ML20091S205
| ML20091S205 | |
| Person / Time | |
|---|---|
| Site: | 05000000, Catawba |
| Issue date: | 07/15/1981 |
| From: | Buckalew W SANDIA NATIONAL LABORATORIES |
| To: | Farmer W NRC OFFICE OF NUCLEAR REGULATORY RESEARCH (RES) |
| Shared Package | |
| ML20090B024 | List: |
| References | |
| FOIA-83-765 NUDOCS 8406180090 | |
| Download: ML20091S205 (48) | |
Text
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Sandia National Laboratories 42-59 Alcuoverase
- f. e a t,9 e n c o p '. g c, July 15, 1981 Mr. W.
C.
Farmer Electrical Engineering Branch Division of Engineering Technology U.S. Nuclear Regulatory Commission Washington, DC 20555
Dear Mr. Farmer:
Enclosed is a preliminary account of the Commission directed test of the Duke Power, Catawba Units 1 and 2, Type K electric penetration connectors.
This enclosure addresses tests performed, test results, and conclusions based on observed connector behavior.
The tests were conducted in accordance with the 1-30-81 version of the " Connector Assembly Test Plan for Duke Power,
Catawba Units 1 and 2 Connectors."
Test plan approval and permission (Feit to Bonzon, 4-8-81) to proceed with the test were received on 4-13-81.
Upon final analysis of the test data, a formal Sandia report documenting detailed procedures and results will be issued.
In the interim, should you have any questions concerning the connector test, please call me.
Sincerely,
/
IV * $!',.3 w i &
W. H. Buckalew Systems Safety Information Divicion 4445 Copi's to:
W.
H.
Rutherford, USNRC P.
M'. McBr ide, Duke 4400 A. W. Snyder 4440 G. R. Otey 4445 L. O. Cropp, File 5.3 4445 L.
L. Bonzon i
[
4445 F. V. Thome l
4445 E. Minor 4445 D. Jeppesen l
4445 W. H. Buckalew
/
\\N B406190090 840320 PDR FOIA JORDAN 83-765 PDR
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CONNECTOR ASSEMBLY TEST OF THE DUKE POWER, CATAWBA, UNITS 1 AND 2 TYPE K PENETRATION / CONNECTOR ASSEMBLY A BRIEF LOOK
SUMMARY
Thk followin 'is a brief account of pertinent events that occurred during'Ahe execution of a Commission directed veri-fication test of certain connectors.
The test was performed o[ behal f of NRC(RES) under the NRC-sponsored Sandia QTE research program.
The purpo e'of this 'ecst was to subject a D.
G. O'Brien Type K instrumentation penetratio'n assembly, complete with mating connectors an4' interconnecting cabling, to the thermal aging, radiation, and stea'm accident phases of the qual-ification t sts performed by O'Brien, during the development stage's of/the penetration and prior to its subsequent installa-tion in the Duke Power, Catawba Units 1 and 2 plants.
Detail s G.'6'Br ien, tests are contained in the O'Brien Report of the D.
.- ?,.
ER-252, 0'15-77.
Although the complete penetration assembly w'as subjected to the.se verification tests, of primary interest
.r was the mating connect 0byar,sembly and, in particular, the t
sealing' components identified. in Figure 1 as the cable grommet yj-and interf aelar seal. J'griefly, during the development stages h
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,of t,e penetrat on, c rcu atances dictated additional development e>phasis be placed on connector design.
As a result, not all components of _ the penetr,atio,'n assembly were fully tested.
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Ultimately, Sandia was requestsdft'o duplicate the qualification
/
tests on a complete, as'installe/,, unit.
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% i A complete Type K penetration unit, with cables and connectors, was purchased from the Duke Power Company.
Included in the pur-chase were funds necessary for wiring of the unit by a Duke Power installation crew.
This assembly task was observed by I&E personnel.
The unit was received at Sandia on 4-15-81.
Testing of j
a the unit commenced on 5-19-81 and was completed on 6-21-81.
'i By 6-26-81, a limited postmortem on the unit had been completed, f
Testing was in accordance with the Enclosure I test plan and with more detailed procedures which will be included in the
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final report.
4 The index of satisfactory assembly performance was based on 0 7/ '
insulation resistance (IR) measurements of the 104 individual N A circuits comprising the assembly.
Specifically, resistance of d
any circuit to the electrical ground plane was required to remain S
above five megohms when tested at 500V DC.
n Insulation resistance measurements remained high during and
.a af ter both thermal aging and radiation.
Loosening of connector
/
coupling rings, Figure 1, was observed after both thermal and radiation aging.
