ONS-2015-058, Engineering Report 555, Oconee, Units 1, 2, and 3 - Ul 1569 Impact and Crush Tests on Keowee Underground Trench Power Cables for Duke Energy Carolinas, Llc.
| ML15139A050 | |
| Person / Time | |
|---|---|
| Site: | Oconee  |
| Issue date: | 03/27/2015 |
| From: | Batson S Duke Energy Carolinas |
| To: | Document Control Desk, NRC/RGN-II |
| Shared Package | |
| ML15139A018 | List:
|
| References | |
| IR 2014007, ONS-2015-058, TIA 2014-05 Engineering Report No. 555 | |
| Download: ML15139A050 (64) | |
Text
ONS-2015-058 TIA 2014-05 Attachment 2 UL 1569 Impact and Crush Tests on Keowee Underground Trench Power Cables for Duke Energy Carolinas, LLC (64 pages, including cover page)
APPLICATION ENGINEERING THE 102 HILLTOP ROAD RAMSEY NJ 07446 COMPANY 201-825-0300(PHONE) 201-327-0273(FAX)
OKONITE engiineering@okonite.com www.okonite.com March 27, 2015 ENGINEERING REPORT # 555 UL 1569 Impact and Crush Tests on Keowee Underground Trench Power Cables for Duke Energy Carolinas, LLC PO No. 00192523 Customer Specification: OSR-0316.00-00-0003 Rev. 0 Okonite FO No. 02-7635 Okonite High Voltage Laboratory Project # 4259
Purpose:
To perform impact, increasing crush and 1000 lbs. crush tests per UL Standard 1569 (Metal Clad Cables, Third Edition dated Aug 31, 1999) (ANSI approval dated 1-6-12) guidelines Sections 24, 25 and 26, as modified by the Duke-Energy document OSR-0316.00-00-0003 Rev. 0, on cable samples provided by Duke-Energy. These tests are performed to demonstrate that the 15 kV and 5 kV single conductor power cables, with bronze tapes, support the cables adequate separation criteria from interlocked-armored and shielded multiconductor cables, in the underground trench between Oconee Nuclear Station and Keowee Hydro Station. Tests details are outlined in the Duke-Energy document OSR-0316.00-00-0003 Rev. 0. All testing was performed under the guidelines of Okonite's 10CFR50 Appendix B program.
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Cable Sample Descriptions: Cable samples were submitted to Okonite by Duke Energy, shipped directly to Okonite's High Voltage Laboratory, 959 Market Street, Paterson, N. J. 07513. Samples, as received, were 60 feet each in length, coiled on wooden shipping pallets. The following table is a list of the test samples submitted.
No ID
-I 11 b-2i- ;Jib 1/C 750 kcmil CU compact round conductor 61x, extruded EPR semicon screen, 220-mils Okoguard EPR insulation (15 kV 133% Level), 24-mil semicon EPR screen, 0.006" bare CU longitudinally corrugated tape shield (Okobon) with a 25% min.
seam overlap, with a seam seal, and 80-mil Okolene (PE) iacket. (2012) 2 1BA750G15 1/C 750 kcmil CU compact round conductor 61x, extruded EPR semicon screen, 260-mils Okoguard EPR insulation (15 kV 173% Level), semicon EPR screen, 2 x 0.010" bronze tape shields, helically applied one with 10% gap and one 12.5% min.
overlap, fiberglass tapes, and 110-mil Okolon CPE-TS jacket. (2011) Duke Specification; OSS-0139.00-00-0010 Ri.
3 1BA250G5 1/C 250 kcmil CU compact round conductor 37x, extruded EPR semicon screen, 140-mils Okoguard EPR insulation (5 kV 173% Level), semicon EPR screen, 2 x 0.010" bronze tape shields, helically applied one with 10% gap and one 12.5% min.
overlap, fiberglass tapes, and 11 0-mil Okolon CSPE jacket. (2005) Duke Specification; OSS-0139.00 0010 R1.
4 3XJ2G8 3/C #2 AWG CU compact round conductor 7x, extruded EPR semicon screen, 140-mils Okoguard EPR insulation (8 kV 133% Level), semicon EPR screen, 0.005" coated CU tape shield, helically applied one with 12.5% min. overlap, 1 x #6 AWG 7x Tinned CU Ground, rubber fillers, fiberglass tapes, 0.025" galvanized steel square Loxarmor, 60-mil Okoseal PVC jacket. (2008) Duke Specification; DPS-1354.01-00-0010 R1.
All of the test equipment used, including calibration information, is listed in the "Equipment List" Attachment No. 1.
Test criteria and Procedures: The following chart outlines the tests criteria and procedures followed as per UL Standard 1569.
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Increasing Direct Burial Test: Impact Crush T 1000 lbs. for 60 sec.
Reference Standard: UL1569 UL 1569 UL 1569 Reference Para: Sec. 24 Sec. 25 Sec. 26 Sample Length: 11 ft. 100" min. 36" min.
Test per Sample: 10 10 3 Distance between tests: 12" 9" 9" Weight: 50 lbs. Increasing 1000 lbs.
