Class 1E Cable Qualification to the Latest IEEE Standards
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1 Class 1E Cable Qualification to the Latest IEEE Standards IEEE NPEC SC-2 Meeting April 7-8, 2009 Knoxville, TN Presented by: John Cancelosi The Okonite Company Ramsey, NJ
2 Overview History of Class 1E Testing IEEE vs. IEEE DBE LOCA Test Vertical Tray Flame Test Qualification Test Program Specimen Selection Aging LOCA & HELB Flame Tests
3 Early Cable Qualification Tests (Pre IEEE ) Early 1960 s - Effects of radiation 60s early 70s Thermal aging to ICEA requirements C Radiation: 100 Mrads gamma Mild LOCA profile
4 Early Cable Qualification Tests Pre IEEE
5 IEEE Standards IEEE Std for Qualifying Class 1E Equipment for Nuclear Power Generating Stations IEEE Std for Type Test of Class 1E Electric Cables, Field Splices and Connections for Nuclear Power Generating Stations
6 Tests to Qualify for Normal Operation Tests to Qualify for Design Basis Event LOCA HELB / MSLB IEEE Qualification (Type) Tests Tests to Qualify for Design Basis Event Fire
7 IEEE Tests to Qualify for Normal Operation Made, tested and qualified to Industry Standards ICEA - AEIC - NEMA Long Term Physical Aging Properties Thermal & Radiation Exposure 1) Aging to End of Life condition 2) Radiation Exposure (50 MRads) 3) Mechanical & Electrical Withstand
8 IEEE Tests to Qualify for DBE -LOCA Thermal & Radiation Exposure Aging to End of Life condition Radiation Exposure Normal Life Dosage (50 MRads) One accident dose (150 MRads) Loss of Coolant Accident simulation Temperature, Pressure & Chem spray Post LOCA Simulation test Mechanical & Electrical Withstand
9
10 IEEE Tests to Qualify for DBE - Flame Vertical wire flame test Vertical tray flame test
11 Vertical Wire Flame Test Procedure 22 specimen Flame impingement 10 below paper flag Flame temp ~ 1530F 15 sec flame application 15 sec off period 5 cycles Pass: < 25% flag damage
12 IEEE 383 VTFT Procedure 8 ft ladder type tray 12 wide Gas burner placed 3 behind tray and 2 ft off the floor Theoretical Heat Input 70,000 BTU/hr Specimens fill at least center 6 of tray width Specimens spaced ½ OD apart Flame Exposure 20 minutes Allow cable to burn until self-extinguished
13 IEEE 383 VTFT Requirement Cable damage cannot reach the top of the specimens. (< 6 feet damage)
14 1974 to 2003 Additional issues, such as Synergistic effects Factory Splices Fire Resistance Multiconductor qualification
15 IEEE Not intended to require re-qualification Type Testing still preferred Emphasizes other methods of qualification Past operating experience Ongoing qualification Qualification by analysis
16 IEEE Changes Vertical Tray Flame Test procedure removed and refers to IEEE Synergistic effects Factory splice qualification Multiconductor qualification Class 1E qualification for normal service must be demonstrated separately from DBE qualification
17 1202 vs VTFT Comparison Both 70k BTU/hr IEEE 1202 Increased Tray loading Decreased spacing (> 1 cables) Bundled small diameter cables (< 0.5 ) Less damage allowed (4.9 ft vs 6 ft) Burner angle (20 ) Test Enclosure Forced Ventilation
18 Tray Loading and Spacing diameter 4 cables 0.6 spacing min. 1.2 diameter 5 cables 0.5 spacing ~8.5 to 11
19 Tray Loading and Spacing diameter 14 cables diameter 10 groups of 3 30 cables ~9 to 11
20 Tray Loading OD = cables cables
21 Cable OD cables fill = 9.7
22 1202 Test Enclosure Sketch from IEEE
23 P/F 383 PVC jacketed power cable 1202
24 Class 1E Qualification Program for a Instrumentation, Control, LV Power & Medium Voltage EPR Insulations 1. Industry Standard Tests 2. LOCA Test 3. Normal Operation Test 4. HELB Test 5. Vertical Tray Flame Test
25 Class 1E Qualification Program EPR-N 1. Industry Standard tests ICEA & UL requirements 1/C: Listed as RHW-2, XHHW-2, X110 VW-1 & Oil Resistant M/C: Listed as Type TC
26 Class 1E Qualification Program MV EPR 1. Industry Standard tests ICEA S & S UL 1072
27 Class 1E Qualification Program EPR-N Insulation 2. LOCA Test Sample selection: Single Conductors: #14 AWG (7x) Cu, EPR-N #16 AWG (7x) Cu, EPR-N Six colors
28
