ML20151A384
| ML20151A384 | |
| Person / Time | |
|---|---|
| Site: | Arkansas Nuclear, Susquehanna  |
| Issue date: | 07/28/1980 |
| From: | Alba A, Burrows A, Shipway G WYLE LABORATORIES |
| To: | |
| Shared Package | |
| ML20151A382 | List: |
| References | |
| 56669, NUDOCS 8010280648 | |
| Download: ML20151A384 (200) | |
Text
{{#Wiki_filter:; TEST REPORT l C REPORT NO. 56669 i l 5:stNtwie scavicts a, $YSTIMS GROUP OUR JOB HO. NE 56669 l
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,- BECHTEL PO'4ER CORPORATION 125 Page Report P.O. Box 3965 San Francisco, CA 94119 DATE 16 May 1980 REVISION A 28 July 1980 ELECTRICAL k' IRE AND CABLE ISCLATION BARRIER MATERIALS TEST FOR THE SUSQUEHANNA STEAM ELECTRIC STATION UNIT 1 AND 2 FOR BECHTEL POh*ER CORPORATION gg0 Fess /OA -
ss D. Se, o S ejr %k2 y, NO.12157 g O t~ . , m STATE OF CALIFORNIA 1 DEPARTMENT ELECTRONICS COUNTY OF RIVERSIDE / ***
**v C. "vrick, being duly sworn, pgpy, ggg, ,
6eposes and says: That the mformation contained in tais report is the result of complets and carefully to ducted tests and is to the beat of his knowledge true . ga ~- and correct in all res
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I l 1 MO REPORT NO. 56669-
,,4 SCitNTIFIC $fRVIC11 & $YSTEMS GROUP i ti:i WE$1tRN OPE RATIONS, NORCO FACIUTY PAGE Ho Revision A 4 t REVISION SHEET PIVISION REVISION APPROVALS PAGES .
LE':TER DATE -ENG._ QA AFFECTED DESCRIPTION OF PSVISION l I l A .- 7-28-80 4, 5, 8, 18 Per Customer Request
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56669 M MM6' RE? ORT NO.
$Cl!NTiflC $tRVICES UY$ftMS GROUP 2
(' WESTERN OPERATIONS. NORCO FACIUTY PAGE W
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CONTENTS Page Number 2 CONTENTS 3 1.0 PURPOSE 3 2.O REFL.ZNCES 3 3.0 MANUFACTURER 4 4.0
SUMMARY
7 5.0 TEST CONDITIONS AND TEST EQUIPMENT REQUIREMENTS, PROCEDURES AND RESULTS 8 6.0 8 6.1 Receiving Inspection 9 6.2 Isolation Barrier Material Tests (Short Circuit Tests) 13 6.3 Insulation Resistance Tests Chafing Test 15 6.4 TEST DATA SHEETS 17 - 31 32 TABLE 1 33 TABLE 2 34 TABLE 3 35 TABLE 4 TABLE 5 36 - 37 38 FIG'JRE 1 39 , FIGURE 2 l 40 FIGURE 3 42 - 118 2HDTOGRAPHS 1 THROUGH 77 NOTICES OF DEVIATIONS NUMBER 1 AND 2 119 - 120 APPENDlX I 121 - 125 i -
l l M M DMS REPORT NO. d'
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scitNitric stavicts a, systru.s otour westeaN OPERATIONS. NoaCo FACluTY PAGE NO 1 t 1.0 PURPOSE The purpcse of this report is to present the procedures used, ! and the results obtained, in the performance of a test program. ' The test program was performed to demonstrate the ability of certain materials to perform as a Control Switchboard Barrier in.accordance with the test program set forth in Reference 2.1 and in accordance'with Reference 2.2.
2.0 REFERENCES
2.1 Rechtel Power Corporation Purchase Order No. 8856-E-398 2.2 Bechtel Power Corporation Test Procedure Drawing Number 8856-E-398, Appendix A, Revision A, " Test Procedure for Electrical Wire and Cable Isolation Barrier !!aterials for the Susquehanna Steam Electric Station, Units 1 and 2" (. 2 .- 3 " General Project Requirements for Quality Assurance on Purchase Orders for 'Q' Designated Items," Specification Number 8856-G-9 3.0 MANUFACTURER Wire and Barrier Materials supplied to Wyle Laboratories by: Bechtel Power Corporation Post Office Box 3965 50 Beale Street San Francisco, California 94119 I l 1 i 1 1 1 l
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56669 M W5 MMS ' REPORT NO.
$Cl!N11FIC $1RVIC?$ & $YSTEMS GRoVP 4
- WESTERN oPERAfioN3, NoRCo FAO!UTY
' AGE W 4.0
SUMMARY
4 .' l A test program was conducted on electrical wires and cables using different types of isolation barrier materials. The
- specimens were subjected to the test program set forth in
.the referenced specification as described in detail in this test report. -The following is a tabulation of the short circuit tests performed and barrier materials used.
