ML091120183

Unit 2 - Additional Information Regarding WBN Unit 2 Corrective Action Programs

ML091120183
Person / Time
Site:	Watts Bar
Issue date:	04/06/2009
From:	Bajestani M Tennessee Valley Authority
To:	Document Control Desk, Office of Nuclear Reactor Regulation
References
TAC MD9182, TAC MD9424
Download: ML091120183 (148)

Text

Tennessee Valley Authority, Post Office Box 2000, Spring City, TN 37381-2000 April 6, 2009 10 CFR 50.54f U.S. Nuclear Regulatory Commission ATTN: Document Control Desk Mail Stop: OWFN P1-35 Washington, D.C. 20555-0001 In the Matter of

)

Docket No. 50-391 Tennessee Valley Authority

)

WATTS BAR NUCLEAR PLANT (WBN) - UNIT 2 - ADDITIONAL INFORMATION REGARDING WBN UNIT 2 CORRECTIVE ACTION PROGRAMS (TAC NO. MD9182 and MD9424)

The purpose of this letter is to provide additional information regarding the following WBN Unit 2 Corrective Action Programs (CAPs): Cable Issues, Electrical Issues, Quality Assurance (QA) Records and the Replacement Items Program (Piece Parts). The CAPs are discussed in Reference 1, section 1.13.1, under items (1) Cable Issues, (5) Electrical Issues, (13) QA Records, and (15) Replacement Items Program, respectively.

Regarding the Cable Issues Program, TVA submitted a proposed approach to resolution of sub-issues of the Cable Issues CAP at WBN Unit 2 different from the approach used for WBN Unit 1 to the NRC on May 29, 2008 (Reference 2). TVA submitted a proposed approach to resolve sub-issues of the Cable Issues CAP using the WBN Unit 1 approach on September 26, 2008 (Reference 3). In Reference 4, the NRC requested additional information. TVA responded to the NRC's request for additional information on January 14, 2009 (Reference 5). Subsequently, a teleconference was held on February 10, 2009, and a public meeting on March 17, 2009 (Reference 6). At the public meeting, TVA presented information to answer the questions from the teleconference. provides the NRC questions from the February 10 teleconference and TVA's responses. Enclosure 2 provides TVA responses to additional NRC questions provided at the March 10 public meeting.

Printed on recycled paper

U. S. Nuclear Regulatory Commission Page 2 April 6, 2009 TVA submitted a proposed approach to resolve sub-issues of the Electrical Issues CAP using the WBN Unit 1 approach on September 26, 2008 (Reference 3). The Electrical Issues CAP was also discussed at the public meeting that was held on March 17, 2009 (Reference 6). Enclosure 2 provides TVA responses to NRC questions pertaining to the Electrical Issues CAP that were raised at the March 17 public meeting.

In Reference 3, TVA requested NRC close the QA Records CAP. In Reference 7, NRC requested additional clarification. Based on a subsequent discussion, TVA will statistically sample the WBN Unit 2 QA records by record type to determine their retrievability, storage integrity and completeness. TVA will resolve any technical or quality problems found.

In Reference 3, TVA requested NRC review and approval of the approach for closing the Replacement Items CAP. In Reference 6, NRC requested additional clarification. Based on a subsequent discussion, TVA will perform back checks of the previously installed replacement items to ensure that a proper documentation trail exists from the warehouse to maintenance history for each of the small number of safety-related components that are not refurbished. provides the listing of open actions required for licensing made in this letter and in Enclosures 1 and 2. 1 declare under penalty of perjury that the foregoing is true and correct. Executed on the 6 th day of April, 2009.

If you have any questions, please contact me at (423) 365-2351.

Sincerely, Masoud Baj~e ni Watts Bar t2 Vice Preside nt Enclosures cc (See page 4):

U. S. Nuclear Regulatory Commission Page 3 April 6, 2009

References:

1.

NRC Safety Evaluation Report Related to the Operation of Watts Bar Nuclear Plant, Unit 2 NUREG-0847 Supplement 21, February 2009

2.

TVA letter dated May 29, 2008, 'Watts Bar Nuclear Plant (WBN) -

Unit 2 - Cable Issues Corrective Action Program for Completion of WBN Unit 2" (T02 080529 001)

3.

TVA letter dated September 26, 2008, 'Watts Bar Nuclear Plant (WBN)

- Unit 2 - Regulatory Framework for the Completion of Construction and Licensing Activities for Unit 2 - Corrective Action and Special Programs, and Unresolved Safety Issues" (T02 080926 001)

4.

NRC letter dated November 25, 2008, "Watts Bar Nuclear Plant - Unit 2

- Request for Additional Information Regarding Cable Issues Corrective Action Program (JAC NO. MD9182)" (A02 081203 001)

5.

TVA letter dated January 14, 2009,'Watts Bar Nuclear Plant (WBN) -

Unit 2 - Response to Request for Additional Information Regarding Cable Issues Corrective Action Program (TAC NO. MD9182)"

(J02 090114 001)

6.

2009/03/17 - Slides and Handouts from TVA Public Meeting (ADAMS Accession No. ML090771062)

7.

NRC letter dated February 11, 2009, "Watts Bar Nuclear Plant - Unit 2

- Status of Regulatory Framework for the Completion of Corrective Action and Special Programs and Unresolved Safety Issues (TAC NO.

MD9424)" (A02 090223 001)

U. S. Nuclear Regulatory Commission Page 4 April 6, 2009 cc (Enclosures):

Lakshminarasimh Raghavan U.S. Nuclear Regulatory Commission MS 08H4A One White Flint North 11555 Rockville Pike Rockville, Maryland 20852-2738 Patrick D. Milano, Senior Project Manager (WBN Unit 2)

U.S. Nuclear Regulatory Commission MS 08H4 One White Flint North 11555 Rockville Pike Rockville, Maryland 20852-2738 Loren R. Plisco, Deputy Regional Administrator for Construction U. S. Nuclear Regulatory Commission Region II Sam Nunn Atlanta Federal Center, Suite 23T85 61 Forsyth Street, SW, Atlanta, Georgia 30303-8931 U. S. Nuclear Regulatory Commission Region II Sam Nunn Atlanta Federal Center 61 Forsyth Street, SW, Suite 23T85 Atlanta, Georgia 30303-8931 NRC Resident Inspector Unit 2 Watts Bar Nuclear Plant 1260 Nuclear Plant Road Spring City, Tennessee 37381 Response to Cable Issues Questions as a Result of February 10, 2009 Conference Call

1. NRC Question 5j, page 27: NRC questioned the calculated length of cable 2PP675A. NRC calculated circuit as 2732 (a), 2722 (b) and 2772 (c) ft. vs TVA calculation (ICRDS) of 4787 ft.

TVA Response:

See Enclosure 2, Section 11, "CCRS Software and Database Verification and Validation"

2. NRC Question 4a, page 21: TVA to provide additional clarification that the condulet was used as a pull point and that the size of the opening was enough to not cause a problem with the bend radius of the cable. Also confirm that 909 condulet was only used for /& C cable.

TVA Response:

Ninety-degree condulets were used in other applications in addition to instrumentation and control cables. The cables that were of concern for the "pull through" issue were smaller gauge cables, since it is impractical to "pull through" larger gauge cables.

As part of the Bend Radius Baseline verification, condulet sizes are being determined for all conduits containing safety-related cable. Sizes will be validated against current TVA standards.

3. NRC Question 5k, page 28: NRC requested additional clarification on the note that indicated further research is needed to determine the exact insulation type.

TVA Response:

This note was added to non-environmentally qualified (EQ) cables that had the same mark number as EQ cables. EQ cables must have a documentation trail to the original contract to ascertain a trail to a specific manufacturer and applicable EQ test. TVA ONMark is used to connect non-EQ cables to data pertinent for calculation basis, such as insulation type, number of conductors, gauge, etc.

This note only makes the user of the Integrated Cables and Raceway Design System (ICRDS) aware of the fact that the EQ collected data for cable with a similar mark number is not applicable to this particular cable.

4. NRC Question la, page 3: Confirm cables were typically hand pulled and that no indications of jamming occurred. Staff finds TVA's methodology based on a single conductor is too restrictive. High tensions from jamming are not included in the TVA pulling tensions calculations that go into calculating SWBP. Therefore the staff finds that TVA's selection process is questionable. Based on this TVA must confirm that all safety-related cables were hand pulled or, if not hand pulled, 1

describe how pulling tensions were monitored for potential jamming and how deviations between calculated and actual pulling tensions were justified.

TVA Response:

See the responses to Questions a and b under "Jamming" in Enclosure 2.

5. NRC Question lb, page 5: NRC requested the voltage level and cable size for the 6 cables in the chart.

TVA Response:

Cable No:

Manufacturer Type Size 1 PL4961A Triangle XLPE w/ PVC 3-1/C-400MCM, jacket 600V 1PL4975A Triangle XLPE w/ PVC 3-1/C-400MCM, jacket 600V 1PL4982B Brand Rex XLPE w/ PVC 3-1/C-400MCM, jacket 600V 1PL4985B Okonite EPR w/ICSPE 3-1/C-400MCM, jacket 600V 2PL4975A Okonite EPR w/ICSPE 3-1/C-400MCM, jacket 600V 2PL4978A Okonite EPR w/ICSPE 3-1/C-400MCM, jacket 600V The complete list of cables including their size, type, voltage delineated in calculation WBPEVAR8905050, Table 4.1.

level, and length is

6. NRC Question 1d, page 6: NRC requested additional information on the exception to G-38. Provide the date of the exception and describe how the 6 to 10 foot interval taping or tying was achieved.

TVA Response:

Exception G-38-WBN-32 was approved on March 3,1994.

As documented in Exception G-38-WBN-32, this was a pull of less than 70 feet in a 5-inch conduit. DCN W-29725-A included design work to install cables 1 PP1 042 and 1 PP1 043 from containment penetration 1 -PENT-293-4 to the WBN Unit 1 reactor coolant pump motor 1 -MTR-68-73. There is no documentation in the implementing work order (WO) 94-04231-00 with respect to how the taping or tying the cable at 6-10 foot interval was achieved. However, because the evidence shows that all three conductors of these cables were cut from one reel (Reel No. WB1 5554), it is logical to conclude that three 70-foot length pieces, one conductor for each phase A, B, and C, were cut and then shaped into triplex formation before the cable was pulled. Page 43 of the WO documents that Nuclear Engineering (NE) instructions were followed and an NE cable specialist witnessed the cable pull. Please note that Exception G-38-WBN-32 was written 2

for a Unit 1 cable. There are no exceptions in G-38 against Unit 2 cables. In the future, if there are any exceptions, the requirements of G-38 will be followed.

7. NRC Question 2a, page 11: Type and size of the four cables. When was parachute cord used at WBN?

TVA Response:

2PS284D: 1/2C No. 14AWG, Copper, Insulation Type PXMJ: 600V; Mark Number WHB-1 2PM516D: 1/4C No. 16AWG, Insulation Type MS: 300V; Mark Number WVC 2PM871 D: 1/4C No. 16AWG, Insulation Type MS: 300V; Mark Number WVC 1M2451B: 1/2C No. 14AWG, Copper, Insulation Type PXMJ: 600V;Mark Number WHB-1 A review of specification G-38, revision 2, shows that for cables No. 4 AWG and smaller the specification permitted use of twine or fish line with a known "break" test of less than maximum tension specified for the cable size. For cables larger than No. 4 AWG, specification permitted use of Manila Rope or reliable break-links of known break strength in place of break ropes. WBN cannot establish the time frame when parachute cord was used to pull cables into conduits.

8. NRC Question 2d, page 13: NRC wants the test report for the coefficient of friction. Justify deviations from the 1185 recommendations for a successful cable pullby (65% vs 20% fill). Also describe what happened to conduits with between 60% an'd 65% fill.

TVA Response:

See response to Question e under Jamming in Enclosure 2 for discussion on friction test.

Conduits were categorized in fill groups. The 60% fill group included cables between 55.00 to 64.99%.

For the WBN Unit 2 project, a review of 5,279 Unit 2 safety-related conduits shows that 5,012 conduits are less than or equal to 40% full. Thus, approximately 95% of the total number of Unit 2 safety-related conduits are within the fill range allowed by G-38/G-40 (i.e., less than or equal to 40% full)..

Engineering has documented an exception to the requirement of design criteria WB-DC-30-22 for the remaining 267 overfilled conduits. This is based on current as-designed data.

For conduits in the pullby evaluation, which are moderate and high risk, cables are eliminated based on the following factors:

They have not experienced a pullby, They are less than 20 feet long, or They are being replaced.

3

There are 8 conduits with fills greater than 35% and 3 conduits with fills greater than 40% using as-installed data. None are greater than 49%. These overfill conditions are justified in ICRDS.

The moderate and high-risk conduits have had the as-constructed data compiled (cables not pulled and actual conduit size identified). For low-risk conduits, the as-constructed data is still being compiled. It is expected that the as-constructed fill will be less than the as-designed fill in many cases.

9. NRC Question 2e, page 14: How many cables in the 492 cable segments were high-pot tested?

TVA Response:

441 cables were tested.

The complete list of cables that were hi-pot tested to validate the threshold between low risk category and moderate risk category can be found in calculation WBPEVAR9006013, Attachment P2. Note that no low risk cables failed the hi-pot test as a result of pullby damage.

10. NRC Question 3b, page 17: What do the cable manufacturers do to meet the purchase specifications? Describe how TVA confirmed that the cable manufacturers met the purchase specification (e.g., SWBP).

TVA Response:

For current 1 E cable purchases, the allowable sidewall pressure is specified in the Certificate of Compliance from the vendor.

11. NRC Question 3d, pages 17-19: Provide the cable types, manufacturers and construction details (size and number) for the 52 conduits.

TVA Response:

The requested information is shown in the table that follows. The manufacturer listed is based on the current as-designed data. The as-constructed Unit 2 data is in the process of being compiled, and therefore, the manufacturer listed is subject to change. Additionally, many of the cables have been subsequently re-pulled or deleted for various reasons. Therefore, the manufacturer for the cables present during the SWP evaluation may not be available. This is noted by N/A.

No.

Conduit No.

Mark Cable No.

Size Manufacturer Number Cables Number Type Cond.

25 WVK MS 2

16 TIME/Anaconda/N/A 3

WVA MS 2

16 TIME/Anaconda 2

2PM6426D 4

WVA MS 2

16 N/A 2

WVA MS 2

16 N/A 3

2PM6444E 2

WVC MS 2

16

_ 1 4

WHB-1 PXMJ 2

14 4

4 2PM7269G 7

WVA MS 2

16 Eaton/Anaconda 4

WTK COAX 23 N/A 2

WWK COAX 20 5

2PM7400B 2

vW COX0 1

WVB XLPE 3

16 19 WVA MS 2

16 3

WWK COAX 20, N/A 22 WVA MS 2

16 6

2 P M 74 0 1A 1

W Y B L E 3

16 1

WvVB XLPE 3

16 4

WTK COAX 23 7

2PM7869D 1

WVA MS 2

16 N/A 8

2PM7872F 1

WVA MS 2

16 N/A 9

2PS704E 4

WHB-1 PXMJ 2

14 AIW 10 2RM438A 2

WTK COAX 23 N/A 14 WHB-1 PXMJ 2

14 N/A 3

WHC-1 PXMJ 3

14 2

WHE-1 PXMJ 5

14 1

WGK PJJ 12 12 1

WGM PJJ 16 12 Cyprus 12 2M3360A 1

WFG-1 PXMJ 7

10 Okonite 1'

WGH PJJ 9

12 Cyprus 2

WHD-1 PXMJ 4

14 N/A 2

WHB-1 PXMJ 2

14 1

WHG-1 PXMJ 7

14 2

WGD-1 PXMJ 4

12 1

WFH-1 PXMJ 9

10

__2 WGG-1 PXMJ 7

12 14 2PLC1184A 1

WHC PJJ 3

14 Cyprus 1

WHB-1 PXMJ 2

14 AIW 1

WHC PJJ 3

14 Cyprus 15 2PLC1185B 1

"C PX 2

14 MW 1

WHB-1 PXMJ 2

114 AIW 1

WHE PJJ 5

14 N/A 16 2PLC1928CWHB-PXMJ 2

14 10 WHB-1 PXMJ 2

14 N/A 1

WHC PJJ 2

14 1

WVA MS 2

16 2

WLN CPJJ 2

10 17 2PLC215B 1

WB PJ 2

1 1

WGB PJJ 2

12 1

WGC-1 PXMJ 3

12 1

WGC PJJ 3

12 2

WHE-I PXMJ 5

14 1

WGD PJJ 4

12 Cyprus 4

WGB-1 PXMJ 2

12 AMW 18 2PLC2303A 1

WHB-1 PXMJ 2

14 AIW 2

WHC PJJ 3

14 Cyprus 1

WGE PJJ 5

12 Cyprus 19 2PLC2519A 3

WDO CPJ 1

400 N/A 20 2PV825E 2

WLN CPJJ 2

10 Plastic 2

WDE-1 PXJ 1

6 AIW 21 2VC1259B 10 WPA SROAJ 1

14 Rockbestos 22 2VC2035B 1

WGE PJJ 5

12 Cyprus-5

1 WGC-1 PXMJ 3

12 AIW 1

WGB-1 PXMJ 2

12 N/A 23 2VC2069B 1

WGB PJJ 2

12 1

WGK-1 PXMJ 12 12 4

WHL-1 PXMJ 16 14 Okonite/Plastic 1

WHH PJJ 9

14 Cyprus 25 2VC2577A 8

WPA SROAJ 1

14 N/A 26 2VC2650B 6

WHB-1 PXMJ 2

14 Rockbestos/AIW/Later 27 2PLCI136A 3

WPJ SROAJ 1

1/0 Rockbestos 28 2PLC1276A 3

WDO CPJ 1

400 N/A 29 2PLC1280B 3

WDH-1 PXJ 1

1/0 N/A 1

WGC-1 PXMJ 3

12 N/A 1

WMT CPJJ 3

12 31 2PLC2763A 3

WDO CPJ 1

400 N/A 32 2PLC2766A 3

WDO CPJ 1

400 N/A 33 2PLC2841B 3

WDO CPJ 1

400 Okonite 34 2PLC2844B 3

WDO CPJ 1

400 General Cable 35 2PLC2850A 3

WDO CPJ 1

400 N/A 36 2PLC2855A 3

WDO CPJ 1

400 N/A 37 2PLC2882A 3

WIDO CPJ 1

400 Plastic 36 2PLC2922B 3

WDO CPJ 1

400 Plastic 39 2PLC631B 1

WLO CPJJ 1

10 Plastic 40 2PLC852A 3

WDO CPJ 1

400 AIW/General Cable 41 2PLC853B 3

WDO CPJ 1

400 General/Plastic /Later 42 2PLC860A 3

WDQ CPJ 1

750 Plastic 1

WFC-1 PXMJ 3

10 AIW 43 2VC1078A 2

WLO CPJJ 3

10 Plastic 1

WGC-1 PXMJ 3

12 AIW 1

WFC-1 PXMJ 3

10 AIW 44 2VC1083B 2

WLO CPJJ 3

10 Plastic 1

WGC-1 PXMJ 3

12 AIW 45 2PP2183A 3

WNB-1 ESPJ 1

2/0 Anaconda 46 2PP2190B 3

WNB CPSJ 1

2/0 Anaconda 47 2PP2191A 3

WNB CPSJ 1

2/0 Anaconda 48 2PP2291A 3

WNB CPSJ 1

2/0 N/A 49 2PP2292A 3

WNB CPSJ 1

2/0 N/A 50 2PP2296B 3

WNB CPSJ 1

2/0 N/A 51 2PP2297B 3

WNB CPSJ 1

2/0 N/A 52 2PP2656A 3

WNB CPSJ 1

2/0 N/A

12. NRC Question 3g, page 19: How was the SWBP corrected for 1B1054G, additional information needed on DCN M-14241 ?

TVA Response:

Conduit 1 BI 054G was reworked in accordance with Design Change M-1 4241 -A as follows:

6

a. Cables 1 B26G, 1 B27G, 1 B31 G and 1 B32G were removed from the conduit 1 B1 054G and replaced.

b. Conduit 1 B1 054G was removed in its entirety.

c. In addition to a shortened 1 B1 054G, two new conduits and two new pull boxes were added to the installation to reduce the length between pull points and hence, sidewall bearing pressure (SWBP).

13. NRC Question 3h, page 20: Provide additional clarification on the sample. How many cables in the 40 conduits?

TVA Response:

The total number of cables in the 40 conduits was 203.

TVA calculation WBPEVAR8603006, Section 5.1, describes the overall program for the resolution of the SWBP issue. TVA established a "smart" sample program

• that involved approximately 10,400 conduits containing Class 1 E cables from voltage levels V2, V3, V4, and V5. Screening calculations were performed to reduce this number to 1,914 conduits containing Class 1 E cables with potential of exceeding the cable SWBP.

After one failure was identified out of 81 conduits in the original sample, the NRC staff asked TVA to walk down an additional 40 conduits in harsh environment to confirm that no other violations of SWBP occurred. The available population included:

Total number of conduits with potential of exceeding SWBP:

1,914 Number of conduits initially walked down to select 81 worst cases:

727 Remaining number of conduits: (1914-727):

1,187 The process of random sample selection is documented in TVA calculation WBPEVAR901 0001, page 11. It included the following steps:

The list of 1,187 conduits was entered into a database. This file was printed out to identify a record number for each of the 1,1 87 records. Random numbers were then generated and compared to the record numbers in the database file.

The corresponding conduit identifiers were then cross-checked against TVA's Computerized Cable Routing System (CCRS) and the plant environmental drawings to determine those conduit records that had no open design change against them. This cross-check resulted in 40 conduits located in harsh environment with no design change against them.

TVA has previously described the entire population in the sample, which included 121 conduits (81 + 40), a statistically significant sample.

7

14. NRC Question 6a, page 29: Confirm that all cables important to safety are included in the WBN Unit 2 CAP program.

TVA Response:

The cables included in the Unit 2 Cable Issues CAP are safety related, as well as EQ and Appendix R cables. Associated cables are evaluated for appropriate electrical separation.

8 Response to Cable Issues and Electrical Issues Questions from the March 17, 2009 Public Meeting

1. Silicone Rubber Insulated Cable NRC Question a: TVA to provide the number of silicone rubber insulated conduit samples taken from Unit 1 and Unit 2.

TVA Response:

Silicone rubber insulated cables manufactured by Anaconda and Rockbestos Corp.

were installed in the WBN Unit 1 and Unit 2 reactor buildings. These cables have 45 mils of silicone rubber insulation covered by either an asbestos fiber braid jacket or an Aramid fiber braid jacket. Units 1 and 2 cables were pulled using the same procedures and by the same personnel, with Unit 2 cable being pulled within approximately six months after Unit 1 cable. The testing samples consisted of five (5) critical case conduits containing Anaconda cable and five (5) critical case conduits containing Rockbestos cable. The following table shows the conduits selected from each unit.

Cable Manufacturer No. of Unit 1 No. of Unit 2 Conduits conduits Rockbestos samples 5

Anaconda samples 2

3 NRC Question b: TVA to provide the total number of silicone rubber insulated cables installed in Unit 2.

TVA Response:

The following table provides the quantity of silicone rubber insulated cables in Unit 2.

Voltage Level No. of Cables V4-Low Voltage Power 52 V3-Control Power 419 V2-Sheilded cables carrying medium-level signals 0

V1 -Shelded cables carrying low-level signals 0

Total 471 NRC Question c: TVA to provide the process/justification used to qualify Unit 2 cables for 40 year life.

TVA Response:

With respect to EQ testing of the silicone rubber insulated cables, the samples of Anaconda and Rockbestos cables removed from WBN Units 1 and 2 were sent to Wyle Laboratories for testing. These samples were aged according to the plant's 1

environmental conditions. The samples were then subjected to a simulated loss of coolant accident environment, including steam/chemical spray. After completion of the accident simulation, the cables were subjected to a mandrel re-bend and a successful hi-pot withstand test for margin assessment.

The silicone rubber insulated cables are rated at 125' C. Although these cables have been installed in situ for over 25 years, most of the Unit 2 cables have never been energized and have remained in an ambient environment. This situation is no different than if a reel of these cables was stored in the warehouse for that duration.

As part of the EQ program, the impact on life due to external heating, i.e., ambient temperatures, will be assessed. It is expected that this impact will be minimal since the ambient temperature is significantly less than the cable rating.

2. Jamming NRC Question a: TVA to provide the results of their review of cable pulling techniques including hand pulled versus assisted pull findings.

TVA Response:

TVA Quality Control Procedure WBNP-QCP-3.5, paragraph 6.3.5.2 required the responsible engineer to provide the following pulling instructions for individual cables on the cable pull slip:

Maximum allowable pull tension in lbs.

Rope pull device size.

Indicate if the pull required power assist.

Special pull instructions.

The WBN Unit 2 project is reviewing cable pull slips for each Class 1 E cable to verify and validate their as-installed configuration. The project is also reviewing the pull slip for each Class 1 E cable to determine if a power assist pull was documented for that cable by the responsible engineer. As of March 25, 2009, the project has reviewed approximately 1,400 cables out of a total Unit 2 Class 1 E cable population of approximately 4,000. This review has found no Unit 2 Class 1 E cable that was pulled using a power assist pull.

NRC Question b: If cases are found where cables were assisted pull, provide the evaluation methodology for ensuring jamming did not occur.

TVA Response:

If a single-conductor Class 1 E cable is found to be installed using a power assisted pull, TVA will evaluate the controls in place during the pull and the jam ratio of the cable. Appropriate corrective action will be taken based on this evaluation. The evaluation and corrective action will be available for review.

NRC Question c: TVA to provide a discussion of the technique for taping single conductors into a triplex configuration along with clarification that the cables in question were reactor coolant pump cables.

2

TVA Response:

As documented in Exception G-38-WBN-32, this was a pull of less than 70 feet in a 5 inch conduit. DCN W-29725-A issued a design to install cables 1 PP1 042 and 1 PP1 043 from containment penetration 1 -PENT-293-4 to the WBN Unit 1 reactor coolant pump motor 1 -MTR-68-73. There is no documentation in the implementing WO 94-04231 -00 with respect to how taping or tying the cable at 6-10 foot intervals was achieved. However, because the documentation shows that all three conductors of these cables were cut from one reel (Reel No. WB1 5554) it is logical to conclude that three 70-foot lengths, one conductor for each phase A, B and C, were cut and then shaped into triplex formation before the cable was pulled. The WO documents that NE instructions were followed and a NE cable specialist witnessed the cable pull.

NRC Question d: Explain why single conductor cables are more likely to jam as compared to the multi-conductor cables.

TVA Response:

IEEE 690-1984 describes the critical jamming ratio as follows:

'When three single-conductor cables are pulled into a conduit it is possible for the center cable to be forced between the two outer cables, when being pulled around a be nd.....................

The technical basis for the above statement is as follows:

Single conductor cables, especially conductor size larger than 1/0 AWG, are very stiff and require a high pull tension to pull them through a conduit. High pull tension can result in excessive SWBP. Because these large conductors are under excessive pull tension, there is greater likelihood that the middle conductor will slip between the two outer conductors when going around a bend thus resulting in a jam. This is especially true if D/d (where D is conduit inside diameter and d is cable outside diameter) approaches 3. When jamming occurs, the pull tension increases exponentially. On the other hand, the multi-conductor cables consist of several individually insulated small conductors with foam or fiber filling the interstices between conductors to provide a round cable shape. Because of this construction, the multi-conductor cables are more pliable and change shape to fit in the available space, making them less likely to jam. Therefore, industry is more concerned with large single conductor cable pulls. Single conductor cable pulls are used for distribution system applications and are generally used as 3 single conductor feeders for auxiliary power distribution in nuclear power plants.

NRC Question e: TVA to provide a discussion of how the coefficient of friction was determined and supporting docketed documentation.

3

TVA Response:

To determine static and kinetic coefficients of friction for cable-to-cable friction with and without lubricant, TVA performed testing in 1989 using the inclined plane method with low normal loads.

The tests were performed with only the weight of the cable sample as a load and two or more cables of one jacket material as the bearing surface. The cable surfaces were made as flat and straight as possible. The test set had cables of each jacket type as a bearing surface for each type of cable to be tested. The sample cables were 6 inches long for each jacket for testing with and without lubricant.

Each test was repeated at least ten times to ensure sufficient data for an average, which became the recorded coefficient of friction for that set. This was done with and without lubricant for static and kinetic coefficients of friction.

The results were presented to NRC at a meeting on November 17, 1989, and submitted to NRC on December 20, 1989, as part of the resolution plan for Unit 1.

NRC Question f: How many Unit 2 conduits were included in the total population of 76 conduits walked down to resolve the jamming issue?

TVA Response:

Thirty nine (39) conduits were Unit 1 conduits and thirty seven (37) conduits were Unit 2 conduits.

3. Support in Vertical Conduits NRC Question a: TVA to provide a definition and characterization of "rework" regarding conduits.

TVA Response:

Rework means that the installation will be modified such that it meets the requirements of TVA specifications. In this case, the specification is G-38, "General Construction Specification for Installing Insulated Cables Rated up to 15,000 Volts",

Section 8.7.1, "Cables Routed in Vertical Conduits-Support Intervals." This section provides the spacing requirements for vertical conduit supports. Cable supports will be added to ClasslE conduits according to the methods described in Section 8.7.2 of G-38, which includes selection of support type and installation practices.

NRC Question b: TVA to provide a justification for the determination that "creep" did not occur in the vertical conduits.

TVA Response:

As discussed in the response to Question c, the "looseness" of the cable will be assessed to demonstrate that the cable was subjected to minimal pressure.

Calculation WBPEVAR9005001 assessed the impact of the SWBP on the cable at the transition due to the weight of the cable vertical drop. This was done based on 4

the cable being at rated temperature. The Unit 2 specific cables have been de-energized and therefore have been at a much lower temperature than rated. This lower temperature, in conjunction with the verification that the cable is "loose,"

provides assurance that insulation creep has not occurred.

NRC Question c: TVA to provide the basis for "hand-lifting" cables.

TVA Response:

Class 1 E cables are supported at or near the top of a conduit run by the curvature of a conduit, the inside radius of condulets, or a pull box. A visual inspection of those conduits that do not meet the G-38 vertical support requirements will be conducted to determine if the cables are loose. This will be measured by a craft's ability to lift the cables off the support point with one hand and without mechanical assistance. The basis for this is that looseness of the cable indicates an insignificant pressure on the cable jacket that is in contact with the surface supporting it. If the cables are found to be under tension, which is indicated by the craft's inability to lift them off the support point, the portion of these cables that has stayed under tension since their original installation will be replaced.

4. Support in Vertical Tray NRC Question a; TVA to amend the submittal to summarize how the vertical cable trays were assessed to determine that no. cable damage occurred.

TVA Response:

WBN performed the following actions to determine that no damage occurred to the safety-related cables in long vertical tray runs:

a. Identified those families of cable trays containing safety-related cables where the potential existed that an adequate support was not provided to meet the recommended requirements of NEC (1987) Article.300-1 9.

b. Performed walkdowns of the trays to determine their exact configuration.

c. Where the length of the vertical drop exceeded the support requirement stipulated in the NEC and a discrete support was not present, prepared a calculation to determine the impact of unsupported load with respect to cable and any connected equipment at the top resulting from (1) the weight on the copper conductors and potential for the load to stretch the copper; (2) pullout of conductors from crimped lugs at termination; (3) potential cutting of cables by tie wraps used to secure cables in trays; and (4) static SWBP at support points.

d. Issued design changes to add tray supports where required.

NRC Question b: TVA to provide a discussion that codifies that no credit was taken for tie-wraps to support vertical cables.

TVA Response:

TVA Specification G-38, Section 8.6.3.2, allows the use of cable tie wraps for the following applications:

(a) Where required to maintain a neat orderly arrangement of cables. Cable ties shall be installed at intervals not exceeding 10 feet.

5

(b) To maintain required nominal spacing between medium-voltage circuits.

TVA calculation WBPEVAR9005001 states that no credit is taken for full support from tie wraps due to lack of EQ of the wraps, and a review of the calculation shows that no credit was taken for such support. This calculation also evaluates the effect of the horizontal section above a vertical tray section. It states that the presence of the cable ties, Vimasco, and fire stops in a horizontal section is considered in establishing a coefficient of friction. However, credit cannot be taken for cable ties in a horizontal section to provide support to a vertical tray section since they are not qualified. The restraint provided by the horizontal section is based on the coefficient of friction between cable jacket and the bottom of the tray in the horizontal section.

This coefficient of friction is based on EPRI EI-3333, Table 5-2.

It should be noted that specific direction on applying a tie wrap to cable is provided in G-38, Section 8.6.4.3, thus negating the concern of indenting the cable jacket by making the wrap too tight.

5. Proximity to Hot Pipe NRC Question a: TVA to provide a definition and characterization of "rework" regarding raceways, including examples.

TVA Response:

A review of TVA calculation WBN-OSG4-139, 'Walkdown of Electrical Raceways Within Close Proximity to Hot Pipes; Data Tabulation and Violation Evaluation,"

indicates that following actions were taken to correct the clearance violations between Class 1 E raceways and hot pipes:

Installed heat shield.

Restrained flexible conduit to obtain 2 inch clearance.

Relocated conduit to obtain required clearance.

Relocated tubing to obtain required clearance.

Installed additional insulation on the pipe to obtain required surface temperature.

This is the rework that was performed on raceways to address this issue.

NRC Question b: TVA to include the methodology used for developing the criteria for "Hot Pipe" configurations in the submittal.

TVA Response:

TVA calculation WBN-OSG4-138, "Class 1 E Electrical Cable/Hot Pipe Clearance Requirements," delineates the criteria for evaluation of "Hot Pipe" configurations.

The primary consideration in developing these criteria in Construction Specification G-40 was the establishment of clearances for electrical cables and piping that must be maintained in order to prevent the electrical cables from overheating due to close proximity to hot pipes that could cause premature aging of the cables.

