ML20031E777
| ML20031E777 | |
| Person / Time | |
|---|---|
| Issue date: | 09/15/1981 |
| From: | Mcdonald D, Reinmuth G NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION IV), NRC OFFICE OF INSPECTION & ENFORCEMENT (IE) |
| To: | |
| Shared Package | |
| ML20031E770 | List: |
| References | |
| REF-QA-99900901 NUDOCS 8110160411 | |
| Download: ML20031E777 (19) | |
Text
_-
U.S. NUCLEAR REGULATORY COMMISSION OFFICE OF INSPECTION AND ENFORCEMENT Docket No.:
99900901/81-04 Environmental Qualification Program:
Independent Verification Test No. 2, Report No. 2 Witness of Environmental Test Equipment Identification:
Test Specimen (s):
Nine single conductor, stranded copper, No. 12 AWG, chemically cross-linked polyethlene (XLPE) insulation (30 mils) with varying combinations of factory splices and insulation repairs.
Nine single conductor, stranded copper, No. 12 AWG, chemically cross-linked polyolefin insulation (30 mils) with varying combinations of factory splices and insulation repairs.
Nine single conductor, stranded cooper. No. 6 AWG, chemically cross-linked polyolefin insulation (45 mils) with varying i
combinations of factory splices and insulation repairs.
Test Organization:
Sandia National Laboratories, Albuquerque, New Mexico 87185 Contract No.:
83101 Inspection Conducted:
Au st 6 & 7, 1981 Sta f f-Cf/lAltl D.G.7cDo'nald,NRCConsultant,LosAlagb's Ddte '
National Laboratory Approved By:
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G. W. Reinmuth, Chief, Vendor and Special Date Projects Branch, IE Summary:
The purpose of this inspection was to observe the progress of the subject environmental qualification program and examine the results to date.
Results:
The review performed during this inspection indicate:
1.
An acceptable pretest data base was established.
2.
The aging, radiation and harsh environment portion of the test conform to the test plan.
3.
Anomalies occurred during the initial portion of the harsh environment test requiring follow-up actions.
4.
All test specimens have demonstrated their functional capabi'.ity during the initial portion of the test.
8110160411 811013 P" QA999 EXISAeL IE 09 99900901 PDR w
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Details Sectier.
Prepared By:
D. G. Mcdonald 4
A.
Persons Contacted E. E. Minor - Sandia National Laboratories (SNL)
D. M. Jeppensen - SNL E. A. Salazar - SNL F. V. Thome - SNL I
B.
General The purpose of the subject test is to independently verify the environ-mental qualification of insulated conductors which contain factory splices and insulation rework.
The test is being conducted by SNL for the NRC in accordance with, " Test Plan for Independent Verification Test of Electric Cable with Factory Splices and Insulation Rework," Rev. 3, dated March 1981.
The purpose of this inspection was to assure that the aging, radiation and harsh environment tests were conducted in accordance with the test plan and to report on 1.he initial results.
The NRC staff representative accomplished this effort by discussions with SNL personnel, review of selected test data, observations of the test facility and witnessing the initial portion of the LOCA/MSLB test.
C.
Test Specimen Preparation 1.
Objectives The objectives of this portion of the inspection were:
a.
To determine that a data base for the test specimen performance characteristics had been established.
b.
To determine that the test specimen had been prestressed (aged).
To determine that the test specimen had been irradiated (aging c.
and accident).
2.
Findings A.
Test Specimens The twenty-seven (27) test specimens are installed on mandrels.
Nine specimens are wound on each of three mandrels.
l provides pictures of the test specimens installed on the mandrels during the radiation portion of the test.
Each of the test specimens are wound around a mandrel twice which provide six or j
seven feet of the insulated corductors for exposure to the test t
conditions.
l l
l
b.
Data Base The test plan required that radiography of the splices and insulation repairs be performed to assess the condition of the splices and the conductor under the insulation repairs.
The test specimens were exposed to both high intensity (150kv) and low intensity (75kv) x-ray radiography in various orientations.