Partial Discharge, VLF tan Special Conditions: A, VLF voltage withstand (See summary for full list of tests.)
Failure if Avg. of 10
> 2 out of crushes No cracks, splits, tears or Acceptance Criteria: 10 make Ž 2000 lbs. rupture of the jacket or electrical to electrical insulation.
contact contact Discussion: Introduction - Testing was performed on February 16 - 19, 2015 at Okonite's facilities in Paterson, New Jersey. The test equipment used were in different locations within Okonite's manufacturing Plant - impact testing (UL 1569, Section 24) performed in the Electrical Testing Laboratory Annex, increasing crush testing (UL 1569, Section 25) performed in the Plant Material's Laboratory and the 1000 lbs. crush test (UL 1569, Section 26) performed in the High Voltage (HV) Laboratory. A Quality Plan (QP), Okonite Plan # 2015-02 was written outlining the tests to be performed, contact information and data record sheets. The exact sequence of tests, as outlined in the QP, was not followed; however, all of the tests were performed. The order of testing was rearranged due to the extreme cold weather the Paterson area was experiencing. The UL Standard requirement for each test was 24.0 +/-8.0°C (75.2 +/-14.4°F), for the test samples, the apparatus, and the surrounding air. Therefore, the test sequence was based on the area, equipment and samples being within the required temperature range. All of the required testing was witnessed by Engineers from Duke Energy.
As a follow-up to the required tests, on February 25 and 26 an additional series of 1000 lb. crush tests for 1-minute (UL 1560 Section 26), was performed in the HV Lab to determine what weight, greater than 1000 lbs. the 1/C 250 kcmil (Sample No. 3) could sustain before a failure. A similar test was performed on the 1/C 750 kcmil cable (Sample No. 2) to a maximum weight of 2000 lbs. and this cable passed the partial discharge, VLF Tan Delta and VLF withstand tests.
However, when this 2000 lbs. test was run on the 1/C 250 kcmil, the cable would not hold voltage and it was determined by insulation resistance measurement that there was damage within the cable insulation. It was later confirmed that 3
cable conductor size and construction is a determinant regarding the amount of compressive force the cable can withstand without failure. This testing is discussed further in the Additional Testing section.
A summary of all testing performed is included in Attachment No. 2.
E UL 1569 Section 26 Crushing Test - Cable Marked for Direct Burial The first test run was the 1000 lbs. crush for 60 seconds, UL Standard 1569, Section 26 (Cable Marked for Direct Burial). This test was done in the High Voltage Laboratory utilizing a frame constructed of steel pipe, which allowed a dead weight of 1000 lbs. applied for 60 seconds, by a flat 2" square horizontal steel plate that crushes the cable at the point at which the cable is laid over a W" diameter steel rod. See Figures 1 and 2.
Figure - 2 The apparatus shown in Figures 1 and 2 were utilized, in the High Voltage Laboratory, in order to perform Very Low Frequency (VLF) Tan Delta and Partial Discharge electrical testing between each crush.
Fligure -1 Electrical testing between crushes was a request per the Duke Energy contract. The standard UL requirement for this test is to perform 3-crushes, at 9" intervals followed by visual examination of the cable for any splits, in either the jacket or insulation, with no electrical testing. Performing the test in the High Voltage Laboratory provided the ability to conduct electrical tests after each crush in one location, with limited handling of each sample.
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The 1000 lbs. of dead weight was generated by a total of the top portion of the frame, plus the combination of lead ingots and iron weights. Each ingot and iron weight was weighed using a calibrated scale ID# SC-4. The actual weight used for compression was 1000.2 lbs. All weight calibration records can be found in Attachment No. 3. The three 1000 lbs. compression tests were performed by compressing the cable sample between a 2" square flat steel plate and a 3/4" diameter solid steel rod (Figure 2). For each test, the 1000 lb. load was applied for 60 seconds.
For each sample, prior to the crush test an initial 60 Hz partial discharge (PD) test, using test set 2CD04, was done at two voltage levels; 1) 30 kV and 2) 200 volts/mil based on the nominal insulation thickness (ICEA/AEIC industry standard). The initial PD tests were followed by a VLF Tan Delta test, test set ID 2-VLF-1, based on the operating voltage of the cable, at steps of 0.5U0 , 11.0U 0 ,
11.5U 0 , and 2.0U 0 (where UO is the nominal phase-ground voltage) for 3-minutes at each step. Following each crush, on each sample, PD testing at 30 kV and 200V/mil were done. Then at the end of the third crush, the test sample was given a VLF Tan Delta test, at the aforementioned steps, in addition to the PD tests. At completion, when all samples were crush tested, the samples were given a VLF withstand test for 30-minutes, at the IEEE 400.2, Table 3, Maintenance test voltage recommended for the cable rating. Therefore, 8 kV rated cables were tested at 10 kV and 15 kV rated cables were tested at 16 kV.
