ML20010C104
| ML20010C104 | |
| Person / Time | |
|---|---|
| Issue date: | 08/12/1981 |
| From: | Agee J, Mcdonald D, Reinmuth G NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION IV), NRC OFFICE OF INSPECTION & ENFORCEMENT (IE) |
| To: | |
| Shared Package | |
| ML20010C100 | List: |
| References | |
| REF-QA-99900901 NUDOCS 8108190123 | |
| Download: ML20010C104 (10) | |
Text
..
U.S. NUCLEAR REGULATORY COMMISSION OFFICE OF INSPECTION AND ENFORCEMENT Docket No.: 99900901/81-01 Environmental Qualification Program:
Independent Verification Test Mo. 4 Report No. 1 Witness of Environmental Test Equipment Identification:
4 Test Specimen:
Electrical Penetration Assembly (EPA)
Type:
K Instrumentation Penetration Mfg:
D. G. O'Brien Equipment Spec. No.:
Duke Power Company CNS-1361.00-00-0003 Serial No.:
4986-F Lot 1216K Test Organization:
Sandia National Laboratories, Albuquerque, New Mexico 87185 i
Contract No.:
B3101 Inspection Conducted:
June 15-17, 1981 Y ft*<-
L///
Staff:
(J.R.Ag66,VendorInspector,RegioniV Date G
N b
9- / 2-9 l 4
c
.__m D.~ M Mcdonald, NRC Consultant, Los Alamos / '
Date National Laboratory b
6'-/J-8/
Approved By:
os m G. W. Reinmuth, Chief, Vendor and Special Date Projects Branch, IE Summary:
The puroose of this inspection is to report on the proy.ess of the subject environmental qualification program and results to date.
i Results:
The review performed during this inspection indicate:
1.
An acceptable pretest data base was established.
2.
The aging, radiation and harsh environment portion of the test conform to the test plan.
3.
Failures occurred during the initial portion of the harsh environment test requiring follow-up actions by the staff.
I i
1 0108190123 810814 PDR GA999 EXISANL 99900901 PDR
-_-_______________-_____-_____a
DETAILS SECTION Prepared By:
J. R. Agee and D. G. Mcdonald A.
Persons Contacted L. L. Bonzon - Sandia National Laboratory (SNL)
W. H. Buckalew - SNL D.-M. Jeppesen - SNL F. V. Thome - SNL P. N. McBride - Duke Power Compary (DPC) 8.
General The purpose of the subject test was to expose a D. G. O'Brien, Type K Instrumentation EPA to a complete environmental qualification test program in accordance with IFEE 323-1974 and NUREG-0588.
The test specimen (EPA) included crosslinked polyethelene (XLPE) cables, D. G. O'Brien connectors and a junction box.
During the initial development and qualification program of the type K EPA, all portions of the assembly weie not subjected to the entire qualification sequence of aging, radiation and LOCA/MSLB test as required by IEEE 323-1974.
This test program was by SNL for the NRC and was conducted in accordance with the " Connector Assembly Test Plan for Duke Power, Catawba 1 and 2 Connectors," Fourth Draft, dated January 30, 1931.
The purpose of this inspection was to assure that the aging, radiation and harsh environ-ment tests were conducted in accordance with the test plan.
provides pictures of the test specimen during the various phases of the test.
The NRC staff representatives accomplished this effort by discussions with SNL and DPC personnel, review of selected test data, observations of the test facility and witnessing the initial portion of the LOCA/MSLB test.
C.
Test Specimen Preparation 1.
Objectives Pie objectives of this portion of the inspection were:
To determine that a data base for the test specimen performance a.
characteristics had been established.
b.
To determine that the test specimen had been prestressed (aged).
c.
To determine that the test specimen had been irradiated.
2-2.
Findings a.
Data Base The EPA used for this test was obtained from DPC where it was assembled by DPC personnel-using normal field installation procedures.
The assembly of a typical EPA was witnessed by an NRC staff member.
SNL developed a detailed procedure to provide a pretest data base for comparing the test specimens performance characteristics during the various phases of the test.
The procedure included requirements for visual inspection, connector torque checks, continuity checks and insulation resistence (IR) measurements.
The detailed procedure and selected data sheets were reviewed by the NRC representatives to assure that an adequate pretest data base had been established and the appropriate data recorded.
b.