This condition was not without precedent and the coupling rings were retorqued, according to specifications, following each phase.
The first insulation resistance measurements during the steam accident phase were taken four hours af ter start of this pha'se and when saturated steam conditions had been achieved (see Fig. '
2 and 3).
At that time, 12 circuits were observed to be either erratic or below the minimum prescribed IR requirement.
At the
conclusion of the accident'(steam) phase, six circuits remained 4
suspect r Three circu'its indicated short or near short circuit conditions, and three circuits indicated IR values of less s
than one megohm.
The postmortem, starting two days after the test conclusion, revealed the following.
T 1)
Cable grommet maiox'ial-had extruded through the conductor feed-through'openingc'in the plug sleeve.
In Figure 4 coupling rings have been removed'and the extruded black
.s s
grommet material is clearly vis'ible.
Figure 5 is a closeup 4
of the ohenomenon.
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3)
Where grrAsmet extrusion occurred, conductor insulation.
was necked down, and in some instances, insulation t
'i s was stripped from the conductor.
Figure 6 shows both u,
conditions, this conduct'or' was removed from a connector s
't which ha' passed all7 IR tests.
1 i
3)
The extrusion process, in some cases, forced baredscon-ductors to the very near vicinity' of the plug sleeve -
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a possible short circuit' cordit.tonh The right hand q 'i
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connector, in Figure 7,.is a good e,xample of this
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process.
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.Mos tub intrusion at the conn'ector module interface was 4) y y
obsery' ed in.manyfinatances - a possible cause of low'
't IR measurements an'd/orIshort circuit.,indicat' ions.
Figure-8 shows moisture accumulation on thelinte facial seal' -
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TEST SYNOPSIS - SALIENT FEATURES 4{
o Receipt The unit was received on 4-15-81.
At that time, the penetration was inspected for damage, unpackaged, and moved to a controlled area.
Following receipt of the torque spanner on 5-12-81, both inboard and outboard coupling rings were torqued to the specified 25 ft-lbs.
Coupling ring rotation necessary to torque was on the order of 90 degrees for all rings, f1 6 3- ) )
Thermal Aging Thermal aging facilities were provided by the Sandia Climatic, Centrifuge, and Devices Testing Division.
The aging was performed in a large walk-in chamber.
Just prior to the aging phase, Climatic Division personnel calibrated the chamber and ran a lengthy regulating performance test.
Following the calibration and performance runs, the entire penetration unit was placed in the temperature chamber.
Figure 9 shows the unit positioned in the oven.
The cables exiting the test chamber, at the left, allow IR measurements to be taken during the aging phase.
Thermocouples were installed to monitor both the inboard connector temperature and " free air" inside the junction box. ' Chamber environment temperature control and measurements were provided by the Climatic Test Division.
Just prior to start up on 5-19-81 and with the test' chamber at room temperature, IR and continuity measurements were taken.
The chamber temperature stabilized at 150*C in approximately 30 minutes.
Free air thermal equilibrium was achieved-in about 3.5 hours5.787037e-5 days <br />0.00139 hours <br />8.267196e-6 weeks <br />1.9025e-6 months <br />'and the connectors stabilized in 6 hours6.944444e-5 days <br />0.00167 hours <br />9.920635e-6 weeks <br />2.283e-6 months <br />.
IR and continuity measurements were taken daily.
PreLand post-test measurements
were almost identica] - 4000 to 8000 megohms.
Although IR measurements decreased at the test onset, a monotone increase toward the post-test values was then observed.
Post Thermal Aging The unit was taken to the Sandia Area-5 High Intensity Adjust-able Cobalt Array (HIACA) facility for radiation aging preparation.
At this time, the inboard junction box was removed.
All inboard and outboard coupling rings were loose.
Q Retorquing of inboard and outboard coupling rings was
- accomplished prior to radiation aging.
In all cases approximately
'Y 360 degrees ring rotation was required to retorque.
One complete 1
v.,
f fj2l coupling ring revolution translated into an axial traverse of b3 L
w' 60 mils.
-k c,tvW ^
,m Radiatiog' Aging 7
s Placement of the unit, in the HIACA, was facilitated'by previously obtained dose-rate maps of the facility, Fig.10.
In sequence, the following steps were taken:
1)
Thermocouples were mounted on inboard connectors and in the " free air" region surrounding both the inboard and outboard penetration regions.
2)
HIACA dose-rate values were re-confirmed with a cali-brated air ionization chamber as 0.722 Mrad (air)/hr.
