ML20059K123
| ML20059K123 | |
| Person / Time | |
|---|---|
| Issue date: | 01/14/1994 |
| From: | Amarjit S Office of Nuclear Reactor Regulation |
| To: | Mccracken C Office of Nuclear Reactor Regulation |
| References | |
| NUDOCS 9402010342 | |
| Download: ML20059K123 (34) | |
Text
f January 14, 1994 MEMORANDUM FOR:
Conrad E. McCracken, Chief Plant Systems Branch Division of Systems Safety and Analysis THRU:
K. Steven West, Chief Special Project Section Plant Systems Branch Division of Systems Safety and Analysis FROM:
Amarjit Singh, Reactor Systems Engineer Plant Systems Branch Division of Systems Safety and Analysis
SUBJECT:
TRIP TO OMEGA POINT LABORATORIES, NUCLEAR MANAGEMENT AND RESOURCES COUNCIL PHASE II THERM 0-LAG FIRE BARRIER TEST PROGRAM The enclosed trip report (Enclosure 1) covers my observations of Thermo-Lag fire barrier test schemes construction by the Nuclear Management and Resources Council for the generic qualification of Thermo-Lag fire barriers throughout the industry.
This report covers the construction performed from January 3 through 7, 1994, at Omega Point Laboratories, Inc. (OPL) Elmendorf, Texas.
Uby Amarjit Singh, Reactor Systems Engineer Special Projects Section Plant Systems Branch Division of Systems Safety and Analysis
Enclosures:
1.
Trip Report, Omega Point Laboratories, Inc.
2.
Tentative Schedule For NUMARC Phase II Test Program J
3.
Drwing - Test Assembly 2-7 4.
NUMARC Phase 2 Test Program, Test Plan 1
DISTRIRUTION:
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January 14, 1994 j
MEMORANDUM FOR:
Conrad E. McCracken, Chief Plant Systems Branch Division of Systems Safety and Analysis THRU:
K. Steven West, Chief Special Project Section Plant Systems Branch Division of Systems Safety and Analysis j
FROM:
Amarjit Singh, Reactor Systems Engineer Plant Systems Branch Division of Systems Safety and Analysis
SUBJECT:
TRIP TO OMEGA POINT LABORATORIES, NUCLEAR MANAGEMENT AND RESOURCES COUNCIL PHASE II THERM 0-LAG FIRE BARRIER TEST PROGRAM The enclosed trip report (Enclosure 1) covers my observations of Thermo-Lag fire barrier test schemes construction by the Nuclear Management and Resources Council for the generic qualification of Thermo-Lag fire barriers throughout
)
the. industry.
This report covers the construction performed from January 3 through 7,1994, at Omega Point Laboratories, Inc. (OPL) Elmendorf, Texas.
Why Amarjit Singh, Reactor Systems Engineer Special Projects Section Plant Systems Branch Division of Systems Safety and Analysis
Enclosures:
1.
Trip Report, Omega Point Laboratories, Inc.
2.
Tentative Schedule for NUMARC Phase II Test Program 3.
Drawing - Test Assembly 2-7 4.
NUMARC Phase 2 Test Program, Test Plan DISTRIBUTION:
. Central File NRC PDR Plant File ASingh
'GHubbard JLyons D0udinot WDean PMadden JHolmes EPawlik, R:III SWest GMulley AThandani CMcCracken 3f SPLB:DSSA6W~
SPLh:DSSA SPLB:DS ASi @h;cf SWest CMcCracken 1/[.]V94 1/g94 1/j/ /94
[G:\\SINGH.0PL)
n Trio Report Industry Group:
Nuclear Management and Resources Council i
i (NUMARC)
Activity:
NUMARC Phase II Thermo-Lag Fire Barrier Test Progrtm i
i Test Facility:
Omega Point Laboratories, Inc.,
Elmendorf, Texas Trip Date:
January 3 through 7, 1994 Reviewer:
Amarjit Singh, NRR/DSSA/SPLB i
Introduction On January 3 through 7, 1994 I visited Omega Point Laboratories, Inc. (OPL),
Elmendorf, Texas to witness and monitor NUMARC's construction of raceway test j
schemes for generic qualification of Thermo-Lag fire barriers throughout the industry. The NUMARC test program for the generic qualification of Thermo-Lag fire barriers includes two phases.
Phase I program was documented in the previous various trip reports.
Phase II includes 11 test configurations (existing industry installations and additional upgrades) funded by NUMARC.
Some of the Phase II program test assemblies have reduced amounts of exposed cable tray length in the furnace.
In lieu of using a horseshoe configuration simular to those which were used in Phase I, some of the test specimens are L-shaped.
This change was not reviewed by the staff.
Industry personnel and contractors contacted during this visit were Richard Lehman of TSI and Cal Bunning of ABB Impell, Michael Jordan of Promatec, Inc.,
Leo Werner, William Nicar, Donald Bagby and Duane Powers of Peak Seals, Inc.
In addition, the following OPL personnel were contacted: Deggary-Priest, President OPL; Constance Humphrey, Quality Assurance Manager and Vice President, OPL; and Kerry Hitchcock, Shop Foreman, OPL.
Construction Activities Observations I observed the construction of a test assembly, Assembly 2-7.
I also audited the following procedures and specifications:
" Procedure for Quality Verification of Fire Resistive Barrier Systems Installed on Electical Cables and Raceways," 0784-00001-P-01 Revision 1 prepared for NUMARC by ABB Impell Corporation dated December 14, 1993.