4.1.1 Barrier Materials _
' TEST CONDITION i RATED CUPJtENT PAIR (A) SHORT-CIRCUIT PAIR (B) @ f RATED BARRIER CONDUCTOR CURRENT TEST BARRIER' CONDUCTOR MATERIAL SIEE CURRD T MATERIAL SIZE CONDITION j NO.
50 MiPS NONE #8 AWG 1 i 1 NONE #8 AWG SILTEMP(T) #8 AWG w/ Jacket 1 2 SILTEMP (T) #8 AWG w/ Jacket 50 AMPS 50 AMPS NONE #8 AWG 2 3 SILTEMP(T) #8 AWG
)
4 DELETED 50 AMPS NONE #8 AWG 2 5 FIBERFRAX ( S) #8 AWG 50 AMPS FIBERFRAX (S) #8 AWG 2 l 6 NONE #8 AWG 50 AMPS NONE #8 AWG 2 7 PLYARC (T) #8 AWG 50 AMPE PLYARC (T) #8 AWG 2 8 NONE #8 AWG 50 AMPS NONE #8 AWG 2 l 9 SUPRA (S) #8 AWG 50 AMPS SUPRA (S) #8 AWG 2 10 NONE #8 AWG 11 SUPRA (S) #8 AWG 50 AMPS NONE +1" #8 AWG 2 50 AMPS SUPRA (5) 48 AWG 2 12 NONE +1" #8 AWG 25 AMPS NONE #8 AWG 2 13 SILTEMP (S) . #14 AWG(SIS) 25 AMPS SILTEMP (S) #8 AWG 2 l 14 NONE #14 AWG(SIS)' 15 DELETED 16 DELETED 0.5 AMPS NONE #8 AWG 2 17 SILTEMP (S) COAXIAL 0.5 AMPS SILTEMP (S) #8 AWG 2 18 NONE COAXIAL 19 DELETED SO AMPS NONE #8 AWG 2 20 FIBERFRAX(T) #8 AWG 10 CONDUCTORS 9' 'UCTE: ' Material name followed by (T) designates " TAPE", (S) designates " SLEEVING"
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d M MM3 REPORT No.
' $CIENTIFIC SERVIC15 & SYSTEMS GROUP $
WESTERN CPERATioNS, NoRCo FACluTY PAGE No
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4.0
SUMMARY
(continued) 4.1.1 Barrier Materials (continued) TEST CONDITION TEST BARRIER RATED CURRENT PAIR (A) CONDUCTOR RATED BARRIER SHORT-CIRCUIT PAIR (B) CONDUCTOR CURRENT h NO. MATERIAL SIZE CURPENT MATERIAL SIZE CONDITION 21 NONE #8 AWG 50 AMPS FIBERFRAX (T) #8 AWG(10 CONDUC- 2 TOPS) 22 GREENFIELD(S) #8 AWG 50 AMPS NONE #8 AWG 2 23 NONE #8 AWG 50 AMPS GREENFIELD (S) #8 AWG 2 24 ICO-RALLY (S) #8 AWG 50 AMPS NONE #8 AWG 2 25 NONE #8 AWG 50 AMPS ICO-RALLY (S) #8 AWG 2 26 NONE #8 AWG 50 AMPS SILTEMP(S) #8 AWG 3 27 NONE #8 AWG 50 AMPS FIBERFRAX(T) #8 AWG ( 3 28 DELETED 29 NONE #14, 20pr(SIS) 25 AMPS NONE #14, 20pr(SIS) 3 30 NONE #8 AWG SO AMPS NONE #8 AWG 2 31 NONE #8 AWG 50 AMPS ICO-RALLY (S) #8 AWG 3 32 NONE #8 AWG 50 AMPS SUPRA (S) #8 AWG 3 NOTE: Material name followed by (T) designates " TAPE", (S) designates " SLEEVING". CURRENT CONDITION: No. 1 - Current on short circuit pair set at rated current, 50 amps, and increased in 10% steps until short circuit pair failure. The temper-ature of the inductor was allowed to stabili::e to a 9F/ Minute , or less, rise at each 10% step. No. 2 - Same as condition No. 1 except initial current applied to short circuit pair was 60% of short circuit current, 180 amps. Reference Notice of Deviation No. 2, Page 120. No. 3 - Short circuit current was steadily increased from rated current until pair failed. Duration ! of test, less than 1 minute. (
r M MME - REPORT NO. h:):.'::e SCIEN117tC 5ERYtCES & 5YSTEMS group 6 WESTERN OPERAftONS, NoRCo FACIUTY PAGE NO a
.4.0'
SUMMARY
(continued) 4.1.2 Insulation Resistance Measurement An Insulat.on Resistance Measurement was performed on the secondary cable (rated current conductor)' prior to and immeniately following the Isolation Barrier Material Tests to determine the performance of the barrier material used. The Insulation Rtyistance Measure on the conductors used in
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Test Nos. 3 3,14 and 29 was less than 1 megohm af ter' the Short Circuit Test. See Pages 36 and 37 for measured and calculated values. 4.1.3 Chafine Test A Chafing Test, 60 strokes with No. 320 aluminum oxide paper, was performed on the non-metallic barrier materials. See Paragraph 6.4 of this report for results. Reference Notice of Deviation No. 1 (Page No.119) for specification change to No. 320 paper from No. O emery paper.
