ML19309G204

Confirmation of Original Qualification Test for Electrical Connectors Used at Browns Ferry Nuclear Power Plant Unit 3.

ML19309G204
Person / Time
Site:	Browns Ferry
Issue date:	12/31/1979
From:	Bonzon L, Buckalew W, Dugan D SANDIA NATIONAL LABORATORIES
To:
References
CON-FIN-A-1051, CON-FIN-A-1051-0 NUREG-CR-1191, SAND79-2311, NUDOCS 8005050127
Download: ML19309G204 (19)

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- .wa.c-r uw.wa.n.n .w u n. www wa; c.m su am, mum w un u;.,mn, n ui. mas eri This report (focuments a part of the Qualification Testing Evaluation (O T E i Proor.im trinq conrfucted by Santiia Laboratones b

Prepared for U. S. NUCLEAR REGULATORY COMMISSION

NOTICE This report was prepared as an account of work sponsored by an agency of the United States Government. Neither the United States Government nor any agency thereof, or any of their employees, makes any warranty, expressed or implied, or assumes any legal liability or responsibility for any third party's use, or the results of su:h use, or any information, apparatus, product or process disclosed in this report, or represents that its use by such third party would not infringe privately owned rights.

The views expressed in this report are not necessarily those of the U. S. Nuclear Regulatory Commission.

Available from National Technical Information Service Springfield, VA 22161

i NUREG/CR-1191 SAND 79-2311 RV CONFIRMATION OF THE ORIGINAL QUALIFICATION TEST FOR ELECTRICAL CONNECTORS USED AT BROWNS FERRY NUCLEAR POWER PLANT UNIT 3 Lloyd L. Bonzon William H. Buckalew Douglas W. Dugan Frank V. Thome December 1979 Sandia Laboratories Albuquerque, NM 87185 operated by Sandia Corporation for the U.S. Department of Energy Prepared for Research Support Branch Of fice of Water Reactor Safety Research U.S. Nuclear Regulatory Commission Washington, DC 20555 Under Interagency Agreement DOE 40-550-75 NRC Fin No. A-1051-0 4

3-4

CONTENTS l

Page l

1. Background, Program Objective 7

2. Test Items Descriptions and Assembly 9

3. Description of Test Profiles- 10 3.1 Radiation 11 l 3.2 Temperature Aging 12 3.3 Accident Test 13

4. Test Results, Conclusions 15 l

l ILLUSTRATIONS Figure ,

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1. View of Connector Boxes in Irradiation Cell 12 l

2. Oven and Associated Controller With Connector Bcxes In-Place in the Oven 14

3. Specified BF3-Connector Accident Test Profile and Data From November 1 and 2,1979 Test 16 j

4. Posttests Disassembly of 250-Vdc Connectors 17

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5. Posttests Disassembly of 480-Vac Connectors 18 5-6

I CONFIRMATION OF THE ORICINAL QUALIFICATION TEST FOR ELECTRICAL CONNECTORS USED 1 AT BROWNS FERRY NUCLEAR POWER PLANT UNIT 3

1. Background , Program Objective Following the Union of Concerned Scientist's petition of November 4, 1977, the NRC Commissioners directed the NRC staff to:

" Arrange for a repeat of the tests to obtain data for the verification of current methodology for environ-mental qualification of electrical canponents. These tests should be performed with a representative sample of commercially available electrical connectors quali-fied in accordance with IEEE-323 (1974) and in use in nuclear power reactor safety systems. When avail- )

able, the test results are to be promptly provided to the Commission." .

The NRC staf f interpreted this action to be aimed at providing information on the methodology of qualification testing using electrical connectors which meet the provisions of IEEE-323. Since no connectors in use at that time had been actually qualified to IEEE-323-1974 (a relatively new standard), the staff responded by directing that electrical connectors previously qualified by licensees for use in operating plants be tested in accordance with the provisions of IEE-323-1971.

To the extent practicable, connector assemblies were to be subjected to the actual aging, radiation, and LOCA-simulation tests for which the ~

connector assemblies had been qualified. In a letter dated May 22, 1978, 7

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D. G. Mcdonald (SEP/ DOR) to R. Feit (RA/RSR), DOR and IE recommended that the following plants / connectors be considered for testing:

BWR (a) Peach Bottom - Pyle National Connectors; or (b) Browns Ferry - Bendix Connectors PWR (a) Palisade: - Viking Connectors ; or (b) Oconee - Viking Connectors flowever, other plants or connectors would also be appropriate due to ". . .

availability of the connectors to be tested, extensive procurement t ime ,

or other constraints."

