ML19270J203
| ML19270J203 | |
| Person / Time | |
|---|---|
| Site: | Comanche Peak  |
| Issue date: | 08/02/1979 |
| From: | GIBBS & HILL, INC. (SUBS. OF DRAVO CORP.) |
| To: | |
| Shared Package | |
| ML19270J201 | List: |
| References | |
| QP-12442, NUDOCS 8001160532 | |
| Download: ML19270J203 (88) | |
Text
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, power conversion products Inc.,
forty two east street, crystal lake, Illinois 60014
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I CMLIFICATION PL@l l - -
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NO. QP-12442 ___'- -
DAIE June 30, 1978 QUALIFICATIO ' OF CLASS lE BATTERY CHARCERS FOR XXAS UTILITIES SERVICE INC.
COMA.'iGHE PEAK STATION AN #P#P A.:NGkROV: f *CP.T c o r e - r . . , . C . ,.m., ,,,. .
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- PURCILiSE CROER - CP-04403 ,
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_G 019M, SY POWER C0!iVERSl0t! PRODUCTS, .?di. Uf_sse,mass & Hitt'. 'iv+
.F C'3YSTAL LA::E, ILLit'0IS, U.S. A. NEW YORK
Ali.' RIGHTS RESERVED BY F0HER CO.T!ERSI0'! Po.000 CTS I!!C.
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REVISION RECORD REVISION 3 -
By f4- Date h #gh 7,h x-Approved by v Date I[/#[47
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NOTICE THIS PLAN SUPERCEDES ALL DRAFTS PRIOR TO JUNE 16, 1978. THE METHODS AND PROCEDURES INCLUDED Ifl THIS PLAN If; CORPORATE ALL COMMENTS RECEIVED FROM PARTICIPANTS PRIOR TO JUNE 16, 1978.
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( 0 1978, BY POWER CONVERSION PRODUCTS IfiC., CRYSTAL LAKE, ILLIN0IS, U.S.A.
ALL RIGHTS RESERVED BY POWEP. CONVERSI0fl PRODUCTS INC.
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TABLE OF CONTEt1TS SECTION TITLE PAGE 1.0 SCOPE 4 2.0 REFEREtiCE DOCUMEtlTS 5-7 3.0 DEFlillTIONS 8-12 4.0 IDEt?TIFICATI0tl 0F THE EQUIPMENT TO BE QUALIFIED 13-14 5.0 QUALIFICATION OF THE SAMPLE CHARGER 15-24 6.0 ACC"oTAtlCE CRITERIA 25 7.0 COMPARISON OF CPSES CLASS 1E CHARGERS TO THE 26 2
.I SAMPLE CHARGER ,
8.0 00CUiENTATION 27
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TABLE OF CONTENTS (CONT.)
APPENDICES TITLE A SPECIFICATIONS FOR THE SAMPLE CHAR r.R CLASS 1E BATTERY CHARGERS 2 B SPECIFICATI0iiS FOR THE CPSES C EVALUATION OF NON-SAFETY RELATED C0"PONENTS D l EyALUATION OF SAFETY RELATED COMP 0t;Ef1TS E LIST OF COMPONENT iia!!UFACTURERS F AGIf!G PROCEDURES - CIRCUIT BREAKERS AftD SWITCHES ,
G DELETED 4 H AGIflG PROCEDURES - t'AGriETIC COMPONENTS 2 I ,
AGING PROCEDURES - WIRE AND CABLE J .
AGIflG PROCEDURES - D.C. ELECTROLYTIC CAPACITORS K' AGING PROCEDURES - CIRCUIT AND ALAR'i BOARDS L FUSES (DOCUMEtiTATI0fi 0F fl0N AGE-RELATED FAILURE MECHANISMS)
M MECHAfilCAL A!iD ELECTRICAL TEST PROCEDURES N RADIATION DATA SEARCH REPORT 0 BURf!-Irl TEST PROCEDURES 2331 007 P STRESS TEST PROCEDURES .
Q SEISMIC TEST PROCEDURES t
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1.0 SCOPE .
This plan will outline the Qualification Program for the Class IE Battery Chargers for the Comanche Peak Station.
It will demonstrate the capability of the Class 1E Battery Chargers to perform their required function over the qualified life period. The Qualification Program is based upon a combination of analysis and. testing.
Included in the program is a generic type test of a sample Class 1E Battery Charger. The specific IE charger or chargers to be qualified in this program are subsequently qualified by analysis and/or testing based upon the generic type test data. At the conclusion of the program, a qualified life for these chargers will be determined. The goal of this program is a g
qualified life of 40 years. The qualification methods are in accordance with IEEE 323-1974. In addition, the methods utilize guidance from the proposed Standard IEEE P-650 " Qualification of Class IE Battery Chargers and Static Inverters for Nuclear Powar Generating Stations" (Draf t #7, May 16, 1978) and IEEE 381-1977. In all cases the Qualification Program Will b'e performed in accordance with the latest available technical data and state of art procedures. The entire Qualification Program will be subject to the requirements of the PCP Quality Assurance Program. The
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battery chargers discussed in this plan are safety related, however, this document addresses only this equipment as a component in the safety related electrical system. The application of this equipment in the plant's electrical system is not within the scope of this document as industry standards exist for this purpose such as IEEE 303-1974,
( s IEEE 279-1971, and IEEE 603-1977.
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2.0 REFERENCE DOCUMENTS 2.1 The following documents are referenced in the generic Qualification Plan for the sample equipment:
IEEE Standards A. 100-1977 IEEE Dictionary of Electrical and Electronics Terms B. 101-1972 IEEE Guide for the Statistical Analysis of Thermal Life Test Data C. 259-1974 Standard Test Procedure for Evaluation.of Systems of Insulatinn for Specialty Transformers D. 323-1974 Qualifying Cl, ass 1E Electric Equipment for Nuclear Power Generating Stations d
(' E. 344-1975 Recommended Practices for Seismic Qualification of, Class 1E Equipment for Nuclear Generating Stations (ANSI N. 41.7)
F. 352-1975 Guide for General Principles of Reliability Analysis of Nuclear Power Generating Station Protection Systems G. 380-1972 Definitions of Terms Used in IEEE Standards on Nuclear
- Power Generating Stations H. 381-1977 Criteria for Type Tests of Class IE Modules Used in Nuclear Power Generating Stations I. 383-1974 Standard for Type Test of Class IE Electric Cables, Field Splices and Connections for Nuclear Power Generating Stations J. P650 (Proposed Standard) Qualification of Class lE Battery DRAFT 10 Chargers and Static Inverters for Nu~1 ear Power Generating Stations. .
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Military Handbooks J. Mil-Hdbk-217-B, Reliability Prediction of Electronic Equipment Notice 1, 7Sep76 National Electrical Manufacturers Association (NEMA) Standards K. PV-5-1976 Constant-Potential Type Electric Utility (Semiconductor Power Converter) Battery Chargers Other Documents L. Wyle Laboratories Test Plan 545/7611, Revision A dated May 22, 1978 PCP Workmanship Manual M.
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PCP Quality Assurance Manual ,
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1 2.2 The following' documents will be referenced in qualifying the specific Class 1E Charger or Chargers:
A. Purchaser's Specification 2323-ES-8b Rev.1 (12-17-70 2 B. PCP Drawing 0-55-15395 Schematic Diagram C. PCP Drawing D-55-1539 Outline and Parts Layout -
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3 3.0 DEFINITI0t1S These definitions establish the meaning of words in the context of their use in this document.
3.1 Age-Related Failure Mechanism - A mechanism of degradation in components or equipment which may result in the failure of the -
equipment under specified service conditions during the qualified li fe.
3.2 Aging (Accelerated) - The process of subjecting components or equipment to stress conditions in accordance with known measurable
((- physical or chenical laws of degradation in order to render its ,
physical and electrical properties similar to those .it would have at an advanced age operating under expected service conditions.
3.3 Aging (flatural) - The change with passage of- time of physical, chemical, or electrical properties of components or equipment under design range operating conditions which may result in degradation of significant performance characteristics. (IEEE Std 381-1977) 3.4 Analysis - A process of mathematical or other logical reasoning that leads from stated premises to the conclusion concerning specific capabilities of equipment and its adequacy for a particular application.
(i 3.5 Break-In Period - That early period, beginning at some stated time during which the failure rate of some items is decreasing rapidly. Also called early failure period. (IEEE Std 352-1975)}} Q}2
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3.6 Burn-In - The operation of components or equipment, prior to
- type test or ultimate application, intended to stabilize their characteristics and to identify early failures. (IEEE Std 100-1977) 3.7 Common-Mode Failure - Multiple failure attributable to a common cause. (IEEE Std 352-1975)
In the context of a single type test, any failure must be examined to determine its potential for occurrence in the same time frame in identical equipment due to the same excitation stress. 3.8 Components - Items from which the system is assembled (for
,k example, resistors, capacitors, wires, connectors, transistors, t -
tubes, switches, springs,etc.). (IEEE Std 380-1972) 3.9 Containment - That portion of the engineered safety features designed to act as the principal barrier, after the reactor system pressure boundary, to prevent the release, even under conditions of a reactor accident, of unacceptable quantities of radioactive material beyond a controlled zone. (IEEEStd 323-1974) 3.10 Demonstration - A course of reasoning showing that a certain result is a consequence of assumed premises; an explanation or illustration, as in teaching by use of examples. (IEEE Std 323-1974) 3.11 Design Basis Events - Postulated events, specified by the safety
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analysis of the station, used in the design to establish the acceptable performance requirements of the structures and systems. (IEEE Std 323-1974) 2331 013
power conversion products Inc. 0 l 3.17 Maintenance Interval - The period, defined in terms of real time, operating time, number of operating cycles, or a combination of these, during which sa':isfactory performance is required without maintenance or adjustments. 3.18 Malfunction - The loss of capability of Class IE equipment to' initiate or sustain a required function, or the initiation of undesired spurious action which might result in consequences adverse to safety. (IEEE Std 344-1975) 3.19 Operating Basis Earthquake (0BE) - That earthquake which could g reasonably be expected to affect the plant site during the operating E life of the plant; it is that earthquake which produces the vibraterr ground motion for which those features of the nuclear cower plant necessary for continued operation without undue risk to the health and safety of the public are designed to remain functional. (IEEE Std 344-1975) 3.20 Operating Experience - Accumulation of verifiable service data for conditions equivalent to those for which particular equipment is to be qualified. (IEEE Std 323-1974) - 3.21 Qualified Life - The period of time for which satisfactory performance can be demonstrated for a specific set of service conditions. ilote: The qualified life of a particular equipment item may be
. changed during its installed life where justified. (IEEE Std 323-1974) 0
f, power conversion products inc. 3.22 Random Failure - Any failure whose cause and/or mechanism make its time of occurrence unpredictable. (IEEE Std 100-1977) 3.23 Sample Equipment - Production equipment tested to obtain data that are valid over a range of ratings and for specific services. . (IEEE Std 323-1974) 3.24 Service Conditions - Environmental, power, and signal conditions expected as a result of normal operating requirements, expected extremes in operating requirements, and postulated conditions appro-priate for the design basis events of the station. (IEEE Std 323-1974) ((- 3.25 Stress Analysis - An electrical and the" mal design analysis of
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component applications in specific circuits tnder the specified range of service conditions. 3.26 Stress Test - A type test performed on a sample equipment which
" stresses" the equipment to the specified range of service conditions.
