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Applicant Exhibit A-60,consisting of Environ Qualification Test Rept for Raychem Nuclear Cable Breakout & End Sealing Kits
	ML20100R386
Person / Time
Site:	Farley
Issue date:	02/19/1992
From:	; BECHTEL POWER CORP.
To:	;
References
	CIVP-A-060, CIVP-A-60, NUDOCS 9204080145
	Download: ML20100R386 (37)
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BCCHTEL EASTERN POWER COMPANY JOB NO. 7597.o3 ACCESSION NO.

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TITLLLNVIRONMENTAL QUALITICATION TEST REPC RT g OT RAYCHEM NUCLEAR CABLE BREAF,0UT AND Et D SEALING I:ITS jgg, JOSEPH M. FARLEY NUCLEAR PLANT ALABAMA POWER CO.

Supplien RAYCHEM CORPORATION P.O. APCO Reg.APC0 PCN No. (If Applic.)

(0715C8) B-87-0-4475

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Permission to proceed does not constitute acceptance or approval of design details. calculations. analyses, test methods or matenats developed or selected by the supplier and does not relieve supplier from full com-

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Environmental Qualification Test Report of Raychem Nuclear Cable Breakout and End Sealing Kits for -

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mats J April 1981 ENVIRONMENTAL QUALIFICATION TEST REPORT OF PAYCHEM NUCLEAR CABLE BREAKOUT AND END SEALING KITS FOR gofESS/

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$8442 2 O CONTENTS Section Title Page 1

1.0

SUMMARY

1 2.0 TEST SPECIMENS 3.0 TEST PROGRAM 5 3.1 Pretest inspection 5 3.2 Thermal Aging 5 3.3 Radiation Exposure 8 9 3.4 Loss of . Coolant Accident and *

O. ,

Main Steamline Break (LOCA/MSLB)

Environmental Exposure 8

4.0 CONCLUSION

S 14 TABLES 16

' APPENDICES 4

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58442-2 FIGURES e '

Title . Page Figure 1 - Sample Construction 2 Figure 2 - Detail of Sample Construction 3 Figure 3 - Mandrel and Samples 6 Figure'4 - Mandret and Samples Immersed in dater 7 Figure 5 - LOCA/MSLS Test Profile 8 Figure 6 - LOCA/MSLB Pressure vessel 10 Figure 7 - Test Schematic 10 Figure 8 - Test Chamber and Samples 12 Figure 9 - Mandrel af ter Removal from Vessel 12 g-

.. . TABLES ,

Table 1 - 1.R. Values -

16 Table 2 - Current Monitoring of Specimens During ,

Simulated LOCA/MSLB Environment 18 Table 3 - Post LOCA/MSLB Investigation Sumary 19 APPENDICES Appendix A - Certificate of Radiation Dose Aogendix B - Data Acquisition Instruments 0055M C

. 58442-2 !

l Page 1 !

O 1.0

SUMMARY

Six Raychem test specimens, each consisting of four cable break-out and four end cap assemblies, were subjected to a test pro-gram based on the guidelines of IEEE Standards 323-1974(1) and 383-1974(2) to determine their suitability for service within the containment of a nuclear generating station.

i The test program consisted of:

1. Thermal aging (0, 1000, 1500 hours0.0174 days 0.417 hours 0.00248 weeks 5.7075e-4 months 9 150*C)

2. Radiation exposurt (200 - 290 Mrads)

3. Simulated loss of ecolant accident combined with main steam-line break (LOCA/MSLB) conditions while the specimens were energized at rated current and voltage. (20 Arms,1000Vrms)

The electrical integrity of the specimens was evaluated by:

O** 1.

Insulation resistance measurements at 500V d-c. .

2. Voltage withstand tests at 3600V rms for 5 minutes.

3. The ability to maintain electrical loading at rated voltage and current during the simulated LOCA/MSLB.

The cable breakout and end cap assemblies demonstrated satisf actory functional performance in this test program. All specimens had a high insulation resistance (>10Mohms) and, with the exception of end cap sample 2-1W1. passed a voltage withstand test at the con-clusion of the test program.

