ML20028B424

Design Verification Test Rept,Internal Panel Control Wiring Separation Criteria.

ML20028B424
Person / Time
Site:	Limerick
Issue date:	09/01/1982
From:	Lees R, Smenke J, Sproat E PECO ENERGY CO., (FORMERLY PHILADELPHIA ELECTRIC
To:
Shared Package
ML20028B420	List: ML20028B419 ML20028B424
References
48503, NUDOCS 8211300372
Download: ML20028B424 (151)

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DESIGN VERIFICATION TEST REPORT Internal Panel Control Wiring Separation Criteria Limerick Generating Station, Units 1 and 2 Philadelphia Electric Company Research and Testing Division Report #48503 September 1, 1982 Prepared:

Edward F. Sproat, III P.E.

pietrica1Engie 3 ing Division i

d I Approved:

Supv.EngineehNuclearGenerationBranch

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Electrical Engineering Division E Approved:

Br h Engi r, Material Tests Branch Re arch a Testing Division n -

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//0/APa0FLODON AL \*

EDWARD F. SPROAT, Ill }

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'I 8211300372 821124 PDR ADOCK 05000352 A PDR

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I I Table of Contents I I. Summary and Conclusions Pace A. Wire Separation Criteria 1 B. Barrier Materials 3 C. Isolation Relays 4 I II. Test Program 1.0 Introduction 6 2.0 Design Bases 2.1 Assumptions of Failure Modes 7 2.2 Review of Existing Design 8 I. 3.0 Description of Test Facilities 3.1 Test Room 12 ,

3.2 Test Equipment 12 3.3 Test Configurations 13 l 4.0 Description of Test Procedt'res

'l 4.1 Determination of Source Conductor Currents 15 4.2 Single Conductor Tests 15 l

4.3 Multiconductor Tests 16 4.4 Isolation Relay Tests 17 4.5 Special Tests 18

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I 5.0 Test Results Page 5.1 Source Conductor Tests i 19 5.2 Single conductor Tests 23 l 5.2.1 Effects of Wire Size 25 l

5.2.2 Effects of Spatial Separation 26 5.2.3 Effects of Barrier Materiale 28 5.2.4 Variations related to Wire Manufacturers 32 5.3 Multiconductor Tests 35 5.3.1 Effects of Spatial Separation 36 5.3.2 Effects of Barrier Materials 36 3.4 Isolation Relay Tests 38 5.4.1 Agastat GP Series 38 5.4.2 Agastat 7000 Series 40 5.4.3 Cutler Hammer M-600 Series 41 5.5 Special Tests 42 III References 43 IV Appendices A. Test Procedure LGS-EE-1 B. Listing of Test Equipment C. Test Reports lI l

D. Photographs 6

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SUMMARY

AND CONCLUSIONS .

Philadelphia Electric Company (PECO) performed a series of tests during 1981 to determine the separation criteria to be applied for internal panel I control wiring at its Limerick Generating Statio.1. IEEE Standard 384-1981 Section 6.6.2 allows the use of other than six inches of spatial separation if a lesser distanca ca.s be shown to be adequate by analysis or test. This report documents the tests and the analyses performed and justifies the a separation criteria that are being used in the wiring of the Limerick control panels. -

I The tests were performed by trained PECO Research and Testing Division personnel in accordance with a test procedure (Appendix A) which was prephr*d by the Electrical Engineering Division. The test procedure was reviewed by both of these divisions as well as the Quality Assuiance Section. The test I procedure and records were also audited during the test program by QA to ensure the validity of the program. The test equipment used and its pertinent calibration information is given in Appendix B.

The test program had three objectives:

I e Confirm the adequacy of the internal panel control wiring separation criteria.

e Determine the adequacy of several barrier materials.

9 I e Confirm the adequacy of the relays being used as icola. tion devices

,, between Class lE and non-lE circuits.

• The program was successful in meeting all of the above stated objectives. The conclusions reached concerning these objectives are stated i below.

s A. 1. ire Separation Criteria Review of the wire separation test re.ults resulted in the I following conclusions:

1. The worst case failure of internal panel wiring for which the I separation criteria must protect adjacent wiring is a sustained overcurrent condition where the magnitude of the

!I current is just below that which will cause the wire to fuse open. This condition generates the greatest quantity of heat over a period of time and has the greatest potential as an ignition source.

2. The heat generated by the above condition for wire siz,o dAWG and smaller is not sufficient to damage an adjacent conductor

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as long as any size air gap exists between the two conductors.

In effect, separation is edequate as long as the overheated conductor does not come into contact with the wiring requiring j separation.

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3. Conductors which experience the overcurrent concliti'on' I described in 1. above will develop significant sag and shift of position due to failure of nylon wire ties. Separation criteria must take this movement into account.

4. Steel wire ties are successful in withstanding the heat generated by the conductors and limit conductor sag to 1 inch when spaced on six inch centers.

5. With no separation between the failed and adjacent wires,

, damage to the adjacent conductor will result only when I unusually high current levels are reached and maintained for a prolonged period of time, usually between five and twenty minutes. For this to occur, the primary overcurrent

[i protective device, i.e., the internal panel fuse, must fail to clear a high impedance fault. For circuits where the currents are limited by a backup fuse or where large magnitude fault currents are quickly cleared, either by a protective device or the self-fusing of the faulted conductor, no damage will result to the adjacent conductor.

~ 6. For a #14AWG SIS wire of the types analyzed, up to 75A continuous current through a faulted conductor will not

. generate enough heat to damage another #14AWG conductor which is in contact with it.

R 7. When Class lE circuits are routed in an enclosed raceway which is in proximity to a conduit containing either a redundant I Class lE or non-Class lE circuit of wire size #6AWG or smaller, no spatial separation is required between the raceways. This exception also applies to raceways carrying redundant instrumentation circuits.

]g 1W From the conclusions drawn above, the following internal panel control wiring separation criteria will be used at Limerick:

'W I e Separation between redundant Class lE wires will be six inches minimum.

e Separation between Class lE and non-Class lE wires will be six g inches minimum except where the Class lE wires are located i , above #10 AWG and smaller non-Class lE wire. In this case,

' one inch separation will be adequate.

e Where the above minimum spatial separation cannot be achieved, either of the following methods are to be used:

L 1. a) For redundant Class lE wires requiring separation, pB maintain a minimum of one inch separation and tie pg both channels of wires with stainless steel wire

[ ties every six inches to a distance where six inches lg of separation is achieved.

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E b) For Class lE wires requiring separation from I non-Class lE wires, maintain a minimum of one inch separation and tie the non-Class lE wires with stainless steel wire ties every six inches to a distance where six inches of separation is achieved.

2. A flame retardant barrier as discussed herein may be used I between the wires requiring separation when spatial separation ir not achievable.

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3. An engineering analysis of the specific circuits involved I shall be performed to justify exceptions to the above criteria. The analysis shall consider the magnitude and duration of a credible high impedance faulted condition and shall be documented by Project Engineering.

B. Barrier Materials Several tests were performed which were intended to prove the adequacy of a fiberglass sleeving as well as flexible steel conduit as materials which could be used to provide equivalent separation I -

where spatial separation is not possible. The results of these tests showed that both materials are more than adequate for their intended function under worst case conditions. The following

, conclusions resulted from review of the test results:

e Steel flexible conduit is adequate to contain the h?ating effects of power and control wiring inside control panels.

e The 1716 Hygrade Thermoflex 1200 fiberglass sleeving is adequate to limit the heating effects of control circuit wires I so that the wires inside the sleeving are not adversely affected,- regardless of the spatial separation between the faulted conductor and the sleeving.

e The sleeving will adequately contain the effects of a faulted conductor of size #10AWG or smaller.

Based on the above conclusions, the criteria for the installation of barrier materials inside panels are as follows:

1. Any power circuits orginating from DC or AC distribution 1 panels or motor control centers which require separation barriers must be enclosed in steel flexible or rigid conduit.

2. 1716 Hygrade Thermoflex 1200 fiberglass sleeving may be used as a separation barrier on control and instrumentatic3 wiring.

Where separation of Class IE wiring is required from non-Class IE wiring, sleeving may be installed on either wire for wire sizes #10AWG or smaller. When the non-Class lE wire is size

1. 6AWG or larger, the sleeving is to be placed on the Class lE I wire. Where separation of redundant Class lE wiring is required, the sleeving is to be applied on both channels of wiring unless both wires are #10AWG or smaller in which case I the sleeving can be placed on either wire.

E C. Isolation Relays Auxiliary relays are used at Limerick to provide isolation between Class IE and non-Class lE circuits. Coil to contact I isolation is utilized in most cases. In some instances, contact to contact isolation is also utilized. Several tests were performed on the types of relays which are utilized as isolation devices, i.e., the Agastat GP, Agastat 7000 Series, and Cutler Hammer M-600.

The test results for each of the above relays are summarized below

, Agastat GP This relay is the most widely used at Limerick for isolation purposes. The test shewed that isolation (greater than 1000M/V was maintained between the coil and contact I' circuits as well as between adjacent contacts in most cases.

. The failure mode of the relay is dependent on the magnitude of the current through the contacts. For currents of 70A and U I greater, the internal wiring of the relay contact arm will open in less than 1 minute. Between 30A and 70A, the plastic contact arm will melt at varying rates which will eventually h

cause the relay to become inoperable. Currents between 50A and 65A cause the most rapid relay deterioration. These current levels also cause deterioration of the wiring in the

@g relay base. This was a concern because the coil circuit

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socket wiring is in contact with adjacent contact socket wiring. The test results showed that despite heavy damage to I

the relay and its base socket, the coil circuit was unaffected by the overloaded adjacent contact circuit at normal operating voltage levels, jW h Because the relay has self fusing characteristics above 70A, wiring to the relay contacts will not experience sustained current greater than 70A. Testing proved that I g #14AWG wire, which is the smallest used for wiring to the 3 relays, can carry up to 75A continuously without significant

, insulation deterioration. For this reason, separation of the V wiring going to the relay coil from that going to the relay contacts is not required. This justifies the following exceptions to the separation criteria stated in Section IA:

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1. Non-Class 1E wires terminating on contacts of isolation relays need not be separated from other wires in the same panel, regardless of safety status or division.

2. Redundant Class lE wires terminating on a common isolation relay need not be separated from each other at l the relay terminals, h

The failure mode of the Agastat GP also places the following restrictions on its use:

The Agastat GP relay shall not be utilized in a circuit where it is wired in a configuration where all of the I following conditions occur:

1. A Class lE circuit and non-Class IE circuit are wired to a set of contacts on a common relay.

2. The contact of the non-Class lE circuit is closed during normal plant operation.

3. The contact of the Class IE circuit must change state to perform its safety function.

This configuration does not occur at Limerick.

Agastat 7000 The Agastat 7000 series relay is a pneumatic time delay I relay that is also used in some circuits to provide isolation between Class lE and non-Class lE circuits. The construction characteristics of the Agastat 7000 make it an ideal isolation I relay in that its contacts are widely spaced and a steel barrier plate separates the contacts from the coil. Also the coil is embedded in an epoxy covering. These features provide both total physical and electrical separation between contacts I and contacts from coil. No electrical breakdown between the coil and contacts were observed during the test.

I The Agastat 7000 also exhibited the same self-fusing characteristics as the Agastat GP with the metal contact arm fusing open in 7 seconds at 90A and 10 seconds at 70A. This provided justification for applying both of the aforementioned I Agastat GP exceptions to the separation criteria for isolation relay wiring to this relay.

Cutler Hammer M-600 The Cutler Hammer M-600 relay is used to provide isolation between Class lE control circuits and non-Class lE I annunciator circuits in motor control centers. It also exhibited ideal characteristics as an isolation relay by providing separate compartments for the coil and the relay h

y contacts. The measured breakdown vcitage between the coil and

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contacts was 16.5 kV with the breakdown voltage between adjacent contacts being 6.1 kV.

The M-600 relay also exhibited self-fusing characteristics. The contact circuit opened at 3 minutes and i 10 seconds with 75A during one test and at 2 minutes during another. Because #14 wire can carry this current continuously without significant insulation deterioration, it was determined that the M-600 relay also qualified for the k, aforementioned exceptions to the separation criteria between W Class lE and non-Class lE wiring. For this reason, the Class lE and non-Class lE wiring in the motor control centers auxiliary relay compartments do not require separation.

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I II TEST PROGRAM 1.0 Introduction The design of Limerick Generating Station was begun in 1970 by General Electric Company and Bechtel Power Corporation. Two years later, G.E.

