Жабдықтың толық бақылау жазбасын сақтай отырып, портативті жерге қосу құрылғысының компоненттерін қалай ауыстыруға болады

When replacing the earthing clamps, cables or connection terminals of a portable earthing set, the equipment must first be taken out of service and the serial number and original configuration of the entire set confirmed. The model, rated performance and connection compatibility of the replacement parts must be verified, and the identification of the old and new components, along with the reason for replacement, must be recorded. Once the replacement is complete, inspections and necessary tests must be carried out in accordance with applicable requirements, and the configuration file and test records must be updated; the equipment may only be put back into service after authorisation has been granted. The key is to maintain a complete link between the original equipment and the new and old components, rather than simply continuing to use the old certification records after replacing parts.

I. What original information must be verified before replacing components?

Portable earthing devices typically consist of earthing clamps, flexible conductors, connection terminals and other connecting components. Together, these components determine the reliability of the entire system’s connections and its fault current withstand capacity.

If one of these components requires replacement, it must first be confirmed to which set of equipment it belongs, what specifications it adheres to, and whether the original configuration has a complete technical basis.

Confirm the complete set’s identification number and original configuration

Each set of equipment should have a unique asset identifier, such as a complete set identification number (Kit ID). If an organisation assigns independent identification numbers to components such as earthing clamps and cables, the corresponding Component IDs should also be verified.

At a minimum, the following must be confirmed prior to replacement:

• Kit ID: The unique asset identification number for the complete earthing assembly.
• Component ID: The unique identification number of the component to be replaced; where no separate serial number exists, traceable information such as model, batch and installation location should be recorded.
• ЖАҚСЫ: The original bill of materials and component configuration.
• Rated performance: The short-circuit current withstand capacity, rated duration and other relevant parameters of the complete system.
• Техникалық құжаттама: Original drawings, product specifications and applicable test reports.
• Reason for replacement: Mechanical damage, connection faults, failure to pass inspection or other confirmed issues.

If the specifications of the original components or the rated performance of the complete set of equipment cannot be confirmed, the manufacturer or the technical staff responsible for equipment management should be contacted first for verification, rather than directly installing parts that appear similar.

Record the actual condition of old components

Before removing old components, their location, model number, identifying marks and reason for replacement should be recorded. Where necessary, photographs of the components and their connection points may be taken to serve as attachments to the maintenance records.

For example, if a phase clamp in a particular earthing assembly becomes deformed, the maintenance record should at least specify which clamp it is, where it was installed, and the reason for its replacement.

If the old component is subsequently scrapped, its serial number and disposal record should also be retained. Physical parts may be disposed of in accordance with approved management procedures, but the historical record must not be lost simply because the part has been removed.

II. How to verify that replacement parts are compatible with the original earthing system?

The fact that a replacement part can be fitted to the original equipment does not necessarily mean that it will meet the original electrical and mechanical performance requirements.

Procurement or maintenance personnel should verify the technical parameters of replacement parts against the original configuration, rather than relying solely on appearance, dimensions or generic product names provided by the supplier.

When replacing earthing clamps

the clamp model, contact structure, connection interfaces, mechanical performance and rated short-circuit withstand capacity must be verified.

Even if two clamps appear similar in shape, there may be differences in contact area, clamping method, connection terminals and performance rating.

If a clamp of a different model is fitted, it must be confirmed that the new configuration still meets the performance requirements of the original complete set of equipment.

When replacing earthing cables

It is necessary to verify the conductor material, cross-sectional area, length, structure, flexibility and corresponding rated performance.

One must not simply assume that a cable with a larger cross-sectional area is necessarily suitable for the original earthing installation. The compatibility between the cable and the clamps and connection terminals is equally important.

Changes in length may also affect the configuration diagram, connection methods and the operating conditions specified in the project requirements; therefore, these must be reconfirmed in accordance with the change requirements.

When replacing connection terminals

Connection ferrules, lugs and other connecting components must be compatible with the conductor and the corresponding clamps.

Particular attention must be paid to verifying the termination structure, dimensions, conductor compatibility, rated performance and the manufacturer’s specified assembly procedures.

Incompatible components must not be forcibly connected through unauthorised on-site modifications.

Why is it necessary to verify the performance of the complete assembly?

ASTM F855-26 sets out the technical requirements for temporary protective earthing equipment, covering earthing clamps, ferrules, cables and complete assemblies separately.

This indicates that the performance of both individual components and the complete assembly must be taken into account. The fact that a single component complies with the relevant requirements does not automatically prove that a new configuration formed by combining it with other components will still meet the rated capacity of the original complete assembly.