Concerning the PD test at the 30 kV level, Okonite and Duke Energy determined, this test would be performed first since 30 kV is the maximum test voltage of the 35 kV (1.5 x Uo) premolded stress cones that were used for the cable terminations. After this PD test the 200 v/mil test would be performed. If PD was not acceptable at the 200 v/mil level, due to stress cone limitation, the 30 kV results would be used since this voltage was still much higher than the cable actual operating voltage, UO. The information presented in this paragraph is summarized in the following table breaks for the four test specimens.
.. 20vml Grun" kV kV 1 115-23-623&5 220 44 84, 8, 12, 16 16 2 1BA750G15 260 52 8 4, 8, 12, 16 16 3 1BA250G5 140 28 2.4 1.2, 2.4, 3.6, 4.8 10 4 3XJ2G8 140 28 2.4 1.2, 2.4, 3.6, 4.8 10 Notes:
- Based on actual insulation thickness. (In addition to 30 kV PD Test.)
- Based on the actual service operating voltage and not the insulation thickness rating.
- Based on IEEE 400.2 Table 3.
Figure 3 illustrates the test setup for the PD and VLF testing. Figures 4 and 5 illustrate the VLF equipment that was used.
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Figure 3 - Setup for 1/C PD Test Figure 4 - VLF Control Unit Figure 5 - VLF Tan Delta Data Unit 6
In summary, all of the test samples passed the UL Standard 1569, Section 26, 1000 lbs. for 60-seconds crush test, based on the dissection and visual examination of the 3- crushed sections of each sample examined. These pieces showed no splits or cracks of either the insulation or jacket, as illustrated by the dissection pictures in Attachment No. 3. In addition, all of the samples passed all of the electrical tests performed after the 1000 lbs. crushes. Therefore, all specimens passed this UL test.
0 UL 1569 Section 24 Impact Test Impact testing was done on each of the cable samples submitted by Duke Energy. The samples were cut to 11 ft. lengths and 10-impact marks, 12 inches apart, were placed on the cable jacket surface. These marks indicated the points of impact for the 50 lb. weight. The 50 lb. weight was held 1 ft. above the cable to generate an impact of 50 ft.-lbs. The height of the weight was set above each sample using a 1-ft. machined aluminum bar as a gauge. A fifty-foot pound impact is the highest force required by UL for cables of the sizes that were tested. All samples were tested with the cable jacket intact. The cable sample jacket was not removed in order to simulate the way the cables are installed and used in service. It should also be noted that this test is typically performed on a multiconductor armored, metal-clad (Type MC) cable, such as Sample #4.
To determine when the cable was damaged by an impact, the cable was connected in series with 208V indicator lamps. For the shielded 1/C cables, the conductor to shield and shield to impact weight was monitored. For the 3/C sample, the cable was monitored for any shorts between the impact weight and the armor, tape shields, grounds, and any shorts between the conductor and tape shields.
The impact test setup is illustrated in the following Figures.
Figure - 6 Sample Impact mark set over steel rod, Sample impacted by weight.
prior to impact.
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Figure - 8 Indicator Lamps Figure - 9 Impact Test Frame Figure 10 - Impact Frame and Weight Figure 11 - Note indicator lamps in the background.
All four samples exhibited a perfect passing score of 10/10 without any continuous or momentary failures. The UL 1569 requirement is that a cable is not acceptable if any lamp lights at more than two of the ten impact points. The results of the impact tests on all samples are shown in the following table.
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18.8-C N N N N Nj N N N N N 10/1 4 18.5-C N N N N N N N N N N 10/10 M UL 1569 Section 25 Crushing Test -All Cables This increasing crush testing was performed on a 5000 lb. rated Tinius-Olson tensile/compression machine, ID# 272, Serial # 83666-2, calibration date of 2/16/15, by Tinius-Olson (Figure 12). Similar to the impact test, the UL Crushing test requires 10 crushes per sample. The sample length is 100 inches with crushing intervals of 9 inches along the sample length. For this test, the cables are crushed until there is a failure. Per the UL Standard, the compression force is continued until one or more of the circuit indicators signal that contact has occurred between the circuit conductors, or between one or more of the circuit conductors and any grounding conductor, the armor, or both. Again, as previously discussed, this test is typically done on multiconductor, metal-clad (Type MC) cable.
' For the medium voltage single conductor cables being tested, a detector circuit was hooked up to indicate when there was a short between either the compression plate and cable shield, or the cable shield and the conductor. Either of these
' modes of failure indicates a split or separation in the overall jacket or insulation, respectively. For each of the ten crushes, on the 1/C samples, the compressive force to create a conductor to shield (CS) indicator signal was recorded and the compression stopped. Ifduring compression a structure to cable shield (SS) short occurred, the test was continued until a CS indicator short occurred, or the 5000 lbs. limit of the tensile tester was reached. For the 3/C armored cable sample, during Figure 12 - Tensile/Compression Test Machine 9
compression if a steel plate (structure) to cable armor/shield (SS) occurred, the test was continued until either a CS, phase-to-phase short A, B, or C, a phase to ground wire indicator short occurred, or the 5000 lbs. machine limit was reached.