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M MM3 REPORT NO- 56669 t, SCl!NilFIC $ERVICE$ & 5YSTEN.5 GRoVP 7 WESTERN oPERAtloN$, NoRCo FACluTY PAGt No 5.O' TEST CONDITIONS A'ID TEST EQUIPMENT 5.1 Ambient Conditions Unless otherwise specified herein, all tests required by the specificati,on were performed at an atmospheric pressure of 30.0 12.0 inches of mercury absolute, and a temperature of 73 118F. 5.2 Instrumentation and Eauipment 5.2.1 Measuring and test equipment utiliced in the performance of this contract have been calibrated by the Wyle Laboratories Standards Laboratory, or a commercial facility utilizing reference standards (or interim standards) whoe. calibra-tion has been certified as being traceable to the National Bureau of Standards. All reference standards utilized in the above calibration system are supported by certificates,
', reports, or data sheets attesting to the date, accuracy, and conditions under which the results furnished were obtained. All subordinate standards, and measuring and test equipment are supported by like data when such infor-mation is essential to achieve the accuracy control required
. by the subject contract.
5.2.2 Wyle Laboratories attests that the commercial sources pro-viding calibration services on the above raferenced equipment, other than the National Bureau of Standards, are in fact capable of performing the required services to the satisfaction i of the Wyle Laboratories Quality Control Department. Certi-ficates and reports of all calibrations performed are retained in the Wyle laboratories Quality Control files and are available for inspection upon request by the customer or government representative. 5.2.3 Actual test equipment used in the performance of this test pro-gram is listed on the appropriate test data. sheets, and included in this report.
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56669 WYlE Nms . meront No. SC'fNTIFIC $ERVICE$ Ai SYSTEMS GRoVP g-WESTEAN oPERAtloNS NoRCO FACIUTY PAGE N0 9 6.0l REQUIREVIICS , PROCEDURES AND RESULTS
- 6.1 Receiving Insoection
. Tested by: A. Burrows Performed: 13 March 1980 6.1.1. Performance Criteria Recuirements .
There shall be no visible evidence of damage to the test specimens upon receipt at Wyle Laboratories. Identification information on the specir. ens shall conform to that contained on the shipping docu-ment. 6.1.2 Test Procedure Upon receipt at Wyle Laboratories, and prior to any testing, the test specimens were visually examined for evidence of damage which may have been incurred in shipment. Results of the visual examination, together with identification information were recorded on the appropriate test data sheets. 6.1.3 Test Materials h The test specimens were identified as follows:
- 1. Raychem. #12 AWG, Coaxial, 5012G1339, XLPE-1978 h
- 2. Haveg Siltemp Sleeving, Type 51,1-inch diameter
- 3. Haveg Siltemp Tape, Type WT65-2, 2-inch diameter
- 4. Carborundum Fiberfrax Sleeving, Type HP-144T, 3/4" diameter
- 5. Carborundum Fiberfrax Tape, Type 3L-144T
- 6. Plymouth Plyarc Tape, Type 3313
- 7. American - BCA Supra unbraided (sleeving) flex conduit, 1 inch diameter
- 8. Greenfield "ype flexible metal galvanized conduit, 1-1/4 inch I diameter l
- 9. ICo-Pally Sleeving, SLV 1200, 3/4 inch diameter
- 10. Thomas and Betts Ty-Rap, TY-27M
- 11. American Insulated Wire, #8 AWG, EPR, Hypalon
- 12. Rockbestes, #14 AWG, SIS Visual examination of the specimens revealed no evidence of damage which may have been incurred in shipment. -l G
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l l M MMS - REPORT NO- - 'f ScifNilFIC $!RVICE$ & SYSTEMS GROUP WCSTEAN oPfRAfloNS, NoRCo FActuTY PACI NO 10 l j J 6.0 RIQUIREMENTS, PROCEnURES AND RESULTS 6.2 1 Isolation Barrier Material Tests (continued) 6.2.2 Test Procedures (continued) The specified barrier material (the test specimen) was applied to either pair "a", pair "b" or both, or neither, as required by the particular test. The tape type and sleeve type barrier material was applied as specified in Dwg. #E-59, Sh. 7B, Rev. 7. Pair "a", the test specimen, and pair "b" were mounted on the test fixture specified in Dwg. #8856-2-398, App. A, Sec. 3. Fourteen i thermocouples, Tla, b through T7a, b, were attached at the specified points on the conductor pairs. Two additional thermocouples, T8 and T9, monitored the ambient temperature at the ends of the paired conductors as shown in Figure #1. Photographs were taken of each test both before and af ter the event.