3)
The_ junction box perturbation to dose / dose rate was experimentally determined to be. 0.917.
Radiation (a i Was begun on 5-29-81.
Figure 11 shows the unit, with inboard junction box removed, being positioned in the test chamber.
An inboard " free air" equilibrium temperature of 50'C was reached in about 5 hours5.787037e-5 days <br />0.00139 hours <br />8.267196e-6 weeks <br />1.9025e-6 months <br />.
Inboard connector termperature sta-bilized at 64 C in approximately 7 hours8.101852e-5 days <br />0.00194 hours <br />1.157407e-5 weeks <br />2.6635e-6 months <br />, while the radiation cell temperature was variable between 32 and 42 C.
On 6-1-81, the Co-60 sources were lowered so that provision for forced air circulation of the penetration could be provided.
Following fan installation, free air and connector temperatures stabilized at 42 and 46*C respectively.
r-i s
Theradiationggingwascompletedon6-9-81.
Total exposure time was 237.5 hours5.787037e-5 days <br />0.00139 hours <br />8.267196e-6 weeks <br />1.9025e-6 months <br /> resulting in an integrated exposure dose f.9X109 of 183 Mrad (Air).
Recall that the junction box dose rate perturbation was.917, hence had the junction box been installed, the exposure dose to the junction box would have been 200 Mrad.
theconclusionofradiationffhgwereabout i
IR values at one half the post-thermal / pre-irradiation values - i.e., in'the range of 2000 to 4000 megohms.
All connector coupling rings were loose and approximately 30 degrees rotation was required to retorque the rings.
Steam (Accident Simulation) Phase Instrumentation for the steam test was extensive.
Included in the thermal measurements were multiple (spatial) measurements near the junction box exterior surface, j unction box interior " free field",
and connector surface.
Thermocouples were-placed on the junction box exterior as shown in Figure 12.
Test chamber internal pressure was also monitored.
Several detectors were included at each thermocouple spatial location.
Steam system and data acquisition and display systems performance were characterized
on several trial runs using a dummy thermal load in the test chamber.
The accident phase was started on 6-15-81.
Initial IR measure-ments were deferred until major transient temperature / pressure excursions had occurred and saturated steam and thermal equilibrium conditions had been established in the test chamber.
These conditions occurred about four hours into the test, Figures 2 and 3.
Initial IR measurements detected several circuits with IR values below specification and several circuits exhibiting erratic 4
readings.
Since several circuits were suspect at this time, a second set of IR measurements was taken approximate 1y 5 hours5.787037e-5 days <br />0.00139 hours <br />8.267196e-6 weeks <br />1.9025e-6 months <br /> later.
This set of measurements identified 12 circuits as being suspect, i.e.,
either erratic IR readings or IR values below 5 megohms.
Erratic IR readings were of concern since it was reasoned that moisture intrusion had occurred.
These 12 suspect circuits were closely monitored for the duration of the steam test.
Just prior to the conclusion of the steam test phase, three circuits had been removed from the AC power source because of excessive current demands on the power supply.
These circuits drew currents in excess of 5 milliamps at 30 VAC, i.e.,
short circuit conditions.
In addition, five other circuits failed to meet the minimum IR specification.
However these circuits would withstand 600V AC to ground with leakage currents in the order of 1/2 milliamperes - about average for all other circuits in the assembly.
At the steam test conclusion, all heater power was removed, the test chamber was purged of spray chemicals and vented to 4
the atmosphere.
Approximately one hour following the test chamber venting, the 600V AC power was removed from all pene-tration assembly circuits.
On 6-22-81, with a chamber temperature of 35'C, IR measure-ments were again taken on all circuits.
At that time all but about 15 circuits, out of 104, exhibited IR values below the minimum specified value.
Without benefit of penetration disassembly we conjectured moisture had intruded the connector assemblies causing the low readings.
Post-Test Disassembly On 6-23-81, representatives (see Enclosure 2) of Duke Power, NRC-IE, Brand-Rex Cables, and Sandia met to-devise a plan for connector-penetration disassembly that would yield maximum failure information with minimum disassembly steps.
CL[
The plan format was left flexible so that changes in disassembly 4
hg procedure would not be discouraged.
Salient features of the disassembly procedure were as follows.
1)
Examine a connector module combination with best perfor-mance characteristics for use as a base line pair, 2)
Determine'if the interconnecting cables could be elimin-ated as a cause of poor performance, 3)
Disassemble the three module connector pairs that exhi-bited'short circuit conditions. - Identify the defective module-connector of each pair, and 4)
If possible determine mechanisms of failure for the defective module-connector.
r-
j Using the procedures, it was determined that the external cabling was not a cause of any circuit f ail ure.