3.27 Type Tests - Tests made on one or more sample equipments to verify adequacy of design and the manufacturing processes. (IEEEStd 323-1974) 3.28 Wear-Out Period - The time interval following the period of constant failure rate, during which failures occur at a greater rate. (IEEE Std 352-1975) . ( 2331 015 t . s
O power Conversion products Inc. -(. I 4.0 IDENTIFICATI0h 0F THE EQUIP.;ENT : TO BE QUALIFIED The Class IE Sattery Chargers for the Comanche Peak Ztation will be qualified using analysis and/or testing based upon actual type testing of a sample Class 1E Battery Charger (sample equipr::ent) hereafter called "the sample charger". The specifications for the-sample charger are included in Appendix A and condensed below: Model No. 35D-130-300 Serial No. 12442-1 Volts 60 Hz 3 Phase AC Input 460
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DC Output 135 Vol'ts 300 Amps Output Ripple .030 Volts rms 75" 46" W 36" D
- 4. . Cabinet Size H By comparison, the Class IE Chargers for the Comanche Peak . Steam Electric ,
Station (CPSES), hereafter called " Station", are detailed in Appendix B and condensed below: , P.O. It!.Mo. CP-0440-B-1 Model No. 3S0-130-300 Vol ts 60 Hz 3 Phase AC Input 460 . 300 Amps DC Output 135 _ Volts Output P.ippie .030 Volts rms 75" H 46" W 36" D Cabinet Size 0 2331 016 a
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ower conversion products inc. P.O. I tem flo. cp_o440_g_2 Model No. 350-130-300 Volts 60 Hz 3 Phase AC Input 460 DC Output 135 Volts 300 Amps Output Ripple .030 Volts rms 75" 46" U 36" D Cabinet Size H P.O. Item No. Model tio. Volts Hz Phase AC Input DC Output Volts Amps Output Ripple Volts rms H D Cabinet Size H
'P.O. Item fio.
1fodel 150. Volts Hz Phase AC Input . DC Output. Volts Amps Output Ripple Volts rms . H D Cabinet Size - H
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Opower conversion products Inc. i 5.0 QUALIFICATION OF THE SAMPLE CHARGER Refer to Figure 1 for a flowchart representation of the qualification process. The flowchart will greatly assist in understanding the qualification steps. Steps 5.1 through 5.5 consist of qualification of the components within the sample charger. In step 5.6, all components are assembled into the complete charger and the charger subjected to a series of type tests to demonstrate the ability of the charger to perform its requir.ed function during normal, abnormal, DE: and post DBE service conditions.
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- FLOWCHART FOR QUALIFICATION OF CLASS 1E BATTERY CHARGERS F23413Z SPEC;F CAftDN DATA [I CLAS5:TT CO.90:i!%TS 70 DET!?JttNZ WTCH ARE SATETT R!t.ATO f. 2 Y
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Pho'PJCTCO.10:itTS AND DtTFtKEST RATIMOS AAF. QUA.ttrtG BT ANALYSIS S &, E 8 AN0/Ca TURTHIt TESTINC. 4 N.7 Fait.URE P20'J11t3 A;i4TSIS FI.KTouu:CE TEST 70 O!'u13:IE CAIC!N: C09.03 rn31 et pxeSOM. REPA!R, 2. C%rtr0N!hT tWALIFIED LITE EQ'J ALS p!!.!$!C 8, A' D/01 NETEST, t'St%C QUALIF7Ds LIFE CF A $PECIFIC
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5.1 Provide Specification Data The first step in qualification is to provide specification data for the following: A. Class IE performance characteristics B. All significant environmental parameters , C. All significant service conditions D. Any other conditions. The above specifications are provided by those responsible for design c., plication of the equipment. The specifications for the sample charger are contained in Appendix A and are actually a composite r of the specifications for many Class 1E Chargers for several nuclear
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plants. , 5.2 Classify Comconents
!! ext all components within the sample charger are classified into two categories: -
A. Non-safety related components (refer to Appendix C) B. Safety related components (refer to Appendix D) Components designated as safety related are those whose failure affects the ability of the charger to perform its required function. 233.1 020 t e
power conversion products inc. I 5.3 Non-Safety Related Comoonents A Failure Modes and Effects Analysis (FMEA) in accordance with IEEE 352-1975 will be performed on all components designated as non-safety related to demonstrate that the failure of these components as.used in the circuit does not affect the ability of the charger
.to perform its required function. Any component determined to be safety related by the Ft1EA will be addressed in 5.4. All components classified as non-safety related af ter the FMEA will be assembled into the sample charger in a new conditini without any additional analysis or testing.
I 5.4 Safety Related Components All components classified as safety related will be analyzed in " accordance with the requirements in this section. 5.4.1 A stress analysis will be performed on all safety related componen,ts to demonstrate that no component is stressed to a point where its aging is accelerated beyond that expected in normal operation. 5.4.2 All safety related components will be classified into one of the two categories below: A. Components with age-related failure mechanisms. B. Components without age-related failure mechanisms. The safety related components are classified into the two. categories above in Appendix D. 2331 021 i Components in category 5.4.2.B need not be aged. They will be assembled into the sample charger in a new condition.
power conversion products inc. .( 5.5 Component Qualification
. To qualify components with age-related failure mechanisms the component shall be aged to the equipment qualified life objective or if the qualified life of the component is less than that of the equipment, then the component shall be aged to its qualified life and assigned a maintenance replacement interval equal to or less than its qualified ,
life. 5.5.1 Determination of f4aintenance Replacement Interval The replacement interval for age sensitive components which cannot meet the desired equipment qualified life will be determined based k - upon either operating experience or component life test data. ( , 5.5.2 Aging Techniques Components with age-related failure mechanisms will be aged in
.accordance with accelerated aging techniques which are technically s
justifiable and the latest state of art. Actual procedures are specified in Appendices F through K. 2331 022
A ower conversion products inc. { 1 5.6 Equipment Qualification IEEE Std 323-1974, paragraph 6.3.2, outlines a specific order in which type testing is to be performed. This sequence is not followed in this plan due to the variations in aging rate of the various components. Since the equipment is to be assembled of aged components, testing of the sample equipment must come after the cor$ponents have
'been aged and the assembly is complete. The type test sequence in this section includes margin in that the components are subjected to additional stresses after aging.
A. Non-safety related and safety related components will be assembled f into a complete piece of equipment (the sample charger) in accordance f with the PCP Ucrkmanship Manual and Quality Assurance Manual. MechaTiical inspection, dielectric testing and functional testing for nomal conditions will be performed in accordance with the procedures in
' Appendix M. Tests will be conducted to demonstrate the following specification conditions in Appendix A, Section 1.0: A,B,C,D,E,F.
B. Since the battery charger is located outside containment, only low levels (typically 1.0 x 10 4 rads or less, total integrated dose) of radiation are encountered. Documentation (refer to Appendix H) will be provided to demonstrate that the ability of the equipment to perform its required function is unaffected by the radiation dose specified. ( i. 2331 023
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- C. The equipment will be subjected to a minimum burn-in of 100 hours (50 hours at full load, 50 hours at no load) at room ambient temperature. The burn-in places the equipment into its normal installed condition and is intended to eliminate infant mortality failures.
D. In order to establish a reference for the measurement of operating parameters and a valid basis for comparison of test results, the sample charger will be subjected to the conditioning process as follows: ( . Place the charger into an environmental test chamber which has. the
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capability of being varied both in temperature and humidity over the required service conditions. With the chamber set at an ambient te".perature of 25 degrees + 5 degrees C and prevailing relative
' humidity, operate the equipment at full load for a period of two hours and document functional performance date for normal conditions in Appendix A,1.0.A, B, C, D, and F. This data will be utilized as reference data for the continued tests to follow. Calibration adjustments may be made to the equipment at this time.
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O power conversion products Inc. E. In order to demonstrate that the equipnent will meet its specified performance characteristics under the specified abnormal conditions as required by IEEE Std 323-1974 refer to Figure 2 and perform the following stress test to the fully loaded equipment in the test chamber: Allow the chamber to increase to the maximum temperature and maximum relative humidity specified in Appendix A. The equipment will be operated at this level for a period of eight hours at the end of which functional performance data (Appendix A,1.0.A, B,' C, D, and F) at maximum, nominal, and mini. rum input voltages will be documented. Allow the chamber to decrease to the minimum temperature specified in Appendix A and maximum relative humidity attainable. The equipment will be operated j k at this level for a period of eight hours at the end of which functional performance data (Appendix A,1.0. A, B, C, D, and F) at maximum, nominal and minimum input voltages will be documented. A complete cycle including the transition period will last a maximum of 24 hours. At the end of the test cycle, the equipment will be allowed to stabilize at room ambient temperature and humidity and a final set of functional performance data (Appendix A,1.0.A, 8, C, D, and F) at maximum, nominal, and minimum input voltages will be documented. The above stress test is described in Figure 2. This test subjects the complete equipment to the worst case and nominal conditions of tempsi ature, humidity, input voltages and output loads (for battery chargers, input frequency variations have no impact on aging). The stress test also adds additional aging (margin) to the In addition, non-aged components are ( previously aged components.
" soaked" at these conditions after the 100 hour burn-in, thus giving additional age-type stress prior to the seismic test.