6

The clearance requirements were established for electrical cables run in conduits or cable trays, either parallel to, or at an angle to, a hot pipe, and located in any of the environmental situations listed on environmental drawings.

The clearance requirements are based on heat transfer analyses that determine the temperature rise in cables caused by the presence of a nearby hot pipe. These analyses account for (1) the resistance heating of the cables, (2) the heat transfer with the surroundings by natural convection and radiation, (3) the heat transfer by radiation between the cable or conduit surface and the piping insulation surface, and (4) the heat transfer by convection between the cables and the boundary layer of the plume arising from the pipe.

Separate treatment is required for different geometries that may exist in the plant.

This is because certain geometries require significantly more clearance than others.

Trying to force the more restrictive clearance requirements to be met for all geometries is not economical or feasible.

The geometries that were analyzed in the TVA calculation were considered to be sufficiently varied to cover the vast majority of cases that exist in the plant. However, if geometries existed that did not conform to any that were analyzed, specific analyses was performed for such cases.

NRC Question c: TVA to provide the basis and assumptions for characterizing the piping fluid and ambient room temperatures.

TVA Response:

TVA calculation WBN-OSG4-138 documents the assumptions for characterizing the piping fluid temperatures as follows:

1. All insulated pipes are assumed to have insulation outside diameter of 39 inches or smaller and to have a maximum operating temperature of 6500 F. The pipes that do not meet these requirements are considered special cases and require specific analyses.

2. All uninsulated pipes are assumed to be 2 inches in diameter or smaller and to have an operating temperature of 600°F or less. The pipes that do not meet these requirements are considered special cases and require specific analyses.

3. Piping with a surface temperature of 1350F or less is not considered to be hot pipe. Electrical conduits in proximity to piping having this surface temperature require no thermal clearance.

The basis for ambient room temperatures is the WBN plant environmental drawings 47E-235 series. These drawings provide ambient temperature in each room of the plant under normal operating as well as accident conditions.

NRC Question d: TVA stated that walk downs of "Hot Pipe" configurations will be conducted as part of project completion to ensure field run conduit configurations meet installation specifications. Include this statement in the submittal.

7

TVA Response:

TVA will conduct a final walkdown of the plant after construction is completed to determine if any violation exists with respect to clearance between the hot pipes and Class 1 E electrical raceways. Violations will be evaluated and resolved.

NRC Question e: TVA to provide TVA's G-40 specification with the submittal.

TVA response:

TVA has included the G-40 specification on the accompanying disk.

6. Puliby NRC Question a: A discrepancy was noted in Section 8.3 of the WBN Final Safety Analysis Report (FSAR) that indicated that the cable fill criteria did not call for evaluation if the fill percentage was exceeded. TVA will submit a correction to the FSAR that will define when evaluations can be performed.

TVA Response:

WBN FSAR paragraph 8.3.4.1.4, "Cable Derating and Raceway Fill," states:

"Conduit containing only one cable is sized for a maximum of 53% cable fill. Conduit containing two cables is sized for a maximum of 31% cable fill, and conduit containing three or more is sized for a maximum of 40% cable fill of the inside area of the conduit."

TVA will add the following statement to this paragraph: "Exceptions for conduit fills of greater than 40% will be evaluated and justified by engineering."

NRC Question b: Include the current configuration of WBN Unit 2 conduit fill percentages. Specifically, provide the number of conduits with greater than 35% and 40% fill for moderate and high risk cables.

TVA Response:

For conduits in the pullby evaluation, which are moderate and high-risk conduits, if cables are eliminated based on the following factors:

They have not experienced a pullby.

They are less than 20 feet long.

The cables are being replaced.

There are 8 conduits with fills greater than 35% and 3 conduits with fills greater than 40% using as-installed data. None are greater than 49%. All of these overfill conditions are justified in ICRDS.

NRC Question c: TVA to include a commitment to pull new cables in accordance with TVA's G-38 specification in the submittaL 8

TVA Response:

All new Class 1 E cable pulls that involve cable pullby will be accomplished in accordance with TVA's specification G-38.

7. Bend Radius NRC Question a: Include the Bend Radius Report that contains interviews with cable vendors, in the submittal.

TVA Response:

The bend radius report, WBN Training Radius Program, R1, is being forwarded to NRC on the accompanying disk.

8. Splices NRC Question a: Provide a definition and characterization of "rework" regarding splices for cables in mild environments.

TVA Response:

For this issue, rework involved the replacement of intermediate splices for Class 1E cables in mild environments that are susceptible to moisture intrusion from flood, line break, or sprinkler activation.

9. Sidewall Bearing Pressure (SWBP)

NRC Question a: Provide a discussion of how the 43 cable samples evaluated were extrapolated to all cable configurations and how margin was applied to SWBP limitations.

TVA Response:

As documented in Attachment 1 of the TVA Central Laboratory Test Procedure, "Sidewall Bearing Pressure Test Composite Results," 43 samples of various cable types and construction from approximately 17 cable manufacturers were tested.,

Representative test results for each voltage class are summarized below.

For low voltage power and control cables, representative results are:

Cable Description Cable Manufacturer Max SWBP lbs/ft 1/C No. 6 AWG Anaconda 2027 1/C No. 2 AWG American Insulated Wire 1957 1/C No. 2/0 AWG Triangle Wire and Cable 2889 7/C No. 14 AWG Okonite 1563 7/C No. 12 AWG Pacific Wire and Cable 1563 9

Based on the above test result, TVA selected a conservative value of 1,000 lbs/ft as a permissible SWBP value for low voltage power and control cables. Using 1,000 lbs/ft provides a minimum margin of 56.3% (1563-1000/1000) and as much as 188.9% (2889-1000/1000) for a 1/C 2/0.

Similarly, representative test results for signal level cables are tabulated below:

Cable Description Cable Manufacturer Max SWBP lbs/ft 3/C No. 16 AWG, Eaton 643 Shielded 2/C No. 16 AWG, Rockbestos 770 Shielded 12/C No. 16 AWG, Brand Rex 1496 Shielded 5/C No. 16AWG, ITT 937 Shielded Based on the above test result, TVA selected a conservative value of 500 lbs/ft as a permissible SWBP value for low voltage signal cables. Using 500 lbs/ft provides a minimum margin of 28.6% (643-500/500) and as much as 199.2% (1496-500/500) for a 12/C No.16AWG, Shielded.

Similarly, for coax cables, representative test results are tabulated below:

Cable Description Cable Manufacturer Max SWBP lbs/ft Coax RG59B/U Raychem 373 2 Coax W/TPs Teledyne 1242 Based on the above test result, TVA selected a conservative value of 300 lbs/ft as a permissible SWBP value for coax cables. Using 300 lbs/ft provides a minimum margin of 24.3% (373-300/300) and as much as 314.0% (1242-300/300) for an 8/C coax special. As was the case on Unit 1, Unit 2 EQ coax cable will be replaced with double jacketed cable.

10. Pulling Cables through 900 Condulets and Mid-Route Flexible Conduits NRC Question a: Provide a discussion of why 12 and 14 gauge wire was determined to be limiting in the submittal.

TVA Response:

As delineated under the silicone rubber insulated cable issue, five critical case conduits containing at lease two 900 condulets in their route were selected that contained cables manufactured by Anaconda and Rockbestos. The installed cables from these conduits were removed and were used as samples for EQ testing. The reason for selecting these No.12 AWG and No. 14 AWG was that, in practice, only

• small gauge cable can be pulled through a condulet without using the condulet as a pull point. Therefore, testing would reveal any insulation damage that may have occurred if the cables had been installed in this manner. These cables were successfully tested for 40 year life.

10

11. CCRS Software and Database Verification and Validation NRC Question a: Provide a discussion on how cable materials are tracked and can be recovered via mark numbers.

TVA Response:

The ONMark database, which is part of ICRDS, identifies the conductor type, including insulation type, associated with a cable mark number. Additionally, the pull record for safety related cables identifies the reel number for the pulled cable. This reel number can be traced to the contract under which the cable was purchased via warehouse records. For EQ cables, the contract number is associated with a specific qualification report, as documented in the EQ binder. In addition, the contract is identified on the cable jacket.

NRC Question b: Provide documentation on how the use of mark numbers is accomplished at the site.

TVA Response:

The process for the use of cable mark numbers is described in ICRDS. The ICRDS procedure states that a WBN cable reel number is recorded on the cable installation record. This cable reel number can be linked to the purchase contract number or TVA's interplant cable transfer documentation through the Warehouse Ledger. The WBN Unit 2 project is currently reviewing cable installation records to establish the pedigree of each Class 1 E cable in Unit 2.

NRC Question c: Provide the percent of cables found deficient during the Unit 1 Verification and Validation of the CCRS database to the resident.

TVA Response:

The following information is being provided to the resident:

The percent of cables found deficient during the Unit 1 Verification and Validation of the CCRS database is documented in paragraph 4.2 of the Cable Issues Corrective Action Program Plan, Revision 3, submitted to the NRC on January 13, 1994.

Out of 4,256 cable records reviewed for EQ cables, 4,012 cables had an exact match between the design and the installation records. This resulted in a discrepancy rate of (4256-4012)/4256=5.7%.

Out of the 244 discrepant cables, 110 cable record inconsistencies were resolved through a document search resulting in database update in some cases (e.g.,

illegible pull cards, misaligned card printer, or mismatch of pull card revision number, mark number, and routing differences).

The remaining 134 cables required field verification of mark number, contract number, and/or routing. This field verification resulted in 100 cables where the design and the installation records matched exactly.

1I

NRC Question d: TVA to provide clarification of design cable length versus installed cable lengths and a discussion'of which length is applied to better explain the calculations for cable 2PP675A, which were presented at the meeting.

TVA Response:

The current record (Rev. 5) in ICRDS for cable 2PP675A shows an overall design length of 4,787 ft. and an overall installed length of 3,155 ft. This cable is broken up into 7 route parts in ICRDS.

The ICRDS program automatically provides the design length based on the route of the cable. When determining the design length for a cable record, the ICRDS program sums the length of each raceway listed in the route of the cable plus any listed non-routed lengths of cable not in raceway but required at the ends for termination. If there is more than one route part, the ICRDS program determines the length of each route part as if it were a separate cable record and then calculates the record design length by summing the part lengths from the route parts of the cable (in this case, 463 + 188 + 16 + 2065 + 188 + 19 + 1848 = 4787). Since ICRDS calculates length in a cumulative manner, it cannot recognize that individual route parts may be a single phase instead of all three phases. In this case, the design length should be determined as follows:

For one of the conductors Route Part 1 (463) + Route Part 2 (188) + Route Part 3 (16) + Route Part 4 (2065) = 2732 ft.

For the other 2 conductors Route Part 1 (463) + Route Part 2 (188) + Route Part 3 (16) + Route Part 5 (188) + Route Part 6 (19) + Route Part 7 (1848) =

2722 ft. for each conductor A review of the cable installation card (with a written date of 5/4/78 and a stamped date of SEP 23 1986), indicates this cable was installed in 2 pieces. One of the pulls was from 3 reels with the cable length from the reels being recorded as having values of 2200 ft, 2175 ft. and 2190 ft. The other pull was from 3 reels with the

,recorded cable length from the cable reels of 972 ft., 962 ft. and 966 ft. The sum of these lengths (2200 + 2175 + 2190 + 972 + 962 + 966 = 9465), divided by 3 provides the average length for one conductor (9465 + 3 = 3155). These are the only lengths shown on the installation cards (there are no records of lengths of cable being trimmed from the cables during the termination process). The calculation of record used 3155 feet as the installed length since this is the most conservative length. This is an in-service cable required for Unit 1 operation.

12. Cable Issues CAP NRC Question a: TVA to provide a discussion outlining the, medium voltage cable testing program and the results of this program.

12

TVA Response:

TVA conducts Very Low Frequency (VLF) testing of underground medium voltage cables in accordance with G-38, Section 19.4.8.1. This specification describes VLF as follows:

Withstand tests performed with a Very Low Frequency (0.1 Hz) alternating current, sinusoidal waveform have been shown to be more revealing of defective cable insulation than high potential DC. Unlike DC, VLF hipots have been shown to be non-destructive to otherwise sound insulation.

WBN Unit 1 has performed VLF testing on all but one essential raw cooling water (ERCW) pump feeder cable. Testing the remaining ERCW pump feeder cable is in progress. To date, data for the seven pumps for which testing has been completed indicate sound cable systems with no problems or anomalies observed. Testing of the diesel generator output supply cables is currently scheduled to be performed during the Unit 1, Cycle 9 refueling outage. After performance testing, periodic testing is planned at 5 year intervals.

13. Flexible Conduit Installation NRC Question a: TVA to include the G-40 specification to document the methodology used for installation of conduit.

TVA Response:

Section 3.6.2 of the G-40 specification provides the methodology for the installation of flexible conduits. The specification is being provided to NRC on the accompanying disk.

NRC Question b: TVA to provide specific discussions for each item in the February 15, 1989 CAP that resolved the Flexible Conduit Installation issue.

TVA Response:

The problems identified with flexible conduits were:

" Inadequate length to account for seismic/thermal movement.

Lack of compliance with minimum bend radius requirements.

Loose fittings.

To resolve these issues for Unit 1, TVA revised design output documents to more specifically define flexible conduit requirements for:

Seismic/thermal movement.

Minimum bend radius.

Tightness of fittings.

A list of flexible conduits attached to Class 1 E pipe mounted devices was then developed to identify those flexible conduits that would experience both seismic and thermal movement. Finally, TVA walked down all Class 1 E flexible conduits and reworked those found to be damaged or in noncompliance with the design output documents.

13

14. Physical Separation and Electrical Isolation NRC Question a: TVA to provide specific discussions for each item in the February 15, 1989 CAP that resolved the Physical Separation and Electrical Isolation issue.

TVA Response:

Resolution of this issue was broken down into three parts:

Inadequate separation between redundant divisions of Class 1 E conduits For WBN Unit 1, as corrective action for the originally identified condition, NE issued design output documents to specify separation requirements. TVA revised site implementing procedures to strengthen inspections for separation requirements. This was followed by reworking the raceways to meet the minimum 1-inch separation requirement.

The long-term corrective action to prevent recurrence was to revise site implementing procedures to require specific signoffs for raceway separation attributes Inadequate internal panel separation between redundant divisions of Class 1 E cables For Unit 1, Design Criteria WB-DC-30-4 was revised to include more detailed requirements for internal panel cables, an engineering output document was issued to define the requirements for internal panel cable separation, and a list of all panels with redundant divisions of Class 1 E cables was developed.

This was followed by walkdowns of panels containing cables of redundant divisions to identify cables that did not comply with the revised engineering output documents. Once identified, nonconforming cables were evaluated to determine acceptability or reworked to meet required separation distances.

In order to prevent recurrence, engineering output documents were revised to ensure that requirements were defined as appropriate, and site implementing procedures were also revised to specify installation requirements and inspection attributes for separation of internal panel cable.

Coil-to-contact and contact-to-contact isolation between Class 1 E and non-Class 1E circuits For Unit 1, a calculation was developed to determine when coil-to-contact and contact-to contact isolation were acceptable, design criteria were revised to specify acceptable isolation methods, and the existing Class 1 E coil and contact devices used as isolators were reviewed to determine if they were qualified for their intended use.

14

15. Torque Switch and Overload Relay Bypass Capability for Active Safety Related Valves NRC Question a: TVA will provide specific discussions for each item in the February 15, 1989 CAP that resolved the Torque Switch and Overload Relay Bypass Capability for Active Safety Related Valves.

TVA Response:

For Unit 1, TVA issued design criteria and corresponding calculations to provide the basis for determining which active valves were required to have their thermal overload relays and torque switches bypassed. System design cri teria or system descriptions were revised to identify which valves within a system required thermal overload and torque switches bypass capability. Design output documents were then revised, and thermal overload and torque switch bypasses were installed where they did not already exist.

To prevent recurrence, Engineering issued the required design input documents.

15 Listing of Open Actions Required for Licensing

1.

TVA will statistically sample the WBN Unit 2 QA records by record type to determine their retrievability, storage, and completeness. TVA will resolve any technical or quality problems found.

2.

TVA will perform back checks of the previously installed replacement items to ensure that a proper documentation trail exists from the warehouse to maintenance history for each of the small number of safety-related components that are not refurbished.

3.

If a single-conductor Class 1 E cable is found to be installed using a power assisted pull, TVA will evaluate the controls in place during the pull and the jam ratio of the cable. Appropriate corrective action will be taken based on this evaluation. The evaluation and corrective action will be available for review.

4.

A visual inspection of the supports of vertical conduits that do not meet the G-38 vertical support requirements will be conducted. If cables are found to be under tension, the portion under tension will be replaced.

5.

A walkdown for "hot pipe" configurations will be conducted after construction completion.

6.

TVA will submit an update to the FSAR Section 8.3.4.1 to allow engineering evaluations of pullby if fill percentages are exceeded.

CERTIFIED TEST REPORT AND CERTIFICATE OF dOMPLIANCE THE OKONITE COMPANY 2276 ROWESVILLE ROAD ORANGEBURG SC 29115 Report No: 6326 DATE : 03/31104 Rag No :42-5405 Page 1 of *t_

Customer;- TENNESSEE VALLEY AUTHORITY NUCLEAR Customer Order Number 31967 Item No: I Code No: WNB-52 / CBR257A Manufacturing Order No: 04-2939-1 Product Code No: 115.23-2928 Manufaicturing Spec: WAN E12.6.01 REV 4 7/21103 Cable

Description:

1/C 210 19X COPPER-8S-140 OKOGUARD EPR-024 SC EPR-005 TINNED COPPER TAPE-NOS OKOLON-SEQ.PRINT-SKV CERTIFICATE OF COMPLIANCE; Issued in conjunction with and subject to OKONITE's standard Warranty and Limitation Liability.

THE OKONITE COMPANY hereby certifies to the customer named above that the above described materials were duly tested during manufacture and that the materials meet or exceed the applicable requirements.

Quantity Ordered Cable QC Length No.

474"07A 474307B Quantity Accepted 6,000 for Shipment 6,120 Shipping Sequential Numbers Footage Top End Test Hole End 3060 4006168 4003100 3080 4003068 4000000 Number of Reels 2

CERTIFIED TEST REPORT The Insulated conductor(s) withstood the following tests:

2$ Kv Ac for 5 Min The Insulated cable conductor(s) has an INSULATION RESISTANCE of rnot less than that corresponding to a constant of 50000 at 15.6 C.

The DC RESISTANCE of the conductor(s) at 26 C does not exceed ICEA values of 0.08260 Ohms per 1,000 ft.

Conductor Continuity PASSED ShIed Continuity PASSED Corona Level per AEIC Ca6 PASSED This report covers material shipped from ORANGEBURG, SC to WAN /BROWNS FERRY We hereby cedify this to be a true and accurate 6opy of results of tests conducted In accordance with orders and specifications listed.

Special Statements for this CTRICOC

'CABLES SHIPPED ARE SAME IN DESIGN AND MATERIALS, AND MANUFACTURED UNDER SAME PROCESS AND QUALITY CONTROLS AS CABLE QUAULFIED BY OKONITE EQ REPORT NQRN 3 R4 MAXIMUM SIDE WALL PRESSURE DURING INSTALLATION - IOOOLBS.,

'REELS ARE SUITABLE FOR EXPOSURE TO AN OUTDOOR ENVIRONMENT FOR AT LEAST TWO YEARS.-

• CABLE SUPPLIED IN ACCORDANCE WITH OKONITE 0S MANUAL REV.5 DTD 8/97.!

'SOFT I ANNEALED COPPER WIRES PRODUCED FOR STRANDED CONDUCTORS HAVE ACHIEVED ELONGATION AND FINISH REQUIREMENTS OF ASTM 83 DURING MANUFACTURE."

• 1 "CABLE SHIPPED MEETS FLAME RESISTANCE REQUIREMENTS OF IEEE 383-1974" THE OKONITE COMPANY DON HOLZ6HUH ENGINEER /MANAGER OF TEST Q-123-C-01 REV 11.2 02/20/02 S

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ntr u 639U 22 003 March 22, 1996 M. C. Brickey, JOB IG-WBN WATTS BAR NUCLEAR PLANT REVISION 1 TO THE CABLE BEND RADIUS PROGRAM PLAN Beginning July 20, 1995, Kent W. Brown of my staff visited Brand Rex, Rockbestos and The Okonite Company for the purpose of reviewing the activities that WBN has undertaken to resolve the issue of tight cable bend radius. As you know, these meetings were held in response to a WBN commitment to the NRC to review the "long-term" portion of the plan for resolution with our major suppliers. Per our agreement with the NRC, the vendors were not requested to "approve" the plan, but to only provide a verbal assessment.

Following those initial meetings, the vendors found that the TVA program was satisfactory as was described in some detail in my memo to you dated July 28, 1995 (B43 950728 005).

It was originally intended that those 10 CFR 50.49, single conductor, low voltage power cables which were found to be above the lower bound but below the ICEA radius would be accepted based on a reduction in life directly proportional to the additional stress. That method would have entailed an assumption that no synergistic effect existed between the additional physical stress and aging and required laboratory confirmation of that assumption as was described in revision 0 of the plan.

However, subsequent walkdowns and inspections showed that all single conductor, low voltage power cables within the scope of 10 CFR 50.49 were trained at or above the ICEA limit, obviating the need for further research in this area and resulting in a reduction in the scope of the plan.

The changes to the long term bend radius plan were discussed with each of the above vendors following their review of a draft of that revision (B43 960321 003). The purpose of that review was to ensure that the vendors still agreed that the plan would achieve the desired objective. The results of those discussions were as follows:

El Brand Rex, in a letter to K. W. Brown dated February 29, 1996 (B43 960321 00 l), noted that they concurred that the plan would ensure early identification of adverse trends and could not identify any deficiencies in the TVA approach for addressing bend radius concerns.

E]

Robert Gehm, Sr of Rockbestos discussed his review of the draft plan with K. W. Brown on February 27, 1996. Gehm noted that Rockbestos had no technical objections to the revised plan.

LI John Cancelosi of Okonite discussed his review of the draft plan with K. W. Brown on March 13, 1996. Cancelosi noted that Okonite also had no technical objections to the revised

plan.

We have included a discussion of the results of the 1995 meetings, the reason for revision I and the results of the 1996 discussions in the revised plan so that it is as comprehensive as possible. Please forward the attachment to licensing so that the NRC commitment can be revised as necessary. If you have questions regarding the above comments please contact Mr. Brown at 751-8227.

R. C. Williams Chief Electrical and I&C Engineer LP4H-C cc (attachment):

RIMS, CSTI3B-C, w/attachment

Watts Bar Nuclear Plant - Training Radius Program, Revision 1

Background

In the late 1970s and early 1980s as TVA was constructing its Watts Bar Nuclear Plant, cables were installed which could not, or did not, meet industry standard training radius requirements. The substandard bends resulted from a variety of causes. For example, the Watts Bar tray system was bought with 12" radius fittings, which resulted in potential violations for all of the larger 8kV cables. In other cases, both low and medium voltage cables were bent too tightly as a result of undersized termination housings supplied by end equipment manufacturers. Finally, TVA's construction forces incorrectly installed some cables as a result of inattention to detail and as a result of insufficient direction from engineering.

While at least one deviation from I.CEA' standards has been noted for almost every category of cable, the most pervasive violations were in the areas of medium voltage power cables and low voltage multiconductor control cables.

In the former category, TVA had contacted its major suppliers in the early 1980s and been granted some relief from the ICEA 12x requirements (see Table I and Attachment 1). Those relaxations had been incorporated into the referenced internal TVA standard2 (Attachment 2).

In the latter category, TVA had established its allowable bend radius based on multiples of the diameter of a single conductor from a multiconductor cable, rather than from its overall diameter. When applied to cables with a large number of singles, this methodology represented a

significant deviation from ICEA requirements (Attachments 2 and'3).

In the mid-1980s, as a result of internal reviews and NRC inspection frmdings, bend radius violations were deemed as potentially programmatic. The reviews and findings indicated that TVA standards lacked a documented basis for deviations from industry requirements.

It was further noted that installations existed where bends were in violation even of the comparatively relaxed TVA standards.

When vendors were contacted to identify the basis for their previous relaxations of low-and medium-voltage bend radius requirements, most were withdrawn.

Table 1 1983 Training Radius Relaxation, Medium Voltage Vendor

]

Multiplier Okonite 4.4 Collyer 8.0 Anaconda-Ericsson 8.4 Rome Cable Corporation 10.9 Essex 7.0 General Cable 7.0 Triangle-Plastic Wire and Cable 7.0 Method of Resolution:

In order to properly assess the significance of the subject deficiencies, TVA embarked upon a program of testing and analysis with the following salient points:

Definition of potential degradation mechanisms resulting from the tight bends and the consequent impact on performance.

Limited literature search and informal industry survey to identify the results of previous research.

Testing to establish the point of onset for the degrading mechanism(s).

Definition of an inspection/acceptance criteria based on the above findings and conclusions with consideration for the cables' normal and

'ICEA Standards S-68-516, "Ethylene-Propylene-Rubber-[nsulated Wire and Cable for the Transmission and Distribution of Electrical Energy" and S-66-524 "Cross-Linked-Thermosetting-Polyethylene-Insulated Wire and Cable for the Transmission and Distribution of Electrical Energy".

2Design Standard DS-E12.1.5, Revision 3, "Minimum Radius for Field Installed Insulated Cables Rated 15,000 Volts or Less."

I

Watts Bar Nuclear Plant - Training Radius Program, Revision I accident service conditions.

Initiation of a long-term plan comprised of condition monitoring, inspections, failure trending, ongoing upgrades and industry participation to ensure early identification of adverse trends.

Following development, a presentation of the program was made to the three primary suppliers of nuclear grade cable to TVA. Each supplier was asked to identify any deficiencies in the TVA approach.

An overview of each of the efforts is provided in the sections which follow.

Evaluation of Mechanism:

Excess bending of safety-related cable is of concern due to the potential impact on performance. To evaluate that impact, the influence of bending was reviewed with respect to the constituent components of the various cable constructions.

For the potential bend radius violations under consideration, the effects fell into two major categories.

The first is the impact of the supplemental elongation imparted to the primary insulation as a consequence of the tight bend, while the latter is the permanent mechanical deformation of critical cable components (i.e. disruption of the extruded shielding system, deformation of the conductor or metallic tape shield).

Each of these categories was reviewed for low-and medium-voltage cable types so that subsequent analysis would account for all known phenomena.

Medium Voltage For medium-voltage cables, three mechanisms were judged to be of potential. concern.

First, bends with radii below those permitted by industry standards result in an additional elongating stress to the insulation system.

Since a cable's qualified life is generally defined in terms of retention of elongation, such an additional pre-stress may be viewed as a potential reduction in life. The stress developed in a bend may be readily determined by the following formula:

Elongation%.

100 2.BendRadiusFactor* I The incremental increase in stress above that experienced by a cable with a "standard" bend is then determined by subtracting the "standard" stress from the value for the overbend.

Based on the installed configurations, conversations with its primary suppliers and testing conducted for T"VA's Browns Ferry Nuclear Plant, a minimum training radius of 8x had been established as a target for resolving WBN issues (this selection was also supported by ICEA1 standards which permit medium voltage cables to be shipped on reels with drum diameters sized to ensure a 7x bend radius). For the 8x bends under consideration in medium voltage cables, the incremental stress is less than 2% (5.9%-

4%, see Table 2). Thus, unlike low voltage power cables bent to l x, 2x or 3x, no special consideration was given to a possible synergisms between physical stress and aging for this category.

Table 2 Elongation as a Function of Bend Radius, %

Multiples of Cable OD Elongating Stress, %

1 33.3 2

20.0 3

14.3 4

I1:1.

5 9.1 6

7.7 8

5.9 10 4.8 12 4.0 Second, overbending may result in interfacial disruptions between a medium-voltage cable's stress 3ICEA Standard A9-428, "Drum Diameters of Reels for Wires and Cables" 2

Watts Bar Nuclear Plant - Training Radius Program, Revision I control layers and the insulation.

These layers (strand shield, insulation, and insulation shield) must remain in intimate contact to ensure proper electric stress distribution and provide protection against corona inception.

Additionally, the helically wound copper tape shield must not become so deformed as to potentially pinch or gouge the insulation and/or insulation shield. Such action would again result in the increased likelihood of corona-induced degradation.

Therefore, it was decided that tests undertaken by TVA would include direct evaluation of both tape shield and interfacial integrity.

The third consideration was for conductor deformation resulting from the bend.

Concern existed that such deformation might result in a residual radial mechanical stress on the insulation

system, Therefore, TVA's test program was designed to consider conductor integrity for both overbent specimens and retrained overbent specimens.

Low Voltage For low-voltage cables, no such interfacial concerns exist due to the absence of electric stress control layers. Only the issues of additional elongating stress and conductor deformation are applicable and were included in TVA's short-term evaluation.

However, as a result of the higher level of incremental mechanical stress imparted to tightly bent low voltage power cables, it was recognized that some potential exists for a synergism between physical stress and aging. This latter phenomenon is discussed as a part of the long-term program.

While the above discussion addresses the significant factors associated with single conductor cable bends, TVA recognized that an additional influence may be present in multiconductor cables.

For these designs, tight bends result in a flattening of the overall jacket such that the cables' cross section becomes oval rather than circular. In such a bend, mechanical stresses are imparted to the individual conductors from the jacket, other conductors and drain wires (where applicable). The magnitude of such forces is influenced by the specific construction of the cable (size and number of conductors, presence of drain wires, tightness of the core and jacket, type of filler material, etc.).

Because of the number of variables involved, TVA opted to follow an existing precedent' within the industry for multiconductor cables and confirm its use through limited bending tests described below (Attachment 4).

Literature Search and Informal Industry Survey:

Literature Search The potential for synergistic effects on nuclear power plant cables has been the subject of considerable interest within the industry since the publication of NUREG/CR-3538', which documented the failure of certain EPR/CPE cables during an in-containment accident simulation test.

The authors of the report postulated (amongst other things) that the failure during their simultaneous testing of material which had successfully endured the vendor's sequential tests may have been the result of a synergism not noted during the original tests. Consequently, several Sandia programs have evaluated the interplay of thermal and radiation aging6.

During the same time frame, the IEEE 4Table I, column A of Rockbestos Technical Bulletin No. 28, "Bending Radii and Installation Practices" 5NUREG/CR-3538, The Effect of LOCA Simulation Procedures on Ethylene Propylene Rubber's Mechanical and Electrical Properties", Larry D. Bustard, Sandia National Laboratories, October 1983.

6NUREG/CR-3629, "The Effect of Thermal and Irradiation Aging Simulation Procedures on Polymer Properties", Bustard et al, Sandia National Laboratories, April 1984. NUREG/CR-409 1, "The Effect of Alternative Aging and Accident Simulations on Polymer Properties". NUREG/CR-4536, "Superheated-Steam Test of Ethylene Propylene Rubber Cables Using a Simultaneous Aging and Accident Environment", Bennett et al, Sandia National Laboratories, June 1986. SAND91-0822, "Aging Predictions in Nuclear Power Plants -

Crosslinked Polyolefin and EPR Cable Insulation 3

Watts Bar Nuclear Plant - Training Radius Program, Revision I Dielectric and Electrical Insulation Society formed a Technical Committee on Multifactor Stress. Its primary research seems to have been directed to high-voltage insulation systems and the combination of dielectric stresses with other factors.

However, an informal literature search has noted the existence of several papers, guides and standards which bear on the issue or provide guidance in the performance of such testing to quantify the effects.

A short review of some of the findings appears below:

IEEE 1064-19917 - This document provides direction for the design and performance of multistress aging programs such as described below to address the cables of concern. The guide adds nothing which impacts directly on the potential thermal-mechanical synergism given a constant mechanical stress.

Instead, the guide seems to assume that such stress is cyclical, being either vibratory or related to thermal expansion and contraction. It suggests that such multistress tests are appropriate when the absence of factor interaction is not confidently known. The IEC also has two documents5 which address this same set of issues. The documents are unavailable within the TVA system and were not consulted as a part of Materials", Gillen and Clough, Sandia National Laboratories, June 1991. SAND88-0754, "Time-Temperature-Dose Rate Superposition: A Methodology for Predicting Cable Degradation Under Ambient Nuclear Power Plant Aging Conditions",

Gillen and Clough, Sandia Natio nal Laboratories, August 1988. SAND90-2009, "Predictive Aging Results for Cable Materials in Nuclear Power Plants",

Gillen and Clough, Sandia National Laboratories, November 1990.

7IEEE 1064-1991, "IEEE Guide for Multifactor Stress Functional Testing of Electrical Insulation Systems"

$IEC 792, part 1, "Multi-Factor Functional Testing of Electrical Insulation Systems, Part 1: Test Procedures", 1985 and IEC 792, part 2, "Multi-Factor Functional Testing of Electrical Insulation Systems, Part 2: Bibliography", 1993.

this study.

IEEE 775-1993' - This document provides some guidance for the performance of a multistress aging program in a radiation environment but adds nothing which bears directly on the potential thermal-mechanical synergism.

Given the low radiation exposure outside of containment, no special consideration is given for this potential stressor.

llstad, et all0 - The subject paper reports on the findings of a study of the influence of mechanical stress on the rate of water tree growth. The authors sharply coiled 12 kV XLPE insulated cables on mandrels, immersed them in room temperature water and energized them at twice their rated potential.

Following conclusion of the six month period of accelerated aging they noted, "The enhanced initiation and growth of vented water trees in the stretched zones is clearly demonstrated". This can be observed from Table I of the subject paper, which is reproduced in Table 2 of this document.

The authors hold to a mechanical damage theory of water tree growth, wherein induced Maxwell stresses at the root of a water-filled craze work to propagate the fracture.