Additionally, during the course of dicassembly it was observed that most connector coupling rings were loose--no more than finger-tight, and in most instances the torque-to-loosen was below the lower indicating limit of the torque tool.
Examination of the " good" connector assembly showed that the cable grommet had extruded through the conductor feed-through holes in the sleeve plug back surface.
In Figure 13 the black material is the extruded grommet.
Further examination of the " good" assembly (see again Figure 6) indicated that 4
in the course of grommet extrusion, connector insulation was pinched or necked down and, in some instances, stripped from the conductor.
Disassembly of three failed connector-module pairs showed the same extrusion of grommet material through the plug sleeve back surf ace conductor feed-through openings.
Moisture was found to be present at the connector-module interface in all cases.
Of the three failed circuits, two were traced to the connec-
~
tor assembly ana one traced to the module. 'Of the two failures s
traced to the connector assembly, both were attributed to
. shorting of the conductor to the plug sleeve at the point of-conductor passage through the plug sleeve.
It was substantiated in the case of a sectioned connector, that-grommet extrusion stripped insulation from the conductor allowing a shorting path between exposed conducter and the plug sleeve.
The other connector
s -
failure was also attributed to a short between connector and plug sleeve.
The one module failure has been attributed to moisture or contamination on the module insulator.
For example, from Figure 8 which shows a module with the interfacial D-seal intact, it may be observed that moisture has intruded N
ss and is present on the interfacial seal surface.
A vacuum N4 was applied to the module, with interfacial seal present, O
for approximately 1 1/2 hours and at the conclusion the h
suspect module pin IR had increased from 1/2 megohm at 500V s
to approximately 50 megohm at 500V.
Removal of the remaining connectors revealed, in almost
\\
all cases, some degree of moisture at the connector module interface. It is believed that this accumulation of molatu're occurred during post-test cooldown and was responsible for the poor IR performance of most circuits during the post-accident (steam) IR measurements.
Examination of the removed connectors showed evidence, in all cases, of grommet extrusion through' the plug sleeve back surface.
CONCLUSIONS Based on test data it is concluded that the basic cause of observed circuit failures can tut attributed to failure mechanism (s) involved with the connector assemblies.
That is~to say, neither interconnecting cables nor penetration modules, per se, were primary causes of failure.
Specifically, evidence would tend to indict the connector assembly cable grommet.
It was observed (see again Figures 5 6,tand.7) that grommet material had extruded.through the
4 v conductor feed-through holes in the plug sleeve back surf aces.
During the extrusion process conductor insulation was " pinched down" or stripped from the conductor or, in some cases, a combination of both.
These alterations to conductcr insulation could lead to either a conductor short circuit condition or the intrusion of moisture.
Moisture intrusion would manifest itself in low IR observations.
It is possible to speculate that moisture intrusion would be most likely to occur during wet conditions and cycling temperatures.
Any cooling cycle could then lead to shrinkage in remaining grommet material and possible moisture intrusion along a conductor at the plug sleeve back surface.
It is less likely but not impossible that some moisture intrusion could have t
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occurred at the connector-module interfaces.
Grommet extrusion is $ery likely the result of thermal E
kvdD expansion rather than connector retorquing.
The preponderence
/'
of material extrusion no doubt occurred during the thermal aging phase of the test.
The following is considered a reasonable explanation of events.- Prior to thermal aging, the connector assemblies were torqued, thus assuring a close fit of all connector components.
During the thermal aging cycle, thermal expansion of.the grommet and interfacial seal occurred.
Pressure relief'was constrained to the axial direction and most. specifically through the plug sleeve / cable interf ace holes.
At the conclusion of thermal aging, the cable grommet and interfacial seal then contracted.
Extrusion of the grommet material resulted in a void within the connector assembly which
was manifested by loose connector coupling rings.
It is believed retorquing at this stage resulted, mainly, in void reduction
[
within the connector.
Assuming connector ring observed rotation to torque is a measure of extrusion created void V
then maximum extrusion occurred during the thermal aging cycle.
Since the connector coupling rings were loose following y 2::t -
d a
the radiation and steam tests, it is possible that additional d
db thermal extrusion occurred during both radiation aging and steam accident phases.
Thermo-physical properties dita
]
d D
for the grommet material were recently made available to q
a us.
These data make note of the grommet materials large c) J bulk coefficient of thermal expansion and suggest that in some 1 'd applications allowance for this property may be necessary.