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9 F. The ability of the equipment to withstand the operational vibration The equipment
' requirements specified will be demonstrated 1.y analysis.
will be subjected to a simulated seismic environment as specified in the equipment specification. The testing will be performed per IEEE 344-1975 and the equipment will be operated during and after the seismic test at rated output and within the specified input voltage range. The equipment must meet its required Class 1E function (Appendix A,1.0.G) during and after the seismic test. G. In order to demonstrate the ability of the equipment to meet its specified performance characteristics during post DBE conditions, an additional stress test using the procedures of 5.6.1.E in accordance k '~ with the post DBE conditions will be performed. H. Upon successful completion of these tests, a functional test shall be performed to meet the performance characteristics for normal conditidns specified in Appendix A,1.0.A, B, C, D, and F, and the sample charger will be considered qualified. 2331 026
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Opower conversion products inc. s I 6.0 ACCEPTANCE CRITERIA
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In the evaluation of the type test results, any sample equipment is considered to have passed when the equipm.cnt meets or exceeds the function required by the equipment specification as determined by the data taken,d.': ring the type test. If any failure occurs during test steps 5.5.2 and 5.6.C the defective component will be replaced with a component that has been subjected to the same aging as the component which it replaces. Should any failure occur during test steps 5.6. A, 5.6.0, and all subsequent testing, it will be analyzed to determine if it is of random or common-mode origin. The failure i' ( will be determined not to be corr.T.on mode if one of the following c-iteria is met: - A. Physical examination of the failed component (s) and its interface (s) determines that a workmanship problem was the cause of failure; e.g. improperly tightened connector, cold solder joint, use of an incorrect component, etc. B. Reexamination of the stress analysis determines that the part is properly applied and any components similarly applied in the tes.t
- sample have had no like failures and the failure is not repeated during subsequent retesting with replacement components. Note:
Consequential component failures caused by the failure ,of a single component are not considered to be of common mode origir..
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', If the above or other methods h?ve not identified the cause of failure, further analysis will be conducted.
Opower conversion products Inc. i 7.0 COMPARISON OF STATION CLASS IE CHARGERS TO THE SAMPLE CHARGER Details will be provided on the differences between the Class IE Charger to be qualified and the sample charger. A complete analysis of components of the other model ratings to demonstrate that no component of the type aged and qualified in the type tests is stressed at a rate higher than that in the qualified model to the extent that a different ag'ag acceleration would have to be employed. Should the analysis determine that either a different aging acceleration test is necessary or an entirely new generic type of part be employed, the part will be aged and seismic tested as a component or assembly .( to a level equivalent to the previous qualification level. Note: Different ratings of the same component family are considered type '" qualified if the applied stress does not exceed that in the qualifi-cation model. A demonstration will be made to verify that the service conditions to which the qualified unit was tested are as severe as those sp'ecified for the units being qualified. Each model rating will be seismically qualified by testing and/or analysis in accordance with IEEE 344-1975 and a determination made that the acceleration of components or assemblies which have age-related failure mechanisms does not exceed that of the sample charger. 2331 029 c ( k
power conversion products Inc. 8.0 DOCUt4EflTATI0t[ 8.1 The following documents will be provided to verify that the Class 1E Charger or Chargers are qualified: A. Qualification Plan - The Qualification Plan will contain a description of the methods and procedures used to qualify a Class IE Charger or Chargers for a specific application. B. Qualification Report - The Qualification Report will contain the following:
- 1. Equipment performance specifications
- 2. Identification of specific features to be demonstrated by the
(( analysis and testing
- 3. Qualification procedures
- 4. Qualification results which shall include:
A. Failure Modes and Effects Analysis (FMEA) for non-safety related components (5.3) B. Stressanalysis(5.4.1) C. Documentation for classification for component qualification (5.4.2) D. Test data, component aging data, accuracy and instrument calibration for each test described in Section 5.5 E. Documentation for radiation analysis (Section 5.6.B) F. Specific failure analysis for any failure occuring during the qualification type tests in Sections 5.6. A, ,5.6.D', and all subsequent tests. 2331 030 ( ( ' G. Identification of equipment qualified life with a summary 3 of justification for the qualified life. This shall include any maintenance replacement components or assemblies.
power conversion products Inc. A APPENDIX A Specifications for the Sample Charger The specifications below represent a composite of specifications for many Class IE Chargers for nuclear generating stations and will be used in qualifying the sample charger. 1.0 Class IE per ~ormance Characteristics A. Input conditions are: 460 VAC i 10%, 60 Hz 1 5%, 3 Phase B. Output conditions are: 135 VOC, 300 ADC C. Output voltage regulation is: 1 0.5% from 0-1005 load D. Output ripple voltage is: 30 mv. rms. without battery connected E. Surge withstand capability is: 4000 V applied to DC output terminals (10 microseconds) 3000 V applied to AC input terminals (20 microseconds) F. Output current limit is: 120% of rated output current G. Required (Class IE) function is:
- 1. Rated output is 135 Volts DC, 300 Amps DC with input variations of 414 VAC to 506 VAC.
- 2. While delivering rated output current and rated output ,
voltage within the input variations specified above, the voltage regulation shall not exceed i 2%, output ripple shall not exceed 1% rms without a battery connected, and all external alarms contacts will remain operational (will not give false ( alarms). flaximum relay contact chatter alloud = 30 milliseconds. A-1 2331 031
power conversion products Inc. [ ~
-)
APPEt! DIX A
- Specifications for the Sample Charcer (cont.)
2.0 Environment . A. Ambient Temperature Minimum 320F (0 0C) Maximum 1220F (500C) Annual Average 860 F (300C) B. Storage Temperature Minimum 320 F (0 0C) Maximum 1220 F (500C) ((. 1 C. Maximum Relative Humidity - Operating 0 to 95 % Storage O to 95 % D. Minimum Pressure Atmospheric Al titude 3300 Ft. 1000 meters E. Operational vibration - not specified . F. Seismic Requirements - See Appendix 0 G. Radiation Type - Gamma H. Dose Rate 0.25 mr/hr Total Dose 1 x 10 4Rads ,- , I. Radio Frequency Interference (RFI) or Electromagnetic Interference (EMI)
- not specified A-2 2331.032
Opower conversion products Inc. A APPENDIX A Specifications for the Sample Charger (cont.) 3.0 Other Considerations A. Significant sequence rate of change, or combinations of performance characteristics and environmental limits have not been specified. B. Outy cycle is continuous. C. No unusual atmospheric contamination has been specified. S([ D. All input and output connections will enter the equipment enclosure from the top. The equipsent will be welded to the floor. E. Dielectric test requirements are specified below (refer to HEMA-PV-5-1976): AC to Ground - 2000 Volts 2331 033 DC to Ground - 1500 Volts AC to DC - 1500 Volts A-3
O . power conversion products inc. APPEllDIX B Specifications for the Station Class 1E Battery Chargers The specifications below include the detailed requirements for the Station Class IE Battery Chargers. If there are differences between the specifications for the station chargers and those for the sample charger, the differences must be analyzed and justification provided in sections 7.0 and 8.0. Additional analysis and/or testing may be required to verify that the qualification of the Station Class IE Battery Chargers is valid. 1.0 Class 1E Performance Characteristics \ '" The required Class 1E performance characteristics are specified by those responsible for design application of the charger and include numberical values for normal, abnormal, DBE and post 08E
' conditions as follows:
2331 034 B-1
a
- O' power conversion products inc.
- APPENDIX B Specifications for the Station Class IE Battery Chargers (cont.)
A. Input conditions are: . . 460 10% Volts, 6015% Hz, 3
- Phase 2 B. Output conditions are: ,
135* Volts 300 Amps
- Max. Float Vo' age, 2-C. Output voltage regulation is: .
T 0.5t from 0 % load to full load 2 ' ( t, D. Output ripple voltage, is: ,,
.030-- Volts rms with battery.
E. Surge withstand capability is: 4000 volts. applied to DC output terminals ( 10 _ microseconds) volts applied to AC in?ut terminals ( 20 '! microseconds) 3000 F. Output current limit is: , 120 % of rated output current. 3 055' . G. Required (Class IE) function is: While delivering rated output current and rated output voltage within the input variations specified above, the voltage regulation shall not ; exceed i1%, output ripple shall not exceed .030V RMS with a battery
$9 I k. , connected, and all external alarms will remain operational (will not give false alarms). Maximum relay contact chatter allowed = 30 millisecond:
B-2 .
~- .. ..- .. -.. .- ..
O power conversion products inc. i. e ' APPEf! DIX B Specifications for the Station Class IE Battery Chargers (cont.) 2.0 Environmed All significant environmenteft parameters are specified by those responsible for design r.pplication of the equipment. The range of environmental conditions specified below includes normal, abnormal, DBE and post DBE conditions. . A. Ambient Temperature F -6 C Maximum 122 F 50 oC Minimum ;n ( '- 2 Annual Average _75 0F 24 C B. Storage Temperature O 2 OC Maximum 122 0F C Minimum 32 of C. Relative Humidity Storage to % Operating 30 to 90 _% . D. Minimum Pressure atmospheric Altitude 792 Ft. _ 241 Meters E. Operational Vibration _, not specified F. Seismic Requirements See__Accendix_Q N. 4 B-3
power conversion produds Inc. -
\ a I
APPENDIX 8 Specifications for the Station Class 1E Battery Chargers , (cont.) ,
~
- G. Radiation Type 9,enn H. Irradiation 0.25 mR/hr 2 Dose Rate Total Dose 103 I. PJI/EMI Requirements not soecified r( e 233.1 037 e e
'(~.
k s B-4
O power conversion products inc. N(
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l . APPENDIX B Specifications for the Station Cla.;s IE Battery Chargers (cont.) 3.0 Other Considerations A. Significant sequence, rate of change, or combinations of specified performance and environmental limits listed in 1.0 and 2.0 are identiffad below: not specified /( s
~
B. The duty cycle-is .. contfnunus . C. Unusual atcospheric contaminations are specified below: N/S D. All input and output connections will enter the equipment from the X _ top bottom as specified in the outline drawing referenced in section 2.2. The equipment will be X welded bolted to the floor as shown in the outline drawing referenced in section 2.2. E. Dielectric test requirements are specified below: . AC to Ground 2000 Volts 2331 038
- ( DC to Ground 1500 t';I ts AC to DC 1500 Vol ts B-5
Opower conversion products Inc. APPENDIX C
' <aluation of Non-Safety Related Components The following items are included in the sample charger. It is believed that the failure of these components will not affect the ability of the charger to perform its safety related function. The justification for this determination will be included in the Qualifi-cation Report.
1.0 Quantity 3 Stock No. 0214266050 Manufa'cturer
- 2 Manufacturer's Part No. 26F1059 2 Value and Rating Smfd/660V. AC Description Paper oil capacitor 2.0 Quantity 3 Stock No. 1102260110 Manufacturer 7 Manufacturer's Part No. FRS 10 Value and Rating 600 Volts AC, 10 Amps Description Fuse Schematic Symbol F14-16 __ Function Protect filter cacacitorslL I
3.0 00antity 1 Stock No. 1262603100 Manufacturer 8 Manufacturer's Part No. 6F30A35 Value and Rating' 600V. AC/24 Amps Description Fuse holder , Schematic Symbol F14-16 Function Hold fuses F14-16 ,
- See Appendix E 2331 039 L
C-1
Opower conversion products inc. I APPEtt0IX C
- Evaluation of Non-Safety Related Components (cont.)