They postulate that the increased stressel resulting from the tight bend supplement the Maxwell stresses and stimulate the growth rate. Since the WBN program is limited to cables in IOCFR50.49 service (where there is no long-term submergence), the concern identified by this paper is not applicable.

de Mattos, et all - The subject paper involved the 9IEEE-775 "IEEE Guide for Designing Multistress Aging Tests of Electrical Insulation in a Radiation Environment" 10"Influence of Mechanical Stress and Frequency on Water Treeing in XLPE Cable Insulation", E. llstad, H. Bardsen, H. Faremo and B.

Knutsen, 1990 IEEE International Symposium on Electrical Insulation, Toronto, Canada.

""Multiple Stress Aging of HV Polymeric Insulation", E. L. de Mattos and C. H. de Tourreil, IEEE Transactions on Electrical Insulation, Vol. 25, 4

Watts Bar Nuclear Plant - Training Radius Program, Revision I testing of EPDM, EPM and silicone rubber weather sheds used in [IV transmission line insulators. The program was multifaceted in that it assessed aging as a function of mechanical, thermal, and electrical stressors in an UV environment. One portion of the program involved the analysis of the effect on aging of mechanical stressors when applied to the slabs of the EPDM and EPM materials only.

According to the paper, "The specimens were placed on steel frames in such a way that the narrow part of the specimen was stretched by 0, 30, or 60%. Two specimens of each material at each of the three stress levels were aged for 1000, 2000 and 3000 hours0.0347 days <br />0.833 hours <br />0.00496 weeks <br />0.00114 months <br />.

This aging was done in an air conditioned room at about 230C and about 40%

relative humidity......

At the end of each aging period elongation at rupture tests were performed.

The variations of the elongation at rupture values of materials A and B aged for up to 3000 hours0.0347 days <br />0.833 hours <br />0.00496 weeks <br />0.00114 months <br /> was less than 10% of the value measured on the new specimens even for the stretch value of 60%. These variations are within the accuracy of the measurement." The absence of significant thermal stresses on the specimens which were elongated makes this paper of limited value for power cables, while at the same time it confirms the assumptions made with respect to control and instrumentation cables.

Wyle test report 17503-I

- Item 3.2 of the subject report, a PE insulated, PVC jacketed cable, was aged (40 years at 750C), irradiated (I Mrad) and accident tested while bent to approximately 1.5x.

The cable successfully withstood the 320'F exposure and subsequent post-LOCA hipot. Thus, no synergism was noted, though the results for this semi-crystalline material may be deceptive for reasons described in the section entitled "Long Term Program".

No. 3, June 1990, pages 52 1-526.

12Wyle test report 17503-1, "Nuclear Environmental Qualification Test Program on Sequoyah Nuclear Station Control Equipment and Cables", TVA contract TV-5607 IA.

Wyle test report 17732-1I" - This test program involved the preaging of 41 low-and medium-voltage specimens followed by a simulated accident exposure.

The specimens (PE, XLPE and EPR insulated) were installed on mandrels which resulted in the cables being bent at their minimum ICEA radius. The intent of the use of the small radius was to permit as many specimens as possible to be installed in a single chamber and not intentionally to evaluate bend radius. Two sets of specimens were prepared. One set received thermal aging equivalent to 40 years and the second 20 years, both at 600C (based on conservative activation energies). The 40 year set received 75 Mrads of radiation (aging plus accident), while the 20 year set received 65 Mrads.

All radiation was applied prior to thermal aging.

The peak accident temperature was 255°F.

Numerous lab related anomalies were recorded, but all cables were found to be qualified either during the initial exposure or during a subsequent re-test (as a result of the anomalies). Thus no synergism was noted, though the results on semicrystalline materials may be deceptive as noted above.

Wyle test report 17740-1'

- This program was similar to the 17732-1 report noted above, except that it was limited to II PE and XLPE specimens which had undergone the 17732-I exposure and the peak accident temperature was approximately 340°F.

Two specimen related anomalies were noted. The first involved a breakdown near the splice to the test lead and was successfully dispositioned. The second 13Wyle test report 17732-1, Nuclear Environmental Qualification Test Program on Various Cables Used Outside Containment (Profile 3) for Tennessee Valley Authority for Use in Sequoyah and Watts Bar Nuclear Generating Stations", TVA contract TV-56071 A.

14Wyle test report 17740- I, Nuclear Environmental Qualification Test Program on Various Cables for use in Sequoyah Nuclear Plant East and West Steam Valve Rooms and East Steam Valve Vault Instrument Rooms and Watts Bar Nuclear Plant North and South Steam Valve Rooms and North Steam Valve Vault Instrument Rooms", TVA contract TV-5607 IA.

5

Watts Bar Nuclear Plant - Training Radius Program, Revision I involved a failure on one XLPE/PVC/PVC specimen, near its connection (though outside the defined transitional area). Thus, this cable was deemed to have failed the valve vault profile. Since this was the second accident test for this specimen (the first having been passed), no direct conclusion regarding bend related synergisms can be drawn.

SAND 78-071815 - This report is a part of a larger program undertaken to assess possible synergistic effects of different aging'and accident scenarios. In this segment of the program, numerous cable specimens were prepared with small radius bends (of an unspecified diameter but well below the 40x of IEEE 383, based on evaluation of the report photographs).

The cables (neoprene, EPR and XLPE insulated) were aged and then exposed to a combined thermal-radiation-pressure-spray LOCA.

All cables held rated voltage and current throughout the test and it was concluded that no significant synergisms existed. Some cracking of the cables jackets was noted in the bend areas (particularly specimen A).

This should not have been unexpected since the thermal aging portion of the pre-aging was carried out at 175 0C, well above the capability for most CSPEjackets. As is the case for the WyleiTVA programs, the results for semi-crystalline materials may be deceptive as noted above.

Bruning and Campbell" - The subject paper deals extensively with multistress aging of polyimide insulation (Kapton) as used by the US Navy. The multi-layer tape insulation is applied in aircraft wiring since its thin walls permit reduction in weight and congestion.

Kapton's high thermal 15SAND78-0718, Preliminary Data Report, Testing to Evaluate Synergistic Effects from LOCA Environments, Frank V. Thoms, Sandia National Laboratories, April 1978 16"Aging in Wire Insulation under Multifactor Stress", A. M. Bruning and F. J.

Campbell, IEEE Transactions on Electrical Insulation, Vol. 28 No. 5, October 1993, pages 729-754.

rating likewise permits the use of high current densities and thus small gauge wire.

Their research showed-that the combination of moisture, high temperature and mechanical strain had led to the premature degradation.

In tests conducted by Bruning, cables exposed to 100*C water for only 64 hours7.407407e-4 days <br />0.0178 hours <br />1.058201e-4 weeks <br />2.4352e-5 months <br /> while bent to approximately l.5x, developed cracks.

Unlike so many of the papers noted above, electrical aging was not the focus of the program and dielectric stress was only applied during periodic hipot testing to assess for the existence of cracks.

Bruning stated that the process at work here is chemical in nature and that the ordinary Arrhenius relationship is altered by virtue of a change in the activation energy resulting from the mechanical strain.

In this equation, E, is the material's activation energy as developed in a single stress test (such as thermal aging) and E,,, is the stress energy.

Thus, the effective activation energy, E,fr, of the reaction of the polyimide with the sorbed water is reduced by imposition of the strain. The reaction is said to lead to chain scission which lowers the overall molecular weight of the polymer. Thus, its aging is accelerated beyond the single stress model.

In principle many of the conclusions noted above for Kapton should also be true for the XLPE and EPR insulations which are the focus of the WBN study.

However, certain qualifiers limit the implied effects.

First, the relative stress applied to the WBN cables is far below that imposed by the Bruning study.

Shugg17 notes that the elongation of Kapton at break is only 70%, compared to 250-500% for the other materials.

Thus, in the case of Kapton, even a standard ICEA bend represents a significant 17"Handbook of Electrical and Electronic Insulating Materials", W. Tillar Shugg, Van Nostrand Reinhold, NY, 1986.

6

U Watts Bar Nuclear Plant - Training Radius Program, Revision I mechanical stress. In contrast, even the reduced bend radii utilized at WBN do not represent a significant percentage of those material's ultimate elongation.

From this we conclude that any reduction of the activation energy by E,,. would be minor.

Second, the Kapton degradation occurred via the hydrolysis process which is not a factor for XLPE or EPR. For insulations typically utilized in the nuclear environment, moisture is not considered an aging stressor. As will be noted below, several individuals contacted as a part of the industry survey noted a similar process involving some materials (notably neoprene) in an ozone rich environment, but none for the WBN materials and environments.

1992 EPRI Workshop"3 - The workshop, jointly sponsored by EPRI, the Office of Naval Research and the Strategic Defense Initiative Organization included eight invited presentations and several breakout sessions among the 65 engineers and scientists from 17 countries who gathered by special invitation. Only the presentations by A. M.

Bruning and J. P. Crine seem to have dealt with the issue of mechanical stress as applied to cable insulation. Bruning's presentation was an overview of the work which has been discussed above. Crine noted, "In the case of mechanical aging of polymers an exponential regime was found at high stresses and a tail at low stresses that is very similar to electrical aging.

In a plot of log of time-to-breakdown versus mechanical stress, one finds a plateau stress for nearly infinite life". Though it appears that Crine's remarks' 9 were given in the 18"Proceedings: Multi-Factor Aging Mechanisms and Models 1992 Workshop", EPRI report TR- [ 03172, June 1994.

19Similar comments are made in, "A Model of Solid Dielectrics Aging", J. P. Crine, Conference Record of the 1990 IEEE International Symposium on Electrical Insulation, Toronto, pages 25-26, Canada, 1990 and in "Aging of Extruded Dielectric Power Cables: Theory", EPRI report TR-1 0 1660, December 1992.

context of combined mechanical and electrical stress rather than mechanical-thermal, the conclusion that low stresses (such as those under consideration) have no effect seems to testify to the notion that the low stresses do not alter the apparent activation energy, a process described above by Bruning and Campbell.

G. C. Stone20 - Stone notes that though models to evaluate mechanical stress are well known for metals, they have infrequently been used for electrical insulation.

He suggests that a model proposed for magnetically induced mechanical stresses in turbine generator end-turns might be appropriate for evaluating insulation fatigue at tight cable bends due to load cycling. The proposed models tend to follow the relationship, "...for metal

fatigue, L H.S.

where S is the amplitude of displacement, L is the number of mechanical cycles to failure (which can be converted to time if the mechanical fatigue frequency is constant, e.g. 120 Hz), and H and J are calculated constants". Stone notes that there has been little experimental verification of this model for electrical insulation, "perhaps since there are few situations where mechanical aging is the dominant form of aging". In consideration of the above, this model obviously would not apply to non-power circuits since no "load-cycling" would occur.

Likewise, its impact would be minimal for typical generating station power cables since their period of thermal-mechanical cycling is typically measured in hours or days rather than so many cycles per second as in the case of the end-turns.

EPRI transmission cable study" - In addition to the 20"The Statistics of Aging Models and Practical Reality", G. C. Stone, IEEE Transactions on Electrical Insulation, Vol. 28 No. 5, October 1993, pages 716-728.

21 "Multi-Stress Aging of Extruded Insulation Systems for Transmission Cables", EPRI TR-100268, 7

Watts Bar Nuclear Plant - Training Radius Program, Revision 1 inverse power model noted above by Stone, the report notes the existence of several exponential models which appear similar in nature to that used by Bruning and Campbell in that they consider the mechanical energy of the stress as reducing effective activation energy of the material.

The report also provided a review of existing test data. One study of a 275 kV cable had shown some conductor movement through the insulation when the operating temperature was in the overload region (90'C to 130*C) as a result of the lateral forces imposed by the conductor and the reduction in the XLPE's compressive modulus at the elevated temperature.

It was noted that, "... conductor displacement at 900C was very small..." and thus their recommendations dealt only with the proper selection of the emergency overload temperature.

Though the cited study does not deal with "aging" in a classical sense, it does deal with the concern for interfacial disruptions. TVA's various load cycle and corona tests, described below, would have evaluated this creep tendency on a macro scale, in that substantial conductor displacement would have resulted in detectable corona discharge.

DOE Aging Management Guide' - The draft guide includes a discussion of several mechanical aging stressors that are considered significant. Included were vibratory stresses, bending and flexing during maintenance activities and thermomechanical-gravitational forces (the latter being a "ratcheting" effect which can occur when power cables are subject to unsupported vertical drops and load cycled). The report does note the possibility of a "tensile failure" as a result of this latter condition but the concern is for the load on the equipment termination as a result of the ratcheting and not any tensile load on the insulation itself.

May 1992.

22"Aging Management Guideline for Commercial Nuclear Power Plants - Electrical Cable and Terminations", Draft Report, April 28, 1995, prepared by Ogden Environmental and Energy Services Company for the Department of Energy.

Industry Survey During the period from 1989 to 1992, TVA's Corporate Cable Specialist contacted several of the leading engineers and chemists in the industry to discuss the WBN cable bend radius program. The contacts were of an informal nature and little documentation of the discussions exists. The intent of the contacts was to ensure that all known effects had been evaluated and to identify the appropriate protocols when laboratory work was required. The listing of course does not imply that those individuals ever reviewed or approved of the WBN program, only that they were surveyed as a part of its development.

Nme I295 Affiliation Jack Lasky Okonite Lasky, the chief engineer at Okonite, suggested that bird caging of the copper was a greater concern than any synergism at the stress levels under consideration. Lasky also had a concern for plastic deformation of certain multiconductor cables under tight bend conditions. He proposed a bend-and-AC-hipot test and believed that there would not be any synergism unless an ozone environment was present.

Bob Gehm Rockbestos Gehm, the chief engineer at Rockbestos, believed that one could readily bend cables to one-half of the ICEA limits without degradation.

He noted that ICEA limits were typically fabricated with power cables in mind.

Thus, when evaluating instrumentation and control applications, considerable margin exists. Suggested a bend test where the exposed copper was evaluated for deformation.

Keith Petty SWEC Petty, the SWEC Corporate Cable Specialist, participated in a bend radius test program with Rockbestos in the late 1970s to assist Palo Verde, Limerick and Perry Nuclear Stations. The programs included bending followed by visual inspection, assessment of conductor deformation, insulation resistance and dielectric breakdown.

Petty also noted that ICEA was considering establishing the bend radius of multiconductor cables as a function of the OD of the singles, rather than as a function of the completed cable.

8

Watts Bar Nuclear Plant - Training Radius Program, Revision 1

.A Larry Bustard Sandia Bustard, one of the key researchers in the cable arena, had a particular concern for CPE jacketed cables due to that materials tendency to shrink at elevated temperature. He noted that Ken Gillen of Sandia had observed some synergism between stress and aging in an ozone environment. Suggested that the brute force approach would be to measure elongation post-LOCA on bent and unbent samples.

R. Arhart DuPont Arhart, the chief cable polymer chemist for DuPont, noted that there were some known synergisms as a result of testing of plastics by the automotive industry,'but that these always involved flexural stressing rather than a fixed stress.

Gary Toman NUS Toman, an engineer with ERC International at the time and a consultant to the NRC on TVA issues, suggested a LOCA on bent cables. He noted that no mandrel rebend would be necessary. He foresaw no problems except in the harshest of areas unless the bend was against a sharp comer.

Chris Diglio Consultant Diglio, who was the chief chemist for Brand Rex at the time, suggested that a program of aging unbent cables, bending a portion of them and then dielectrically breaking them all down would provide a basis for comparison.

R. Luther Consultant Luther, former Cable Specialist for Northeast Utilities, restricted his commenits to medium voltage, where he proposed an adaptation of the AEIC load cycle and corona test to assess the effect of bending on the insulation/shield system.

Morton Brown Consultant Brown, the former chief cable polymer chemist for DuPont and now a consultant for A. Schulman, noted the existence of synergisms for certain plastics used in the automotive industry. He stated that the automotive industry frequently used a "bent loop" test where the specimen is wound on a form and then exposed to the desired stressor (frequently UV).

Following this test, they optically check the plastic for the existence of stress cracks.

Joe Groeger Altran Materials Engineering Groeger, the former Assistant Director of the University of Connecticut's Electrical Research Center, had been involved in numerous programs which had evaluated cables aged under tight bend conditions. As was typical of many of the programs noted above, the second aging stress applied was voltage rather than thermal, In contrast to the work by [lstad cited above, Groeger had observed no increase in the rate of treeing due to the presence of a mechanical stress unless the cable had residual axial stresses (from the extrusion process). In this case, the compression of the insulation on the inner radius may have been the source of the observed difference rather than the existence of the additional stress on the outer radius. Groeger noted that the protocol should have relieved those stresses before commencing the aging cycle in order to avoid the uncertainty.

The TVA bend radius plan was also discussed in that time frame with other vendors/consultants who had no particular recommendations but provided feedback on the TVA plan. Those individuals were as follows:

Name Bob Fleming Steve Sandberg Paul Cardello 1995 Affiihation Kerite Delta Surprenant Consultant 9

Watts Bar Nuclear Plant - Training Radius Program, Revision 1 Table 2 (Table I of listad et. al.)

Measured number of vented water trees from the insulation screen of the sharply coiled cable per 5 mm long section (equal to an area of 230 mm 2)

Number per circumference position Radius of Aging time curvature (years) tension compression (mm) 2 3

4 5

6 50 0.3 32 32 32 13 14 9

0.5 68 72 58 10 4

6 70 0.3 21 25 42 14 11 5

0.5 26 71 71 17 10 2

100 0.3 33 16 32 8

8 12 0.5 51 90 91 19 2

to Testing to Establish "Lower Bound":

In order to assess the parameters discussed above, tests were initiated by TVA at its Central Laboratories Services Department23 (CLSD) in Chattanooga and at The Okonite Company2" in Ramsey, NJ.

These evaluations, which are type test in nature, were conducted in accordance with each lab's quality assurance program.

The first CLSD program consisted of the bending of single conductor cables, ranging in size from 16 AWG to 500 MCM, (low and medium voltage) on specially constructed forms.

The "lower bound" for such a specimen was tentatively regarded as the radius at which significant deformation occurred plus one cable diameter (lx) or the minimum practical bend, if no deformation was noted. An additional specimen was then bent to this "lower bound" and subsequently retrained to a larger radius (typically the ICEA radius).

This step was intended to demonstrate that the nonelastic components (conductor, tape shield, etc.)

would not deform during the retraining. In order to simulate conditions in "mid-run", the strands of the conductor were soldered together so that they could not move past one another to relieve the bending stress.

This was deemed a conservative factor, since many of the tight bends actually occur in the near vicinity of the termination where such movements are indeed possible.

In the case of the medium-voltage test program, if the tape shield integrity was still present (no separation, no gouging or pinching, etc.) and excessive conductor deformation (i.e., birdcaging) had not occurred, the "lower bound" value was confirmed. In all cases, the lower bound for medium voltage cables turned out to be a function of the theoretical loss of overlap of the metallic tape shield rather than conductor deformation or interracial disruptions. The postulated separation was determined by comparing the minimum permissible tape overlap (10%) as directed by ICEA requirements or TVA procurement specifications with the bend factor which results in that degree of stress. Since the tape 23 CLSD Report 90-1014, "Test to Document Cable Bend Radius Damage", June 1990. CLSD Report 90-1817, "Multi-Conductor Cable Bend Radius Damage Tests", January 1992. Additional tests were also performed for TVA's Bellefonte Nuclear Plant and reported in 92-0459. Those results were consistent with the WBN programs.

24The Okonite Company Report 02-6451, "Final Test Report for Cable Bend Radius, Corona and Load Cycle Testing of 8Kv Medium Voltage Cables",

1992.

I0

Watts Bar Nuclear Plant - Training Radius Program, Revision I does not stretch, the bend was assumed to have produced a loss of overlap corresponding to the stress.

Thus, for medium voltage the lower bound23 was determined to be four2 6.

As noted above, WBN's target training radius for its medium voltage (8 kV rated) cables used in Class I E applications is 8 times the cable's outer diameter which produces less than two percent additional elongating stress than the ICEA recommended value of twelve times. Compared to the ultimate capability of these insulations, this increase is insignificant. The critical issue for these cables is the insulation-to-shield integrity.

Using the same method used by the industry to qualify a cable system design (Load Cycling and Corona Testing), WBN developed and performed a series of tests to address this issue. However, in contrast to the protocol in AEIC Specifications CS5 and CS61', WBN's tests were performed on cable bent to a four times (4x) multiplier and retrained to 8x, The cables tested met the AEIC requirements and thus established the integrity of the insulation-to-shield systems even when subjected to a moderate bending stress.

For low voltage cables, the lower bound was reached when the non-standard bend produced a 3% conductor deformation 2" or at the minimum practical bend when that did not occur (the 3% criteria was established following discussions with various cable vendors). The lower bound for low-voltage cables 10 AWG and smaller was set at a bend radius factor of one and was set at two for cables 8 AWG and larger.

In order to ensure that the guidance provided in Rockbestos Technical Bulletin 28 was adequate for multiconductor cables which had been previously bent down to, but not below the lower bound and then retrained, additional testing was performed on ten specimens. Since the concern for this construction type is for insulation deformation (as opposed to the conductor), the test plan called for the measurement of insulation thickness at the point of greatest deformation.

The cables were deemed to be acceptable as long as the wall thickness measured at that point exceeded the ICEA minimum (ie 90% of the nominal wall thickness).

All specimens met the above criteria.

Development of Inspection/Acceptance Criteria:

Having thus defined the mechanisms of concern and having established lower bound values, a review was initiated to correlate this information with industry standards, vendor letters, voltage and current loading requirements, cable construction, and environmental parameters.

2 As noted above, the "lower bound" values defined the onset of damage and were not used to establish permissible training radii in the field.

26Additional tests were performed for TVA's Browns Ferry Nuclear Plant on 5kv cables bent to 6x.

Those tests were conducted at Cable Technologies Laboratories in New Brunswick, NJ. The results, documented in Report 93-007, were consistent with the Okonite findings.

27Association of Edison Illuminating Companies Specifications, CS5, "Thermoplastic and Cross-Linked Polyethylene Insulated Shielded Power Cables Rated 5 through 35 KV" and CS6, "Ethylene Propylene Rubber Insulated Shielded Power Cables Rated 5 through 69 KV" 28Percent conductor deformation was determined by dividing its post-bend diameter by the Given the severity of the environmental conditions postulated in certain areas (and its regulatory environment), WBN decided to take a conservative approach in primary containment and the main steam valve vault and utilize less restrictive criteria elsewhere based on test results and analysis.

Results are summarized in Table 4. Several comments regarding the table are warranted:

Class I E 10 CFR 50.492" cables located inside of primary containment and the main steam pre-bend diameter and subtracting I from the result.

2910 CFR 50.49, Title 10 of the Code of Federal Regulations, Part 50 (Domestic Licensing of Production and Utilization Facilities), section 49, "Environmental Qualification of Electric Equipment Important to Safety for Nuclear Power Plants".

II

Watts Bar Nuclear Plant - Training Radius Program, Revision 1 valve vault will comply with industry standard bend radius factors. This is in recognition of the severity of the accident environmental transient in these areas. Cables found to be bent below the lower bound will be replaced.

Medium-voltage Class I E cables required to support Unit I operation have been inspected to ensure at least an 8 times bend radius factor.

This training radius, factor is consistent with recommendations based on independent testing performed by some TVA vendors. None of these cables are located in primary containment or the valve vault. Environmental transients in the remainder of the plant are significantly lower with respect to both magnitude and duration.

Cables which were above the lower bound (4 times) but less than 8 times will receive a high-potential withstand test at maintenance levels30 prior to Unit I startup subsequent to their retraining. Cables found to be bent below the lower bound will be replaced.

Low-voltage single conductor power cables in 10 CFR 50.49 service but installed in areas ohe.r than the primary containment and the main steam valve vault will be accepted "as-is", provided that they are not bent below their lower bound. Cables found to be bent below the lower bound will be replaced31.

30 Institute of Electrical and Electronics Engineers (IEEE) 400-1980, "Guide for Making High-Direct-Voltage Tests on Power Cable Systems in the Field."

311t was originally intended that those 10 CFR 50.49, single conductor, low voltage power cables which were found to be above the lower bound but below the ICEA radius would be accepted based on a reduction in life directly proportional to the additional stress. That method would have entailed an assumption that no synergistic effect existed between the additional physical stress and aging and required laboratory confirmation of that assumption as was described in revision 0 of this plan. However, Low-voltage single conductor cables which are in 10 CFR 50.49 control applications and are located outside of the primary containment and the main steam valve vault may be accepted "as-is" without a reduction in qualified life.

Cables found to be bent below the lower bound will be replaced. Control cables are generally accepted to operate at or near ambient temperature because of the minimal current loading within this voltage level. Elimination of this factor significantly reduces concerns for this age-related phenomenon. Figure 1 is a typical plot for EPR Type 1I when used in control applications. Assuming values of 1. 1 eV for activation energy and 601C for conductor temperature results in a "qualified life" of in excess of 900 years for this 90'C material. Reducing the initial elongation by the differential stress imposed by the tight bend is shown to be of no effect for the plant's 40-year life.

Low-voltage multiconductor power, control, and signal cables which are in 10 CFR 50.49 service outside of primary containment and the main steam valve vault and multiconductor power cables which are not in 10 CFR 50.49 circuits but are in containment or the valve vault may be retrained and used without subsequent walkdowns and inspections showed that all single conductor, low voltage power cables within the scope of 10 CFR 50,49 were trained at or above the ICEA limit, obviating the need for further research in this area. The scope of the inspections was identified in WBPEVAR,9007015 (section 7) and carried out under DCNs M-09484-A, M-10189-A, M-10464-D, M-10823-A, M-10950-A and M-1095 I-A).

As was noted in the NE response to action item 712 of the WBN Independent Design Review Assessment, "No data sheets were received per the above DCN requirements, thus no cables remained installed at a radius which requires a reduction in qualified life" (see attachment 7.0, item 3). Additional confiration that this assumption was not used was obtained by a review of Tabs B and G of the EQ binders containing PXJ and CPJ cables (WBN EQ CABL-002, 008,021, 032, 043, 044, 050, 051, 052, 053).

12

Watts Bar Nuclear Plant - Training Radius Program, Revision 1 reduction in life provided they are not bent to less than the lower bound for their individual conductors. Cables found to be bent below the lower bound will be replaced. The training radius factor applied to this family (see Table 332) gives consideration to both the size and number of individual conductors. Restricting the bends in this manner limits the forces produced between the constituent components of a multiconductor cable. By eliminating this issue of concern, the 10 CFR 50.49 cables may now be regarded as qualified for their full life since the smallest bend allowable per this bulletin is 4x the diameter of a single conductor. This value corresponds to ICEA guidance.

Low-vo)tage Class I E single conductor power cables in non-10 CFR 50.49 service inside of containment or the main steam valve vault will be accepted "as-is" provided that they are not bent less than the lower bound. Cables found to be bent below the lower bound will be replaced. Since these cables have no accident service requirements, the pre-LOCA end-of-life criterion previously discussed is not applicable. However, a typical "projected life" analysis, as shown in Figure 2, indicates a minimum of 40-year service life for bends at the lower bound and above3".

EPR Power Cables, Non 50.49 EPR Control Cables 180% 0,,a@luh-Q0%

Figure 2 Figure 1 Table 3 Multiconductor Training Radius Factor

[

No. of Conductor3 4

9 or less 8

10-19 12 mom than 19 All 10 CFR 50.49 and RG 1.9711 single-jacketed coax cable in harsh environment (much of which had been installed under 33These non-50.49 power cables have no accident service requirements, thus no common mode failure mechanism exists even if aging/physical stress synergism were identifie. Any resulting failures during their required normal environment operation would be random in time.

'"Regulatory Guide 1.97, "Instrumentation for Light-Water-Cooled Nuclear Power Plants to Assess Plant and Environs Conditions During and, Following and Accident", May 1993.

32Table I, column A of Rockbestos Technical Bulletin No. 28, "Bending Radii and Installation Practices" 13

Watts Bar Nuclear Plant - Training Radius Program, Revision 1

• relaxed requirements, Attachments 2 and 5) has been replaced as a result of a concern for jacket integrity following the installation process.

While jackets are generally considered sacrificial for most other cable types, a breach in a coaxial cable's jacket could lead to moisture wicking up the braid and shorting out the connector.

To ensure the integrity of this moisture barrier, TVA adopted a new design for its harsh environment coaxial cables. The new design incorporates a second jacket, which serves as the "sacrificial layer",

while the inner jacket acts as the moisture barrier. The new double-jacketed cables will be installed to meet ICEA requirements.

The remaining cables will be used "as-is."

These cables either are not exposed to accident service conditions or are not required to mitigate the consequences of such an accident.

As such, the margins associated with the remaining cables exceed even those described above.

Long-Term Program:

In order to ensure the mechanisms pertinent to cable performance under small bend radius conditions have been properly evaluated for age-related consequences of such bends on normal and accident service, a long-term cable bend radius program plan has been established.

It's key components include a condition monitoring, inspections, failure trending, ongoing upgrades and.

industry participation.

Cable Condition Monitoring TVA has initiated a cable monitoring and trending program for WBN. The program invokes a combination of meggering, high-potential testing and visual inspection to ensure the continued integrity of cables in safety-related systems.

WBN's cable condition monitoring program has been developed to comply with the recommendations set forth in IEN 86-493s.

3SUSNRC IE Information Notice (IEN) 86-49, "Age/Environment Induced Electrical Cable Failures."

Since the scope of lEN 86-49 is much broader than bend radius, the cable condition monitoring aspect of TVA's long-term bend radius program addresses medium voltage power, control voltage, and instrumentation voltage as well as the previously mentioned low voltage power cables. However, the program does emphasize monitoring of feeder cables to large motors (100 hp or larger), because of their consequent higher rate of aging due to their thermal loading and cycling. This results in the routine dielectric examination of the very circuits expected to first display signs of postulated degradation when overbent.

Additional confidence is provided by implementation of a program that merges the following test and inspection data to ensure the early identification of undesirable trends.

Periodic Testing Periodic insulation resistance testing on a random selection of 80 percent of 100 horsepower and larger Class IE motors will be performed on an interval not to exceed 2 refueling outages for WBN. This testing will be governed by the plant preventive maintenance program36. The specific details of the test and acceptance criteria are addressed on a case by case basis by the governing maintenance instruction".

Testing of Class IE 6.9kV and 480V motors 100 hp and larger is initially done from the breaker cubicles, with motor connected, and therefore, includes verification of the motor power cables. If results indicate degraded or questionable insulation, and cleaning or drying of the motor windings, etc. is unsuccessful in bringing the motor/cable into compliance with the acceptance criteria, the motor leads are then disconnected from the power feeder cables and each is tested separately.

A general description of the test is provided below but may 36Site Standard Practice (SSP)-6.02, "Maintenance Management System."

37Maintenance Instruction (MI)-57.108, "Insulation Resistance and Continuity Tests for Rotating Machinery, Cables, and Transformers."

14

Watts Bar Nuclear Plant - Training Radius Program, Revision I vary, as previously mentioned, depending on the specific load:

1.

A megger test to ground using 2,500V direct current (DC) on 6.9kV circuits and 1kV DC on 480V circuits is performed.

2.

Insulation resistance readings are recorded at I and 10 minutes after initiation of megger testing for 6.9kV 'and 1 minute for 480V circuits. The minimum acceptable insulation resistance for the 6.9kV circuits is 8 megohms and 1.5 megohms for the 480V circuits. In addition, Polarization Index (PI) is calculated for 6.9 kV motors in accordance with site procedures using the following formula:

PolarizationIndex-TenMinuteReading OneMinuteReading With motor and cable connected the acceptable PI is 2. When testing the cable by itself, the minimum acceptable PI is 1. The lower minimum acceptable PI for the cable by itself is due to station cables having low charging times because of their relatively short lengths.

3.

A DC step voltage test is performed on the 6.9kV circuits with the phases (cable conductors) connected together.

The test voltage is slowly increased in IkV DC increments up to and including 13kV. Leakage current readings are taken after 3 minutes at each interval. The test results are then plotted on a graph of voltage versus leakage current.

A cable is adequate if the plot is an approximately straight line without a "knee."

The above acceptance criteria are consistent with those recommended by industry standards (e.g.,

IEEE 141 and IEEE 400)"'.

It is noted that 38IEEE 141-1993, "Recommended Practice for Electrical Power Distribution for Industrial Plants" and IEEE 400-1990, "Guide for Making High-Direct-Voltage Tests on Power Cable Systems in the consistent with industry thinking, WBN no longer performs routine DC hipot test on cables which have been subject to long-term submergence".

Inspection Each time devices required to mitigate IOCFR50.49 events (which are located in harsh environments) are entered, low voltage control, instrument level, medium voltage, or low voltage power field cables are visually inspected.

This inspection provides visible indication of premature cable deterioration inside equipment and is accomplished through the Environmental Qualification and Preventive Maintenance Programs.

Failure Analysis and Trending In order to identify potential adverse conditions, trending of maintenance history is performed. When an adverse trend is substantiated"°, a corrective action program document is initiated in accordance with site procedures"1. Thus, via the corrective action program, the extent of condition and cause (e.g., bend-radius splice, submergence, etc.) are determined and appropriate actions taken.

Ongoing Upgrades New installations involving Class I E cables are required Field."

39EPRI TR-10 1245, "Effect of DC Testing on Extruded Cross-Linked Polyethylene Insulated Cables," January 1993 and "Effect of D.C. Testing Water Tree Deteriorated Cable and A Preliminary Evaluation of V. L. F. as Alternate," G. S. Eager, B.

Fryszczyn, C. Katz, H. A. Elbadaly and A. R. Jean, IEEE Transactions on Power Delivery, Volume 7, Number 3, July 1992, Pages 1582-1591.

4SSP-6.04 - "Equipment History and Failure Trending."

41SSP-3.04 - "Corrective Action Program."

15

Watts Bar Nuclear Plant - Training Radius Program, Revision I to meet the current Corporate42 and Site procedures 43, which were revised to reflect industry standards, These procedures also require that during maintenance and modification activities an attempt is to be made to bring the portion(s) of previously installed Class IE cable being disturbed into compliance with current requirements.

