becomes necesse. y, Class IE cables will be marked with a " train" color band.
Associated cables will be marked with a white band and a ' train" coloi-band.
No Class 1E or associated Class 1E cables shall be color coded in the field before receiving written approval from Engineering.
3.2.14 Verify Separation In general, all Class IE cables and associated cables are jacket color-coded througnout their entire length. However, cables that require field colo
- oding will be so worked at intervals not to exceed five fee.
Cables that have been field color coded are so marked with I manently colored tape; tape band coloring supercedes jacket color code.
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TUGCO CA -
INSTRUCTION NUMBER REVISICN ISSUE DATE PAGE TEXAS UTILITIES GENERATING CO.
CPSES QI-QP-11.J-28 21 g 8 1984 11 of 31 I
a.
Separation between field run redundant Class 1E cables and Class 1E/ Non-Class 1E cables within equipment shall be mintained in accordance with the equipment speci fication.
If the specification gives no separation requirenents, the minimun separation distance between redundant Class 1E and Class IE/Non-Class 1E cables shall be greater than or equal to 6 inches.
In cases where the above separation criteria cannot be maintained, barriers shall be installed between the cables.
Barriers used for separation will ts as follows (See for typical examples):
1.
Metallic conduit; including Servicair Company FC 33 flexible conduit.
2.
Two sheets of fire retardant material sepa rated by. a minimum of 1/4" of air space or thermal insulating material.
3.
A single barrier with a 1" mintained air space i
or thennal insulating material between the camponents or devices and the barrier.
c.
Power supply feeds to instrument and control ' room di stribution panel 3 shall be installed in solid enclos raceways
.s shown on G&H design drawi ngs.
(Examp conduit) d.
Redundant Class IE circuits shall enter in separate apertures and terminate on separate teminal blocks or connectois as shown on G&H design drawings.
e.
The following cabinets hr.ve been analyzed and are exempt from the separation requirements; hat: eve r, equipment that provides for channel or train separation shall be utilized when available.
NOTE:
TBX for Unit I and TCX f,or Unit 2.
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h8ER REVISION I
PAGE TEXAS UT1UTIES GENERATING CO.
QI-QP-11.3-28 21 12 of 31 g
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NIS Cabinets T-X-NIELCA-01 (4
Cabinets)
Solid State T-X-ESELSP-01 (Logic & Output Protection System Cabinets only)
Solid State T-X-ESELTC-01 (Test Cabinet:;)
Protection Systen Upgrade Protection T-X-XIELSS-50
' & Sune111ance Process Racks T-X-XIELRK-01 T-X-XIELRK-02 T-X-XIELR K-03 T-X-XIELRK-04 f.
Protection channel wi ri ng, safety-train wi ri ng, and Non-safety train wiring within panels IPC1, IPC2, IPC3, IPC4 will be in different wire bundles. These bundles will be separated to the maximum extent practicable.
3.2.15 Verify Splicing rN Cables shall be installed fran origin to destination without s
f splices unless specifically called for on the latest Y
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A approved Engineer drawings.
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Cables will be spliced by one of the following methods:
hY, N' a.
Bolting compression type lugs back-to-back with d
silicone bronze or stainless steel hardware; b.
In-line crimp type splice connector.
600V In-Line Splice Insulation Sleeves e
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cable insulation sleeves.
Heat shrinkable insulation sleeve r--f. ham-+= "ead in the f lications shown
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e on the ed Engineer n drawings:
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Field cable connections to motors rated up to 600 volts;
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So' d
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Control an unentation connections; N
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INSTRUCTION NUMBER REVISION ISSUE DATE PAGE
~EXAS UTluTIES GENERATING CO.
CPSES QI-QP-11.3-28 21 g 3 1984 13 of 31 d.
Overall Jacket for multicc.nductor connection splices; e.
480 volt switchgear bus connections; f.
Where tenninal lugs / blocks provided wi th equipment for 600 volt power. cables are not large enough to accanodate the power cables, it is acceptable to terininate the power cables directly on the starter or breaker units in equi pment such as nocr-tentrol Centers. If the starter or breaker will not facilitate the existing cable a smaller cable may be spliced using the following ampacity and location guidelines:
1.
The ampacity of the minimum size cable being spliced shall be equal to or greater than the rating of the overcurrent protective device being used.