" Vendor Purchasing Specification and Quantity Assurance Requirements,"
Purchase Order No. 1085Q dated November 8, 1993.
e )
Test Plan, Revision 0, " Fire Endurance Tests of Articles Protected with the Thermo-Lag Fire Barrier System, Revision 0," dated December 13, 1993.
"Non Conformance Reporting," Procedure No. QCP-0018, Revision F, dated April 1, 1993.
" Installation of TS-MS-0045B/45B(f)," Procedure No. IP-0045, Revision C dated July 1, 1991.
" Receiving, Handling and Storage Inspection," Procedure No. QCP-0050, Revision E, dated April 1, 1993.
Test Assembly 2-7 is a 1-hour, baseline specimen consisting of two 24-inch wide by 4-inch high aluminum ladder back cable trays and two 6-inch wide by 4-inch high aluminum ladder back cable trays.
Each cable tray contained a single layer of cables.
The horizontal and vertical tray segments, bottom and sides of one 6-inch and 24-inch tray were protected with a single panel using Thermo-lag score and fold joints. Stainless steel banding was installed within 2-inches of butt joints and at 12-inch maximum intervals.
The Thermo-Lag fire barrier material used were 1/2 inch (nominal) panels with ribs and stress skin. On the horizontal and vertical runs, the panels were installed with ribs perpendicular to the rungs. On the radial bends, the ribs were oriented parallel to the rungs. The ribs and stress skin were on the inside of the Thermo-Lag enclosure. All joints were pre-buttered with Thermo-Lag 330-1 trowel grade material.
Thermocouples were placed at 6-inch intervals on the exterior surface of the tray rails underneath the fire barrier material. One bare copper conductor with thermocouples was also installed on top of the single layer of cables in the longitudinal center of the tray, positioned parallel to and above the bare copper conductor which was installed on the cable tray rungs. One bare cooper conductor with thermocouples was installed on the top of the cable tray rungs along the entire length of the cable tray run at the longitudinal center of the tray and was secured to each tray rung.
One bare copper conductor with thermocouples was installed below the cable tray rungs along the entire length of the cable tray run near the longitudinal center of the tray (offset approximately 1 inch from the conductor above tray rungs).
Fire testing of Assembly 2-7 is tentatively scheduled for January 27, 1994.
The schedule of remaining testing of the other assemblies is stated in.
The installers appeared to be skilled and trained.
I observed installer training conducted by Calvin Banning of ABB Impell and also reviewed their training records which verified that the installers and control inspectors were trained and qualified.
I also reviewed, the receipt and inspection records, and concluded that the materials were received and inspected in accordance with the OPL program requirements as established by NUMARC purchase order. Additionally, ABB-Impell performed source and receive inspection in accordance with their procedures.
. Summary The fabrication of the NUMARC test assembly was accomplished in a skilled and a professional manner. The installers carefully followed procedures and consulted with engineering staff when questions arose. The OPL and NUMARC's quality control and quality assurance personnel monitored the construction activities daily and properly which verified the adequacy of installations.
i
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Tentative Schedule for NUMARC Phase II Test Program Test Design Start Barrier Moisture Proposed Assembly Drawings Barrier Application Equilibrium Test Application Completion Date 2-9 12/13/93 12/15/93 12/21/93 01/11/94 01/26/94 2-7 12/16/93 01/03/94 01/05/94 01/26/94 01/27/94 2-10' 12/24/93 01/06/94 01/10/94 01/31/94 02/14/94 2-1 12/18/93 01/11/94 01/13/94 02/03/94 02/15/94 2-3 12/24/93 01/17/94 01/18/94 02/08/94 02/16/94 2-8 01/08/94 01/19/94 01/25/94 02/15/94 02/23/94 2-2 01/08/94 01/26/94 01/31/93 02/21/94 02/24/94 2-6 01/08/94 02/01/94 02/03/94 02/24/94 02/25/94 12-11 01/15/94 02/07/94 02/10/94 03/03/94 03/22/94
)
2-4 01/15/94 02/14/94 02/16/94 03/09/94 03/23/94 2-5 01/15/94 02/17/94 02/25/94 03/18/94 03/24/94 l
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- 3. NO EDGE GUARDS SHALL BE USED.
- 4. RADIAL BEND EDVERAGE TO UTILIZE SEPARATE HITERED P!ECES. I BAND SHDULD BE USED TD SECURE EACH MITRED 3CCTION UNLESS ADDITIONAL REINrQRCEMENT IS REGUIRED (2 BAND 3 MAX 1
- 5. INSTALL MATERIAL DN TRAYS FIRST AND SUP9 ORT MEM3ERS LAST.
- 6. EXTEND THERMD-LAG COVERAGE ON SUPPORT NEM3ERS 9' O(IN.) 7010' (MAX.) AS NEASURED rRDH DUTSIDE Or TRAT ENVELOPE ALDNQ ANY CCNTINUDUI SU*PCRT STEEL CONDUCTIVE PATR DRIENTATIDN Dr V-RIBS FOR PANELS ON $UPPORTS IS NDNCRITICAL.
- 7. EXTEND THERHD-LAG COVERAGE THROUGH TDP Dr TE37 ruRNACE FOR NDMINAL DISTANCE Dr 12'.
- 8. INSTALL THERMD-LAG PANELS SUCH THAT SIDE PANEL PIECES ARE PLACED IN COMPRE33IDN BETVEEN TOP AND 30TTDM PANEL PIECES.