Industry Participation TVA is currently actively participating in the development of standards and test methodologies relating to cable installation issues. TVA personnel are participating in IEEE working groups responsible for IEEE-422, 690, and 1185 and are members of 383 and 1186". Furthermore, TVA is one of the major sponsors 42TVA Design Standard, DS-E12.1.5, Revision 4, dated June 22, 1994, "Minimum Radius for Field-Installed Insulated Cables Rated 15,000 Volts and Less and "General Construction Specification G-38, "Installation, Modification, Maintenance of'Insulated Cables Rated Up to 15,000 Volts".

4 MMI-57.113 - "Cable Bend Radius",

Instrument Maintenance Instruction (IM I)- 101 -

"Instrument Maintenance Planning and Work Activity Guidelines", IMI-200 - "Periodic Calibration of Plant Instrumentation and Control Equipment", "Cable Pulling for Modification/Addition Instruction (MAI) -

3.3 - "Cable Terminating, Splicing, and Testing for Cables Rated Up To 15,000 Volts" and Modification/Addition Instruction (MAT) - 3.2 -

"Cable Pulling for Insulated Cables Rated Up to 15,000 Volts."

44IEEE 383-1992, "Standard for Type Test of Class I E Electric Cables, Field Splices, and Connections for Nuclear Power Generating Stations",

IEEE 422-1986, "Guide for the Design and Installation of Cable Systems in Power Generating Stations", IEEE 690-1984, "Standard for the Design and Installation of Cable Systems for Class I E Circuits in Nuclear Power Generating Stations", IEEE

• 1185-1994, "Guidelines for Installation Methods for Generating Station Cables" and IEEE-P 1186, "Recommended Practices for the Evaluation of of EPRI Cable Life Program and a member of the peer review group for EPRI Cable Diagnostics Project. As a result, TVA will be cognizant of developments within the industry concerning condition monitoring and bend radius and will incorporate them as appropriate.

Vendor Feedback In July 1995, Corporate Cable Specialist, Kent W.

Brown visited Brand Rex, Rockbestos and The Okonite Company for the purpose of reviewing Revision 0s of the plan that WBN had undertaken to resolve the issue of tight cable bend radius.

Prior to the meetings an overview of this issue was prepared and provided to the three companies. Because of the detail provided in the white paper, no formal presentation of the issue was made. Mr. Brown gave a general overview of the key points and provided clarifications as requested. Per our agreement with the NRC, the vendors were not requested to "approve" the plan, but to only provide a verbal assessment. A general review of the vendor response is as follows:

July 20, 1995 BICC Brand Rex, Willimantic, CT 860-456-8000 John L. Macchia President Jerry Liskom Market Manager Ed Aberbach Product Engineer Richard Metz QA Engineer Chris Durland Senior Applications Engineer, B ICC, West Nyack, NY Following the discussions, Mr. Macchia stated that Brand Rex believed that the bends in question should pose no problems for the subject cables. He stated that industry bend radii were known to be conservative but acknowledged that the degree of conservatism has not been established. While he did not believe that such a program should have been necessary, he noted that BICC Brand Rex was in agreement with the actions to date, as well as those Installed Cable Systems for Class IE Circuits in Nuclear Power Generating Stations."

45 Memo from R. C. Willimas to M. C.

Brickey dated July 28, 1996 (B43 950728.005).

16

Watts Bar Nuclear Plant - Training Radius Program, Revision I remaining to be completed.

July 24 and 25, 1995 Rockbestos, East Granby, CT 860-653-8300 Robert Gehm, Sr.

Chief Engineer Robert Konnick, Jr.

Product Engineer As at Brand Rex, Mr. Brown provided a general overview of the history of cable problems at WBN relating to the issue of bend radius. Mr. Gehm, who had been one of those originally surveyed, believed that the proposed program was sound, though beyond that which should have been required of TVA.

In support of that position he cited three considerations beyond his original comments.

First, he noted that most of the ICEA limits were developed in support of paper-lead cables.

The helically wound paper tapes have practically no elasticity and required conservative measures to ensure that the layers did not tear or buckle. When extruded dielectrics.came into wide usage, Mr.

Gehm stated that there simply was no compelling reason to change the then current bend radius factors.

Second46, he noted that nuclear grade Raychem products (typically cross-linked polyolefins) function by ensuring that there is a residual recovery force present after heat-shrinking. Extensive testing of these products for nuclear service has failed to identify any synergism between that stress and thermal aging. Third, Mr. Gehm noted that it did not appear that WBN had taken full credit for the fact that even power cables do not run at or near 900C. He observed that the reduction of the stressor certainly results in a corresponding reduction of any potential synergism.

Regarding ICEA bend radius limits, TVA agrees with Gehm's position but note that the basis for selection of 46Comments two and three pertain to the postulated synergism between physical stress and aging and have thus been made moot (along with the TVA responses) given the absence of bends below ICEA allowables for single conductor power cables in 10 CFR 50.49 service.

the appropriate multiplier (paper-lead or polymeric) has not been published and thus it is difficult to take credit for when bending the latter type tighter than the standards based on the earlier materials permitted.

With respect to the residual stress in Raychem products, Gehm is correct. However, the concerns expressed for the thermal annealing of other semi-crystalline materials would likewise apply to the previous Raychem testing.

It is for that reason that Raychem products are tested in both the aged and unaged condition since the unaged product would have a higher residual stress and therefore have a higher for potential for splitting.

Raychem takes great pains in choosing its application ranges to limit those forces.

Gehm conceded that Raychem had thus not been aged in such a manner as to fully retain the stress but noted that this had elicited no regulatory concern and could see no reason why the WBN cables under similar conditions should be of any more concern.

Thus, while the parallel is true, the successful testing of one material applied within its design limit (Raychem) does not automatically cover the use of another material stressed beyond its design limit (cable).

We agree that there is substantial margin in our cable sizing process given the use of load multipliers, the assumption of no load or time diversity, the assumption of filled raceways and the use of maximum normal ambients.

As with other conservatisms, the great difficulty lies in the quantification of those margins.

Furthermore, this approach assumes that the affect of aging and stress is small and can thus be offset by the application of margin, but this involves assuming that which we have been asked to prove.

July 26 and 27, 1995 The Okonite Company, Ramsey, NJ 201-825-0300 John Cancelosi Mgr. of Application Eng Following the customary review and discussion, Mr.

Cancelosi stated that Okonite had no problem with WBN's program as described. It was their opinion that much of the work was well beyond that which should have been necessary but that the program as described was logical anid comprehensive. It was his opinion that the results of the work would be of general interest to the industry and that TVA should consider publication or presentation of the data.

17

Watts Bar Nuclear Plant - Training Radius Program, Revision I The changes to the long term bend radius plan which necessitated revision 1 of this document were discussed with each of the above vendors by K. W. Brown in February and March 1996 following their review of a draft of that revision (B43 960321 003). The purpose of that review was to ensure that the vendors still agreed that the plan would achieve the desired objective. The results of those discussions were as follows:

Brand Rex reviewed the draft plan and in a letter to K.

W. Brown dated February 29, 1996 (B43 960321 001) noted that they concurred that the plan would ensure early identification of adverse trends and could not identify any deficiencies in the TVA approach in addressing bend radius concerns.

Robert Gehm, Sr of Rockbestos discussed his review of the draft plan with K. W. Brown on February 27, 1996.

Gehm noted that Rockbestos had no technical objections to the revised plan.

John Cancelosi of Okonite discussed his review of the draft plan with K. W. Brown on March 13, 1996.

Cancelosi noted that Okonite had no technical objections to the revised plan.

Conclusigon As a result of the actions undertaken by TVA, including testing, field inspection, and rework; 10 CFR 50.49 cables inside containment and main steam valve vaults meet industry standard bend radius criteria. For the remaining cable population, TVA will utilize less restrictive bend radius criteria with corresponding adjustment of qualified life, where appropriate.

Ongoing condition monitoring, inspections and failure analysis, will provide TVA the necessary confirmation of the foregoing evaluations.

Attachments 1.0 Okonite, letters dated June 7, 1983 (EEB 830610014),

September 29, 1983 (EEB 831004003) and August 19, 1986 (B43 860821003).

2.0 TVA Design Standard, DS-E12.1.5, Revision 0, dated September 20, 1983, "Minimum Radius for Field-Installed Insulated Cables Rated 15,000 Volts and Less".

3.0 Rockbestos, letters dated September 8, 1983 (EEB 830913008) and July 25, 1986 (B43 860729003).

4.0 Rockbestos Technical Bulletin No. 28, revision 3, dated April 25, 1979.

5.0 Brand Rex, letters dated August 29, 1983 (EEB 830906006),

September 26, 1983 (EEB 830930009) and July 29, 1986 (B43 860820004).

6.0 TVA Design Standard, DS-E12.1.5, Revision 4, dated June 21, 1994, "Minimum Radius for Field-Installed Insulated Cables Rated 15,000 Volts and Less".

7.0 NE response to action item 712, WBN Unit 1, Independent Design Review Assessment, 12/27/1994 (see item 3).

18

Watts Bar Nuclear Plant - Training Radius Program, Revision I Table 4 Watts Bar - Cable Bend Radius Summary MV Power I/c LV f

m/c LV I/c ta/c Signal Coax Power Power Control Control 50.49 I/C or NISVV n/a b

b b

b b

h Other larsh a

d C

e C

C h

Non 50.49 I/C or MSVV n/a f

c 9g g

h,g Other larsh a

g 9

IE Mild a

g gg g

g g

(a) if< LB, replace*

if> LB, retrain to > 8x (b) if< LB replace' if> LB, retrain to ICEA (c) if< LB replace" if> LB based on the OD of the singles, retrain to Rockbestos Technical No. Bulletin 28.

(d) if< LB replace*

if> [CEA use-as-is (inspections revealed no cables with a bend radius > LB and < [CEA)

(e) if< LB replace' if> LB use-as-is based on margin analysis and long-term programs (f if< LB replace' if> LB use-as-is based on projected life (g) use-as-is based on margin analysis and long-term programs (h) IOCFR50.49 and RG 1.97 cables to be replaced in harsh areas with new double-jacketed construction

• Replace In some cases the entire cable will not be replaced. Where possible, only the portion of the cable where the training radius'is less than acceptable will be replaced. For example, cables or portions of cable reworked or replaced under the new site cable installation procedures may be excluded from the reinspection/rework design change notices.

Table Abbreviations: LB l/c mi/c I/C MSVV LV MV lower bound (4x for MV cables, 2x for LV cables 8 AWG and larger and Ix for LV cables 10 AWO and smaller) single conductor cable multiconductor cable inside containment main steam valve vault low voltage (typically 480vac) medium voltage (6.9 kVac phase-to-phase) 19

FRONT SIDE OF SPECIFICATION REVISION NOTICE (SRN)

FOR A GENERAL ENGINEERING SPECIFICATION QA RECORD June 23, 2004 Holders of G-40 TVA GENERAL ENGINEERING SPECIFICATION G-40 (R15) FOR " INSTALLATION, MODIFICATION AND MAINTENANCE OF ELECTRICAL CONDUIT, CABLE TRAYS, BOXES, CONTAINMENT ELECTRICAL PENETRATIONS, ELECTRIC CONDUCTOR SEAL ASSEMBLIES, LIGHTING AND MISCELLANEOUS SYSTEMS" SPECIFICATION REVISION NOTICE SRN-G-40-79 AFFECTS: All Plants; section 3.12.10, 3.12.11 and 3.12,12.

INSTRUCTIONS: The attached pages constitute an advance revision to the subject specification.

Insert these pages in that specification in accordance with the instructions on the reverse side of this memo and then file the memo in the front of each controlled copy of the specification.

SIGN ES/APPROVAL:

PRIZARED DESIGF4 VFVEIF 1CATJ0N--*.

APPR&

JO o DATE DATE The effective date of this SRN is 90 days from the date of issue or sooner upon incorporation into site procedures.

The requirements of this SRN are not retroactive. The RIMS number of the SA/SE for this SRN is B43 040623 002.

C. R. Butcher Manager, Electrical Engineering Corporate Engineering (LP 4H-C) kwb Attachment cc (Attachment):

EDMS, K.W. Brown

DCRM, WR4Q-C LP 4H-C LP 4D-C Attached is the SIGNED ORIGINAL; please distribute copies of this memo and its attachment(s) to all holders of controlled copies of this general engineering specification and release the RIMS copy.

BACK SIDE OF SPECIFICATION REVISION NOTICE (SRN)

Page 1 of 1 SRN-G-40-79, FILING INSTRUCTIONS REMOVE AND DESTROY I

REPLACE WITH General Engineering Specification G-40 INDEX dated August 25, 2004 Pages: 75 From-G40 R15 General Engineering Specification G-40 INDEX dated June 23, 2004 Pages: 75 From SRN-G-40-79

TENNESSEE VALLEY AUTHORITY NUCLEAR POWER ELECTRICAL ENGINEERING GENERAL ENGINEERING SPECIFICATION G-40 INSTALLATION. MODIFICATION AND MAINTENANCE OF ELECTRICAL CONDUIT, CABLE TRAYS. BOXES, CONTAINMENT ELECTRICAL PENETRATIONS. ELECTRIC CONDUCTOR SEAL ASSEMBLIES. LIGHTING AND MISCELLANEOUS SYSTEMS 11111 I1 11111 I11 1 i liii 5754552786 CHAT GCS ALL G-40 082400 15 REVISION R14 R15 R16 R17 R18 RO f R-EPARED CH Sudduth KW Brov,,n VERIFIED APPROVED FW Chandler JK Greene

"'I I

'j L Nk(,C-?

.DB Weaver RC Williams f~.C. tVU[ia*t*

LATE 08/06/75 1/20/1999 DATE 08/06/75 1/20/1999 1 /24106

INSTALLATION, MODIFICATION AND MAINTENANCE OF G-40 ELECTRICAL CONDUIT CABLE TRAYS, BOXES, REV 15 CONTAINMENT ELECTRICAL PENETRATIONS, ELECTRIC CONDUCTOR SEAL ASSEMBLIES, LIGHTING AND MISCELLANEOUS SYSTEMS Revision Log Rev. No.

DESCRIPTION OF CHANGE-Date 14 This revision incorporates the following SRNs:

01/20/1999 SRN-G-40-74 (B43 950614 001) - Revised section-3.2.1.12-B for Browns Ferry Nuclear Plant.

0 SRN-G-40-75 (B43 950709001).- Revised sections 3,2.1.15.A and 3.2.2.9 for Watts Bar Nuclear Plant.

a SRN-G-40-76 (B43 950713 007) - Removed Appendices W_ X Y and Z for All Plants.

Duplicate notes for Figure 3.2.6-3-1 were deleted from the end of section 3.2.6.3. the font size of the notes was reduced to distinguish them from the body of the Gspec and allow them to be on the same page as the formula.

The page reference in the definition of FL was therefore eliminated.

No Safety Assessment was performed for this revision since one had been performed on June 14. 1997 (B43 970614 001) on G40 rev. 13 along with SRNs 74, 75 and 76.

The effective date and retroactivity of any SRN included in this revision is as noted in the SRN.

15 This revision incorporates the following SRNs:

08/25/2000 SRN-G-40-77 (B43 990721 001) - Revised section 3.2.2.9 on internal conduit sealing. An SA/SE was performed for this SRN (T25 990721 957)_

SRN-G-40-78 (B43 991116 001) - Revised sections 1.1.2. 3.2_1.15.A, 3.2.2.4. 3.2-6. l.G.4-3.3.5 and 6 as a result of the Triennial Reviewof the Gspec. An SA/SE was performed for this SRN (B43 991115-001).

The following editorial changes were also made during this revision:

Re-added:the heading to section 3.2.6, "Flexible Conduit" which had been inadvertently dropped during earlier revisions Corrected the spelling of"Patel" in Table 3.2.6.3-2.

In note 2 for Table 3-2.6.3-2*and reference 6.19 changed the calculation identifier to CD-Q0999-000001. In order to maintain the tie to its original identifier: included the following: "(previously' CEB-CQS-449, B41 940620 001)".

No Safetv Assessment was performed for this revision since one had been performed for revision 13 along with all subsequent SRNs as noted above.

The effective date and retroactivit-of any SRN included in this revision is as noted in the SRN.

ii_

INSTALLATION, MODIFICATION AND MAINTENANCE OF G-40 ELECTRICAL CONDUIT CABLE TRAYS, BOXES, REV 15 CONTAINMENT ELECTRICAL PENETRATIONS, ELECTRIC CONDUCTOR SEAL ASSEMBLIES, LIGHTING AND MISCELLANEOUS SYSTEMS TABLE OF CONTENTS Page PR E FA C E v

1.0 GENERAL 1

1.1 S co p e.............................................

1 1.2 Drawings and Other Documents.....-

3 1.3 Responsibilities 5

1.4 D efi nitions 5

2.0 M A T E R IA L S I................................................

6 2.1 General 6

2.2..

M ajor or Special M aterials.................................

7 2.3 M iscellaneous M aterials 8

2.4 Material Storage and Handling......................................

15 3.0 IN ST A L L A T IO N......................................................................................................

16 3.1 G eneral.

16 3.2 Conduit....................................................

16 3.3 Conduit Boxes........................................................

66 3.4 Cable Trays 69 3.5 Manholes and Handholes........................................

71 3.6 Cable Trenches and Underfloor Ducts 72 3.7 Electric Conductor Seal Assemblies (ECSAs) 72 3.8 Containment Electrical Penetrations 73 3.9 Lighting System....................

.73 3.10 Communication System.........................

74 3.11 Secunity Systems

........................................................ 74 3.12 M arking and Identification 74 3.13 T olerances 76 4-0 VERIFICATION REQUIREM ENTS 77 4.1 Exposed Conduit 77 4.2 Embedded Conduit 78 iii

INSTALLATION, MODIFICATION AND MAINTENANCE OF ELECTRICAL CONDUIT CABLE TRAYS, BOXES, CONTAINMENT ELECTRICAL PENETRATIONS, ELECTRIC CONDUCTOR SEAL ASSEMBLIES, LIGHTING AND MISCELLANEOUS SYSTEMS G-40 REV 15 TABLE OF CONTENTS (Continued)

Paac 4.3 Boxes 4.4 Cable Tray 4.5 Manholes. Handholes. Trenches. and Undcrfloor Ducts 4.6 Electric ConductorS

.ss

, bfics SI A......s.........bli..................

4.7 Containm ent Electrical Penetrations 4.8 L ig h ting S y stem..............................................................................

4.9 Com m unication Security System s 5.0 TESTING/ACCEPTANCE REQUIREMENTS 80 81 83 84 84 85 85 86 86 86 87 87 87 90 5.1 5.2 5.3 5.4 G e n e ra l..........................................................................

Containm ent Electrical Penetrations Electric Conductor Seal Assemblies Lighting System........................................................................

6.0 R E F E R E N C E S..................................................

APPENDIX J - SOURCE NOTES jv

INSTALLATION, MODIFICATION AND MAINTENANCE OF G-40 ELECTRICAL CONDUIT CABLE TRAYS, BOXES, REV 15 CONTAINMENT ELECTRICAL PENETRATIONS, ELECTRIC CONDUCTOR SEAL ASSEMBLIES, LIGHTING AND MISCELLANEOUS SYSTEMS PREFACE-This. General Engineering Specification supersedes TVA General Construction Specification No. G-3 for Browns Ferr, Nuclear Plant and all future nuclear plants.

It also supersedes Sequoyah Nuclear Plant Project Construction Specification No. N2E-860.

This specification is intended to be-a general guide: therefore, it does not define installation procedures for all possible configurations.

The materials used in the construction of nuclear plants (and other projects) are continually reviewved by the Division of Occupational Health and Safety (OC H&S). Policy and Coordination Branch, for their acceptability to the health. and safety of personnel.

Should a. material, specified herein become restricted from use. an equivalent materialfapproved by the, OC H&S. Policy and Coordination Branch, shall be used.

Since this specification applies to more than one plant. generic wording must be used to express the requirements. Interpretations or specific applications for each plant which differ from the wording in this specification shall be addressed by the Nuclear Engineering group at the site.. This shall be accomplished by obtaining NE review and concurrence with revisions to site procedures which implement the specification interpretations.

Changes which incorporate wording in this specification verbatim or are outside the scope of this specification do not require NE review.

V

INSTALLATION, MODIFICATION AND MAINTENANCE OF G-40 ELECTRICAL CONDUIT CABLE TRAYS, BOXES, REV 15 CONTAINMENT ELECTRICAL PENETRATIONS. ELECTRIC CONDUCTOR SEAL ASSEMBLIES, LIGHTING AND MISCELLANEOUS SYSTEMS 1.0 GENERAL 1.1 Scope 1.1.1 This general engineering specification describes the minimum engineering requirements for materials receiving, storage and handling, and installation, modifications and maintenance of electrical conduit, cable trays, boxes, containment electric penetrations, electric conductor seal assemblies, lighting and miscellaneous systems for all nuclear plants, with the exception of those portions of the design under separate contract.

Procedures or instructions provided by the contractor shall be followed for those portions of the design under separate contract.

This specification supplements and amplifies the instructions given on the design drawings.

1. 1.2 Preapproved (prior to construction) variances / exceptions, which have been dispositioned by engineering, but do not constitute a generic change to the requirements of this specification are issued in Exception Manuals wvhich are issued and distributed by the applicable site in accordance with NEDP 10. Distribution of these manuals shall be made to all holders of controlled copies of this specification (G-40).

1. 1.3 Browns Ferrv Nuclear Plant:

1.1.3.1 During maintenance activities, only that portion of the. TVA field-installed conduit raceway system being disturbed is required to meet G-40 requirements. Restoration maintenance are those conditions wvhere electrical equipment requires a disconnection of its externally connected conduit system so that maintenance or rework can be performed. Examples of restoration maintenance are:

A.

When a failed electrical component-such as a solenoid valve, has to be replaced (via a work request).

B.

Equipment rework, such as the need to rewind a motor.

which requires moving the equipment to a service center.

C.

When conduit is temporarily moved to facilitate the removal/addition of equipment such as a tank, piping. or ventilation, duct.

i

INSTALLATION, MODIFICATION AND MAINTENANCE OF G-40 ELECTRICAL CONDUIT CABLE TRAYS, BOXES, REV 15 CONTAINMENT ELECTRICAL PENETRATIONS, ELECTRIC CONDUCTOR SEAL ASSEMBLIES, LIGHTING AND MISCELLANEOUS SYSTEMS 1.0 GENERAL (Continued)

I 1.3.2 Restoration maintenance to flexible conduit that does not meet G-40 requirements at BFN can be made, provided the following conditions are met:

A.

When specified. the flexible conduit shall be reconnected as dcfined on design drawings.

B.

When not defined on design drawings, flexible conduit containing cables listed as safety-related on the Q-list should be reconnected to meet the requirements of Section 3.2.6 unless an approved variance is provided in Appendix W.

C.

Flexible conduits which do not contain Q-list cables may be installed or replaced to the best available configuration.

1.1.3.3 When conduit systems that are part of the vendor furnished equipment (such as panels, racks, skid-mounted assemblies, motors. etc.) are required to be removed or replaced for maintenance, it may be returned to the as-found length.

The removal and reconnection of vendor conduit does not constitute restoration maintenance.

The replacement of vendor installed conduit is considered restoration maintenance.

The repair or replacement of vendor supplied conduit systems shall be in accordance with established plant procedures/instructions.

INSTALLATION, MODIFICATION AND MAINTENANCE OF ELECTRICAL CONDUIT CABLE TRAYS, BOXES, CONTAINMENT ELECTRICAL PENETRATIONS, ELECTRIC CONDUCTOR SEAL ASSEMBLIES, LIGHTING AND MISCELLANEOUS SYSTEMS G-40 REV 15 I

I II III ll I

1.0 GENERAL(Continued) 1.2 Drawintzs and Other Documents 1.2.1 It is the responsibility of engineering to prepare detailed design drawings and standards for the installation of conduit systems and conduit boxes, The latest revision of the documents or a site-specific document with the same number listed below, in effect at the time of installation, shall be followed.

DS-El.2.1 DS-E 1.2.2 DS-E13.1.4 DS-E13.1.6 DS-E13.1.7 DS-E13. 1.11 DS-E13.6.1 D

DS-E13.6.2 Electrical Nameplates (Browns Ferry Nuclear Plant and all hvdroelectric-and fossil-fuel plants)

Electrical Equipment Nameplates Sequoyah and Subsequent Nuclear Plants Conduit - Maximum Cable Diameter for Various Rigid Steel Conduits Spacing of Locknuts on Steel Conduit Dimensions of Rigid and Flexible Metal Conduit Bends PVC Conduit

Raceways, Conduit Box Minimum Requirements Design Racewavs. Use of Conduit Bodies in Conduit Systems SD-E 13.1.1 Expansion/Contraction Embedded

Aluminum, Metal. and Steel Conduit Joint for Intermediate SD-E13.1-2 SD-El.3,4.1 Expansion and Deflection Fitting for Embedded Aluminum.

Intermediate Metal, and Steel Conduit Concrete Reinforcement Bar Insulation to Reduce Induction Heating

INSTALLATION, MODIFICATION AND MAINTENANCE OF ELECTRICAL CONDUIT CABLE TRAYS, BOXES, CONTAINMENT ELECTRICAL PENETRATIONS, ELECTRIC CONDUCTOR SEAL ASSEMBLIES, LIGHTING AND MISCELLANEOUS SYSTEMS G-40 REV 15 1.0 GENERAL (Continued) 1.2.1 (Continued)

• SD-EI3.6.3 SD-EI3.6.5 SD-E15.3.3 SD-EIS.3.4 N3C-944 G-14 G-29 G-34 Conduit Boxes. Frames, and Covers Conduit Box Connection (Watertight)

Conduit. Cable and Wire Identification Tags (Browns Ferry Nuclear Plant and all non-nuclear projects)

Racewavs. Cable and Wire identification Tags (Sequovah Nuclear Plant and All Subsequent Nuclear Projects)

Watts Bar Nuclear Plant - Engineering Requirements Specification.

"Conduit and Conduit Support. Installations" TVA General Engineering Specification.

"Selecting, Specifying. Applying. and Inspecting Paint and Coatings" TVA General Engineering Specification (Volume VII), "Process Specification for

Welding, Heat Treatment.

Nondestructive Examination, and Allied Field Fabrication Operations" TVA General Engineering Specification.

"Repair of Concrete" TVA General Engineering Specification.

"Surface Preparation, Application, and Inspection of Special Protective Coatings for Nuclear Plants" G-55 4

INSTALLATION, N1ODIFICATION AND MAINTENANCE OF G-40 ELECTRICAL CONDUIT CABLE TRAYS, BOXES, REV 15 CONTAINMENT ELECTRICAL PENETRATIONS, ELECTRIC CONDUCTOR SEAL ASSEMBLIES, LIGHTING AND MISCELLANEOUS SYSTEMS 1.0 GENERAL (Continued) 1-2.2 Where specific instructions are lacking on design documents, engineering shall be requested to provide the necessary information on a case-by-case basis.

1.2.3 It shall be the joint responsibility of engineering. construction and modifications/maintenance to record changes on the design drawings that were made during construction, modification or maintenance for the as-built record in accordance with established administrative and quality assurance procedures.

1.3 Responsibilities Corporate Engineering Electrical (CE-E) is responsible for the contents of this document.

The respective site construction manager. engineering manager, modifications manager or maintenance manager. acting directly or through properly authorized agents, is responsible for enforcing the requirements of this general engineering specification.

The Lead Engineer in the site engineering organization is responsible for enforcing the requirements of this specification.

1.4 Definitions 1.4.1 Class I E. The safety classification of electrical equipment and systems that are essential to emergency reactor shutdown, containment isolation, reactor core cooling and containment and reactor heat removal or otherwise are essential in preventing significant release of radioactive material to the environment.

1.4.2 Compatible. A material suitable for use with adjoining materials and the environment (i.e., proper size, similar materials, such that no adverse reaction occurs, able to withstand temperature, radiation and other harmful parameters for the area, as recommended for use by the respective manufacturer).

5

INSTALLATION, MODIFICATION AND MAINTENANCE OF G-40 ELECTRICAL CONDUIT CABLE TRAYS, BOXES, REV 15 CONTAINMENT ELECTRICAL PENETRATIONS, ELECTRIC CONDUCTOR SEAL ASSEMBLIES, LIGHTING AND MISCELLANEOUS SYSTEMS 1.0 GENERAL (Continued) 1.4.3 Seismic Catevorv I (Class I at BFN).

Those structures. systems or components which perform primary safety functions. They are designed and. constructed to assure achievement of their primary safety functions at all times including a concurrent Safe Shutdown Earthquake (SSE).

1.4.4 Seismic Cateteorv I(L) (Class.II at BFN). Those portions of structures, systems or components which perform secondary safety functions to the extent that only limited-structural integrity is required. They are designed and constructed to assure achievement of their limited structural integrity at all times including a concurrent SSE.

1.4.5 Safe Shutdown Earthquake (SS.E).

An--earthquake which produces the maximum vibratory ground motion for-which structures, systems and

.components which perform a primar-safety function are designed to remain functional.

1.4.6 Verif-. An act of confirming. substantiating and assuring that an activity or condition has been implemented in conformance -with the specified requirements. Observation of each activity (event) is required.

1.4.7 Wet Location. Installation underground or in concrete slabs or masonry in direct contact with the earth, and locations subject to saturation with water or liquids, and locations exposed to-weather and unprotected:

210 MATERIALS 2.1 General 2.1.1 Materials used in the installation of electrical raceway systems shall be in accordance with TVA standard specifications: otherwise, they shall meet the requirements of recognized industrv standards (i.e., Undervriter's Laboratories

[ULI:

National Electrical Manufacturer's Association

[NEMA]) for the cla~s of service for which they are intended or shall be approved by engineering.

The materials shall be compatible with the environment and configuration in which they are to be located.

6

INSTALLATION, MODIFICATION AND MAINTENANCE OF G-40 ELECTRICAL CONDUIT CABLE TRAYS, BOXES, REV 15 CONTAINMENT ELECTRICAL PENETRATIONS, ELECTRIC CONDUCTOR SEAL ASSEMBLIES, LIGHTING AND MISCELLANEOUS SYSTEMS 2.0 MATERIALS (Continued) 2.1.2 Standard specifications applicable to the procurement of electrical conduit and fittings are:

SS-E2 1.000 Rigid Aluminum Conduit SS-E21 -001 Rigid Steel Conduit (Zinc Coated)

SS-E21.002 Fittings for Conduit and Outlet Boxes 2.1.3 Throughout this specification materials are referenced as "similar to" or equal to" a specific vendor or manufacturer.

Where this occurs, engineering shall -be consulted for an approved "similar" or "equal" material.

2.2 Maior or Special Materials Major materials and those of a special nature used in the installation shall be designated on detailed design drawings or standard drawings, described in the electrical bill of material.

7

INSTALLATION, MODIFICATION AND MAINTENANCE OF G-40 ELECTRICAL CONDUIT CABLE TRAYS, BOXES, REV 15 CONTAINMENT ELECTRICAL PENETRATIONS, ELECTRIC CONDUCTOR SEAL ASSEMBLIES, LIGHTING AND MISCELLANEOUS SYSTEMS 2.0 MATERIALS (Continued) 2.3 Miscellaneous Materials These materials are of a standard nature and shall be purchased directly by construction, modifications-or maintenance, Included are conduit bodies and covers, conduit fittings, joints and terminations, flexible conduit and other minor materials necessary for installation.

Refer to General Engineering Specification G-38 for requirements for cable ties, tags and markers.

2.3. 1. a.

Conduit accessories such as metallic conduit bodies, fittings, joints, standard couplings, and terminations (except for slip joints as permitted 'in Sections 3.2.3,7 and 3.2.3.8 and as noted below) shall be of the threaded type and approved for use with conduit systems which serve as the equipment grounding conductor.

b.

Die cast zinc conduit fittings and connectors shall not-be used-inside the reactor building primary containment which has a boric acid containment spray system-

c.

Onfly malleable iron or steel fittings shall be used.-

d.

Nonmalleable cast iron fittings and bodies may be used with aluminum conduit, only when approved by Nuclear Engineering on a case basis.

8

INSTALLATION, MODIFICATION AND MAINTENANCE OF G-40 ELECTRICAL CONDUIT CABLETRAYS, BOXES, REV 15 CONTAINMENT ELECTRICAL PENETRATIONS, ELECTRIC CONDUCTOR SEAL ASSEMBLIES, LIGHTING AND MISCELLANEOUS SYSTEMS 2.0 MATERIALS (Continued) 2.3.2 In certain embedded conduit applications, it may be impractical. or very costly to use threaded couplings. When these situations are encountered, threadless couplings (such as manufactured by Thomas and Betts or equivalent) may be used if the following conditions are satisfied:

23.2.1 The manufacturers instructions regarding installation of thrcadless couplings shall be followed.

2.3.2.2 Threadless couplings shall. be concrete tight.

2.3.2.3 Threadless couplings shall be made watertight and rustproof in accordance with Section 3.2,4.2.

2.3.2.4 The conduit systems shall be.adequately braced or supported on each side of the threadless coupling to maintain the integrity of the fitting during concrete pours.

2.325 The threadless couplings shall be electrical!y continuous or shall be made electrically continuous by means of a bonding strap or ground cable attached to the conduit system on each side of the fitting.

2.3-4 Split couplings shall not be used in new installations inside category I structures. Engineering approval for their use as a replacement.of existing split couplingsis contingent upon the following:

2.3.4.1 The manufacturer.s instructions concerning installation of the split couplings (such as tightening of bolts) shall be carefullv observed.

2.3.4.2 Where grounding of the conduit system is required and to be accomplished by brazing a ground wire to the top of the split coupling, the neoprene gasket shall be temporarily removed before the brazing process. Brazing shall be done in accordance with General Engineering Specification G-29 (Volume VII).