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E ncloJure 1.
l Connector Assembly Test Plan for Duke Power, Catawba 1 and 2, Connectors to be coordinated for the U. S. Nuclear Regulatory Commission Research Support Branch, RSR by Sandia Laboratories, Albuquerque Submitted:
4/28/80 Second Draft 11/1/80 Third Draft:
12/22/80 Fourth Draft:
1/30/81 m.
4/28/80 11/1/80 12/22/80 1/30/81 Proposed Verification Program for the Duke Power /D. G.
O'Brien Type K Penetration Connector Assembly Program Objective Following the Union of Concerned Scientist's petition of November 4, 1977, the NRC Commissioners directed the NRC staff to:
" Arrange for a repeat of the tests to obtain data for the verification of current method-ology for environmental qualification of elec-trical components.
These tests should be per-formed with a representative sample of comme'r-cially available electrical connectors quali-fled in accordance with IEEE-323 (1974) and in use in nuclear power reactor safety systems.
When available, the test results are to be promptly provided to the Commission."
The staff have interpreted this action to be aimed at pro-l viding information on the methodology of qualification test-l ing using electrical connectors which meet the provisions of IEEE-323.
The staff responded by directing that electrical connectors previously qualified by licensees for use in operating plants be tested in accordance with the applicable version of IEEE-323.
To the extent practicable, connector assemblics will be subjected to the actual aging, radiation, and LOCA-stimulation tests for which the connector assemblies have been qualified.
Inspection and Enforcement (IE) staff have evaluated some of the various utilities' connector hardware and quali-fication documents.
The first test in this series, selected by IE, used Bendix connector assemblies as installed in Browns Ferry Unit 3, that test was documented as SAND 79-2311, NUREG/CR-1191, dated December 1979.
The second in the series, as selected by IE staff and outlined in this test plan, will use D. G. O'Brien connector assemblies mated to an O'Brien instrumentation penetration.
The connectors and penetration were among those acquired for installation in Catawba Units 1 and 2.
During the development program of the Type K module-connector assembly, circumstances were such that only certain items of the assembly were subjected to the entire sequence of aging, radiation and LOCA/MSLB environments.
Specifically the assembly connector component was only partially qualified by test.
e 4/28/80 11/1/80 12/22/80 1/30/81 It is the objective of this program to subject a Type K pene-tration assembly to the entire environmental and accident aging processes.
The complete assembly is to include mated cables and connectors and at least one junction box.
Test Item Descriotion The Type K penetrations and auxiliaries are manufac-i tured by the D. G. O'Brien Co. in accordance with Duke Power specification CNS-1361.00-00-0003.
Units of this type are used to penetrate the containment at Catawba Units 1 and 2.
The unit to be used in this test is currently on hand at the Catawba Station.
It was acquired, by Duke Power, at the
^
time of acquisition of the instrumentation penetration units presently being installed at the Catawba Station.
In Figure 1, a drawing of the type K instrumentation penetration is presented.
The penetration is shown complete with module, connectors (plugs), junction boxes, and flange pressure gauge.
For purposes of clarity only one module appears in the drawing.
However, the unit being acquired for this test has eight each of two module types for a total of 16 modules.
Assembly of Test Items Using mating connectors (plugs) and appropriate cabling, the penetration unit will be wired so that pairs of like modules will be interconnected.
In Figure 2 a typical interconnection between.
like modules is shown.
Note the straightforward approach, i.e.
Pin A is connected to Pin A, etc.
The wiring necessary to interconnect the paired modules will be the responsibility of Duke Power Company.
The standard Duke procedures, CNM-1361.00-00ll and CNS-1390.01-0073, will be followed during connector (plug) wiring.
Quality Control Inspection will be in effect to insure that the above procedures are followed.
Assembly of the wired mating connectors to the appropriate modules will be by Duke Power personnel.
Every effort will be made to assure a product typical of field-installed units.
n Since the assembly of connectors to modules requires a special torquing tool,;a Duke Power representative will retorque all connectors on the penetration assembly after its receipt at Sandia and prior to any tests on the unit.
Background
The qualification history of the type K module /connec-tor was discussed in detail in the April 1980 draf t of this test plan.
r 7
4/28/80 11/11/80 12/22/80 1/30/81 In that draft, the partially qualified component of the penetration. assembly was identified as the connector unit.
As a result it was proposed /that the connector, along with sufficiept mating assembly, Fe subjected to the aging i
and accident sequence.
The purpose of the mating assembly wus not for, verification but to serve as an interface during functional tests.