- 10. PANELS TO BE INSTALLED VITH STRESS SKIN SIDE FACING PROTECTED COMMODITY.
- 11. FOR HORIZDNTN AND VERTICAL TRAY SEGMENTS INSTALL PANELS VITH V-RIBS DRIENTED PARALt.[L TO RUN Dr TRAY. PANELS INSTALLED CN SIDE RAILS TO MAVE V-RIBS DRIENTED VERTICALLY DN HCRIZENTAL TRAY $ECMENT AND K3RIZDNTALLY DN VERTICAL TRAY SEGMENT.
i V-RIS DRIENTATIEN rQR HITERED PIECES ON RADIAL BEND IS NDNCRITICAL (CRAFT j
PREROGATIVD.
- 12. CABLE TRAY SMALL M3T BE PRE-BANDED.
- 13. V-RIBS ON PANELS MAY BE PLATTENED IN AREAS Dr TRAY SIDE RAIL FLANGES AS REQUIRED TDR TIGHT JCINT FIT-UP.
- 14. max! HUM A!NT CAP BETVEEN PANELS DURING rIT-UP !$ t/4',
l
- 15. A5 REQUIRED BY TRAY SPLICE PLATE HARDVARE, SEPARATE SPLICE PLATE CDVERS (VITH BANDING) ARE ACCEPTABLE.
- 16. TDUCH-UP Dr PRE-BUTTERED JO!NT3 AFTER INSTALLATION IS ACCEPTABLE TO OCMPENSATE FDR SHRINKAGE Dr TROVEL GRADE MATERIAL TD DETAIN 1/2' (MIN.) TO D/B' (MAX.) Drf.
- 17. ALL JOINTS BETVEEN PANELS SHALL BE SQUARE DR BUTT TYPE, I.E, PANELS SHALL NOT BE BCVELED AT JOINTS EXCEPT Ir REQUIRED AT RADIAL RENDS.
- 10. LDT NUMBER TRACEADILITY AND INSTALLED LOCATION SHAlt BE MAINTAINED FOR ALL THERMD-LAG HATERIALS.
- 19. THERMD-LAG 3 HALL NOT BE APPLIED TO TEST ITCM UNT!L RELEASED BY TEST LABDRATORY.
21 ALL CUESTICA3 PCRTAINING TO THERMD-LAG MATERIAL APPLICATION SMALL 3E RESDLVED VITH THE ENGINEER PRIOR TD !NSTALLATIC4 ABB IMPELL CORP.
PROJ. ND. 0784-00001 NUMARC PHASE 2 TEST PROGRAM REv.
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- 2. REFER TO SH 9C FOR TYPICAL INSTALL Ai![H DCTES.
- 3. kTFE R Til DVG DIB4-00005-U-000 FOR REVISION HISTORY.
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2 STAINLE33 STEEL BANDING TD BE INSTALLED VITHIN 2' CF BUTT JCINTS AND AT 12* (MAX.)
INTERVAL $ VMERE POSSIBLE. CLOSER 3AND SPACING 13 PERMIS$1BLE VHERE NECESSARY TO RESULT IN A SECURE INSTALLATION CHINIMUM CF 1 BAND PER INDIVIDUAL PIECD.
- 3. NO EDGE GUARDS SHALL IE USED.
- 4. RA01AL BEND COVERAGE ON ONE SIDE TO UTILIZE SEPARATE MITERED PIECES.1 BAND SHOULD BE US SECURE EACH HITERED SECT 10N UNLESS ADDITIONAL REINFORCEMENT 11 RECU! RED (2 3 ANDS MAX.).
S. INSTALL MATERIAL ON TRAYS FIRST AND SUPPORT MEMBERS LAST.
- 6. EXTEND THERM 0-LAG COVERAGE ON SLPPORT MEM3ERS 9' (MIN.) TO 10' (MAX.) AS MEASURED FROM QUTSIDE OF TRAY ENVELOPE ALCNG ANY CONTINUCUS SUPPORT STEEL i
CONDUCTIVE PATH. ORIENTATION OF V-RIBS FIR PANELS ON SUPPORTS IS NONCRITICAL.
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B. FOR HCRIZONTAL AND VERTICAL TRAY SEGHENTS, BOTTDM AND $1 DES OF TRAYS TO BE PROTECTED VITH* A SINGLE PANEL L3!NG 3 CORE AND FDLD JOINTS. SINGLE PANEL TET BE SECURED VITH STAINLE33 STEEL BANDING (24* $ PACING 0.C.) PRIOR TO INSTALLATION OF TDA PANEL. TCP Or TRAYS TO BC PROTECTED VITH A SINGL,E PANEL.
- 9. SCORE AND FDLD JOINTS ON HORIZONTAL AND VERTICAL TRAY SEGMENTS TO BE FILLED VITH TROVEL GRADE MATERIAL TO A 1/2*(MIN.) 5/B'(MAX.) DFT.
- 10. CNE (1) NUTT JCINT DN BOTTOM PANEL SHALL DE POSITIONED AT NOMINAL CENTER OF HDRIZONTAL SPAN:
- 11. PANELS TO BE INSTALLED VITh STRES3 IKIN SIDE FACING PROTECTED CCMHDDITY.
- 12. FOR HOR'.ZONTAL AND VERTICAL TRAY SEGMENTS INSTALL PANE't S VITH V-RIBS DRIENTED PARALLEL TO RUN CF TRAY. V-RIB CRIENTATION FOR MITERED PIECES ON RADIAL BEND IS NONCRITICAL (CRAFT PREROGATIVE).