2.3.4.3 The joint shall be made watertight and rustproof in accordance with Section 3.2,4.2.

9

INSTALLATION, MODIFICATION AND MAINTENANCE OF G-40 ELECTRICAL CONDUIT CABLE TRAYS, BOXES, REV 15 CONTAINMENT ELECTRICAL PENETRATIONS, ELECTRIC CONDUCTOR SEAL ASSEMBLIES, LIGHTING AND MISCELLANEOUS SYSTEMS 2.0 MATERIALS (Continued) 2.3.5 Threads on conduit or conduit stubups. which have been damaged to the extent of preventing the installation of couplings, shall be rethreaded using conventional threading equipment.

Where this repair method is impractical, Threadmaker Conduit Fittings (Crouse-Hinds).

or equivalent. may be used for extending the conduit system.

Copper-silicon alloy. brass. or plastic conduit plugs shall be used where spare conduits are terminated in wet places, except for conduits penetrating fire barrier (see Section 3.2.1.9).

If additional restrictions or limitations are required on miscellaneous materials to be purchased by construction, modifications.or maintenance, these restrictions shall be so stated on the design drawings.

2.3.6 Bellefonte Nuclear Plant 2.3.6.1 Stainless steel flexible conduit -shall be used inside primary containment.

The. following types of stainless steel flexible conduit are acceptable for these application:

A.

ServicAir Company SS60. SS63 or SS63C series, or B.

American Boa, Inc-, type NBI-0 or NBI-l series, or equal.

Connector fittings of compatible material available from the respectable manufacturer shall be used. The stainless steel flexible conduit and appropriate connector fittings shall be installed in accordance with the manufacturer's instructions: however, no pressure test of the stainless steel flexible conduit is required, unless required as a part of equipment seal.

2.3.6.2 Pressure-tight stainless steel flexible conduit (ServicAir SS63C extra flexible stainless steel), as defined on design drawings and as approved for use by engineering, shall be used for installations where an equipment seal is required.

10

.INSTALLATION, MODIFICATION AND MAINTENANCE OF G-40 ELECTRICAL CONDUIT CABLE TRAYS, BOXES, REV 15 CONTAINMENT ELECTRICAL PENETRATIONS, ELECTRIC CONDUCTOR SEAL ASSEMBLIES, LIGHTING AND MISCELLANEOUS SYSTEMS 2.0 MATERIALS (Continued) 2.3.6.3 In areas outside primary containment/dcwvell, liquid-tight flexible metal conduit with a svnthetic jacket (similar to the Anaconda Company. Brass Division. "Scaltite-type UA" for available sizes, or equal) and connectors (similar to Ideal Industries, Incorporatedr "Vap-Oil-Tight" series, or equal) shall be used for flexible conduit applications, unless otherwise noted on design-drawings. Stainless steel flexible conduit described above may be used in these areas.

2.3.7 Sequoyah Nuclear Plant 2.3.7.1 The following flexible conduit shall be used for applications inside primar-containment and may be used outside primal containment. Liquid-tight flexible metal conduit with a synthetic jacket in trade sizes through 4 inches shall meet the requirements of UL 360, and liquid-tight connector fittings shall be used which meet the requirements of UL 5 14B.

Anemet Inc. Type EF with compatible connector fittings shall be used for 5-inch and 6-inch trade sizes.

2.3.7.2 Stainless steel flexible conduit with a convolute core structure (similar to ServicAir Company type SS60, SS63 or SS63C; or American Boa, Incorporated, type NB1-0 or NBI-1 series) and connector fittings or compatible material (available from the respective supplier) may be used in other areas, except inside primary containment. The stainless steel flexible conduit and appropriate connector fittings shall be installed in

'accordance with the manufacturer's instructions. however.

no pressure test of the stainless steel flexible conduit is.

required. unless required as part of the equipment seal.

Stainless steel flexible conduit installations for Class IE applications shall be analyzed by Civil Engineering for seismic qualification.

2.3.7.3 Flexible conduit connector fittings shall be of the type approved for providing continuous ground continuity.

i1

iNSTALLATION, MODIFICATION AND MAINTENANCE OF G-40 ELECTRICAL CONDUIT CABLE TRAYS, BOXES, REV 15 CONTAINMENT ELECTRICAL PENETRATIONS, ELECTRIC CONDUCTOR SEAL ASSEMBLIES, LIGHTING AND MISCELLANEOUS SYSTEMS.

2.0 MATERIALS (Continued) 2_-.8 Watts Bar Nuclear Plant 2.3:8. I American Boa. Incorporated. Type NBI-0 stainless steel flexible conduit and connector fittings of compatible material (available from the supplier) shall be used inside primary containment and the main steam valve vaults.

The stainless steel flexible conduit and appropriate connector fittings shall be installed in accordance with the manufacturer's instructions.

The manufacturer instructions requiring the application of the primer to the inside of the conduit and the threaded portion of the seal and the instruction to apply RTV compound-to the threaded portion.of the conduit seal-is not required.

Liquid-tight flexible conduit installed inside containment prior to April 1. 1994. is acceptable. ýNTiN., After April 1.

1994. if rework involving replacement of liquid-tight flexible conduit inside containment occurs, American BOA shall be used and installed in accordance w\\ith the requirements. of this section.

2.3.8.2 Liquid-tight flexible metal conduit with a synthetic jacket and liquid-tight connector fittings may be used in all other areas.

Trade sizes through 4 inches shall meet the requirements of UL standards. Anemet Inc.. Type *EF with compatible connector fittings shall be used for 5-inch and 6-inch trade sizes.

Note: Unless otherwise restricted by design dravings.

American BOA. Inc flexible metal conduit as specified in section 2.3.8-1 may be used in any location where use of liquid-tight flexible metal conduit with a synthetic jacket is permitted.

123

INSTALLATION, MODIFICATION AND MAINTENANCE OF G-40 ELECTRICAL CONDUIT CABLE TRAYS, BOXES, REV 15 CONTAINMENT ELECTRICAL PENETRATIONS, ELECTRIC CONDUCTOR SEAL ASSEMBLIES, LIGHTING AND MISCELLANEOUS SYSTEMS 2.0 MATERIALS (Continued) 2.3.8.3 Replacement of ServicAir Company stainless steel flexible conduit shall be as follows:

A.

The replacement of TVA installed, ServicAir Company stainless steel flexible conduits utilized in Class It applications inside primary containment and the main steam valve vaults shall comply wvith Section 2.3.8.1.

Replacement of TVA installed ServicAir stainless steel flexible conduit in the Turbine Building is not required unless the flexible conduit is subsequently reworked. If rework does occur in the future, the Service Air Company stainless steel flexible conduit shall be replaced in accordance with Section 2.3.8.2. In all other plant areas, the replacement of TVA installed Service Air Company stainless steel flexible conduits utilized in Class IE applications shall comply with Section 2.3.8.2.

B.

Replacement of TVA installed Service Air Company stainless steel flexible conduits utilized in non-Class IE applications is not required unless the flexible conduit is subsequently reworked.

If rework does occur in the future, the Service Air Company stainless steel flexible conduit shall be replaced in accordance with Section 2.3.8, 1 or 2.3.8.27 as applicable.

C.

Vendor installed Service Air Company stainless steel flexible conduits on a vendor qualified (Class IE) packaged unit does not require replacement except as follows. If TVA has modified the vendor's configuration in the past or if TVA modifies the vendors configuration in the future (relocate components, add components. etc).

then change out of the vendor installed Service Air Company stainless steel flexible conduits shall also be performed: replacement shall be the same as described for TVA Class IE installations in section 2.3.8.3.A above.

Change out of vendor installed Service Air Company stainless steel flexible conduits on a vendor's packaged unit which is unqualified shall be the same as for TVA non-Class IE installations described in Section 2.3.8.3.B above, W',N-7 1.3

INSTALLATION, MODIFICATION AND MAINTENANCE OF G-40 ELECTRICAL CONDUIT.CABLE TRAYS, BOXES, REV 15 CONTAINMENT ELECTRICAL PENETRATIONS, ELECTRIC CONDUCTOR SEAL ASSEMBLIES, LIGHTING AND MISCELLANEOUS SYSTEMS 2.0 MATERIALS (Continued) 2.3.9 Browns Ferry Nuclear Plant 2.3.9. I Liquid-tight flexible metal conduit with a synthetic jacket and liquid-tight conncctor fittings may be used in all areas.

Trade sizes through 4-inch shall meet the requirements of UL standards.

Anemet Incorporated.

Type EF or Electric-flex type LT with compatible connector fittings shall be used for 5-inch, trade sizes.

23.9.2 Wh'en shown on design.drawings. it shall be permissible to use pressure-tight stainless steel flexible conduit with a convolute core structure (similar to Service Air Company Type SS60.

SS63.

or SS63C:

American Boa Incorporated. Type NB 1-0 or NB 1-I series or Patel/EGS) and connector fittings of compatible material (available from the respective supplier) at BFN_

Pressure-tight stainless steel flexible conduit (ServicAir SS63C extra flexible stainless steel), as defined on the design drawings and as approved for use by engineering, shall be used for installations where an equipment seal is required.

2.3.9.3 Liquid-tight flexible metal conduit with a synthetic jacket (similar to the Anaconda Company, Brass Division.

"Sealtite type UA" for available sizes or equal) and connectors (similar to Ideal Industries. Incorporated.

"Vap-OiI-Tight" series or equal) shall be used for flexible conduit applications, unless otherwise noted on design drawings. Stainless steel flexible conduit described above may be used in these areas.

14

INSTALLATION, MODIFICATION AND MAINTENANCE OF G40 ELECTRICAL CONDUIT CABLE TRAYS, BOXES, REV 15 CONTAINMENT ELECTRICAL PENETRATIONS, ELECTRIC CONDUCTOR SEAL ASSEMBLIES, LIGHTING AND MISCELLANEOUS SYSTEMS 2.0 MATERIALS (Continued) 2.4 Material Storage and Handling 2.4.1 External threaded. ends of conduit and fittings-shall be protected during-shipment, storage, and handling to prevent damage and exclude dirt, moisture, and other foreign substances.

2.4.2 Conduit shall not be stored on end, but must be sloped for-drainage when stored in an ANSI N45.2.2 Class D environment.

2.4.3 Conduit, conduit fittings and conduit boxes may be stored to ANSI N45.2.2 Class D requirements.

2.4.4 To prevent warping during storage, plastic conduit shall be stacked on a.

smooth, flat surface in an area not directly exposed to the rays of the sun.

Spacers of 1-inch soft wood, approximately 2 feet apart, should be used between layers. of conduit. Manufacturer's shipping bundles may also be used for direct storage.

15

INSTALLATION, MODIFICATION AND MAINTENANCE OF G-40 ELECTRICAL CONDUIT CABLE TRAYS, BOXES, REV 15 CONTAINMENT ELECTRICAL PENETRATIONS, ELECTRIC CONDUCTOR SEAL ASSEMBLIES, LIGHTING AND MISCELLANEOUS SYSTEMS 3.0 INSTALLATION 3.1 General 3.1.I Installation of conduit. boxes. fittings and accessories shall conform to the latest design drawings, standards and specifications described in Section 1-2 and manufacturer's instructions provided in the vendor catalog for the particular part number or instructions provided with the contract. In the event of a conflict between design drawings. standards or this specification. this specification shall govern: however, for Watts Bar.

conflicts between these documents and N3C-944, the N3C-944 shall govern.

3.1.2 Unless specifically called for on the detailed design drawings or otherwise permitted (see Section 3.2.2.4) by site specific procedures. structural steel or reinforcing bars-shall not be cut or drilled in category I structures.

3.2 Conduit 3.2.1 General 3.2.1.1 Conduit exposed to the weather, embedded in concrete or in wet locations shall, be sloped for drainage. If it is not possible to slope or if the slope causes interferences -the installation shall be analyzed by engineering and resolved prior to completion. Embedded conduit systems shall be rigidly supported and braced in position to avoid settling or floating and to prevent the formation of air pockets if heavv batches of concrete are placed on the conduit.

16

INSTALLATION, MODIFICATION AND MAINTENANCE OF G-40 ELECTRICAL CONDUIT CABLE TRAYS, BOXES, REV 15 CONTAINMENT ELECTRICAL PENETRLATIONS. ELECTRIC CONDUCTOR SEAL ASSEMBLIES, LIGHTING AND MISCELLANEOUS SYSTEMS 3.0

[NSTALLATION (Continued) 3.2.1.2 To protect the cables during installation, a bushing, chase nipplc or conduit bodies (such as a condulet) shall be used at the end of aconduit run where it terminates at a piece of equipment or cable tray.

Where equipment, design prohibits their use due to space limitations, these conduit accessories max be omitted provided the end of the conduit is deburred and one of the following options exercised:

A.

• The end of the conduit shall be beveledor rounded to at least a 1/16-inch radius. or B.

The end of the conduit shall be fitted with a collar (i-e.. a plastic protective end cap for protecting cable. during installation).

NOTE: Conduit bushings may be eliminated at Watts Bar Nuclear Plant (-WBN) equipment for flexible conduit fittings and other connectors if all the following conditions apply:

(1) there are no sharp edges or burrs which could contact the cable, (2) the edge of the fitting or connector is rounded by the manufacturer to a minimum 1/16-inch or contains an insulated' sleeve, to preclude any damage, (3) the cable jacket has not been removed, and (4) the cables are not pulled tightly across the edge of the fitting.

3.2.1.3 The total sum of all bends in a conduit run shall not exceed 360' between pullpoints.

17

INSTALLATION, MODIFICATION AND MAINTENANCE OF G-40 ELECTRICAL, CONDUIT CABLE TRAYS, BOXES, REV 15 CONTAINMENT ELECTRICAL PENETRATIONS, ELECTRIC CONDUCTOR SEAL ASSEMBLIES, LIGHTING AND MISCELLANEOUS SYSTEMS 3.0 INSTALLATION (Continued)r 3.2.1.4 Field-installed pullpoints, such as conduit bodies. shall be adcquately sized to accommodate the required splices or lerrninations (e.g.. interfaces wvith devices with pigtails) as applicable, or in accordance with Design Standard DS-E13.6.2. and to accommodate-the minimum training radius of the cable (see Section 3.2.1.3 of General Engineering Specification G-38). Conduit bodies shall be inspected for sharp edges or burrs which-could contact the cables, and if present. ground smooth prior to installation.

A-Conduit bodies shall not be installed as pull points in conduit systems to be used-for the installation of medium voltage (5 to 15KV) power cables.

B.

Standard conduit bodies shall not be. installed as pull points for 300 kcmil and larger low voltage power cables:

however, mogul fittings may be used if they allow the cable to maintain minimum training radius requirements at all times (G-38 Section 3.2. 1.3). 'F,.* Straight conduit bodies may be installed for injecting lubricant.

3.2.1.5 Provisions shall be made for supporting cables in vertical conduit runs if required by General Engineering Specification G-38, Section 3.2.1.9. Conduit bodies (ELLS, TEES) shall not be installed at the top of vertical conduit sections that exceed:

25 feet in length for conduit sizes 1-1/2" and

smaller, 20 feet in length for 2" and 2-1/2" conduit.

15 feet in length for 3" conduit.

12.5 feet in length-for 4:' conduit, and 10 feet in length for 5" conduit, unless othervise authorized by engineering:

If a pullpoint is required at the top of a vertical section exceeding the lengths above, a conduit box shall be installed. For vertical runs less than the lengths above.

standard conduit bends are preferred at the top of the vertical run in lieu of conduit bodies. The minimum cable training radius shall not be violated-(see Section 3.2.1.3, General Engineering Specification G-38). kk-8--

18

INSTALLATION, MODIFICATION AND MAINTENANCE OF G-40 ELECTRICAL CONDUIT CABLE TRAYS, BOXES, REV 15 CONTAINMENT ELECTRICAL PENETRATIONS, ELECTRIC CONDUCTOR SEAL ASSEMBLIES, LIGHTING AND MISCELLANEOUS SYSTEMS 3.0 INSTALLATION (Continued) 3.2. 1.6 After a conduit run is completed. it shall be examined and cleaned out. Anv accumulation of trapped liquids shall be removed.

3.2 1.7 Conduit identification tagging shall accompany the conduit installation.

The tagging and identification shall be as designated on the conduit design drawings and/or conduit schedule and in accordance with Standard Drawing SD-E 15.3.3 or SD-E 15.3.4. Unscheduled-lighting conduits arc exempted from this requirement.

In yard areas where conduits are exposed to the natural environment, the conduit tag may be of 1/2-inch minimum width stainless steel or aluminum ribbon material wvith the designation made using a Dvmo tapewriter (or equivalent).

For additional identification requirements of exposed conduits see Section 3.2.6.

3.2.1.8 Reducers (or enlargers) may be used in the following applications:

A.

To mate up the incoming conduit (rigid. or flexible) to a device supplied with hubs or knockouts which do not match

,the size of the incoming conduit (reduction in conduit size.

unless specified on design drawings, must be approved by engineering and documented on appropriate drawings) or B.

To mate up rigid conduit to flexible conduit where mismatched conduit sizes are specified on design drawvings.

or to oversized conduit fittings.

Coat male threads as defined on design drawings: wvhere not defined, coat per Section 3.2.4.2 or Section 3.2.4.3.

3.2.1.9 Where design drawings do not specify otherwise. spare conduits and wall sleeves wvhich penetrate fire barriers shall be sealed and end capped with steel-conduit plugs. If conduit/sleeve configurations do not permit steel conduit plugs or caps to be used. refer to design drawings for altemate methods of sealing.

19

INSTALLATION, MODIFICATION AND MAINTENANCE OF G-40 ELECTRICAL CONDUIT CABLE TRAYS, BOXES, REV 15 CONTAINMENT ELECTRICAL PENETRATIONS, ELECTRIC CONDUCTOR SEAL ASSEMBLIES, LIGHTING AND MISCELLANEOUS SYSTEMS 3_0 INSTALLATION (Continued) 3._?1.10 Rigid conduit fittings shall be installed wrench tight using commonly available tools: wrench tight shall be defined as "not being able to rotate or remove by hand at the joint or fitting". Rigid conduit fittings may be backed off up to a maximum of one full turn for alignment purposes. When this occurs, a lock nut or a Right Angle K-Clamp (by Appleton Electric Co.)

shall be installed at the fitting to ensure-electrical continuity.

3.2.1.11 Sequoyah Nuclear Plant A.

Separation of Conduit From Pipes I.

Rigid and flexible conduits shall be separated from hot pipes and their insulation (system numbers 0L 03. 05.

06 12. 15 43 44 62. 68. 74. and all branch lines two-inches and larger connecting to these systems up to the first normally closed isolation or check valve) as noted below (valve stems and bonnets are considered part of the pipe):

a.

Conduits and Vertical Hot Pipes Conduits running adjacent to hot pipes (both parallel and nonparallel) shall have a minimum separation of six inches.

b.

Conduit and Horizontal Hot Pipes Conduits running parallel to and above hot pipes shall be separated from the pipe a minimum of 1.5 times the diameter of the pipe including the insulation. The zone of influence shall also include the area six inches outside the pipe insulation (see -Figure 3.2.1.11-I).

Conduits running adjacent to and below hot pipes (both parallel and nonparallel) shall be separated b\\

a minimum of six inches-Conduits in nonparallel configurations located above hot pipes shall be separated by a minimum of six inches.

20

INSTALLATION, MODIFICATION AND MAINTENANCE OF G-40 ELECTRICAL CONDUIT CABLE TRAYS, BOXES, REV 15 CONTAINMENT ELECTRICAL PENETRATIONS, ELECTRIC CONDUCTOR SEAL ASSEMBLIES, LIGHTING AND MISCELLANEOUS SYSTEMS 3.0 INSTALLATION (Continued) 3.2.1.11 (Continued)

NOTES:

(0)-

Flexible conduits connecting to end devices attached to hot pipes should be oriented perpendicular to the pipe-and shall, not be routed above the hot pipe, unless approved by engineering.

(2)

If the.pipe insulation-has-been removed.

an insulation thickness-of four and one-half inches shall be-used for determining separation distances or the design insulation thickness shall be obtained from the drawNings.

(3)

No conduit separation. from. instrument sensing lines is required for temperature considerations.

(4)

Conduits and pipes are considered to be parallel if they form an angle of less than 20' to each other.

21_

INSTALLATION, MODIFICATION AND MAINTENANCE OF G-40 ELECTRICAL CONDUIT CABLE TRAYS, BOXES, REV 15 CONTAINMENT ELECTRICAL PENETRATIONS, ELECTRIC CONDUCTOR SEAL ASSEMBLIES, LIGHTING AND MISCELLANEOUS SYSTEMS 3.0 INSTALLATION (Continued) 3.2.

I.1 (Continued)

B.

Appendix R Conduit Separation

1. Compliance -with the intent of IOCFR50 Appendix R is based on physical separation between cables for redundant functions. Essential Appendix R Fire Safe Shut Down (FSSD) conduits identified in CCRS shall be installed within the areas identified-on the Appendix R separation sketches and instructions provided in the design change notice (DCN) or engineering change notice (ECN)-Mod package.

2.

As-installed location of essential Appendix R conduits shall be field-verified; Nuclear Construction (NC) shall notif' the Nuclear Engineering (NE) lead electrical engineer upon completion of essential Appendix R conduit installation.

3.

Essential Appendix R (FSSD) conduits shall not be relocated (more than inches-horizontal) without NE notification and vritten concurrence.

22

INSTALLATION, MODIFICATION AND MAINTENANCE OFG-40 ELECTRICAL CONDUIT CABLE TRAYS, BOXES, REV 15 CONTAINMENT ELECTRICAL PENETRATIONS, ELECTRIC CONDUCTOR SEAL ASSEMBLIES, LIGHTING AND MISCELLANEOUS SYSTEMS 3.0 INSTALLATION (Continued) 3.2.1.12 Browns Ferry Nuclear Plant A.

Separation of Conduit from Pipes New installations of rigid and flexible conduits shall be separated from hot pipes and their insulation as noted below:

1.

Conduits and Vertical Hot Pipes Conduits running adjacent to insulated hot pipes (both parallel and nonparallel) shall have a minimum separation of six inches.

2, Conduit and Horizontal Hot Pipes Conduits running parallel to and above insulated hot pipes shall be separated from the pipe a minimum of 1.5 times the diameter of the pipe including the insulation. The zone of influence shall also include the area six inches outside the pipe insulation (see. Figure 3.2.1.1 - 1). Conduits running adjacent to and belowv hot pipes (both parallel and nonparallel) shall be. separated by a minimum of six inches. Conduits in nonparallel configurations located above hot pipes shall be separated by a minimum of six inches.

23

INSTALLATION, MODIFICATION AND MAINTENANCE OF ELECTRICAL CONDUIT CABLE TRAYS, BOXES, CONTAINMENT ELECTRICAL PENETRATIONS, ELECTRIC CONDUCTOR SEAL ASSEMBLIES, LIGHTING AND MISCELLANEOUS SYSTEMS G-40 REV 15 3.0 INSTALLATION (Continued) 3.2. 1.11 (continued) 1.5 x O.D.

Pipe

/

Plu..

uti O.A.

Pipe InsultiOu

- Zone of Intluenc, f., a H szon z L Hom ripe Ceacecrlna of Poc Pipe Pipe Figure 3.2.1.11-1 Hot Pipe Zone Of Influence for Browns Ferr 24

INSTALLATION, MODIFICATION AND MAINTENANCE OF 1G-40 ELECTRICAL CONDUIT CABLE TRAYS, BOXES, REV 15 CONTAINMENT ELECTRICAL PENETRATIONS, ELECTRIC CONDUCTOR SEAL ASSEMBLIES, LIGHTING AND MISCELLANEOUS SYSTEMS 3.0 INSTALLATION (Continued) 3-2.1.12 (Continucd)

NOTES:

(1)

FleCihle.conduit* connecting tit end devices attached to hot pipes should be oriented perpendicular to the pipe and shall not he routed above the hot pipe.

unless approved by engineering.

(2)

If the pipe insulation has been removed. an insulation thickness of three inches shall bhe used t6r determnining separation distances or the design insulation thickness shall be obtained irom the drawings.

(3)

No conduit separation fiom instrument senslng lines is required for temperature considerations.

(4)

Conduits and pipes are considered to he parallel if they lbrm an angle ofless than 2(0' to each other.

25

INSTALLATION, MODIFICATION AND MAINTENANCE OF G-40 ELECTRICAL CONDUITCABLE TRAYS, BOXES, REV 15 CONTAINMENT ELECTRICAL PENETRATIONS, ELECTRIC CONDUCTOR SEAL ASSEMBLIES, LIGHTING AND MISCELLANEOUS SYSTEMS 3.0 INSTALLATION (Continued) 3-2.1-13 Conduit. conduit fittings and conduit bodies shall be sealed as required by design output documents.

3.2.1.14 Conduits greater than six feet in length containing medium voltage (V5) and low voltage (V4) power cables shall be separated. from other conduits by a minimum of one fourth the diameter of the larger conduit.

26

INSTALLATION, MODIFICATION AND MAINTENANCE OF G-40 ELECTRICAL CONDUIT CABLE TRAYS, BOXES, REV 15 CONTAINMENT ELECTRICAL PENETRATIONS, ELECTRIC CONDUCTOR SEAL ASSEMBLIES, LIGHTING AND MISCELLANEOUS SYSTEMS 3.0 INSTALLATION (Continued) 3.2.1.15 Watts Bar Nuclear Plant A.

Separation of Conduits From Pipes 'c'r'.

The following table identifies the walkdown inspections of existing conduitinstallations and the associated calculations that provide evaluations and dispositions. All future installations shall meet the requirements established in the paragraphs following the table.

PIPING 1 TEMPERATURE

[ WALKDOWN DISPOSITION SIZE NUMBER CALCULATION

> 2"

> 250"F WD-11 WBN-OSG4-139 WBN-OSG4-221 All 140"F - 250"F WD-38 WBN-OSG4-139 WBN-OSG4-221

< 2"

> 250°F WD-38 WBN-OSG4-139 I WBN-OSG4-221 The. criteria established in the following paragraphs is for installations (after 10-21-91) at Watts Bar Nuclear Plant based on bounding cases as established in calculation WBN-OSG4-138.

This calculation is based on all insulated hot piping having an operating temperature of 650'F and an insulation surface temperature range of approximately 176°F to 224°F and all uninsulated hot piping having a surface temperature of 600'F.

Calculation WBN-OSG4-138 also establishes that no thermal clearance requirements apply for piping with a surface temperature of 135°F or less as specified in WBN-OSG4-170 or the operating mode calculations for the piping system.

The following separations are for conduits containing power cables, i.e., medium voltage power, V5, low voltage power, V4, and those control power cables classified as, V3. For separation requirements for conduits containing non power cables, ie., low level signal, V1, medium level signal, V2, and control, V3 which are not control power see Section 3.2.1.15.A.6.

1. Conduits shall be separated from pipes and pipe components by the minimum distances specified in Watts Bar Nuclear Plant Engineering Specification N3C-941. The separation distances described below shall be added to the thermal growth separations specified in N3C-941.

27

INSTALLATION, MODIFICATION AND MAINTENANCE OF G-40 ELECTRICAL CONDUIT CABLE TRAYS, BOXES, REV 15 CONTAINMENT ELECTRICAL PENETRATIONS, ELECTRIC CONDUCTOR SEAL ASSEMBLIES, LIGHTING AND MISCELLANEOUS SYSTEMS 3_0

[NSTALLATION (Continued) 3.2. I 15 (Continued) 2-Where running.parallel.

rigid and flexible conduits shall be separated from insulated hot piping up to 39" O.D. (including insulation) as noted below.

Hot piping includes piping for systems 01. 02. 03A. 03B, 05, 06, 15, 43, 62,

63. 68. 74. and all branch lines two inches and larger connecting.to these systems up to the first normally closed isolation or check valve. Valve stems and bonnets are considered part of the pipe.

a.

Conduits adjacent to or below insulated hot piping (horizontal and vertical)

Conduits running parallel to hot piping and located adjacent to or below this piping shall have a minimum separation of six inches from the pipe.

b.

Conduit above insulated hot piping (horizontal and vertical)

Conduits running parallel to and above insulated hot piping shall be located outside the zone of influence for the hot pipe-The zone of influence is as shown in Figure 3-2.1.15-1 where "X" is equal to 1.5 except for those pipes in rooms identified in Table "A". For the rooms identified in Table "A". use the specific distance or the value of "X" shown in Table "A", as applicable.

iNSTALLATION, MODIFICATION AND MAINTENANCE OF G-40 ELECTRICAL CONDUIT CABLE TRAYS, BOXES, REV 15 CONTAINMENT ELECTRICAL PENETRATIONS, ELECTRIC CONDUCTOR SEAL ASSEMBLIES, LIGHTING AND MISCELLANEOUS SYSTEMS 3.0 INSTALLATION (Continued) 3.2. I. 15 (Continued)

3.

Where

, unning parallel, rigid and flexible conduits shall bc separated from uninsulated hot piping and tubing 2" and smaller as noted below.

Hot piping includes piping. tubing. valve stems, and bonnets for systems 01, 02. 03A. 03B, 05.

06, 7. 12, 15. 43. 44. 62. 63'68. 74. and 77.wu'h

a.

Conduits. adjacent to or below 2" and smaller uninsulated hot piping and tubing (horizontal and vertical).

Conduits running parallel to uninsulated hot piping and located, adjacent to or below that piping shall have a minimum separation of 1'-

10" from the pipe.

b.

Conduits running above uninsulated hot piping and tubing (2" and smaller, horizontal and vertical).

Conduits running parallel to and above hot pipes-shall be located outside the zone of influence for the hot pipe.

The zone of influence is as shown in Figure 3.2.1-1S-2.

using the distances of 1'-1 1" for 1/2" or less piping and tubing, 3'-2" for piping and tubing greater than 1/2" up to I", and 4'-4" for piping and tubing greater than 1" up to 2".

29

INSTALLATION, MODIFICATION AND MAINTENANCE OF ELECTRICAL CONDUIT CABLE TRAYS, BOXES, REV 15 CONTAINMENT ELECTRICAL PENETRATIONS, ELECTRIC CONDUCTOR SEAL ASSEMBLIES, LIGHTING AND MISCELLANEOUS SYSTEMS 3.0 rNSTALLATION(Continucd) 3.2.1.15 (Continued)

4.

Where running non-parallcl (see note 3),.rigid and flexible conduits shall be separated from insulated and uninsulatcd hot piping and tubing (horizontal or vertical) as noted below for systems 01. 02, 03A. 038.

06. 15, 43. 62. 63. 68 74, and branch lines two inches and larger connecting to these systems up to the first normally closed isolation or check valve.

These separation requirements also. apply to. uninsulated piping and tubing for systems 7-12. 44. and 77. Valve stems and bonnets are considered part of the pipe:

WO,-

a.

For conduits running non-parallel to hot piping and tubing insulated or uninsulated and located adjacent to or below that piping and tubing; the minimum separations distance shall be six inches from the pipe.

b.

Conduits running above and. non-parallel to insulated hot piping and tubing shall be located outside the zone of influence for the hot pipe.

The zone of influence is as shownk in Figure 3.2.1.15-1 using a distance of 10" for piping 4-3/8" O.D. and smaller 3-5" for piping with an O.13 greater than 4-3/8" up to 39".

Piping O.D. includes insulation.

c.

Conduits running above and non-parallel to uninsulated hot pipes and tubing shall be located outside the zone of influence for the hot pipe.

The zone of-influence is as shown in Figure 3.2.1.15-2 using a distance of 1-3" for tubing less than 1/2" O.D. and 2'-9" for 2" OD. down to 1/2" O.D. pipe and tubing.

5.

Piping for systems other than those identified in paragraphs 21 3 and 4 have no thermal clearance requirements.

Separation distances shall satisfy" the requirements of Engineering Specification N3C-941 in all cases.

30

INSTALLATION, MODIFICATION AND MAINTENANCE OF G-40 ELECTRICAL CONDUIT CABLE TRAYS, BOXES, REV 15 CONTAINMENT ELECTRICAL PENETRATIONS, ELECTRIC CONDUCTOR SEAL ASSEMBLIES, LIGHTING AND MISCELLANEOUS SYSTEMS 3.0 INSTALLATION (Continued) 3,2-1.15 (Continued)

6. Conduits shall be separated from pipes and pipe components by minimum distances specified in N3C-941. The separation distances described below shall be added to the thermal growth separations specified in N3C-941. Conduits containing non power cables. i.e..

low voltage signal. V I. medium voltage signal, V2 and control. V3. which are not control power shall be separated from hot piping by distances specified in Table B. These clearances apply to hot piping and all branch lines connecting to this piping up to the first normally closed isolation or check valve. Valve stems and bonnets are considered part of the pipe.

31

INSTALLATION, MODIFICATION AND MAINTENANCE OF G-40 ELECTRICAL CONDUIT CABLE TRAYS, BOXES, REV 15 CONTAINMENT ELECTRICAL PENETRATIONS, ELECTRIC CONDUCTOR SEAL ASSEMBLIES, LIGHTING AND MISCELLANEOUS SYSTEMS 3.0 INSTALLATION (Continued) 3.2. I.15 (Continued)

NOTES (For paragraphs 2. 3. 4. 5. and 6)

(I)

Flexible conduits connecting to end devices attached to hot pipes shall he routed to minimize intrusion into the zone of influence. Flexible conduit shall be rcstraincd as iccessary to assure that separation requirements are maintained fbr normal operating conditions.

(2)

If the pipe insulation hits been removed, an insulation thickness of' lbur and one-half inches shall be used for deternining separation distances or the tl'sien insulation thickness shall he obtained li-rom the drawingq.

(3)

Conduits and pipes arc considered to he parallel irthex form an angle ofles, than 20' to each other.

(4)

For vertical conduit that runs parallel wvith vertical hot piping tbr more than ten feet. Engineering shall be contacted to provide the necessary clearanccs.

(5)

For conduits (I E only) being installed in the RB-SO I. 2. 3. and 4 rooms and Titration. Radio Chemlab and Counting rooms.

Engineering shall he contact:ed to provide the hecessaiw clearances required to any hot piping.