2.
The splice shall be located inside the equipment and shall be made within 6 feet of the termination point.
In cases where the splice cannot be located inside the equipment, it is allowed to add a splice box.
This splice box shall also be mounted within 6 feet of the termination point.
NOTE:
The QC Inspector shall verify solder splice connections as delineated in Reference 1-G.
3.2.16 Verify Component Installation The QC Inspector shall verify the installation of all Class IE Instrumentation devices that are self-contained, that is one that does not have a site installed remote sensor or electromechanical interface, for proper mounting, location, and orientation, and the tennination of instrumentation or control cable and/or thermocouple wire.
The QC Inspector shall verify all Class 1E and associated component installations that utilize solder connections are in accordance with Reference 1-G.
i NOTE:
These devices will be installed by the electrical craft.
Those instruments installed by I & C are not within the scope of this procedure.
f 3.2.17 Verify Internal Components The QC Inspector shall verify that all craft site installed i
internal components are the correct range, type, rating in accordance with latest design or vendor documents.
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%g, TNGCC CA yg
I hCTION REVISION I
PAGE TEXAS UT1UTIES GENERATING CO.
QI-QP-11.3-28 21 gg 14 of 31 l
inspections shall be performed wh;.n the incon.ing wires are terminated to these devices.
If a wire is tenninated on a I
terminal block and associated components have been installed in the - field to this teminal block, QC shall inspect these components.
QC shall also inspect breakers in AC and DC distribution panels to assure the device has the proper amperage rating.
3.2.18 Verify Heat Shrinkable Cable Sleeves Prior to using heat shrink material, the QC Inspector shal'1 verify that the proper kit is being used. All nuclear heat shrink kits will have the prefix or suffix (N) to indicate nuclear material.
Each kit component's interior will have a red adhesive substance to indicate same.
NOTE:
It is pemissible to field cut WCSF-12N tubing into six inch lengths.
The cutting should be done with a sharp knife, a paper cutter or a pair of sci ssors.
If a knife is used, the tubing should be cut on a flat surface with a once-through motion.
Alternative applications of kits or alteration of kits, except as noted in existing Raychem instructions, must be approved by Electrical Engineering.
Generic approvals will be made via a letter from Engineering with concurrence from Quality Engineering.
Other approvals will be made via Operation Travelers.
The method of approval shall be indicated on the termination card.
Heat shrinkable nuclear splice kits will normally be accompanied with a sheet of installation instructions to be followed as well as.the criteria stated herein.
When individual heat shrink sleeves are used, they are to be considered as a kit consisting of a single part.
Inspection Guidelines l
The following are some additional guidelines that shall be used during the inspector's inspection to determine the acceptability of nuclear heat shrink installation:
a.
Area of cable in which heat shrink material will be applied shall be cleaned wi th a cable cleaning l
solvent - i.e. trichlorothane or Engineering approved equal; I
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INSTRUCTION ISSUE REVISION TEXAS UTIUTIES GENERATING CO.
PAGE l
CPSES i
Q1-QP-11.3-28 21 15 of 31 Jg g jgg4 l
i b.
Shrink sleeves by starting shrinking process at approximate center of sleeve and then heat towards I
each end; l
c.
Satisfactory installation of sleeves will be indicated
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by:
- 1..
Smooth, consistent contact between sleeve and cable;
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2.
Ret. adhesive flow showing at each end. Adhesive flow indicates complete shrinking and cable contact ensuring a positive envirorrnental seal.
NOTE:
' Lack of the above steps will require a reheat process until shrinking
.i s complete.
d.
Inner conductor splices shall be staggered to avoid bottle neck effect and to ensure a uniform heat shrink process.
Sleeves are to 'be centered over spliced areas; e.
Jackets shims shall be used when applicabic for unifonnity of heat shrinking process; f.
The QC Inspector shall verify solder splice connec ans as delineated in Reference 1-G prior to start of
!at shrink activity.
g.
Overheating of sleeves will be indicated by obviaus blistering (flaking) of surface and should be removed and replaced.. Removal of sleeve can be done by cutting the sleeves longitudinally avoiding full penetration to next layer and reheating causing the sleeve to split i
and become easy to remove; h.