1

. The test program was conducted by Wyle Laboratories, Norco, California during the period of August,1979 to February,1980. I 2.0 TEST SPECIMENS '

005505 9 Each test specimen was comprised of four cable breakouts and four end caps forming a loop as shown in Figure 1. The cable

() breakouts were tested as part of a transition splice assembly e

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58442 2 Page 2 O e 4

Multiconductor T Cable (#14 Awg Conductors)

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(1) Raychem Cnmp Connector, D6CS1 (2) Raychem WCSF N, insulating Sleeve. Size 115, 6 inches, S1119 Adhesive (3) Raychem WCSF N, insulating leeve, Size 300,

( 15 inches, S1119 hesive (4) Raychem WCSF N, insulating Sleeve, Size 300. -

21 inches, uncoated -

(5) Raychem 403A112 52, Cable Breakout S1119 Adhesive (6) Rockbestos Firewall lli Insulated Cable.

5/C,14 Awg, XLPE Insulation and Jacket (7) Rockbestos Firewall lil Insulated Wire.

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58442-2 Page 4 connecting three No. 14 AWG wires from a multiconductor cable to h three No. 12 AWG single conductor wires. Details of the cable breakout and end cap samples tested are shown in Figure 2. The materials used to make the connections are also listed. A total of 24 cable breakouts and 24 end caps were used for the test program.

Because of availability, a five. conductor cable (5/C No.14) was i used for each test specimen loop. Only three of the five con-ductors were actually used to avoid an excessive number of test vessel penetrations and energizing circuits. The two unused conductors were cut back with the cable jacket inside the splice assembly.

Tne wire insulations in the test specimen loops were color coded for ease of identification during the test. The red and black wires were continuous throughout the test loops and had voltage and current applied. The white wire was terminated in end caps at four places as shown in Figure 1 and therefore could not have current applied. Voltage was applied to the white wire from each end of the test loop. The white wire in the two cable breakout assemblies and end caps in the middle of the test loop was isolated anc could not be energized.

To evaluate the sealing effectiveness of the cable breakout assembly, the crimp splice joining the black insulated wire in eacn cable breakout assembly was left uninsulated, in this way, any water. leakage into the assembly would be detected. In all cases the red and wnite wire crimp slices were covered with

. WC5F N heat shrinkable tubing.

A length of uncoated WCSF (without adhesive lining) was recovered over each cable breakout assembly and end cap. 005508 The ends of the specimen loop were spliced to single conductor No.12 extension wires using a transition splice assembly similar to the samples tested except that all internal Crimp splices

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58442-2 Page 5 h -

were covered with WCSF-N. The extension wires connected the specimen loops to the test vessel penetrations.

3.0 TEST PROGRAM 3.1 Pretest inspection The specimens were visually inspected upon receipt at Wyle Laboratories. There was no evidence of damage due to shipping.

3.1.1 Functional Test (Baseline Data)

Each specimen was immersed in water and given a voltage withstand test of 3.6kV a c for five minutes. All cable breakouts and end caps were immersed during this test. Specimen 2-2 failed the baseline voltage withstand test. The wire insulation was found to be damaged. Specimen 2-6 was used to replace 2-2 to allow 0 the thermal aging-to proceed. A replacement for specimen 2-2 x was provided by Raych'em. All other specimens passed the baseline test.

While still innersed for the above test, the insulation resis-tance (IR) of each specimen was measured at 500V d-c. These results are given in Table 1 on page 14.

The measurements were made on both the black and red insulated wire in each specimen loop and on the white wire at each end of the loop.since the white wire was not continuous throughout the loop .' Therefore, four measurements of both IR and voltage withstand were recorded on each specimen.

The continuity of the red and black insulated wires in each specimen loop was also verified with a low voltage ohmeter. 005bOS 3.2 Thermal Aging o

d Two of the six specimen loops were wrapped onto a 20-inen dia-meter stainless steel mandrel and tied in place. The mandrel and r

53442 2 Page 6

O specimens were placed in an air-circulating oven operating at h 150.*C (302*F) for 500 hours0.00579 days 0.139 hours 8.267196e-4 weeks 1.9025e-4 months . At that time, two additional specimen loops were added to the mandrel, and the oven aging continued for another 1000 hours0.0116 days 0.278 hours 0.00165 weeks 3.805e-4 months . Af ter renoval from the oven, i

the two remaining specimen loops were then added to the mandrel.

Thermal Aging Specimen No. (Hours at 150*C)1 1

2-1 1500 j 2-6 1500 2-2 1000 2-3 1000 2-4 0 2-5 0

, The mandrel, with the specimens in place, is shown in Figure 3.

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0 0 1 Both 1000 and 1500 nours at 150*C exceed the required aging time to simulate 40 year life at 90*C for the cable.

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%/ Note Several other types of specimens were also tested in this program ar.d are shown on the mandre). This report covers only the cable breakout and end cap assemblies. Tne other specimens are the subject of separate reports.