4.0 Quantity 1 Stock No. 0821500320 Manufacturer 36 Manufacturer's Part No. T35-DMV-050-UW/ Scale Value and Rating 0-500 A. DC Description 2% Accuracy DC ammeter Schematic Symbol AM Function DC current moni or 5.0 Quantity 1 Stock No. 0801150320 Manufacturer 36 Manufacturer's Part No. T3S-DVV-150-U Value and Rating 0-150V. DC Description 2% Accuracy DC voltmeter a
'- Schematic Symbol VM Function DC voltaae monitor . . .
6.0 Quantity 1 Stock No. 98-3019 modified Manu facturer 28 Manufacturer's Part No. 1416 Description 0-120 hour timer Function Changes charcer output from float to equalize manually and from equalize to float automatically. 7.0 Quantity 1 Stock No. DSI Description Q-55-13034 Rev. ) Pilot light assembly Description Consists of: Oty, Manufacturer Mfg. Part No. 1 29 30099-0 Receptacle 1 29 P5B120 Bult 1 30 135-3271 Lens Function AC (on) pilot light t ' 2331 040 C-2
. R-4 power conversion products inc. APPENDIX C Evaluation of Non-Safety Related Components (cont.) 8.0 Quantity 1 Stock No. 96-1136 Manufacturer 26 Manufacturer's Part No. 8258B ValJe and Rating 115 VAC Description AC undervoltage relay Schematic Symbol K3 Function AC undervoltage monitor 9.0 Quantity 1 Stock No. 96-2771 Manufacturer 27 Manufacturer's Part No. KUPilA15 Value andR'ating 115 VAC Description Relay Schematic Symbol K2 Function Fan-out relay 10.0 Quanti ty 1 Stock No. 96-1131 Manufacturer 27 Manufacturer's Part No. KUP11015 Value and Rating 115 VDC Description Relay Schematic Symbol K1 Function Fan-out relay 11.0 Quantity 1 Stock No. 91-3202 Manu facturer 1 Manufacturer's Part No. DSLV120T2-01 Value and Rating 120 VDC Description Low DC Voltage Relay Schematic Symbol DSL Function Low DC Voltage Relay 2331 041 C-3
O Jpower conversio: products Inc. t i APPENDIX D Evaluation of Safety Related Components Items listed on the followiag pages are safety related components. The column headings are explained below: DESCRIPTION - the industry standard nomenclature for the component QTY. - quantity (number of components of this type in the equipment) STOCK NO. - the internal PCP stock number shcrin on the bill of material MFG. APP.E - the manufacturer of this component is listed in Appendix E MFG. P/N - the manufacturer's part number for this component RATING - significant parameters (input or output) for this component
\ REF. DES. - the reference designation on the schematic diagram ,
FUNCTION - the function of the component in the equipment AGE-RELATED FAIL. MECH. - age-related failure mechanism; if the component has age-related failure mechanisms, the letter "Y" is shown.in this column. If not, the letter "N" is listed. AGING PRO. (APP.) - the appropriate aging procedure can be found in the appendix listed in this column 2331 042 D-1
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SArtif RIt.A7ED CD:trONt4T LIST ACC FCIAT!g ACI:fG s MrC. N r r.. RET. TAIL. 4[CH. FROC. AFP. ( P/d RAffffC Dr.S TVNCTION YE S( Y )N0(p ) (AFF.) StSCRJPt!0N CTY. 570C1C 130. 1314212312 3 THED 136125VL ' 1254 C81 AC Protection Y r C[rcuit Sresker 1 I 1314280207 3 THJK #26400WL 400A C32 DC Protection Y r Cfrcuit $ rester 23 TXA7 400 Interconnection Y g vite & Cabis I fat 6 0557529005 6 C5-400-co-C02 75cA/900Y CRI-6 Fect if ter / Control N . T.., r i s t or * . 5 471PD4;20 t10A/1200V CR4 Ilochisig Diode N Olode 1 0$5#731206 5 IN3290 100A/300V CR7 Circulating stede ut D! ode 1 05$1023003 A2 Contro1 Y g 91-2802 1 11 VVCR1001 115/230 1 Amp 1f fler Board 1 YPle-1019-115-3 Al I!rtng Circuit Y g 11 3113 11 fir!nr Soard 1 35-130-CS A3 control ti c2 Sensing Soard 1 T 35-28tt 1 e Y H 2 N 3 04147 1 73 A. C , Power Tree.sformer Transfcrmar _ 1 LI 'r11ter Y g Choke 1 04506
#0CA/130V T1-3.9-11 SCR Proteetton N 11062!3240 7 FAA4 00 ruse 6 I Y a 10 0221215373 2 scr:1e 13001rotsCvec C1 ritter Capacitor 7 1113225010 7 7C0-1 1A.250V F4-8.11.13Contral Protection N ruse 31eeder p C 0132152215 13 -cn6 15 0 A .2154 R1 Faststor , t e:9:K14 5A/120VAC 5'42 r/g selection Y r Swit:% U 1 17-8520 12 k
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'q 5arge Suppressor 50042'4 R3.R6 Range A41ustrent u CS Fot entlees ter i 211H21200 18 g-- i Cn j 82 . 1'4 Ru Ksage Adjusteent M 0118022183 16 Pestster ' 1
' structure y D-15 1538-03 10 Cabinet 1
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APPENDIX E List of Manufacturers No. Manufacturer Location 1 Power Conversion Products Inc. Crystal Lake, Illinois 2 General Electric - Capacitors Columbia, South Carolina 3 General Electric - Breakers Plhinview, Connecticut 4 National Geneva, Illinois 5 International Rectifier El Segundo, California 6 Syntron Div., FMC Corporation Broomfield, Colorado 7 Bussman St. Louis, Missouri j k 8 Marathon Waco, Texas 9 Wakefield Wakefield, Massachusetts' 10 Alloy Welding Melrose Park, Illinois 11 Vectrol Lincolnwood, Illinois 12 Cutl er-Hammer Broadview, Illinois 13 Ohmite Skokie, Illinois 14 Centralab Milwaukee, Wisconsin 15 Stackpole Kane, Pennsylvania 16 Allen-Bradley Milwaukee, Wisconsin 17 Western Cullen Chicago, Illinois 18 Crompton El> Grove Village, Illinois 19 Cinch-Jones Elk Grove Nillage, Illinois ( i 20 General Electric-Terminal Blocks Philadelphia, Pennsylvania Cleveland, Ohio 21 Glastic Corporation
=
22 Yokagawa Corporation of knerica E'.nsford, New York E-1 2331 045
Opower conversion products Inc. APPENDIX E , List of Manufacturers
~
(cont.) No. Manufacturer Location 23 Samuel Harris Waukegan, Illinois 24 Westinghouse Electric Corporation Beaver, Pennsylvania 25 Fenwal Ashland, Massachusetts 26 Time Mark Corporation Tulsa, Oklahoma 27 Potter & Brumfield Princeton, Indiana 28 Zenith Timer & Controls Chicago, Illinois ( 29 Sylvania Salem, Massachusetts 30 Dialco Brooklyn, New York 31 C.T.S. Corporation Elkhart, Indiana 32 Molex Lisle, Illinois 33 Haveg, Inc. Winooski, Vermont 34' L'i ttlefuse Des Plaines, Illinois 35 Trantec Columubs, Nebraska 36 Modutec Norwalk, Connecticut 2331 046 .( 1 E-2
Opower conversion products Inc. d 1 APPEtIDIX F Aging Procedures - Circuit Breakers and Switches (cont.) 1.0 Circuit Breakers The number of cycles required for all necessary testing prior to plant operation is a maximum of 20 cycles (10 times per year x 2 years). The number of plant maintenance cycles is 4 times per year or 160 times for 40 years maximum. The number of customer planned cycles for equipment or plant maintenance is 2 ' times per year or 80 times for 40 years maximum. The circuit breakers will be cycled a total of k I 260 times to simulate 40 years of service. The cycling will occur ., with a representative charger operating at full rated load. 2.0 Switches (Floet-Equalize) The number of cycles required for aU necessary testing prior to plant operation is a maximum of 20 cycles (10 times per year x 2 years). The number of plant maintenance cycles is 4 times per year or 160 times-for 40 years maximum. The number of customer planned cycles for equipment or plant maintenance is 12 times per year or 480 times for 40 years maximum. The switch will be cycled during the stress test and seismic test a total of 660 times to simulate 40 years of service. 2331 047 g F-2
' power conversion products inc.
APPENDIX F Aging Procedures - Circuit Breakers and Switches General The predominant age-related failure mode of circuit breakers and switches in typical Class 1E Battery Charger applications is of a mechanical fatigue nature as induced by switching cycles. Due to the continuous operating mode of this equipment, circuit breakers, control and power switches (and their associated annunciating relays) are only cycled during testing, preventive and corrective maintenance and during plant shutdown pericds. A determination of anticipated number of cycles during the qualified life will be made based on the [ sum of the following:
- Number of cycles required for all necessary testing prior to plant opera tion.
- Estimated number of equipment maintenance cycles.
- flumber of customer-planned cycles for any purpose (equipment or plant maintenance, etc.)
The breakers and switches will then be cycled under simulated service conditions. Coil insulation systems associated with the breakers and switches if normally de-energitec (e.g. shunt trip coil) need not be aged. If normally energized, they will be aged. 2331 048 d F-1 6"A% M
power conversion products Inc. N) I . APPENDIX H Aging Procedures - Magnetic Components General The life of any magnetic component is_ determined by the insulation system (IEEE 259-1974). An insulation system will be employed on ' which thermal evaluation has been performed and correlated temperature versus age data has been done in accordance with IEEE 259-1974. Magnetic components will be subjected to accelerated aging to the desired qualified life at the selected temperature and time in accordance with documented thermal evaluation data. Accelerated ( aging will be performed in accordance with one nf the procedures of section 3.2 of IEEE 259-1974. Procedures The following magnetic components are used in the sample charger: Quanti ty 3 Part flo. 04747 Manufacturer 1 Description Transformer Schematic Symbol T1A,B,C Function Isolate input and reduce crimary AC Rating , 22.56 KVA voltage to usable level. Class of Insulation 220 C 2-Max. Hot Spot Temp. 1500 C at 35 0C ambient 2331 049 X
' H-1
Opower conversion products Inc. d i APPENDIX H_ Agir.a Procedures - Magnetic Components (cont.) Quantity 1 _ Part No. 04606 Rev. 1 Manufacturer 1 Description Choke Schematic Symbol L1 Function Filter OC output Rating 2.00 milli-henries at 300 amos DC Class of Insulation 220 0C Max. Hot Spot Temp. at 1500C at 350C ambient In the analysis in this section, the ambient within the cabinet is
- 50C above the specified annual average ambient temperature to account for temperature rise within the cabinet. The magnetics above consist of copper magnet wire, steel core material and insulation materials.