- 13. CABLE TRAYS SHALL BE PRE-BANDED, BAND $ PACING 24' ClC.
- 14. V-RIBS ON PANEL $ MAY BE FLATTENED IN AREAS OF TRAY SIDC RAIL FLANGES AS REQUIRED FOR TIGHT JOINT FIT-UP.
- 13. MAXIMUM JOINT GAP BETVECN PANELS DURING FIT-UP IS t/4'.
- 16. AS REQUIRED BY TRAY SPLICE PLATC HARDVARE, SEPARATE SPLICE PLATE COVERS (VITH 3ANDING) ARE ACCEPTABLE.
- 17. TOUCH-UP OF PRE-3 UTTERED JOINTS ATTER INSTALLAT!DN IS ACCEPTA3LE TO COMPENSATE i
FOR SHRINKAGE OF TROVEL GRADE MATERIAL TO DBTAIN 1/2* (MIN.) TO 5/8* (MAX.) DFT.
!B. ALL JOINTS BETVEEN PANELS SHALL BE $0UARE CR BUTT TYPC, !C, PANELS SHALL NOT 3E BEVELED AT JOINTS EXCEPT IF REQUIRED AT RAD!AL BENDS.
- 19. LOT NUMBER TRACEABILITY AND INSTALLED LOCAT[CN SHALL BE MAjNTAINED T"R ALL THERMD-LAG MATERI ALS.
- 20. THERMO-L AG SHALL NOT BE APPLIED TO TEST ITEM UNTIL RELEASED BY TEST LABORATORY.
- 21. ALL QUESTIONS PERTAINING TO THERMD-LAG MATERIAL APPLICATION SHALL BE RESOLVED 1
VITH THE ENGINEER PRIOR TO INSTALLATICN.
ABB IMPELL CORP.
PROJ. NO. 0784-00001 REV.
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i PHASE 2 TEST ASSEMBLIES Assembly 1 or 3 B/U Test Commodity Description Barrier Description H ur 2-1 1
B 3/4",2",4" and 6" dia. AL conduits Preshaped " half round" conduit sections 2-2 1
B 3/4",2" and 3" dia. AL conduits Prefabricated panel " box" configuration U
3/4",2" and 3" dia. AL conduits Prefabricated panel " box" configuration with reinforced joints and seams B
3/4" and 2" dia. AL conduits Preshaped " half mund" conduit sections with 3M Fire Dam 150 caulk for outdoor applications 2-3 3
B 3/4",3" and 6" dia. AL conduits Preshaped " half round" conduit sections 2-4 3
U 3/4",3" and 6" dia. AL conduits Preshaped " half round" conduit sections with upgrade 2-5 3
U 3/4",3" and 6" dia. AL conduits Preshaped " half round" conduit sections with upgrade 2-6 3
B 3/4",2" and 3" dia. AL conduits Prefabricated panel " box" configuration U
3/4",2" and 3" dia. AL conduits Prefabricated panel " box" configuration with reinforced joints and seams 2-7 1
B (2) 6"x4" AL cable trays (1) tray with " score and fold" design (1) tray with "4 separate piece" design, i
B (2) 24"x4" AL cable trays (1) tray with " score and fold" design w/ additional bare copper conductor under (1) tray with "4 separate piece" design rungs i
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PIIA9E 2 TEST ASSEMBLIES (Cont.)
Assembly 1 or 3 B/U Test Commodity Description Barrier Description Hour 2-8 1
U (2) 6"x4" AL cable trays (1) tray wrscore and fold" (upgrade) design (1) tray w/"4 separate piece"(upgrade) design U
(2) 24"x4" AL cable trays (1) tray w/" score and fold" (upgrade) design w/ additional bare copper conductor under (1) tray w/"4 separate piece" (upgrade) design rungs 2-9 1
U 36"x4" AL cable tray "4 separate piece" design with upgrade (1-2)
(from Phase 1)
(pre-band horizontal portion at 24" intervals')
2-10 3
B (2) 6"x4" AL cable trays (1) tray with " score and fold" design (1) tray with "4 separate piece" design B
(2) 24"x4" AL cable trays (1) tray with " score and fold" design (1) tray with "4 separate piece" design 2 11 3
U (2) G"x4" AL cable trays (1) tray w/" score and fold" (upgrade) design (1) tray w/"4 separate piece" design (1) tray w/" score and fold" (upgrade) design U
(2) 24"x4" AL cable trays (1) tray w/"4 separate piece" design i
NOTE: Assembly number may not constitute sequence of tests.
FIRE ENDURANCE TESTS OF ARTICLES PROTECTED WITH THE THERMO-LAG @*
FIRE BARRIER SYSTEM l
NUMARC Phase 2 Test Program' TEST PLAN, Rev. O i
December 13,1993 i
Prepared for:
Nuclear Management and Resources Council (NUMARC) 1776 Eye Street, N.W. Suite 300 i
Washington, D.C. 20006-3706 f" "Os
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NUMARC TEST PLAN, Rev. O December i3,1993 Phasa 2 Test Program Page ii ABSTRACT This document consists of a Test Plan to describe the procedures and techniques to be utilized during the performance of the NUMARC Phase 2 Program to address Thermo-Lag Fire Barrier Material.
The methodology riecessary for the evaluation of all Phase 2 test configurations is described herein.
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i The details and instructions contained herein will be followed in the performance of this test project.
