
Anatomy of a Medium-Voltage Splice
Reliable splices depend on qualified workers who deeply understand cable contents, construction and behavior when exposed to electrical stress.
Open the trench, vault or manhole. Strip back the jacket. Expose the neutrals. Remove the semicon and insulation. Crimp the connector. Rebuild the conductor shield, insulation and semicon. Seal the outside. This splicing routine eventually becomes second nature for medium-voltage cable splicers, which can make some workdays feel like a rote checklist to slog through. […]

Accelerating Safety Through Technology: A People-First Approach
Cultural readiness is required to reap the maximum benefits of new tech tools.
Utilities are investing millions of dollars in drones, automated monitoring systems and artificial intelligence applications. These tools offer unprecedented safety and operational advantages as grid complexities evolve – assuming crews willingly use them as intended. New technology should make it safer and easier for frontline workers to execute their tasks, particularly when stressed or fatigued. […]

Spiritual Preparation for Safer Work
Turn ideas like “I am my brother’s keeper” into consistent behavior, not merely situational intent.
The previous articles in this series examined two factors that strongly influence personal safety. Accountability is the idea that meaningful improvement begins when workers accept responsibility for their own safety decisions. Through mental preparation, workers gain an understanding of the ways in which temperament, emotional triggers and habits affect their judgment under pressure. This article […]

Confronting Data Bias to Improve Safety Outcomes
Effective mitigation requires leaders to regularly audit data, standardize definitions and measurement practices, and create psychologically safe reporting environments.
In safety management, data is often treated as objective truth. Leaders use incident rates, near-miss reports, injury trends and predictive models to guide them as they prioritize risk and allocate organizational resources. Yet data can quietly mislead us, particularly when bias is embedded in what we collect and our measurement and interpretation methods. Effective, ethical […]

Your Lineworkers, Your Legacy
I’m not sure how I became an analyst. It wasn’t something I planned for. Various types of analyst roles exist, but I primarily analyze incidents, breaking down and studying the elements of events to identify causes and effects. Incident analysis, done well, ultimately helps prevent undesired future outcomes. Over the last 15 years, I have […]

Easing the Transition to Utility Safety Leadership
Our industry’s frontline workers are commonly promoted to supervisory positions in rapid fashion. Some struggle with the transition as they discover that their new role involves far more than increased compensation, a fancier title and the keys to a company pickup truck. This installment of “Voice of Experience” addresses important points about lineworker leadership transitions […]

March-April 2026 Q&A
Q: Why does an EPZ pole connection need to be close to the worker’s feet? A: In an equipotential arrangement, if the bus is inadvertently energized, the length of the bonding cable from the grounded conductors to the structure will affect the voltage across the worker. The worker is only exposed if they contact the […]

The Armor of Safety
Self-discipline means consistently protecting ourselves.
Discipline equals freedom. That’s a leadership dichotomy that Jocko Willink and Leif Babin address in Chapter 12 of their book “Extreme Ownership.” Similarly, in the Bible, just before instructing the Ephesians to don their spiritual armor, Paul urges Christians to live disciplined lives according to the Ten Commandments “so … that you may enjoy long […]

Eliminate Hazard Awareness Delay
It’s 2 a.m. on an early fall day in Northern California’s Sierra foothills. The winter rains haven’t arrived yet. A large tree limb in the area snaps and falls on a distribution line, triggering a fault powerful enough to trip circuit breakers at a substation 15 miles away. Alarms sound in the company’s control center. […]
Utility Safety Podcast – Deep Dive – The Zero Trust Protocol – Surviving the Underground Vault
In this episode, we go beneath the surface into the high-stakes, “unforgiving” world of medium-voltage underground cable splicing. Drawing from Mark Savage’s expert insights in Incident Prevention Magazine, we explore why cable identification isn’t just a technical task—it’s a survival skill. We break down the “Zero Trust” philosophy where every cable is treated as lethal […]
Reliable splices depend on qualified workers who deeply understand cable contents, construction and behavior when exposed to electrical stress.
Anatomy of a Medium-Voltage Splice
Open the trench, vault or manhole. Strip back the jacket. Expose the neutrals. Remove the semicon and insulation. Crimp the connector. Rebuild the conductor shield, insulation and semicon. Seal the outside.
This splicing routine eventually becomes second nature for medium-voltage cable splicers…
In the News
Cultural readiness is required to reap the maximum benefits of new tech tools.
Accelerating Safety Through Technology: A People-First Approach
Utilities are investing millions of dollars in drones, automated monitoring systems and artificial intelligence applications. These tools offer unprecedented safety and operational advantages as grid complexities evolve – assuming crews willingly use them as intended.
New technology should make it safer and easier for frontline workers to execute their tasks, particularly when stressed or fatigued. Deploying drones to conduct post-storm inspections, for instance, keeps workers safely distanced from hazardous areas while potentially speeding up triage efforts. Digital pre-job briefing forms…
Turn ideas like “I am my brother’s keeper” into consistent behavior, not merely situational intent.
Spiritual Preparation for Safer Work
The previous articles in this series examined two factors that strongly influence personal safety. Accountability is the idea that meaningful improvement begins when workers accept responsibility for their own safety decisions. Through mental preparation, workers gain an understanding of the ways i…
Effective mitigation requires leaders to regularly audit data, standardize definitions and measurement practices, and create psychologically safe reporting environments.
Confronting Data Bias to Improve Safety Outcomes
In safety management, data is often treated as objective truth. Leaders use incident rates, near-miss reports, injury trends and predictive models to guide them as they prioritize risk and allocate organizational resources.
Yet data can quietly mislead us, particularly when bias is embedded in w…