For the conductor sizes tested the UL Standard requirement states a cable is not acceptable if the average of the 10 crushes, to conductor contact, is less than 2000 lbf. Visual examination is not required; however, at the request of Duke Energy, selected specimens from each sample were dissected. The results of the compression testing are presented in the following table. From the results, for all samples, the average of 10-crushes for conductor to shield contact was over the UL crushing requirement of 2000 lbf. In fact, there were no indicator signals below 2280 lbs. as indicated by the first crush on Sample #4. Therefore, all samples passed the UL requirements.
Crush Test - lbs. to Failure Date Tested: 2/18/15 AVERAGE Cable Sample .. (Legend: SS = Structure - Shield CS = Conductor - Shield A B,, C-G = (lbf.)
Sample Temp.
1 2 3 4 5 6 7 8 9 10 3620S 3810SS 3600SS 3750 SS 3860 SS 4000 SS 3900 3400 41 1 21.6CC 4910 5000 3660 CS 5000 5000 5000 5000 3370 CSS 4417 Stop Stop Stop Stop Stop Stop 2 23.6"C 3990 CS 4110 CS 4280 CS 5000 CS 4030 CS 3950 CS 3600 CS 4080 CS 4330 CS 4160 4153 CS 3410 CS 2600 30.
3 24.6"C 3250 CS 2930 CS 3030 CS 3180 CS 2690 CS 3115 CS 3290 CS 3600 CS CS 3(09.5 1 (12) CS (is) 2280SS 2700SS 3510SS 26005S 5000 3720 5000 5000 50 48 4 24.6"C 5000 5000 490 5000 5000 4862 Stop So Stp Sýtop A-G C-C-G tp S-topII Stop B-G Stop Stop I
Stop Yellow indicates crush specimens selected for dissection.
Number in parentheses indication additional crush test point that was dissected for this sample.
Figure 13 - Buzzer box setup. Figure 14 - Sample during crushing.
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Following this crushing test, the selected crushing points from each of the samples were cut out, dissected and visual examined. Photos of the dissections can be found in the Attachment No. 5, with the title identifying the UL test, cable sample ID and sample crush number.
0 Additional Testing on Samples 1BA750G15 and 1BA250G5 At the completion of the UL Direct Burial Crush Test, Duke Energy requested that these two samples, with the three 1000 lbs. crush points also be crushed at 2000 lbs. for 60-seconds, at one point. Following the crush, the sample would be subjected to a PD test, VLF-TD and a VLF 30-minute withstand test, at the maintenance test level. This 2000 lbs. crush test would be performed on the Tinius-Olson tensile/compression machine, in the Materials Lab and then be brought back to the HV Lab for the electrical tests.
1BA750G15:
Following the 2000 lbs. crush test the sample was brought back to the HV Lab and given four PD tests, at voltages of 16, 32, 40 and 52 kV. For all four tests, the PD was below the 5 pC industry standard for new cable. The sample was then subjected to a VLF-TD test at 4, 8, 12, and 16 kV. The first three voltages were at 3-minute steps and the last 16 kV test was a 30-minute withstand test.
The cable passed all the tests. The 2000 lbs. crush point was cut out and dissected. The dissection revealed no cracking or splits in the jacket, bronze tapes, or the insulation of the cable. Pictures of the dissection can be seen in Attachment No. 6, entitled 2000 LBS. 60-SECOND CRUSHING TEST SAMPLE #2 1BA750G15 DISSECTION PICTURES.
1BA250G5:
Based on the successful performance of the 1/C 750 kcmil 15 kV cable a similar test was proposed for the 1/C 250 kcmil 5 kV cable. The direct burial crush test sample, with the previous three 1000 lbs. crush points was taken to the Tinius-Olson tensile/compression machine and given a 2000 lbs. 60-second crush, at a new point along the sample. The sample was brought to the HV Lab and set up for PD testing. However, as the voltage was being increased the sample failed and the voltage could not be raised. An insulation resistance (IR) test of the sample indicated low IR implying something had happened to this sample. It should be noted that during the crushing test the buzzer box did not indicate any failure. A dissection of the 2000 lbs. crush site revealed that something had occurred during the test, as illustrated in the following pictures.
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Figure - 15 Figure- 16 2000 lbs. Crush Site Jacket & Top Bronze Shielding Tape Removed Figure - 18 Figure - 17 Cable Insulation Cut Lengthwise Voltage Second Bronze Shielding Tape Removed Failure Hole Top Half Revealed Voltage Failure From the dissection it was determined that the 2000 lbs. crush created some damage to the insulation; such as, a small crack or split, and when voltage was applied, for the PD test between the conductor and shield, a failure occurred.
It was decided another sample of this 140-mil cable would be cut and tested This new sample was obtained from what was left of the original length sent from Duke Energy, and therefore, had never been subjected to any testing. Again the Tinius-Olson tensile/compression machine was used and the sample was connected to the buzzer box. We started with 1800 lbs. and increased the compression at 100 lb. increments to 2000 lbs. After testing, without any buzzer indication, it was agreed to take another new sample, of the same cable, and 12
repeat the three 1000 lbs. crushes followed by a 2000 lbs. crush. Similar to the previous test there was no buzzer indication of failure. The cable was brought back to the HV Laboratory and set-up for PD testing. Once voltage was applied, there was an indication of a cable failure. The sample was given an IR test, which indicated low insulation resistance confirming failure of the insulation had occurred. This led us to question the threshold of this cable. The 2000 lbs. that was applied to the 1/C 750 kcmil 15 kV cable, must be too high for the 1/C 250 kcmil 5 kV cable, since it has a thinner insulation thickness and smaller conductor.