Do not flex assembly until cool because *.his can cause discontinuities in process.
i 3.2.19 End Caps for Electrical penetrati m Asymbly The installation of heat shrinkable end caps utilized on the spare conductors on electrical penetration assemblies shall be in accordance with the end caps manufacturers instruction.
TUGCC CA
h8ER N
REVISION PAGE TEXAS UTIUTIES GENERATING CO.
l ES QI-QP-11.3-28 g g 1934 16 of 31-21 The QC -Inspectors inspection sponsibility shall be that of verifying a proper and satisfactory installation of the end cap.
The end cap shall confonn to the cable and completely encapsulates the. end of the conductor after installation.
This inspection is one of verifying after installation and is not a witness function.
It is not necessary for' the Inspector to record the kit number of the end cap on the Inspection Report when end caps being installed on spare conductors of electrical are penetration assemblies.
3.2.20 Verify Prefabricated Cable Crimoino The frequency of inspection for verifying that crimping tool testing is performed in accordance wi th test /
calibration procedures shall be performed aftar use in the field, prior to reissuance.
Verification of prefabricated cable crimping will be performed to' assure that the proper connectors, contacts, tools and crimp height are used in accordance with manufacturer's instructions for the prefabricated cables supplied under specific TUGC0 Purchase Orders.
For specific i :ntification of Purchase Orders, contact types, tools, etc., refer to Attachment 6.
There may be instances where no vailable specific tool and/or die calibration for certair. :ontacts due to design (i.e., open barrel contact such as irndy SC16) exist.
In these cases post crimp inspection shall be rade according to the dimensional requirements of Attachment 6 and the following tensile strength tests:
WIRE SIZE (AWG)
MINIMUM TENSILE STRENGTH (Pounds) 22 10 20 16 18 20 16 30 14 60-12 70 10 80 NOTE:
Contact shall not become separated from the wire when subject to a direct pull of the value specified above for one minute.
The QC Inspector shall be cognizant that the criteria as delineated in this instruction is not applicable to any solder connection.
%g, TUGCO CA
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INSTRUCTION REVISION ISSUE TEXAS UTIUTIES GENERATING CO.
.QI-QP-11.3-28 21 g g 1984 17 of 31 3.2.21 Verify Connec' or Free of Damage t
Verify that the connector used is that connector specified on the vendor drawing, and that it is assembled per the vendor drawing.
Verify that the connector is free from damage by visually inspecting the shell to assure it is not deformed, has no chips, cracks or burrs and the lock is free to turn, if requi red.
3.2.22 Verify Pin /Pluo Orientation The QC Inspector shall pe rfonn a pin / plug orientation verification for multi-pin connectors in accordance with Engineering or vendor drawings.
Providing that the pin / plug orientation was not accomalished during an in-process inspection, the prefabricated cables' wires shall be given a continuity test.
The QC inspector shall verify that a continuity test is perfonned.
This test is to establish that continuity exists between each pin and the corresponding pin at the other end.
3.3 00CUlENTATION Inspection Report (s) associar.ed with this procedure may be
. packaged as part of a traveler installation or as part of other procedurt and IR's as necessary to canplete a process or item install ion (Reference 1-I).
% Clas nnination inspections shall be documented on
, nspection eport (Attachments 1 and 2).
- 9) Attachmentis used for doc ng a pas installation m
on) inspection.
Attachment 2
s used for documentation of anhocess and/or witnes og inspection and the type of inspection sha @ xeu un une 1 K. will be used to verify crimping tool test was performed as delineated in " Veri fy Prefabricated Cable l
Crimpi ng".
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- TUGCO CA
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TEXAS UTILITIES GENERATING CO.
CPSES QI-QP-11.3-28 21 18 of 31I l
Handling of revisions to termination cards when the new card set is received with changes which do not affect the actual installation, such as a new card showing a change in systen
- number, will have the infonnation ' from the old card traDif r_ red to the new card'ano tne revision ntsnber of the E
old cards noted on tne new cara ov crarr.
ints infonnation is w oe reviewec for accuracy by QC and this review documeWea on Attachment 4 ior filing in vault. The new set of cards are now handled as completed, the 01d card may be destroyed.
If cable is reworked as a result of renoving unique flex conduit cr flex conduit from conduit raceway, rework shall be docisnented on the appropriate Ins pection Report (Attachment 7).