Your Lineworkers, Your Legacy
I’m not sure how I became an analyst. It wasn’t something I planned for. Various types of analyst roles exist, but I primarily analyze incidents, breaking down and studying the elements of events to identify causes and effects. Incident analysis, done well, ultimately helps prevent undesired future outcomes.
Over the last 15 years, I have analyzed a half-dozen apprentice training yard accidents and watched two videos of apprentice-involved incidents. These events are reminders that lineworkers frequently learn their lessons the hard way. I continue striving to change that fact because – fa…

Easing the Transition to Utility Safety Leadership
Our industry’s frontline workers are commonly promoted to supervisory positions in rapid fashion. Some struggle with the transition as they discover that their new role involves far more than increased compensation, a fancier title and the keys to a company pickup truck. This installment of “Voice…

March-April 2026 Q&A
Q: Why does an EPZ pole connection need to be close to the worker’s feet?
A: In an equipotential arrangement, if the bus is inadvertently energized, the length of the bonding cable from the grounded conductors to the structure will affect the voltage across the worker. The worker is only expose…

Self-discipline means consistently protecting ourselves.
The Armor of Safety
Discipline equals freedom. That’s a leadership dichotomy that Jocko Willink and Leif Babin address in Chapter 12 of their book “Extreme Ownership.”
Similarly, in the Bible, just before instructing the Ephesians to don their spiritual armor, Paul urges Christians to live disciplined lives accordi…
Eliminate Hazard Awareness Delay
It’s 2 a.m. on an early fall day in Northern California’s Sierra foothills. The winter rains haven’t arrived yet. A large tree limb in the area snaps and falls on a distribution line, triggering a fault powerful enough to trip circuit breakers at a substation 15 miles away. Alarms sound in the comp…
Opinion
Anatomy of a Medium-Voltage Splice
Mark Savage
Accelerating Safety Through Technology: A People-First Approach
Kaitlyn Albertoli
Spiritual Preparation for Safer Work
Tom Cohenno, Ed.D., CSP, CUSP, NBC-HWC
Confronting Data Bias to Improve Safety Outcomes
Gina Vanderlin, CSP, CHMM, CIT, CUSP
Video
Anatomy of a Medium-Voltage Splice
Open the trench, vault or manhole. Strip back the jacket. Expose the neutrals. Remove the semicon and insulation. Crimp the connector. Rebuild the conductor shield, insulation and semicon. Seal the outside. This splicing routine eventually becomes second nature for medium-voltage cable splicers, wh…
Featured Topics
Reliable splices depend on qualified workers who deeply understand cable contents, construction and behavior when exposed to electrical stress.
Anatomy of a Medium-Voltage Splice
Open the trench, vault or manhole. Strip back the jacket. Expose the neutrals. Remove the semicon and insulation. Crimp the connector. Rebuild the conductor shield, insulation and semicon. Seal the outside.
This splicing routine eventually becomes second nature for medium-voltage cable splicers…

Cultural readiness is required to reap the maximum benefits of new tech tools.
Accelerating Safety Through Technology: A People-First Approach
Utilities are investing millions of dollars in drones, automated monitoring systems and artificial intelligence applications. These tools offer unprecedented safety and operational advantages as grid complexities evolve – assuming crews willingly use them as intended.
New technology should make…

Turn ideas like “I am my brother’s keeper” into consistent behavior, not merely situational intent.
Spiritual Preparation for Safer Work
The previous articles in this series examined two factors that strongly influence personal safety. Accountability is the idea that meaningful improvement begins when workers accept responsibility for their own safety decisions. Through mental preparation, workers gain an understanding of the ways i…

Effective mitigation requires leaders to regularly audit data, standardize definitions and measurement practices, and create psychologically safe reporting environments.
Confronting Data Bias to Improve Safety Outcomes
In safety management, data is often treated as objective truth. Leaders use incident rates, near-miss reports, injury trends and predictive models to guide them as they prioritize risk and allocate organizational resources.
Yet data can quietly mislead us, particularly when bias is embedded in w…

Your Lineworkers, Your Legacy
I’m not sure how I became an analyst. It wasn’t something I planned for. Various types of analyst roles exist, but I primarily analyze incidents, breaking down and studying the elements of events to identify causes and effects. Incident analysis, done well, ultimately helps prevent undesired future…

Easing the Transition to Utility Safety Leadership
Our industry’s frontline workers are commonly promoted to supervisory positions in rapid fashion. Some struggle with the transition as they discover that their new role involves far more than increased compensation, a fancier title and the keys to a company pickup truck. This installment of “Voice…