\ The 50 ampere per 50 millivolt shunt was used in the secondary cable pair (pair "a"). This provided a ene ampere per millivolt calibration on the Omegaline, dual pen recorder. A 300 ampere per 100 millivolt shunt was used in the short-circuit pair (pair "b")
providing a 3 ampere per millivolt calibration. For Tests No. 26, 27, 29, 31 and 32, the 300 amp /100 mv shunt was replaced with an l 800 ampere per 50 millivolt shunt. This shunt provided a 16 ampere l per millivolt calibration. l Thermocouples No.1 through 16 and the output voltage of the D.C. power supply providing the short-circuit current were monitored with a Model 2240A Fluke Datalogger. Scan and print-out were at 20 second intervals. At completion of the test setup, rated current as specified in
,NEC-1978, TABLE 310-16 was applied to pair "a" and 180 amperes initial current was applied to pair "b" on all tests following Test No. 1. 'In Test No.1 pair "b" was set at rated current and increased in 10% steps from that value. Temperature on thermocouple l Tlb was allowed to stabilize to a rate of 9F/ minute or less. Once temperature stabilization had been reached, the chort-circuit current was increased by 10% of the maximum current required to " fail" the 1 short-circuit pair. Previous exploratory test runs with the particu-lar No. 8 AWG conductor showed that 300 amperes were required to fail the short-circuit pair in 5 to 10 minutes. Therefore, the current increases after temperature stabilization were in 30 ampere steps 57
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$CIENilFIC $(RVICES & SYSTEMS GROUP yy WEsTfRN OPERATION 5, NoRCo FACIUTY PAGE No 6.0' PEQUIREMENTS, PROCEDURES AND RESULTS -
6.2 Isolation Barrie?: Material Tests (continued) 6.2.2 Test Procedures (continued) until 300 amperes were reached. The current was then maintained at 7 300 amperes until the cable pair failed. A representative response pattern resulting from this schedule - (Schedule #1) is presented in Figure No. 2. At the point of failure the current was immediately removed from pair "a"~and pair "b". The test setup was again photographed. The test specimen, pair "a", and pair "b" were removed from the test fixture and visually examined for signs of deterioration and defor-mation. Another Insulation Resistance Measurement was then performed on the secondary cable (pair "a"). See pages 36 through 37. The short-circuit current schedule was revised by the customer for ( Tests No. 26, 27, 29, 31 and 32 (refer to Notice of Deviation No. 2) . Instead of a 10% increase after temperature stabilization, the current was steadily increased until the cable pair failed; failure to be achieved in less than 1 minute. Figure No. 3 is a representative profile of the revised schedule (Schedule No. 2). Temperatures were monitored and recorded at 8-second intervals rather than at 20 second intervals. The 300 ampere per 100-millivolt shunt was replaced with an 800-ampere per 50-millivolt shunt which provided a 16-ampere per millivolt calibration. The specified number of tests were run sequentially as listed in Dwg. No. 8856-E-398, App. B, with the exception of Tests No. 6, 10, 25 and 30 which were run out of sequence at the request of the customer. Test Nos. 24 and 28 were deleted and two additional tests were added by the customer. The two additional tests; Nos. 31
. and 32, were identical to Test Nos. 25 and 27, respectively.
M MMS REPORT NO. 56669 3 SCIENTIFIC $1RVICES & $YST1#.$ GROUP 12 WESTERN OPERATIONS. NoRCO FActuTY ' 'ACI NO 6.0 PEQUIPIMENTS , PROCEDUPIS AND RESULTS 6.2 Isolation Barrier Material Tests (continued) 6.2.3 Test Results In all the Short Circuit Tests, rated current continued to flow without interruption in the rated current pair (pair "a") during the test duration. Isolatien Barrier Material Tests conducted, b. wrier material used, test conditions, and elapsed times are recorded in Table No. 1, Page 32. Visual observations during and immediately following the test'are recorded in Table No. 2, Page 33. Visual examinations of barrier material and cable pair "a" are recorded on Pages 25 through 30 Temperatures are recorded in Table No. 3, Page 34 See Appendix I for typical datalogger printout of temperatures during test. Foriyid>.tional information, refer to the data sheets included in thi, irort. The test setup and specimen photographs are shown in photograph Numbers 1 through 5, and 8 through 67. .g
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M MMO REPORT NO. 56669
^7,$ 50ltNilfic SERvlCES & SYSTEMS CtouP 1 13 WESTERN oPtRATioN$, NoRCo fACIUTY PAGE M 6.0 ' REQUIREMENTS, PROCEDURES AND RESULTS
~6.3 Insulation Resistance Test Tested by: A. Burrows Performed: 20' March-1980 through 8 April 1980 6.3.1 Performe_nce Criteria Requirements Reference 2.2 The barrier caterial performance in the Barrier Material Tests shall'be measured in terms of the insulation resistance of the secondary cable (pair "a"). The formula for the minimum acceptable values of insulation resistance is:
'R = K LOG lO Where: R = Insulation Resistance in megohms per 1000 feet K = A constant for the grade of insulation
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D = Diameter over the insulation
- d = Diameter under the insulation Also: 1
- = Summation of 1000/L intervals of length L = 1000 1 L RL Rg = Insulation Resistance in megohms per length L
' The Insulation Resistance shall be measured before and immediately after the Barrier Material Test on the secondary cable (pair "a")
using the water bath method of ASTM 257(78) , Sec. 6.1.11. The water bath shall be maintained at 60F. 6.3.2 Test Procedures Prior to performing the Barrier Material Test, the middle 8 feet of'the secondary cable (pair "a") was immersed in a water bath to which a small amount of sodium chloride was added to improve the conductivity of the water per ASTM 257, Sec. 6.1.11. The cable was allowed to stabilize to the water bath temperature. The insulation resistance was measured in accordance with
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$CitNTIFIC 3ERVICES & $Y5ftMS CRoVP WESTEAN oPERAfloN1, NotCo FACIUTY g i Pact No I 6.0 REQUIREMENTS, PROCEDURES AND RESULTS 6.3 Insulation Resistance Test (continued) 6.3.2 ' Test Procedures (continued)
IPCEA S-19-81, Sec. 6.23.2 with one end of the conductor pair shorted together effectively giving 16 feet of insulation measure-ment. Actual time, water temperature, and insulation resistance were recorded for each test. The inner and outer diameters of the conductor insulation were measured and recorded following the Insulation Resistance Mea-"rement. Immediately after performing the Barrier Material Test, pair "a" was again subjected to the Insulation Resistance Measurement Test above, except that the inner and outer diameters of the insula-tion were not measured. From the insulation resistance values and diameter measurements q the following values were calculated, using a Tl Programable 59 calculator and the performance criteria formula, and the data were tabulated for comparison. R Minimum acceptable insulation resistance value in megohms per 1000 feet RL _ Minimum acceptable insulation resistance value in megehms per 16 feet R' Eqvivalent insulation resistance in megohms per 1000 feet calculated from measured insulation resistance ( R 'L) or. 16 feet of conductor.
- 6. 3. 3. Test Results All pre-test insulation resistance measurements exceeded the
" minimum requirements. In the post test measurements all exceeded the minimum requirements, except in Test Nos, l'3, 14 and 29. See Table No. 5, Page 36 ,
For additional information refer to the test data sheetc included in the report. The test setup is shown in Photograph 6 and 7. 4
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M MMS REPORT NO 56669 scittmnc stavicts 8. 5YSTLv.5 Citour 15 f.{ ""$ -~WESTUtN
- oPERATloNS, NokCo FACluTY - PAGE '+3 6.0' REQUIPIMENTS, PROCEDURES AND PISULTS
'6.4 Chafing Test Tested By: A. Burrows Performed:- 18 April.'1980
- 6. 4.1 s Perfonnance Criteria Reauirements Reference 2.2-The non-metallic barrier materials shall be subjected to 60 strokes of No. 320 aluminum oxide (J cloth) paper with approx-imately 2-pounds of hand pressure. (Reference Notice of Devia-tion No. 1, original requirement of No. O emery paper changed .
to No. 320 paper.) 6.4.2 Test Procedures
\ One specimen of aach of the non-metallic barrier material was subjected to a Chafing Test. Each test specimen was mounted in a test fi::ture that allowed 12 inches of exposed specimen ,
to be tested. The test specimen was stroked 60 times with No. ' 320 Aluminum Oxide (J cloth) paper and approximately 2-pounds hand pressure (Refer to Notice of Deviation No.1) . At the completion of the chafing procedure, photographs were taken of the overall test setup as well as close-ups of the chafed area itself. 6.4.3 Test Results ,
.l Visual examination with a microscope revealed the following condition. of non-metallic barrier material surface fiber after performance of a Chafing test.
.l. ICO-Rally Sleeving, Type SLV-1200 showed approximately 2% l to 3% damage to surface fibers. '
- 2. Siltemp Tape, Type WT65-2 showed approximately 10% to 15%
. damage to surface fibers.
- 3. Siltemp sleeving, Type SI showed approximately 5% to 10%
damage to surface fibers.
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i 6.0 REQUIREMENTS, PROCEDURES AND RESULTS 6.4 Chafina Test (continued) 6.4.3 Test Results (continued)
- 4. _ Fiberfrax Tape, Type 3L-144T - unable to accurately judge percentage of damage to surface fibers because of the irregular pattern of the fibers. Damage, however, was not extensive.
- 5. Fiberfrax Sleeving, Type HP-144T - unable to accurately judge percentage of damage to surface fibers because of the irregular pattern of the fibers. Damage, however, was not extensive.
For additional information refer to the test data sheets included in this report. ( The test setup and post tests are shown through 77.