I commenced the Limerick unique design for the reactor safety ar.d instrumentation systems. In early 1974, the decision was made to improve plant safety and reliability by changing the electrical system design from two divisions to four divisions. By this time, the building design had been I frozen and it had been decided to utilize the General Electric Power Generation C .ntrol Con. plex (PGCC) concept. These factors combined to limit the amount of panel space that would be available for the installation of electrical control and instrumentation components.

The potential for problems associated with the separation of the four safety-related divisions inside the PGCC was magnified when IEEE Standard 384-1974 and Regulatory Guide 1.75 were issued in 1974. These documents required that isolation devices be provided between Class lE and non-Class lE circuits and also imposed separation requirements between Class lE and I non-Class lE circuits that heretofore were required only between redundant Class lE circuits.

division plant.

These requirements in effect made Limerick a five As design progressed, it became obvious that it was impossible to meet the "six inches or a barrier" separation requirements between Class lE and non-Class lE internal panel wiring because of physical space limitations. A h

I Limerick-unique set of separation criteria for internal panel wiring was generated and implemented for the design and fabrication of the PGCC. These criteria were:

1. Maintain six inches separation or a flame retardant barrier between redundant Class IE divisions.

2. Maintain six inches separation where possible between Class LE and non-Class lE wiring. Where this is not physically possible due to space limitations, maintain at least one inch separation or provide a flame retardant barrier.

3. Auxiliary relays will be used as isolation devices.

Section 6.6.2 of IEEE 384-1981 allows the use of less conservative separation criteria than "six inches or a barrier" provided that tests or I

analysis are performed to establish adequate minimum separation distances.

The test program described in this report provided the experimental data necessary to analyze the adequacy of the Limerick internal panel wiring separation criteria and to justify their use.

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2.0 Design Bases 2.1 Assumptions of Failure Modes separation criteria are intended to protect redundant safety-related equipment from a common mode failure caused by a potential hazard. In order to determine what separation requirements are appropriate, the potential I hazard to be protected against must be identified. Section 6.6.2 of IEEE 384-1981 states: "The minimum separation distance between redundant Class 12 equipment and wiring internal to the control switchboards can be established I by analysis of the proposed installation." Internal to control panels, the only potential hazard that exists is an electrical failure which results in a sustained overcurrent condition on components and conductors. The design basis, then, for the panel internal wiring separation criteria is to protect against the effects of a worst case electrical failure internal to the control panel.

The panel internal wiring separation criteria are not intended to limit I. the effects of an external exposure fire in the vicinity of the panel.

Alternate shutdown systems designed in accordance with 10CFR.50, Appendix R I

provide the required safe shutdown capability in the event of an exposure fire which is assumed will destroy the entire control panel (Reference 2).

In order to perform a test program to verify the adequacy of the wiring I separation criteria, it was necessary to define the worst case electrical failure that could be postulated internal to a control panel. Certain assumptions were made regarding the failure mode to be simulated to ensure I that ample conservatism would be embodied in the test results.

assumptions used were consistent with those accepted by the Nuclear Regulatory Commission (NRC) for a test program conducted by Franklin The i

Institute Research Laboratories (FIRL) on conduit separation criteria at the Toledo Edison Davis-Besse Nuclear Power Station (Reference 3) . That test program made the following assumptions which were also used in the tests and analysis contained in this report:

1. The cable or equipment in the circuit develops a fault that is not cleared due to the failure of the primary overcurrent protective device.

2. The fault current level is just below the long-term trip point of the next higher level overcurrent device.

I 3. The impedance of the fault udjusts itself automatically to maintain the fault current magnitude at a constant level as the resistance of the wire increases due to heating.

4. There are no other loads on the same circuit which would cause the next higher level overcurrent device to trip.

5. The overloaded wire can maintain the continuous overheated status without the operator being aware of the condition.

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I The above assumptions are applicable to tests which simulate the effects I of wiring faults which cause sustained overcurrent conditions. Reference 3 showed that the heating effects of this type of failure with the above assumptions had the greatest impact on adjacent wires, therefore, this failt.re mode was chosen as the design basis for the Limerick test program.

2.2 Review of the Existing Design In order to determine the test parameters that had to be used to simulate the worst case conditions that could occur at Limerick, it was necessary to review the various sources of power to all control circuits.

These power sources can be categorized as follows:

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e 120 125 120 VAC from AC distribution panels VDC from DC distribution panels VAC from control circuit transformers in motor control centers and load center unit substations e 480-120 VAC,lp, 10 kVA transformer X516 to the Rod Position I Information System e 125 VDC from the DC motor control centers As the result of the review the worst case control power circuit was identified which is circuit 15 from the RPS/UPS 120 VAC distribution panels.

I It provides power to the Reactor Protection System (RPS) relay boards, C609 and C611. Figure 2-1 gives a schematic representation of this circuit.

The circuit is normally fed from the bypass transformer which in turn is I fed directly from a 480 VAC motor control center through a 100 A type HFB thermal magnetic breaker. When low voltage from the source is detected by the static switch, it automatically fast transfers to the inverter. The greater amount of fault current is available to the RPS circuits from the I bypass transformer becaqse the inverter is automatically current limited to 220A at reduced voltaJe. For these tests, it was assumed that the RPS circuits were fed from the bypass transformer which will supply 313A at rated I voltage.

In reviewing the Limerick design, the following observations confirmed l that the circuit in Figure 2-1 was indeed the proper circuit to use as the W

design basis worst case:

.g 1. Fault current available to control circuits powered from 480-120 i5 VAC control transformers in the McC's is linited by the transformers' internal impedance. For example, a 350 VA

transformer will limit the fault current on its secondary side to 40A. The worst case is the 500 VA transformer which is utilized in very few circuits. It will produce 115A.

2. The fault current available to control circuits powered from control circuit transformers in load centers is limited by the primary side fuse which will allow only 90A continuous on the transformer secondary side if the secondary side fuses (60A) fail to clear the overcurrent condition.

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5 l FIGURE 2-1 i

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3. Control circuits which receive power from either the AC or DC I

j distribution cabinets are fused within their respective consoles or '

relay boards with 5, 10, 15, and 20 ampere fuses. These fuses are

,. the primary overcurrent protective devices for these circuits. Tha I secondary, or next higher level of overcurrent protection for these circuits, is at the AC and DC distribution panels. The AC panels contain molded case circuit breakers, the largest of which is 30A.

I The DC panels and the inverter distribution panels use fusible switches. The largest fuse on these circuits (other than the design basis circuit in Figure 2-1) is 70A.

4. Fault current available to the Rod Position Indication System I (RPIS) panel C616 is limited by 3-30A fuses in parallel which are the backup overcurrent devices to an internal circuit breaker.

5. Fault current available in the DC control circuits powered from the DC motor control centers is limited by two sets of fuses in series.

The backup overcurrent protection is provided by the DC power circuit switch fuses, the largest of which is 40A.

6. For the circuit in Figure 2-1, the 100A fuse acts as the backup overcurrent protection device for all internal panel wiring except 8 the wires that connect the power bus to the fuse blocks and the two incoming #6AWG wires. The 100A KAB fuse will pass 120A continuously, therefore, it can be assumed that any wire in the I panel could experience 120A continuously while any #6AWG and bus wire could experience continuous currents up to 360A if the 100A fuse failed to clear. The 360A maximum continuous current level I was determined by calculating the amount of current through the bypass transfonner that would produce a 13% voltage drop. At that voltage, the redundant, safety-related undervoltage sensing relays would trip the RPS feeder breakers shown in Figure 2-1, I interrupting the current. The 13% takes into account the undervoltage relay tolerance.

It can be seen from the above review that the circuit selected is the worst case configuration because of the magnitude of fault current that is available continuously. The actual installation of this circuit uses steel conduit to encase the power conductors from the AC panel to the RPS Al bus.

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I This is typical of all power circuits entering the PGCC from AC and DC distribution panels to the internal panel fuses. Flexible steel conduit is used for this purpose inside panels and PGCC floor sections.

The analyses presented above assume that the normal circuit power source provides the fault current. A condition can be postulated, however, which could cause higher available fault currents than those determined above. At Limerick, 480V power and control cables are routed in common cable trays. As a result, it can be postulated that an exposure fire could affect the cables in a tray whereby a 480V power circuit conductor will hot short to a control I conductor of an adjacent cable in the tray. The power circuit source then becomes the fault current source for the control circuit wiring.

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The largest thermal magnetic trip breaker feeding a 430 V power circuit I in a tray is a 200A frame breaker with a thermal trip rating of 150A. This size breaker would trip before the fault current reached the 360A current determined abover however, it would pass continuously more than the 120A that was determined for the smaller size wires. It is therefore necessary to I assume that wires smaller than #6 AWG will experience the highest current which will pass continuously without the wire burning open. These current levels were determined by the tests discussed in Sections 4.1 and 5.1 and I used in the remainder of the test program.

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l 3.0 Deceription of Test Facilities 3.1 Test Room All tests were performed in the laboratories of Philadelphia Electric 1 Company at the main office. A room in the Materials Testing Lab was utilized ,

because of several desirable features. The room measures 19.5 ft. by l 10.5 ft. with glass windows extending along one entire wall which allow constant observation (See Figure 3-1) . The room is also equipped with an exhaust hood. This was utilized to clear the room of the smoke and fumes generated by the overheated wires during the tests. The exhaust fan is a I size which minimizes air velocity through the room which was necessary to simulate panel internal conditions. Observations of the smoke produced 7

I during the tests indicated that the heat generated was radiated in a normal distribution and not directed towards the exhaust fan. Ambient temperature in the room was monitored by thermocouples in several different locations to detect any measurable heat produced. It is concluded that the room reaeonably simulated the environment internal to a control panel.

3.2 Test Equipment The equipment utilized for performing all tests and measurements is the property of Philadelphia Electric and is controlled in accordance with Research and Testing (R&T) Division Procedures.

I All equipment is periodically calibrated and has calibration stickers attached which indicate the dates when the last calibration was performed and when the calibration expires. The sticker also indicates the equipment accuracy and the initials I of the calibration technician. All calibrations are performed in accordance with approved R&T Division procedures by trained personnel. All testing was also performed by trained R&T Division personnel.

Current magnitudes of up to 360A were required for the test program.

The current was supplied by a General Electric 75 kVA induction regulator and varied by adjusting the output voltage. Current was measured through a current transformer on the output lead of the regulator.

A Leeds and Northrup multi point recorder was used to measure and record I pertinent test data, i.e., current, voltage, ambient temperature and conductor temperatures.

I A complete listing of all test equipment used and their pertinent data is contained in Appendix B.

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l 3.3 Test Configuration I The basic configuration that was used for all separation tests was two parallel conductors, each approximately six feet long, supported on the rungs I of a cable tray which was turned on its side (See Appendix D photographs) .

One of the conductors was termed the source conductor and was connected to the induction regulator. It was subjected to high magnitude currents to tI

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simulate high impedance fault conditions. The other conductor was termed the target conductor. It carried current of either SA for wire sizes #20 and

1. 18, or SA and 15A for #14AWG and was monitored for current continuity and 9

temperatures during the test. The effects of the heat released by the source I conductor on the target were evaluated after the test via DC resistance measurement and AC high voltage withstand capability, fl Six foot lengths of wire were tested so that the end heat sink effects of the wire terminations would not affect the test results.

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I 4.0 Description of Test Procedure (Appendix A) 4.1 Determination of Source Conductor Currents Tests 43, 44 and 45 were performed at the beginning of the test program.

I The purpose of these tests was to determine the maximum continuous current that could be carried by the three wirej sizes used as source conductors, I i.e., #6, #10 and #14AWG. The total I R losses of the source conductor integrated over time are maximized at this current level and therefore it was assumed that the failure mode caused by that current would be the worst case in terms of its effects on the target conductor. This assumption was substantiated in Reference 3 and in our subsequent testing where the source I current was increased to the point of the conductor failing open.

l The tests were conducted by passing the specified current through a Ks length of the specified size wire. The current was held constant during the test. Temperatures of the conductor and its insulation were recorded via thermocouples during the test and the test was continued until the I temperatures stabilized or the condactor failed open. The highest current level tested which did not cause conductor failure was used in the later separation tests.

The results of the single conductor maximum heating tests are discussed in Section 5.1.

4.2 Single Conductor Tests I

Tests 1 through 28 were intended to identify the failure modes and characteristics of several sizes of wire, the effects of spacing between the source and target on these failure characteristics, and the adequacy of barrier materials to prevent propagation of the failure of the source to the l target conductor. Target conductors sizes in the tests were #20, #18 and e #14AWG, These sizes were selected because they are the predominately used sizes in panels and because they have the least insulation thickness, thereby I making them more susceptable to insulation failure due to an adjacent heat source.