- f (N t N R3 Deggdy N. Priest, President Date i
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.NUMARC TEST PLAN, Rev. O December i3,1993 Phase 2 Test Program Page lii TABLE OF CONTENTS ITEM PAGE r-1.0 Scope 1
2.0 Objective 1
3.0 Acceptance Criteria 1
4.0 ' Definitions 2
5.0 Responsibilities 3
6.0 Prerequisites 6:
7.0 Procedure 11 8.0 Data Systems 13 i
9.0 Fire Test Report 13 i
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4 TEST PLAN, Rev. O FIRE ENDURANCE TESTS OF ARTICLES PROTECTED WITH THE THERMO-LAG @
FIRE BARRIER SYSTEM NUMARC PHASE 2 TEST PROGRAM 1.0 SCOPE This test plan describes the methods and guidelines to be utilized for the preparation of test specimens, installation of the THERMO-LAG 8 (hereafter referred to as "Thermo-Lag") Fire Resistive Barrier Systems 'and other raceway fire barrier materials as aoplicable, performance of fire endurance and hose stream tests, temperature monitoring, and all applicable documentation of these tasks and the test results. The test program will be performed under the auspices of Nuclear Management Resources Council (NUMARC). NUMARC will have total management responsibility for all i
aspects of this program.
2.0 OBJECTIVE The objective of these tests is to qualify protective fire barrier systems for redundant essential cables. Successful results of this test program will provide documented evidence that the fire barrier systems will satisfactorily withstand an ASTM E119-88 fire exposure for a periods of one hour or three hours, followed by a hose stream test.
i 3.0 ACCEPTANCE CRITERIA The acceptance criteria for this test program will be in accordance with the U.S. Nuclear Regulatory Commission's proposed position dated November 20, 1992 and NUREG 0800 except for provision ofinformational thermocouples for cable tray test items as described in Section 6.7 of the Test Plan and no informational thermocouples on cables. The performance of each fire barrier system will satisfy this criteria provided the following conditions are met:
l 3.1 Temperature - The average of any thermocouple series installed for test acceptance purposes as described in Section 6.7 shall not exceed 250 F above the average initial temperature. The maximum reading for any single thermocouple installed for test acceptance purposes shall not exceed a temperature rise of 325 F above its initial temperature.
1 3.2 Hose Stream Test / Barrier Inspection - Following the fire endurance test, accessible portions of each test assembly shall be subjected to a j
water hose stream test as described in Section 7.2 of the Test Plan.
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NUMARC TEST PLAN, Rev. O December k3,1993 Phase 2 Test Program Page 2 Following the hose stream test, a visualinspection of outer surfaces of each protective envelope will be conducted as described in Section 7.3.
No evidence of burnthrough or openings in the barrier shall be identified, such that the raceway or cables are visible.
3.3 Cable Visual Inspection - Providing items 3.1 and 3.2 are satisfactory, visual inspection of the cables is not required. However, if either of these criteria are not met, the barrier material shall be removed and the cables inspected visually for indication of thermal degradation as described in Section 7.4. Visual cable inspection will only apply to cable tray test assemblies.
4.0 DEFINITIONS 4.1 ' Test Deck - A horizontal,8' x 13' assembly designed to support the test item in position within the test furnace.
4.2 Test Item - All materials associated with raceways, including supports and cables (excluding fire barrier materials).
4.3 Test Assembly - The combination of the test item (s), thermocouples, i rotective envelope and test deck, all organized into a single assembly.
4.4 Fire Penetration Seal-Any fire stop seal systems which are required to be installed inside raceway assemblies and hence are to be considered part of the test item under evaluation. Seals which are designed to close the remainder of the opening between the test deck and the test item are not considered to be penetration seals, and are not considered critical items nor part of the test item.
4.5 Thermocouple - An electrical assembly used to measure temperature, consisting of an electrically-welded, fusedjunction of dissimilar metals and their respective leads to the data acquisition system.
The thermocouple leads are insulated with materials capable of withstanding the moisture and heat requirements of the test 1
environment.
4.6 Raceway - For purposes of this project, any conduit, tray, junction box, pull box, LB or other item designed to enclose, protect and route electrical cables (or any combination thereoD will be considered to be a raceway.
4.7 Air Drop - For purposes of this project, any assembly of bare copper conductors with thermocouples not enclosed ithin a raceway will be considered to be an air drop.
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1 NUMARC TEST PLAN, Rev. O December 13,1993 Phase 2 Test Program Page 3 i
I 4.8 Fire Resistive Barrier System - A specific construction of devices, materials or coatings installed around, or applied to, the test item.
Also called a Protective Envelope System.
4.9 Baseline Barrier Configuration - A one or three hour Thermo-Lag Fire Barrier System designed and installed to represent existing utility configurations as descdbed in the EPRI Generic Test Plan.
1 5.0 RESPONSIBILITIES 5.1 Nuclear Management and Resource Council (NUMARC) 5.1.1 Assume, through its contractor, total management responsibility of this test program and establish all required interface with the U.S. Nuclear Regulatory Commission (NRC) and industry utility representatives.
5.1.2 Provide those materials not supplied by utilities as required to construct the test assemblies. Such materials may include but are not limited to tools and equipment, raceway components, cabling, penetration seal materials, fire resistive barrier system materials, etc.
5.2 Electric Power Research Institute (EPRI) 5.2.1 Provide industry survey data to be used for consideration and selection of the test assemblies covered by Phase 2 of the NUMARC test program.