The concept of a partial assembly was re-jected on the basis the assembly,would need to be manufactured and henCe Would not neCOssarily bp representative of the pre-sertly installed units.
It was subsequen,tly proposed that a Duke Power penetration unit available at the Cacawba Station be used in the connector verification program.
This penetration assembly, acquired with installed units, when assembled with mating' connectors and interconnecting cabling would be quite representative of installed items; certainly more so than any after the fact fabricated item.
Test Procedures General The penetration assembly will undergo the aging -
accident sequence in the as-received condition. i.e., with a junction box installed on the inboard side of the assembly.
An exainple of the test configuration is shown in Figure 3.
In Figure 3 the penetration assembly is shown positioned in the LOCA/MSLB test chamber.
Note that the inboard portion of the penetration assemblylia completely enclosed in the inboard junction box.
Note also the instrumentation / test cabling extending from 'the outboard side.
Because the penetration assembly is mounted vertically, the pressure equalizing-condensation dr9 n vent shown in Figure 3 was repositioned 1
from position V to' position V.
One exception to the above configuration will occur during the radiation aging cycle.
Dimensions of the Cobalt-60 irradiation chamber are such that the inboard assembly complete with junction box cannot be accommodated.
It will be necessary to irradiate the inboard penetration unit without the junction box.
The junction box dose attenuation ef fect will be measured and appropriate adjustment made in the irradiation time.
Environments to which the.issembly will be subjected are:
Thermalaginh.
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1.
2.
Radiation 3.
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4/28/80 11/11/80 12/22/80 1/30/81 The above tests will be, generally, in accordance with those described in the D. G. O'Brien reports ER-252 and con-forming to QA-TM-185/191 of that report.
The test will be performed in the following sequence and will adhere to the concepts contained in the Sandia Department 4440 Quality Assurance Program Plan.
1.
Baseline - visual and functional 2.
Thermal aging 3.
Post aging functional - visual 4.
Radiation 5.
Post radiation functional - visual 6.
Accident 7.
Post accident - functional - visual Acceptable performance of the assembly will be on the basis of accept-reject criteria listed in a succeeding section of this proposal.
Specific I.
Protest - Baseline A.
Visual inspection 1.
general appearance 2.
radiographs if appearance warrants B.
Functional 1.
continuity-checkforcontinugtyandcorrectness 2.
insulation resistance - 5 x 10 ohms 6 500 VDC between each conductor and all other conductors connected to ground (shell).
3.
Penetration internal pressure - note and record II.
Thermal Aging A.
General Thermal aging shall' be conducted in a forced cir-culating air furnace.
There shall be no obstruction to flow across the test specimen.
Equipment is to be isolated from furnace walls and from any primary radiant energy source.
B.
Test requirements 1.
150*C + 2*C 2.
168 hours0.00194 days <br />0.0467 hours <br />2.777778e-4 weeks <br />6.3924e-5 months <br /> duration 3.
check continuity and insulation resistance once i
daily 4.
internal pressure - note and record L
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4/28/80 11/11/80 12/22/80 s
1/30/81 C.
Post
- test 1.
insulation, resistance 2.
continuity 1
3.
visual 4.
internal pressure - note and record III.
Radiation Exposure.
+
A.
General The penetration assembly will be subjected to the' dose rate and integrated dose.specified in th,e succeeding t
section on test requirements.'
Configuration of the Sandia irradiation source geometry is adjustable so that dose rate and/or radiation field dimensions'may be tailored to specific needs.
Considering the penetration dimensions-less
' junction box-and the requirement to maintain the radiation dose rate below'l megarad/hr a source configuration, considered compatible withsths requirements, was assembled and mapped.
In Figure'4 the r'esults of tha't mapping mare presented.
As may be observed, enten,t of uniformity of the radiation fieldtexceeds the penetration dimensions.
. Additionally radial placement of source pencils assures dose uniformity s
in the radial direction.-
s s
\\ Concerbink r'emova'liof.the' inboard junction box, the following steps will be taken.
With the desired n'ouYce con-figuration, Figure.4, dose'raterwill be determined with a calibrlted' air ionization chamb'er both with and.without the junction;Uox.
Very simply :tdese differences in-observed
' dose rat'es canibe attributed to'junctlion' box perturbations.
Then the penetration aging time will..be adjusted to reflect the dose. rate observed with the juristion box'in plade. - Temper-ature of>the environment is to be' monitored and maintained at or below the, normal 110*F operating. temperature.' Dose
\\ measurement techniques and.detectoricalibrat, ion will be tracea.ble-to the libs.