Reliable splices depend on qualified workers who deeply understand cable contents, construction and behavior when exposed to electrical stress.
Anatomy of a Medium-Voltage Splice
Open the trench, vault or manhole. Strip back the jacket. Expose the neutrals. Remove the semicon and insulation. Crimp the connector. Rebuild the conductor shield, insulation and semicon. Seal the outside.
This splicing routine eventually becomes second nature for medium-voltage cable splicers, which can make some workdays feel like a rote checklist to slog through. But each procedural step exists to help ensure precision electrical devices are competently dismantled and rebuilt. Reliable execution is more likely when splicers understand the logic at the root of each step. This article explores that logic in greater detail.
Examining the Layers
A modern medium-voltage cable, whether insulated with cross-linked polyethylene (XLPE) or ethylene propylene rubber (EPR), is built in layers from the inside out. The conductor is at the center. A semiconductive strand shield (conductor shield) sits around it, covered by a thick layer of insulation. Atop that insulation is a second semiconductive layer (insulation shield), followed by a metallic shield or concentric neutral, and finally a protective jacket.
During manufacturing, each cable layer is extruded and assembled in controlled factory conditions to create a smooth, predictable electric field from the conductor to ground. Cutting into the cable interrupts its field control system, designed by the manufacturer to last decades. Industry professionals use splice and termination kits to reconstruct these systems.
Reconstruction work begins with the conductor, which could be copper or aluminum, concentric or compact stranded. Splicers must confirm correct installation of connectors. Ideally, conductor and connector metals will be the same; copper-aluminum connections risk corrosion. Note that an under-crimped connector or a connector with the wrong die marks is a built-in hot spot. Adequate crimping squeezes the metal to create a low-resistance, mechanically strong joint that will not loosen, shift or change shape under thermal cycling or fault current. Inadequate crimping means extra heat during normal operation that stresses insulation from the inside out.
Smoothing the Electric Field
Surrounding the conductor is the inner semiconductive layer, also called the conductor shield. Its job is to smooth the electric field at the conductor’s surface. A stranded conductor is full of sharp edges and tiny gaps. If we directly apply insulation over those strands, the electric field will concentrate at each strand tip and across each tiny air pocket. Those spots can ionize under medium-voltage stress, prompting partial discharge that erodes insulation. The conductor shield fills the voids, bonds to the insulation, and presents a smooth, nearly cylindrical surface at the same potential as the conductor. When stripping this layer during a splice, use specialized tools and correct depth settings to ensure a clean finish with no ridges or gouges. These are not cosmetic efforts; a single nick in the insulation or jagged edge left on the conductor shield is a future stress point that could lead to breakdown.
The main insulation layer, either XLPE or EPR, blocks system voltage from ground. It is more than thick rubber or plastic, polarizing when voltage is applied. The electric field sets up radially from the conductor to the insulation shield. Stress is highest at the inner surface, near the conductor; it is lowest at the outer surface. Cable manufacturers spec materials and thicknesses to ensure maximum stress does not exceed insulation breakdown strength or the level at which partial discharges will begin. Stress is best handled by smooth, uniform insulation.
Employers and trainers take note: Because weak points typically result from scratches, inadvertent cuts, contaminants and moisture on insulation surfaces, splicers must be qualified to use specialized tools, strip cable in a controlled fashion, and competently clean tools, cable and equipment.
Weak points are the reason insulation levels exist. Clearly, the wall of a 15-kV cable with 133% insulation is thicker than one with 100% insulation. Thick insulation is intended for systems in which ground faults could take up to an hour to clear. Thinner, 100% insulation is not designed for those conditions (clears a fault in 60 seconds or less). Critically, as we choose cables and accessories, we also choose our dielectric margins should something go wrong.
Uniform Ground Potential
A cable’s outer semiconductive layer is functionally similar to the conductor shield, managing the electric field at the insulation’s outer surface. This layer bonds to the insulation, keeping its surface at a uniform ground potential. During normal operation, the electric field is almost entirely located between the conductor and this shield; little of it exists in the jacket or surrounding soil and air, which explains why a qualified person can safely touch a grounded shielded cable that contains thousands of volts.
Splicers must cut back this outer semicon layer to the exact length specified by the splice or termination kit’s instructions. The cutback distance, the straightness and smoothness of its edge, and the exposed insulation’s cleanliness are nonnegotiable details, determining how electrical stress will behave once the splice or termination is energized. A crooked or ragged semicon edge elevates local stress. Dirt and moisture encourage tracking. When we take time to perfectly dress the edge, we are shaping the future electric field.