3.4 DISCREPANCIES Discrepancies found during inspection shall be documented on the IR (Attachment 1, 2, 3 4 or 7) and/or a NCR per References 1-F and 1-0 respectively, as directed by the QA/QC Supervisor.
f i
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PROCEDURE NUMBER REVISION ISSUE TEXAS UTILITIES GENERATING CO.
DATE PAGE CPSES r( [IQI-QP-11.3-28 21
,pjN 8 584 19 i
of 31 7
M Y.% \\h d
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ITDIE4 maSPECTION ATTm8UTES I
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(V) 1.
Werify flex conduit installed 1
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I (V) 2.
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Verify cable and eahle cc....;ct t trd marsament Verifv 1.-
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-.8-.,1L _
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fv) 4 Verify cable continuity check nerformed I
ful E.
Warifv r.rc... c lue or cc...xter/cennxtient tvoe. tire anil Ptant,,tane (V) 8.
Werify tev9mination (V) 7_
Werify minimum bend reduis, inner cabinet routing, and table tecure ful A Warify cable identification t
(V) 9.
ferify c.--
--._r3 ineta11atinn I
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Veffy internal tecaration.
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20 g 31 ATTACHMENT 2 gt.Dh O
9 34 e W,&f +r W O&
CCuaNCNE PEAK STEAM ELECT 4ic S TA TICM 1
2 s,.re-y INSPECTION REPCMT A
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ITOs ulk
'cl INSPtCTION aTTMISUTES Catt 3 a ft,;ng
,2 ia si (V) 1. l Verify flex conduit installed i i !
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(V) 2. I Verify proper cable being terminated l ; I I
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Verify cable and cable connect card agreement 1 : I i
i b.
Verify jumper cable installed (if required)
I (V) 3.
' Ve-ify cable continuity check perfrrried l l l
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'l (V) 4.
l Verify Jacket / insulation removal I
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Verify inner conductors insulation not cut i !I I
I fif applicable) l II l
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Ve ri fy lackets/ insulation soudrely cut l l l l
! c.
Verify proper length of exposed conductors l l {
l (V) 6.
Verify oroner tools I
l NOTE! Aeolicable only when this inspection is I
i i
actually observed.
I '
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) a.
Verify coperession tool calibration i I l b.
Verify appropriate dies are utilized I ii I
(V) 6. i Verify cable shielding 8 ' i l
(V) 7 j Verify nroper lu? or connector / connections tyne. Stre.
{
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( V) 8.
I Verify creceration of surfaces and bolted connections i
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Verify Drocer su* faces Dreparation
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Verify proper harevere l i i
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Verify torttue recuirenwnts I ( ;
l (V) 9.
I Verify terminations l t t
(V)10. I Verify minimum bend radius, inner cabinet routinn and l t
land cable secure l e (
(V)11 l Verify cable identification i
1 (W)12. l Vert fy solicing j
i i
(Continued)
Form Na 3 TUGCC CA
PROCEDURE NUMBER REVISION ISSUE TEXAS UTIUTIES GENERATING CO.
DATE PAGE CPSES QI-QP-11.3-28 21 JUN 8W 21 of 31 g 3 j_G. -
p jkACHMENT2(Cont.)
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CDM ANCMC PDK STU M ELECTRfC STATICM INSPECTION REPORT QI.QP-11.3 28 Rev.'
(sL**.nestat.)
Sheet 2 of 2 FOA Fi.'U. MUCIfiGS. SEI SHEET 1
- 30. ET ITtts SAft 88 na IN5rECTICN ATTRISUTZ3 3
smeanma
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.s fV) 13.
Verify component instattation i I I I
Y IV) 14-Veeffy heat thrf ahhle anetene enhle t1.svet I i i I
(V) 15. lModule letter desionatinn and candnetne identisiestiaa l l I l
I recorded in block 14 and end cap verified.
I I 8 I
(W) 16. I Verify Din / plug orientation and continuity check.
I 4 8 i
(V) Mverify connector free h ice l l 1 i
(V) C Verify internal tocarn Ha-U l I l 1
(W) 19.15 pare conouit connection instrument port plucced & toreuedl l I i
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PROCEDURE NUM8ER REVISION ISSUE TEXAS UTIUTIES GENERATING CO.