Thermal Aging The thermal aging portion of the test was conducted at t% SNL environmental test facility.
The test specimen was installed in a circulating air furnace and exposed to 150 C temperature j
for one hundred sixty eight (168) hours.
Continuity checas, IR measurements and internal pressure checks on the test specimen were performed and recorded daily.
10 The baseline IR measurements were in the 10 ohm range. Jhe IR values decreased during the thermal aging process to 10 -
8 10 ohms.
However,-the post aging measurements indicate the IR values recovered to approximately the same values as the baseline data.
The EPA internal pressure was maintained during the aging process.
Subsequent to thermal aging the connector coupling rings were observed to be loose and required retorquing to maintain the specified 25 ft.-lbs. torque.
Selected data sheets and records were reviewed by the staff representatives to assure that the aging portion of the test complied with the test plan.
It should be noted that i
verification of the torque on the connector coupling rings was required; however, the necessity for retorquing to maintain'the specified 25ft.-lbs. was not anticipated.
SNL contacted the NRC staff and a determination was made to retorque the connectors and continue with the test.
Each of i
the connector assemblies required approximately one (1) full turn of the coupling ring, i
I
_. c.
Radiation The test specimen was irradiated at the SNL High Intensity Adjustable Cobalt Array (HIACA)8 facility.
The required total integrated dose (TID) of 2 x 10 rads and the dose rate of
.75 M rads / hour was achieved using a cobalt 60 source.
The facility size required that the junction box be removed during the irradiation.
To assure that the test specimen would receive exposure, measurements were taken to determine the attenuation provided by the junction box.
The total exposure time was reduced by approximately nine (9) percent to account for shielding effects of the junction box.
Flux mapping of the radiation exposure area was performed by using two hundred fifty (250) photo diodes.
The calibration of the photo diodes was verified by a Victoreen ion chamber.
ThepostradiationmeasuremengindicatetgattheIR-decreased from the pretest values of 10 ohms to 10 ohms. The EPA internal pressure was maintained.during the irradiation process.
It was noted that each of the coupling rings were loose following radiation and required approximately one sixth (1/6) turn to maintain the specified 25 ft.-lbs. torque (See Section C.2.b).
Selected data sheets and records were reviewed to assure that the radiation portion of the test complied with the test plan.
3.
Summary Based on the information provided above, the staff found that the detailed procedures used in establishing the pretest data base, the thermal aging and the radiation portions of the test were performed in accordance with the test plan requirements.
D.
Harsh Environment Test 1.
Objectives The objectives of this portion of the inspection were:
a.
To determine that the detailed test procedure conformed to the test plan.
b.
To determine that the test configuration conformed to the test plan.
c.
To varify that the test facility was capable of performing the harsh environment test and that the initial portion was conducted in accordance to the detailed test procedures.
1 1
. ~.. -..., - -
d.
To observe the test facility personnel and their performance of the test to assure that the information, data, and any deviations or anomalies were accurately documented.
2.
Findings a.
Test Procedure The SNL staff had developed a detailed test procedure which was used in performing tiu Sarsh environment portion of the test.
The procedure include. tb> required actions and details for the preparation and opera' :on of the:
(1) Steam system (2) Instrumentation (3) Profile conditions (4) Startup and run conditions NRC staff representatives reviewed the test procedure and the preliminary data used to develop the procedure.
The test facility system, equipment and controls were identified by using the procedure for guidance and the operational characteristics were described by SNL personnel.
b.
Test Specimen The test specimen installed in the test chamber was the same unit which had been subjected to the preconditioning tests.
The normal installation of the EPA would be in a horizontal position with the junction box vented at the bottom.
The test specimen was mounted in the vertical position with the original vent hole sealed and a vent hole provided at the bottom of the junction box for the test configuration as identified in the test plan.
The external cable harnesses were terminated on sliding link terminal blocks and wired per the test procedure.
This configuration allowed the electrical loads to be provided during the test with provisions for performing the continuity and IR measurements.
The test plan required that continuity and IR mea;urements be performed and the EPA pressure be recorded daily during the test.
The details for performing the required continuity and i
IR measurements were provided in the test procedure.
- However, j
since the test plan required only daily measurements, the l
test procedure did not specifically identif, when the measu*e-ments were to be made.