From that date, Inspection and En forcement (IE) staf f evaluated some of the various utilities' connector hardware and qualification documents and directed that Sandia proceed with the first test in this series using Browns Ferry-Bendix (BF3) connectors. The principal objective was that the test was to duplicate, as closely as practicable, the actual Browns Ferry Connector tests; it is understood that these original tests were intended to conform to the requirements of IEEE-323-71, with the addition o f a (Browns Ferry specified) thermal aging preconditioning requirement.

The order for the connector hardware was placed through a Bendix-authorized distributor on August- 2,1978 with delivery completed on November 1, 1978. Concurrently, Draf t 1 of' the Sandia-generated impl e-menting test plan was forwarded to NRC staff, for review and approval, on I August 11, 1978. Based on staf f comments, Draft 2 of the plan was sub-l

'mitted on February 16, 1979 followed by Draft 3 on May 1 and Draft 4 on l

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i The test plan specifically applied to the Browns Ferry Unit 3 (BF3)

, connector assemblies ; the applicable (background) documents for this test plan are:

(a) Tennessee Valley Authority, Purchase Requisition 150639, dated April 18, 1978.

(b) " Assembling Browns Ferry Nuclear Plant Bendix Connectors ,"

dated June 22, 1978.

(c) "Te s t Procedure for Browns Ferry Bendix Connectors, Revision," undated.

i The primary document, which the test plan intended to duplicate is:

1 4

(d) " Qualification Test for Electrical Connectors Used at Browns Ferry Nuclear Power Plant Unit 3," Report 4

No. 43854-2, Wyle Laboratories , March 28, 1978.

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-2. Test Items Descriptions and Assembly Three each of two different types of electrical connectors were tested. Both types are manufactured by Bendix and used inside containment at Browns Ferry, Unit 3 (BF3), operated by the Tennessee Valley Authority (TVA).

Max im um Operating Identification Operating Current Qty, Manu fac ture r Numbers Voltage (A) 3 Bendix Plug: 250 Vdc 1.0 10-214628-51S Receptacle:

10-214028-51P 3 Bendix Plug: 480 Vac 17.5 10-214636-78S ,

Receptacle: l 10-214036-78P' l l

l These Bendix connectors were purchased by Sandia through a Bendix-authorized distributor. Electric cable was furnished by TVA _ from spare 9

cable of the same type used at BF3. The Bendix 250-Vdc connector assemblies consisted of wire size No. 12 CPJ cable on the plug end and wire size No. 12 Vulkene cable on the receptacle end of the connectors.

The Bendix 480-Vac connector assemblies consisted of wire size No. 10 CPJ cable on the plug end and wire size No. 10 vulkene cable on the receptacle end of the connectors. CPJ and Vulkene cables consist of cross-linked polyethylene with the CPJ cable having a PVC insulating jacket.

Construction of six of each of the connector assemblies was conducted by BF3 staf f using an assembly and potting procedure developed by BF3 staf f (used in field assembling connectors) and approved / certified by IE staff. Initial assembly took place on January 29-30, 1979 at the BF3 site and was completed on February 26-27. All connectors were potted to appro-priate specifications prior to any testing. The actual assembly was observed by IE staff; af ter completion of the assemblies, IE certified that they were acceptably equivalent to the in-place connectors at BF3 before any simulation tests were conducted.

The Bendix 250-Vdc connectors are equipped with 12 pins. Its wiring configuration was such that all pins were used during testing. The Bendix 480-Vac connectors are equipped with 14 pins: 12 were wired into a single-l phase circuit. In each case, the 12 pins were wired to form a series /

parallel circuit that gave a voltage difference between pins within the connector as well as passing current to simulate a load.

Following final assembly, six of each of the wited and potted assemblies were shipped to Sandia Laboratories ( Albuquerque) for emnple-l tion of the entire confirmation-of-qualification test series.