3.2.1 Functional Tests The mandrei wi'h t the specimens in place was immersed in water for functional tests as described in 3.1.1. This was accom-plished by splicing long extension leads to each end of the test loops. The splices between the specimens and tne extension leads were covered with WCSF-N heat shrinkable tubing. The mandrel in the water is shown in Figure 4 All specimens again passed the 3.6kV a-c voltage withstand test for five minutes. The insulation resistance values are given in Table 1 on page 14.

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3.3 Radiation Exoosure $

, All the specimens, while still on the mandrel, were subjected to ganma radiation from a Cobalt-60 source. The total air equivalent 0 8 dose given the specimens ranged from 2.0 x 10 to 2.9 x 10 rads.

6 The dose rate was between 0.32 and 0.47 x 10 rads per hour. The certificate of radiation dose is shown in Appendix A.

3.3.1 Functional Tests The functional tests were again performed as described in 3.1.1.

All specimens passed the voltage withstand test. The insulation resistance values are given in Table 1.

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. Page 9 O( 3.4 Loss of Coolant Accident and Main Steamline Break (LOCA/MSLB) Environmental Exposure (continued)

The specimens on the mandrel were placed in a test chamber capable of exposing the' specimens to the steam and chemical spray environment shown in Figure 5.

The extension leads were brought out through penetrations in the vessel to allow the specimens to be energized during the exposure. The specimens were energized at 1.OkV a-c to ground and carried a current of 20 amperes at 25'C ambient at the start of the simulated accident. The current was allowed to drop 45 the resistance in the conductors increased at elevated temperatures. Current values during the test are recorded in Table 2 on page 15.

Fuses were installed in the voltage circait for each specim'en so that during the exposure a breakdown in the insulation of one ',

specimen would not af fect the voltage applied to the' others.

Schematics of the test chamber and energizing circuit are given in Figures 6 and 7 respectively. All data acquisition instruments used in the test program are listed in Appendix B.

The chemical spray consisted of 6200 ppm of boren 50 ppm of hydrazine buffered to a pH of 10.5 with trisodium phosphate.

The spray was applied at the top of the vessel through a hori-zental spray header at a rate in excess of 0.15 gpm/ft 2 (6ctualfiowvariedfrom.26to.81gpm/ft). 2 S

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I 3.4.1 Test Results During the course of te LOCA/MSLB environment exposure, all ,

energized spe.imens hold the rated current. The capability to supply voltage continuously throughout the test was impaired on some specimens due to insulation failures in the test loop other than at the test samples themselves. The 1.0kV a-c was {

necessarily terminated on these specimens when the fuse opened.

A complete discussion of the anomalies associated with the loss of voltage is given'in section 3.4.2.

I Insulation resistance values measured at selected times during the LOCA/MSLB exposure are given in Table 1 on page 14.

3.4.2 Post LOCA/MSLB Inspection At the conclusion of the test profile (Figure 5), the test ves-sel was' flooded with tap water. The specimens were then given a

. voltage withstand test, and the insulation resistances measured. '

The resul'ts of the insulation resistance tests are given in Table 1. The vessel was then opened and the cause for some of the specimens being unable to hold rated voltage investigated.

The test vessel with the specimens in place is shown in Figure 8.

Figure 9 shows the test specimens af ter removal from the test vessel.

The extension wires were cut inside the vessel so that the mandrel could be removed. This also allowed the test vessel penetrations to ba inspected. It was found that fome of the

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- wires in the penetration hao a low insulatinn vsistance and would not pass the 3.6kV a-c voltage withstand test. The specimens associated with the penetration wires having a low insulation resistance were retested imersed in water (see Figure 4). The retest of specimens 2-1R, 2 2B, and 2-5W2 showee g 9 high values of insulation resistance and all specimens passed T"f t the voltage withstand test. The low values previously measured i on these specimens can therefore he attributed to the test vessel penetrations and not the specimens.

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58442-2 Page 13 0 3.4.2 Post LOCA/MSLB inspection (continued)

Some specimens had high values of insult. tion resistance through-out the simulated LOCA/MSLB test but dropped in insulation resistance or did not pass the voltage withstand test when the vessel was flooded with water. It was found that the low values were caused by cracks in the extension wire insulation away from the mandrel area. The samples again had high insulation resist-ance values and passed the voltage withstand test when the man ,

deel was removed from the vessel, the extension wires repaired, and the mandrel re-immersed in water. The insulation values are given in Table 1.