Pretest inspections and measurements were performed in accordance with the test plan to provide a dar. base for comparing the test specimens performance characteristics during various phases of the test.
In addition to the radiography and visual requirements, continuity checks and insulation resistance (IR) measurements were taken and recorded.
The test specimens were submerged in room temperature tap water during the IR measurements.
Selected radiography pictures and data sheets were reviewed by the NRC representative to confirm that an adequate pretest data base had been established and that the appropriate data had been recorded.
c.
Thermal Aging The thermal aging portion of the test was conducted at the SNL environmental test facility.
The test specimens were installed in circulating air furnaces and exposed to the temperatures and times specified in the test plan.
The test plan required that post-aging IR measurements be taken while the test specimens were submerged in room temperature tap water.
The acceptance criteria for the test was:
(1) IR measurements be 10 x 106 ohms at 500 Vdc between the cables and the submergence test chamber (ground).
(2) The 500 Vdc shall be maintained for one minute.
(3) Voltage tolerance 15% and resistance readings 110L The test specimens were moved to the SNL High Intensity Adustable Cobalt Array (HIACA) facility and installed in the exposure chamber to perform the IR tests.
Three of the test specimens did not meet the acceptance criteria of 10 x 106 ohms.
An investigation was performed by SNL to determine the location of the failures and the probable cause.
Details of the investigation and the results are documented in the Office of Inspection and Enforcement Report, Docket No. 99900901/81/03, dated July 15, 1981.
It was determined, as the result of the investigation, to exclude test specimens #1 and #10 from the test. The failures were determined to be caused by handling of the test specimens.
Test specimen #19 would continue to be monitored during the remainder of the test.
l
d.
Radiation Aging and Accident The test specimens were irradiated at the SNL HIACA facility.
The radiation exposure % implemented in two stages.
The aging portion, which cansisted of a total of 50 x 108 rads and a dose rate of 60 K rads / hour, was completed prior to the thermal aging.
IR measurements were taken and recorded after the radiation aging.
The accident portion, which consisted of 1.5 x lid rads and a dose rate of.75 Mrad / hour, was completed subsequent to the thermal aging.
The IR measurement:, were taken and recorded.
Test specimen #19 continued to have a low reading.
Flux mapping of the radiation exposure area had been performed prior to the test specimens being exposed to assure that they received the required total integrated dose (TID) specified in the test plan.
The radiation exposure as achie%ed u3ing a Cobalt 60 source.
3.
Summary Based on information provided and the review of selected records, the staff representative found that the procedures used in establishing the pretest data base, the thermal aging and the radiation portions of_the test were performed in accordance with the test plan req; ire-ments.
D.
Harsh Environment Test 1
1.
Objectives The objectives of this portion of the inspection were:
a.
To determine that the detailed test procedure conformed to the test plan.
b.
To determine that the test configuration conformed to the test plan.
c.
To verify that the test facility was capable of performing the harsh environment test and that the initial portion was conduc?.ed in accordance to the detailed test procedures.
d.
To observe the test facility personnel and their performance of thr. test to assure that the information, data, and any deviet. ions or anomalies were accurately documented.
2.
Findings a.
Test Procedure The SNL staff had developed a detailed test procedure, Enclosure 2, which was used in performing the harsh environment portion of
the test.
The procedure included the required actions and details for preparation and operation of the:
(1) Steam and chemical spray systems.
(2) Instrumentation.
(3) Electrical loading and IR measurements for the test specimens.
(4) Profile conditions.
(5) Startup and run conditions.
b.
Test Specimen _s_
The test specimens installed in the test chamber were the same units which had been subjected to the preconditioning tests. The external test specimen leads were terminated on sliding link terminal blocks and wired per the test procedure.
This configuration allowed the electrical loads to be provided during the test with provisions for performing IR measurements.
An external power supply and load b a k were utilized to provide 480 Vac at 11 amperes to the test specimens.
Backup capability was built into the system. The SNL personnel were observed performing the actions and measurements identified in the test procedure.
All required actions and meaLuremeats were being accurately performed and documented.
c.