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s B.M Test requirgments 3
\\ 1. 'i 2 x 10 - rads ( AIR) +10%
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- 2. idose rate not to exceed 10 rad /hr,g
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4/28/80 d,
11/11/80 12/22/80 1/30/81 IV.
Accident Test A.
General I
This test is to be a combination of LOCA, MSLB, and thermal shock environments.
The LOCA and thermal shock i
environments are straight forward although the duration of the thermal shock has not been specified.
The steam line break phase of this environment, as outlined in the Duke Power Specification CNS-1361.00 0003, calls for an initial rise in temperature and pres-4 sure from ambient to 340*F and 15 psig, respectively, in 10 seconds.
The Sandia facility, at this time, cannot duplicate the specified transient rather, the temperature-time profile appearing in the Figure 5 is more typical of the Sandia facility capability.
For improved perspective, Figure 6 has been included.
In this figure are plotted the Duke Power specified transient, an actual D. G. O'Brien qualification' profile, and the estimated Sandia capability.
consideration of the specified thermal transient and the Sandia capability prompted an inquiry of several commercial laboratories as to their transient tem'perature capabilities.
At the present time, none of those laboratories polled could duplicate the specified temperature-time profile.-
The rise time of the Sandia facility could probably be " sharpened" some with the variation of available parameters but it would.
in no way approach the specified 10 second value.
- However, when the thermal lag. introduced by the junction. box presence is considered, the actual connector environment probably rises much more slowly than the specified environment rine time.
Actual positioning of temperature sensors in the test chamber and about the penetration will depend upon the temperature-distribution within the test chamber ~.. This distribution will be determined during pretest steam per-formance evaluation of the chamber.. A tentative temperature and pressure diagnostic: scheme is shown in Figure-7. ' Temper-ature' sensors will be placed so that spatial ~ temperature distributions near the junction box surface may be monitored.-
a At' least one' temperature sensor will be positioned in' box.
interior so that some knowledge of module tempera'ture history may be obtained.
Access to the junction box interior will be through_ vent "V"--a pressure; equalizing.and-condensate _ drain.
-vent.
r' B.
Test Requirements (see'also FigureJB) 11.
=340*F.+ 10'F 6 15 psig + 5 psig'for 10 minutes'--
rise tTme 10' seconds, but see also above and en-Jclosed temperature (profile 2.: urop. tof 300_'F,in.c10J to '30 minutes -
~
4/28/80 11/11/80 12/22/80 1/30/81 3.
300'F i 10'F 9 15 psig 1 5 psig for 80 minutes 4.
drop to 250*F i 5'F 915 psig i 5 psig hold for 18 hours2.083333e-4 days <br />0.005 hours <br />2.97619e-5 weeks <br />6.849e-6 months <br /> a.
when temperature stabilizes 9 250*F a thermal shock to consist of either water spray at 40*F directly onto junction box - time duration to be not less than one minute.
b.
following thermal shock - chemical spray to be used for duration of test.
Composition of the spray (IEEE-323(1974)) is as follows:
.028 molar H B 3
.004 molar Na O
NaOH to make a pH $
lb.5 9 77 F 5.
drop to 228'F i 5'F 9 5 psig i 5 psig hold for 120 hours0.00139 days <br />0.0333 hours <br />1.984127e-4 weeks <br />4.566e-5 months <br /> a.
spray continues 6.
600 VAC to be applied between all conductors and the connector shell during entire test--see Figure 9.
7.
continuity and insulation resistance to be checked daily 8.
penetration internal pressure - note and record daily C.
Post test 1.
insulation and continuity tests 2.
internal pressure - note and record Acceptance-Rejection Criteria General Acceptable electrical performance of the penetration assembly is based on the Duke Power Company specification CNS-1361.00-00-0003.
Thie specification requires that " Type K penetration assemblies shall-be designed.to maintain a minimum 7
insulation resistance of 1 x 10 ohms when tested at a potential of 500 volts DC....
All resistance measurements are to be made between each conductor and all other conductors connected to ground."
So that functional tests may be performed, the penetration j
unit to be supplied to Sandia will have like pairs of modules-j connected, electrically, in series.
Although Duke Power selected this wiring configuration, they questioned the applicability
- of the CNS-1361.00-00-0003 insulation resistance, requirement for l
4/28/80 11/11/80 12/22/80 1/30/81 this wiring configuration and agreed to determine what effect, if any, interconnecting modules should have on the minimum acceptable insulation resistance requirements.
The Duke position, regarding series connected modules was tran-mitted to Sandia in a letteg dated January 23, 1981, Dover (Duke Power) to Buckalew (Sandia)
The Duke position is as follows.