- in Photograph Nos. 68
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Report No. 55669 WQ gg Page No. 17 DATA SHEET Customer C INd A Job No. N[ wg4 fspp. o,,, 3-/3. N s o.cm.n $t A7kWEb DATA 95tF - RECEIVING INSPECTION No.of Specimens Received: M /rh s Record identification information exactly as it appears on the tag or specimen: Manufacturer $fC V 1'74 $$ftr Part Numbers SEL bATA V/tger O How does identification information appear: (name plate, tag, painted, imprinted, etc.) W r R* . ?AW7~/A 0 d 00 H7"A/ W ( U Serial Numbers:' mon / Examination: Visual, for evidence of damage, poor workmant. hip, or other defects, and completeness of identification. Inspection Results: There was no visible evidence of damage to the specimens unless noted below.
- If additional space is required for serial numbers, use an additional paw, or reference first functional test data sheet (if applicable).
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Rsport No. 56669 Page No. 19 WYLE LABORATORIES , L DATA SHEET gg ISOIATION BARRIER Custom., Bechtel__ Powe r Jeb. No. 56669
ornora tion D.t. Test $tari.g 3-20-80 P.e4 H. - See Receivine Inspection D.t. T.it Complet.d 4-19-80
$/H See Receivino Inseection Amb. Temp 77 .'100F s ,.., DWG EP356-E-398 Ph.t. YES_
P.,.. Test M .J. NA
- 5 p..f m.a T.., As Required
, g, SEE RECEIVING INSPECTION REQUIREMENTS The insulated conductor pairs shall be separated by an isolation barrier test specimen. The speciraens shall be subjected to high temperature produced by an insulated conductor pair undergoing a short-circuit condi-tion. The test specimen and the insulated conductor pairs shall be closely packed and touching for a minimum of 72 inches along their lengths.
A barrier material shall be applied to pair "a" (rated current) or pair "b" (short circuit current) depending on the particular test. The barrier material shall cover all points with less than 6-inches clearance between pair "a" and pair "b". The test specimen and cable pair "a" (rated current) shall be examined visually for any deterioration, and de. formation resulting from high temperatures. Acceptable damage shall be that which allows cable pair "a" to carry its rated current throughout the test. Insu3ation resistance measurements of cable pair "a" (rated current) shall i:e made prior to and immediately following the test. The performance of the given barrier material shall be measured in terms of the insulation resistance values of the test specimen before and after the test. Cable pair "a" (rated current) shall have an insulation resistance in megohms - 1000 feet at a temperature of 15.6 C (600F) of not less than the talue of "R" where : , 1 R = K log 10 D, l t d i R = Insulation Resistance in Megohms - 1000 f t. l K = Constant for the Grado of Insulation D = Diameter Over the Insulation , d = Diameter Under the Insulation A chafing test shall be performed for each of the non-metallic barrier materials. The test shall consist of fine grade er.ery cloth (Refer to NOD #1) rubbed unidirectionally along a'l-foot sample for 60 strokes. A hand pressure of approximately 2 pounds shall be used. The percentage of broken surface fibers in the worst 1-inch square area shall be recorded and the sample shall be photographed.
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=.... Q. C. Form Approval 8k/- 4,,,,,,g a p m u o,,,, ,5% </_.pc
WYLE LADOO ATCRIEO Report No - -56669 DATA SHEET , Page No. 20
) k .a . CUSTOMER Bechtel Power Corporation Test TiHei ISOLATION BARRIER 3** "*C*i#i"9 1"'E Di ^
Spedmen Job No.56669 5/N See Receivins Insoection l Port No. See Receiving Inspection Dde 4-18-80 - l l Revision h ' THIS PAGE LEFT INTENTIONAILY BLANK
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i 4, l l l l w.we-QC Form ApprovolM SHEET OF
WYLE L AOCR ATORIEO Report No. 56669 DATA SHEET Page No. 21 CU370Mfit Bechtel Power Corporation
. Test Titles ISOLATION BARRIER Spedmen See Receiving Inspection 56669
$fy See Feceiving InspectT6~n pan go, See Rcceiving Inspection 4-18-80 PROCEDURE, The insulated conductor pairs, designated cable pair "a" (rated current) and cable pair "b" (short circuit current) respectively, were prepared in 10-foot lengths. The outer cable jackets were removed, with the exception of Test No. 2, leaving the insulated conductors. Approximately 6 inches of insulation was removed from the ends of each conductor and the conductor ends tinned.
The middle 8 feet of cable pair "a" (rated current) was 'innersed in 'a water bath to which a small amount of sodium chloride was added to improve the conductivity of the water per ASTM 257, Sec. 6.1.11. The test specimen was allowed to stabilize to the water bath temperature. The insulation resistance was measured in accordance with IPCEA S-19-81, Sec. 6.23.2 with one end of the conduc.;or pair shorted together effectively giving 16 feet of insulation measurement. A::tual time, water temperature, I and insulation resistance were recorded for each test. The inner and outer diameters of the conductor insulation were measured and recorded following the insulation resistance measurement. The specified barrier material was applied to either pair "a", pair "b", or both, or neither as required by the particular test. The tape type and sleeve type barrier material was applied as specified in Dwg.