Metallic Shield and Outer Jacket Functionality
Depending on the cable, the metallic shield located outside the insulation shield could consist of helically wrapped concentric copper neutrals, flat copper straps, copper tape with overlap, or a corrugated metal sheath. This shield performs critical functions: providing a low-impedance path for fault current; allowing protective devices to clear faults quickly; carrying the small charging current that flows through the insulation during normal operation; and confining the electric field, limiting stress exposure. In many distribution designs, the metallic shield also serves as the return path for unbalanced load current.
Any cuts to the cable also cut the metallic shield. If we do not restore continuity using properly sized and installed bonds, braids and spring clamps, we change how future faults will travel and where voltage will rise during abnormal conditions. Floating and poorly bonded shields are associated with dangerous potentials, delayed fault clearings and changes in electric field behavior near splices. Bonds are rebuilt by gathering every neutral wire and reattaching them according to the company’s approved reshielding process, restoring the safety system surrounding the insulation.
A cable’s outer jacket prevents water penetration, defends neutrals against corrosion, and safeguards shields and insulation from physical damage. When we strip the jacket to make a splice, we create a potential path for water entry. Modern cable manufacturers use water-swellable tapes and powders to address this reality, but they also rely on good seals. Some splice and termination kits call for use of specific mastics and sealant wraps and instruct users to add rejacketing sleeves over their splices; these actions greatly assist in protecting a cable’s contents. Moisture, corrosion and thermal cycling undermine splices that are electrically perfect but poorly sealed, leading to their eventual failure.
Geometric Stress Control
The cable layers described above work together to control electrical stress. The stress present in an intact section of cable is purely radial and behaviorally predictable. Trouble begins with the introduction of a shield cutback, termination or other discontinuity point where the electric field must bend. In those cases, the field no longer runs straight out from the conductor, instead curling along the insulation’s surface and into the surrounding air, causing longitudinal stress and creating areas in which the field can potentially bunch up. If the outer shield ends abruptly, with bare insulation continuing, the electric field crowds around that sharp edge. Concentrated stress under operating voltage produces corona and tracking, especially in humid and contaminated conditions, eroding materials and potentially leading to a flashover or failure.
Geometric stress control (i.e., the use of shape to spread out the electric field) solves the problem. The stress cones and internal contours of premolded and cold-shrink terminations and taped splices are designed to extend a conductive or semiconductive surface beyond the shield edge so that potential drops gradually over a longer path. Capacitive and resistive stress grading using tapes and mastics with special electrical properties takes this idea one step further. Applied in precise patterns at the shield cutback, the materials pull some of the electric field into themselves, distributing the voltage drop over their length. Pattern instructions that call for an exact number of half-lapped layers, starting precisely at the semicon edge and ending at a specified distance, are the result of laboratory design and testing.
Conclusion
A medium-voltage splice is a field-built extension of a cable’s original design. The conductor must be solid and correctly installed. Its surrounding conductor shield and insulation must be uniform and clean. The semiconductive layer must reestablish smooth electric field boundaries. The metallic shield must be continuous and grounded. The jacket must seal and prevent water and other physical damage.
When medium-voltage splicers understand why each cable layer exists, a splice or termination kit’s instructions begin to look less like suggestions and more like what they truly are: a roadmap to restoring a cable’s safe, factory-quality performance. Well-made splices disappear into lines, quietly doing their work during storms and faults without drawing attention. Achieving that level of reliability is a direct result of qualified splicers who understand cable contents and construction, how electrical stress behaves inside cable, and the significance of each cut, crimp and wrap.
About the Author: Mark Savage is the owner of DeadBreak, a service-disabled veteran-owned small business providing underground distribution and transmission training, consulting and field services. A U.S. Marine Corps veteran with over 25 years of experience in underground construction and emergency response, Savage is a credentialed journeyman cable splicer/lineman and qualified medium-voltage splicing trainer. Reach him at msavage@deadbreak.us.