Thermal degradation of the insulating materials determines the life of these components. The insulation materials consist of layer to layer and wire insulation. The copper magnetic wire used is classified as 2200 C insulation. The layer to layer insulation used consists of a high temperature resistant polyamide polymer and is classified as Class H insulation. 2331 050
.(
H-2
Opower conversion products inc. ( APPEf10IX H
- Aoing Procedures - Magnetic Components (cont.)
The insulation curves reveal that operation at 150 0C yields an expected life of approximately 1 x 10 8hours (using the lower 95% confidencelimit). This is an expected life of 100,000,000 hours or 1141 years and far exceeds the qualified life objective. An accelerated aging test will be conducted as described below. Data from the insulation chart will be used to age the magnetics. Testing at 2300C for 7.5 x 102 = 750 hours is equivalent to 400,000 hours at 1500C (350C ambient) which exceeds our life objective. The_ values of maximum hot spot temperatures stated above are based upon PCP engineering design data. Actual hot spot tests nave been conducted demonstrating that these values are accurate. Procedures
- 1. Equipment recuired A. Iline (9) transformers - PCP #04747 B. Three (3) chokes - PCP #04606 C. Hipot tester 0
D. Temperature chamber capable of temperatures = 230 C 2331 051 (, H-3
power conversion products Inc. i APPENDIX H Aging Procedures - Macnetic Components (cont.)
- 2. Procedures A. Dielectric test magnetics and record.
- 8. Energize oven to obtain 2300C + 3 C C. Remove one set of transformers and chokes after 562h hours to simulate 30 years of life.
D. Remove the last set after 750 hours to simulate 40 years of life. {( E. Perform an insulation resistance test to check the integrity of the insulation system. F. Failure is defined as a dielectric breakdown in any of the components. 2331 052
.~,
a H-4
Opower conversion products Inc. APPEMDIX I Aging Procedures - Wire and Cable General Wire and cable used will be qualified for temperature, humidity, and time required for normal service of this equ.r.nent by the methods described in IEEE Standard 383-1974. The basis for qualification will include pre-aging data to simulate qualified life (such as Arrhenius plots with 95% confidence limits). Uire and cable used in the sample charger will be thermally aged in accordance with this data. Where practical, wire will be aged in harnesses with connectors and terminal blocks attached in order to test the integrity of the connection methods employed in the aged condition. Mechanical ~ cycling of connectors as employed in this equipment ie, not an aging factor. Interconnections shall be aged by the thermal and mechanical stresses induced by the burn-in test (5.6.C), the stress test (5.6,0), and the seismic test (5.6.E). Procedures In accordance with IEEE 383-1974, proceed as follows:
- 1. Equipment needed .
A. Two complete wire and cable harnesses acquired from model 350-130-300 battery charger, S/N 12442-01. B. One temperature chamber capable of temperatures = 150 C. 2331 053 I-1 .
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power conversion products inc. I APPEf4 DIX I Aging Procedures - Wire and Cable (cont.)
- 2. Procedure A. Measure and record length of representative sample wire.
B. Install harness in oven. The harness will be suspended in the oven with continuous air circulation simulating service conditions. C. Energize oven to obtain 136 0C + 20C. D. Remove one harness after 126 hours to simulate 30 years life at 35 0C annual average ambient within the cabinet. Measure ( and record length of sample. Failure is defined as more than 50% elonga tion. A representative sample of the aged wire shall be bent around a mandril 40 times to verify lack of brittleness of the wire insulation. Evidence of brittleness to the extent that the wire insulation fractures or cracks shall be cause for rejection. E. Remove the last harness af ter 168 hours to simulate 40 years life at 350C annual average ambient within the cabinet. Measure and record length of sample. Failure is defined as more than 50% elonge' ion. A representative sample of the aged wire shall be bent around a mandril 40 times to verify lack of brittlenes's'of the wire insulation. Evidence of brittleness to the extent that the ( wire insulation fractures or cracks shall be cause for rejection. 2-2 2331 054
power conversion products inc. APPENDIX J Agina Procedures - DC Electrolytic Capacitors General The life of a DC electrolytic capacitor in filter applications is proportionately related to the core temperature, working voltage and ripple current. Accelerated aging of DC electrolytic capacitors will be achieved by subjecting the capacitors to rated core temperature and rated working voltage for the rated life or less. The rated life is the life published by the capacitor manufacturer when the capacitor is operated within rated conditions. f cceleration factors ( are developed from the ratio of operation at rated conditions to operation under actual conditions. Procedures Quantity 20 Stock fio. 0221215373 isaau fact.urer 2 Manufacturer Part No. 86F 198L Value/ Rating 7300 mfd./150'!. DC Description Dry aluminum electrolytic Schematic Symbol C1 Function Filter capacitor The rated values for this capacitor are shown below: Rated life = 500 hours Rated core temperature = 95 C Ra ted working vol tage = 150V. DC Rated ripple current = 9.69 amps
,I. ,
3 J-1 W *
- Mhh4
power conversion products Inc. I APPEf4 DIX J Aging procedures - DC Electrolytic Capacitors (cont) Refer to the specified annual average ambient temperature (Appendix A). The annual average ambient is specified as 300 C. . To allow for temperature rise of 50C inside the cabinet, the ambient air around the capacitor is specified as 35 C. Thus the actual operational values for this capacitor are shown below: Average ambient temperature = 35 0C Case temperature = 35 C - Core temperature = 35.03 C ((- , 3 .' b'orking vol tage = 135V. DC
. . 2 Ripple current = 4.07 amps Core temperature and ripple current calculations are attached at the conclusion of this appendix. Using the life multiplier curves supplied by the capacitor manufacturer (showr at the conclusion of this appendix), the expected life for this capacitor is 500 hours X 202.1 =
101,050 hours. 101,050 hours = 11.5 years, however the manufacturer has 2 stated that this is an expected life in that the capacitor will continue to function after 10 years. It is not an end of life value. 2331 056 t .A s J-2 6 -- N g e - ag
~~
Opower conversion products Inc. 1 APPErlDIX J - Aging Procedures - DC Electrolytic Capacitors (cont.) Based upon the above data, the conservative approach dictates that an appropriate replacement interval for these capacitors is 10 years. To age the capacitors to 10 years (87,600 hours), simply operate the capacitors under the following conditions: Test Hours Core Temperature Working Voltage 500 950C 150V. DC Since the actual operational ripple current has little affect on raising the core temperature above the ambient temperature, the test temperature (950C) will be the ambient temperature of the chambar. In the actual test, several samples will be aged to different periods giving a large group of aged capacitors for the equipment test. Test levels are shown here: C5re Te[noerature Working Voltage Test Hours Life Years 95 C 150V. DC 500 10.0 95 C 150V. DC 400 8.0 95 C 150V. DC 250 5.0 At the end of each test period, the following values will be checked: (1) Capacitance (2) ESR (Equivalent Series Resistance) , 2331 057 ( 7 J-3
power conversion products Inc. '.( c APPENDIX J Aging Procedures - DC Electrolytic Capacitors (cont.) _ Aging Procedure - Capacitors
- 1. Equipment needed A. 80 pieces, capacitor, 7300 mfd.150 VDC, G.E. !86F198L B. Temperature chamber, A+L !SK-1108 C. I voltage source, 150V, 10 A D. AC ammeter, 0-5A AC, 0.5% accuracy E. Capacitance bridge F. Monitoring Equipment
( -
- 2. Procedure A. Measure and record ESR, capacitance of all capacitors.
B. Connect capacitors in parallel with hook-up wire. C. . Place capacitors in ovens. D. Energize voltage source. E. Energize oven to 95 C. F. Remove 26 capacitors after 250 hours to simulate 5 years life. G. Remove 26 capacitors after 400 hours to simualte 8 years life. H. Remove the remaining capacitors after 500 hours to simulate 10 years life. 2331 058 ( J-4
)power conversion products inc.
tlI I APPENDIX J
- Aging Procedures - DC Electrolytic Capacitors (cont.)
- 2. Procedure (cont.)
I. After each of the above times check parameters in (N) above and record. J. Failure is defined below: (1) Capacitance shall not be less than 90% of the published value. (2) The equivalent series resistance shall not be greater than 175% of the initial measured value. ((( 2331 059 O 5 .. 4 J-5
Opower conversion products Inc. i.f ' I APPENDIX J Aoino Procedures - DC Electrolytic Capacitors (cont.) Calculations of Riople Current, Core Temperature and Expected Life For G.E. 86F198L Capacitors Ripple Current = Ripple Voltage Impedance (Xc) Ripple voltage is measured at .030 volts at full rated output. X
- c 2nfc
= 1 ;( 2 x 3.142 x 360 x .0073 's .,
1
= = 6.05 x 10-2 16.512 03 = .495 Amps Ripple Current = ,f0 2331 060
( J-6
4. 0' power conversion products inc.
.i APPENDIX J Aging Procedures - DC Electrolytic Capacitors (cont.) .
Calculation of Core Temp (1) Core Temp (OC) = (CRF) (103) IESR\.833+pgg, 2 ( AREA / or (2) Core Temp (OC) = (CRF) (Case Temp.-AMB.) + AMB. D = Dia. (in.) L = Case Length (in.) CRF = Core Rise Factor = 1.068 + .31154 x Can Dia. AREA = Surface Area of Can = frD 2 + vrDL 4
;( I = Ripple Current (Amps)
AMB = Ambient Temperature (OC) . ESR = Equivalent Series Reisstance (ohms) Acceleration Factors (3) A 1 = 2 (T Max-Core)/10 (Due to Chemica.1 Kinetics) (4) A2"Il at Rated Voltage and Temperature It at Derated Voltage and Temperature (5) A=A1xA2 Table I - Base Life Ambient Temperature Design Core Temoerature M Mf_e_ 500 hrs 850C 950C 84F 850C 95 C 86F 500 hrs 850C 1050C 88F 1500 hrs 850C 1150C 92F 1000 hrs
~
2331 061 J-7
d '
= - ._
LIFE MULT1 FLIER FOR J 2 TTPE 86F/64F 2 RATED V01.TM2
- 50. 55. 40. 65. 70. 75. 80. 85. 90. 95. 100.