5.3 ABB Impell Corporation i
5.3.1 In coordination with EPRI and NUMARC, establish the i
criteria, guidelines, drawings, recommendations, etc., to govern the construction of the test items.
l 5.3.2 In coordination with EPRI and NUMARC establish the criteria, guidelines, drawings, recommendations, etc., to govern the installation of the fire penetration seal systems as indicated on applicable drawings.
J 5.3.3 In coordination with EPRI and NUMARC establish the criteria, guidelines, drawings, recommendations, etc., to govern the installation of the fire resistive barrier system matedals to the test articles.
l 5.3.4 Provide the specific raceway fire barrier system installation procedures.
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NUMARC TEST PLAN, Rev, O December 13,1993 Phase 2 Test Program Page 4 5.3.5 Coordinate with utilities to provide materials representative of existing or future site installations, as available.
5.3.6 Coordinate with utilities to provide Thermo-Lag Fire Barrier System and penetration seal materials and installetion tools and equipment, as available.
5.3.7 Provide scheduling of personnel, equipment and material necessary to perform the installation and QC documentation of the fire barrier system materials utilizing the appropriate installation procedures.
5.3.8 Coordinate all phases of the fire test preparation with the testing organization including approval of variations from the test methodology described herein.
5.3.9 Coordinate the application of the fire barrier system and penetration seals to the test articles.
5.4 Peak Seals, Inc.
5.4.1 Provide qualiSed quality control personnel for this test program for the purpose of assuring that raceway fire barrier systems and penetration seals as applicable are installed and documented in accordance with applicable ABB Impell procedures.
5.4.2 Provide qualified labor personnel for the construction and application of all raceway fire resistive barrier systems and -
penetration seals as applicable.
5.4.3 Provide the testing organization with all applicable fire barrier / penetration seal installation and QA/QC documentation.
5.5 Omega Point Laboratories, Inc. (OPL) 5.5.1 OPL shall coordinate with ABB 1mpell Corporation to develop the Phase 2 Test Plan.
5.5.2 Provide and prepare the test furnace, deck and slab assemblies and provide all required test instrumentation in accordance with Appendix B Quality Assurance Program and other applicable procedures.
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NUMARC TEST PLAN, Rev. O December 13,1993 Phass 2 Test Program Page 5 5.5.3 Provide thermocouples and thermocouple calibration and instrumentation, furnace temperature probes, storage temperature and relative humidity recorder.
5.5.4 Procure, on NUMARC's behalf, those materials not supplied by utilities as required to construct the test assemblies. Such materials may include but are not limited to tools and equipment, fasteners, raceway components, cabling,.
penetration seal materials, fire resistive barrier system materials, etc.
5.5.5 Assemble, install and document the installation of all trays, conduits, etc..
Provide computer-generated drawings of raceway systems which clearly indicate dimensions, thermocouple locations, etc.
5.5.6 Observe and document the installation of all fire barrier system materials and penetration seals to the test articles, and attendant instrumentation on each test article.
5.5.7 Conduct the fire endurance and hose stream tests.
5.5.8 Inspect and document the physical condition of all fire barrier i
systems for each test article following completion of water hose i
stream test.
5.5.9 Document the test parameters and provide a formal detailed written report of the test program and test results.
5.5.10 Provide VHS video and 35mm photographic coverage of the i
uncovered test item, appropriate portions of the fire barrier installation procedure, the clad test article prior to testing, the fire and hose stream tests, and the post-test disassembly of the test article.
5.5.11 Provide equipment for, monitor and document conditioning of fire barrier materials as described in Section 6.10, prior to the Sre endurance testing.
5.6 Laboratory Quality Assurance / Quality Control 5.6.1 Receive, inspect, and record all test articles and fire barrier materials.
Verify the quality control documentation (lot numbers, etc.) of the fire barrier system materials used in the test program.
Receive, inspect and log the physical characteristics of materials as appropriate.
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NUMARC TEST PLAN, Rev. O December $3,1993 Phase 2 Test Prograra Page 6 5.6.2 Verify and document the materials used and construction of test items comply with applicable drawings.
5.6.3 Witness the processes utilized in the installation of the fire barrier systems and penetration seal materials, and suitably document observations in event logs, inspection reports, etc.
5.6.4 Inspect and document the instrumentation of the test articles.
5.6.5 Provide written calibration documentation of all thermocouples,
-l measurement devices and data acquisition systems used in this j
test program.
5.6.6 Provide Personnel Certincations and Qualifications.
5.6.7 Document Quality Assurance / Quality Control inspections on Laboratory checklists or traveler packages for each test i
assembly.
6.0 PREREQUISITES 6.1 General Test Configuration Requirements The raceways used in this test program shall be representative of configurations in use and shall be specified and designed by NUMARC and its contractors.
6.2 Traceability Requirements To insure that the materials used in this test are representative of those in actual use, all aspects of traceability as required by the Laboratory QA Program shall be applied. OPL will maintain all such documentation for the program.
All thermocouples used in this test program shall be traceable to the respective thermocouple manufacturer, with calibration certification, provided by Omega Point Laboratories.
6.3 Dimensioned Drawings 6.3.1 All test articles shall conform to the dimensioned drawings provided by ABB Impell. All changes to these drawings shall be made by revision or design change " redline" process in u
accordance with applicable ABB 1mpell procedures.
Final revisions of all drawings shall be delivered to OPL for inclusion A *o, O
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NUMARC TEST PLAN, Rev. O December 13,1993 Phase 2 Test Program Page 7 into or use in preparing final test reports. Final, dimensioned drawings for test report purposes will be prepared by OPL.