Cultural readiness is required to reap the maximum benefits of new tech tools.
Accelerating Safety Through Technology: A People-First Approach
Utilities are investing millions of dollars in drones, automated monitoring systems and artificial intelligence applications. These tools offer unprecedented safety and operational advantages as grid complexities evolve – assuming crews willingly use them as intended.
New technology should make it safer and easier for frontline workers to execute their tasks, particularly when stressed or fatigued. Deploying drones to conduct post-storm inspections, for instance, keeps workers safely distanced from hazardous areas while potentially speeding up triage efforts. Digital pre-job briefing forms that incorporate AI-driven alerts offer crews enhanced, real-time understanding of worksite risks before they arrive.
But successfully rolling out newly adopted safety technologies is no small feat. Frontline buy-in depends on an organization’s cultural readiness. How can readiness be achieved? A sustainable strategy begins with people. It is then enforced via process and enhanced by technology. In that order.
Safety Lives in the Field
Safety starts at the top, but it lives in the field. Frontline workers will notice if senior leaders only speak about safety during budget meetings. By incorporating it into daily tailboards, performance metrics, public commitments and organizational strategy, leaders demonstrate that safety is a nonnegotiable organizational value.
Critically, leaders must be good listeners, consulting frontline workers for their firsthand insights into the organization’s operational risks and inefficiencies. Feedback loops assist decision-makers in determining the merits of new safety solutions. These loops are especially helpful when piloting AI-driven systems, whose accuracy is shaped through human oversight.
Technology buy-in often expands as workers witness the impact of their feedback. For example, one utility that uses an AI tool to enhance infrastructure inspections noted a boost in tool adoption when crews began gathering for post-shift debriefings. The time crew members spent analyzing AI images of their jobsites, flagging errors and feeding that data into the model increased its future reliability and relevance.
Change Management
Workers will commonly shelve new technology tools that are poorly rolled out. Leaders have various options to mitigate this risk, including appointing organizational safety champions as liaisons between field crews and technology/innovation teams; hosting cross-functional workshops during which information technology, operations and safety personnel collaborate to address adoption barriers; and celebrating quick wins that underscore new technology’s advantages.
Dominion Energy offers a good example. As part of a drone and AI implementation project, the utility designated safety liaisons to facilitate communication between leadership and field teams, which played a significant role in building early momentum for the broader rollout.
Employee Training
Technology can only be as effective as its users. Thus, employers must ensure their employees are trained to best leverage its value. Some utility organizations are using other technologies to assist with training, such as virtual- and augmented-reality applications that simulate real-world scenarios, reducing risk to trainees.
Peer mentoring, which combines relational and procedural learning, often complements formal industry training. Pairing seasoned lineworkers with younger, less experienced employees can be mutually beneficial, enhancing technology skills transfer and reinforcing institutional and industry wisdom.
Safety Accelerants
With the right people and processes in place, utilities can use new technologies to accelerate safer field operations. Consider the following three examples.
1. Drones
Drone adoption has become increasingly common within industry organizations. For instance, in 2023, New York Power Authority invested $37.2 million in its drone program. Integrated into these unmanned aerial systems are high-resolution cameras, light detection and ranging (lidar), and thermal sensors that enhance fault and damage detection capabilities while limiting worker hazard exposure and bucket truck deployments.
Frontline buy-in becomes more likely when crews feel confident that the data collected by company drones will be accurate, easily accessible and fully integrated into their workflows. Some utilities have addressed this by implementing joint flight validation sessions during which pilots and field technicians collaborate to review drone inspection footage. These sessions can uncover technological and procedural blind spots and reinforce to personnel that drones are considered tools, not worker replacements.
2. Artificial and Visual Intelligence
AI accelerates the identification of infrastructure corrosion, vegetation risks and structural faults at a scale that humans alone can’t match. Beyond speed and scale, human-in-the-loop AI models incorporate experienced inspectors to validate and refine model outputs, helping to reduce errors, build user trust and strengthen organizational learning.
Field safety can be dramatically enhanced when AI learns from humans and humans trust its support. During Hurricane Harvey, for example, one utility used AI-powered drone data to safely route repair crews away from flooded roads and damaged assets, improving response times while minimizing crew hazard exposure.
3. Substation Monitoring
Substations are sometimes inspected just once a year by a single technician. Today, AI-enabled monitoring systems offer 24/7 surveillance that alerts users to overheating, smoke, fire, unauthorized access incidents and PPE violations in real time. Some monitoring systems also act as a second set of eyes for lone workers, detecting falls and prolonged inactivity and triggering alerts.
Moving the Needle
As the U.S. electrical grid grows more complex, frontline employee safety and system resilience increasingly depend on the power and influence of strong, healthy organizational cultures. New technologies alone won’t improve safety or other outcomes. Utilities begin to move the needle when leadership sets clear intentions, builds and refines processes that reinforce cultural values, and rolls out new technologies with ample training and respect for workers.
About the Author: Kaitlyn Albertoli is co-founder and CEO of Buzz Solutions (www.buzzsolutions.co), a California-based provider of visual intelligence solutions to inspect, maintain and secure energy infrastructure.
Editor’s Note: Learn more from Kaitlyn in a recent podcast interview with iP’s Kate Wade, available at https://utilitysafety.podbean.com/e/utility-safety-podcast-using-visual-intelligence-to-strengthen-utility-infrastructure/.
Turn ideas like “I am my brother’s keeper” into consistent behavior, not merely situational intent.
Spiritual Preparation for Safer Work
The previous articles in this series examined two factors that strongly influence personal safety. Accountability is the idea that meaningful improvement begins when workers accept responsibility for their own safety decisions. Through mental preparation, workers gain an understanding of the ways in which temperament, emotional triggers and habits affect their judgment under pressure.
This article builds on those concepts by addressing spiritual preparation, a third factor not nearly as commonly discussed that nevertheless plays a critical role in how people behave on the job.
Spiritual…