The remaining specimens had cracked wire insulation on the test loops around the mandrel. In these cases, the specimens were removed from the mandrel and individually immersed in water for In this way, the cracked wire could be isolated. Tne

/7 , r test.

remaining specimens, except 2-58, gave high insulation resist- .

ance values and passed the voltage withstand tests when tested

with the cracked wire insulation out of the water. This could not be done with specimen 2-5B since the crack in the wire insulation was too close to the 2nd of the cable breakout. An insulation resistance value could not be obtained on this spe-cimen because the surf ace leakage gave an erroneous value. This specimen did, however, pass the voltage withstand test using an aluminum foil ground plane.

End cap asser.bly 2-1W1 had a dielectric failure through the end of the cap af ter repeated over-voltage testing (up to 6kV b H

- a c) used to locate the cracked wire insulation during the 1,0 post-test investigation. The f ailure occurred at the end of the h cap where the cut strands of the No. 12 wire contacted the end CD cap.

None of the low insulation resistances recorded during the test were attributable to the Raychem test samples themselves.

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58442 2 Page 14 O 3.4.2 post t.0CA/MSLB Inspection (continued) h Visuil examination of the sleeves used over the cable breakouts and end caps showed surf ace degradation and some superficial crazing. This was most apparent on specimens 2-4 and 2-5.

A summary of the findings during the post LOCA/MSLB investigation is given in Table 3 on page 16.

4.0 CONCLUSION

S Six test specimen loops, each containing four cable breakout assemblies and four end cap assemblies, were subjected to an extensive test program including thermal aging, radiation exposure, and simulated LOCA/MSLB environmental exposure.

During the LOCA/MSLB exposure, the specimens were energized at rated current and voltage.

All specimens demonstrated satisf actory electrical, performance at the conclusion of the test progchm. Wire insulation cracks and low resistance of some wires in the test vestel penetrations caused apparent low values 'in some of the specimens, but sub-sequent testing substantiates the functional ability of these assemblies. All specimens , at high insulation resistance values and (except for one end cap assembly) passe. the voltage with-stand test at the conclusion of the program.

The em.st,ts of this comprehensive test program confirm, by type testing, tne adequacy and suitability of the Raychem cable breakout and end cap assemblies for use on Class IE systems '

within the containment of a nuclear power generating station.

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58442-2 Page 15 REFERENCES (1) !EEE Standard 323-1974, "!EEE Standard for Qualifying !E Equipment for Nuclear Power Generating Stations."

(2) IEEE Standard 383-1974, "!EEE Standard for Type Test of Class IE Electric Cables, Field Spitees, and Connections for Nuc < ar Power Generation Stations."

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I 58442-2 Page 19 G* TABLE 3 POST LOCA/MSLB INVESTIGATION

SUMMARY

Specimen Aging Time Time Voltage No, at 150*C Was Apnlied Results 2-lR 1500 Hours 12 Minutes Penetration failure. Passed subsequent VWT.

2-1B 1500 Hours 7 Days Cracks in wire insulation.

Passed subsequent VWT.

2-lW1 1500 Hours 31 Days Completed test at rated voltage with good IR's. Dielectric fail-ure of end cap during receated VWT's.

2-iW2 1500 Hours 31 Days Completed test.

2-2R 1000 Hours 1 Day Cracks in wire insuletion. * ,

Passed subsequent VWT.

2-2B 1000 Hours 12 Minutes Penetration failure. Passed subsequent VhT.

2-2W1 1000 Hours 3 Days Cracks in wire insulation.

Passed subsequent VWT.

2-2W2 1000 Hours 31 Days Completed test.

2-3R 1000 Hours 31 Days Post test failure in wire insu-lation. Passed subsequent VWT.

2-3B 1000 Hours 31 Da'ys Post test failure in wire insu-lation. Passed subsequent VWT.

t oossaa 2-3W1 1000 Hours 31 Days Completed test.

2-3W2 1000 Hours 31 Days Completed test.

h ;5g M,TrMe ' - - - - - - -

58442-2 Page 20 O TABLE 3 (CONT.). 8 POST-LOCA/MSLB INVESTIGATION

SUMMARY

Specimen . Aging Time -Time Voltage No. at 150*C Was Applied Results , _,

2-4R Unaged 15 Days. Cracks in wire insulation.

Passed subsequent VWT.

2 4B Unaged 1 Day Crack in cable jacket and wire insulation. Passed subsequent VWT.