At a later date, February 25 and 26, 2015, another 250 kcmil sample was prepared for further crush testing to determine what the threshold would be for this cable size. Since there was a limited amount of cable available, a shorter piece, approximately 97", was cut from the original length that was used for the direct burial test. The four previous crush sites where cut out, yielding a long enough piece to put termination ends on and do more crush tests. Ten crush points where placed along the cable at 5" intervals. The sample was given an initial PD test at 28 kV and passed. Following the PD test, the sample was given a VLF-TD test at 1.2, 2.4, 3.6, and 4.8 kV at 3-minute steps. The sample also passed this test. Figure 19 shows the test sample set up for preliminary testing.
In order to test the sample between crushes we used the newly fabricated test frame in the HV Lab to crush the cable. This was the same frame used in the first 1000 lbs. for 60-seconds direct burial tests (Shown in the right of Figure 19). Knowing that 1000 lbs. was already acceptable, the test was started at 1100 lbs. The plan was to increase the weight in 100 lb.
increments, using 100 lb. ingots until there was an electrical failure. Weights were weighed with the calibrated scale, and added to the 1000 lbs. that was already on the frame. (See calibrated weight data sheets Attachment No. 3)
Figure - 19 Threshold Crush Test Sample After each additional weight increment crush, electrical testing was performed to determine if the weight threshold had been reached. The sample was given an IR test using IR test set 4-T-01, a VLF-TD at 1.2, 2.4, 3.6 and a 30-minute VLF withstand test at 4.8 kV, and PD test at 28 kV. These were the test levels previously established for this voltage class of cable. The following table summarizes the weight added at each interval and the electrical test results.
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- #3 -- -o - --
______ Initial 1 2 3 4 5 6 7 8 Ingot Weight - 98.6 101.4 98.6 102.6 97.8 99.6 100.2 100.2 (lbs.)
Total Weight - 1098.8 1200.2 1298.8 1401.4 1499.2 1598.8 1699.0 1799.2 (lbs.) I I I IR(T() 9.09 5.23 7.16 21.2 2.11 3.72 2.38 4.59 5.89 VLF Withstand at 4.8 kV 6.7 7.0 7.2 7.3 7.1 6.4 6.2 6.2 6.5 30-minutes Tan A(10-3)
PD@pC)<
28 kV_(pC)III 3 <3 3 <3 < 3 3 3 3 Failure From the above table it can be seen that the threshold for this cable sample was established at 1800 lbs. and the safe threshold would be 1700 lbs. Interestingly, it should be noted, that the cable passed both the IR test and the VLF withstand test, after the 1799.2 lbs. crush. The cable did not fail until the rise in voltage from 8 - 10 kV for the PD test. From this, we can surmise that the failure damage due to the 1799.2 lbs. was minimal and of high dc resistance, that the previous two tests were not sufficient to cause a failure at the damage site. It wasn't until the higher voltage of the PD test, that the damage site could not sustain the voltage level and failure occurred. Both of these damage sites, #7 and #8 were dissected and documented. Pictures of the dissection can be found in Attachment No. 7, entitled Threshold Crushing Test Sample #3 1BA250G5 Crush Site #7 (1699.0 lbs.) Dissection Pictures and Attachment No. 8, entitled Threshold Crushing Test Sample #3 1BA250G5 Crush Site #8 (1799.2 lbs.)
Dissection Pictures. The additional pictures for crush site #8 show close-ups of the cross section of the failure. Based on the photos, it was determined that the amount the cable was compressed at site #8 was between 38 and 45-mils.
Conclusion:
Based on all the results presented the cables easily passed all the UL 1569 Sections 24, 25, and 26 tests for armored (Type MC) cables. The impact testing resulted in no failures of any samples after 10-impacts per sample.
The increasing crushing test showed the samples to surpass, significantly, the 2000 lbs. average by 2.21, 2.10, 1.55, and 2.43 times for samples 1, 2, 3, and 4 respectively. Supplemental PD and Tan Delta testing, for the direct burial test of multiple 1000 lbs. crushes for 60-seconds, demonstrated electrical insulation integrity with significant margin of > 70%. Furthermore, the threshold testing of the two bronze taped samples clearly show the added protection provided by the tapes. The crushing resistance increase over the standard 1000 lbs. on the 1/C 750 (Sample 2), by 1000 lbs. and the 1/C 250 (Sample 3) by 700 lbs.