Service Conditions A pretest check was completed to assure availability of the steam supply system and chemical spray.
The test was initiated in accor-dance with the test procedure. provides the required test profile.
The test plan did not require preheating and the test was initiated with the test specimens at ambient temperature.
The test temperature was monitored by seven (7) thermocouples located in the test chamber and five (5) thermocouples monitoring the steam and chemical supply I
systems.
The test chamber pressure was monitored continuously by an electronic pressure transducer.
Additional pressure indication was provided by a Heise pressure gauge.
The temperature and pressure were recorded by the data acquisition system which is described in the following section.
The initiation and control of the test profile was observed to assure that the test procedure was being followed. The initial portion of the test, including the chemical spray, complied with the test procedure.
d.
Instrumentation The data acquisition system consisted of magnetic tapes with high speed recorders and an x y recorder as backup.
The components of
the system provided the required accuracies, response times and variable time bases necessary to record the data and evaluate any anomolies or deviations.
The instrument calibration tags were checked to assure that the instruments were within their calibration period.
the instruments had been calibrated by SNL wiht standards traceable to the National Bureau of Standards.
The SNL personnel were observed making the required notations on the strip chart and paper tapes to identify test conditions, time base or other changes in the test status to assist in the post test analysis.
e.
Preliminary Results The acceptance criteria for the test was:
(1)
IR measurements be 10 x 108 ohms at 500 Vdc between the insulated conductors and ground.
(2) Functional capability be demonstrated by applying 480 124 Vac and the insulated conductors supply 11 il amperes to an external load for the duration of the test except when IR measurements are being performed.
All the test specimens have demonstrated their functional 1
capability during the initial portion of the test.
The IR measurements have indicated that some of the test specimens do not meet the 10 x 108 ohms at 500 Vdc identified as the acceptable value.
All of the test specimens were in the 108 - 107 ohm range during the portion of the test witnessed with the exception of test specimens No. 19, 20 and 21.
A measurement could not be obtained during the first transient peak on these test specimens.
However, measurements were recorded in the 108 ohm range during the second transiant peak and for the remainder of the test witnessed.
The measurements were taken with the voltages varying between 10 and 500 Vdc.
As the test progressed and the temperature and pressure were ramped down, the IR values and voltage generally increased with some of the readings in the 108 ohm range at 500 Vdc.
The significance of the low IR measurements cannot be determined at this time.
The objective of the test, as indicated in the test plan, is to demonstrate the qualification of electric cable (insulated conductors) witn factory splices and insulation rework.
The functional capability of all the test specimens has been demonstrated, as required by NUREG-0588, by maintaining the 480 Vac while supplying an 11 arr. pere load.
Moisture was observed at the external connections of some of the No. 6 AWG test specimens and around the compression fittings where the insulated conductors exit the test chamber.
The moisture decreased as the temperature and pressure were ramped down.
i
- m. -
t The significance of the low IR readings and the moisture observed cannot be determined at this time.
All test specimens are maintaining their functional capability as identified in the test plan.
The SNL personnel are devising a disassembly procedure to identify, isolate and determine the cause of the low IR readings and the cause of the moisture leaking from some of the test specimens.
lhe relationship of the low IR readings and the moisture extrusion to the functional operability requirement will be dependent on the results of the SNL post-test investigations.
3.
Summary Based on the information provided above, the staff found that; the detailed test procedure and the test configuration conformed to the j
test plan; the test facility was capable of providing and controlling the service conditions; and the SNL personnel performed all required actions and documented the required data and information in accordance with the test plan requirements.
The initial results indicate that the test specimens have demonstrated their functional capability; however, the anomolies which have occurred will require follow-up actions.
The results of the test, post-test investigations and the resultant conclusions will be documented by SNL and will include the necessary data and informatien to support the conclusions as required by HUREG-0588.
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CHECKLIST FOR STEAM /CilEMICAL SPRAY TEST (Para 4.9.3)
I.
Pre-Test Conditioning A.
Prepare Chemical Spray Solution (24 hrs in advance of
)
start of test) 1.