- 95. 5.3 4.7 4.1 3.5 3.0 2.6 2.2 1.8 1.5 1.2 1.0 94 5.7 5.1 4.4 3.8 3.3 2.8 2.3 1.9 1.6 1.3 1.1
- 93. 6.2 5.5 4.8 4.2 3.A 3.0 2.5 2.1 1.7 1.4 1.2
- 92. 6.8 6.0 5.2 4.5 3.8 3.2 2.7 2.3 1.9 1.5 1.2
- 91. 7. 4 6.5 5.7 4.9 4.2 3.5 2.9 2.4 2.0 1.6 1.3
- 94 8.1 7.1 6.2 5.3 4.5 3.8 3.2 2.6 2.2 1.8 1.4
- 49. 0.8 7. 7 6.7 5.7 4.9 4.1 3.4 2.8 2.3 1.9 1.5
- 88. 9. 6 8.4 7.3 6.2 5.3 4.4 3.7 3.0 2.5 2.0 1.7
- 87. 10.5 9.1 7.9 6.7 5.7 4.8 4.0 3.3 2.7 2.2 1.8 84 11.4 9.9 8.6 7.3 6.2 5.1 4.3 3.5 2.9 2.4 1.9
- 85. 12.4 10.8 9.3 7.9 6.6 5.6 4.6 3.8 3.1 2.P 2.1 84 13.5 11.7 10.1 8.5 7.2 6.0 5.0 4.1 3.3 2. ' 2.2
- 83. 14.7 12.7 10.9 9.2 7. 8 6.5 5.4 6.4 3.6 2.* 2.4
- 82. 16.0 13.8 11.8 10.0 8.4 7.0 5.8 4.7 3.9 3. 2.6
- 81. 17.4 15.0 12.8 10.8 9.1 7.5 6.2 5.1 4.2 3.6 2.7'
- 80. 19.0 16.3 13.9 11.7 9.8 8.1 S.7 5.5 4.5 3.6 2.9
- 79. 20.6 17.7 15.1 12.7 10.6 8.8 7.2 3.9 4.8 3.9 3.2
- 78. 22.5 19.2 16.3 13.7 11.4 9.5 7.8 6.4 5.2 4.2 3.4
- 77. 24.4 20.9 17.7 14.5 12.3 10.2 8.4 6.8 5.6 4.5 3.7
- 76. 26.6 22.7 19.2 16.0 13.3 11.0 9. 0 7.4 6.0 4.9 3. 9
- 75. 28.9 24.6 20.8 17.3 14.4 11.9 9.7 7.9 6.4 5.2 4.2 74 31.4 26.7 22.5 18.8 15.5 12.8 10.5 8.5 6.9 5.6 4.5
- 73. 34.2 29.0 24.3 20.3 16.8 13.8 11.3 9.2 7.5 6.0 4.9
- 72. 37.2 31.4 24.4 21.9 18.1 14.9 12.1 9.9 8.0 6.5 5.2
- 71. 40.4 34.1 28.5 23.7 19.5 16.0 13.1 10.6 8.6 7.0 5.6
- 70. 43.9 37.0 30.9 25.A 21.1 17.3 14.1 11.4 9.3 7.5 6.0
- 69. 47.7 40.1 33.4 27.7 22.7 18.6 15.2 12.3 10.0 8.0 6.5
- 68. 51.9 43.5 36.2 29.9 24.5 20.0 16.3 13.2 10.7 8.6 6.9
[ 67. 56.4 47.2 39.1 32.3 26.5 21.6 17.6 14.2 11.5 9.3 7.5
- 66. 61.2 51.1 42.3 34.9 28.5 23.3 18.9 15.3 12.4 10.0 8.0 65, 66.5 55.4 45.8 37.' 30.8 25.1 20.3 16.5 13.3 10.7 8.6 W 64 72.3 60.0 49.5 40.7 33.2 27.0 21.9 17.7 14.3 11.5 9.2 P-63.
62. 78.5 85.2 65.1 70.5 53.6 57.9 43.9 47.4 35.8 29.1 23.6 19.0 15.3 12.3 9.3 38.6 31.3 25.3 20.5 16.5 13.3 10.6 4 61. 92.5 76.3 62.6 31.2 41.6 33.7 27.3 22.0 17.7 14.2 11.4 c. 60. 59. 100.4 109.0 82.7 89.5 67.7 73.2 55.2 59.6 44.9 48.3 36.3 39.1 29.3 23.6 25.4 19.0 15.3 12.3 31.6 20.4 16.4 13.2 2 58. 118.3 97.0 79.1 64.3 52.1 42.1 33.9 27.3 22.0 17.4 14.1 W 57. 128.3 105.0 85.5 69.4 56.1 45.3 36.5 29.4 23.6 18.9 15.2
- 56. 139.2 113.6 92.4 74.9 60.5 48.8 39.3 31.6 25.3 20.3 16.3 y $5. 151.0 123.0 99.8 80.7 65.2 52.5 42.2 33.9 27.2 21.8 17.5 g 54 163.8 133.1 107.8 87.1 70.2 56.5 45.4 36.4 29.2 23.4 18.8 O $3. . .7 144.0 114.5 93.9 73.6 60.8 48.8 39.2 31.4 25.1 20.1 o 52. 192. 155.9 125.8 101.3 81.5 65.4 52.5 42.1 33.7 27.0 21.6 51, 208.9 144.6 135.8 109.2 87.7 70.4 36.4 45.2 36.2 29.0 24.9
- 50. 226.4 4 146.6 117.8 94.5 75.7 60.7 48.6 38.9 31.1 24.9 49 245.4 19 . 154.3 327.0 101.7 81.5 65.2 32.2 41.7 33.4 26.7
- 48. 264.0 213.3 170.9 136.8 109.5 87.6 70.1 56.1 44.8 35.8 28.6 47 288.2 230.6 4.5 147.5 117.9 94., 75.3 60.2 48.1 38.5 30.7
- 46. 312.3 249.3 19 159.0 127.0 101.4 81.0 64. 7 51.7 41.3 33.0
- 45. 338.3 269.5 214.8 171.3 136.7 109.0 87.0 69.5 55.5 44.3 35.4 44 366.4 291.3 231.8 .6 147.1 117.3 93.5 74.6 59.6 47.5 38.0
- 43. 396.9 314.8 250.1 198. 158.3 126.1 100.5 80.2 63.9 $1.0 40.7
- 42. 429.8 340.1 269.7 214.2 170.4 135.6 108.0 86.1 68.7 54.8 43.7 41, 465.3 367.5 291.0 230.8 .3 145.8 116.1 92.5 73.7 58.8 46.9 40, 303.7 397.0 313.8 248.6 197. 156.8 124.7 99.3 79.1 63.1 50.3
- 39. 545.3 428.8 338.4 267.7 212.2 48.5 134.0 106.6 84.9 47.7 54.0
- 38. 590.1 463.1 364.9 288.3 228.3 1 2 143.9 114.5 91.2 72.6 57.9 37 638.6 500.2 393.4 310.5 245.6 194., 154.6 122.9 97.8 77.9 62.1 36, 691.0 540.0 424.1 334.3 264.2 209.3 46.1 132.0 105.0 83.6 66.6
- 35. 747.5 583.1 457.2 3**- 284.2 225.0 le 4 141.7 112.7 89.7 71.5
- 34. 8 08. 6 629.4 492.7 3. 4 305.7 241.8 191. 152.2 121.0 96.3 76.7
- 33. 874.6 679.4 531.0 417.1 !.d.7 259.9 205.9 1.4 129,8 103.3 82.2
- 32. 94 5. 8 733.2 572.3 448.9 353.5 279.2 221.1 17 ' 139.3 110.8 88.2 31, 1022.7 791.3 616.6 483.1 3fo.1 300.1 237.5' 188.3 149.5 118.9 94.6
- 30. 1105.7 853.8 664.4 519.9 408.7 322.4 225.0 202.1 .5 127.6 101.5 29, 1195.3 921.2 715.7 359.5 439.5 34A.4 273.9 217.0 172. 136.8 108.9
- 28. 1291.9 993.7 771.0 602.0 472.5 372.2 294.1 232.9 184.8 144.8 116.8
- 27. 1396.3 1071.9 830.4 647.8 507.9 399.9 315.8 250.0 198.3 5 125.3 26, 1508.8 1156.1 8 94.4 696.9 546,0 429.6 339.1 268.3 212.8 169. 134.3 25, 1630.2 1246.8 963.2 749.7 58 6.9 461.5 364.1 288.0 228.3 181.2 44.1 e
*Multip11ere reeutting in life predictione exceeding 10 years shmid not be used due to the existance of secondary f ailure modes set considered to the development of this table.
y 2331 062 e oe, em. *M' H
' power conversion products inc.
1 . APPENDIX X Aging Procedures - Circuit and Alarm Boards Circuit Boards General Circuit boards may consist of devices with age-related faflure mechanisms and devices without age-related failure mechanisms. An analysis will be performed of all components on the board to determine if any have age-related failure mechanisms. If there are no components with age-related failure mechanisms on the circuit board, it does not have to aged prior to the type test. If there are components with age-related failure mechanisms on the board, (k the component which has the shortest qualified life determines the qualified life of the board. All components with age-related failure mechanisms will be aged to the qualified life of the "short life" component in accordance with the aging techniques in this section. These components may be aged on or off the circuit board. If aged off the board, care shall be taken to insure that the components are not damaged during assembly onto the board. ( 2331 063 i K-1
~~
p ' poveer conversion products Inc. RA s b APPENDIX K Aging Procedures - Circuit and Alann Boards (cont.) . Procedure A stress analysis of each circuit board will be performed in accordance with Mil-Hdbk-2178 to verify that no component is stressed to a point where its aging is accelerated beyond that expected in normal operation. The only " age sensitive" devices which exist on circuit boards Al and A2 are transformers which will be aged in accordance with Appendix H. The test procedure is described below. After the magnetics are aged to their 40 year life condition, they. will be h.' installed in the circuit boards for use in the equipment type test. No other " age sensitive" components are included on the other circuit boards. The magnetics above consist of copper magnetic wire, steel core material and insulation materials. Thermal ~ degradation of the insulating materials determines the life of these components. The insulation materials consist of layer to layer wire and insulation. The copper magnetic wire used is coated with an insulation consisting of poly-urethane with a nylon jacket and is classified as Class A (105 degrees) insulation. The layer to layer insulation used is Kraft Class A paper. An accelerated aging test will be conducted as described.below: w $$\ 2331 064 D K-2
power conversion products Inc. i r APPEtt0IX X Aging Procedures - Circuit and Alarm Boards (cont.) Aging Procedure
- 1. Equipment To Be Aged A. tiine (9) transformers - Vectrol #A31-9010-7 B. Five (5) transformers - Vectrol #1-9010-119 C. Fifteen (15) transformers - Vectrol !A-9010-4
- 0. Five (5) Vectrol disk torrite transformers
- 2. Test Equipment k A. Hi-pot tester .,
B. Temperature chamber
- 3. Determination of Test Paraceters In order to determine the temperature at which the transformers
' wili be aged, it is necessary to determine the actual operating temperature of the device and utilize this data for calculating aging parameters.