The required measurements were taken daily and documented on data sheets as required by the test t
_. plan.
The SNL personnel were observed performing the actions and measurements identified in the test procedure.
All required actions and measurements were being accurately performed and documented.
c.
Service Conditions A pretest check was completed to assure availability of the steam supply system, chemical spray, and water supply for the low temperature thermal shock.
The test was initiated in accordance with the test procedure.
The test plan did not require preheating and the test was initiated with the test specimen at ambient temperature.
The test temperature was monitored by fourteen (14) thermo-couples located in the test chas er, inside the junction box, on the connectors, in the chemical solution and at the steam inlet.
The test chamber pressure was monitored continuously by an electronic pressure transducer.
Additional pressure indication was provided by a Heise pressure gauge.
The temperature and pressure were recorded by the data acquisition system which is described in the following section.
The exterior of the test chambers, including the EPA and assemblies was insulated.
It had been demonstrated during trial runs that the insu11ation assisted in maintaining accurate control of the test profile although the use of the insulation was not identified in the test plan or procedure.
The initiation and control of the test profile was observed to assure that the test procedure was being followed.
The initial portion of the test, including the chemical spray and thermal shock, complied with the test procedure.
The thermal shock was a special requirement of the test plan which required the test specimen to be subjected to 40 F water for at least one (1) minute following stabilization of the test temperature at 250 F.
The purpose of this special requirement was to assure tLe integrity of the glass / metal seal interface of the EPA.
Instrumentation The data acquisition system consisted of magnetic tapes with high speed recorders and an x y recorder as backup.
The components of the system provided the required accuracies, response times and variabls time bases necessary to record the data and evaluate anv.aomolies or deviations.
The instrument calibration tags were checked to assure that the instruments were within their calibration period.
The instruments had been calibrated by SNL with standards traceable to the National Bureau of Standards. The SNL personnel were observed L
making the required notations on the strip chart and paper tapes to identify test conditions, time base or other changes in the test status to assist in the post test analysis.
e.
Preliminary Results The acceptance criteria for the test was:
6 (1)
IR measurements be 5 x 10 ohms at 500 VDC between each conductor and all other conductors and ground.
(2) Circuit continuity be maintained.
(3) 600 VAC applied and maintained between all conductors and ground.
The 600 VAC was applied to all circuits prior to initiation of the test. At 250 F saturated steam conditions, approximately three (3) hours into the test, the 600 VAC was removed and the continuity and !9 measurements taken and recorded.
Twelve (12) of the one hundred four (104) circuits exhibited low gr erratic (IR) readings below the acceptance valve of 5 x 10 ohms at 500 VDC.
The 600 VAC could not be reestablished on two (2) of the twelve (12) circuits.
Both circuits drew excessive current which tripped the 600 VAC power supply.
3.
Summary Based on the information provided above, the staff found that; the detailed test procedure and the test configuration conformed to the test plan; the test facility was capable of providing and controlling the service conditions; and the SNL personnel performed all required actirns and documented the required data and information in accordance with the test plan requirements.
NRC staff representatives will return to SNL the 1:aek of June 22, 1981 to assist in devising a disassembly procedure for the test specimen to identify, isolate and determine the cause of the failures identified in Section 0.2.e. of this report and any other failures which may occur.
The DPC representative indicated that DPC, D. G. O'Brien and Brand Rex Cable Co. would assist in developing the orocedure and evaluating the failure mechanism (s).
TEST SPE CIME'i - PREPAPATIO'i r0P I D R A DI ATI n';
Y nt
.w v.
DM i i
[
j i
<a.,
p
. 33 $y3g, g
A 5 7, jl
/
c g
h
- k.
i m'!
1 en n
f ",
f l
- j g.y f
.8,, g ;
p r
cyp)
>e e
l
- 4 5
ll il, ik 9 ^ b-lp+
/mys 1 4,4
,7 m
q g
4 k
l c },
h3 g,h[
- Ij S
1,..
, I/
i.
=
s w
tR R w p,,..
v s,
A 5,
j 4
po.
. g 1
c d
de b c..1 :.t.
n
- {,
n
.-3 as
.-w
~
.m.E 1
w Et.$,.
~,'5 _',,~
C$
~ a' s'
~
~&.