29 Class 1E Qualification Program EPR-N Insulation 2. LOCA Test Sample selection: M/C 3/C #14 AWG Cu, EPR-N, cabled, binder tape, TS-CPE jacket 3/C #14 AWG Cu, EPR-N, cabled, binder tape, CSPE jacket 1 Pr #16 AWG Cu, EPR-N, #18AWG drain wire, Cu laminate tape, XLPO jacket
30
31 Class 1E Qualification Program MV EPR Insulation 2. LOCA Test Sample selection: 1/C #6 AWG Cu, SC-EPR, MV EPR, SC-EPR, Cu tape, cable tapes, TS- CPE jacket
32
33 Class 1E Qualification Program 2. LOCA Test Non aged specimens Aged specimens Radiation 50 Mrads (gamma) Thermal C C
34 Class 1E Qualification Program 2. LOCA Test Accident radiation dose Mrads Current & voltage loaded Temp-Pressure-Chem Spray profile Charging current monitored Periodic IR measurements
35 LOCA Profile
36 Margins Double peak Voltage: ø-ø Rated voltage applied ø-grd Radiation Normal aging: 50 Mrads - gamma Accident: 150 Mrads - gamma Thermal Aging: 60 years
37 Class 1E Qualification Program LOCA Test EPR-N Specimens 42 1/C wires Six 3/C cables Three 1 Pr cables LOCA Test MV EPR Specimens Three 1/C cables
38 LOCA Test Specimens 42 1/C wires Six 3/C cables Three 1 Pr cables Three 1/C cables
39 Class 1E Qualification Program 3. LOCA Test Results All samples: Maintained voltage & current Withstood Post-LOCA Simulation Test Straighten & Recoil (40 x OD) 80 v/mil ac withstand
40 IR IR Mohms-1000 Mohms-1000 ft ft Class 1E - Qualification Program 3. Post LOCA Test Results Post LOCA Long Term Moisture #14 #16 AWG 0.025" 0.030" EPR-N IR values are avg of 2 specimens IR values are avg of 2 specimens Time Time - - months months Non-Aged Non-Aged
41 Class 1E - Qualification Program 3. Post LOCA Test Results Instrumentation jacket integrity Specimen Jacket Resistance - Vdc after 1 minute Charging Current 600Vac after 1 minute Unaged 3.5 E3 < 1 ma 3 150C 2 165C 1.5 E6 < 1 ma 4.3 E1 < 1 ma
42 Class 1E Qualification Program 3. Normal Operation Test Sample selection: Single Conductors #16 AWG (7x) EPR-N six specimens #6 AWG Cu, SC-EPR, MV EPR, SC-EPR, Cu tape, cable tapes, TS-CPE jacket three specimens
43 Class 1E Qualification Program 3. Normal Operation Test Aging Radiation 50 Mrads (gamma) Thermal C C
44 Class 1E Qualification Program 3. Normal Operation Test Mechanical & Voltage Withstand Straighten 20 x OD bend 80 volt/mil ac withstand test
45 Class 1E Qualification Program 4. HELB Test Specimens #16 AWG Cu, EPR-N #6 AWG Cu, SC-EPR, MV EPR, SC-EPR, Cu tape, cable tapes, TS-CPE jacket
46 Class 1E Qualification Program 4. HELB Test Non-aged & aged specimens Temp Press Chem spray profile Current & voltage loaded Charging current monitored Periodic IR measurements
47 Temperature (F) High Energy Line Break Test Temperature / Time Profile HELB Temperature Profile Time (Seconds)
48 HELB EPR-N Test Specimens
49 Class 1E Qualification Program 4. HELB Test Results All samples: Maintained rated voltage & current Withstood Post-LOCA Simulation Test Straighten & Recoil (40 x OD) 80 v/mil ac withstand
50 Class 1E Qualification Program 5. IEEE 1202 VTFT Test Results 600 V Constructions: 3/C #14 AWG EPR-N, cabled, binder tape, TS-CPE jacket 3/C #14 AWG EPR-N, cabled, binder tape, CSPE jacket 1 Pr #16 AWG EPR-N, #18 AWG drain wire, Cu laminate tape, XLPO jacket
51 Class 1E Qualification Program 5. IEEE 1202 VTFT Test Results 2 kv Constructions: 3/C #14 AWG EPR-N, cabled, binder tape, TS-CPE jacket 3/C #14 AWG EPR-N, cabled, binder tape, CSPE jacket 1/C #6 AWG EPR-N
52 Class 1E Qualification Program 5. IEEE 1202 VTFT Test Results 5 kv Construction: #2/0 AWG Cu, SC-EPR, MV EPR, SC-EPR, Cu tape, cable tapes, TS- CPE jacket
53 EPR-N Qualification Reports Engineering Report # 526 Class 1E Qualification of Okonite FMR-N Insulated Cables For Nuclear Power Generation Stations MV EPR Engineering Report # 527 Class 1E Qualification of Okoguard Insulated Cables For Nuclear Power Generation Stations
54 IEEE Summary Re-qualification not required Allows other types of qualification Addressed 74 to 03 issues VTFT (1202) more severe Qualification Test Program EPR-N & MV EPR insulations qualified to & for Normal, LOCA, HELB & IEEE and 60 year accelerated aging
55 Any Questions? The Okonite Company Ramsey, NJ 55
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