. 2-4W1 Unaged 31 Days Completed test. .

2-4W2 Unaged 1 Day : Cracks in wire insulation.

O .

Passed subsequent VWT.'

e' I 1

2-SR- Unaged 31 Days Penetration

f ailure.. ~ Passed I subsequent VhT.

2-5B Unaged 4 Days Cracks in wire -insulation.

Passed subsequent VWT.

2-5W1 Unaged- 31 Days Completed test.

2-5W2 Unaged , 18 Days Penetration failure. -Passed '

- . subsequent VWT.

2-%R 1500 Hours 30 Days. Post test failure'in wire insu- .

lation. Passed subsequent VWT. )

2-6B 1500 Hours 31 Days Completed test.

1500 Hours 31 Days Completed test.

2-6W1 0055E4 ,

2-6W2 1500 Hours -31 Days Completed test.

O l APPENDIX A CERTIFICATION OF RADIATION DOSE f '

O e

4 4

g 005525 i

58442-1 Pane Al h

b ;

J ai.mies i e. .o.a.i o. a VA esoo ce we a..aw. -

cones. Pe<n. canteen. esso.

Rockwell (2131 s45 10oo International CERTIFICATE OF OAMMA RADIATION DOSE CUSTOMER Wyle Laboratories PURCHASE ORDER NO. 8057 Wyle Job No. NDQ 58442 DATE IN Octobe'r 26, 1979 TIME IN 11:00 AM DATE OUT November 21, 1979 TIME OU T 8:00 AM 0

MINIMUM DOSE , 2.0 X 10 RADS MAXIMUM DOSE 2.9 X 10 0RADS

. Signature e 2((

em O'

Eersazzamammer- _ _

W* ' O O *e M 6 g *4gg gg 6

6 O

t APPENDIX B .

LIST OF DATA ACQUISITION INSTRUMENTS Oe .

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DJ 28~ Amp Powerstat Elect. Co. 1758C 0-280 WAC N/A SY5ilM Call 88All0N 740/480 Yac Iransformer. Westinghouse 6C98-018 litVA I?tV0ut N/A SY511 89 C.All8AAil0N 0~ 200 ~mA 0_!g!tal_Mu!dmeter flute 8010A 0-2000 VAC 8188 _ 13-12-79 11-12-80 f 0.51 Asp Probe flute N/A 7691 06-25-79 06-29-80 !).01 l_000:1 Ratio Shunt laeston 0041218 50 Amp /50mW 8183 01-15-19' 01-20-80 !O.51 l

0041218 50 Asp /50sv ,8184 01-15-79 01-20-80 10.55 l

Shunt _Weston Weston 0041218 50 Amp /50mW 8185 01-15-79 01-20-80 10.5%

-Shunt 0- 28 Amp

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Superfor Elect. Co. 1258C- 0-280 VAC N/A ST511 M CAtl8AAll(pt Powerstat JTyp. 3)

Iransformer (Typ. 3) UNE. N/A 1000:6 Ratio N/A 5 I 5 11 ft CALIBRATION Venturl Barco 550 1 300 gpm 8166 12 16-79 12-16-80 fl1 -

Pressure Transducer Valldyne OPI5 0

_-100 psi 7460 SYST M CALIBRATION !.251 l H.P. Fl32A 0-500 mv 7613 SYST M CALIBRATION *C.21 Recorder Recorder H.P. 7132A 0-500 av 7612 SYSI N CAtl8AAll04 *0.21 Delta Press. Cauge 6arton IA-49053-1 0-80 in W.'. 1784 09-03-79 01-03-80

251 Fluke 2160A 328 to' +F50*f 8290 09-04-79 09-07-80 !24

._O_ l. g. Thermometer l 8401 10-12-F9 10-12-80 *2*F

_Olg ,_ thermometer _ flute 2_I60A _-328 to *F50*F 019. Thermometer fluke 21604 -328 to eF50*F 8012 08-13-79 08-17 80 *2*f ,,

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ML20100R386

Contents

Text

SUMMARY

4.0 CONCLUSION

SUMMARY

4.0 CONCLUSION

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M1 =5 A"s se ==s 4 O

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SUMMARY

SUMMARY

Navigation menu

ML20100R386

Text

SUMMARY

4.0 CONCLUSION

SUMMARY

4.0 CONCLUSION

= eum e ems == =

M1 =5 A"s se ==s 4 O

= = =

= =

= l ca = Ac e

=

w W6 e g

SUMMARY

SUMMARY

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