Effective mitigation requires leaders to regularly audit data, standardize definitions and measurement practices, and create psychologically safe reporting environments.
Confronting Data Bias to Improve Safety Outcomes
In safety management, data is often treated as objective truth. Leaders use incident rates, near-miss reports, injury trends and predictive models to guide them as they prioritize risk and allocate organizational resources.
Yet data can quietly mislead us, particularly when bias is embedded in what we collect and our measurement and interpretation methods. Effective, ethical safety leaders continuously work to recognize and address these distortions.
Exploring Various Biases
A widely cited World War II-era example illustrates the dangers of biased data. During the war, Allied forces studied returning aircraft to determine where additional armor was needed. Analysts initially recommended reinforcing areas with the most visible bullet holes. Statistician Abraham Wald challenged this reasoning, highlighting what is now known as survivorship bias. He observed that the only aircraft analyzed were those that survived their missions. Aircraft that failed to return home had likely sustained catastrophic damage to areas where no bullet holes were observed on the surviving planes. Wald’s insight suggested that undamaged areas required reinforcement, not the visibly damaged ones.
Survivorship bias remains a powerful warning for leaders whose safety programs rely on incomplete or filtered data. However, it is only one source of potential distortion.
Selection bias occurs when data is drawn from an unrepresentative sample. In a utility environment, this could happen when organizations heavily rely on information from crews or regions with strong reporting cultures while underestimating risk in areas where incidents and near misses are less likely to be reported. Leaders may inadvertently prioritize the wrong hazards when the dataset does not reflect the entire population.
Even when data is broadly collected, confirmation bias can still emerge (i.e., leaders subconsciously favor data that supports their existing beliefs or assumptions). For example, if management believes a particular work practice is safe, near-miss data that challenges their belief may be discounted or dismissed as anomalous. Over time, selective interpretation reinforces blind spots and weakens organizational learning.
Measurement bias can be introduced at the point of data capture, resulting in inconsistently defined or poorly standardized safety data. Metrics that depend on subjective judgment – such as what qualifies as a safety observation or near miss – can vary widely among supervisors, crews and contractors. When measurement practices differ, trends become unreliable and comparisons across departments or time periods lose meaning.
Historical bias arises when data reflects outdated assumptions, norms or exclusions that no longer align with today’s workforce or operating environments. Caroline Criado Perez’s book “Invisible Women: Data Bias in a World Designed for Men” highlights how systems built on incomplete data can overlook entire populations. In safety-critical industries, this could appear in PPE design, equipment ergonomics or training materials developed for a narrow segment of the workforce, leaving others at elevated risk.
More recently, algorithmic bias has emerged as organizations increasingly adopt predictive analytics and other safety tools driven by artificial intelligence, which can inherit and amplify patterns embedded in historical data. Any algorithms trained using past incident data that underrepresents certain hazards, job roles or worker groups may consistently underestimate risk in those areas. Since algorithmic outputs often appear objective, this bias can be difficult to detect and challenge without deliberate oversight.
Overcoming Vulnerabilities
Embedded bias distorts safety intelligence and can create organizational vulnerabilities. Resources may be misdirected. Early warning signs could be missed. Emerging hazards might remain invisible until a serious incident occurs. Overreliance on lagging indicators like recordable injury rates could create a false sense of security, especially in high-risk utility operations.
Biased data can also further erode trust. Reporting declines when frontline workers witness leadership decisions that conflict with their lived experiences, deepening the data gap.
Despite these risks, high-quality data remains indispensable to effective safety management, enabling organizations to identify trends, prioritize controls, evaluate interventions, and shift from reactive responses to proactive prevention. Decisions made without data are often driven by anecdotes and intuition.
The challenge, therefore, is not whether to use data but how to use it thoughtfully and with full awareness of its limitations.
Recognizing bias is the first step. Leaders should routinely ask, who is missing from this dataset? What assumptions shaped these metrics? What risks could be hidden? A questioning approach encourages more accurate, proactive, ethical decision-making. Leaders who understand bias are more likely to consult multiple data sources, blending quantitative indicators with qualitative insights from job observations, worker feedback and learning teams. Most importantly, confronting data bias helps to ensure that safety systems are designed to protect all workers, not just those most visible in the data.
Intentional effort is required to turn awareness into action. Organizations must routinely audit safety data for gaps and inconsistencies, standardize definitions and measurement practices, and foster psychologically safe reporting environments. As use of predictive analytics and other AI tools expands, transparency and human oversight are essential. Leaders must treat model outputs as decision aids – not decision-makers – and be accountable for how data-driven insights are applied in the field.
Conclusion
Numbers carry authority, shaping organizational budgets, priorities and narratives. However, as Abraham Wald demonstrated decades ago, some of our greatest threats may never appear in the data we see. Safety leaders who understand and deliberately question, test and correct for biases ultimately position their organizations to more effectively mitigate risk.
About the Author: Gina Vanderlin, CSP, CHMM, CIT, CUSP, is the customer operations health and safety program manager at PSEG Long Island. With over 15 years of experience leading EHS initiatives in high-reliability industries, she remains passionate about elevating safety from a compliance function to a strategic driver of culture, engagement and operational excellence. Reach Vanderlin at gina.vanderlin@psegliny.com.