I'm The tests were conducted by paralleling the source and target conductors lJ ,

over a six foot length. The target was energized to carry a 5 ampere current at 125 VDC. The source was energized to the current levels found in the

, tests described in Section 4.1. Each test varied the spacing .between the i

'W l target and source or specified the use of a barrier material with no spacing.

The current through the source conductor was maintained at the specified

-l current levels as the resistance increased to add conservatism to the test.

The current through the target was constantly monitored for any variations.

,I Temperature of the target was monitored via thermocouples at several i' locations including the expected hotspot in the middle. Average temperature ll of the target was also monitored by recording the voltage drop across the l' conductor. The test duration was based on the target temperatures observed, i.e., the test was terminated after the target temperature stabilized for a period of time or began to decrease.

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I To cotablich tha cdequ:cy cf th2 b rrisr matsrial, csvarel Both steel flexible I

configurations and installation methods were tested.

conduit and 1716 Hygrade Thermoflex 1200 fiberglass sleeving were used and the sleeving was tested as a barrier on both the source and target conductors. The conduit was only used on the source as that was the most I conservative case. Several configurations for the sleeving were tested to give maximum flexibility for different installations ~.

2g The acceptability of each configuration tested was determined on the basis of the following acceptance criteria:

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l. The target conductor must maintain its current carrying capability.

) 2. After the test, the resistance of the target insulation measured at 500 VDC must be at least 100 megohms.

3. The target conductor should withstand an AC dielectric test for one minute at 2.2 kV for #20 and #18AWG, 4 kV for #14AWG wire.

The continuity test is the most important of the above criteria as it determines that the target conductor can perform its intended function. The DC resistance test is also important because it is a measure of the integrity of the insulation which is required to prevent the target from shorting to other wires or panel steel. The 500 VDC level of the measurement provides added conservatism as the panel internal wires are for low voltage I instrumentation and 120 VAC or 125 VDC circuits only. The AC withstand test provides n measure of the degree of degradation that was experienced by the target during the test. The voltage levels selected were based on the levels to which the manufacturer subjects new wire prior to shipment and were not I intended to represent voltage levels that would actually be experienced at Limerick. For this reason, if a test configuration passed the first two acceptance criteria, it was considered acceptable.

The locations on the target where the DC resistance and the AC withstand measurements were made were determined for each test based on visual observations. The location or locations which experienced the greatest I temperatures andc*or discoloration and physical degradation were selected for the test measurements and noted on the test report.

The results of the single conductor tests are discussed in Section 5.2.

4.3 Multiconductor Tests Tests 32 through 40 involved the use of multiconductor configurations as source conductors to verify that the criteria resulting from the single conductor tests are adequate when failures occur in multiconductor cables.

I Two source conductor configurations were tested: 2 - #14AWG conductors in a 7 conductor #14AWG Rockbestos cable and 2 - #6AWG single conductor G.E.

Vulkene SIS wires together. These were selected as they are two prevalent I

multiconductor configurations inside control panels and because the 2 - #6AWG source conductors represent the worst case source as shown in Section 2.2.

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l The test procedure and measurements made for the multiconductor tests I were the same as those for the single conductor tests with the exception of the source conductor. For the #14 multiconductor tests, two adjacent conductors were selected from the cable and paralleled. 180 amperes total or I 90 amperes each was used as the source current.

were connected in series and 360 amperes was used as the source current.

The 2 - #6AWG conductors This configuration represents the worst case circuit shown in Figure 2-1.

The determination of the adequacy of the barrier materials to resist the failure of the multiconductor configurations was another objective of this I series of tests. Both flexible aluminum and steel conduit were tested as barriers to contain the failure of the 2 - #6AWG SIS wires but only flexible steel conduit is used internal to the panels at Limerick. Fiberglass sleeving was tested as a barrier for the #14 multiconductor cables both on I the source and on the target.

The results of the multiconductor tests are discussed in Section 5.3.

4.4 Isolation Relay Tests i Section 7.2.2.1 of Reference 1 requires that devices which provide isolation between redundant Class lE circuits or between Class lE and non-Class lE circuits be tested so that the capability of the device to perform its isolation function is demonstrated, considering the levels and durations of fault current and transient voltage. While Limerick has not cornitted to meeting the requirements of Reference 1, a series of tests were performed on three types of relays which are used as isolation devices to determine their suitability: Agastat GP, Agastat 7000 and Cutler Hammer M-600.

The two objectives of the isolation relay tests were: 1) to confirm l that the Class lE circuits would not be degraded below an acceptable level by any failure of non-Class lE or redundant Class lE circuits connected to the isolation relay, and 2) to confirm the adequacy of the Limerick separation criterion which allows no separation between wires terminating on a common isolation device in the vicinity of that device. To meet the first objective, the breakdown voltage between adjacent contacts and between the coil terminals and adjacent contact terminals were measured. In addition, I sustained overcurrents were passed through several relay contacts both normally open and normally closed. The resulting damage to the relay and any g effects on relay operation were recorded. The second objective of the g isolation tests was also satisfied by these overcurrent tests by measuring the current levels required to open circuit the isolation devices and comparing them to the levels required for wire damage.

After the overcurrent tests, DC resistance measurements were made between contact terminals and coil terminals to confirm that the isolation capability of the relay was still adequate.

Several relays of each type were tested and the results are discussed in Section 5.4.

f_ ~"-

I 4.5 Special Tests As the test program progressed, certain phenomena were observed which I required further study. As a result, certain special tests were performed which were not part of the original test plan.

Sag tests S-1 through S-4 were performed to quantify the amount of sag I that various size conductors would experience with a given amount of current and wire tie spacing. These tests were required when it became obvious that single conductors would experience larger than expected displacements due to l

j

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thermal expansion and nylon wire tie failure when subjected to overcurrents.

I The results of these tests are discussed in Section 5.5.

Test 23 was repeated to test the two wire types that are used I predominately, i.e. G.E. Vulkene SIS and Rockbestos Firewall III SIS. Tests 23V and 23R respectively tested the characteristics of these two wire types to determine if their insulation system differences would change the results I of the single conductor tests. These test results are discussed in Section 5.2.4.

Tests 24A and 24B were performed to confirm the capability of the I fiberglass sleeving material to contain the open circuiting effects of #14AWG wire. The test results are discussed in Section 5.2.3.

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8 5.0 Test Results This section of the report provides the results and analyses of the I tests performed during the test program. It also provides the justification of the conclusions drawn in Section I of this report.

I 5.1 Source conductor Currents As discussed in Section 4.1, the purpose of tests 43 through 45 were to determine the maximum current which various size conductprs could carry continuously, thereby maximizing the heat generated by I R effects which I could damage adjacent wires. These tests were all performed using General Electric Vulkene SIS wire.

Test series #45 on #6AWG were performed first. Current magnitudes of 150, 200 and 360 amperes were used. The 360 amperes was carried continuously I for twenty four minutes when the test was terminated while the average conductor temperature measured via voltage drop across the conductor peaked at 1671*F after nine minutes. As 360A was the maximum continuous current level that could be expected per Section 2.2, this current level was used for I all tests where the source conductor was #6AWG. At this current level, the wire started smoking after 1-3/4 minutes and the insulation began falling off af ter 6-3/4 minutes. Maximum conductor temperature was reached after 9 I minutes and the conductor cooled to 1300*F by the end of the test due to the deterioration of the insulation and the resultant exposure of the conductor' to air. Flames were observed during several of the tests. Figure 5-1 shows the average conductor temperatures versus time for #6AWG wire at the various I current levels tested.

Test Series #44 was performed on #10AWG wire at 100, 150, 175 and 200 I amperes. 175 amperes was the maximum current carried continuously while the conductor reached a peak average temperature of 1556*F after seven minutes.

The final average temperature stabilized e': ll78'F. The insulation suffered I severe degradation and produced significanc quantities of smoke. No flame was observed during the tests. Figure 5-2 shows the average conductor temperature vs. time for #10AWG wire at various current levels tested.

Test series #43 was conducted on #14AWG wire at 50, 75, 90 and 100 amperes. The maximum current which was carried continuously was 90 amperes and the conductor reached a peak average temperature of 1225'F. At this

'l current level, the insulation produces smoke, chars and finally powders. No iW flame was observed during any of the tests. At 75A, the conductor peak I average temperature was 510*F with no discernible insulation deterioration.

Two tests (43D & 43d) were run at 100 amperes, one with the conductor I supported every nine inches, and the other with the conductor only supported at the ends of its six foot length. The purpose of this was to determine if I

the large amount of seg of about five inches that occurred when the conductor was overheated would cause it to fail open prematurely. No discernible I difference in the failure modes were observed and in fact, the supported conductor actually failed approximately thirty seconds earlier than the lg unsupported conductor. This difference is considered to be insignificant.

jg Figure 5-3 shows the average conductor temperature versus time for #14AWG wire at various current levels tested.

l lI I (

I I FIGURE 5-1 l

l AVERAGE CONDUCTOR TEWPERATURE VS. TIME

1. 6 AWG WIRE lI l 1800 -

3 I

1500 lI 300 I

I -

1000 -

f I

.I 200 500 -

I 20e I

I O -

I g ,

10 20 30 TINE (NINUTES)

I

-2 I

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I FIGURE 5-2 AVERAGE CONDUCTOR TEMP. VS. TIME

1. 10 AWG WIRE '

l ' ~

CIRCUlf OPENED A

1800 200

.g .

I i,00 -

I I ,,,,

3 i,0 i g j i. -

[

t I

,00 I .

I I

I I i 10 20 30 TIME (MINUTES) l 1 _ - .

I -

I FIGURE 5-3 g AVERAGE CONDUCTOR TEMP. VS. TIME

1. 14 AWG WlRE I

CIRCULI OPENE0 100A (43d) 1900 -

CIRCU!T OPENEO 100A (430) 1500 -

I A

90

/ .'

5 m 1000 -

I I

'I I 000 s I .

I , e I

1 I O-10 I

20 l

30 TINE (NINUTES) l

I -

A general observation of the failure modes of the single conductors I tested is that when the p rrent magnitude is not quite enough to cause conductor failure, the I R heating effects will increase the conductor temperature to a maximum which is below the melting point of copper and then the cooling effect of air on tge conductor due to the insulation I deterioration will override the I R heating and cause the temperature to fall. At this point, a small incremental increase in current will cause a large increase in conductor temperature and could cause conductor failure.

W Insulation ignition was only observed during the testing of the #6AWG ,

wire both within conduit and without (See photo D-1) and once during Test 18

< when the insulation of a #10 AWG wire in sleeving ignited on the portion of the wire outside of the sleeving. At no time during the test program did any  :

] wire smaller than a #6AWG which wt i not in conduit or sleeving experience ignition of its insulation, either when it was tested as a source or as a target conductor.

The explanation of why this occurs only for the larger conductors can be

, found in Figure 5-4. The trends show that the larger conductor will experience higher temperatures for longer periods of time. The sustained y

high temperature causes a deterioration of the insulation adjacent to the

' conductor which in turn generates gases under pressure. The offgassing of the insulation breaks down its chemical makeup and as the decomposed insulation is exposed to higher temperatures for longer periods of time, the material will ignite. This ignition is initiated by the ignition of the I combustible gases from the insulation as documented in Reference 4. The addition of sleeving or conduit around the conductor helps maintain the elevated temperatures. Apparently, the smaller conductors cannot sustain I this elevated temperature long enough to allow sufficient concentrations of gas to accumulate to cause ignition. This would explain the observation that no ignition takes place when high fault currents cause conductor failure in short periods of time, even though temperatures as high as the melting point of copper were reached. This observation was common to both types of wire i tested, i.e., GE Vulkene SIS and Rockbestos Firewall Nuclear SIS. The

! insulation on both types of wire is cross-linked polyethylene which is flame i retardant and qualified to IEEE Standard 383 flame test requirements.

Based on the above, it is concluded that electrical failures will not l

l I cause insulation ignition on wires with flame-retardant cross-linked polyethylene insulation of sizes #10 and smaller as long as they are not enclosed in barrier materials.

5.2 Single conductor Tests

[ Tests 1 through 16 tested various sizes of single conductor wire with

and without fiberglass sleeving at various separation distances. While specific observations and conclusions are discussed in the following l sections, certain general observations can be made from the test results.