(6)

The separation of conduits from hot piping is baLsed on cables with a rating of 9O7C or ahove qualilication temperature (see 3.2 1A15A).

(7)

The conduit separation requirements are ba.,ed on insulated pipe maximum O.D. (including insulation) of 39" (for all voltage levels), uninsulated hot pipe maximum O.D. of 2" (for NV3 control povter. NV4. and NV5 leves) and uninsulated pipe maximum O.D. of 39" (for N\\VI. NV2. and V3 control levels). Engineering shall be contacted to provide the necessary clearances lor larger hot pipe OD.

(8)

An existing conduit may he removed and replaced with it conduit of the same size or smaller in the same location without verilication of separation distances, except in those cases where the original installation required the modilication (e.g.

notching) of-piping insulation. In such cases. NE approval must he obtained prior to reinstallation of'the conduit.

(9)

No conduit separation from instrument sensing lines is required for temperature considerations.

32

INSTALLATION, MODIFICATION AND MAINTENANCEO G-40 ELECTRICAL CONDUIT CABLE TRAYS, BOXES, REV 15 CONTAINMENT ELECTRICAL PENETRATIONS, ELECTRIC CONDUCTOR SEAL ASSEMBLIES, LIGHTING AND MISCELLANEOUS SYSTEMS 3.0 INSTALLATION (Continued) 2 15 (Continued)

B.

Appendix R Conduit Separation I

Compliance with the intent of I OCFR50 Appendix R is based on physical separation between cables for redundant functions. Essential Appendix R Fire Safe Shut Down (FSSD) conduits identified in CCRS shall be installed within the areas identified on the Appendix R separation sketches and instructions provided in the design change notice (DCN) or engineering change notice (ECN)-Mod package.

2. As-installed location of essential Appendix R conduits shall be field verified.

Nuclear Construction. (NC).

shall notif the Nuclear Engineering (NE) lead electrical engineer upon completion of essential Appendix R conduit installation.

3.

Essential Appendix R (FSSD) conduits shall not be relocated (more than 6 inches horizontal) without NE notification and written concurrence.

23

INSTALLATION, MODIFICATION AND MAINTENANCE OF ELECTRICAL CONDUIT CABLE TRAYS, BOXES, CONTAINMENT ELECTRICAL PENETRATIONS, ELECTRIC CONDUCTOR SEAL ASSEMBLIES, LIGHTING AND MISCELLANEOUS SYSTEMS G-40 REV 15 3.0 INSTALLATION (Continued) 3.2.1.15 (Continued)

TABLE "A" **

CLEARANCE VALUES BY ROOM NUMBERS FOR PARALLEL CONDUITS INSTALLED ABOVE HOT INSULATED PIPING DISTANCE OR "X" FOR FIGURE 3.2,1.1 5-1 OUTSIDE DLAMETER OF INSULATED PIPE ROOM NO'S" ELEVATION A1, A2, Al1I, A 10,A12, A13 729.0 RB ANNULUS ALL RB-LOWER COM PT, RACEWAY & PRESS RMS ALL RB-INSTR. ROOM 716.0 Al, A2, A3, A4, A7, AIO, A13, 77Z0 A14, A15, A1S Al, A2, A3, A4, A5, A9, A17, 757.0 A21, A22, A23, A24, A25, A26, A27, A28 A2 737.0 C3, C4, C5, C6, C7, C8, C9 6920 C6, C12, C13' C15 7255.0 G1, C4 705,0 R

C UPPER COMPT.

ALL Al 786.5 A I, A2 763.5 Al 77.5.25 A14, A15 729,0" C1, C2, CIO 692.0 C1 755.0 R*lACCUM & FAN t*MS ALL All 772.0 4,5 742.0 1,2. 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 760.5 13, 14.

PIPING LESS THAN 4-3/8" UP TO 23" (VALUE

" 23-UP TO 39" 4-3/8" (DISTANCE)

OF "X" in inches)

(VALUE OF X"in inches) 1-4" 3.55 1.70 1-4" 2.90 1.50 1'4" 1.87 1.50 0'-6' 1.50 1.50 Al,A2, A3, A4 782,0 Room descriptions and location drawings are shown on 47E235-00 drawing series.

This table applies to insulated piping systems 01, 02, 03A, 03B, 05, 06, 15, 43, 62, 6a, and 74.

OEM

INSTALLATION, MODIFICATION AND MAINTENANCE OF G-40 ELECTRICAL CONDUIT CABLE TRAYS, BOXES, REV 15 CONTAINMENT ELECTRICAL PENETRATIONS, ELECTRIC CONDUCTOR SEAL ASSEMBLIES, LIGHTING AND MISCELLANEOUS SYSTEMS 3.0 INSTALLATION (Continuedd) 3.2.1 15 Watts Bar Nuclcar Plant (Continued)

Zoii of hrflarre for a Horizntal ln-tlated hot Pipe S.eý ihotes below of Hot O.D. Pipe Insulation 6",

Figure 3.2.1.15-1 (For Watts Bar only)

Notes:

A)

For separation of insulated piping in systems 01. 02. 03A. 03b. 05. 06. 15, 43.62. 63. 68 and 74 from conduits containing NV3-control power. NV4. or NV5 cables.

1)

For rooms listed in Table "A". this dimension equals the specific distance provided or "X" \\ O.D. pipe insulation. where a value of "X" is provided.

2)

For rooms not listed in Table "A". this dimension equals the specific distance provided in the applicable paragraph for conduits located above pipe. or 1_5 x O.D. pipe insulation.. where no specific distance is provided.

3)

The minimum distance in all cases is 6"-

_2.5

INSTALLATION, MODIFICATION AND MAINTENANCE OF G-40 ELECTRICAL CONDUIT CABLE TRAYS, BOXES, REV 15 CONTAINMENT ELECTRICAL PENETRATIONS, ELECTRIC CONDUCTOR SEAL ASSEMBLIES, LIGHTING AND MISCELLANEOUS SYSTEMS 3.0 INSTALLATION 3.2.1.15 (continued)

Zonre of1ritfence for a Horiwntal Unmmilated Hot Pipe Centerline of Hot Pipe See nxotes below J 1-,- 101, Figure 3.2.1.15 Zone Of Influence For Horizontal Uninsulated Hot Pipes (For Watts Bar Only)

NOTES:

A)

For separation of uninsulated piping in systems 01.02. 03A. 03B, 05, 06. 07, 12. 15. 43, 44. 62.

63. 68. 74. and 77 from conduits containing NV3-control power, NV4. or NV5 cables.

1)

This dimension equals the specific distance provided in the applicable paragraph (see 3.2.1-15.3.b. and 3.2.1,15.4.c ) for conduits running above pipe.

2)

The minimum dimension is 1'- 10" in all cases.

INSTALLATION, MODIFICATION AND MAINTENANCE OF ELECTRICAL CONDUIT CABLE TRAYS, BOXES, CONTAINMENT ELECTRICAL PENETRATIONS, ELECTRIC CONDUCTOR SEAL ASSEMBLIES, LIGHTING AND MISCELLANEOUS SYSTEMS G-4V REV 15 3.0 INSTALLATION 3.2.1, 15 (Continued)

TABLE B*

CLEARANCE VALUES FOR CONDUITS CONTAINING CONTROL LEVEL. V3,. MEDIUM LEVEL SIGNAL. V2. AND LOW LEVEL SIGNAL VI CABLES FROM HOT PIPES Conduits above, and parallel All other conduits to pipe to pipe orientations Insulated Pipes Systems 01. 03A. 03B. 15.

5 inches 1 inch 43.62. 63. 68. and 74 All other systems See Section 3.2. I.15.A.5 See Section 32..15.A.5 Uninsulated Pipes Piping diameter 2" and less 8 inches 2 inches in Systems 01 02. 03A.

03B. 05. 06. 07. 12. 15. 43,

44. 62. 63. 68. 74, and 77 Piping diameter greater than 2" in System 01. 02. 03A.

36 inches.

6 inches 03B. 05. 06. 07. 12, 14. 43,

44. 62. 63. 68, 74. and 77 All other uninsulated piping See Section 3.2.1.15.A.5 See Section 3.2.1.15.A.5

• QIR MNMWBN93007 RO (T31 930408 986) 37

INSTALLATION, MODIFICATION AND MAINTENANCE OF G40 ELECTRICAL CONDUIT CABLE TRAYS, BOXES, REV 15 CONTAINMENT ELECTRICAL PENETRATIONS, ELECTRIC CONDUCTOR SEAL ASSEMBLIES, LIGHTING AND MISCELLANEOUS SYSTEMS 3.0 INSTALLATION (Continued) 3.2.2 Exposed Conduit 3.2.2.1 Exposed conduits shall be run in straight lines parallel to column lines, walls or beams. Where conduits are grouped, the bends and fittings shall be installed to present an orderly appearance. Unnecessary bending or crossing shall be avoided.

3.2.2.2 In seismic Category I structures (Class I at BFNP), exposed conduits shall be supported as defined by design drawings.

Rigid conduit attachments to end devices (i.e., all conduit bodies for making-splices, oversized conduit bodies for accommodating minimum training radius requirements, rigid conduit for installing equipment seals, etc.) shall be installed in accordance to design drawings to ensure that the end device will not be damaged due to stress created by excessive weight.w-9 3 2.2.3 Malleable iron 1-hole pipe straps, clamps, U-bolts, hangers or close bracket-type pipe suppprts may be used.. Pipe backspacers should be used for the.' 1-hole malleable iron pipe supports where it is desired to hold a conduit run away from the surface to eliminate offsetting the conduit at the fittings.

3.2.2.4 In nonseismic (non category I) structures, galvanized steel members may be drilled or punched for conduit supporting bolts provided the holes are immediately coated with zinc-dust zinc-oxide paint (in accordance wvith ASTM A780, Annex A2) and galvanized or rust-resisting bolts are used.

Threaded stud bolts, Nelson stud anchors or equivalent may be used instead of drilling or punching steel members.

3.2.2.5 In moist locations and in locations where appearance is of importance,.

precautions shall be taken, such. as by use of strap-type wrenches or equivalent means, to avoid injuring the galvanized coating of steel conduits or surface of stainless steel conduit:

38

INSTALLATION, MODIFICATION AND MAINTENANCE OF G-40 ELECTRICAL CONDUIT CABLE TRAYS, BOXES, REV 15.

CONTAINMENT ELECTRICAL PENETRATIONS, ELECTRIC CONDUCTOR SEAL ASSEMBLIES, LIGHTING AND MISCELLANEOUS SYSTEMS 3.0 INSTALLATION (Continued) 3.2.2.6 Beginning with the Watts Bar Nuclear Plant. exposed conduit containing Class I E wiring shall have its division of separation identified (by marking. tagging. or taping) with the respective background color code at intenrals not to exceed 15 feet in accordance with Electrical Standard Drawing SD-E 15.3.4.

3.2.2.7 When in the vicinity of piping which must be insulated, the conduit shall be adequately spaced away from the pipe to avoid interferences when the pipe is insulated.

3.2.2.8 Two conduit bodies having three conduit openings each (e.g.. two "Tee" condulets) ma-be used where one conduit body having four conduit openings (e.g.7 an "X", condulet) is specified on design drawings.

The conduit interconnecting the two conduit bodies shall be sized in accordance with Design Standard DS-E 13.1.4.

This configuration is treated as a single conduit body. and the conduit interconnection is not required to be uniquely identified if it is 12 inches-or less in length.

Contact engineering when the interconnecting conduit is greater than 12 inches in length.

322.29 Watts Bar Nuclear Plant-Conduits containing 10 CFR50.49 cables shall not have threaded portions (i.e.. condulets. junction boxes, couplings or unions, etc.) and flexible sections located below, postulated HELB flood levels identified on the Environmental Data Drawings 47E235 series.

When more than one applicable flood level is provided, the highest level shall be used. When a conduit passes through a wall/floor, the conduit shall be evaluated based on the new conduit location.

If it becomes necessary to route conduits below the HELB flood levels identified in 47E235 series drawings. contact Site Engineering to determine if they contain 10 CFR 50.49 cables.

After 7/7/95. installation of conduits containing 10 CFR 50.49 cables below the postulated MELB flood levels identified on the Environmental Data Drawings shall require specific approval on design output documents.

Unless otherwise stated on Design Output Drawing. any conduit which exits a room below the postulated MELB flood level for that room shall be sealed in accordance with drawing 45W883. Sheet 6 to preN ent water egress to other areas."2 N-4 39

INSTALLATION, MODIFICATION AND MAINTENANCE OF G-40 ELECTRICAL CONDUIT CABLE TRAYS, BOXES, REV 15 CONTAINMENT ELECTRICAL PENETRATIONS, ELECTRIC CONDUCTOR SEAL ASSEMBLIES, LIGHTING AND MISCELLANEOUS SYSTEMS 3.0 INSTALLATION (Continued)

Conduit scaling to prevent water accumulation in conduit or entering equipment, on a case-by-case basis with prior SE approval on the Work Instruction Document at a location specified by SE, is permitted. Sealing shall be accomplished by packing approximately I" depth of ceramic fiber damming around cables and in voids between cables/conduits (damming shall be used on either side of silicone foam) and injecting 3" minimum Dow Corning 3-6548 Silicone RTV Foam.

CAUTION: The above seal is not to be used as a firestop, nor as a 50.49 pressure / moisture seal.

3.2.3 Embedded Conduit 3.2.3.1 A minimum 2-inch clearance shall be maintained between conduits embedded in poured concrete walls or floor slabs, except that detailed-design dimensions shall be adhered to adjacent to conduit terminations, etc., where area is restricted.

Conduits and conduit sleeves, when located in a bank or group form in a wall pour, may be adjusted as required to line up the -bottom outside edge of the smaller sized conduit with the bottom outside edge of the largest conduit in the group in order to continue the group run on a common exposed support.

Likewise, grouped conduits in a floor or ceiling slab may be shifted enough to take advantage of a common exposed wall or column support. For tolerances for embedded conduit runs, see Section 3.13.2.

Conduits embedded in switchyards and transformer yards shall maintain a 1-inch minimum clearance between conduits.

3.2.312 In switchyards and transformer yards all single conduit or groups of conduits shall be encased in concrete with the outer coverage a minimum of 2-1/2 inches.

3.2.3.3 Where embedded in concrete, extreme care shall be taken to anchor aluminum and nonmetallic conduit so that it will not be floated when the concrete Is placed.

3.2.3.4 Embedded conduit shall be rigidly supported to withstand concrete vibrators or batches of mass concrete placements.

3.2.3.5 In supporting embedded steel, aluminum or plastic conduit, extreme care shall be taken to avoid-damage to the surface of the conduit if welding or brazing is used near the conduit. In no case-shall the-conduit be welded or brazed to the support. Plastic conduit in duct runs shall not be supported by reinforcing steel forming closed magnetic loops; preformed plastic spacers shall be used-See Electrical Standard Drawing SD-E1 3.4.1.

40

INSTALLATION, MODIFICATION AND MAINTENANCE OF G-40 ELECTRICAL CONDUIT CABLE TRAYS, BOXES, REV 15 CONTAINMENT ELECTRICAL PENETRATIONS, ELECTRIC CONDUCTOR SEAL ASSEMBLIES, LIGHTING AND MISCELLANEOUS SYSTEMS 3.0 INSTALLATION (Continued) 3.2.3.6 Concrete curbs shall be provided where specified on design drawings.

3.2.37 Slip joints shall be installed in accordance with Electrical Standard Drawing SD-E13.1.1. where embedded conduits cross expansion or contraction joints. as defined and located on design drawings.

3.2.3.8 Wherever slip joints are used. suitable bonding in accordance with Electrical Standard Drawing SD-EI311.1 shall be provided around the joint to ensure a continuous-ground circuit: Where use of expansion and deflection-type fittings (see Standard Drawing SD-E13.1.2) are defined in design drawings. the manufacturer's instructions shall be followed in making ground connections.

3.2.3.9 Except as noted below or unless othcrwise specified on design drawings, all embedded conduits turning out of poured concrete shall terminate with a standard coupling flush with the surface of the concrete.

Where the thickness of the concrete is not adequate to accommodate the minimum bending radius of the conduit (see DS-E13.1.7). one of the following options max' be exercised:

A.

A short radius elbow may be used where approval has been obtained from engineering.

(Short radius elbows must also be shown on design drawings. See Section 3.2.4. 1 Item G).

B.

Where terminating into surface of floor-mounted boxes or equipment, a standard radius field bend or manufacturer's bend may be used and extended beyond the concrete surface as needed to complete the 90-degree bend. If necessary to avoid interferences or to accommodate the minimum bending radius of the cables. the end of the 90-degree bend projecting beyond the concrete surface may be cut, if the cut end is deburred and handled in accordance with Section 3.2.1.2 Items A or B.

4-'

INSTALLATION, MODIFICATION AND MAINTENANCE OF 40 ELECTRICAL CONDUIT CABLE TRAYS, BOXES, REV 15 CONTAINMENT ELECTRICAL PENETRATIONS, ELECTRIC CONDUCTOR SEAL ASSEMBLIES, LIGHTING AND MISCELLANEOUS SYSTEMS 3.0 INSTALLATION (Continued) 3.2.3.9 (Continued)

C.

Where the conduit bend must be terminated in a coupling to allow the conduit system to be extended beyond the wall or floor surface-the coupling may extend beyond the surfce as needed.

to complete the 90-degree bend.

D. Where the difference in being able to comply with Section 3.2,3.9 and. DS-EI3,1.7 is small, the straight portion of the bend may be cut as required, if the minimum bending radius (dimension A. DS-El3.1.7) is not altered and the bend is rethreaded to the original specifications.

3.2.3.10 In duct runs the metallic conduit shall be grounded at each manhole or handhole by brazing the ground wire to the top of the conduit coupling or by using grounding bushings.

3.2.3.11 Holes for conduits may be drilled in hardened concrete: however.

no reinforcing steel will be cut or damaged during the drilling operation. The reinforcing steel may be located by removing the cover concrete.

Holes may be relocated up to 8 inches in any direction from the dimensions specified on design drawings and may be canted from one face to the other to avoid the reinforcing steelý After installation of the conduit, the damaged concrete shall be repaired in accordance with, TVA General Engineering Specification No. G-34.

3.2.3.12 The conduits shall be identified in such a manner that permanent tag identification can be made at a later date.

3.2.3.13 The conduits shall be swabbed immediately (before any concrete

,which may have sipped inside the conduit has had a chance to harden) after the concrete pour is complete.

INSTALLATION, MODIFICATION AND IMAIFNTENANCE OF.-

40 ELECTRICAL CONDUIT CABLE TRAYS, BOXES.

REV 15 CONTAINMENT ELECTRICAL PENETRATIONS, ELECTRIC CONDUCTOR SEAL ASSEMBLIES, LIGHTING AND MISCELLANEOUS SYSTEMS 3.0 INSTALLATION (Continued) 3.2.4 Rigid Metal Conduit 3.2.4,1 General A.

Metallic conduit systems, whether embedded or exposed, shall be installed in accordance with those portions of the NEC, which ensure that the systems will be adequately grounded and electrically continuous to function as the equipment grounding conductor.

B.

When necessary to achieve electrical continuity (per NEC).

bonding jumpers shall be installed between the rigid metal conduit and the enclosure (ie.. box. cabinet. switchgear cable tray). This shall be accomplished by using UL-listed ground clamps or fittings approved for grounding. These bonding jumpers shall be sized in accordance with conduit size as listed in Table 3.2.4. 1-I.

C.

When boxes-do not have threaded hubs or bosses (or as in Section 3.3.1.3). conduits shall be securely fastened to boxes and cabinets, each-..vith a locknut and a bushing inside the box and a locknut outside. (See Electrical Design Standard DS-E13_1-6 for locknut spacing requirements.)

The conduits shall be of such length that when-the bushings are screwed tight against the ends of the. conduits, no appreciable space will be left between the bushings and the locknuts.

D.

To avoid hotspots or sparking during fault conditions. locknuts shall be firmly tightened against the box. Care shall be taken to prevent deforming the box. As an alternative, a coupling may be used on the end of the conduit system and a chase nipple inside the enclosure (box or cabinet) to connect the enclosure and conduit together. To ensure that the enclosure and conduit are electrically continuous, theT&B grounding wedge having the UL label shall be used.

Unless otherwise specified by the manufacturer, the Wedge may be installed inside or outside (preferred) the enclosure.

43

INSTALLATION, MODIFICATION AND MAINTENANCE OF ELECTRICAL CONDUIT CABLE TRAYS, BOXES, CONTAINMENT ELECTRICAL PENETRATIONS, ELECTRIC CONDUCTOR SEAL ASSEMBLIES, LIGHTING AND MISCELLANEOUS SYSTEMS G-40 REV 15 3.0 INSTALLATION (Continued) 3.2.4.1 (Continued)

Table 3.24.1-1 Bonding Jumpers for Ensuring Electrical Continuity of Electrical Conduit System Conduit Size 1/2 Copper Jumper Size (AWG) for Power Conduits

1. 6 Copper Jumper Size (AWG) for Control, Medium-Level Signal and Low-Level Signa[-Conduits-

1. 6 3/4 1

1-1/2 2-1/2

1. 6

1. 4

1. 2 3

1. 2/0

1. 2/0

1. 2/0*

1. 2/0

1. 6

1. 4

1. 2

1. 2

1. 2

1. 2

1. 2 4

These AWG sizes may be reduced to match the largest available ground cable in the vicinity when it is not practical or possible to extend the bonding jumper to a larger ground cable. Engineering must review and approve such deviations on a case by case basis. If required to match existing ground cables, cable sizes may be increased without engineering approval.

NOTE: Bonding jumpers for ensuring electrical continuity of electrical conduit systems shall be installed such that the ground cable is held firmly in place. Torquing is not required.

Compound 'Kopr-Shield' shall be applied to the mating surfaces of the connections.

INSTALLATION, MODIFICATION AND MAINTENANCE OF G-40 ELECTRICAL CONDUIT CABLE TRAYS, BOXES, REV 15 CONTAINMENT ELECTRICAL PENETRATIONS, ELECTRIC CONDUCTOR SEAL ASSEMBLIES, LIGHTING AND MISCELLANEOUS SYSTEMS 3 0 INSTALLATION (Continued) 3..14.1 (Continued)

E.

Running threads on field threaded conduits shall not be used on metal conduits except for short nipples which are used to extend the conduit systems.

F.

Welded or brazed grounds on conduit runs shall be done on the top of couplings onlh. and extreme care shall be taken to avoid iniurv to the inner surface of the conduit by excessive heating.

The welded or brazed joint shall be coated with asphaltum, RTV sealants or equivalent.

G.

Unless otherwise noted. standard radius field bends (see Electrical Design Standard DS-E13.1.7) or manufacturer's bends (bending radius as specified in NEC) shall be used wNhere. needed in metal-conduit systems. Special. long radius bends (bending radius greater than Electrical Design Starhdard DS-El3.1.7 or NEC requirements) shall be used where specifically called for on design drawings or where otherwise needed to complete the installation of the conduit system-Short radius elbows. (bending radius less than Electrical Design Standard DS-EI3.1.7 or NEC requirements) shall not be used unless specified on design drawings.

45

INSTALLATION, MODIFICATION AND MAINTENANCE OF G-40 ELECTRICAL CONDUIT CABLE TRAYS, BOXES, REV 15 CONTAINMENT ELECTRICAL PENETRATIONS, ELECTRIC CONDUCTOR SEAL ASSEMBLIES, LIGHTING AND MISCELLANEOUS SYSTEMS 3.0 INSTALLATION (Continued) 3.2.4.1 (Continued)

H.

Field Bends

1.

Field bends for metal conduit-shallbe made such that the internal diameter of the conduit is not materially changed and the protective coating on the inside and outside of the conduit is not significantly damaged.

2.

WVhcn making field bends, a certain amount of necking, flattening-nicks, kinks. splits, dents and/or damage to the protective coating can be expected to occur.

Field bends which result in a kink or split in the conduit shall be abandoned. Likewise. if a nick should occur which actually penetrates the wall of the conduit. the bend shall not be used.

'4-Nicks and abrasions resulting in significant damage to the protective coating should be repaired by spraying or painting galvanize on the damaged areas.

46

INSTALLATION, MODIFICATION AND MAINTENANCE OF G

ELECTRICAL CONDUIT CABLE TRAYS, BOXES, REV 15 CONTAINMENT ELECTRICAL PENETRATIONS, ELECTRIC CONDUCTOR SEAL ASSEMBLIES, LIGHTING AND MISCELLANEOUS SYSTEMS 3.0 INSTALLATION (Continued) 3.2*4. 1 (Continued) z When the following conditions are satisfied, less severe necking, flattening. dents, and nicks which could not result in damage to the cable insulation during-pulling are acceptable:

a.

The bending equipment being used-is correct for the application.

b.

The manufacturer's instructions and recommendations pertaining to the use of the bending equipment are being followed.

c.

The bending equipment is functioning properly (i.e.. making bends which do not result in kinks.

splits, or damage to the conduit coating).

Heat shall not be applied in making any metal conduit bend.

(See Section 3.2.5.4 for field bends for nonmetallic conduit.)

1.

Die cast zinc conduit fittings and connectors shall not be used inside. the reactor building primary containments w\\hich have a boric acid containment spray system.

J.

Except for conduits containing battern board supply cables.

sections of existing aluminum conduit runs may be replaced with rigid steel conduit without requiring revision to drawings.

47

INSTALLATION, MODIFICATION AND MAINTENANCE OF G-40 ELECTRICAL CONDUIT CABLE TRAYS, BOXES, REV 15 CONTAINMENT ELECTRICAL PENETRATIONS, ELECTRIC CONDUCTOR SEAL ASSEMBLIES, LIGHTING AND MISCELLANEOUS SYSTEMS 3.0 INSTALLATION (Continued) 3.2.4.1 (Continued)

K.

Conduit fittings and conduit bodies (tees, LBs) installed within the rigid conduit system shall be compatible to the strength requirements of the conduit.

1.

For rigid conduit, the bodies and.fittings shall be malleable iron or steel-See Standard Specifications referenced in 2.1.2 2-Nonmalleable cast iron fittings and bodies may be used with aluminum conduit only wvhen approved by TVA Nuclear Engineering on a case by case basis.

3.2.4.2 Steel Conduit and Intermediate Metal Conduit Steel and intermediate metal conduit joints and connections shall be made weathertight and rustproof by means of the application of a-thread compound which will not insulate the joint. Each field-cut thread shall be cleaned to remove the cutting oil before the compound is applied.

An electrically conductive antiseize compound for metal surfaces (Thomas and Betts Company "Kopr-Shield"'; Jet-Lube, Incorporated, "SS-30"; Burndy "Penetrox E"; or equivalent) shall be applied, to the male-conduit threads-3.2.4.3 Alumninum Conduit A.

Rigid aluminum. conduit installed outdoors or in wet locations shall be provided with aluminum fittings.

The use of aluminum conduit in areas containing corrosive materials should be avoided. Galvanized fittings (such as type EYS) may be used in special cases as designated by engineering. Care must be taken to prevent the contact of aluminum conduit with corrosive materials in places where moisture can accumulate.

B_

Strap-type wrenches should be used to avoid scratching and gouging the aluminum conduit.

48

INSTALLATION, MODIFICATION AND MAINTENANCE OF G-40 ELECTRICAL CONDUIT CABLE TRAYS, BOXES, REV 15 CONTAINMENT ELECTRICAL PENETRATIONS, ELECTRIC CONDUCTOR SEAL ASSEMBLIES, LIGHTING AND MISCELLANEOUS SYSTEMS 3.0 INSTALLATION (Continued) 3.2.4.3 (Continued)

C.

Aluminum conduit joints at couplings or fittings shall be made wcathertight by application of an clectrically conductive. antiseize compound for metal surfaces (Thomas & Bctts Company "Kopr-Shicld" or "Aluma-Shield:"

Jct-Lube.

Incorporated, "SS-30("

Bumdv Corporation "Penetrox E." or equivalent)-

Satisfactor' mixtures such as zinc dust and vaseline (50-50 by weight). or a heavy cup greasc containing 25-percent graphite may be used. Aluminum threads shall not be coated-with red lead or other lead compounds-Each field cut.thread shall be cleaned to remove the cutting oil before the compound is applied-D.

Standard benders may be used for aluminum conduit except that electrical metallic tubing (EMT) benders shall be used for conduit I inch in diameter and below.

Use an EMT bender 1/4-inch larger than the conduit size. i.e.. 1-1/4 inches for, 1-inch rigid, I inch for 3/4-inch rigid-E.

In addition to the methods described in Section 3.2.4.1. aluminum conduit may be grounded by inserting a galvanized steel coupling in the run, brazing the ground \\wire to the top of the coupling and carefully coating the joint with asphaltum, RTV sealant or equivalent-F_

Aluminum conduit, conduit fittings or components shall not be used inside reactor, building primary' containments that have a boric acid spray system that would react with aluminum to produce excessive hydrogen.

49

INSTALLATION, MODIFIiCATION AND MAINTENANCE OF G-40 ELECTRICAL CONDUIT CABLE TRAYS, BOXES, REV 15 CONTAINMENT ELECTRICAL PENETRATIONS, ELECTRIC CONDUCTOR SEAL ASSEMBLIES, LIGHTING AND MISCELLANEOUS SYSTEMS 3.0 INSTALLATION (Continued) 3._,4A4 Electrical Metallic Tubing (EMT)

EMT. a thrcadless,. thin-wall steel conduit requiring special threadless fittings for couplings and terminations may be used in exposed and embedded applications in office and service buildings-Installation shall be in accordance with Article 348 of the National Electrical Code. latest edition.

3.2.5 Plastic Conduit (PVC) 3.2.5.1 To prevent warping during storage, plastic conduit shall be stacked on smooth. flat surface in an area not directly exposed to the rays of the sun.

Spacers of 1-inch soft wood. approximately 2 feet apart, should be used betwcen layers of conduit. Manufacturer's shipping bundles may also be used for direct storage.

3.2.5.2 Refer to DS-E 13.1.11 for applications of embedded PVC conduit. Where plastic conduits are encased in concrete (such as in duct banks between buildings), the conduits shall be anchored with preformed, plastic spacers before concrete placement. The conduits and spacers shall be located as shown on design drawings.

3.2.5.3 Plastic conduit may be cut with a hacksaw. After cutting, ends shall be trimnmed and rough edges smoothed.

The area to be solvent welded (outside of conduit and inside of coupling or fitting) shall be free from dust, dirt, grease. and moisture. Use PVC cleaner for cleaning. Polyvinl chloride (PVC) solvent shall be brushed liberally on the and of the conduit and inside the fitting or coupling when making a joint. After fitting has been pushed on. it should be twisted one-fourth turn to spread the solvent evenly.

Continue to hold joint for 15 seconds so that conduit does not push out of fitting.

3.2.5.4 Bends for nonmetallic conduit are usually purchased as required for the conduit system, but for special cases may be made in the field. Extreme caution should be observed when anv source of heat is near plastic conduit. Field bending can be accomplished by the use of a "hot air-cold air" blower-a hand-type hair dryer is reconmmended by the manufacturers.

50

INSTALLATION, MODIFICATION AND MAINTENANCE OF G-40 ELECTRICAL CONDUIT CABLE TRAYS, BOXES, REV 15 CONTAINMENT ELECTRICAL PENETRATIONS, ELECTRIC CONDUCTOR SEAL ASSEMBLIES, LIGHTING AND MISCELLANEOUS SYSTEMS 3.0 INSTALLATION (Continued) 3.2.6 Flexible Conduit 3.2.6-1 General A-Flexible conduit shall be used to interface the rigid conduit system with electric equipment and devices that rotate, vibrate, are subject to thermal movement, or where seismic considerations must be taken into account. '*:

It shall also be used for connecting flush and recessed lighting fixtures to rigid conduit systems when so indicated on design drawings-B.

Flexible conduit installed in straight lengths (reference Section 32.1.1 Item J of G-38) mav be used within a rigid, exposed conduit run to;

1.

Avoid interferences.

2.

Cross an expansion-contraction joint.%here the rigid conduit is attached to the structure on each side of the joint.

3, It mav.also be used to interface between cable trays and/or equipment. Attachment of flexible conduit to cable trays shall require site engineering approval prior to installation.

C.

Flexible conduit secured with P2558 series unistrut 2-hole straps, instead of connecting to equipment with standard flexible conduit fittings, may utilize ferrules supplied by approved flexible conduit connector vendors on the end(s) of the flexible conduit to protect the cables.

Ferrules must have rounded ends and be of the screw-in type to ensure position retention.

51

INSTALLATION, MODIFICATION AND MAINTENANCE OF G-40 ELECTRICAL CONDUIT CABLE TRAYS, BOXES, REV 15 CONTAINMENT ELECTRICAL PENETRATIONS, ELECTRIC CONDUCTOR SEAL ASSEMBLIES, LIGHTING AND MISCELLANEOUS SYSTEMS 3.0 INSTALLATION (Continued) 3.2.6.1 (Continued)

D.

The electrical continuity of the conduit system shall be preserved-I.

This electrical continuitv shall be achieved bv installing a bonding strap or ground cable across stainless steel or liquid-tight flexible conduit by connecting to the raceway and/or equipment/end device. This shall be accomplished by using UL-listed ground clamps or fittings approved for grounding. Bonding jumpers shall be sized in accordance with conduit size-as listed in Table 3.2.4.1-1. For support purposes, cable ties shall be adequate. to secure the grounding conductor to the flexible conduit.

This bonding jumper is not required on 1/2". 3/4". and 1" liquid-tight flexible metal conduit if a, b. and c below are met:

a.

The installed length of flexible conduit is 6 foot or less and the rigid conduit section or the end component are adequately grounded and provides a ground return path (NEC 350-5, and 351-9).

b.

All fittings are UL-listed. and

c.

The conduit is used only for

control, medium-level, or low-level signal cables or low voltage power (20 amps or lower).