#E-59, Sh. 7B, Fe v . 7. l I
i Pair "a" and pair "b" were mounted on the test fixture specified I in Dwg. #8856-2-398, App. A, Sec. 3. Fourteen thermocouples, Tla, b through T7a, b, were attached at the specified points on the conductor pairs. Two additional thermocouples, T8 and T9, monitored the ambient temperature at the ends of the pair conductors, as shown in Figure #1. Photographs were taken of each test both before and af ter the event. A 50-ampere per 50-millivolt shunt was used in the test specimen pair (pair "a"). This provided a one ampere per millivolt calibration on the Omegaline, dual pen recorder. A 300-ampere per 100-millivolt shun +: was used in the short-circuit pair (pair "b") providing a 3-ampere per millivolt calibration. For Test No. 26, 27, 29, 31 and 32 the 300 amp /100 my shunt was replaced with an 800-ampere per 50-millivolt shunt. This shunt provided a 16-ampere per millivolt cali-bration. wme QC Form ApprovafM $HEET OF
Report No. 56669 rage No. 22 WYL E LA BOM ATOR EES DATA SHEET Bechtel Power Cornoration CUSTOMER g , ISOLATION BAnRIER 56669 Test Title See Receiving Inspection gg See Receiving Inspection Specimen S/N _ 4-18-80 pg go, See Receiving Inspection PROCEDURE _ (continued)- 1 through 16 and the output voltage of the D.C. d Themocouples No. power supply providing the short-circuit current were monitoreScan and print-o with a Model 2240A Fluke Datalogger. 20-second intervals. At completion of the test setup, rated current "a" and 180 as specified amperes in NEC-1978, TABII 310-16 was applied to "b" pair initial current was applied ontoall pairtests "b" wasfollowing1, set at rated current pairand Test No. 1. In Test No. Temperature on thermocouple increased in 10% steps from that value. Once T1b was allowed to stabill:e to a rate of h 90F/ ircuit currentor less. minute temperature stabilization had been reached, the s ort-c f il" the was increased by 10% of the maximum current required to " aPrevious short-circuit pair. 300 amperes were required to fail j lar No. 8 AWG conductor showed that Therefore, the current the short-circuit pair in 5 to 10 minutes. increases after temperature stabilization were in 30-ampere stepsThe curren f b until 300 amperes were reached. A representative response 300 amperes until the cable pair failed. (Schedule #1) is presented in pattern resulting from the schedule Figure No. 2. At the point of failure the current was immediately removed from The test setup was again photographed. pair "a" and pair "b". "a" were removed from the tes t The test specimen and cable pair fixture and visually examined for signs of deterioration and defor-mation. A post-test insulation resistance measurement of cable . pair "a" was then taken. The short-circuit current schedule was revised byntthe customer Test Nos. 26, 27, 29, InsFtead of a 10% increase after temperature stabilization, ilure to bethe curre was steadily increased until the cable pair f ailed; f aFigure ,No. 3 is a rep achieved in less than 1 minute. (Schedule No. 2) . Temperatures were ond profile of the revised schedule monitored intervals. and recorded at 8-second intervalsr rather than at an 800-ampere per 50-millivolt shunt which provided a 16-ampere pe millivolt calibration. ( SHEET OF
*** QC Form Approve!M
WYL E L AECM ATORIEO Report No. 56669 , DATA SHEET Page No. 23 d CU$ToMER 9eheel pewn- comorei nn
" Test Titfe *enumrem na c orro Specimen See ' Receiving Inspection a yo,56669 5/N See Receiving Inspection Port No. See Receiving Inspection g 4-18-80 PROCEDURES (continued)
The specified number of tests were conducted sequentially as listed in DWG No. 8856-E-398, App. B, with the exception of Test Nos. 6, 10, 25 and 30 which were conducted out of sequence at the request of the . custom-er. Test Mos. 4 and 28 were deleted and two additional tests were added by the. customer. The two additional tests: Nos. 31 and 32, were identical to Test Nos. 25 and 27, respectively. Beginning with Test No. 30, which S ,, was conducted out of sequence, and for all subsequent tests, 8" lengths /t of #16 AWG solid conductor insulated wire was used in addition to ty-raps to bind pair "a" and pair "b" together. The additional ties were requested-by the customer. - Specimens of five non-metallic barrier materials were subjected to a Chafing Test. Each test specimen was mounted in a test fixture that allowed 12 inches of exposed specimen to be tested. The test specimen was stroked 60 times with No. 320 Aluminum oxide (J cloth) paper and approximately 2-pounds hand pressure (refer to Notice of Deviation No. 1).
,e At completion of the chafing procedure, photographs were taken of the .L overall test setup as well as close-ups of the chafed area itself.