1. In all tests, if the source conductor did not come into contact j with the target, no damage was sustained by the target. For this I reason, the separation criteria should be such that it can be f assured that the two wires requiring separation will not come into j direct contact.

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I FIGURE 5-4 SOURCE CONDUCTOR AVG. TEMP. VS. TIME I 19oo -

(ALL WIRES GE YULKENE SIS)

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I iooo -

I -

.. . n oo.

I ,ioin g ,i o n o' I _-

n 1000 l

I I

I ooo _

I I

I I I l o in to I

30 g TINE (NINUTES)

I

2. Under sustained overcurrent conditions, the temperatures reached by the conductor may cause the following:

I e Failure of nylon wire ties i I e Significant conductor sag l

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/I These two mechanisms could combine to cause significant movement of the hot conductor during its failure process and thereby cause damage to adjacent wires. The separation criteria should either be written to prevent the wire from moving into contact with a wire I requiring separation from it, or they should provide for the installation of an appropriate barrier material.

I 3. Hygrade Thermoflex 1200 fiberglass sleeving is an adequate barrier material which can prevent propagation of a failure between adjacent wires even when no spatial separation exists.

The above general observations are substantiated by the test reports in Appendix C and discussed in greater detail in the following sections.

5.2.1 Effects of Wire Size The single conductor tests varied the size of both the target and the I source conductors to evaluate the effects of wire size on the test results.

The quantitative results of varied wire sizes on source conductor temperature were discussed in Section 5.1. For the currents used on the source conductors in the single conductor tests, Figure 5-4 shows temperature versus I time for each size conductor. It can be seen that the larger conductor will 9 'nerate more heat because of the greater magnitude of current that it carries.

The selection of target wire sizes to be tested with each e ~.e source was based on the actual wiring configuration shown in Figure 2-1. #18AWG wire is the smallest size utilized in the C609 and C611 panels, with the

,I najority of wiring being #14AWG. Most single conductor tests utilized #18 or

1. 14 AWG wire for this reason. Several tests were performed with #20AWG wire because it is used in some low voltage applications in control panels.

It immediately became obvious during the tests where no separation was provided that regardless of target wire size, the heat generated by any size I of source conductor was sufficient to damage the target conductor if the two came into contact. The test results did not reveal any configurations where the size of the target conductor affected the outcome of the test.

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5.2.2 Effects of Spatial Separation As noted above, the lack of any spatial separation between the source and the target conductors provided a means by which the failure of one I conductor could cause the failure of an adjacent conductor. Tests 23, 23R, 23V and 23-14/14 all were conducted with a #14AWG source and with the target conductors in contact. In tests 23, 23R and 23V, 90A was the source current I and in these cases, the #20 Vulkene, the #14 Rockbestos, and the #14 Vulkene wires respectively all passed. There was some visual discoloration of the insulation (see photos D-2 and D-3) but all acceptance criteria were met, including the hi-pot test. Test 23-14/14, however, was a repeat of test 23R using 100A as the current through the source. At this higher current level, significantly higher conductor temperatures were reached in approximately four minutes. This resulted in the gross failure of the target insulation I which was obvious by visual inspection. Based on this result and the capability of larger conductors to generate greater temperatures as discussed in Section 5.1, it is concluded that some amount of spatial separation must be maintained.

To determine the amount of spatial separation that would be required to I prevent propagation of a failure to an adjacent conductor, several tests were I performed with various initial separations provided. Test 3 used a #6AWG source conductor supported at nine inch intervals by steel wire ties and with one inch separation from a #18 AWG target. The target was located below the I source so that it would be exposed to a greater amount of heat as the source conductor sagged towards it. During this test, the temperature of the target insulation rose from 84.2*F to a peak of 197.6*F after ten minutes. The post I

test acceptance criteria were easily met and the 40 kV breakdown voltage that was measured on the target showed that the target insulation indeed did not suffer any adverse effects during the test. Hi-Pot measurements were made on the target at those areas which experienced the greatest amount of I discoloration due to the heating effects. These results indicated that one inch separation is more than adequate and in fact, a lesser separation is justified because less than one inch of separation occurred as the source I conductor sagged towards the target. It was therefore concluded that air provides sufficient thermal insulation to prevent the damage of an adjacent conductor of any size by an overheated conductor as large as #6AWG. This conclusion was supported by observation and measurements made during subsequent separation tests.

An unexpected phenomenon was observed during the single conductor tests

,l which showed that the one inch separation criteria between Class lE and W non-Class 1E wiring would not be adequate: Extensive conductor sag was observed on the source conductors. In addition, the heat generated caused failure of the nylon wire ties used to secure the source conductor to the

,I test fixture, regardless of the conductor size. These two mechanisms combined to allow the source conductor to experience significant movement; in some cases up to five inches downward as in test 15B. This five inch sag is considered to be larger than that which could be expected to occur inside a I panel because it occurred on a six foot long, freestanding horizontal conductor which is not representative of the wiring configuration inside I congested control panels. Based on the significant movement of the source conductor that was observed, it was concluded that the one inch separation criteria between IE and non-lE wiring would have to be abandoned and that six I

inches of separation would be required.

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l I An exception to the six inch criteria proved to be acceptable. When the source conductor was located below the target, one inch of vertical separation was adequate because as the conductor sagged, more separation was I obtained and it was not possible for the two to come into contact. For this reason, the Limerick separation criteria allow only one inch separation between Class 1E and #10 AWG and smaller non-Class lE wires when the Class lE j

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I wiring is located above the non-lE wiring.

Because it is necessary to prevent the faulted conductor from coming into contact with the adjacent conductor from which it requires separation, I an alternative means had to be found to prevent this contact when the required spatial separation cannot be achieved. Because the failure of the nylon wire ties permitted the large displacement of the source conductor, I stainless steel wire ties were utilized to limit the conductor movement. All sizes of source conductors were secured with these wire ties during various tests. No wire tie failures were experiencrJ. By using these steel wire ties, conductor movement was limited to vertical upward and downward displacements caused by conductor expansion during the tests. The maximum displacements that could occur using these steel wire ties were mearured for various size conductors during special tests which are described more fully I in Section 5.5. Displacements of one-half of an inch both up and down were observed. Based on this information, the Limerick separation criteria allow one inch separatien between redundant Class lE wiring or between Class lE and non-Class lE wiring when the conductors that can be considered as the source conductors are tied in place using stainless steel wire ties.

The test results discussed in this section translate to tf e following criteria:

Wher redundant Class lE wires are less than six inches apart, one inch I separation is adequate provided both divisions of wiring are secured by stainless steel wire ties every six inches to a point where six inches of separation are achieved. Where separation of Class lE from non-Class

=

I lE wiring is required, one inch of separation is adequate if non-Class lE wiring is secured by stainless steel wire ties every six inches to a

, point where six inches of separation is maintained, or if the Class 1E l wiring is located above non-Class lE wiring and the non-Class lE wiring l

is #10 AWG or smaller.

All tests described in this section were performed using a sing 3e

'g conductor SIS wire suspended in air. Bundles of wires were not tested but 3 the results of these tests are deemed applicable to wire bundles for the following reasons:

e M eause wires of only the same division are bundled together, the failure of an adjacent wire in the same bundle as the failed source conductor is acceptable.

e When the failed conductor is located on the outside of the bundle, it will be predominately surrounded by air and, therefore, can be lg expected to respond as a single conductor.

lW e When the failed conductor is located in the bundle and is surrounded by other wires, it can be expected to respond similarly I to the conductors in the multiconductor tests described in Section 5.3.1.

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I 5.2.3 Effects of Barrier Materials The results discussed in Section 5.2.2 showed that spatial separation of wiring is required to ensure that the failure of a wire due to sustained I overcurrent will not propagate to an adjacent wire. Because of the space and design limitations of control panels, the space required for separation is not always available. For this reason, it is necessary to use materials

~g which will act as barriers to prevent propagation of electrical failures. Up g *o the time of this test program, only flexible steel conduit had been used g as an encapsulation barrier for internal panel wirfr.g. Because of its bulkiness, it was decided to try to qualify a -leeving material which would provide the same degree of protection but with easier installation and less space.

g Flexible steel and aluminum conduits were tested to measure their

, g adequacy as barriers. The results of these tests are discussed in Section 5.3.2 because the tests utilized multiconductor source wiring to provide g

worst case configurations.

A fiberglass sleeving was tested as a batrier material ir. the single 5 conductor tests. Tests were performed by plading the sleeving on either the

[l source or the target conductor and were repeated using various wire sizes.

W The sleeving used in all tests was Hygrade Thormoflex 1200 fiberglass e sleeving manufactured by the Markel Corporation of Norristown, PA.

The first configuration tested was -in Test 5 where sleeving was installed on the #6AWG source conductor which carried 360A. A #18xC, target was placed in contact with the source. At approximately.10 minutes into the test, the source conductor reached a recorded average temperature of 2079'r and burned through the sleeving. "he target conductor was severely damaged and this configuration was judged to have failed by visual observation.) The

I recorded temperature of 2079'F for the conductor is 98'F above the mel' ting point of copper of 1981*F. In several later tests, temperatures above 1981*F were again recorded, all on source conductors which were encapsulated with I fiberglass sleeving. A possible explanation for this discrepancy is as follows

The conductor temperature was calculated from measured variations in voltage drop across the conductor due to resistance changes. As the copper began to change from the solid to the liquid phase, resistance of the I conductor continued to increase, thereby indicating a higner temperature.

Because all observations of this discrepancy occured when sleeving was on the conductor, the sleeving may have also contributed to the error by keeping the I molten conductor formed for a longer period before failure by providing support to the conductor. Further investigation into the nature of the temperature discrepancies is beyond,the scope of this test program and not l deemed relavent to its results.

Test 7 was next performd with basically the same configuration except

, that the sleeving was placed on the target conductor. For this test, three different methods of installation of sleeving were tested:

l 1. Sleeving was installed by inserting the wire through the sleeving tube. Ends were secured with fiberglass tape.

2. Sleeving was cut length rise and wrapped twice aroung the target.

Ends were secured with fiberglass tape.

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3. Sleeving was cut lengthwise ar.d wrapped with a 1 lap installation and then wrapped with fiberglass tape (3M Scotch #69) .

I The results of this test were narkedly different from the results obtained in Test 5. The sleeving in this test configuration acted as an additional high temperature insulation on the target conductor and prevented l

I I the source conductor from penetrating the insulation system and shorting to the targets whereas in Test 5, the sleeving could not contain the molten copper of the melting #6AWG conductor. The average so9rce conductor temperature reached 1682*F in this test. None of ihe above installation I methods experienced a breach of the fiberglass sleeying during this test.

Only installation method #2 failed to pass the acceptance criteria and that was only a marginal failure at one of the two locations tested which I experienced the highest temperatures during the test. Insulation resistance at that point measured 95 megohms at 500 VDC and AC breakdown voltage was 1.8 kV, only 400 volts lower than the 2.2 kV acceptance level. Rated current of I 5A was carried continuously through the test. Visuel nost test observations showed that the thermoset insulation of the 41BAWQ tacget was significantly damaged by heat during this test. The sleeving in effect became the insulation system for the target and performed in an adequate manner.

Test 5 showed that sleeving could not be used on a conductor as large as

1. 6AWG. Because #10AWG wire is used extensively in the Class lE switchgear I relaying circuits, Test 18 was performed to determine if the sleeving could contain the effects of a failure of a #10 AWG wire. The test was performed using 200A as the source conductor because that current level produced the nighest temperatures as shown in Figure 5-2. The source conductor eventually failed open inside of the sleeving. The sleeving material, however, was not

• breached at any time during the test. The #18 AWG target conductor was attached to the source conductor with steel wire ties and was compressed I against the sleeving. Post test examination revealed that the insulation on the target was extensively damaged at these contact points; however, adjacent to these contact points' where less than ene-quarter inch of separation I existed during the test, the insulation passed all post test acceptance criteria and the target carried SA continuously. Actual installations in panels vary from this configuration in that wires of different divisions are not bundled together; therefore, wires with sleeving would not be bundled I with wires from which they require separation. Because the results of Test 18 showed that extremely efficient heat transfer via direct wire to sleeving contact with pressure is required to damage the. target wire with a #10 AWG I source, the separation criteria allow the use of sleeving on any wire size

1. 10 AWG and smaller.