For conditions where the bonding jumper is presently not installed, any future rework of existing stainless steel or liquid-tight flexible conduits will require the installation of the above required bonding jumpers concurrent with the rework activities-52

INSTALLATION, MODIFICATION AND MAINTENANCE OF G-40 ELECTRICAL CONDUIT CABLE TRAYS, BOXES, REV 15 CONTAINMENT ELECTRICAL PENETRATIONS, ELECTRIC CONDUCTOR SEAL ASSEMBLIES, LIGHTING AND MISCELLANEOUS SYSTEMS 3-0 INSTALLATION (Continued) 32.6.1 (Continued)

For equipment with more than one flexible conduit connection (i.e.. MCC's. switchgear, valves, R-panels. etc.). which have common end points, it is acceptable to provide only one ground jumper from the rigid conduits/cable tray to the equipment as long as:

a.

All conduits are jumpered together either at the common support or at the equipment.

b.

The ground cable is sized for the largest conduit, and

c.

The flexible conduits are attached to a common point at the equipment.

d.

For flexible conduits which are not physicalIy/electrically attached to the equipment and/or raceway, the ground jumper shall extend from the equipment to the. raceway.

Flexible conduits routed from different supports will require, separate ground jumpers, sized as indicated in Table 3.2.4.1-1.

53

INSTALLATION, MODIFICATION AND MAINTENANCE OF G-40 ELECTRICAL CONDUIT CABLE TRAYS, BOXES, REV 15 CONTAINMENT ELECTRICAL PENETRATIONS, ELECTRIC CONDUCTOR SEAL ASSEMBLIES, LIGHTING AND MISCELLANEOUS SYSTEMS 3.0 INSTALLATION (Continued) 3.2.6.1 (Continued)

E.

Flexible conduit.shall be installed between conduit fittings in exposed lengths not exceeding 72 inches, except as noted on design output documents. Rigid conduit should be located as near the equipment and device as practical. The flexible conduit shall be prepared, assembled, and installed in accordance with manufacturer's instructions provided in the vendor catalog for the particular part number or instructions provided with the contract. If the flexible. conduit fitting vendor requires the compression nut to be torqued, the vendor supplied valves shall be used. If torquing is not required by the flexible conduit fitting vendor, the compression nut shall be installed wrench tight using commonly available tools. Wrench tight shall be defined as "not being able to rotate. or remove by hand at the joint or fitting.,WBN-12 NOTE:

Based on the justification provided-in Appendix Y variance 4 for W/BN and Letter from T&B (A) torquing of T&B flex-conduit fittings to a numerical value other than wrench tight is not required. This applies to all sites.

NOTE:

Flexible conduit connector bodies should be installed and tightened into the end device prior to installing the flexiblc conduit. When compression nuts are torqued or tightened, care shall be taken not to exceed the maximum torque value for the end device.

F.

The minimum recommended bend radii listed in Table 3.2.6.3-2 shall not be violated'."-l" (Other types of flexible conduit max, be acceptable; however, engineering approval shall be required prior to installation.) Flexible conduit should be installed without twist and oriented away from heat radiating sources, such as a hot pipe and its insulation (see Section 3.2. 1. 11 for separation distances for Watts Bar and Sequoyah Nuclear Plants and Section 3.2.1.12 for Browns Ferry Nuclear Plants). After installation, the flexible conduit shall not be stretched tight between flexible conduit fittings.

54

INSTALLATION, MODIFICATION AND MAINTENANCE OF G-40 ELECTRICAL CONDUIT CABLE TRAYS, BOXES, REV 15 CONTAINMENT ELECTRICAL PENETRATIONS, ELECTRIC CONDUCTOR SEAL ASSEMBLIES, LIGHTING AND MISCELLANEOUS SYSTEMS 3.0 INSTALLATION (Continued) 3.2.6.1 (Continued)

G.

Flexible conduit entering the top or side of boxes. equipment, and devices requiring external sealing in accordance with Engineering design documents shall be installed utilizing a vendor supplied or vendor recommended 0-ring seal between the box, equipment, or device and the flexible conduit fitting. This is not a requirement itf I.

The box-equipment. or device has a threaded hub.

2.

Welded hub is provided as part of the enclosure, or

3.

No open terminations exist inside the enclosure.

4.

This is not a requirement for BFN if. it is sealed in accordance with drawing 0-45 B891-1.

5.

For BLN.

the joint between the installed conduit.

connector and the outside of the electrical enclosure is coated with a minimum of a 1/8" bead. of RTV 738 sealant or approved equal.

Where. design output documents for Watts Bar Nuclear Plant show flexible conduits, short.sections of rigid conduit of equal size or larger, may be substituted for a portion of the flexible conduit where the conduit enters a fitting, provided the rigid section is for seismic support anchoring, has been approved by Civil Engineering, and the remaining length of flexible conduit meets all requirements of this specification.

55

INSTALLATION, MODIFICATION AND MAINTENANCE OF G-40 ELECTRICAL CONDUIT CABLE TRAYS, BOXES, REV 15 CONTAINMENT ELECTRICAL PENETRA-kTIONS, ELECTRIC CONDUCTOR SEAL ASSEMBLIES, LIGHTING AND MISCELLANEOUS SYSTEMS 3.0 INSTALLATION (Continued) 3.2.6. 1 (Continued)

H, Where liquid tight (synthetic jacket) flexible metal conduit has damage which penetrates the PVC jacket. it shall be replaced, or.

repaired as noted below:

a.

Liquid Tight PVC Jacket Flex Conduit I.

Ensure there is no significant damage to the metallic core of the conduit (no sharp, edges inside the conduit). If the metallic core has been penetrated or is broken, the flexible conduit should be replaced.

2.

Clean the area where the damage has occurred using a clean rag and denatured alcohol, or equivalent.

3.

Wrap at least one half-lapped layer of 3M Company Scotch 22 Electrical Tape or equivalent for a minimum 2-inch distance on each sideof the damaged synthetic jacket, or to the end of the conduit such that it extends under the gland nut.

NOTE: Where the above flexible conduit exists inside dnvwell at Browns Ferry Nuclear Plant and inside primary' containment or in the main steam valve vault at other nuclear plants, it shall not be repaired but replaced.

INSTALLATION, MODIFICATION AND MAINTENANCE OF G-40 ELECTRICAL CONDUIT CABLE TRAYS, BOXES, REV 15 CONTAINMENT ELECTRICAL PENETRATIONS, ELECTRIC CONDUCTOR SEAL ASSEMBLIES, LIGHTING AND MISCELLANEOUS SYSTEMS 3.0 INSTALLATION (Continued) 3.2.6.1 (Continued)

b.

ServicAir Stainless Steel Conduit ServicAir flexible conduit is considered damaged and shall be replaced if any core damage. any broken strands of the braid or any burn marks exist prior to installing the cable. since there is no repair method. If conditions exist to the extent described below after cable installation the conduit shall also be replaced. If the damage has been caused due to a bend radius violation, the more restrictive requirements contained in the notes for Table 3.2.6-3-2 apply instead of those listed bclow:

I.

Core (metallic bellows) is visibly damaged (e-g.

flattening/ distortion of cross section or kinks).

2.

For conduits which serve as a pressure boundary (environmental seal), greater than 10% of the braid strands are visibly broken.

For conduits which do not serve as a pressure boundary, greater than 20% of the braid strands are visibly broken.

3.

Burn marks in outer braid. which occurred from an outside source (i.e. not from a fault inside the conduit) are acceptable provided that there are no bum marks or discoloration on the core and bum does not result in broken strands in excess of item 2 above.

4.

Conduit is pulled loose from end connectors and the flexible conduit or connector parts are visibly damaged (bent or broken). Reassembly is acceptable if the parts are not visibly damaged and the flex conduit can be reconnected as originally installed.

The cable shall be inspected by Nuclear Engineering for damage at the exposed location in accordance with G-38 section 3.7, prior to reconnection.

57

INSTALLATION, MODIFICATION AND MAINTENANCE OF ELECTRICAL CONDUIT CABLE TRAYS, BOXES, REV 15 CONTAINMENT ELECTRICAL PENETRATIONS, ELECTRIC CONDUCTOR SEAL ASSEMBLIES, LIGHTING AND MISCELLANEOUS SYSTEMS 3.0 INSTALLATION (Continued) 3.2.6.1 (Continued)

c.

American Boa Stainless Steel Conduit American Boa flexible conduit is considered damaged and shall'be replaced if any core damage, or any burn marks exist prior to installing the cable, since there are no repair methods.

If conditions exist to the extent described below after cable installation the-flexible conduit shall also be replaced. If the damage has been caused due to a bend radius violation, the more restrictive requirements contained in the notes for Table 3.2.6.3-2 apply instead of those listed below:

1.

Flattening/distortion, kinks or excessive indentation of core (metallic bello\\\\s). Indentations in the outer surface of the bellows not exceeding 1/8 inch in depth on no more than 10% of the bellows are acceptable provided the wall is not broken or torn.

2.

Conduit is pulled loose from end connectors and the flexible conduit or connector parts are visibly damaged (bent or broken). Reassemblv is acceptable if the parts are not visibly damaged and the flexible conduit can be reconnected as originally installed, The cable shall be inspected by Nuclear Engineering for damage at the exposed location in accordance with G-38 Section 3.7, prior to reconnection.

Bum marks on the core.

INSTALLATION, MODIFICATION AND MAINTENANCE OF G-40 ELECTRICAL CONDUIT CABLE TRAYS, BOXES, REV 15 CONTAINMENT ELECTRICAL PENETRATIONS, ELECTRIC CONDUCTOR SEAL ASSEMBLIES, LIGHTING AND MISCELLANEOUS SYSTEMS 3.0 INSTALLATION (Continued) 3.2.6.1 (Continued)

1.

Flexible conduits at the end devices max-be increased by one standard size above the design specified size without engineering approv.al or-revision of design drawings, provided the last two rigid conduit supports are sized to accommodate the larger flexible conduit.

J.

For Watts Bar Nuclear Plant rework or maintenance of installed flexible conduits in Category I structures after May 26. 1989.

shall comply with the following criteria to ensure conformance with the critical case evaluation by Civil engineering I.

Flexible conduit may be removed and reinstalled or replaced without increasing the length of the flexible-conduit or changing the length of the cantilevered section of rigid conduit. including couplings and fittings.

2.

Flexible conduit may be removed and reinstalled or replaced meeting the requirements of this specification, except as defined on WBEP design output documents.

3.

Flexible conduit removed and reinstalled or replaced not meeting the requirements of Section 3.2.6.1 Item J.1 or J.2 shall be approved by engineering.

K.

Wire mesh grips max' be installed at the Flex conduit connector in order to prevent pull out of the flex conduit from the connector.

The wire mesh grip may be installed as a new installation or for repair of existing installations.

Approved Manufacturers of these devices are Crouse-Hinds.

Thomas & Betts. Appleton, Kellems. The wire mesh grip shall be installed in accordance with the manufacturers instructions.

59

INSTALLATION, MODIFICATION AND MAINTENANCE OF G-40 ELECTRICAL CONDUIT CABLE TRAYS, BOXES, REV 15 CONTAINMENT ELECTRICAL PENETRATIONS, ELECTRIC CONDUCTOR SEAL ASSEMBLIES, LIGHTING AND MISCELLANEOUS SYSTEMS 3.0 INSTALLATION (Continued) 3.2.6.2 Floor-Mounted Equipment and Devices.

Seismic Thermal Movement Considerations in Seismic Category I (Class I at BFN) Structures *\\L3 During a-seismic event. flexiblc conduit will allow for relative displacement of equipment or devices and a rigid conduit system. To ensure that movement of the rigid conduit system and movement of floor mounted equipment (such as motors, electrical boards. and panels) are independent during a seismic event, the following installation procedures shall. be observed unless otherwise noted on design drawvings:

A.

When conduits connect to seismic Category I (L) floor-mounted equipment. an 18-inch minimum exposed length of flexible conduit shall be installed between the flexible conduit fittings at the rigid conduit coupling and the equipment. The actual minimum conduit length required for a particular installation shall be as specified on design drawings or as calculated using the equation in Figure 3.2.6.3-1. This minimum length of flexible conduit will, ensure that floor-mounted: Class IE equipment is capable of sufficient movement (i.e..

combined thermal/seismic movements) in any direction. The minimum bend radii for flexible conduit given in Table 3.2.6.3-2 shall not be violated.

B.

Where physical limitations prevent the installation of flexible conduits in accordance with Section.3.2.6.2 Item A minimum requirements, the construction, -modifications, or maintenance electrical engineer shall be notified for resolution.(by established procedures) with site engineering.

C.

In cases where flexible conduit is used for alignment purposes only and both ends of the flexible conduit are rigidly attached to the same seismic structure, the relative displacement between ends is zero and therefore exempt from thermal/seismic considerations.

D.

Conduit connections to cable trays should be avoided: however, if conduits are connected to seismic Category I cable trays, an 18-inch minimum length of flexible conduit shall be installed as indicated-in Section 3.2.6.2 Item A.

60

INSTALLATION, MODIFICATION AND MAINTENANCE OF G-40 ELECTRICAL CONDUIT CABLE TRAYS, BOXES, REV 15 CONTAINMENT ELECTRICAL PENETRATIONS, ELECTRIC CONDUCTOR SEAL ASSEMBLIES, LIGHTING AND MISCELLANEOUS SYSTENSIS 3-0 INSTALLATION (Continued) 3.2-6.3 Pipe-Mounted Devices. Thermal Seismic Movcment Considerations "'i.

A.

Where electrical connections must be made to devices (such as motor-operated

valves, solenoid-operated valves and temperature switches) w\\hich are attached to a mechanical flow system designed for thermal movements, flexible conduit shall be used to compensate for any expansion/contraction and seismic movement.

B.

Typically. flexible conduit connected to pipe-mounted electrical devices which are subject to thermal movements are in the 1/2-inch through 1-1/2-inch range. Excessive lengths in smaller flexible conduit sizes should be avoided to decrease stress and prevent pull-out at flexible conduit fittings.

C.

Seismic Category I (Class I at BFN) Structures Flexible conduit to pipe-mounted devices in seismic Category I structures shall be installed to compensate for. combined thermal/seismic movements.

The minimum length of flexible conduit shall be as specified on design drawings or as calculated using the equation in Figure 3.2.6.3-1.

This minimum length of flexible conduit wiii ensure that pipe-mounted devices are capable of sufficient movement in any direction. The minimum bend radii for flexible conduit given in Table 3.2.6.3-2 shall not be violated.

D.

Nonseismic Structures Flexible conduit to pipe-mounted devices in nonseismic structures shall be installed to compensate for thermal movements only. However. installine conduit per the equation given for seismic Category I structures will provide adequate compensation for nonseismic thermal movements.

61

INSTALLATION, MODIFICATIO N AND MAINTENANCE OF G-40 ELECTRICAL CONDUIT CABLE TRAYS, BOXES, REV 15 CONTAINMENT ELECTRICAL PENETRATIONS, ELECTRIC CONDUCTOR SEAL ASSEMBLIES, LIGHTING AND MISCELLANEOUS SYSTEMS 3.0 INSTALLATION (Continued) 3.2.6.3 (Continued)

Ritgid Conduit

-Rigid Conduit Support Coupling flexible Conduit Fitting

~-~~-YExposed Flexible-Condui r Rigid Conduit Support

.-- Flexible Conduit Fitting

--- 7-Exposed Flexible

'Top of Floor.-Mounted Equipment Figure 3.2.6.3-1 Typical Arrangement of Floor-Mounted Equipment or Pipe-Mounted Devices The equation for calculating the minimum length of exposed flexible conduit required between flexible conduit fittings, between flexible conduit fitting and an intermediate support point or between intermediate support points, is as follows:

62

INSTALLATION, MODIFICATION AND MAINTENANCE OF C-40 ELECTRICAL CONDUIT CABLE TRAYS, BOXES, REV 15 CONTAINMENT ELECTRICAL PENETRATIONS, ELECTRIC CONDUCTOR SEAL ASSEMBLIES, LIGHTING AND MISCELLANEOUS SYSTEMS 3.0 INSTALLATION (Continucd) 3.2-6.3. (Continued)

FL=

SD-+-K Where.

FL Minimum. exposed Ilexible conduit lengh between 1clxiblc conduit litiing*s.

(See Notes I and 2 page 65)

SD7 Field measured straight-line distance between the center line points of the flexible conduit linings. (ifthe straight-line distance is obstructed such that an exact measurcment cannot he made. the field engineer shall conservatively estimate thedistancc using a combination of measurements if required.)

K I inch tr floor-mounted equipment and for conduits crossing seismic interce boundaries for maximum seismic movement:

(WBN) 3-1.-4. inches for connections to the steel containment vessel for maximum combined seismic thermal'DI3A movement:

4 inches for conduits attached to cable trays or cable tray supports for maximum seismic movement: or 4 inches for pipermounted devices for maximum comhined seismic,'thennal movements, except as noted on design drawings.

(Movements are in any direction.)

(Note that for items anached to the steel containment vessel, the movements must he added i.e.. for a cable tray attached to the steel containment vessel, the maximum total movem;!nt would he 7-1 4 inches.)

K I* inch for floor-mounted equipment or (all other nuclear

,4 inches for pipe-mounted devices planLt)

(1 inch llexihle conduit length is required for maximum seismic movement in any direction: 4-inch flexible conduit length is required for maximum combined seismic'thermal movement in any direction at all nuclear plants).

Note I:

For flexible conduit cut length. the field shall add to the minimum calculated length (FL)- the flexible conduit length required for conduit fittings and any additional length required for bend radii. The minimum bend radii for flexible conduit given if)

Table 3.2.6-3-2 shall not be violated. Any exceptions to minimum calculated lengths (FL) andlor minimum bend radii shall be approved by engineering.

Note 2:

Exposed flexible conduit lengths shall not exceed 72 inches or he less than IX inches (28 inches for ServicAJr S63C). except as noted on design output documents.

For exceptions not noted on design output documents including conduit support drawings or an approved variance in Appendices W..X Y or Z. contact engineering for resolution.

63

INSTALLATION, MODIFICATION AND MAINTENANCE OF ELECTRICAL CONDUIT CABLE TRAYS, BOXES, CONTAINMENT ELECTRICAL PENETRATIONS, ELECTRIC CONDUCTOR SEAL ASSEMBLIES, LIGHTING AND MISCELLANEOUS SYSTEMS G-40 REV 15 3.0 INSTALLATION (Continued) 3.2.6.3. (Continued)

A - Radius Table 3.2.6.3-2 Minimum Bend Radii for Flexible Metal Conduit All Dimensions are in inches Conduit Trade Size 1/2 3/4 1

1-1/2 2

2-1/2 1

3 4

5 6

Flexible Conduit Manufacturer and A - Radius to inside of conduit as shown in figure above Type SEE NOTES ON FOLLOWING PAGE Anaconda Seal Tite 3.5 50 6.0 5.5 7.0 9.5 15.0 17.0 20.0 30.0 Type UA O-Z Gedney Flexi-3.0 3.5 6.0 5.0 7.0 9.5 11.5 14.0 Guard Type.UAG Liquatite Electric-3.0 4.2 5.5 4:5 6:0 8.0 10.0 12D0 Flex Type LA (Type (17.5)

(22.5)

LT)___________

American Flexible 3.25 425 6.5 9.0 11.13 14.63 17.5 24.0 Conduit Ameri-Tite Type UIL American Boa Type 1.23 1.38 2.55 3.81 4.54 5.27 8.74 12.20 14.71

• NBI-O and NBI-1 see note see note see note see note see note 1 see note 1 1

1 1

1 ServicAir SS60, 2.5 3,8 5.0 7.5 10.0 12.0 15.0 20.0 25.0 30.0 SS63 and SS63C Anemet, Inc.

22.0 30.0 Patel/EGS 75

INSTALLATION, MODIFICATION AND MAINTENANCE OF G-40 ELECTRICAL CONDUIT CABLE TRAYS, BOXES, REV 15 CONTAINMENT ELECTRICAL PENETRATIONS, ELECTRIC CONDUCTOR SEAL ASSEMBLIES, LIGHTING AND MISCELLANEOUS SYSTEMS 3.0 INSTALLATION. (Continued) 3.2.6.3 (Continued)

NOTES FOR TABLE 3.2.6.3-2:

American Boa (Type NBI-0 and NB1-1) flexible metal conduit larger than 2 inch (trade size) shall not be used for attachments to pipe-mounted devices, 2 The values contained in this table are based on manufacturers information and TVA calculation CD-Q0999-000001 (previously CEB-CQS-449, B41 940620 001).

3.

Once flexible conduit has been inalled per the requirements of-this specification, the as-found bend radius configuration of the flex is acceptable as long as no damage has occurred including:

a.

Kinking of flexible conduit so that the minimum bend radius (listed above) is obviously violated.

b.

Obvious surface damage of flexible conduit from denting, weld arc strikes, tearing of'stainless steel or pvc jacket as applicable, or fatigue cracks (See Section 3.2.6.1).

c_

Pullout of flexible conduit from its end connections (See Section 3.2.6.1).

When detected, bend radius damage shall be evaluated by engineering and corrected accordingly.

4.

The flexible conduit types which have numerical bend radius values provided in this table are the only types which are approved by this specification for installation (i.e. those sizes with "'-" are not approved and have not been approved unless justified in an exception contained in this specification), Additional types must be approved by listing the required bend radius values in this specification prior to procurement or installation. This will be accomplished by an engineering analysis of the materials, engineering data.and construction of the conduiL Other brands even though similarrare not to be assumed to be equal.

65

INSTALLATION, MODIFICATION AND MAINTENANCE OF

. G-40 ELECTRICAL CONDUIT CABLE TRAYS, BOXES, REV 15 CONTAINMENT ELECTRICAL PENETRATIONS, ELECTRIC CONDUCTOR SEAL ASSEMBLIES, LIGHTING AND MISCELLANEOUS SYSTEMS 3.0 INSTALLATION (Continued) 3.3 Conduit Boxes 3.3.1 General 3.3.1.1 Boxes shall be of the type and size as specified on design drawings. They shall be located as shown on design drawings and shall not be installed if damaged. Where large boxes are embedded. they shall be'properly braced on the inside so that concrete placement will not deflect them. Threaded holes in box frames shall be protected from damage.

3.3.1.2 Outlet boxes in architectural tile or masonry unit walls shall be installed strictly in accordance with design drawings and for best appearance, 3.3.1.3 Where watertight conduit connections to junction boxes without threaded hubs or bosses -are required (see Electrical Standard Drawing SD-EI3.6_5), Appleton type HUB conduit hubs. or equivalent, may be used in place of welded hubs.

3.3.1.4 Exposed noncurrent-carr.ing metal parts of fixed equipment and boxes shall be grounded.

Equipment not secured to, and in. metallic contact with, grounded structural steel shall be connected to the grounding system by brazing the grounding cable to the equipment and then carefully coating the joint with asphaltum. RTV sealant, or equivalent; or by bolted-connections to the box. or equipment.

3-3.1-5 For general information concerning field fabricated boxes, see Electrical Standard Drawing SD-E13.6.3-1.

3.3.1.6 Appleton type "PTC" threaded pull boxes may be used as cable pull boxes or to install splices in order to achieve cable or splice bend radius.

All such installations in Category I structures shall be installed in accordance to approved design output documents.

66

INSTALLATION, MODIFICATION AND MAINTENANCE OF G-40 ELECTRICAL CONDUIT CABLE TRAYS, BOXES, REV 15 CONTAINMENT ELECTRICAL PENETRATIONS, ELECTRIC CONDUCTOR SEAL ASSEMBLIES, LIGHTING AND MISCELLANEOUS SYSTEMS 3.0 INSTALLATION (Continued) 3-3.2 Painting Field-fabricated surface-mounted boxes shall be painte& inside and outside.

immediately after fabrication. Field-fabricated flush-mounted boxes shall be painted on the inside and the exposed parts only. Primer paints shall be lead free.

Boxes outside the primary_ containment shall be primed in accordance with General Engineering Specification G-147 Part No. 1-310 and finish coated the same color and type of coating as the surrounding area. Boxes located-inside the primary containments shall be coated in accordance with General Engineering Specification G-55 and the plant-specific coating specification as follows:

BFN Project Engineering Specification NIA-930 BFNP-N-955 SQN Project Engineering Specification N2A-93 SNP-N-971 WBN Project Engineering Specification N3A-932 WBNP-N-9711 BLN Project Engineering Specification N4A-933 BLN-N-971 Boxes that are purchased may be touched up if paint is nicked using the above requirements.

3.3.3 Seismic Mounting Surface-mounted conduit boxes located in seismic Categor. I structures shall be seismically mounted. Where the mounting. surface is poured concrete. boxes shall be attached to embedded steel plates or mounted to the concrete with bolt anchors as shown on equipment seismic support design drawings.

Seismic mounting of flush or surface boxes to masonry-walls shall be in accordance with specific design details.

67

INSTALLATION, MODIFICATION AND MAINTENANCE OF G-40 ELECTRICAL CONDUIT CABLE TRAYS, BOXES, REV 15 CONTAINMENT ELECTRICAL PENETRATIONS, ELECTRIC CONDUCTOR SEAL ASSEMBLIES, LIGHTING AND MISCELLANEOUS SYSTEMS 3.0 INSTALLATION (Continued) 3.3.4 Identification MarkinE Junction boxes and/or pull boxes shall be labeled in accordance with the applicable design drawings with the applicable color scheme defined for the respective nuclear plant (see applicable Electrical Design Standard DS-El.2.1 or DS-EI.2.2).

For those not shown on design drawings, the size lettering shall be determined by construction. modifications. or maintenance, depending on the box size.

The use of self-sticking mylar markers (e.g., AMP Special Industries or LEM. Products. Incorporated). self-adhesive polyester markers (eg:, W. H. Brady Company), or equivalent-is a suitable means for. box identification markings.

For future work at Bellefonte only beginning after 07/01/93 Junction boxes and/or fabricated pull boxes as shown on design drawings shall be labeled in accordance with the Design Standard drawing DS-E1.2.2. Fittings (i.e. TEE's & X's) that are shown on design drawings and are utilized as pull boxes shall be considered an extension of the conduit system and identified in accordance with Electrical Standard drawing SD-E15.3.4.

Box identification shall be as shown on design drawings.

3.3.5 Internal Protection Against Rust and Corrosion In most instances, boxes are installed well in advance of actual cable terminations.

Many boxes or panels may also have electrical components installed therein. To provide. protection against rust or corrosion until the cables are terminated and the installation completed. one of the following methods may be used. For the first and second methods, the applicable portions of the TVAN Safety and Health

'Manual shall be observed during the applications of coating and subsequent preparation of terminal blocks for permanent cable connections.

Section 3.3.5 Item C is the preferred method.

A.

Use of CRC No. 2-26 for 1-2 year storage period.

Before terminating cables, clean terminal blocks by brushing (using linseed oil if necessar))

and then burnishing.

B.

Use of CRC Lectra Shield coating on terminal blocks for 2-5 -ear storage (or even for 1-5 year storage). Use Exxon's Stoddard Solvent No. 627, or an equivalent, to remove the coating from terminal blocks and then burnish them before making final electrical connections.

68

INSTALLATION, MODIFICATION AND MAINTENANCE OF 40 ELECTRICAL CONDUIT CABLE TRAYS, BOXES, REV 15 CONTAINMENT ELECTRICAL PENETRATIONS, ELECTRIC CONDUCTOR SEAL ASSEMBLIES, LIGHTING AND MISCELLANEOUS SYSTEMS 3.0 INSTALLATION (Continued) 3.3.5 (Continued)

C.

Use of Zerust vapor capsules or Cortec VCI-160 tape. Inspection and/or replacement shall be in accordance with manufacturer's specifications.

3.3.6 On a casc-by-casc basis, with prior Nuclear Engineering approval on the Work Instruction Document. weep holes up to 1/4" in diameter may be drilled in the low points of non-safety junction/pull boxes, as required, to prevent water accumulation.

3.4 Cable Trays 3.4.1 Cable trays and accessories shall be installed in accordance with design drawings and engineering approved instructions.

3.4.2 Tray segments. fittings, connectors and hold down clips should be aligned before fasteners are installed.

Bolt holes shall not be enlarged unless approved by engineering.

3.4.3 Bolted fasteners shall be torqued in accordance with design approved documents.

Bolts through a tray side rail shall bc drawn up flush with the tray siderail's interior surface with the bolt head inside the tray and the lockwasher (if required) and nut outside. Rivets shall be installed in accordance with engineering output documents.

3.4.4 Vendor supplied hex head bolts may be substituted when too short to pass through multiple thicknesses of tray side rails and connector fittings.

Bolt substitution shall be in accordance with the following:

Minimum ASTM A307 Same diameter as the vendor-supplied bolt Free of sharp edges or burrs Of suffilent length to ensure adequate thread engagement 69

INSTALLATION, MODIFICATION AND MAINTENANCE OF G40 ELECTRICAL CONDUIT CABLE TRAYS, BOXES, REV 15 CONTAINMENT ELECTRICAL PENETRATIONS, ELECTRIC CONDUCTOR SEAL ASSEMBLIES, LIGHTING AND MISCELLANEOUS SYSTEMS 3.0 INSTALLATION (Continued) 3.4.5 Sharp edges shall be avoided at splice-connector joints, expansion joints, dividers and tray cover cutouts.

Tray dropouts shall be installed where cables exit downward, at tray end points or through the tray bottom.

Cables resting on divider edges end plate edges and exiting tray covers shall have chafe protection provided by applying a 6" + or - 1/2" length of Hypalon cable jacket material (PXJ. PXN'IJ or EPSJ) which has been slit to allow it to fit around the cablC(s)/cable tray hardware (e.g. siderails. rungs. end plates, etc.). or the cover-opening or divider shall be lined with rubber or weather resistant polyethylene grommeting material.

The--width shall be sufficient to insure protection of the cable surface and the edge. The.jacket covering material shall be fastened to the cable/cable tray hardware by use of nylon or tefzel tie wraps which meet the requirements of G-38 Sections 2.2.8.J and 2,2.8.2 (Reference G-38 Section 3.2.1.8 Item B for other requirements on placing cables in trays).

The requirements of this paragraph are not intended to replace requirements for vertical cable support contained in G-38 Section 3.2.1.8.6.

3.4.6 Provisions for attaching vertical cable supports (such as Kellums grips) to seismic structures such as walls, ceilings, etc.. other than the cable tray itself shall be provided at the time of tray installation. This may be a structural steel support mounted on a wall or floor or to the tray support structure as specified by design output documentation. To identify when this is required see G-38 section 2.2.8.1 and 2.2.8.2-.

3.4.7 Cut edges of trays shall be smooth and clean. The cut surface shall be coated with zinc-rich paint immediately after the cut. Bent or dented travs.or fittings shall not be installed without approval by engineering.

/70

INSTALLATION, MODIFICATION AND MAINTENANCE OF G-40 ELECTRICAL CONDUIT CABLE TRAYS, BOXES, REV 15 CONTAINMENT ELECTRICAL PENETRATIONS, ELECTRIC CONDUCTOR SEAL ASSEMBLIES, LIGHTING AND MISCELLANEOUS SYSTEMS 3.0 INSTALLATION (Continued) 3-4.7 The tray system shall be electrically continuous and grounded in accordance with design drawing details and General Engineering Specification G-47.

3.4.8 Outside trays of vertical stacks penetrating any floor or platform'.shall.have. covers extending 6 feet above the floor or platform to provide physical protection of the enclosed cable unless design drawings dictate othervise.

Additional tray covers shall be installed in accordance with design drawings.

3.4:9 At expansion Joints, tray shall be installed in accordance with dimensions, edge details. cable support distances. and special. fitting details shown on design drawings.

3.4-10 Vertical spacing between cable trays within the same tier or stack shall be 12 inches bottom-to-bottom of trays unless otherwise specified on design drawings-3.5 Manholes and Handholcs 3.5.1 Manholes and-handholes shall be constructed in accordance with approved engineering output documents.

Precast manholes shall be free of damage and installed according to engineering-approved instructions.

3.5.2 Concrete inserts for cable rack or tray supports shall be installed on manhole and handhole walls in accordance with design drawings.

Cable supports shall be installed as designated on design drawings:

3.5.3 Manhole and handhole excavation, backfill and concrete, materials. shall be in accordance with design output documents.

3.5.4 End bells shall be used to terminate nonmetallic conduits inside manholes.

All metallic conduit shall be terminated with appropriate insulated grounding bushings or chase nipples.

3.5.5.

All exposed metallic parts within the manhole/handhole, including conduit bushings shall be grounded to an internal loop and connected to the grotind grid in accordance with General Engineering Specification G-47.

3-5.6 Any space remaining, where ductbanks do not fully occupy the space for the conduits at the wall shall be sealed with concrete grout.

71

INSTALLATION, MODIFICATION AND MAINTENANCE OF G-40 ELECTRICAL CONDUIT CABLE TRAYS, BOXES,.

REV 15 CONTAINMENT ELECTRICAL PENETRATIONS, ELECTRIC CONDUCTOR SEAL ASSEMBLIES, LIGHTING AND MISCELLANEOUS SYSTEMS 3.0 UNSTALLATION (Continued) 3-5.7 Manholes and handholes shall be maintained free of standing water to the extent practical. Provisions (i.c., sump pumps or drains) shall be made to remove standing water. Standing water as a result of low areas. uneven surfaces or surfaces designed to drain to other sumps. or surfaces designed for minimal water levels (i.e.. handholes or french drains) is acceptable as long as the water level in the manholes and handholcs containing safety related-cables is below all cables and electrical devices. Also see section 3.2. 1.1 3.5.8 Manholes and handholes shall be identified as shown on design output documents.

3.6 Cable Trenches and Underfloor Ducts 3.6_1 Underfloor duct systems and cable trenches shall be free of damage and installed in sizes and locations as shown on design drawvings and in accordance with engineering-approved instructions.

3.6.2 Excavation. backfill and concrete materials shall be in accordance with design output documents.

3.6.3 Underfloor duct systems and cable trenches shall be. identified as shown on design output documents.

3.7 Electric Conductor Seal Assemblies (ECSAs) 3.7.1 ECSAs for conduit shall be installed at instruments and at end devices as specified on design drawings.