DATE PAGE CPSES e
QI-QP-11.3-28 21
,HJN 81]S1 22 of 31 A \\
b hre ATTACHMENT 3 O* (o
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Verify Prefabricated Cable Crimoing l
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INSTRUCTION TEXAS UTIUTIES GENERATING CO.
NUMSER REVISION ISSUE DATE PAGE CPSES OI-0P-11.3-28 21 JUN I 23 of 31 ATTACHMENT 4 gg,g Qg Q M'J ' S #
CCanaN C>st stan sTEsan EulC ~ nsC S TAT;CN w
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1.l Temination Card Revision
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I b 'AllWornistion on preds card transcribed l
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1 Revision Nisaber of old card noted ll l
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INSTRUCTION TEXAS UTILITIES GENERATING CO.
NUMBER REVISION ISSUE DATE PAGE CPSES qI-QP-11.3-28 21
.!UN 8 1984 24 31 of ATTACHMENT 5
~
1.
CABLE-CABLE A) FREE AIR
- 8) WITHIN APPROVED FIRE STCP PATERIAL nset 2.
CA8LE-BARRIER (00L.LE BARRIER SEPARAiED 8Y 1/4" AIR SP,ARE OR APPROVED THERMAL INSULATIMG MATERIAL) s*
1.
e48LE-8ARRIER ($!NGLE BARRIER)
{.
l' MINIMJM AIR SPACE OR THERFAL INSULATING PATERIAL ON ONE SIDE.
CA8LE. COMPONENT. ETC., MAY TOUCH l.
~
OM OPPOSITE SIDE.
4.
CA8LE-NETAaLIC CONDUIT
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5.
METALLIC CCNDUIT4ETALLIC C0fCUIT j
CONDUIT PAY inUCH OO 1
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INSTRUCTION N
REVISION ISSUE TEXAS UTIUTIES GENERATING CO.
DATE PAGE CPSES QI-QP-11.3-28 21 JUN 8 1984 25 Of 31 TABLE 1 TOOL DESCRIPTION (AMP)
TOOL I.D.#
WIRE SIZE DIE Heavy Head (penetrations 69355 8
Fixed die only)
Heavy Head 59239-A 10-12 Fixed di e 31odel AG 69061 8
48752-- 1 (model W)
Model M
- 46121, 14-26 Fixed die Model P 47387 16-14 Fixed die Model R 47386 22-16 Fixed die 49935 22-10 Fixed die Hydraulic Crimper 69099 6-350MCM Interchange-able (see below) l Pydraulic Crimper 69082 500MCM-Interchange-l 1000 MCM able (see below)
Die for Hydraulic Tool Wire Size Anp. Part No. --
48752-1
- 8 69133-1
- 6 69134-1
- 4 46765-2
- 2~
46767-2 2/0 46750-2 4/0 46751-2 250 MCM 46753-2 350 MCM 46755-2 500 MCM 46757-2 750 MCM 46760-2 1000 MCM R
1
%g, TUGCC CA
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INS CTION REVISION I
PAGE TEXAS UTluTIES GENERATING CO.
8 QI-QP-11.3-28 21 Of 3 1984 26 31 TABt.E 1 (continued)
Drain wire connections of shielded #16 AMG cables shall be:
1.
Butt splices MP Part No. 330367, 330368 2.
Ring-tongue MP Part No. 53405-1 thru 53422-1*
Part nunber is dependent on stud size.
CPF-14535 EX0 Sensor Connectors to be utilized in the core cooling nonitor system are manufactured by MP Products.
MP PRODUCTS Connector Contact Tool Die Crimp Height 201345-1 66103-4 90277-1 Yellow
.039 :.005 (1) 205-210-1 1-66506-0 90312-1 Red
.0305
.002(2) 205-204-1 1-66506-0 90312-1 Red
.0305 2.002 (2) 205-208-1 1-66506-1 90312-1 Red
.0305 t.002 (2)
(1) Infonnation from MP Instruction 1S7574 and EX0 Senors drawing number 1120002, Rev. A.
(2) Information fonn MP Instruction 157694 and EX0 Senors drawing nuraber 1120002, Rev. A.
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TUGCC CA
INSTRUCTION TEXAS UTluTIES GENERATING CO.