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Report Written by:
E. J. Bartolucci "
inager Applications Engineering Tests Performed by:
Fra Krajic Director Cable Evaluation Laboratory 1
Gr-0/ge Dobrowoiski Manager Low Voltage Engineering Laboratory Eddy 4in Staff Electrical Engineer Tom DiBennedeto Senior Lab Technician vgse Moran Senior Lab Technician Approved b L I-John Cancelosi VP Applications Engineering 15
EQUIPMENT LIST
-01 0-15 GC45-11681 10/22/2015-voltage I est r,,+ I Arni I rr h~incnn I n- LOOKV 251 GC54-10012 10/13/2015 PD
Attachment No. 2 STHE OKONITE COMPANY Duke Energy Carolinas. LLC Oconee Nuclear Station PO 00192523 Okonite F/O 02-7635 HV Lab Project # 4259 Customer Specification: OSR-0316.00-00-0003 Rev.0
SUMMARY
OF TESTS DONE UL 1569 DIRECT BURIAL CRUSH TEST 115-23-6235 (750KCM Cu, 220 mils, Bare LCS 15kV):
" Initial PD prior to Direct Burial Crush Test at 30kV
" Initial PD prior to Direct Burial Crush Test at 44kV (200 V/mil)
- Initial VLF-TD testing prior to Direct Burial Crush at 4, 8, 12, & 16kV (3 minute steps)
" Post Direct Burial Crush (Mark #1) PD at 30kV
- Post Direct Burial Crush (Mark #1) PD at 44kV (200 V/mil)
" Post Direct Burial Crush (Mark #2) PD at 30kV
- Post Direct Burial Crush (Mark #2) PD at 44kV (200 V/mil)
- Post Direct Burial Crush (Mark #3) PD at 30kV
- Post Direct Burial Crush (Mark #3) PD at 44kV (200 V/mil)
- VLF-TD testing post Direct Burial Crush Test at 4, 8, 12, & 16kV (3 minute steps)
- All marks dissected and documented with photos.
IBA 750G15 (750KCM Cu, 260 mils, 2 x 10-mil Bronze tapes Shield 15kV):
- Initial PD prior to Direct Burial Crush Test at 30kV
" Initial PD prior to Direct Burial Crush Test at 52kV (200 V/mil)
" Initial VLF-TD testing prior to Direct Burial Crush at 4, 8, 12, & 16kV (3 minute steps)
" Post Direct Burial Crush (Mark #1) PD at 30kV
- Post Direct Burial Crush (Mark #1) PD at 52kV (200 V/mil)
- Post Direct Burial Crush (Mark #2) PD at 30kV
" Post Direct Burial Crush (Mark #2) PD at 52kV (200 V/mil)
" Post Direct Burial Crush (Mark #3) PD at 30kV
" Post Direct Burial Crush (Mark #3) PD at 52kV (200 V/mil)
Page 1 of4
Attachment No. 2
" VLF-TD testing post Direct Burial Crush Test at 4, 8, 12, & 16kV (3 minute steps)
" All marks dissected and documented with photos.
1BA250G5 (250KCM Cu, 140 nils, 2 x 10-mil Bronze Tapes Shield 5kVM:
" Initial PD prior to Direct Burial Crush Test at 28kV (200 V/mil)
- Initial VLF-TD testing prior to Direct Burial Crush at 1.2, 2.4, 3.6, & 4.8kV (3 minute steps)
- Post Direct Burial Crush (Mark #1) PD at 28kV (200 V/mil)
- Post Direct Burial Crush (Mark #1) PD at 30kV
- Post Direct Burial Crush (Mark #2) PD at 28kV (200 V/mil)
- Post Direct Burial Crush (Mark #2) PD at 30kV
" Post Direct Burial Crush (Mark #3) PD at 28kV (200 V/mil)
" Post Direct Burial Crush (Mark #3) PD at 30kV
- VLF-TD testing post Direct Burial Crush Test at 1.2, 2.4, 3.6, & 4.8kV (3 minute steps)
- All marks dissected and documented with photos.
" Insulation (crush at 3/4" rod) was taken to our Materials Lab to measure deepest indentation on each Mark:
Mark #1: 800/pm (31.5 mils)
Mark #2: 650/pm (25.6 mils)
Mark #3: 750/pm (29.5 mils) 3XJ2G8 (3/C #2 A WG Cu, 140 mils, LOXArmor, 8k V):
- Initial PD prior to Direct Burial Crush Test at 28kV (200 V/mil)
" Ran Initial VLF-TD testing prior to Direct Burial Crush at 1.2, 2.4, 3.6, & 4.8kV (3 minute steps) three times with three different configurations for comparison purposes.
Configuration #1: All three phases in parallel Configuration #2: One phase tested Configuration #3: All phases in series
- Post Direct Burial Crush (Mark #1) PD at 28kV (200 V/mil)
" Post Direct Burial Crush (Mark #2) PD at 28kV (200 V/mil)
- Post Direct Burial Crush (Mark #3) PD at 28kV (200 V/mil)
" Post Direct Burial Crush (Mark #3) PD at 30kV
- VLF-TD testing post Direct Burial Crush Test at 1.2, 2.4, 3.6, & 4.8kV (3 minute steps)
- All marks dissected and documented with photos.