2331 Ot.5 C K-3
..7 O power conversion products Inc.
($ i APPENDIX X Aging Procedures - Circuit and Alarm Boards (cont.) , Aging Procedure (cont.)
- 4. Procedure .
A. Dielectric test on the magnetics at 1500V. . B. Install specimens. ,
' C. Energize oven to desired temperature. ,
D. Remove all remaining specimens after specified time to simulate 40 years life. (See test report for details'.) Dielectric test all specimens as in (A) above. fi[' s E. Failure is defined as a dielectric breakdown in any of the specimens."' Alarm Boards . A stress analysis of each alarm board will be performed in accordance lii,1-Hdbk-217B to verify that no component is stressed to a point where its aging is accelerated beyond that expected in normal operation. The alarm boards are evaluated below. Alarm Board Evaluation A stress analysis will be performed for all alarm boards included within the equipment. The only components on the boards which are age sensitive are the Potter & Brumfield relays which v{ill be analyzed and eged per Appendix G. 2331 066
*i .
K-4
Opower conversion products inc. APPENDIX L Fuses (Documentation of Non Age-Related Failure Mechanisms ) Fuses in Class 1E Sattery Chargers are used to protect semiconductors, instrumentation and power and control circuits. t stress analysis will be furnished to demonstrate that the fuses are properly applied in circuits with respect to ampacity, voltage and temperature. Specifically, adequate temperature margin will.be provided to preclude an increase in temperature rise at the fuse or fuse holder termination beyond the fuse rating. Documentation will be provided to verify that, subject to the design and inspection programs above, age does not represent a coranon mode failure for the fuses used. ,
~
2331 067
' L-1 m MMO*
9
a. Opower conversion products inc. - APPENDIX M liechanical and Electrical Test Procedures The following mechanical inspection and electrical test procedures will be followed as referenced in the Qualification Type Test (section 5.6): A. fiechanical Inspection The battery charger will be given a complete visual and mechanical inspection. The following inspection points will be verified:
- 1. All units to be checked to assure there are no loose nuts, bolts, screws, or parts loose in chassis.
- 2. No components missing.
s(
- 3. All components tight.
- 4. Al nuts tight.
- 5. Lockwashers on all screws, except where a rivnut is used.
- 6. Screws in all holes.
- 7. ' Proper size hardware used: lugs, screws, nuts, etc.
- 8. Wires extending through lugs flush or not over 1/16 inch.
- 9. Lugs will be mounted as follows: I lug, open side down, 2 lugs, bottom one, open sid; down and top one, open side up.
- 10. Stress bend in all wires and leads.
- 11. Wires harnessed and run neatly.
- 12. Hires not against or close enough to any heat-producing component which could cause deterioration of wire insulation.
2331 0o8 n.1
. )power conversion products Inc.
I. ( , APPENDIX M Mechanical and Electrical Test Procedures (cont.) A. Mechanical Insoection_(cont.)
- 13. No burned insulation or components.
- 14. Wires not too tight or too much excess wire.
- 15. Components flush on board except where mounted with clamp or potted.
- 16. Tracks on P.C. boards not cut or broken.
- 17. Proper soldering of all solder connections.
- 18. Serial number tag installed.
j( 19. P.C. boards and all components and parts clean of all solder and flux.
- 20. No scratches on chassis or units.
- 21. All units to be blown out. .
B. Electrical Inspection Note: Industry standard, NEMA PV-5-1976 shall be the basis of resolving any questions of interpretations and procedures unless specifically excluded. 1.0 Test configuration and test equipment shall be arranged as shown in Dwg. Q-55-13327-323. 1.1 Input waveform of the supply line shall not contain more
.( than 3% waveform distortion from a normal sinewave.
n-2 2331 009
Opower conversion products Inc. 1 APPENDIX M I4echanical and Electrical Test Procedures (cont.) B. Electrical Inspection (cont.) 1.2 l'f the supply voltage is polyphase, the line to line unbalance must be less than 5% at the start of test. Line balance shall be
~
verified with the unit operating at full load. 1.3 Input metering requirements: 1.3.1 Input voltage to the unit under test (UUT) shall be measured h with an AC voltmeter accurate to at least 2% and readable to 2%. Voltage ceasurements shall be made at the UUT input terminal connections. 1.3.2 Input current to the UUT shall be measured with a current transformer type AC ammeter accurate and readable to at least 2%. Care shall be taken that the meter shall read only the UUT current. flote: If the UUT input current imbalance exceeds 10%, discontinue testing. 2.0 Output connections Unless otherwise specified, the UUT output shall be connected to the resistive load bank cables that are bundled together. The cables shall be sized such that under full load current (FLC) the total voltage drop between the UUT and the load shall [ be less than 0.1 VDC. 2331 070 ti-3
power conversion products Inc. I h APPEt: DIX M idechanical and Electrical Test Procedures (cont.)
~
- 8. Electrical Inspection (cont.)
2.1 UUT output voltage shall be measured at the UUT output terminals with a meter accurate to %. Note: For routine testing of identical products, the voltage measurement may be made with a DC voltmeter accurate to 1% and repeatable to 1% provided that:
- a. Periodically the product is verified to conform to specifi-i k cation requirements with a meter of %% accuracy, and .,
- b. The UUT performance is such that the worst case of meter error and unit performance combined will be within specification limits.
2.2' UUT output current shall be measured with a calibrated shunt and millivoltmeter accurate to h%. The shunt shall be connected between the UUT negative output terminal and the negative load cable. flote: For routine testing of identical products the output current readings may be made with a calibrated direct reading ammeter or shunt and millivolt meter accurate to 2; provided that the output current is set by the load conditions such that the load current shall be at least 2% above the ( required FLC.
,a 2331 071
power conversion products Inc. ~ . APPENDIX M Mechanical and Electrical Test Procedures (cont.)
- 8. Electrical Inspection (cont. )
2.3 UUT ripple voltage measurement shall be read at the output terminals of the charger with a true RMS or Quasi-RMS reading AC voltmeter accurate to at least 2%. Note: For routine testing of identical products ripple measurements may be made with an RMS calibrated peak reading AC voltmeter
~ provided that:
- a. Evidence is established that the UUT ripple waveform does
>k not contain abnormal noise components (by periodic oscilloscope ,
i , observation) and
- b. True RMS reaoings are taken periodically.
2.3.1 When specified by the specifications (Appendix A), output noise measurements may require one or more of.the following special measurements:
- a. Readings at the UUT output terminals
- b. Oscilloscope records (photographs) of the noise
- c. Peak to peak measurements (oscilloscope) 233'l 072 i.C M-5
k)power conversion products Inc. (k 1 APPErl0IX M Mechanical and Electrical Test Procedures (cont.) B. Electrical Inspection (cont.) 3.0 Performance Testing 3.1 Testing will be conducted as specified in section 5.6 and will normally be in the sequence listed in Table 1. However, for reasons of efficiency, the test sequence may be altered, provided that:
- a. In all cases the dielectric strength test must be performed
.( '"
8: before any other electrical testing is attempted, and
- b. All of the tests required by Table I are completed.
Table 1 Spec. Para. Test Name Dielectric Strength 4.1 Circuit Operation 4.2 Range Adjustment 4.3 Overload Set 4.4 Voltage Regulation 4.5 Ripple Voltage 4.6 Surge Withstand 4.7 4 2331 073 M-6
power conversion products Inc. I APPEtlDIX M Mechanical and Electrical Test Procedures (cont.) B. Electrical Inspection (cont.) 4.0 Detailed test procedures 4.1 Dielectric strength testing shall be in accordance with i:Ef'A PV-5-6.02 except that where experience las shown that the short circuiting of semi-conductors and capacitors is not required it may be omitted. Dielectric testing shall be performed before the burn-in only. 4.2 Circuit operation testing shall proceed only after successful completion of the dielectric strength test. 4.2.1 Apply AC voltage to the UUT, while monitoring the input current, input voltage, output voltage, and UUT meters. As soon as it is established that the UUT is performing properly, adjust the input AC.to its nominal value, verify adjustment of controls, etc. 4.3 Range adjustment shall be performed with the UUT operating under nominal input conditions, and an output load of approximately 50%. Unless otherwise specified, the following range's will apply. t l lote that the UUT must exceed the indicated ranges but not exceed JL the absolute limits. 2331 074 M-7
power conversion products inc. (k A I . APPEilDIX M Mechanical and Electrical Test Procedures (cont.) B. Electrical Inspection (cont.) Absolute Limits UUT Volts Float Range Equalize Range Float " Setting" Float Equalize 130 124.8-135.2 134.2-145.2 130.2 100 min. 150 max 4.4 Overload setting (current limiting) shall be performed with the UUT adjusted for its nominal setting, as defined above, in the float mode, with the load connected and the input voltage at nominal line. Increase the load current to 125% FLC,* keeping ( , the input voltage at nominal line, and adjust the overload settidg to secure the following output voltage under the above conditions.
- UUT Setting Overload Output Volts 130.2 105.0 + 5
~
- Other values than 125% FLC may be required by the detailed specifications (Appendix A). Ilhen provided, transfer to the equalize mode and verify that the UUT meets the above table also. ,
2331 075 M-8
O power con.ersion products in:. i. h APPEi.'0IX f4 liechanical and Electrical Test Procedures (cont.)
- 8. Electrical Inspection (cont.)
4.5 Voltage regulation testing shall be performed to demonstrate that the combined effects of line and load variations will not result in a deviation in charger output greater than that allowed by the UUT specification. Since a UUT is being delivered with the float and equalize settings not factory set, it is not necessary to establish the exact set point for this test. At
'- no time will a UUT be acceptable if it evidences a negative .,
slope-to-load regulation curve, i.e. voltage must not increase with increasing load. Note: i;ormally as a convenience, the data required for ripple voltage should be taken simultaneously with the data for voltage regulation. Proper readings of meters should be noted during regulation testing. Definition of Regulation (Ref. 2.8, PV-5-1.14):
+% Regulation = E(h) - E(1) x 100 E(h) + E(1)
Where: E(h) is the highest UUT output voltage recorded E(1) is the lowest UUT output voltage recorded ( 2331 076 fi-9
Opower conversion products Inc. I, APPENDIX M Mechanical and Electrical Test Procedures (cont.) B. Electrical Inspection (cont.) 4.5.1 Voltage regulation records for performance testing will be taken with the UUT in the float mode, resistive load connected, A and with input ovltages of rated low, nominal and high line. minimum of five different levels of load current shall be taken as follows: 100% FLC, 75% FLC, 50% FLC, 25% FLC, 0* FLC.