Turn chemical tank spray " EAST
- pump switch OFF.
2.
Chemical tank water level at approximately 700 gals (15 in. from top of tank).
3.
Turn on immersion heaters and pre-heat the water to 120*F i 10*F (approximately 24 hrs).
4.
After water has reached desired temperature, turn on mixer and carefully add the following chemicals to the heated water:
115 lbs of H B03 (Boric acid) commercial grade 3
106 lbs of Na2 2 3 (Sodium Thiosulphate) commercial 80 grade 72 lbs of NaOH (Sodium Hydroxide) commercial grade 5.
When chemicals have been thoroughly mixed, turn off mixer and add sufficient water to bring the water level in the tank to 6.75 in. from the top of the tank (totel depth = 65.25 in., approx. 800 gals)
.([djust as necessary) 6.
Verify that the solution pH = 10.5 0.3 7.
Verify spray metering readouts are calibrated (102 reading on the flow meter scale =.35 gal / min) 8.
Verify that all spray lines are connected and fittings are tight.
9.
Verify that all spray line valves from chemical tank to the test chamber are positioned properly.
B.
Prepare Steam System (' Prior to start of test) 1.
Torque test chamber flange bolts to 60 f t-lbr (wet the threads with WD40 prior to installation) and all penetration plate bolts to 130 5 in-Ibs (wet tapped holes with WD40)
,2-2-
Install Heise pressure gage and the two electronic pressure transducers (0-30 psig range and 0-200 psig range) on the test chamber head and isolate the 0-30 psig (low range) gage.
Zero the test chamber Heise gage and the Heise gage on the regulator outlet (upstairs).
3.
Install the test chamber main flange drip pans and the spray diverter shields.
4.
Check the accumulator operating water level and fill as necessary.
5.
Verify Boiler water inlet in "open" position.
6.
Verify Boiler steam outlet in " closed" position.
7.
Boiler water make-up system is ON.
8.
Energize the Boiler, verify that operating current
~
is 70 amps (maximum).
9.
When boiler has built up 50 lbs steam pressure (minimum), open boiler steam outlet and begin charging the accumulater.
10.
Charge accumulator to 175 t 5 psig.
NOTE:
Boiler pressure will be approximately 190 + 10 psig to provide the desired accumulator pressure and due to the design of the boiler regulator, constant attention and re-adjustment of the regulator will be necessary while the boiler is operated in the 150-200 psig range.
C.
Energize Cable Test Circuits 1.
Attach power leads to the cable terminal blocks per attached wiring diagram.
2.
Turn on load bank and verify that 480t 24 VAC @
li tlA is applied across the cable circuit.
O
' Enclosure 2
.3 -
3.
Verify that all load bank cooling fans are ON and operating (four exhaust fans on top of cabinet and five intake fans on the bottom).
D.
Pre-heat Steam Lines 1.
Set the mainline regulator (upstairs) to 125 psig i5 psig.
2.
Verify that the steamline valve inside the test cell is closed. Slowly open the main steam valve (upstairs) and adjust the mainline regulator as necessary to 125 psig + 5 psig.
3.
By-pass steam trap as necessary to bleed off accumulated condensation.
4.
Allow accumulator pressure to return to 175 t 5 psig.
(approximately 1S min.).
While the accumulator is recharging, set strip chart recorder drive to 6 in/ min.
and zero both pens with no input to either channel.
Verify that one strip chart channel is connected to No. 6 thermocouple inside the test chamber and the other pen is connected to the 0-200 psig pressure transducer.
Set the Autodata 9 scan rate to 10 sec and the Autodata 10 scan rate to 1 min.
Synchronize i
the TIME readings of both data loggers.
II.
Steam Dump (Test Sequence per Fig. 1 -- Temp /ptessure profile) 1.
Verify that the mainline regulator (upstairs) is pre-set at 125 psig as indicated by the upstairs Heise gage.
l 2.
T-1 minute - Start the countdown 1 minute prior to steam dump.
3.
T-30 seconds - Isolate the in-cell steam trap line.