IEC 61230:2008 similarly emphasises the electrodynamic and electrothermal performance of portable earthing and earthing short-circuiting equipment under short-circuit conditions, with its rated capacity being related to parameters such as current, duration and peak factor.

Therefore, when replacing components, the following principle should be observed:

The specifications and test evidence for new components must match the actual configuration of the complete set of equipment; the compliance of the entire assembly cannot be confirmed based solely on the ratings of individual parts.

If the replacement part does not belong to a configuration approved by the manufacturer or covered by existing technical evidence, the necessary technical assessment and approval should be completed first, before deciding whether supplementary verification is required.

III. How to retain the original equipment identification number and component history after replacement?

Following the replacement of components, it is not necessarily required to change the asset number of the complete set of equipment; however, the link between the original configuration and the new configuration must be retained.

It is recommended that the identity of the complete set of equipment, the identity of the components and the configuration version be managed separately.

Under what circumstances can the original Kit ID be retained?

If the equipment has merely had an approved, compatible component replaced, and the identity of the complete set of equipment and the original design basis remain valid, the original Kit ID may be retained in accordance with the organisation’s asset management system.

Мысалға:

The original earthing assembly is numbered ES-028, and one of its earthing clamps is numbered CL-013.

An inspection revealed that this clamp had sustained mechanical damage and required replacement.

Following technical verification, the original component was replaced with a compatible new clamp, CL-047.

Upon completion of the necessary inspections, tests and approvals, the equipment may continue to use ES-028 as its asset number; however, the records must clearly state:

• The original component CL-013 has been removed and is no longer in use.
• The new component CL-047 has been installed in the designated location.
• The date, reason and person responsible for the replacement have been recorded.
• The post-replacement configuration and applicable technical documentation have been updated.
• The equipment has completed the required verification and has been re-authorised.

If the organisation employs configuration version management, this change may be recorded as Revision B, whilst retaining the historical content of Revision A.

It should be noted that an update to the configuration version does not automatically imply that the rated performance of the entire set of equipment is carried forward. Whether the original rated performance remains valid still requires supporting technical justification.

Under what circumstances is it necessary to establish a new equipment identity?

If the replacement exceeds the scope of the originally approved configuration, for example:

• There has been a substantial change to the original cable structure or key rated parameters;
• Fixtures or connection types not covered by the original technical documentation have been replaced;
• The entire assembly has been redesigned or substantially rebuilt;
• the rated performance and test evidence for the original configuration can no longer demonstrate the suitability of the new configuration;

then a determination should be made in accordance with the organisation’s and project’s change management requirements as to whether the product configuration, rated performance or identity of the complete set of equipment needs to be redefined.

Where necessary, a new equipment number should be established, and the new equipment record should be linked to the history of the original equipment, rather than directly overwriting the old record.

How should a component replacement record be completed?

The following is an example of a record for the replacement of a grounding clamp.

The above reference numbers and records are for illustrative purposes only and do not represent actual product test or repair results.

By using this method of record-keeping, subsequent managers can trace the original configuration of the equipment via the Kit ID to confirm which parts have been replaced, by whom, and which test documents support the current configuration.

If an organisation uses QR codes or an electronic equipment management system, these records can also be linked to the same asset file, eliminating the need to create a completely separate file for every routine maintenance task.

For further guidance on the management of complete equipment numbering, component identification and lifecycle records, please refer to the Guidance on the Identification and Traceability of Portable Earthing Devices.

IV. Which test records need to be updated following the replacement of components?

This is a common issue that arises during the component replacement process.

Existing test reports may only cover the original configuration, or may only certify the performance of a specific model, configuration or test sample.

When components are changed, one cannot simply assume that all old reports remain applicable to the new complete set of equipment.

Original test reports should be retained

Original reports form part of the equipment’s historical technical documentation and should not be discarded simply because components have been replaced.

They can still be used to demonstrate the technical condition of the equipment in its original configuration and provide a basis for comparison for subsequent modifications.

However, it is essential to distinguish between the following:

Retaining old reports does not mean that they automatically validate the performance of the replaced components.

Maintenance personnel should verify the model, configuration, test conditions and scope of application covered by the original reports to determine whether they can continue to support the new configuration.

Which replacements require a reassessment of the test basis?

If the replacement part is a compatible component already approved within the original authorised configuration, and the relevant evidence covers the replacement assembly, the corresponding post-replacement inspections and tests should be carried out in accordance with the applicable inspection procedures.

If earthing clamps, cables or terminals of different specifications are used, or if the connection structure has changed, it is necessary to reassess whether the original test evidence remains applicable.