* "0" indicates that the UUT will have no load resistance
( connected but may be supplying "tricklf" charging to the test ,, battery (if present). As a practical matter 1% or less FLC will be accepted as "0". 4.6 Output ripple measurements are taken across the output terminal of the battery charger. The RHS reading will be taken at full load only and no load. Full load is the worst case condition. . 5.7 AC and DC transient surges shall be applied across the input and output terminals respectively as specified in UEFA-pV-5-6.14. The surges used shall be equivalent to or greater than those specified in Appendix A. The surge withstand test shiall be (- performed before the burn-in (5.6.C). 2331 077 M-10
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power conversion products Inc. APPENDIX N Radiation Data Search Report IRT Corporation Report INTEL-RT-5199-001 Rev.1-7/16/76 documents that the material and components included within the sample equipment 3 are not affected by radiation levels of 1.4 x 10 rads gamma integr&ted dose. Additional data is furnished in the report to docucent no affects at 1.0 x 104 rads. In a telephone conversation with Mr. John Harrity of IRT Corporation on November 18, 1977, it was specified 7 by Mr. Harrity that a maximum dose rate of 1.0 x 10 rads /sec. would not affect the performance of these components over the b integrated doses specified in the report. This level exceeds the _ level specified in Appendix A and thus the equip:aer.' is qualified foF the radiation level specified. A copy of the report will be included in the complete Qualification Report. 2331 079 ( s N-1
Opower conversion products Inc. Ik APPENDIX 0 Burn-In Test Procedures 1.1 The battery charger will be subjected to 50 hours continuous operation with nominal 480 VAC, 3 phase power input and no load on the 135 VDC output.
- 1.2 The battery charger will Se subjected to 50 hours continuous operation with nominal 480 VAC, 3 phase power input and PCP furnished 300 amp load on the 135 VDC output.
- The 480 VAC input power consumption will be approximately 100 amps.
k
- Note; Refer to Appendix A. This value may range from 125 volts to 135 volts DC depending upon the number and type of battery cells
used in the application. The value of 135 volts DC will be used in the burn-in test as it is the "wcrst case" condition. 2331 080 0-1
Opower conversion products inc. k ~ l APPENDIX P Stress Test Procedures 1.1 The battery charger will be subjected to 8 hours continuous operation in a environmental chamber with nominal 480 VAC, 3 phase. power input at 500 C (122 F), 90 to 95% relative humidity. Operation will be at 300 amps load at 135 VDC.
- 0 0 1.2 The environmental chamber will be cooled to 0 C (32 F), using CO , as rapidly as possible, while maintaiaing the humidity at the 2
maximum attainable level. 1.3 The battery charger will be operated at the 300 amp output load ( '- for 8 hours at 0 0C, 90-95L -elative humidity. 1.4 The environmental chamber will be shut down and the temperature allowed to return to ambient. The AC input power to the battery charger will be disconnected during this period. 1.5 The above test will be conducted over a 24 hour maximum period.
- The value of 135 volts DC will Le used in the stress test as it .
is the " worst case" condition. 2331 081 4 P-1
' power conversion products Inc.
i ) APPENDIX 0 Seismic Test Procedures
- 1. Mounting .
1.1 Specime6 Orientation , A 130 volt battery charger, approximately 75" high x 26" wide x 36" deep, weighing approximately 3000 pounds, hereinafter called the specimen, will be placed on the Wyle multiaxis Seismic Simulator Table such that the base of the specimen will be flush with the top of the table. The specimen will be oriented such that its longitudinal axis will be colinear with the longitudinal axis of
. the table. For the second axis of test, the specimen will be .
rotated 90 degrees in the horizontal plane. 1.2 Specimen Tie-Down The mounting base of the specimen will be welded to the 1(yle Mul'tiaxis Seismic Simulator Table. The mounting of the specimen will simulate as closely as practical the actual in-service configuration. tielding procedures will be in accordance with PCP 3 process specification 77-15 and 77-16. 2331 082 ( Q-1
.l . (:)power conversion products Inc. APPENDIX Q Seismic Test Procedures (cont.) 2.0 Excitation 2.1 Simultaneous Biaxial Excitation Each horizontal axis will be excited separately, but each one will be excited simultaneously with the vertical axis (longitudinal simultaneous with vertical, then lateral simultaneous with vertical). The horizontal and vertical input acceleration levels will be phase incoherent during the multifrequency tests. { 2.2 Resonant Search Test A low-level (approximately 0.2 g horizontally and vertically) biaxial sine sweep shall be performed to determine resonances in both the front-to-back/ vertical and the side-to-side / vertical orientations. The sweep rate will be one octave per minute from 1 Hz to 50 Hz. 2331 083 Q-2
Opower conversion products Inc.
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i APPENDIX 0 Seismic Test Procedures (cont.) 2.3 Multifrequency Tests The specimen will be subjected to 30 second ducation simultaneous horizontal and vertical phase-incoherent inputs of random motion consisting of frequency bandwidths spaced one-third octave apart over the frequency . ar.;e of I Hz to 40 Hz. The amplitude of each one-third octave frequency bandwidth will be independently adjusted in each axis until the Test Response Spectra (TRS) envelope the Required Spectra. The resulting table motion will be analyzed by a spectrum analyzer at a damping of 1%, 2%, 5% OBE, and 2%, 3%, 5% SSE ard plotted at one-third octave frequency intervals over the frequency range of interest. In addition to the required tests, calibration tests will be performed. Five (5) Operating Basis' Earthquake (0BE) tests, followed by a full-level Design Basis Earthquake (DBE) test will be performed in both the front-to-back/ vertical and the side-to-side / vertical orientations. This sequence of tests satisfies the aging requirements of the IEEE Standard 344-1975. 2331 084 e s 0-3
. - . . . =
power conversion products inc. I APPENDIX Q Seismic Test Procedures (cont.) 2.3 italtifrequency Tests (cont.) The CBE and DBE Required Response Spectra (RRS) will be generated by making composites (horizontal and vertical) of the Required Spectra for the applicable power plants. The appropriate RRS is attached. A 10% margin will be added to the RRS to satisfy the con-servatism requirements of the IEEE Standard 323. It is assumed that the Required Response Spectra vill be within the capabilities [ of the Hyle test machine. . 2.4 Excitation Control Control accelerometers will be mounted on the table at locations
- n. ear the base of the specimens.
3.b Specimen Response Twenty two each specimen-mounted uniaxial piezo-electric accelero-meters will be located on the test specimen during the test program. FM tape and oscillograph recorders will provide a record of each accelerometer response. Transmissibility plots of the specimen response accelerometers from the resonant search tests will be provided. Test Response Spectrum plots of the control and specimen-mounted accelerometers will be provided from one Design Basis Earth;uake (DBE) test and one OBE test in each test orientation. o-4 2331 085
Opower conversion products Inc. t 1 APPEl:0IX Q Seismic Test Procedures (cont.) 3.0 Specimen Response (cont.) Horizontally-oriented accelerometers and vertically-oriented acceler meters will be placed at the several location. 4.0 Electrical Powering Electrical powering of 480 VAC, 3 phase, 60 Hz, at 100 amperes or less, for operation of the specimen will be provided. ( 5.0 Electrical Monitoring Five (5) channels of electrical monitoring will be recorded on an oscillograph recorder during the test program. These channels may be used to ascertain electrical continuity, spurious or improper operation, contact chatter, etc. , before, during and af ter the seismic excitation. The following will be monitored on the test specimen:
- 1) AC input voltage phase A to phase B
- 2) AC input voltage phase B to phase C
- 3) DC output voltage
- 4) DC output current
- 5) !;ormally closed (when charger is operating) contacts of all the alarms
( 2331 086 Q-5
power conversion products Inc. k APPENDIX Q Seismic Test Procedures (cont.) 6.0 Electrical Load A resistive load (300 amps DC) will be connected to the specimen 135 VDC output during the test program. 7.0 In-Process Inspection The records will be checked for equality of performance after each test. The specimen will be examined for possible damage following all
. violent tests such as at severe structural resonance. .,
All important vibration effects will be logged (including specimen response at all accelerometer locations). Photographs will be taken of any noticeable physical damage that . may occur. 8.0 Report A certification-type report will be issued subsequent to completion of testing. This report will be signed by a Registered Prof'essional Engineer and will summarize the maximum g levels, details a>d re-commendations concerning deficiencies and repairs, photographs of test setups, accelerometers, failures, etc. The report,will also i contain a list of test equipment used, calibrations, and Instrumentation Log Sheets and transmissibility plots of all accelerometers. 2331 087 Q-6
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7 -s w ' power conversion products Inc.,
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forty two east street, crystal lake, Illinois 60014 telephone 815/459 9100
- twx 910/634 3356 I
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4 FOR ANY ADDITIO.!AL If! FORT'ATIO1 i I C0:! TACT: MR. CHRIS F. SEYER EXECUTIVE VICE-PRESIDEili ( ,
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2331 088
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TEXAS UTILITIES SERVICES, INC. AGENT FOR TEXAS UTILITIES GENERATING COMPANY ACTING FOR DALLAS POWER & LIGHT COMPM;Y TEXAS ELECTRIC SERVICE COMPANY TEXAS POWER & LIGHT COMPANY COMANCHE PEAK STEAM ELECTRIC STATION UNIT NOS. 1& 2 IEEE 323-1974 ENVIRONMENTAL QUALIFICATION OF BATTERY CHARGERS IEEE 344-1975 SEISMIC QUALIFICATION OF BATTERY CHARGEPS SPECIFICATION NO: 2323-ES-8B PURCHASE ORDER: CP-0440B VENDOR: POWER CONVERSION PRODUCTS, INC.
- 1. QUALIFICATION PLAN:#QP-12442, REV. 4
- 2. QUALIFICATION REPORT: #0R-12442, REV. 3 2331 089 GIBBS & HILL, INC.
ENGINEERS-DESIGNERS-CONSTRUCTORS NEW YORK
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TEXAS TEXAS UTILITIES DALLASUTILITIES AGENTSERVIC S I TEXAS P ACTING FOR E,I TEXAS OWER GENERATING F M.C ELECTRI P C
& OR OWER & SERVLIGHT COMP COM ANY ICE C LIGHT OMP PANY L COMP ANY ANY COMANCHE PEAK IEEE UNITSTEAME 32 NOS. LECT s
3-19 74 1 IEEE 3 & RIC 44 2 STAT Ic'e ENVIRONMENTAL 1975BATTERY SEISMIC BATTERY CHARGERS QU QUALIFICATION ALIFIC CHARGERS AT ION OF OF SPECIFIC PURCHA VEND E OR :S ATION ORD O ER:N : 23 UALIFICATION PL PC2E8 P 3 S B ALIFICATION REP AN:# OWER O 04408 0P 1 CONV 244 2, ERSI RT: N
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