Your Lineworkers, Your Legacy
I’m not sure how I became an analyst. It wasn’t something I planned for. Various types of analyst roles exist, but I primarily analyze incidents, breaking down and studying the elements of events to identify causes and effects. Incident analysis, done well, ultimately helps prevent undesired future outcomes.
Over the last 15 years, I have analyzed a half-dozen apprentice training yard accidents and watched two videos of apprentice-involved incidents. These events are reminders that lineworkers frequently learn their lessons the hard way. I continue striving to change that fact because – far too often – the hard way becomes the final act to what could have been a great life.
I was once asked to write an opinion about a root cause analysis (RCA) conducted by OSHA and a utility. The analysis focused on a singular event that put three apprentices in the hospital. OSHA performs RCAs only to identify whether employers are at fault. The analysis I was asked to write about stated that the incident’s cause was various physical conditions and procedural mistakes. But while the conditions and mistakes were causally related, none was the true root cause.
That concerning realization is the reason I wrote this article: to clarify what a good RCA entails and explore its relationship with lessons learned from training accidents.
A Peculiar Art Form
RCA is a peculiar art form that requires analysts to be knowledgeable about safety standards and human performance principles. Numerous utilities use RCA software applications, mostly algorithm-based methodologies designed to help investigators determine the most likely root cause. The applications were developed to standardize RCAs, offering guided protocols to prevent investigator errors. However, the human element can still impact results. A persistent issue with RCA application use is listing, evaluating and interpreting the causal factors that preceded an incident.
Causal factors contribute to the incident under investigation, but they are not the root cause. The root cause is the singular event that prompted the incident; if it had not occurred, the incident would not have occurred either.
I recently reviewed two incidents so similar in nature that the same investigation report could have been written for both. In these cases, which took place a few years apart, investigators used RCA software to determine a root cause. The only difference between the two final RCA reports? You guessed it: the identified root cause. Two entirely different RCA conclusions resulted from the very same causal factors. My point here is that an RCA application is only effective when users complete the software training and stick to its process. Root causes are not always easy to determine, and they are not always what we initially believe they are – which brings us back to training.
Introducing Thom and Goob
To demonstrate rodeo-style hurt man rescue, an apprentice named Thom climbed to the top of a distribution pole. He successfully reached the mannequin only because of his portable fall protection device. Thom then fumbled with the rigging, desperately trying to get the mannequin down in four minutes. He could hear encouragement from the ground, shouts of “Go, go, go,” “Wrap this,” “Pull that,” “Reach around that.” Finally rigged, Thom reached around the mannequin and, using the hawkbill knife that he had sharpened to a razor’s edge for the demonstration, cut his own fall protection. He fell 38 feet, right into life in a wheelchair.
In another rescue incident (see https://youtu.be/gaH7pK-6n84), a worker nicknamed Goob also inadvertently cut his fall protection. I don’t know how that worked out for him, but for lineworkers reading this, the lesson is found in Goob’s now-infamous rescue fail.
We have an industry training shortcoming that is exacerbated by our need to get lineworkers trained and in the air (or in the ditch). The problem lies in the difference between objective and subjective training goals. Earlier, I stated that Thom’s portable fall protection device was the sole reason he reached the mannequin. Neither Thom nor Goob was subjectively competent enough to successfully complete their tasks. The difference between subjectivity and objectivity plays a considerable role in training, particularly when training trainers.
Subjectivity vs. Objectivity
Objective evaluation is rooted only in facts and goals. Subjective evaluation is influenced by the evaluator’s personal experience, feelings and opinions. In this context, “personal experience” is legitimate hands-on utility industry experience.
Note: To be clear, I believe that good instructors possess a great amount of career experience and industry knowledge. This is not an indictment of on-the-job (OTJ) training using lineworker mentors. I am a product of the OTJ process and have great respect for those who taught me. Negligence and incompetence are not the issues I am addressing here. The problem is generic in nature and perhaps even a hidden organizational defect.
Thom, the apprentice who made it to the mannequin, fell victim to two objective influences that resulted in his fall. First, he was not a competent climber. It is unlikely that Thom would have climbed a 40-foot pole had he not been wearing a personal fall arrest system (PFAS). He was allowed to do so because he had trained in a PFAS that everyone believed would prevent his fall. Using the system, Thom got to the top of the pole, but his hook sets were tentative. His body was off-center and uncomfortably oriented because he did not periodically adjust his PFAS during ascent.
The “git-r-done” mentality was the second objective influence. Although I love 1990s-era Larry the Cable Guy, he didn’t do us any favors, but it’s not really his fault. Git-r-done was a comedy phenomenon that made light of simple men using unsophisticated methods to complete manly tasks, resulting in their unrestrained celebration. I am in favor of all those things, especially the unrestrained celebration, but the industry may have taken git-r-done too far.
Encouragement from people on the ground was an additional event precursor in both Thom’s case and Goob’s case. Objectively, both apprentices were working hard to succeed; it is human nature to seek approval from others. But the level of problem-solving Thom and Goob displayed demonstrated that the two men did not possess the competence needed. Goob’s pole strap was too far out, and he displayed poor foot positioning and poor rigging management skills. Thom’s circumstances were the same. He explained to me that he had not felt confident in his climbing skills while on the pole but believed his PFAS would protect him. When Thom reached the top, his problem-solving skills were compromised by his lack of experience and the pressure of well-intentioned coworkers shouting encouragement from below.
Competence is the first goal of industry training. Next, trainees are coached to both competently and efficiently complete their tasks. Until an apprentice demonstrates adequate problem-solving and skill competency independent of trainer instruction, the process must be unrushed and orderly. An apprentice simply climbing to the top of a pole is an objective measurement of quality. Climbing to the top with demonstrated skill is a subjective measurement.
Where Do RCAs Fit In?
Trainer competency was the root cause of Thom’s incident, Goob’s incident and the other training yard incidents I referenced earlier. But that is not because the trainers were incompetent. Rather, they had not been sufficiently trained to train other workers. I hate making that statement without first preparing readers because these incidents truly were not the fault of industry trainers. They did not lack lineworker skills or knowledge; they lacked understanding of the individuals who they were training. An effective trainer understands the nature of the trainee and recognizes subjective indicators of their competence to safely perform learned skills. Those trainers with effective technology transfer skills understand the nature of the learning and the learner, training modalities, subjective indicators of training success and objective competency measures.
Falls accounted for two of the previously referenced training yard incidents. In both instances, the instructors bowed to trainee pressure, deviating from their planned training methodologies to instead oversee speed-climbing events. One apprentice climbed off the top of a pole. The other gaffed himself and almost bled to death. Neither had climbing skill characterized by good hook sets, technique, hand position and body orientation. In fact, neither even looked up while ascending.
In yet another case, apprentices used trial and error to learn how to compress sleeves with a 60-ton press. Blown hydraulic hoses hospitalized two individuals. The utility’s investigation blamed a failed hose that “should have been capable of containing the hydraulic pressure.” But the RCA revealed that the hose had been plugged into a universal pump open-center system, which prematurely forced pressure into the hose of the closed center head, preventing operation of the spring-loaded quick coupling. The apprentices forced the coupling and broke the hose. So, the problem wasn’t a faulty hose but an objective-based training issue: “Squeeze the sleeve without bending it.” That initial introduction to the task and the training methodology lacked requisite preparation and instruction elements, which should have been audited by observing the steps via an orderly process.
The Bottom Line
I am now going to use RCA to lobby for a comprehensive review of the nature of our industry’s training. We have too many examples of trainees pushed beyond their skill level, and they are not limited to climbing in 100% fall protection. Let’s audit our training processes, including how we train our trainers, ensuring that we provide them with the technology transfer skills they need to successfully pass on their experience, craft skills and other knowledge.
A utility manager once challenged me about the cost of training the organization’s trainers. He said it was frustrating to spend the time and money just for them to eventually leave. His attitude is one more example of mistakenly relying on objective concerns. His subjective concern should have been, what if we don’t train our trainers and they stay?
About the Author: After 25 years as a transmission-distribution lineman and foreman, Jim Vaughn, CUSP, has devoted the last 28 years to safety and training. A noted author, trainer and lecturer, he is a senior consultant for the Institute for Safety in Powerline Construction. He can be reached at jim@ispconline.com.