Page 2 of 4
Attachment No. 2 1BA250G5 & 3XJ2G8
- After Direct Burial Crush Test, both samples were connected in parallel; VLF-TD withstand test post Direct Burial Crush Testing at 10kV (30 minute step) 115-23-6235 & ]BA 750G15
- After Direct Burial Crush Testing, both samples were connected in parallel; VLF-TD withstand test post Direct Burial Crush Testing at 16kV (30 minute step)
Extra Testing ("2,0001bf for 60 Seconds Crush Test"):
1BA250G5:
" On the already terminated/tested Direct Burial Tested sample, nine inches away from the last crushed mark, the sample was crushed at 2,O00+/-501bf for 60 seconds using Tinuis Olsen Test Set and then subjected to PD testing. However, sample failed at 2,000+/-501bf crush mark while raising the voltage. Marks dissected and documented with photos.
" Using the Tinius Olsen Crush Test Set, a "dummy" sample was subjected to four different crushes using the Electrical Buzzer Box as an indication if a conductor-to-shield failure occurred.
We started with 1,8001bf and increased in 100+/-501bf increments. After testing it at 2,00+/-5l01bf without a buzzer failure twice, it was agreed that we would repeat the three 1,000 pound crushes (UL 1569 Direct Burial Crush Test) and one 2,000+/-50 pound crush. Therefore, on an eleven foot remnant sample that was initially going to be used for a 501b Impact Testing without a jacket, this sample was used instead to duplicate the previous test, but using the Tinius Olsen Test Set.
The sample unfortunately failed again at the 2,000O=501bf Mark (Mark #4). This eventually led us into questioning the threshold of this construction: Please see Extra Testing "60 Second Threshold Crush Test at Various Pound-Forces IBA 750G15:
" On already terminated and Direct Burial Tested sample, a section was crushed at 2,000+501bf for 60 seconds using Tinius Olsen Test Set and then subjected to various PD tests at different voltages (16, 32, 40, & 52kV).
" VLF-TD testing post "2,0001bf for 60 Seconds Crush Test" at 4, 8, 12, & 16kV (4, 8, & 12kV were three minute steps & 16kV 30 minute withstand test)
- Mark dissected and documented with photos.
Extra Testing ("60 Second Threshold Crush Test at Various Pound-Forces"):
JBA25OG5:
- Initial PD prior to Direct Burial Crush Test at 28kV
" Initial VLF-TD testing prior to "Threshold Testing" at 1.2, 2.4, 3.6, & 4.8kV (3 minute steps)
- Based on the "2,0001bf for 60 Seconds Crush Test", we established that this sample will fail at the 2,000+501bf mark upon energizing the sample. Curiosity led us to try to determine what was Page 3 of 4
Attachment No. 2 the threshold or failing point of this sample. Therefore, after cutting out the crushed marks (Marks # 1-4), an untested remnant piece of the cable was used. The sample was tested using our newly fabricated "Direct Burial Crush Test Frame". The test was started at 1,1 00lbs and increased in 1001b increments until a failure occurred using 1001b lead ingots. Remarkably, after subjecting the sample to 1799.2lbs and then seeing the sample exhibit normal IR and passing a 4.8kV 30 minute VLF-TD withstand, the cable failed between 8-10kV while attempting to perform a 28kV PD test.
Note: After each crush, IR, PD (28kV), & VLF-TD withstand (4.8kV for 30 minutes) testing was completed. Length of entire sample was 97", terminals-ends 14 inches, and marks spaced out 5 inches.
" Marks #7 (1,6991bs) & #8 (1,799.2lbs) were dissected and documented with photos. Mark #8 failure was also taken to our Materials Lab for further evaluation; failure "blow-out" depth was measured as well at approximately 45mils.
UL 1569 IMPACT TEST
" All four samples exhibited a perfect passing score of 10/10 without any continuous or momentary failures.
UL1569 CRUSH TEST
" All samples passed and exceeded an average of >2,0001bs. Full results will be reported in final report.
" Customer requested which two marks to dissect from each sample (Not required). Marks were dissected and documented with photos:
- 115-23-6235: Mark #3 & 4
" IBA 750G15: Mark #4 & 7
" 1BA250G5: Mark #12 & 15
" 3XJ2G8: Marl #4 & 7 Non-dissected crushed samples were also mailed to Albert & Steve:
- 115-23-6235: Mark #1; 3,6201bfStructure-to-Shield
" IBA 750G15: Mark #1; 3, 9901bf Conductor-to-Shield
" 1BA250G5: Mark #1; >5,0001bfNo Failure
" 3XJ2G8: Marl #1; 2,2801bf Structure-to-Shield Page 4 of 4
Attachment No. 3 Calibrated Weights Data Sheet Device Used: Pelouze Weight Scale Device ID #: SC-4 DATE: 2/10/2015 ACCURACY: +/-0.2%*, +0.5%** CALIBRATED BY: FK/EN/GD
- As per MS Standard Section 8-11-1 for 0-50 lbs range
- As per MS Standard Section 8-11-1 for >51 lbs range ID # Nominal Measured Value Value Lead Ingot #1 100lbs 103.4lbs Lead Ingot #2 100lbs 100.Olbs Lead Ingot #3 100lbs 103.Olbs Lead Ingot #4 100lbs 97.4lbs Lead Ingot #5 100lbs 99.8lbs Lead Ingot #6 100lbs 98.8lbs Lead Ingot #7 100lbs 99.6lbs Lead Ingot #8 100lbs 99.6lbs Lead Ingot #9 501bs 59.2lbs Lead Ingot #10 501bs 59.4lbs 2.5, 5, & 101b Barbell Plates 17.5 17.2lbs Top Frame 122.2lbs 501b Impact Weight 501bs 51 .Obs 9 9 COMMENTS: Duke Power; Project #4259 - UL1569, Section 26, Direct Burial Crush Test &
UL1569, Section 24, Impact Test.