6.3.2 OPL will prepare drawings of all installed barrier materials on the test assemblies. These drawings will identify all joints, dimensions, material types, upgrade techniques, etc. Final drawings will be prepared by OPL.
6.4 Test Configurations 6.4.1 General The test articles shall be sufficiently secured to the test deck and sealed by Laboratory personnel, in accordance with instructions and drawings. The test deck, unless otherwise specified, will consist of an 8 ft x 13 ft steel deck, reinforced with structural steel elements sufficiently to carry the load of the test items, and insulated with 4" (1 hour1.157407e-5 days <br />2.777778e-4 hours <br />1.653439e-6 weeks <br />3.805e-7 months <br /> test) or 6"(3 hour3.472222e-5 days <br />8.333333e-4 hours <br />4.960317e-6 weeks <br />1.1415e-6 months <br /> test) of ceramic Sber insulation, held in place with impaling pins spaced nominally
~,
12" o.c. Concrete (all or partial) decks can be used if specified by ABB Impell.
6.4.2 Test Articles All test articles will be constructed in accordance with drawings provided by ABB 1mpell Corporation. Installation of fire resistive barrier materials will be in accordance with applicable drawings provided by ABB Impell Corporation and documented as described in Section 6.3.
6.5 Cable Loading Requirements Each cable tray test article will contain a single layer of cables to represent, on a " generic" basis, typical cable types and sizes used in similar utility installations.
The specific ca' oles and loading requirements shall be as specified by ABB Impell and will consist of an approximate 1/3 mix of power, instrumentation and control cables.
Actual cable tray fill densities and cable diameters will be documented in the final test report.
6.6 Cable Installation An itemized listing of cable types and quantities including fill density installed in cable tray test articles will be prepared by the Laboratory and included in the final test report. Cable location withi:1 the test articles shall be documented and included with data to be evaluated by the Laboratory.
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NUMARC TEST PLAN, Rev. O December 13,1993 Phase 2 Test Program Page 8 6.7 Thermocouple Installation All thermocouples used in this test program shall be provided and installed by the Laboratory, with QC surveillance by Laboratory personnel. The thermocouple wires shall be calibrated (by Lot No.)
prior to installation and/or use, and applicable quality control documentation for record purposes generated. All thermocouples will consist of 24 GA, type K, Chromel-Alumel (Special Limits of Error:
il.1 C) electrically welded thermojunctions, with Teflon 8 insulation.-
Calibration will consist of manufacturer-supplied (and audited as Class A Vendor as defined in OPL Quality Assurance Procedures Manual, Rev. B) certifications of calibrations at five temperatures of thermocouples taken from both ends of each purchased lot number.
All thermocouples shall be located on and within each test article in accordance with the following requirements:
NOTE:
Thermocouple locations which differ from the following criteria shall be documented in the final test report.
For cable tray, thermocouples for test acceptance purposes shall be located at 6 inch intervals on the exterior surface of the tray rails underneath the fire barrier material. Thermocouples will also be installed at 6 inch intervals on 8 AWG bare copper conductors as follows:
One bare copper conductor with thermocouples for test acceptance purposes shall be installed on the top of the cable tray rungs along the entire length of the cable tray run at the longitudinal center of the tray and will be secured to each tray rung.
One bare copper conductor with thermocouples for test acceptance purposes shall be installed on top of the single layer of cables in the longitudinal center of the tray, positioned parallel to and above the bare copper conductor which is installed on the cable tray rungs.
Additional copper conductors, similarly supported, with thermocouples for test acceptance purposes will be used for cable trays containing tee j
sections.
One bare copper conductor with thermocouple for._i_nformational, purposes shall be installed below the cable tray rungs'along the entire length of the cable tray run near the longitudinal center of the tray J
(offset approximately 1" from the conductor above tray rungs) and will be secured to each tray rung.
Additional bare conductors with
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NUMARC TEST PLAN, Rev. O December 13,1993 Phase 2 Test Program Page 9 thermocouples for informational purposes may be installed within the cable tray fire resistive barrier envelopes as specified by NUMARC, through its contractor. In all cases, such additional bare copper I
conductors shall be fully documented in the final test report.
For air drop configurations, two 8 AWG bare copper conductors will be used in lieu of cables. Thermocouples for test acceptance purposes shall be located at 6 inch intervals on the conductors.
For conduits, thermocouples for test acceptance purposes shall be located at 6 inch intervals on the exterior bottom surface of the conduits and fittings, such as condulets directly beneath the fire barrier. Additional thermocouples for test acceptance purposes will be located at 6 inch intervals on a single 8 AWG bare copper conductor to be installed inside each individual conduit.
For junction boxes and other box enclosures, a minimum of one thermocouple for test acceptance purposes will be centrally located on the exterior surface of each exposed face of the enclosure. One thermocouple shall be placed for every square foot of surface area per face and at a point within 1" of each penetration / connector interface.
6.8 Installation of the Fire Barrier system to the Test Articles i
i Fire Resistive Barrier System materials shall be installed by Peak Seals, Inc. in accordance with applicable design drawings to be issued by ABB Impell. Details of the Fire Barrier System configurations including fasteners, orientation of structural ribs, etc., shall be documented in the final test report.