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l 3. Description of Test Pro files l

l Three of each of two types of connectors were subjected to the pre-scribed series of tests with the remaining six connector assemblies saved as spares. This test series consisted of the following:

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a I - Acceptance II - Baseline Functional III - Baseline Mechanical / Dimensional I 3 IV - Radiation V - Postradiation Functional / Mechanical VI - Temperature Aging VII - Postaging Functional / Mechanical VIII - Accident Test IX - Postaccident Functional / Mechanical X - Posttests Inspections 3.1 Radiation The connector assemblies were exposed to Cobalt-60 radiation doses totalling 68.5 Mrads (air) at an averaged dose rate of 0..'6 Mradii. >> ring i the period April 4-9, 1979. By comparison, the specified values were 69  :

Mrad and 0.77 Mrad /h, respectively, to be attained withtn +10%.,

1 The total 90-h irradiation interval was accomplisted in four 22.5-h periods with the specimens rotated to achieve a more ut iform total dose.

Concurrently, selected temperatures were recorded; the maximum measured 1

temperature was 35'C with the temperatures generally r inging between i 30' to 34*C. Figure I shows a view of the connector boxes in place inside the irradiation facility, i

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Figure 1. View of Connector Boxes in Irradiation Cell 3.2 Temperature Aging All of the electrical connectors were subjected to a two-part s im u-lated aging test during the period, April 10 24, 1979. The specified ag-ing times / temperatures / tolerances are shown below; the humidity was not controlled (i.e., was ambient).

Ag ing Aging Temperature Aging Time Atmosphere 217 * +6 *F 60 +0.1 h 8 Air 217* +6*F 180 +0.1 h b Nitrogen d

60 h in air at 217'F is intended to simulate 6 mo in air at 130*F.

b lS0 h is intended to simulate 18 mo in 130*F nitrogen with a maximum of 4% oxygen.

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l Each test item was placed in the temperature chamber (i.e., oven) in a manner to avoid overheating from radiant ef fects from the chamber-heating elements (Figure 2). The temperature chamber was vented to the atmosphere to prevent buildup of outgasing products, particularly chlorine gas, from the test item inside the chamber. The air inside the chamber was distributed uniformly at an average velocity of about 250 f t/ min; pretest flow measurements in an open chamber were made and recorded. The air-aging was conducted for 59 2/3 h at 217' +3*F and was completed on April 13, 1979.

Following the air aging, the oven was purged with flowing nitrogen and the oven chamber brought to, and restabilized at, 217*F. The temperature was maintained (+3*F) for 179 2/3 h and was completed on April 24. During nitrogen-aging, a continuous flow of nitrogen was maintained , averaging i about 1/5 ft 3/m.

During all phases of the aging tests, selected specimen and environ-

, ment temperatures were recorded; the data indicated stabilized tempera-tures ranging between 218' and 220*F.

3.3 Accident Test Programmatic delays in completing the test series were experienced I during the period April 24 to November 1,1979. The delays were a result o f two fac tors. First, it was necessary for NRC staff to define the de-sired test profile so as to envelope both the originally specified and actual test profiles. Second, the necessary steam-generation equipment had to be assembled and a number of demonstration runs conducted to prove that the profile could be attained. During this 6-mo period , the con-nectors were stored in locked cabinets under ambient conditions; Sandia staf f believes that the storage resulted in insignificant additional de-gradation and " age."

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The connector assemblies were installed in the autoclave test chamber on October 31, 1979. Circuit continuity checks were performed and the as-semblies instrumented to load and measure voltage and current. The test chamber was instrumented with numerous temperature and pressure sensors located to provide indications that the environments were correctly at-tained and maintained.

The electrical connector test assemblies were subjected to the acci-dent test profile shown in Figure 3 and as detailed in established test procedures on November 1-2, 1979. The 250-Vdc connector assemblies were energized throughout the entire test. The 480-Vac connector assemblies were energized during the first 5 minutes, between minutes 15 and 18, and between minutes 57 and 60.

All aspects of the test were within the specified tolerances except for a few minutes at approximately 2 h when the tenperature exceeded the desired (110*C) value by +7'C.

4

4. Test Results, Conclusions All aspects of the test were considered satisfactorily completed. All connector assemblies passed the specifications of the test series; in particular, the assemblies carried their specified current / voltage loads during the accident-test phase. Posttest inspections (Figures 4 and 5) indicated little or no degradation of the connectors.

It is concluded that the test series completed on the specified BF3 connectors confirms the original qualification tests on the same type connectors as documented in Wyle Laboratories Report No. 43854-2, dated March 28, 1978.

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