I In order to further investigate the ability of the fiberglass sleeving to contain the effects of a failing or failed conductor, a series of cdditional tests were run using #14 AWG wire as the source. Tests 24A and 24B used different sleeving installation configurations and 90A as the source I current. When the sleeving was placed on the source conductor, the heating characteristics of the wire were changec s substantially. Figure 5-5 shows a comparison between the average con & actor temperatures measured for two #14AWG I wires both carrying 90A, one with sleeving and one without. It can be seen that the sleeving acts as a thermal insulation and accelerates the heatup and eventual failure of the wire. Even with these higher temperatures and the eventual failure of the conductor, the sleeving was not breached in either I Test 24A or 24B.

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I FIGURE 5-5 CONOUCTOR AVG. TEMP. VS. TIME AT 90A WITH AND WITHOUT SLEEVING (ALL WIRES ROCKBESTOS SIS)

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I 2500 -

l l circuli 2000 PENE0 - 3 WITH !LEEVING l

I (TEST 248) 1500 -

I o' W/0 SLEEVING l 1000 -

(TEST 23V)

I I '" -

'I l 1 I I O 5 10 15 I TIME (MINUTES) 5

I In Test 24A, the sleeving had two installation configurations, i.e.,

I 1) the sleeving slipped over the wire and, 2) the sleeving split and wrapped with a 1 lap and taped with fiberglass tape. Neither configuration was ruptured during the test.

Test 24 (see photos D-4 and D-5) tested a #14AWG source with 90A and

1. 20AWG target with 5 amps current and no separation. The source conductor had sleeving installed on it. The test continued for twenty minutes with the NI peak target insulation temperature reaching 522*F. The post test examinations indicated that no breach of the sleeving occurred and that the target conductor passed all acceptance criteria tests.

Test 25 used sleeving on a #20 AWG target conductor with a #14 AWG source conductor carrying 90A. The target carried 5A continuously and was in E

I I full contact with the source during the test. This configuration passed all of the acceptance criteria.

j g Test 25A (see photos D-6, D-7, Ds8) was performed with a #14AWG source g and a #18 AWG target in contact with no separation and sleeving on the target. A source current of 100A was used. This configuration also passed all acceptance criteria however, the source conductor still did not fail so I it was decided to repeat the test at a higher current level. Test 25C used the same configuration with 125A source current. This test proved to be the worst case sleeving test for single conductors for the following reasons:

1. Source conductor temperature reached a peak av-rage temperature of over 1900*F and maintained that level for over ten minutes prior to failure which came 19.6 minutes into the test.

2. During the test, the center of the source sagged and came to rest on the target sleeving. The sleeving was therefore directly in I contact with a glowing #14AWG conductor for approximately 18 minutes. (See photo D-9) ,

After the source burned open, the following observations were made (See jI photo D-10):

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1. The fiberglass sleeving had not been breached.

f I 2. The target conductor continued to carry the SA current throughout the test.

3. The lowest insulation resistance reading at the point where the source had rested on the target during the test was 145 megohms at 500 VDC.

4. The AC breakdown voltage at that point was 1.5 kV.

I Based on these results, it is concluded that the Thermoflex 1200 fiberglass sleeving is an adequate barrier material for preventing the propagation of electrical failures to adjacent conductors. The sleeving will I continue to exhibit these same insulation properties through the life of the plant because it contains no organic materials which could degrade via an aging process.

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I When the test results of 25C are reviewed in conjunction with the results of the other tests described in this section, the following criteria for the use of the fiberglass sleeving are justified:

Sleeving may be used on control and instrumentation circuits only.

Power circuits which originate from AC or DC distribution panels or motor control centers which require separation barriers must be enclosed in steel iI flexible conduit (See Section 5.3.3). When separation of Class lE wiring is required from non-Class lE wiring, the sleeving may be installed on either wire for wire sizes #10AWG and smaller. When the non-Class lE wire is larger than #10AWG, install the sleeving on the Class lE wire. Where separation of redundant Class lE wiring is required, sleeving in to be installed on both 7 channels of wiring unless both wires are #10AWG or smaller. In that case, the sleeving need be applied to only one division of wire.

" 5.2.4 Variations Related to Wire Manufacturers In order to determine if the separation criteria derived from this test q program would be sensitive to the types of wire that may be used, it was decided to perform tests using the two types of wire that are predominant in I

control panels at Limerick. Both General Electric Co. Vulkene SIS and Rockbestos Firewall SIS were used in a number of tests. Both types of wire have stranded copper conductors with 600 Volt cross-linked polyethylene

)'

thermoset 30 mil insulations. Both have been qualified per IEEE Standard 383-1974.

Two other types of single conductor wire are used in the Limerick I control panels. Several panels have a few circuits wired with Tefzel insulated 600 V wire. The Tefzel wire represents much less than 1% of all PGCC wire and was not tested because Tefzel has the same maximum operating I

temperature as cross-linked polyethelene, approximately three times the tensile strength, better dielectric constant and better flame resistance (Reference 5). It also has a self-ignition temperature approximately 330*F higher than flame-retardant cross-linked polyethylene. This wire is also qualified to IEEE 383-1974 and therefore would exhibit the same if not better flame retardant characteristics as the test specimens. In a few instances

1. 12AWG THHN wire is used to provide non-Class lE 120 V feeds to interior I panel light fixtures and utility receptacles. This wire has a heat resistant, 15 mil thermoplastic insulation rated at 90*C which is also flame retardant. This wire has not been qualified to IEEE 383-1974. In those cases where it is used, it is totally encapsulated in either metallic conduit or fiberglass sleeving. When it is less than six inches from Class 1E wire, it is installed in metallic conduit. The different types of multiconductor cables that are used inside panels are discussed in Section 5.3.

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I To determine if the characteristics of a source conductor would be I affected by the type wire used, the data from several tests was reviewed.

Figure 5-6 compares the conductor average temperature versus time for #14AWG wire of the two types at two current levels. It can be seen that at 90A, the Rockbestos achieved a peak average temperature approximately 180*F higher than the GE Vulkene. At 100A, the GE Vulkene wire achieved a much higher temperature and eventually failed cpen whereas the Rockbestos wire stabilized at approximately 1275'F. The most likely explanation why this difference in I characteristics occuted is that during Test 25A, the Rockbestos wire was in contact with the target wire which acted as a heat sink. The GE wire in Test 43d was in open air. This is a reasonable explanation given the sensitivity I of this size wire to small variations in current and heating as discussed in Section 5.1. A comparison of the 90A characteristics shows similar characteristics for the Rockbestos and Vulkene wires. The 2.4% difference in conductor average temperature between the two types of wire is not considered significant.

To determine if the insulation difference would affect the results of any sleeving or separation tests, Tests 23R (Rockbestos target) and 23V (vulkene target) were performed with all other variables being equal. Both

1. 14AWG target conductors were sleeved and in contact with a #14AWG source carrying 90A. Both wires passed all acceptance criteria after the tests, I including showing infinity resistance readings at 500 VDC and no breakdown at 4 kV for one minute. (See photos D-2 and D-3)

I Based on these results and analyses, it is concluded that the Limerick separation criteria are not dependent on which of the wire types discussed herein is utilized. Furthermore, based on the observations discussed in I Section 5.2.3 where significant insulation deterioration was observed internal to the sleeving in Test 7, it is concluded that the criteria are applicable to all types of flame-retardant wire because the sleeving material will take the place of any deteriorating insulation and prevent propagation of the wire failure to the sleeved conductor.

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1985 f VULKENE 100A (TEST 43a)

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A VULKENE 90A (TEST 43-90)

A 1000 - ROCKBESTOS 90 _

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500 FIGURE 5-6 CONDUCTOR AVG. TEMP. VS. TIME

1. 14 ROCKBESTOS AND VULKENE SIS 90A AND 100A I I I I l 0 5 10 15 20 25 W M M M M M M M M M Q BE g TES Q g g g g g

5.3 Multiconductor Tests Tests 32 through 40 involved the use of multiconductor configurations as the source conductor to verify that the criteria which resulted from the I single conductor tests described in Section 5.2 are adequate when failures occur in multiconductor cables.

tested:

Two source conductor configurations were 2-#14AWG conductors in a 7 conductor #14AWG Rockbestos Firewall III cable to represent control circuit faults; and 2-#6AWG single conductor G.E.

'I Vulkene SIS wires to represent power circuit faults. Both of these configurations are widely used in the PGCC, but single conductor power

{ circuits are run in steel conduit.

The results of these tests supported the conclusions reached from the single conductor tests. No changes to the separation criteria were needed as j

I the result of these tests even-though the amount of heat produced from the source conductors was double that produced in the single conductor tests.

Specific results are discussed in the following sections.

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Besides the configurations tested, Raychem 600 volt Flamtrol multiconductor control cable is utilized throughout the PGCC. The Raychem g Flamtrol insulation is a radiation cross-linked polyethylene (XLPE) with I fire-retardant additives and is used as both the conductor insulation and the overall cable jacket. The Rockbestos cable tested utilizes a flame-retardant XLPE insulation for the conductors and a flame-retardant neoprene jacket.

Both cables are qualified per IEEE 383-1974 and Flamtrol has been shown to I have similar and in some cases better fire-retardant characteristics than

. neoprene jacketed XLPE multiconductor cable (Reference 6). Also, Reference 7 reported that electrically initiated ignition of multiconductor control cable l

E proved to be impossible unless the jacket of the cable was removed. This was .

also confirmed by the tests described in this section as the multiconductor cables never experienced ignition. In addition, flame-retardant XLPE such as

$g that of the Flamtrol cable has a self-ignition temperature approximately fg 240*F higher than flame-retardant neoprene according to tests performed by 6

Raychem in accordance with ASTM D 1928-68, Standard Method of Test for Ignition Properties of Plastics. For these reasons, the Rcychem cable was sI not tested as it will exhibit overcurrent withstand properties at least as good as the Rockbestos cable tested.

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I 5.3.1 Effects of Spatial Separation Because multiconductor power circuits requiring separation are always contained in flexible steel conduit in control panels, the only separation l tests that were performed without barrier materials were with the l multiconductor #14AWG control cable as the source. Test 32 was performed with two #14 conductors in the source cable connected in parallel with 180A

'I source current to simulate 90A per conductor. A #20AWG target conductor was placed in contact with the source cable. The results of this test showed that spatial separation was required from multiconductor control cables as I the target conductor was not able to pass either the resistance or breakdown tests. The jacket of the cable was breached in several places during the test and the exposed conductors were visible. It should be noted that i

I approximately ten minutes after the start of the test, the measured resistance of the source circuit began falling and continued to decrease for the duration of the test. Post-test examination confirmed that this was due to the deterioration of the insulation on adjacent conductors, thereby, in effect increasing the cross sectional area of the source conductor. It was also observed that the presence of the additional conductors in the cable gives support to the source conductors and, therefore, the multiconductor I cable does not experience the large magnitude of sag that is experienced by the single conductors.

Based on the above observations. it was determined that the same spatial separation criteria that apply to single conductors wculd also apply to multiconductor control cables even though the absence of significant sagging could justify a less stringent set of criteria. This course was selected to keep the field installation criteria as simple as possible .

5.3.2 Effects of Barrier Materials In order to determine if the fiberglass sleeving material used in the single conductor tests veuld be satisfactory in preventing the propagation of a failure of a multiconductor control cable to an adjacent single conductor, Tests 33 and 34 were conducted. In Test 33, a #18AWG target conductor was placed in contact with the multiconductor #14AWG control cable source which was inside the sleeving. 180A was used as the source current until

) I approximately 18 minutes into the test when the current was increased to 250A in order to try to cause the source conductor te burn open. This was done because the resistance of the source conductor began decreasing at approximately ten minutes into the test as previously observed. The source I' failed open approximately thirty seconds later. At no time during this test did the sleeving on the source conductor rupture and the target conductor passed all acceptance criteria.

In Test 34, the same procedure was followed as Test 33 except the source current was increased to 200A from 180A at approximately 22 minutes into the I test and the sleeving was placed on the target. The source conductor circuit opened at 23 minutes. As in the previous test, the target conductor with the sleeving passed all acceptance criteria even though it was in contact with l the source cable (See photo D-ll).

l Based on the results of tests 33 and 34, the sleeving can be used as a barrier material on either single conductor or multiconductor control cables.

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I For pown ..rcuits, Test 5 showed that sleeving was not adequate to contain the etfeeis of a faulted #6AWG conductor. The power circuits requiring sepanEnn which enter control panels are run in flexible steel conduit and are wally 'wo single conductor wires. #6AWG wire is the I predominant size med. k at 40 was run to determine if the flexible steel conduit was in fact an ao uate separation barrier. In this test, two #6AWG source conductora were cormected in series and run through a one inch flexible steel conduir. A #- N G target conductor was tyrapped to the top of

]Bl the conduit. No sleevu q w a used in this test and the source current was

[ 360A. At approximately eight minutes into the test, flames were visible lg inside the conduit and temperatures in excess of 500*F were recorded on the target conductor insu ation. The test was continued for twenty minutes. At f5 no time did the flames breach the conduit or come into contact with the g

target conductor (See photo D-12).