NU C ER WSION ISSUE DATE PAGE CPSES QI-Q P-11.3-28 21 27 of 31 i
l l
TABLE 2 CABLE STRIPPING IDENTIFICATION WIRE TOOL NUMBER SIZE Hand Stripper Ideal #45-092 10 - 22 AWG Knife (Small)
Ideal #45-127 3/16 - 3/4 0.0.
Knife (Large)
Ideal f45-129 3/4 - 1h 0.D.
Amp Stripper (Prefabricated Cables)
Anp #601-827-1 12 - 22 AWG i
%%i TUGCC CA b
INSTRUCTION TEXAS UTILITIES GENERATING CO.
NUM ER REVISION ISSUE DATE PAGE CPSES QI-QP-11.3-28 21 of 1984 l 28 31 ng
- ATTACHMENT 6 i
PREFABRICATED CABLE CONNECTOR CONTACTS 1.
CP 605 Reliance Electric Prefabricated cables supplied under this order prima rily connect the main control boards to termination cabinets.
These - connectors and contacts are Burndy Trim Trio style connectors.
BURNDY CONNECTORS
_ Connector Contact Tool Die Crimp (b) Height G2B SC016 M-156 M8ND N16RT24
.057
.003 G6F UTM-2 CM-11
.058
.003 SM16 M-156 M8ND N16RT24
.057
.003 RC 16M-23028 M8NO N16RT21 (a) a.
Use Go-No GO gauge No. P-G324 2.
CP 611B Westinghouse Prefabricated cables supplied. under this order prima rily connect the auxiliary relay racks to termd 7 tion cabinets.
These connectors and contacts are Amp produ s.
AMP PRODUCTS Connector Contact Tool Die Crimo (b) Heicht 203959-5 66101 90067 Fixed (1)
.0510 m.0015 Fixed die cannot be substituted.
a.
b.
Crimp height may be measured with either a standard caliper or crimp height ccmpa rator No. RS-1019-SL.
c.
CP-0001 Westinghouse Prefabricated cables supplied for t r.e solid state protection systen utilize both Amp and Burndy Trim Trio connector type s.
The Anp products connector is used for #20-24 wire size and Burndy connectors for #16 wire size.
1 Penn ma.
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INSTRUCTION REVISION ISSUE TEXAS UTILITIES GENERATING CO.
^
PAGE QI-QP-11.3-28 21 y gg 2 9 of 31 ATTACHMENT 6, Continued -
k p Products (2)
Connector Contact Tool Die Crimp Height 203959-5 201328-1 45099 Fixed (1)
- 34136 59239-4 59239-4 Fixed (2)(3)
- 34071 47387-1 47387-1 Fixed (2) (3) 1.
Use Go/No-Go gauge. This is a calibrated item.
2.
Lug guide on tool not required for these splices.
3.
Use Paragraph B-7 to conduct tensile and strength test.
- Applies to Westinghouse active valves only.
Burndy Tri Trio Connector Connector Contact Tool Die Crimp Height G6F RC16M-23028 10 N16RT21 -
RH16-23 0
N16RT21 1.
Use Burndy plug gauge No. P-G324, 2.
Per kp Products IS Sheet 1786.
Buchanan Crimp Tool Products Contact Tool Di e Crino Check RC20M-12 MS-3191-1 Fixed (1)
CR20M-12 MS-3191-1 Fixed (1)-
1.
Use Paragraph 3.1 or Go/No-Go Gauges per Buchanan Instruction IS-101 1/27/77.
i TUGCC CA
I h8ER REVISION I
PAGE TEXAS UTIUTIES GENERATING CO.
QI-QP-11.3-28 21' g4 30 31 ATTACHMENT 6(continued)
CPF-14535 Exo Sensor Connectors to be utilized in the core cooling monitor systen are manufactured by Amp Products.
Amp Products.
Connector Contact Tool Die Crimp Height 201345-1 661.03-4 90277-1 Yellow
.039 :.005(1) 205-210-1, 1-66506-0 90312-1 Red
.0305 :.002 (2) 205-204-1 1-66506-0 90312-1 Red
.0305
.002 (2) 205-208-1 1-66506-1 90312-1 Red
.0305
.002(2)
(1) Infomation fran Anp Instruction 157574 and Exo Sensors drawing number 112D002, Rev. A.