Since the series arrangement of modules will provide parallel resistance paths to ground for the interconnected modules, the minimum insulation resistance should be lowered to reflect this condition.
This position is interpreted, by Sandia, to mean that theminimumacceptagleinsulationrgsistancerequirementshouldbe lowered from 1 x 10 ohms to 5 x 10 ohms.
Response
It is not anticipated that performance criteria will influence the mechanics of this test, i.e. the test will proceed to completion regardless of measured insulation resistance values.
During the performance of this test the following actions will apply.
A.
Aging Sequences -- nonpowered phases should insulation resistance less than 5 x 106 ohms be observed at the specified measurement intervals, appropriate NRC and Duke Power persons will be promptly advised.
Suspect circuits will continue to be tested throughout the aging sequences.
B.
Accident Sequence -- 600 VAC power phase.
The actions of A (above) will be appropriate except in the case that the insulation resistances fall to a level that leakage currents become excessive.
In the case of excessive leakage current, the circuits responsible for the excessive current will be removed from the power buss.
Again this condition will be promptly reported.
Final Reoort A final report will be issued on this test.
It will in-clude all data sheets and other pertinent details.
l
- See also the addendum to this test plan.
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ADDENDUM #1 Electrical Penetration Specification for Series Connected Modules S e
L L Dt'Im POWER COMPANY { oi;ximAL OFFICES 73. 422 50UTH CHURCM STREtt C11 Alu.orrE, N. C. 2S242 1 January 23, 1981 Sandia Laboratories Division 4445 Albequerque, New Mexico 87185 ATTENTION: W. H. Buckalew
SUBJECT:
Duke Power Company Catawba Nuclear Station Electrical Penetrations Specification CNS-1361.00-00-0003 i FILE: CN-1361.00
REFERENCE:
- 1) NRC Environmental Qualification Confirmation Testing of one (1) Catawba Type "K" electrical penetration
- 2) Acceptance criteria for electrical penetrations We have investigated the acceptance criteria required for the Catawba Type "K" electrical penetrations.
As you are aware, our. specification CNS-1361.00-00-0003 requires that the Catawba Type "K" electricql penetrations maintain a minimum insulation resistance of 1 X 10' ohms a when tested at a potential of 500 VDC in the qualification environments. This insulation requirement is between each individual pin to each Other individual pin and between each individual pin to ground in.a single module. It should be noted that this required insulation resistance value is conservatively higher than the actual requirement of the instrument system and that this is ~ the same acceptance criteria as used in the - original qualification testing. The test plan that you have proposed to use for the NRC environmental qualification confirmation test requires two (2) modules;to be wired in series. This arrangement provides parallel resistance paths to ground i which will decrease the test readings to below what would be experienced for a single module. We feel that this should be incorporated into the test proposal. There were additional acceptance criteria requirements in the test - procedures and test reports which were established by D.G. O'Brien. Inc. These requirements included Hypot testing at 2200 VAC and maintaining an insulation resistance of a minimum of 1 X 108 ohms when tested at a potential' of 500 VDC in the qualification environments. 'These D.G. O'Brien requirements' were not required by Duke Power Company or IEEE Std. 317-1972 for qualifying the Catawba Type "K" electrical penetration assemblies. g- --v
v Sandia Laboratories Page 2 January 23, 1981 l l If you have any questions please contact R. P. Dover at (704) 373-4627, or P. M. McBride at (704) 373-4398. Yours truly, C. J. Wylie, Chief Engineer Electrical Division ygg-K.R e BY: R. P. Dover APPROVED: T. J. Al-Hussaini CJW/TJA/RPD/kkm cc: T. J. Al-Hussaini P. M. McBride J. L. Crenshaw W. J. Foley W. Rutherford, USNRC s
y s ~. Attendance List Pre-Disassembly Conference Daniel Mcdonald NRC Consultant LASL J. R. Agee Equip. Qual. Engr.
- NRC, O.I.E.,
Arlington P. M. McBride Equip. Spec. Duke Power G. C. Rogers Assistant Eng. Duke Power Qual. Test. R. J. Flaherty Constultant Life Cycle Engineering E. Walton Engr. Mgr. Brand-Rex Co. P. K. Das Mg-R/D Brand-Rex Co. l I H. P. Hilberg Eng. Mgr. D.G. O'Brien r. E. Salazar Sandia D. Jeppesen Sandia F. Tnome Sandia L. Bonzon Sandia W. Buckalew Sandia b -_}}