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The post-test acceptance criteria were all met by the target conductors therefore, it was concluded that steel flexible conduit is an acceptable barrier material for power circuit coriductors and no spatial separation from I' the conduit is required.

yg The results of this test can also be used to justify relaxation of the g requirements of Reference 1, Section 6.1.3.3.(2) which states that the mimimum separation distance between enclosed raceways requiring separaticn is one inch. The results of test 40 show that when a power cable of size #6 AWG 1 l or smaller is enclosed in conduit, no separation is required from enclosed M raceways carrying redundant cables of any type as the additional raceway steel jacket would provide substantially more heat protection to the circuit insulation than was shown to be sufficient in this test. For this reason, I' when a Class 1E circuit is routed in an enclosed raceway which is in proximity to a conduit containing a redundant Class lE or non-Class lE d circuit of wire size #6 AWG or smaller, m spatial separation is required between the raceways. It is apparent that ti.is exception to Reference 1 could be relaxed to include even larger wire su.es based on the lack of damage to the unprotected target conductors in Test 40s however, as further testing was not done, it was decided to retain the large margin of

( conservatism demonstrated by the results of this test.

. g While Test 40 results are used to justify the one inch conduit g separation exception for heat transfer concerns, the effects of EMI on adjacent circuits was also considered. Reference 3 documents tests which proved conclusively that EMI generated by faults on circuits in conduit will not adversely affect adjacent instrumentation circuits regardless of separation distance. These results also justify the absence of separation between redundant instrumentation enclosed raceways as these circuits are

.E routea in raceways without any power and control cabling, therefore, a source

!E of fault current does not exist. For these reasons, this exception to Reference 1 is justified.

( Test 40 was repeated using aluminum flexible conduit. The aluminum conduit experienced severe damage and melting in several areas (See photo D-18). The target conductor was severely damaged and was judged to have I failed by visual examination. Based on this test, aluminum flexible conduit is not an acceptable barrier for power circuits when spatial separation cannot be achieved.

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I 5.4 Isolation Relay Tests I As discussed in Section 4.4, the two objectives of the isolation relay tests were: 1) to confirm that the Class lE circuits would not be degraded I below an acceptable level by the failure ci non-Class lE or redundant Class 1E circuits connected to the isolation relay, and 2) to confirm the adequacy of the Limerick separation criteria which permits no separation between wires I terminating on a common isolation relay. The test procedures used are given in Appendix A and are discussed in Section 4.4.

The test results showed that the three different types of relays tested I are all acceptable isolation devices. In addition, their overcurrent failure modes support the exception to the separation criteria which allows no separation between wires terminating on isolation relays. .All relays tested

'g exhibited self-fusing characteristics rhich will interrupt current levels of g the magnitudes which could cause wire insulation deterioration before deterioration begins to occur.

5.4.1 Agastat GP Series All tests were performed on Agastat GPI relays mounted in ECR0095-001 I socxets. The AC breakdown tests performed on the Agastat GP relays showed that adequate electrical isolation is obtained both between adjacent contacts and between coil and contacts. The breakdown voltage between a coil circuit I terminal and the adjacent contact terminal was above 6 kV. The breakdown voltage across a normally open C-form contact was above 5 kV. Breakdown voltage between adjacent contacts was above 5 kV. These levels indicate satisfactory overvoltage isolation properties for 120 VAC and 125 VDC control circuit isolation.

Overcurrent tests were performed at various current levels to determine the overcurrent failure modes of the relay. At 90A, the contact circuit I opened in less than ten seconds. From Figure 5-3 and data sheet 43-90, it can be seen that a #14AWG conductor will not have reached a temperature at I

which insulation deterioration will take place or at which damage can occur to an adjacent conductor. At 80A, the circuit opens in approximately 10 seconds and at 70A, the circuit opens in approximately 40 seconds. At each of these current levels and respective durations, no damage occurs to a I #14AWG conductor in the circuit. This was confirmed by observation as each current circuit was wired with #14AWG wire. This wire size is the smallest that is used in control circuits utilizing isolation relays.

The failure which causes the circuit interruption is internal to the relay. A wire which connects the movable arm of the C-form contact to the relay terminal fused open in all of the above overcurrent tests. This wire size appears to be #20AWG and it becomes part of any circuit utilizing the I relay contacts; therefore, this self-fusing characteristic will protect n11 circuits utilizing Agastat GP contacts. Based on this conclusion, the following exception to the separation criteria discussed so far is allowed:

Non-Class lE wires terminating on contacts of Agastat GP and ETR relays I need not be separated from other wires in the same panel, regardless of safety status or division. Redundant Class lE wires terminating on a common isolation relay need not be separated from each other at the relay terminals.

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I The Agastat ETR relay is a solid state time delay relay which has the same wiring to its movable contact arm as the GP. For this reason, the above exception is considered to be applicable to the ETR.

I Most Agastat GP relays at Limerick are mounted in ECR0095-001 relay sockets. These sockets contain wiring from screw terminals to the relay base sockets. This wiring is used in the coil circuit and is in contact with wiring in the adjacent contact circuits. For this reason, further l overcurrent tests were performed to determine if damage to the relay socket

'- W wiring could cause a failure of the coil circuit wiring. Test were performed

$g at 30A, 60A and 70A. A synopsis of the observations at various overcurrent 5 eve 8 is presented in Table 5-1. Most damage to the relay and its base was generated during the SOA and 60A tests (See photo D-13).

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4 Post test resistance measurements were made at 500 VDC to determine if 2

I the electrical resistance between adjacent contacts or between the coil I circuit and adjacent contacts was degraded below acceptable levels by the

.g sustained overcurrent conditions. Two relays were tested at the SOA and 60A 3 current levels. All resistance readings were in excess of 5000 megohms inspite of the severe damage noted in Table 5-1 (See photo D-14) . A third relay was tested at 30A, 80A, and 70A. After the test, all resistance readings were infinity except for the resistance between terminals B1 and M1 which was 0 at 500 VDC. El is a coil terminal and M1 is the adjacent contact arm terminal. A visual inspection did not reveal the source of the

.I short. No wire damage was visible in the base, however, carbon was visible on the wire insulation in the vicinity of the B1 contact (See photos D-15 and D-16). When the resistance between these terminals was measured with an ohmmeter, an infinite resistance was measured. Another reading was taken at I' 500 VDC and again zero resistance was measured. The relay coil current was then energized at 120 VAC. While the coil was energized, the voltage on the M1 terminal was measured to ground. No voltage was present. Based on this

.I information and visual observations, it was concluded that the zero resistance reading was caused by tracking across the carbon deposit noted above on the base wiring insulation at 500 VDC. At 120 VAC, the tracking I phenomenon did not occur and the contact circuit was electrically isolated from the coil circuit. Because these relays are not used in cir uits above 125 VDC or 120 VAC and because examination indicated that this failure was f randon due to the lay of the base wiring and not a common mode failure, the degradation observed during this test was considered to be allowable.

The failure modes observed during these tests prohibit the use of the I Agastat GP and ETR in circuits where all of the following conditions occur because the relay eventually becomes inoperative:

'E 2- Circuit 5 of different divisions *r* wired to contact 5 on a common g relay.

2.

I The contact of one of the divisions or the non-Class lE circuit is closed during normal plant operation.

3. The contact in the other Class lE circuit must change state to perform its safety function.

Based on the tests results discussed in this section, the Agastat GP and I ETR relays are considered to be satisfactory isolation devices.

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I Table 5-1 I Agastat GP Relay Overcurrent Tests Damage Synopsis Current Duration Damage 90A (10 sec. Internal wire fuses open. No other relay

, or base damage.

80A 10 sec. Internal wire fuses open. -No other relay or base damage.

70A 40 sec. Some melting of contact arm retainer material.

60A Indefinite contact arm retainer totally melted.

Insulation on wire in base totally burned away.

some damage to adjacent wire in base for coil I circuit. Base plastic melted and distorted near circuit terminals. Relay eventually becomes inoperable from melted contact arm retainers.

50A Indefinite Same d'. mage as at 60A but slower deterioration.

30A Indefinite Slow melting of contact arm retainer. Relay eventually becomes inoperable.

I 5.4.2 Agastat 7000 Series I The Agastat 7000 pneumatic timing relay is self-contained and does not use a socket as does the Agastat GP. For this reason, intermediate level overcurrent tests were not performed because failure of internal or base I

wiring was not a concern. The minimum breakdown voltage between a coil terminal and an adjacent contact terminal was 7.2 kV. Breakdown between adjacent contact terminals was at 3.6 kV or above. The coil in this relay is physically separated from the contacts by a steel plate as well as an epoxy coating around the coil. The breakdown between the coil and contacts took place external to the relay.

The overcurrent tests on three relays resulted in the following I observations:

e At 90A, the maximum time the contact circuit remained continuous I was seven seconds.

• At 70A, the maximum time the contact circuit remained continuous was ten seconds.

e At 60A, the uit remained continuous indefinitely.

e All circuit interruptions were caused by the melting of the contact arm on the movable C-form contacts (See photo D-17).

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I e After the overcurrent tests, the other contacts were still operable and the coil circuit was unaffected.

e Resistance measurements at 500 VDC between the coil terminals and adjacent contact terminals as well as between adjacent contacts all I. measured infinity.

Based on the above, it is concluded that the Agastat 7000 relays are acceptable isolation devices for use in 120 VAC and 125 VDC control circuits.

They also have self-fusing characteristics similar to those of the Agastat gps therefore, the wiring to the contacts of this relay need not be separated from other wiring within the same enclosure.

i 5.4.3 Cutler Hammer M-600 Series The Cutler Hammer M-600 relay is a self-contained relay which has separate compartments for each contact as well as for the coil. It does not ut.ilize a socket, therefore, intermediate overcurrent tests were not performed. The lowest breakdown voltage between the coil and contact l

g terminals was 16.5 kV, and was 6.1 kV between adjacent contact terminals.

The overcurrent tests on two relays resulted in the following observations:

e At 90A, the maximum time the contact circuit remained continuous l was 24 seconds and the relay continued to function.

e At 75A, the maximum time the contact circuit remainec[ continuous was 190 seconds and the relay continued to function.

e At 60A, the contact welded after appro::imately ten minutes with I local heating which caused melting of part of the contact casing.

The relay became mechanically inoperative due to melting plastic entering the operating solenoid piston.

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e Resistance measurements at 500 VDC between the coil terminals and r

adjacent contact terminals as well as between adjacent contacts all measured infinity.

5 g Based on the above, it is concluded that the Cutler Hammer M-600 relays are acceptable isolation devices for use in 120 VAC and 125 VDC control circuits. They also have self-fusing characteristics similar to those of the I Agastat gps therefore, the wiring to the contacts of this relay need not be separated from other wiring within the same enclosure. It will have the same restrictions on its use as noted for the Agastat GP and ETR in Section 5.4.1.

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5.5 Special Tests A special set of sag tests were conducted to quantify how much I displacement various size conductors would experience due to thermal expansion. The objective of the tests was to develop a minimum spatial separation criterion which could be utilized when wires are secured with steel wire ties which will restrict their movement. Table 5-2 shows the results of these tests. It can be seen from these results that the maximum displacement that can be expected when wires are supported every six inches is inch. This displacement can occur in any direction; therefore, if wires are separated by more than 1/2 inch and the wire considered to be the I potential source conductor is secured every six inches with s. teel wire ties, then the two wires will not come into contact. Based on the above, the following exception to the Limerick separation criteria is allowed:

One inch spatial separation between redundant Class lE wiring is I sufficient if both channels of wiring are secured every six inches with stainless steel wire ties to the point where six inches of separation is achieved. For separation between Class lE and non-Class lE wiring, one inch is sufficient if the non-Class lE wire is secured every six inches with stainless steel wire ties to a point where six inches of separation I is acheived.

I Table 5-2 Results of Sag Tests Wire Total a Test #

S-1 Size 14 Current 100 A Sag h"

S-2 13 60 A "

S-3 10 175 A "

I S-4 6 360 A "

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III REFERENCES l

1. Standard Criteria for Independence of Class 1E Equipment and Circuits, IEEE 5tandard 384-1981.

2. Summary of meeting held May 18, 1981 to Discuss Control Room Fire Design Criteria, dated June 4, 1981, USNRC with Arizona Public Service Co., Docket STN 50-528/529/530, Palo Verde Units 1, 2 and I 3.