Where necessary, supplementary verification should be carried out by personnel or organisations with the appropriate competence.

ASTM F2249-26 covers the inspection and electrical testing of in-service temporary protective earthing jumper assemblies and may serve as a reference for test methods in the electrical verification of applicable equipment.

However, this standard does not replace specific maintenance procedures, design change assessments or approvals for use. The actual tests to be performed should be determined based on component changes, applicable standards, manufacturer’s instructions and project requirements.

What should the updated technical file contain?

The file for the replaced equipment should be able to answer the following questions:

1. What component was originally in use?
2. Why was replacement necessary?
3. What is the model, batch or serial number of the new component?
4. Why is the new component considered compatible with the original configuration?
5. Are the original test reports still valid? On what basis?
6. What inspections and tests were carried out following the replacement?
7. Who reviewed and approved the equipment for reuse?

If supplementary testing is required, the actual test methods, dates of execution, results, report numbers and corresponding approval information should be recorded.

Where there are significant differences between the old and new configurations, the relevant Bill of Materials (BOM), configuration drawings and rated performance documentation should also be updated.

One should not merely amend the parts list whilst continuing to use old test records that do not substantiate the performance of the new configuration.

For inspection and testing requirements regarding in-service equipment, please refer to the Guidance on Periodic Inspection and Testing of Portable Earthing Devices.

V. When can the equipment be returned to service after replacement?

The completion of component replacement on a earthing system does not automatically mean that it has been restored to a serviceable condition.

Before re-authorising the equipment for use, it must be confirmed that all of the following conditions are met.

1. The replacement work has been completed and has passed inspection

It must be confirmed that the components replaced are approved, that the installation and connections comply with the manufacturer’s requirements, and that no unauthorised mechanical damage, connection anomalies or other defects have been found.

For replacements involving termination structures, connection bushings or clamp connections, visual inspection alone should not be the sole basis for authorisation.

2. There remains valid evidence of the rated performance of the entire assembly

It must be confirmed that the configuration following the replacement is supported by the relevant technical documentation.

If the original rated performance cannot be maintained, a reassessment must be carried out and follow-up measures determined in accordance with applicable requirements.

The use of parts with a higher nominal rating must not automatically be taken to mean that the complete earthing system has attained a higher short-circuit current withstand capacity.

3. Applicable inspections and necessary tests have been completed

The prescribed inspections and tests must be completed in accordance with approved maintenance procedures, applicable standards and the specific details of the replacement.

If test results are unsatisfactory, or if the relevant technical conditions cannot be confirmed, the equipment must remain out of service, and a decision regarding further repair, replacement or scrapping must be made based on the results.

4. Traceability records have been updated

The equipment file for the entire system must accurately reflect the current configuration.

At a minimum, the following must be linked:

• The equipment’s main serial number.
• Identification details of the original and new components.
• Reason for replacement, date and person responsible.
• The current configuration version and applicable technical documentation.
• Inspection and test records following replacement.
• Audit conclusions and details of the approving personnel.

Where key records are missing, it may not be possible to demonstrate the correspondence between the equipment’s current configuration and the test documentation, even if the components have been successfully installed.

5. Obtaining formal release approval

Finally, an authorised person shall confirm, in accordance with the applicable management procedures, whether the equipment meets the conditions for return to service.

Upon approval, the equipment status shall be updated and the equipment shall be returned to service or released for use.

If approval is not granted, the equipment shall remain isolated and the necessary follow-up actions shall be documented.

For manufacturers, equipment managers and power project procurement teams, it is recommended that component replacement be treated as a controlled configuration change rather than a simple part replacement.

Provided that the identity of the original equipment, the relationship between old and new components, configuration compatibility, valid test evidence and the final approval status can be confirmed, a complete and auditable chain of traceability can be maintained following the replacement of components.

JINPOWER supplies portable earthing leads and related earthing equipment. For projects requiring the replacement of earthing clamps, cables or connection terminals, the purchasing party should first provide the original equipment model, component specifications, configuration drawings and applicable rated performance requirements, before confirming with us the available component configurations and corresponding technical documentation.

көрініс JINPOWER earthing leads and earthing device products.

Техникалық ескерту: Component replacement, testing and re-authorisation for use must be carried out by competent personnel in accordance with the manufacturer’s requirements, applicable standards and approved equipment maintenance procedures. Where changes to fault current withstand capacity or the performance of the complete assembly are involved, the equipment must not be deemed fit for reuse based solely on the appearance of the components or their nominal parameters.