3.7.2 ECSAs shall be free of damage and installed and terminated in accordance with engineering-approved instructions and supported in accordance with design drawings.

3.7.3 ECSAs shall be identified as shown on design output documents.

/2

INSTALLATION, MODIFICATION AND MAINTENANCE OF G-40 ELECTRICAL CONDUIT CABLE TRAYS, BOXES, REV 15 CONTAINMENT ELECTRICAL PENETRATIONS, ELECTRIC CONDUCTOR SEAL ASSEMBLIES, LIGHTING AND MISCELLANEOUS SYSTEMS 3.0 INSTALLATION (Continued) 3.8 Containment Electrical Penetrations 3.8.1 Containment electrical penetrations shall be free of damage and installed in accordance with design drawings and engineering-approved instructions.

3.8.2 Cables at containment electrical penetrations shall be terminated in accordance with General Engineering Specification G-38.

38.3 Fit-up. welding, verification and testing of penetration connection to containment vessel shall be done in accordance with ASME B&PV. Division I.Section III, Subsection NE for Class MC components.

3.8.4 Containment electrical penetrations shall be identified in accordance %xith design output documents.

3.9 Lightinq System 3.9.1 Installation of the lighting s-stem, including lighting transformers. lighting panels.

fixtures, switches. contactors. eight-hour battery packs, unscheduled lighting conduits, branch circuits and associated supports. -shall be performed in accordance with design drawings.

3,9.2 Fixture assemblies shall be installed with all lamps and appurtenances (i.e..

starters/ballasts. individual lighting transformers. and fixture wiring).

Bent.

dented or-broken fixtures shall not be installed without engineering approval.

3.9.3 Lighting fixtures in Seismic Categorv I (Class I at BFN) areas shall be mounted/secured as shown on design output documents.

3.9.4 Lighting cable and terminations shall be installed in accordance with General Engineering Specification G-38.

3.9.5 Components (i:e.. boxes) which make up the lighting system shall be grounded in accordance with this specification.

3.9.6 Lighting conduits, fixtures and components shall be identified as shown on the drawings.

73

INSTALLATION, MODIFICATION AND MAINTENANCE OF G-40 ELECTRICAL CONDUIT CABLE TRAYS, BOXES, REV 15 CONTAINMENT ELECTRICAL PENETRATIONS, ELECTRIC CONDUCTOR SEAL ASSEMBLIES, LIGHTING AND MISCELLANEOUS SYSTEMS 3.0 INSTALLATION (Continued) 3.10 Communication System 3.10.1 Installation of the-communication systems, including low-level intraplant paging and communications.

telephone.

sound-powered phone

jacks, radio communications. alarm equipment. fire/emergency communications, unscheduled conduits and support systems shall be located and installed in accordance with design drawings and enginecring-approved instructions.

3.10.2 Communication system equipment in seismic Category I areas shall be mounted/secured in accordance with design output documents.

• 3.10.3 Communication cable and terminations shall be installed in accordance with General Engineering Specification G-38.

3.10.4 Conduits and-components (i.e., boxes) which make up the communications system shall be grounded in accordance with this specification.

3.10.5 Communication fixtures and components shall be identified as shown on the drawings.

3.11 Security System Security system hardWare and components of an electrical nature shall be-installed in accordance with design drawings and engineering-approved instructions. Wiring shall be in accordance with design drawings and General Engineering Specification G-38.

3.12 Marking and Identification 3.12.1 Exposed Class lE and associated circuit raceway systems shall be permanently marked in accordance with Electrical Standard Drawing SD-E]5.3.3 or SD-E15.3.4 at end points and should be marked at points of entry and exit from enclosed areas.

3.12-2 Cable tray marking shall normally be done when the cable tray installationsare completed and before cable installation. The cable tray identification markings shall be as defined on the respective engineering project cable tray drawings.

7/4

I-NSTALLATION, MODIFICATION AND MAINTENANCE OF G-40 REV 15 ELECTRICAL CONDUIT CABLE TRAYS, BOXES, CONTAINMENT ELECTRICAL PENETRATIONS, ELECTRIC CONDUCTOR SEAL ASSEMBLIES, LIGHTING AND MISCELLANEOUS SYSTEMS 3.0 INSTALLATION (Continued) 3.12.3 Beginning with Watts Bar Nuclear Plant and subsequent nuclear plants, the respective voltage level markers shall be located on at least one exterior side surface of cable trays designated for Class I E circuits (train or channel) at intervals not to exceed 15 feet and at points of entry to and exit from enclosed areas.

3.12.4 Each cable tray system (by voltage level) shall be identified with node numbers (for computer routing of cables) at intermediate points as shown on design drawings (cable tray node diagrams). These markers shall conform with the color code scheme defined for each respective nuclear plant (see Table A, B, or C on Electrical Standard Drawing SD-E15.3,4).

Markers for trays designated for nondivisional cables shall be white background with black lettering. The markers shall be of the self-sticking Mylar type or self-adhesive. polyester type (Brady's B-361 or Electrotag's T-1002-R) installed per manufacturer's instructions.

3.12.5 All exposed non-Class I E raceway systems except lighting systems shall be permanently and distinctively marked to identify the system as non-Class 1E in accordance with SD-E15.3.3 or SD-E 15.3.4.

3.12.6 Boxes, ECSAs and containment electrical penetrations shall be identified in accordance with engineering app roved output documents.

3.12.7 All conduit at the faces of manholes and handholes shall have permanent identification tags or markers in accordance with Section 3.2.1.7.

3.12.8 Manholes and handholes shall be permanently identified in accordance with design drawings.

3.12.9 Lighting, communications equipment and security equipment shall be tagged or marked where required by design drawings.

3.12.10 When cables are directly buried, a 4" wide (minimum) red warning tape (Seton Identification Products or equal) shall be placed approximately 6" above the cables to alert personnel to their presence. [SRN 79]

3.12.11 When conduits are directly buried (with or without a protective concrete cap) a 4" wide (minimum) red warning tape (Seton Identification Products or equal) shall be placed approximately 6" above the condufits (or protective concrete cap) to alert personnel to their presence. Where a group of conduits. is so routed and its width exceeds twice that of the tape, additional tapes shall be placed on 12"-A3" centers. [SRN 79]

3.12.12 Duct banks shall be overlaid with a 4" wide (minimum) red warning tape (Seton Identification Products or equal) shall be placed approximately 6" above the top of the concrete to alert personnel to its presence. Where the width of the duct bank exceeds twice that of the tape, additional tapes shall be placed on 12"-1 " centers. [SRN 79]

75

INSTALLATION, MODIFICATION AND MAINTENANCE OF G-40 ELECTRICAL CONDUIT CABLE TRAYS, BOXES, REV 15 CONTAINMENT ELECTRICAL PENETRATIONS, ELECTRIC CONDUCTOR SEAL ASSEMBLIES, LIGHTING AND MISCELLANEOUS SYSTEMS 3-0 INSTALLATION (Continued) 3ý13 Tolerances Horizontal and vertical spacibig between trays and conduit of different divisions of separation shall be maintained as shown on design drawings within tolerances of minus 0 inch for horizontal spacing. and minus 0 inch for vertical.

3.13.1 Cable tray installation tolerances shall be in accordance with design drawings or engineering approved instructions.

For installation tolerances not covered by design drawings or instructions. use:

A.

Horizontal locations shall be +/-2 inches of specified dimensions in. both.-

lateral and loniitudinal directions-except as noted above.

B.

Vertical locations shall be +/-1/2-inch of specified dimensions except as noted above.

.3.13.2 Embedded conduit terminations shall be located within 1/2-diameter of the conduit or 1-inch, -whichever is greater unless greater accuracy is required to avoid interference, to allow spacing and clearance for fittings, or to permit insertion into terminating devices.

3.13.3 The maximum variance for elevations of ductbanks at manhole faces shall not exceed +6 inches to -I inch. Also see section 3.2. 1.1.

3.13.4 On pre-engineered designs, the conduit and box location tolerance shall be +/- 6 inches.

For field-routed and located equipment, tolerance limits are not applicable.

76

INSTALLATION, MODIFICATION AND MAINTENANCE OF G-40 ELECTRICAL CONDUIT CABLE TRAYS, BOXES, REV 15 CONTAINMENT ELECTRICAL PENETRATIONS, ELECTRIC CONDUCTOR SEAL ASSEMBLIES, LIGHTING AND MISCELLANEOUS SYSTEMS 3.0 INSTALLATION (Continued) 3.13.5 Lighting fixtures shall be located in accordance with the following:

A.

Lighting fixtures, except for emergency and standby lighting units. may be relocated up to +/- 12 inches of design location as long as no unlighted areas are created.

B.

Standby and emergency lighting unit locations may be adjusted as long as all areas needcd for operation of safe shutdown equipment and access and egress routes remain illuminated.

C.

Fixtures in grid systems or suspended ceilings shall be installed as-located on design drawings with. tolerances to accommodate grid location.

4.0 VERIFICATION REQUIREMENTS This paragraph shall definethe activities and physical attributes that must be verified to assure that the installed or restored condition conforms to design requirements.

These requirements apply to new installation and modifications. For maintenance activities, only" those attributes being affected by the. activity are applicable. The context of "verification' as used in this paragraph does not define a specific organization's responsibility.

4.1 Conduit 41.1 Verify" that conduit is of the correct type and size. (Section 3.1. 1) 4.1.2 Verify that conduit utilizes acceptable fittings/hardware and-that all couplings/fittings are w\\rench tight (i.e.. cannot be loosened by hand). (Sections 3.2.1.4, 3.2.1-10, 3.2.2.8 and 3.2.4.1 Item K)

4. 1.3 Verify. that conduit (routing dimensioned on drawings) is installed in accordance with drawings. (Section 3. 1. 1) 4.1.4 Verify' that conduit terminates at correct equipment/devices and correctly utilizes any designated routing such as embedded sleeves, penetrations. etc.

(Section 3.1.1) 4.1.5 Verify bv visual examination that conduit and fittings are not damaged. (Section 3.I.1)

INSTALLATION, MODIFICATION AND MAINTENANCE OF G-40 ELECTRICAL CONDUIT CABLE TRAYS, BOXES, REV 15 CONTAINMENT ELECTRICAL PENETRATIONS, ELECTRIC CONDUCTOR SEAL ASSEMBLIES, LIGHTING AND MISCELLANEOUS SYSTEMS 4.0 VERIFICATION REQUIREMENTS (Continued) 4.1.6 Verif' that conduit is correctly identified.

4.1.7 Verify" that provisions for cable supports in vertical conduit are installed where required, (Section 3.2.1.5) 4.1.8 Verify the use of thrcadcompounds and that conduit is touched up with zinc-rich paint when galvanization is damaged.

4.1.9 Verify that the number of bends between pullpoints does not exceed 3600.

(Section 3.2.1.3) 4.1.10 Verifv that conduit is grounded as required (grounding bushings, expansion joints jumped, flexible.conduit jumped). (Section 3.2.4.1 Item A) 4.1.11 Vcrify that conduit is installed in accordance to design drawings to maintain.

required physical separations between redundant safety divisions.

4.1.12 Verify conduit attachments to end devices. (Section 3.2.2.2) 4.1.13 Verify-that flexible conduit lengths meet the requirements of Section 3.2.6.

4.1_ 14 Verify that flexible conduit bend radius is in accordance to Table 3.2.6.3-2.

4.1.15 Verifr correct span distance between supports (Section 3.2.2.2).

4.1.16 Verify proper distances from piping (Section 3.2.1.11, 3.2-1.12 and 3.2.2. 7)-

4.2 Embedded Conduit 4-2.1 Verify that conduit is the correct type and size. (Section 3.1.1) 4.2.2 Verify that conduit utilizes acceptable fittings/hardware and that all couplings/fittings are wrench tight such that they cannot be loosened by hand.

(Sections 3.2.1.4. 3.2.1.10, 3.2.2.8 and 3 2.4.1 Item K) 4.2.3 Verif-that conduit end points or points where conduit exits concrete are installed in accordance with design drawings.

4.2.4 Verify" bv visual examination that conduit and fittings are not damaged.

7 8

INSTALLATION, MODIFICATION AND MAINTENANCE OF G-40 ELECTRICAL CONDUIT CABLE TRAYS, BOXES, REV 15 CONTAINMENT ELECTRICAL PENETRATIONS, ELECTRIC CONDUCTOR SEAL ASSEMBLIES, LIGHTING AND MISCELLANEOUS SYSTEMS 4.0 VERIFICATION REQUIREMENTS (Continued) 4.2.5 Verify correct use of thread compounds for metallic conduit and verify that conduit is touched up with zinc-rich paint when galvanized coating is damaged.

(Sections 3.2.4.2 and 3.2-4-3 Item C) 4.2.6 Verify that conduit is supported and secured to avoid movement during concrete placement, (Section 3.2.3.3) 4.2.7 Verilf the required.spacing between adjacent conduits. (Section 3-2.3.1) 4.2.8 Verify that conduits have minimum concrete cover as specified on design drawings. (Section 3.2.3.2) 4.2.9 Verif' that conduit terminations at walls. floors and ceilings are capped and that spare sleeves are sealed and capped. (Section 3.2. 1.9) 4.2.10 Verify that conduit exits the concrete perpendicular-to the surface (+/- 10 degrees).

(Section 3.2.3.9) 4.2. 11 Verify that bonding for continuous ground across expansion joints has been installed. (Sections 3.2.4.1 Item A and 3.2.3.8) 4.2.12 Verifx that PVC joint-compound is applied in accordance with PVC manufacturer recommendations. (Section 3_2.5) 4.2.13 Verify that conduit slopes towards manholes and handholes. (Section 3.2. 1. 1) 4.2.14 Verify that ductbank plastic spacers are adequately installed. (Section 3.2.3-5) 4.2.15 Verify conduits to be embedded are positioned correctly before concrete is placed.

(Section 3.2.3. 1) 4.2.16 Verif-all embedded conduit bends before concrete placement. (Section 3.2.3.9) 4.2.17 Verify that conduit is properly identified after concrete placement.

(Section 3.2.1.7., and 3.12.7) 4.2.18 Verify' that conduits are swabbed immediately after concrete placement. (Section 3.2). 3.13) 79

INSTALLATION, MODIFICATION AND MAINTENANCE OF G-40 ELECTRICAL CONDUIT CABLE TRAYS, BOXES, REV 15 CONTAINMENT ELECTRICAL PENETRATIONS, ELECTRIC CONDUCTOR SEAL ASSEMBLIES, LIGHTING AND

,MISCELLANEOUS SYSTEMS 4.0 VERIFICATION REQUIEMENTS (Continued) 4.2.19 VerifW that conduit caps/plugs are installed where required and that plastic or aluminum conduit plugs arc not used in fire barriers. (Section 3.2.1.9) 4.3 Boxes 4.3.1 4.3.2 4.3.3 4.3.4 4.3.5 4.3.6 4.3.7 4.3.8 4.3-9 Verify that the box is type specified on drawings. (Section 3.3.1)

Verify that the box is of the correct size. (Section 3.3.1)

Verify that the box is installed in accordance with design drawings.

(Section 3.3.1)

Verifv by visual examination that the box is not damaged. (Section 3.3. 1)

Verifý- that damaged paint or finish is touched up. (Section 3.3.2)

Verify that exposed metal parts of boxes are grounded. (Section 3.3.1.4)

Verify that embedded boxes are attached to the forms before concrete is placed.

(Section 3.3.1.1)

Verify boxes are labeled properly. (Section 3.3.4)

Verify that weepholes are provided where required. (Section 3.3. 1) 80

INSTALLATION, MNODIFICATION AND MAINTENANCE OF G-40 ELECTRICAL CONDUIT CABLE TRAYS, BOXES, REV 15 CONTAINMENT ELECTRICAL PENETRATIONS, ELECTRIC CONDUCTOR SEAL ASSEMBLIES, LIGHTING AND MISCELLANEOUS SYSTEMS 4.0 VERIFICATION REQUIREMENTS (Continued) 4.4 Cable Tray 4.4. 1 Verifi that all cable trays arc located, installed and identified in accordance with design output documents and applicable site procedures. (Section 3.4.])

4.4.2 Verify' that cable tray identification is in accordance with the following:

4-4-2.1 Browns Ferry:

A.

Drv*vell trays Self-sticking mylar markers (e.g., LEM Products. Inc.)

shall be used to -identifv tray designations.

Letter sizes and background color are the same as those described in Section 4.4.2 Item B.

B.

Trays outside primary containment

1.

Nondivisional trays are identified by a white rectangle 3-1/2 inches high by 12 inches long painted on the side of the tray.

The tray designation is painted on the white background in black. block letters 3 inches high.

2.

Travs used for ESS cables are identified by a vellow rectangle 3-1/2 inches high. with lenghs required. painted on the side of the tray. The tray designation is painted on the yellow background in black. block letters 3 inches high. followed by ES-I or ES-Il in black, block letters 2 inches high.

Painting material shall be in accordance with General Engineering Specification G-14.

4.4.2.2 Sequovah. Watts Bar and Bellefonte:

In accordance with design output documents.

81

INSTALLATION, MODIFICATION AND MAINTENANCE OF G-40 ELECTRICAL CONDUIT CABLE TRAYS, BOXES, REV 15 CONTAINMENT ELECTRICAL PENETRATIONS, ELECTRIC CONDUCTOR SEAL ASSEMBLIES, LIGHTING AND MISCELLANEOUS SYSTEMS 4-0 VERIFICATION REQUIREMENTS (Continued) 4.4.3 Verif, that cable tray components are in good condition, free from handling or installation damage. and without burrs or protrusions caused by field cutting.

(Section 3.46) 4.4.4 Verify that cut edges and other bare metal tray surfaces are coated, and all damaged protective coatings repaired in accordance with General Engineering-Specification G-14 and applicable site procedures. (Section 3.4.6) 4.4.5 Verify that all cable tray covers are installed when required as shown on design output documents with the fasteners attaching covers to tray properly torqued or secured in accordance with design output documents. (Section 3.4.8) 4.4.6 Verify that cable trays are grounded in accordance with design output documents and General Engineering Specification G-47. (Section 3.4.7) 4.4.7 In accordance with design output documents, and applicable site procedures, verifn that tray fasteners: (Section 3.4.4)

A.

Are the proper size and type B.

Have the proper thread engagement (minimum thread engagement shall be the thickness of one nominal bolt diameter).

C.

Have lockwashers, where applicable, properly installed and visibly seated.

D.

Have spline bolt heads, where applicable, properly installed and visibly seated.

E.

Have proper torque %%here applicable F.

Have protrusions oriented toward the outside of the tray-62 I

INSTALLATION, MODIFICATION AND MAINTENANCE OF G-40 ELECTRICAL CONDUIT CABLE TRAYS, BOXES, REV 15 CONTAINMENT ELECTRICAL PENETRATIONS, ELECTRIC CONDUCTOR SEAL ASSEMBLIES, LIGHTING AND MISCELLANEOUS SYSTEMS 4.0 VERIFICATION REQUIREMENTS (Continued) 4.5 Manholes. Handholes. Trenches. and Underfloor Ducts 4.5.1 Verify that manholes. handholes. trenches-and underfloor ducts are of the correct types as specified by design drawings. (Section 3.5. 1) 4.5.2 Verify that manholes. handholes, trenches. and underfloor ducts are installed in accordance with design drawings. (Section 3.5.1) 4-5.3 Verify by visual examination that manholes. handholes. trenches, and underfloor ducts are not damaged. (Sections 3.5.1. and 3.6.1) 4.5.4 Verif, that manholes, handholes, trenches, and underfloor ducts are identified and marked. (Sections 3.5.8 and 3.6.3) 4.5.5 Verify, that end bells for nonmetallic conduit are installed in manholes and handholes where required. (Section 3.5.4) 4.5.7 Verify that metallic conduit ends in manholes and handholes are terminated with appropriate insulated grounding bushings or chase nipples. (Section 3.5-4) 4.5.8 Verify' ductbank entr' into manholes and handholes for complete sealing. (Section 3.5.6) 4.5.9 Verify that grounding is installed in accordance with design drawings.

(Section 3.5.5) 4.5.10 Periodically verify that manholes and handholes containing safety related cables are free of standing water as defined in Section 3.5.7. (Section 3.5.7) 83

INSTALLATION, MODIFICATION AND MAINTENANCE OF G-40 ELECTRICAL CONDUIT CABLE TRAYS, BOXES, REV 15 CONTAINMENT ELECTRICAL PENETRATIONS, ELECTRIC CONDUCTOR SEAL ASSEMBLIES, LIGHTING AND MISCELLANEOUS SYSTEMS 4.0 VERIFICATION REQUIREMENTS (Continued) 4.6 Electric Conductor Seal Assemblies (ECSAs) 4.6.1 Verif\\" that each ECSA is the correct type as specified on design drawings.

(Section 3.7. 1) 4.6-2 Verif that ECSA is installed in accordance with design

drawings, engineering-approved instructions, and site procedures.

Verify that ECSA terminates at the correct equipment. (Section 3.7.2) 4,6.3 Verify by visual examination that ECSAs are not damaged. (Section 3.7.2) 4.6.4 Verif-y that ECSA is properly identified. (Section 3.7.3) 4.7 Containment.Electrical Penetrations 4.7.1 Verif,: that each containment electrical penetration is the correct type as specified and located on drawings. (Section 3.8. 1) 4.7.2 Veri,' that contaiiment electrical penetrations are properly installed in accordance with design drawings and engineering-approved instructions. (Section 3.8.1) 4.7.3 Verifx-by visual examination that containment electrical penetrations are not damaged. (Section 3.8.1) 4.7.4 Review containment test records to ensure that all tests were performed and recorded for plant records. (Section 3.8.3) 4.7.5 Verify that containment electrical penetrations are identified correctly.

(Section 3.8.4)

INSTALLATION, MODIFICATION AND MAINTENANCE OFG-ELECTRICAL CONDUIT CABLE TRAYS, BOXES, REV 15 CONTAINMENT ELECTRICAL PENETRATIONS, ELECTRIC CONDUCTOR SEAL ASSEMBLIES, LIGHTING AND MISCELLANEOUS SYSTEMS 4.0 VERIFICATION REQUIREMENTS (Continued) 4.8 Lightin" Systcm 4.8.t1 Veri lighting system installation to ensure that components are as specified on the design drawings. (Section 3.9-1) 4-8.2 Verify that lighting system components are installed in accordance with design drawings and that any specified lighting levels are achieved. (Sections 3.9.1. 39.2 and 3.9.6) 4.8.3 Verify that lighting sy'stem components are not damaged. (Section 3.9.2) 4.8.4 Verify that components are identified as required b% design drawings. (Section.

3.9.6) 4.9 Communication and Security Systems 4.9.1 Verify that components are as specified on design drawings. (Section 3.10.1) 4.9.2 Verify-that components are installed in accordance with design drawings.

(Sections 3.10.1 and 3.10.2) 4.9.3 Verify that components are not damaged. (Section 3.10.1) 4.9.4 Verify that components are identified as required by design drawings. (Section 3.1.0_5) 4.9.5 Watts Bar Nuclear Plant Verify that the essential Appendix R Fire Safety Shut Down (FSSD) conduits are installed within the boundaries identified on the Appendix R separation sketches and instructions provided in the DCN or ECN-Mod package. Verification is not required for DCNs/ECN-Mod packages which do not include Appendix R separation sketches or instructions.

85

INSTALLATION, MODIFICATION AND MAINTENANCE OF G-40 ELECTRICAL CONDUIT CABLE TRAYS, BOXES, REV 15 CONTAINMENT ELECTRICAL PENETRATIONS, ELECTRIC CONDUCTOR SEAL ASSEMBLIES, LIGHTING AND MISCELLANEOUS SYSTEMIS 5.0 TESTrNG/ACCEPTANCE REQUIREMENTS Testing. and acceptance criteria are delineated belowý.

Site procedures-shall provide-detailed implementing instructions including documentation methods and forms-Tests specified in this section are installation acceptance tests unless otherwise stated.

5.1 General Tests and checks shall be made in accordance with engineering-approved test equipment instructions or engineering instructions.

5.2 Containment Electrical Penetrations 5.2.1 Gas leak-rate test shall be performed on each electrical penetration assembly.

including the aperture seal(s). The test shall be performed with the equivalent leak-rate of dry nitrogen at design pressure and at ambient.temperature. The total leak-rate shall not exceed a value equivalent to (1)10- std cm'/s of dry nitrogen or less as specified by engineering-approved instructions.

NOTE: When the method of penetration attachment is by welding, the aperture seals (the welds) should be tested as part of the containment integrated leak-rate test (ILRT).

5.2.2 Electrical Tests After the penetration -assembly is installed, each conductor shall be tested in accordance with the following:

5.2.2.1 Cables shall be tested for continuity and insulation resistance tested at 500V dc. Medium-voltage power cables shall have a minimum resistance of 100 megohm between conductors and between conductor and ground.

Other cables shall have a minimum resistance of 10 megohm.

5.2.2.2 High-voltage dielectric strength tests shall not be performed on penetration cables unless directed by engineering.

8 6

INSTALLATION, MODIFICATION AND MAINTENANCE OF G-40 ELECTRICAL CONDUIT CABLE TRAYS, BOXES, REV 15 CONTAINMENT ELECTRICAL PENETRATIONS, ELECTRIC CONDUCTOR SEAL ASSEMBLIES, LIGHTING AND MISCELLANEOUS SYSTEMS 5.0 TESTING/ACCEPTANCE REQUIREMENTS (Continued).

5.2.2 (Continued) 5.2.2.3 The preceding electrical tests may be performed before or after external (field) cables are connected to the penetration assembly. In either case, the lesser of allowable test voltages for external cables or penetration cables shall be utilized. (External field cables shall be tested in accordance with General Engineering Specification G-38).

5.3 Electric Conductor Seal Assemblies Electric conductor seal assemblies with integral cables and requiring in-line splices shall be tested prior to termination for continuity and insulation resistance in accordance with manufacturer's instructions. In the absence 'of manufacturer's instructions, testing shall be in accordance with General Engineering Specification G-38. After termination, no special testing.

of electric conductor seal assemblies-is required.. This.section does not preclude or eliminate the requirement for the performance of post-pulling tests on the external cable.

5.4 Lightin,-Systern 5.4.1 Cable shall be installed and tested in accordance with General Engineering Specification G-38.

5.4.2 Fixtures and lamps shall be functionally tested.

5.4.3 Areas designated for preoperational testing shall be tested for adequate illumination in accordance with test instructions.

6.0 REFERENCES

6.1 General 6.1.1 TVAN Standard Drawings, Design Standards, Design Guides and General Engineering Specifications listed in section 1.2.1 6.1.2 ANSI N45.2.4-1972, Installation, Inspection, and Testing Requirements for Instrumentation and Electric Equipment During the Construction of Nuclear Power Generating Stations - Section 4, first paragraph, second sentence to end of section.

6.1.3 TVAN Standard Specification, SS-E21.000, Rigid Aluminum Conduit 6.1.4 TVAN Standard Specification, SS-E21.001, Rigid Steel Conduit (Zinc Coated) 6.1.5 TVAN Standard Specification, SS-E21_002, Fittings for Conduit and Outlet Boxes 6.1.6 General Engineering Specification-G-38, Installation; Modification. and Maintenance of Insulated Cables Rated Up to 15,000 Volts 6.1.7 NEDP-10, Design Output, 6.1,8 UL 360, UL Standard for Safeýy Liquid-Tight Flexible Steel Conduit 6.1.9 Calculatiori CD-Q0999-000001 (previously CEB-CQS-449, B41 940620 001), G-40 Bend Radii for American Boa Flexible Conduit 87

INSTALLATION, MODIFICATION AND MAINTENANCE OF G-40 REV 15 ELECTRICAL CONDUIT CABLE TRAYS, BOXES, CONTAINMENT ELECTRICAL PENETRATIONS, ELECTRIC CONDUCTOR SEAL ASSEMBLIES, LIGHTING AND MISCELLANEOUS SYSTEMS 6.1.10 UL 5 14B, UL Standard.ftr Safit' Fittinz.-Yfor Conduit and Outlet Boxes 6.1.11 General Engineering Specification G-47. Installation. Modification and Maintenance of Electrical Grounding Sv.szem.s and Lightning Proiection Sysvitems 6.1.12 General Engineering Specification G-29. Welding. Materials and Nondestructive Examination 6.1.13 General Engineering Specification G-34. RCqUirements Jol-Repair of Concrete During Construction. Modification0N and Mfaintenance 6.1-14 General, Engineering Specification G-55. Technical and Programmatic Requirements for the Protective Coating Programn for T"A Nuclear Plants 6.1.15 General Engineering Specification G-14. Selecting. Specifiing, Applying and Inspecting Paint and Cocitings 6.1.16 Code of Federal Regulations. I0CFR50 Appendix R 6.1.17 Code of Federal Regulations. 101CFR50.49 6.1.18 NFPA 70. National Electric Code 6.1.19 7TVIN.Yaqfl and Health Manual 6.1.20 ASTM A307' Standard Specification f/or Carbon Steels Bolts and Study. 60.000 psi Tensile Strength 6.1.21 ASME B&PV, Division 17 Section III, Subsection NE. Rules for Construction of Nuclear Power Plant Components. Class MC Components. Non-lnierfiled 6.2 Browns Ferry 6.2. I No. G-3. Construction Specification./or Browns Ferry Nuclear Plant and all Future Nuclear Plants (withdrawni. included as historical reference only) 6.2.2 Drawing 0-45B891-1. Conduit and Grounding. Details of Electrical Equipment Waterproofing and Sealing.

6.2.3 NIA-930. BFNP-N-955, BFN Project Engineering Specification. Special Protective Coating Syistems Approved for Use in Coating Service Levels I and II and Corrosive Environments 6.3 Sequoyah 6.3.1 N2E-860, Sequo 'ah Nuclear Plant Project Construction Specification. (withdrawn, included as historical reference only) 6.3.2 SQN Project Engineering Specification. N2A-93 1. SNP-N-97 1. Special Protective Coating Systems Approved far Use in Coating Service Levels I and II and Corrosive Environments 6.4 Watts Bar 6.4.1 WBN-OSG4-139, Walkdown of Electrical Racewayvs within Close Proximit, to Hot Pipes, Data Tabulation and Violation Evaluation.

6,4,2 WBN-OSG4-22 1, Class IE Electrical Cable Hot Pipe Requirements for Special Cases 6.4.3 WBN-OSG4-138, Class IE Electrical CablelHot Pipe Clearance Requirements 6.4.4-WBN-OSG4-170, Mechanical Systems Operating at 135For Greater 6.4.5 Watts Bar Nuclear Plant Engineering Specification, N3C-944, Conduit and Conduit Support Installations 6.4.6 Watts Bar Nuclear Plant Engineering Specification. N3C-941, Commodity Clearance Requirements 6.4.7 Environmental Data Drawings 47E235 series. Environmental Data, Environment - Mild and Harsh 6.4.8 QIR MNMWBN93007 RO (T31 930408 986), Separation Requirements for Non-Pmoer Cables in 69 roximi7 to Hot Pipes for Incorporation Into G-40 6.4.9 ASTM A780. Standard Practice for Repair of Damaged and Uncoated Areas of Hot-Dip Galvanized Coatings 6.4. 10 45W883. Sheet 6. Conduit and Grounding. Penetration Sealing and Fire Stop Details 88

INSTALLATION, MODIFICATION AND MAINTENANCE OF ELECTRICAL CONDUIT CABLE TRAYS, BOXES, CONTAINMENT ELECTRICAL PENETRATIONS, ELECTRIC CONDUCTOR SEAL ASSEMBLIES, LIGHTING AND MIISCELLANEOUS SYSTEMS G-40 REV 15 6-4. I WBN Project Engineering Specification. N3A-932. WBNP-N-971 I. Special Protective Coating Si'stems Approved.cbr Use in Coating S-vice Levels I and II and Corrosive Environments 6.5 Bellefonte 6.5.1 BLN Proqect Engineering Specification. N4A-933. BLN-N-971, Special Protective Coating Systems Approved for Use.in Coating Service Levels I and 11 and Corrosive Environments.

89

INSTALLATION, MODIFICATION AND MAINTENANCE OF G-40 REV 15 ELECTRICAL CONDUIT CABLE TRAYS, BOXES, CONTAINMENT ELECTRICAL PENETRATIONS, ELECTRIC CONDUCTOR SEAL ASSEMBLIES, LIGHTING AND MISCELLANEOUS SYSTEMS APPENDIX J SOURCE NOTES SOURCE SOURCE NOTE APPLICABLE NOTE TRACKING DOCUMENT SECTION NUMBERS BLN-I NCO850468001 & NCO850468002 326.1 G WBN-1 L4485 1003807 3,2.1.5 WBN-2 L44860128806. MSC-00991. NC0920042754.

3.2. 1.3 MC851220804001 WBN-3 L44860819807. WBRD 50-390/86-27.

3.2-6.-.A.

NCO860099003. WBRD 50-391/86-23.

3_2.6.2.

MSC-03978. NCO890048003 3.2.6.3 WBN-4 L44900305802. NC09000200(06. WBP890421 3.2.2.9 WBN-5 L4490101 1801. NRC CDR 390/90-03.

3.2.I-15.A WBP900264SCA,.NCO880283004 WBN-6 L449006 15802. NCO900002020. WBP900256PER 3.2,1.4.B-WBN-7 WBSCA930163 2.3.8.3 C WBN-8 NCO.880283056 3.2. 1,1 5.A WBN-9 L448703168053.22 WBN-10 SCRWBNEEB8548 R-2.3-8.1I WBN-l I MSC-03979. NCO890048004. L448902 15801, Watts Bar 3.2.6. 1.F Electrical Issues CAP WBN-12 MSC-03980. NCO890048005. L44890215801. Watts Bar 3.2.6. 1.F Electrical Issues CAP J

90 m

III