3. Investigation of Safety-Related Aspects of Conduit Spacing, Franklin Institute Research Laboratories, F-C4609, February 1977.

4. L. J. Klamerus and R. H. Nilson, " Cable Tray Fire Tests", Sandia Laboratories, SAND 77 - 1125C, July 1977.

5. Wire and Cable Engineering Guide, Brand-Rex Company, Publication WC-78, 1978

6. Flame Resisting Tests on Various Types of Control Cable, Test

[

Report EM #277, Raychem Corporation, June 23, 1970.

7, Meeting Minutes of NPEC 77-2, Appendix SB, Page 4, Report and Comment on Cable Fire Testing at Sandia Laboratory by L. J. Klamerus, July 27, 1977 I

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LGS-EE-1 Rev. 3 i

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,I I TEST PROCEDURE DESIGN VERIFICATION TESTS FOR INTERNAL PANEL WIRING SEPARATION CRITERIA Limerick Generating Station, Units 1 and 2 I

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3 3/19/82 Added Section 8.2.8 *

'g 2 11/1/81 Added Relay Isolation EFS RJL PKP JJG E Tests 1 9/14/81 Revised Acceptance EPS RJL SJ S JHH Criteria Due to Inaccuracies in Leakage Current Measurements x

I O B

7/10/81 6/23/81 Issue for Test Reissue for Review EFS EFS RJL JBC SJS SJS JJS JJS s

A 5/15/81 Issue for Review EFS JBC SJS JJS Rev. Date Reason for Issue Resp, EE RST QA No. Eng. Reviewed l

TEST PROCEDURE LGS EE-1 Design Verification Test for Internal Panel Wiring Separation Criteria Rev. 3 l

I Limerick Generating Station Page 1 of 14 I

1 l-1.0 Purpose l

The purpose of the testing to be performed in accordance

! with this procedure is to:

a) verify the adequacy of the separation criteria l implemented on internal panel wiring as required by IEEE Std. 384-1974.

l b) determine the adequacy of Hygrade Thermoflex sleeving naterial to prevent the propagation of a failure of an over loaded conductor to an adjacent conductor.

l 2.0 Scope The results of the tests performed in accordance with these procedures v.'ll be applicable to all internal control panel wiring at L.' a erick Generating Station. The test results I will be includad in reports to be prepared by 2esearch and Testing Division. The bases for and the results of the tests will be analyzed in a separate report to be prepared by P.E.Co. Electrical Engineering Division.

3.0 Acceptance criteria In all tests listed in Section 8.2 of this procedure, a target and source cable or conductor are identified. The intent of these tests is to measure the effe' cts on the target conductor caused by overcurrent conditions in the d source conductor.

to be acceptable if the current carrying capability of the The configuration tested is considered I target conductor is not decreased, the DC insulation resistance does not drop below 100 megohns and insulation can withstand a dielectric test for one minute the =

without breakdown at the voltage specified in Section I 8.1.11. For tests where sleeving is applied, .the sleeving is considered to form part of the conductor insulation.

4.0 Quality Assurance Requirements 4.1 The tests performed in r,ccordance with these procedures I will provide safety-related design verification and must be performed in accordance with the Limerick Quality Assurance Plan, Section 11.0 and Research and Testing Division procedures as applicable.

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i TEST PROCEDURE LGS EE-1 Design Verification Test for Internal Panel Wiring Separation Criteria Rev. 3 Limerick Generating Station

4.2 As part of the test report, a list of all instr.c.aents used I in the test program are to be provided which wiil include the following information:

a) Description b) Hanufacturer c) 'Iype/Model Number d) Serial Number e) Range / Features f) Accuracy g) Date Calibrated Test personnel shall be trained in accordance with Research I4.3 and Testing Division Procedure RT-02-50002, Procedure for Qualification and Training of Research and Testing Division Personnel.

5.0 Measurements The following measurements are to be taken and recorded for I5.1 each test:

a) Current and voltage drop vs. time for $hesource I conductor b) Current and voltage drop vs. time for the target j h conductor c) Averge temperature of source conductor vs. time d) Average temperature of target conductor vs. time i e) Surface temperature of target conductor insulation vs.

l time l f) Outer surface temperature of source conductor sleeving when used.

l g) Outer surface temperature of target condiactor sleeving when used.

h) Insulation DC resistance with test voltage of 500 1 50 VDC after the test. The measurement will be read 60 I seconds after voltage is applied and at pointsvith insulation discoloration or which experienced the TEST PROCEDURE LGS EE-1 Design Verification Test for Internal Panel Wiring Separation Criteria Rev. 3 I Limerick Generating Station Page 3 of 14 I

highest tempertures during the test. When sleeving has been applied to the target conductor, resistance shall be measured through the sleeving.

h) Duration of test.

1) Ambient temperature in the test room. The velocity of the room exhaust should be kept to a minimum to I simulate enclosed panel conditions.

5.2 All temperature measurements should be taken at expected hot spots which are near the center of the test specimen.

5.3 Temperature of conductor insulation is not required when temperature is taken of sleeving on that conductor.

5.4 Required equipment accuracies are to be determined by test personnel.

6.0 Test Materials a) Wire The single and multiconductor cables to be tested were I obtained from General Electric Co. and were purchased under the same purchase part number drawings as those used in the Power Generation Control Complex (PGCC).

Rockbestos Firewall Nuclear SIS wire will be used for all s18 AWG and selected #14 AWG tests. These wires are to be used for all testing performed under this procedure and are qualified to IEEE Std. 383-1974.

b) Sleevinq The sleeving to be installed when called for in the I test description is Markel Corporation 1716 Thersofler 1200-FR-1, except as noted. Sleeving size to be applied to conductors are as follows:

Wire Size Sleeving Size I # 6 AWG

1. 10 514 7/16"

1. 2 8 4 (Type 1718 Theraflex 500-FR-1)

I #18 & 20 7/c - #14

1. 14 5/8" c) Flexible Steel Conduit i TEST PROCEDURE LGS EE-1 Design Verification Test for Internal Panel Wiring Separation Criteria Rev. 3 Limerick Generating Station Page 4 of 14

I one inch florible steal conduit equivalent to P.E.Co.

I Code 129-14526 will be used as indicated in Section 8.2.2.

d) Tape Glass cloth electrical tape, 3M Scotch #69 vill be used to secures sleeving to the conductor. One wrap is to be applied at each end of the sleeving.

e) Tyraps Where specified, AMP stainless steel tyraps shall be used to secure wires.

7.0 Documentation Test documentation will be produced by Research and Testing I Division. This documentation will consist of certified data sheets and sketches containing the following information listed for each test performed:

a) Source conductor size b) Target conductor size c) Initial spacing between source and target conductors d) The measurements listed in Section 5.0 e) Whether or not the acceptance criteria stated in

• Section 3.0 were met.

A listing of the , test equipment information stated in Section 4.0 will also be provided. The data sheets will be signed by the tester and by his supervisor.

8.0 Test Descriptions 8.1 General Procedures

1. Record number of test being performed and room ambient temperature.

2. Make provisions for temperature measurement of the source and target conductor.

3. Connect target and source conductors to current source.

4. Check instrumentation for function.

TEST PROCEDURE LGS EE-1 Design Verification Test for Internal Panel Wiring Separation Criteria Bev. 3 I Limerick Generating Station Page 5 of 14 5

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5. Energize current source to required level.

6. Record temperature, currents, and time at regular intervals.

7. Maintain current through the source conductor at the required level, +10 Amps.

I 8. Maintain DC conductor.

current at specified level +10% on target I 9. Continue the test until temperature stabilizes for at least the target conductor 30 Shorter periods after stabilization may- be used if minutes.

early test results show no further target degradation I occurs af ter stabilization.

10. Measure insulation resistance through target conductor insulation.

11. Perform a dielectric withstand test for 1 minute at the I ,

same locations as determined for the insulation resistance measurements. The AC test voltage shall be 4kV for wire sizes #10-814 AWG and 2.2kV for wire sizes

1. 18 and #20 AWG.

8.2 Test configurations 8.2.1 Single Conductor Tests Perform Tests 43, 44, and 45, then proceed with the following tests.

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I Test 1 Source Conductort #6 AWG, Amps as determined i

in Test 45.

I Target Conductor: #18 AWG, 5A Configuration: Target conductor 1/4 inch above and parallel to source conductor i g Sleeving: None 3 If acceptance criteria (AC) are met, go to Test 4 If acceptance criteria (AC) are not net, go to Test 2 Test 2 Source Conductor: Same as Test 1 l Target Conductor: #18 AWG, 5 Aaps l Configuration: Target conductor 1/2 inch above l I and parallel to source conductor Sleeving: None If AC are met, go to Test 5 If AC are not net, go to Test 3 Test 3 Source Conductor: Same as Tests 1 i

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TEST PROCEDURE LGS EE-1 Design Verification Test for I Internal Panel Wiring Separation Criteria Limerick Generating Station Bev. 3 Page 6 of 14 5

3 Target Conductor: #18 AWG, 5 Aaps I Configuration: Target conductor 1 inch above and parallel to source conductor Sleeving: None I If AC are met, go to Test 5 If AC are not met, go to Test 5 Source Conductor: Same as Test 1 I

T ast 4 Target Conductor: #18 AWG, 5 Amps Configuration: Target conductor in contact with and parallel to source conductor I Sleeving: None If AC are met, go to Test 5 If AC are not met, go to Test 5 Test 5 Source Conductor: Same as Test 1 Target Conductor: Same as Test 1 Configuration: Target conductor in contact with, above and parallel to source conductor.

Sleeving: On source conductor I If AC are met, go to Test 7 If AC are not met, go to Test 7 Test 6 Deleted Test 7 Same as Test 5 except place sleeving on target conductor only I If AC are met, go to Test 11 If AC are not met, go to Test 8 I Test 8 Source Conductor: Same as Test 1 Target Conductor: Same as Test 1 Configuration: Target conductor in contact I with, above and parallel to source conductor Sleeving: On both conductors If AC are met, go to Test 11 If AC are not met, go to Test 11 Test 9 Deleted Test 10 Deleted Test 11 Source Conductor: #10 AWG, Amps as determined in Test 44 or 120A, whichever is lower.

Target Conductor: #18 or #20 AWG, 5A Configuration: Target conductor 1/4 inch above and parallel to source conductor.

I Sleeving: None If AC are met, go to Test 14 If AC are not met, go to Test 12 I TEST PROCEDURE LGS EE-1 Design Verification Test for I Internal Panel Wiring Separation Criteria Limerick Generating Station Rev. 3 Page 7 of 14

Test 12 Same as Test 11 except target conductor 5 is 1/2 inch above and parallel to the source conductor.

I If AC are met, go to Test 15 If AC are not met, go to Test 13 Test 13 Same as Test 11 except target conductor I is in 1" above and parallel to source conductor.

If AC are met, go to Test 15 If AC are not met, go to Test 15 Test 14 Source Conductor: Same as Test 11 I Target Conductor: Same as Test 11 Configuration: Target conductor in contact with & parallel to source conductor.

Sleeving: None If AC are met, go to Test 15 1 If AC are not net, go to Test 15 I Test 15 Same as Test 14 except sleeving on source conductor only If AC are met, go to Test 16 If AC are not net, go to Test 16 Test 16 Same as Test 15 except sleeving is on target conductor only If AC are met, go to Test 20 i If AC are not met, go to Test 17 I Test 17 Same as Test 16 except sleeving on both conductors.

If AC are met, go to Test 20

, If AC are not met, go to Test 20 Test 18 Same as Test 15 except use 200 A current I thru source conductor use s18 AWG as target.

Test 19 Deleted Source Conductor: #14 AWG, Amps as determined I Test 20 in Test 43 Target Conductor: #18 or #20 AWG, 5A Configuration: Target conductor 1/4 inch above I and parallel to source conductor.

Sleeving: None If AC are met, go to Test 23 If AC are not net, go to Test 21 Test 21 Same as Test 20 except target conductor TEST PROCEDURE LGS EE-1 Design Verification Test for Internal Panel Wiring Separation Criteria Rev. 3 I Limerick Generating Station Page 8 of 14

I is 1/2 inch above end parallel to the I source conductor.

If AC are met, go to Test 22 If AC are not met, go to Test 24 I Tnst 22 Same as Test 21 except target conductor one inch above and parallel to source conductor.