Approved by: DATE: 2/10/2015 HVL-0 I7a,
Attachment No. 3 Calibrated Weights Data Sheet Device Used: Pelouze Weight Scale Device ID #: SC-4 DATE: 2/25/2015 ACCURACY: +0.2%*, +0.5%** CALIBRATED BY: JM
- As per MS Standard Section 8-11-1 for 0-50 lbs range
- As per MS Standard Section 8-11-1 for >51 lbs range ID # Nominal Measured Value Value Lead Ingot #11 100lbs 98.6lbs Lead Ingot # 12 100lbs 101.4lbs Lead Ingot # 13 100lbs 98.6lbs Lead Ingot #4 100lbs 102.6lbs Lead Ingot #15 100lbs 97.8lbs Lead Ingot #16 100lbs 99.6lbs Lead Ingot #17 100lbs 100.2lbs Lead Ingot #18 100lbs 100.2lbs
+ i
+ I-
+ 4-
+ +
COMMENTS: Duke Power; Project #4259 - UL 1569, Section 26, Direct Burial Crush Test &
UL1569, Section 24, Impact Test.
Approved by: DATE: 2/10/2015 HVL-01 7a,
Attachment No. 4 1000 LBS. 60-SECOND CRUSHING TEST UL STANDARD 1569 SECTION 26 SAMPLE # 1115-23-6235 SAMPLE #2 1BA75OG15 SAMPLE #3 1BA250G5 SAMPLE #4 3XJ2G8 DISSECTION PICTURES
1000 lbs. Direct Burial Cable Sample Dissection Pictures Sample #1 ID: 115-23-6235 Mark #1 Mark #2 Mark #3
.0
1000 lbs. Direct Burial Cable Sample Dissection Pictures Sample #2 ID: 1BA750G15 Mark #1 Mark #2 Mark #3
- IIIIIIIIIIIIII 4
1000 lbs. Direct Burial Cable Sample Dissection Pictures Sample #3 ID: 1BA250G5 Mark #1 Mark #2 Mark #3
1000 lbs. Direct Burial Cable Sample Dissection Pictures Sample #4 ID: 3XJ2G8 Mark #1 Mark #2 Mark #3
Attachment No. 5 UL STANDARD 1569 SECTION 25 CRUSHING TEST - ALL SAMPLES DISSECTION PICTURES
UL STANDARD 1569 SECTION 25 CRUSHING TEST SAMPLE #1 115-23-6235 DISSECTION PICTURES OF CRUSH AREA #3
e U
UL STANDARD 1569 SECTION 25 CRUSHING TEST SAMPLE #1 115-23-6235 DISSECTION PICTURES OF CRUSH AREA #4
11 I
1 UL STANDARD 1569 SECTION 25 CRUSHING TEST SAMPLE #2 1BA750G15 DISSECTION PICTURES OF CRUSH AREA #4
w
UL STANDARD 1569 SECTION 25 CRUSHING TEST SAMPLE #2 1BA750G15 DISSECTION PICTURES OF CRUSH AREA #7
UL STANDARD 1569 SECTION 25 CRUSHING TEST SAMPLE #3 1BA250G5 DISSECTION PICTURES OF CRUSH AREA #12
UL STANDARD 1569 SECTION 25 CRUSHING TEST SAMPLE #3 1BA250G5 DISSECTION PICTURES OF CRUSH AREA #15
I a
UL STANDARD 1569 SECTION 25 CRUSHING TEST SAMPLE #4 3XJ2G8 DISSECTION PICTURES OF CRUSH AREA #4
F --- -I UL STANDARD 1569 SECTION 25 CRUSHING TEST SAMPLE #4 3XJ2G8 DISSECTION PICTURES OF CRUSH AREA #7
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Attachment No. 6 2000 LBS. 60-SECOND CRUSHING TEST SAMPLE #2 1BA750G15 DISSECTION PICTURES
Attachment No. 7 THRESHOLD CRUSHING TEST SAMPLE #3 1BA250G5 CRUSH SITE #7 (1699.0 LBS.)
DISSECTION PICTURES
U
Attachment No. 8 THRESHOLD CRUSHING TEST SAMPLE #3 1BA250G5 CRUSH SITE #8 (1799.2 LBS.)
DISSECTION PICTURES