Reliable splices depend on qualified workers who deeply understand cable contents, construction and behavior when exposed to electrical stress.
Anatomy of a Medium-Voltage Splice
Open the trench, vault or manhole. Strip back the jacket. Expose the neutrals. Remove the semicon and insulation. Crimp the connector. Rebuild the conductor shield, insulation and semicon. Seal the outside.
This splicing routine eventually becomes second nature for medium-voltage cable splicers…

Cultural readiness is required to reap the maximum benefits of new tech tools.
Accelerating Safety Through Technology: A People-First Approach
Utilities are investing millions of dollars in drones, automated monitoring systems and artificial intelligence applications. These tools offer unprecedented safety and operational advantages as grid complexities evolve – assuming crews willingly use them as intended.
New technology should make…

Turn ideas like “I am my brother’s keeper” into consistent behavior, not merely situational intent.
Spiritual Preparation for Safer Work
The previous articles in this series examined two factors that strongly influence personal safety. Accountability is the idea that meaningful improvement begins when workers accept responsibility for their own safety decisions. Through mental preparation, workers gain an understanding of the ways i…

Effective mitigation requires leaders to regularly audit data, standardize definitions and measurement practices, and create psychologically safe reporting environments.
Confronting Data Bias to Improve Safety Outcomes
In safety management, data is often treated as objective truth. Leaders use incident rates, near-miss reports, injury trends and predictive models to guide them as they prioritize risk and allocate organizational resources.
Yet data can quietly mislead us, particularly when bias is embedded in w…

Reliable splices depend on qualified workers who deeply understand cable contents, construction and behavior when exposed to electrical stress.
Anatomy of a Medium-Voltage Splice
Open the trench, vault or manhole. Strip back the jacket. Expose the neutrals. Remove the semicon and insulation. Crimp the connector. Rebuild the conductor shield, insulation and semicon. Seal the outside.
This splicing routine eventually becomes second nature for medium-voltage cable splicers…

Cultural readiness is required to reap the maximum benefits of new tech tools.
Accelerating Safety Through Technology: A People-First Approach
Utilities are investing millions of dollars in drones, automated monitoring systems and artificial intelligence applications. These tools offer unprecedented safety and operational advantages as grid complexities evolve – assuming crews willingly use them as intended.
New technology should make…

Turn ideas like “I am my brother’s keeper” into consistent behavior, not merely situational intent.
Spiritual Preparation for Safer Work
The previous articles in this series examined two factors that strongly influence personal safety. Accountability is the idea that meaningful improvement begins when workers accept responsibility for their own safety decisions. Through mental preparation, workers gain an understanding of the ways i…

Effective mitigation requires leaders to regularly audit data, standardize definitions and measurement practices, and create psychologically safe reporting environments.
Confronting Data Bias to Improve Safety Outcomes
In safety management, data is often treated as objective truth. Leaders use incident rates, near-miss reports, injury trends and predictive models to guide them as they prioritize risk and allocate organizational resources.
Yet data can quietly mislead us, particularly when bias is embedded in w…