(2) Infony tion from Amp Instruction IS7694 and Exo Sensors drawing number 112D002 Rev. A.
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INSTRUCTION 3
UTIUTIES GENERATING CO.
NUM ER D3O ISSUE PAGE
- DATE, CPSES QI-QP-11.3-28 21 JUN 8 884 31 of 31 l
b3us $ A'S' -
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1 LIST CA8LES CCNTA!NED [N FLEX CONDUIT IN BLOCK 14 4
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REPA!R/ INSTALLATION OF FLEI CONDUIT PER NCR I I e
! Of?P05fff0N f1, I
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I NO vis!BLE DAMAGE TO CA8tE JACKET OR INSULATION i
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TEXAS UTIUTIES GENERATING CO. ~N OATE QI-QP-11.3-26.0 21
.JUN 8 54 7 of 26
]
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k n
M k-OS-SC/
i largest Raceway. This distance shall be increased 1
for the additional entries by the amount of the 2(>I sum or tae diemeters or eii otaer nece er entries l
on the same wall of the box. The distance between N
Raceway entries enclosing the same conductors shall not be less than 6 times the trade diameter of the l
largest Raceway.
3.
Systems over 600V and NIS system Box size requirements for systems over 60W and NIS systems will be provided by Electrical Engineering.
3.1.3 -
Cable Slack,
The QC Inspector shall verify that 2 inch minimum slack is provided 'at transition points between cable tray sections at different elevations and at conduit entries to cable. trays and hahmen Category ctu res.
(C 3.1.4 Cable Soac_ 'o for Power Cable v
l The QC Inspector verify that cable spacing, when re-l quired, is properly maintained.
Maintained spacing between cables shall be measured edge to edge.
The cri ria for maintained and non-maintained cable spacing is as 'ollows:
a.
Maintained spacing for bundled cables--
Single conductor cables run as a two (2) wire circuit or four (4) wire circuit shall be bundled together and tied to the cable tray rungs witn maintained spacing between each bundle with the exception of 600 V power and 8kV cable. Maintained spacing shall be twice the diameter of one conductor of the bundled cable.
See the following example for bundling and spacing of cables:
e.g.:
I co oo 88
)
ye T19.A;:1ng
{ Cable Buadle b.
Maintained spacing for 600V and 8kV cable -- Pcwer cables run in cable tray shall have maintained cable spacing where so indicated in the cable and raceway schedule and Cable Pull Ca rds.
Maintained spacing between cables shall have a minimum of one-quarter of the diameter of the largest cable.
Also, a minimum TUGCC CA.
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i INSTRUCT 1CN ISSUE REVISION PAGE NUMBER CATE TEXAS UT1UTIES GENERATING CO.
CPSES QI-QP-11.3-26.6 2f 2; e 384 8 of 26 separation of one-quarter of the cable diameter shall be maintained between side rail-of cable tray and ad-jacent cable.
An example of maintained spaced cable with each three-phase circuit consisting of three (3) separate single conductor cables (one conductor per phase) is as follows:
e.g.:
Y C3 B3 A3 C2 B2 BI
- C1
- A2 1 *
- Indicates maintained spacing between cables.
, J able Tray Maintained and non-maintained cable spac'ng- "In a few i
c.
cases, non-maintained and maintained-spac.ed cable will be mn in 'the same tray where indicated in the Cable and Raceway Schedule.
In these instances either the non-maintained and maintained-spaced cables shall be n2n on opposite sides of the tray as shown in the example below or all the cable (both non-maintained and_ maintained-spaced) s..all be run as maintained-l spaced cables as shown in the examples and described in the text above."
i a -
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e.g.:
000 f
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- - ~ ~t where, ~~ a - maintained spaced cables b-this distance must be equal or greater than the outside diameter of the la rgest maintained spaced cable c-non-maintained spaced cables NOTE:
"It is not necessary for maintained-spaced cab"les to confonn to thes-requirements at transition points in the tray
- ten (ie., where entering or exiting cable tray, cable tray tees and crosses, etc. ---).
However,..lis random lay should not be more than four feet.
3.1.5 Cable Ties Cable ties shall have a positive locking device to prevent slippage.
Cable tie surfaces in contact with cable jackets shall be relatively smooth with no sharp projections, burrs, etc., which could damage the jacket.
mococA
,