6.9 Fire SealInstallation t
Upon completion of the fabrication and installation of the fire barrier systems to the test articles (or prior to, depending upon the situation),
all openings in the test articles shall be sealed by Peak Seals, Inc. in accordance with applicable design drawings. All openings in the test deck and slab assemblies shall be sealed by the laboratory. All internal raceway fire stops will be sealed by Peak Seals, Inc. as applicable.
Failure of the fire seal shall not necessarily constitute a failure of the protective envelope. The type of fire seal used shall be as specified by ABB Impell.
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t NUMARC TEST PLAN, Rev. O December 13,1993 Phase 2 Test Program Paga 10 6.10 Preburn Inspection 6.10.1 Prior to the commencement of the fire endurance test, a thorough check of each test assembly and associated equipment (including data recording equipment) and completion of applicable Laboratory QA/QC checklists shall be performed and documented by the tasting laboratory.
6.10.2 ABB Impell shall inspect the Fire Barrier System for surface defects, etc. prior to test.
6.10.3 Written approval of the construction, assembly, installation and instrumentation will be supplied by ABB Impell and the Laboratory prior to performance of each fire exposure test (a sign-off sheet for this purpose will be supplied by the Laboratory).
6.10.4 Prior to commencement of the fire endurance test, the completed test specimen shall be equilibrated with the laboratory environment. The moisture content of the Thermo-Lag Fire Barrier Materials shall be documented at regular intervals prior to the fire endurance test to demonstrate establishment of equilibrium conditions. A Delmhorst, Model DP hand held meter (or equivalent), suitably calibrated, shall be used for measurement of moisture content.
7.0 PROCEDURE 7.1 Fire Endurance Test
)
J 7.1.1. The protected test article shall be exposed to the standard time / temperature curve found in ASTM E119 (88) for a j
minimum period of one or three hours.
The test shall be performed in accordance with the U.S. Nuclear Regulatory Commission's proposed position dated November 20,1992 and applicable sections of NUREG 0800, except where noted for j
thermocouple placement (Section 6.7).
]
4 7.1.2 The testing organization shall adapt their testing procedures to assure the fire test complies with the requirements established in all referenced portions of referenced standards. Any changes, revisions, or deviations required to comply with this i
requirement shall be documented and properly justified and i
included as a part of the final test report.
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s NUMARC TEST PLAN, Rev. O December 13,1993 Phase 2 Test Program Page 11 7.2 Water Hose Stream Test 7.2.1 Immediately following the fire endurance test, accessible surfaces of the protected test article shall be subjected to the water hose stream test. The hose stream test will be applied using a 30 angle spray nozzle with a minimum pressure at the.
no zle of 75 psi at a distance of 5 feet, for a 5 minute duration.
The minimum flow from the nozzle shall be 75 gpm. Proper safety precautions shall be exercised. Only those personnel reqaired to perform the hose stream test shall be allowed in the -
immediate area, and only then with appropriate breathing apparati.
t 7.3' Protective Envelope Inspection 7.3.1 Following the Water Hose Stream Test a visual inspection will be conducted of the outer surface of the protective envelope including all material and seams. The condition of the envelope will be documented, including any locations where there is evidence of burn through or opening of the barrier, on a " Barrier Inspection Data Sheet." In addition, cables will be inspected for any signs of visual degradation. All inspection data will be-recorded in the final test report.
7.4 Cable Inspection 7.4.1 As required by the recorded temperatures of thermocouples installed on raceway surfaces or bare copper conductors and the-protective envelope inspection described above, visual inspection of cables (where installed) shall be performed. The physical i
condition of cables shall be detailed on " Cable Inspection Data -
Sheets" in the final test report. Attributes utilized for visual inspection of cables include, but are not necessarily limited to the following:
a.
Jacket swelling / blistering, splitting / cracking, discoloration or melting.
b.
Shield exposed, c.
Conductor insulation exposed, degraded or discolored.
d.
Bare copper conductor exposed.
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c NUMARC.
TEST PLAN, Rev. 0 December 13,1993 Phase 2 Test Program Page 12 i
8.0 DATA SYSTEMS 1i 8.1 During the fire exposure period, the thermocouples will be scanned at one minute intervals or less. Data storage for reporting purposes will be at one minute intervals, although the furnace thermocouples will be scanned and displayed every 15 seconds, to allow close control of the furnace. A printer output and scanning of all other thermocouple data j
will also be done a; intervals of one minute or less, but will r.ot be included in the test report (however, this record will be filed in the QC document. file at the Laboratory).
The test report will contain thermocouple data at one minute intervals.
8.2 Monitoring of all thermocouples will be terminated upon completion of the fire endurance test.
9.0 FIRE TEST REPORT i
9.1 The Laboratory will submit a report on the results of the test and thermocouple data.
9.2 The Laboratory will assemble the final test report, containing the I
collected data and required quality control documentation.
9.3 The test report shall be prepared in sufficient detail to summarize the total testing activity. The report shall include as a minimum:
a)
Date of the test b)
Location of the test c)
Description of the test furnace and test articles d)
Calibration documentation of all thermocouples e)
Qualification and certification for test personnel f)
Test prccedures used g)
Acceptance criteria
'I h)
Quality control records for-
'i Test article construction l
Qualification and certification for installation and inspection personnel i
Identification and installation ~ of fire barner material
- - Thermocouple locations i)
Computer printout and graphic results of the fire endurance test.
I j)
All raw data including thermocouple measurements -
k) 35mm and VHS video photographic coverage of the test project 1)
Provide a chronological log (Event Log) of all activities from receipt of materials through final test report m)
Post test protective envelope inspection records and results f* * "Og o-
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