. : "r= ~ :--T,,.s.h
- h f'~
g g
y h,,,.
l
_ fn/"sLc TEST 3PE CIl1E'; - PDE papATIn, Fgc 1
l
+
1 l
~
l Edi j
7, g
t 1
<x
- nis, I
y,'+
46
?
~
~- -
u
=
'w
- c..
N,2 a
[h i
- Ng f f'
%&dlth m.=..
sa s
c 1
l l
1
~
p
.y
'g ;.w, j j
+ j
. A,-
^ ', '
. g w.1 3.,
o.
,,... ;. 4,[.c- ;%f-a.sg: L_
- 9. y.c.p..,.
ge.
i +.
w %.
.. 4p. 7 -
'?
- 4...
-% n
. c.ft-
_c g-.., $. ;
, p.q. w.
g., g 4;~. w;
- . 7....
.y._,
, ~-
u, y
~
-.._ [
- P
. ;, s k,yyy
,.{. + '
3.,, -
5 y,y 7
7,,.
.a
\\
fR
~
.'?
'~~\\
y*-
JLM f 5%, -
t 1
-d '.,..
-:. ?;
fa
. ~
)
e, 1
~
~.j v '
=Eime, ;
_4 s :.Q.
,'x
..~:.
r.
1 i%'g,4 ' - -
. 4. *'='_ t -
s g
~ 1..
...%. ;W -
.x 1
2..
,p.
.,,. g,
..+
~; 2 g,..
lv t,a,.
r.g.?.
',, p 7 4,,.y. < (
1 4;,
s 2,.
e.,,
.t s,. p.,.g.
w
..cq.
- d.
f.
9.qf L.
+
+,;
t-.'i..- %, r
,+M W.
- ~.
9>
l
,, l ' ::(,
.. + :: >
Q
~.
~ '[ f.f. ' ;,
,b '
' ' x t-[ 2. C N Y,;, N. ~/ Y [
g q
k c
P t
m $f-Q.y J. ? ^ j.
{
+a I
- f;'
s.tenumm.,,e,,
A. y:
.z -
y
.y, l
s,,
~ - -
, 4. _..
-v
. g.. _
y, Qj,.
?,..
s---
g g. _
=pa < ~;;. ; '
W
'k.*
s 1
.s._
1 4,
~
f
?
1
.'[
-Q.
~[
g
. gyi, y.-
h5le,*p.j.
4
[',.
1 2 c:g L a ;.fl ?.. _. -
Si V
j
,(g. '#
l i $.
.. ',..... 'l
.. g 4,,4s IIjfpI
'.i
- i.,1 e ; 2..Q,,o.h.g. t T b' +j
F:
l t;b3
. ~ gw..
-d;f%+ y,ytr.I;L f"
s yc [
- % g-('l '., ;--
. !* pp,7 Q-.
c.
s.-
,o y.
7.
- 1 u
n
..- o u s V...
J'LLf i
,p 4.
~
i g
.;. '.... c..f.~
7-
'v o
.w,
.r
. 13 - 9 ;j.
- p..
r
- , ;c.-
R,.'_...g:;.. p -.
q,4%...
s.
fp. ;4. " m. j;..
w j
s l
~
's
}'~
p' f. '. '
- '.g-k,
- h
..$ p. -
-pl.
y^
,s
. !qc- - -
- et t.
., ', '. :-c W.
n :
s' 4..
y
, 4 ' s.
.i.d.l 7
. f,, ' ut.% ilW
'tJ. - 4 e&w'; 4
.r-
-.,' N.
~y
'M.;.
7
^ '
' ' ;. ^ p )..
'; \\
h'..
.[
<:.-.";((
am m - -
eA.
m
_ - (;
- yj r~~, ? ? g.
.. i l-e f ;. [ y y >,s: 3x g
.4 g.
yg y (%1V+,
,y _ g..,,.,,
^
s, z
..s_.. M-y.. s, n. y ;,.. _ _ga.,
_p ys_.3,,,
~.;.;;y.
s, p. y s y g, h. i,;
4,;
i@
n' at
.a i f,'., y
- s f s.. -
s, W <
4,.
?
t
- J l q. (,;ffL'?..,Qf.. jh, em bE
'r..,
- f p.
4 f
y
. 3. y....e
.. y# -
1 w
=
lj f((]jn.,g g; (. 3. [.
[.
4-
,~,.. v y... ;
u
]
.