Bleed off pressure by opening the steam trap by-pass valve (close the by-pass valve as soon as the pressure has been relieved).
4.
T-15 seconds - Start the two data loggers (Autodata 9 and 10), turn strip chart recorder chart drive to "ON" and open the valve on the condensate line from the Test Chamber.
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-4 5.
T ( Steam Dump) - Open the st'am line valve in the cell, quickly ren.-ove the valve handl and vacate the cell.
c 6.
T+15 seconds - Turn on the chemical spray pump (" EAST" pump switch) and verify flow rate indicator scale reads 102 (.35 gals / min).
7.
T+30 seconds to 1 min - Adjust the upstairs (main steam line) regulator to read 115t 5 psig as indicated on the upstairs Heise gage (115 psig corresponds to 174*C).
NOTE:
When the regulator has been adjusted and the J
pressure has stabilized, enter the GIF and adjust the 0-200 psig pressure transducer to track the Heise gage reading (20 psig = 1 volt) 8.
T+2 hrs (approx.) - Remove power (480 VAC) from cable circuit and perform IR test (per Fig. 1 Temp / Pressure Profile).
Perform IR test on each cable by opening the sliding links.jon the terminal blocks.
NOTE:
Power must be removed each time the IR Test is performed -- reapply power at the conclusion of each IR Test after the sliding 1.nks have been replaced into the proper configuration.
9.
T+3 hrs - Turn chemical spray OFF and begin Temp / Pressure ramp down per Fig. 1.
Observe and record the chemical spray reservoir tank liquid level and verify the desired spray flow rate, i.e.,
12.2 gal /in 0 0.35 g'af/ min
= 1.72 in/hr decrease in the chemical spray tank liquid level.
l 10.
At the conclusion of ramp down, prepare for the ini-tiation of the second Temp / pressure excursion per Fig. 1 (see step 5 above).
s l
l 11.
T+5 hrs 15 seconds - Repeat steps 6 and 7 above.
i l
12.
Per Fig. 1, Temp / Pressure Profile, perform IR Tests at each temperature plateau as indicated -- remember to remove the 480 7AC power before each IR Test and reapply after IR Test concluded.
13.
T+24 hrs - Turn chemical spray OFF (" EAST" Pump) and continue step function temperature ramp down procedure per Fig. 1.
C 14.
T+96 hrs (4 days) - Concurrently with the last ramp down step from 129'C to 103*C the By-Pass regulator must be pre-heated as follows:
a.
Verify that the by-pass /2-1/2" line valve to the Super Heater is closed.
b.
Open the 1/2" regulator by-pass valve and the 1" motor operated regulator by-pass valve.
c.
Warm-up the By-Pass regulator (and associated feed lines) by running low pressure steam through the Super Heater steam separater strainer drain
- line, d.
When the By-Pass regulator (and lines) are " warmed,"
set the 1/2" regulator to 4 psig.
Open the test chamber condensate line steam trap bypass valve and leave it open for the remainder of the test.
e.
Disconnect the 0-200 psig pressure transducer that leads from the strip chart recorder.
Activate the 0-30 psig pressure transducer.
Adjust the 0-30 psig transducer to track the test ch'mber a
Heise gage reading.
Verify that the 0~36 psig output is being properly logged on the monitoring equipment.
15.
T+4 days thru Conclusion of Test - Continue steady state steam pressure testing for the remaining 29 days of the Fig. 1 Profile. Perform an IR test once each week (remember to remove 480 VAC power prior
]
to each IR test).
III.
Re-Test Procedure 1.
If steam pressure, or any other component of the test environment, is lost or improperly altered due to unforseen circumstances, the environmental conditions present at the point of interruption shall be restored and an IR Test shal.1 be performed.
If the Test Engineer and the results of the IR Test dictate, the test
- ~
~
attained at the point the test was interrupted.
Return to the desired test pressure plateau in a gradual manner (over a period of several minutes).
2.
If there are random failures of individual cable samples, these specific cables shall be noted and removed from the 480 VAC test circuit.
The testing of the remaining cables shall not be interrupted if possible.
Q O
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7/6/81
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