I If AC are met, go to Test 24 If AC are not met, go to Test 24 T est 23 Source Conductor: Same as Test 20 I Target Conductor: Same as Test 20 Configuration: Target in contact with and parallel to source conductor.

I If AC are met, go '.o Test 24 If AC are not met, go to Test 24 Test 24 I Same as Test 23 except sleeving on source conductor If AC are met, go to Test 25 If AC are not met, go to Test 25 Test 25 Same as Test 24 except sleeving on target conductor If AC are met, go to Section 8.2.2 tests I If AC are not met, go to Test 26 4

~

Test 26 Same as Test 25 except sleeving on both target & source conductors If AC are met, go to Section 8.2.2 tests If AC are not met, go to Section 8.2.2 tests Test 27 Deleted

• Test 28 Deleted 8.2.2 Multiconductor Tests Test 29 Source Conductor: 7/c-814, same current as Test 20 through 2 conductors that are adjacent Target Conductor: #18 or #20 AWG, 5A I Configuration: Target conductor 1/4 inch above and parallel to source conductor.

Sleeving: None I If AC are met, go to Test 32 If AC are not met, go to Test 30 Test.30 Same as Test 29 except target conductor I is 1/2 inch above and parallel to source conductor TEST PROCEDURE LGS EE-1 Design Verification Test for I Internal Panel Wiring Separation Criteria Limerick Generating Station Rev. 3 Page 9 of 14 I

I If AC cro ont, go to Test 33 If AC are not net, go to Test 31 Tast 31 Same as Test 30 except target conductor is one inch above and parallel to I source conductor.

If AC are met, go to Test 33 If AC are not met, go to Test 33 Test 32 Source Conductor: Same as Test 29 Target Conductor: Same as Test 29 Configuration: Target in contact with I and parallel to source conductor.

If AC are met, go to Test 33 If AC are not met, go to Test 33 Test 33 Same as Test 32 except sleeving source conductor I If AC are met, go to Test 34 If AC are not met, go to Test 34 Test 34 Same as Test 33 except sleeving on I target conductor If AC are met, go to Test 38 If AC are not met, go to Test 35 Test 35 Same as Test 34 except sleeving on both conductors I Test 36 If AC are met, go to Test 38 If AC are not met, go to Test 38 Deleted Test 37 Deleted i

Test 38 Same as Test 34 except source conductor lI in 1" flexible steel conduit Go to Test 39 I Test 39 Same as Test 38 except target conductor in 1" flexible steel conduit Go to Test 40 Test 40 Source Conductors: 2- 1/c #6, Amps as determined by Test 45 I Target Conductor: #20 AWG, 5A Configuration: Source horizontal, target in contact and parallel to source Sleeving: Source in 1" flexible steel conduit If AC are met, end test

• j If AC are not met, go to Test 42 TEST PROCEDURE LGS EE-1 Design Verification Test for I Internal Panel Wiring Separation Criteria Limerick Generating Station Bev. 3 Page 10 of 14 I

I~

• Test 41 Deleted Test 42 Same as Test 40 except add sleeving on target conductor End Test 8.2.3 Single Conductor Maximum Heating Tests Test 43 Source Conductor: #14 AWG For each of the following currents, record the maximum or equilibrium temperature of the insulation and the conductor:

a) 360 A g b) 200 A g c) 150 A d) 100 A e) 50

• Af ter completion of the five (5) above tests, perform a test at 25 amps above I ,

and another at 25 amps below the value which produced the highest temperature.

' I Use the current which produce the highest temperatures in 'Aa tests starting with Test 20.

I Test 44 Source Conductor: s16 AWG Use same procedure and values as Test 45.

Use the current which produced the highest s -

temperatures in the', tests starting with Test 11.

Tnst 45 Source Conductor: 86 AkG Use the same procedure as Test 43 with I the following current values for the first five (5) measurements: s I a) b)

c) 360 A 250 A 200 A' I d) e)

150,t 100 A Use the current which produced the highest temperatures in the tests starting with Test 1. ,

I TEST PROCEDUBE LGS EE-1 Design Verification Test for Internal Panel Wiring Separation Criteria I

Rev. 3 Limerick Generating Station Page 11 of 14

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E 8.2.4 Additional Tests i

I Additional tests may be performed as required during the course of the test program. These additional tests and/or deviations from this procedure shall be adequately documented. ,

8.2.5 Aqastat GP Isolation Rela': Test 8.2.5.1 Test Objectives:

a. Determine voltage at which flashover will occur between adjacent contacts.

b. Determine if a sustained overcurrent through a closed -

contact with the coil energized will prevent other contact operations on drop out.

c. Determine if overcurrent thru a closed contact with the I relay coil deenergized will prevent other contact operation on pick cp.

d. Determine if overcurrent condition thru terminals T .or T will cause a relay change of state or failure of the coil circuit.

8.2.5.2 Test Materials

a. Agastat GPI relays, 120 VAC coils All circuits to be connected with #14AWG wire b.

8.2.5.3 Test Procedure Test 1 1. Determine breakdown voltage between T1 and R1

2. Determine breakdown voltage between 64 and B4 Tost 2 1. Apply 120 VAC to terminals B1 - B4 to pick up relay

2. Apply 90A thru terminals T1-51 and maintain until l3 relay drops out or contacts fuse or veld.

lg l

Record time of failure.

3. Open the coil circuit and check to see that contacts have changed state. ,

4. Record any f ailures.

l Test 3 1. Apply 90A thru terminals R4-54 until contacts fuse E or weld-l3 2. Apply 120VAC to terminals B1-B4 to energize relay coil

3. Verify proper operation of relay contacts I

I TEST PROCEDURE Design Verification Test for Internal Panel Wiring Separation Criteria LGS EE-1 l

Rev. 3 l Limerick Generating Station Page 12 of 14 I

8.2.6 Aqastat 7000 Irelation Rolev Tvt Test 1 '

1. Determine breakdown voltaife between terminals 1 and 3

2. Determine breakdown voltage between terminals L1 and 1 I Test 2 1.

2.

Apply 90A thru terminals 3 - 5 (until circuit opens.

Check resistance at 500 VDC between L1 and 5 I

I 3.

4.

5.

Check resistance at 500 VDC between L1 and 3 Check resistance at 500 VDC between L2 and 5 Check resistance at 500 VDC between L2 and 3

6. Check relay operation for change of state I Test 3. 1. Apply 60A thru terminals 4-6 until circuit-opens

2. Check resistance at 500 VDC between L1 and 6 I 3.

4.

5.

Check resistance at 500 VDC between L1 and 4 Check resistance at 500 VDC between L2 and 6 Check resistance at 500 VDC between L2 and 4

6. Check relay operation for change of state A. Inspect celay internals and record observation.

B. Record all measurement taken above.

I C.

D.

Record relay model # S Seriale Repeat tests on 2 additional relays.

8.2.7 Cutler Hammer M-600 Isolation Relay Test Test 1 1. Determine breakdown voltage between terminals 1 and 4

2. Determine breakdown voltage between terminals 1 and 7

Test 2 1. Energize coil with 120 VAC through t.erminals 7 and 8

2. Apply 75 A through terminals 2 and 5 until circuit burns open. Note time to failure.

'3 3. Check resistance at 500 VCD between ters 7 and 1.

3 4. Check resistance at 500 VDC between tera 7 and 2

5. Check resistance at 500 VDC between tera 8 and 1

6. Check resistance at 500 VDC between ters 8 and 2

7. Check relay for operation of remaining contacts l

I I

I

,g TEST PROCEDURE LGS EE-1 g Design Verification Test for Internal Panel Wiring Separation Criteria Rev. 3 1

I Limerick Generating Station Page 13 of 14

E* Test 3 1. Apply 60A thru teroinala 3 and 6

2. Check resistance at 500 VCD between terminals 7 and 3 I 3.

4.

5.

Check resistance at 500 VCD between terminals 7 and 1 Check resistance at 500 VCD between terminals 8 and 3 Check resistance at 500 VCD between terminals 8 and 4

6. Check relay for operation of contact on terminals 1-4 A. Inspect relay internals and note observations B. Record all measurements taken above I C.

D.

Record relay Models and Serial #

Repeat test on an additional relay,.

8.2.8 Sao Test Attach one sample of each size wire listed below to the I test stand using stainless steel tyraps spaced every six inches. Measure maximum deflection observed while the conductor is carrying the current specified.

Test Eire Size Current S-1 #14 100A S-2 #18 60A S-3 #10 175A S-4 # 6 360A I

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ll TEST PROCEDURE LGS EE-1

'W Design Verification Test for Internal Panel Wiring Separation Criteria Rev. 3

'I l

l Limerick Generating Station Page 14 of 14

. E I l l

i I

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I

!I Appendix B lI l

i Test Equipment r I

I I

I I

l 1

1 I

1 I

I

!I 1

'I I

I Appendix B Listing of Test Equipment SOURCE CURRENT SYSTEM (Accuracy as determined by test is no worse than 2.0% accuracy) l Item Type or I.D. Manufacturer's Calibr.

W Icription Mfgr. Model Number Range Accuracy Expir.

KVA Induction G.E.Co. Inductrol 58-0023 0-400A Accuracy None Igulator Determined by external Current Transf.

and Meters Currant Transformer G.E.Co. JCW-0 56-2829 400 to 5A 0.5% 6-9-91 eter, Indicating G.E.Co. P3 01-1072 0-5 Amp 0.25% f.s. 3-19-82 (full scale) star, Indicating G.E.Co. P3 01-6203 0-1.5+ 3.0 0.25% f.s. 1-24-82 C rrent Transducer Halltiplier CT510A2 710147-131 0-5 Amp AC 0. 5% - 6-9-82 (AC to DC) 0-1 ma DC R; cord:r-Multi Point L&N 250 52-3274 0-10 mv DC 0.25% f.s. 6-11-82 s.

II SOURCE VOLTAGE SYSTEM (Accuracy as determined by test is no worse than 2.0% Accuracy)

Item Type or I.D. Manufacturers Calibr.

Description Mfgr. Model Number Range Accuracy Expir.

jnvarter AC to DC Mosley A-lM 79-0386 0-10 VAC= 1.0% f.s. 6-5-82 a 0-10mvde or, 0-25 VAC= 1% f.s. 6-5-82 0-10mvde Recordar L&N 250 52-3274 0-10mvde 0.25% f.s. 6-11-82 cord 2r-Single Point L&N AZAR-H 52-3236 0-10mvde I

I lI

'I B-1

I I

II TARGET CURRENT SYSTEM (Accuracy as determined by test is no worse than 24 Accuracy)

Item Type or I.D. Manufacturer's Calibr.

esqiption Mfgr. Model Number Range Accuracy Expir.

WC Voltage Regulator Sorenson ACR-1000 58-0000 95-130 to 0.25% 7-82 (Automatic) 120 Volts Power Supply HBS M256FP 4747 0-25 Amp Accuracy None determined by external meters diccting Ammeter G.E.Co. P3 01-1081 0-5 Amps 0.25% f.s. 3-9-82 Weston 931 01-1217 0-25A 0.5% f.s. 3-8-82 cording Ammeter Esterline AW 01-8011 0-5 Amps 14 f.s. 8-3-82 L&N oscilli- S-491700 SA to 250mv 1.0% 7-82 runt graph ndicating Digital Hewlett 3465A 57-6642 0-100mv 0.02trdg + 6-82 ltmeter Packard I digit R;; corder-Multi Point L&N 250 52-3274 4.5 to 0.25% f.s. 6-11-82 5.5A TARGET VOLTAGE SYSTEM (Accuracy as determined by test is no worse than 24 Accuracy)

Item Type or I.D. Manuracturer's Calibr.

Deccription Mfgr. Modnl Number Range Accuracy Expir.

diccting Digital VM Fluke 8040A 57-6575 0-200mv 0.03% rdg 4-19-82

+ 3 digits corder L&N 250 5'-3274 0-1.0 Volt 0.25% f.s. 6-11-82 l TARGET INSULATION TEMPERATURE SYSTEM (AccSracy as determined by test is no worse than 24 Accuracy) l l Item Type or I.D. Manufacturer's Calibr.

I D ;cription Mfgr. Model Number Range Accuracy Expir.

Ormocouple Type J t 4*F R;;cordar L&N 250 52-3274 0-572*F 0.25% f.s. 6-11-82 i 4'F gSzcb y6/82 l

t B-2

l I

I I

l Appendix C Test Reports b

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witog.(vr..:t.;o.4  %\te, t-EL APS ED TIME. G.,:,,;, tee ~ ~ '

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s. ore. A,' Cpe E L AT' S ED TI M E ( :. t. .) .

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