RESULTS Isolation Barrier Test A post-test visual examination of each test specimen and cable pair "a" (rated current) was perfor.ned. The results of the post-test visual examination are presented following the Chafing Test results. The test number, barrier materials, applied currents and elapsed times are presented in Table No.1, Page No. 32. A visual observation was made during and immediately following each Isolation Barrier Material Test. l Those observations are presented in Table No. 2, Page No. 33. l l Temperature readings at the point of failure of pair "b" are summarized ) in' Table No. 3 by test number and thermocouple number. ' Pre-test and post-test insulation resistance values (R ' L) were recordad and compared with each other and with the calculated minimum insulation resistance value (RL ) for the particular type of conductor used in the test. Results are summariced in Table No. 5. Evident from Table No. 5. V ,, QC Form ApprovelM $HEET OF
.. . . ~ _ , ._
WY L E LAOCO ATORIED
- DATA SHEET rage no. 24 fL # CUSTOMER Dochtel Power Corocration Ted TiHet ISOLATION BARRIER ,
l Spoo. men See Receiving Inspection Job Ho. 56669 5/N Caa
"~ai"4"O 7 ema *4 mn Pan No. can pa-aivine Tnspaction Date 4-19-80 1
d l RESULTS (continued) l 1 is a discrepancy in the calculated values of Rg with apparently I constant values of R. The variation from test-to-test of R I, values using the.same R value is a combined result of, (1) differences in conductor diameter measurements of pairs cut from the same cable (refer to Table No. 4) , and (2) the rounding of calculated values to the proper nu=ber of significant figures. The minimum insulation resistance (R) was calculated from the relationship: R = K LOG as esc d ed in W re @ ements of M s repo d. 10 In all the Isolation Barrier tests, rated current continued to flow without interruption in the cable pair "a" (rated current) during the test duration. Chafine Test k, Visual examination with a microscope revealed the following condition of non-metallic barrier material surface fiber after performance of a Chafing test.
- 1. ICO-Rally Sleeving, Type SLV-1200 showed approximately 2% to 34 damage to surface fibers.
- 2. Siltemp Tape, Type WT65-2 showed approximately 10% to 15% damage to surface fibers.
- 3. Siltemp Sleeving, Type SI showed approximately 5% to 10% damage to surface fibers.
- 4. Fiberfrax Tape, Type 3L-144T - unable to accurately judge percentage of damage to surface fibers because of the irregular pattern of the 9 fibers. Damage, however, was not extensive.
- 5. Fiberfrax Sleeving, Type HP-144T - unable to accurately judge percentage of damage to surface fibers because of the irregular pattern of the fibers. De. mage, however, was not extensive.
q+ QC Form Approvo1M SHEET OF
WYLE LAcon ATCQl* Report No. 56669 DAM SHEM rage No. 2s iks i CUSTOMER nachtei power cegaration Test Titles tc: nit.m nv nAne m Specimen See Receiving Inspection g y 6669 gjg See Receiving Inspection q Port No, _ See Receiving Inspection g , 4-18-80 ' POST VISUAL EXAMINATION For the purpose of this examination, the following definitions apply: CHARRING: Decomposition of insulation material to a dark, carbonlike, melted substance, with a hard or crumbly texture; caused by heat or flame. DISCOLORATION: A darkening of insulation material from heat or flame, no deterioration (i.e. melting, charring, or blistering) . BLISTERING: A softening and raising (bubbling) of small sections , (approximately 1/2" to 1" in diameter) of insulation l material by heat or flame. MELTING: A softening and deforming of insulation material by heat or flame; no charring involved. Post-test Visual Examination of the barrier material and pair "a" revealed the following: Test No. 1 This test was labeled the " worst case". No barrier material was used. The cable pairs were packed close together and ty-rapped. Considerable charring of the insulation on pair "a" occurred where the pairs were physically touching. Test No. 2 Siltemp tcpe was used on both pair "a" and "b". The cable outer hypalon jacket was also left on both pairs. There was no visual evidence of damage to the barrier or pair "a". Test No. 3 Siltemp tape was used on pair "a". At the " failure" point, pair "b" erupted in flames and burned for 30 seconds. The flames self-extinguished. There was some discoloration on the barrier material at several points, but no visible , damage. Pair "a" did not appear to be affected by the test. There was no visible damage noted. Test No. 5 Fiberfrax sleeving was used on pair "a". There was general darkening in color along the entire length of the barrier - material. At the ty-rap points, the ty-raps melted and the barrior material was black (burned) . There were no visible holes in the material or any other visible damages. , 1 Pair "a" insulation was blistered and ' charred where it came I 7s , in close contact with the barrier. l
" . L, '
w su e QC Form Approvolg SHEET OF
Rsport No. 56669 WYL E LADOR ATCRIED DATA SHEET Page No. 26
- p. CUSTOMER
".e r @ ra on Test T1Hei ISOLATION BARRIER
$g, See Receiving Inspection g 56669 s/N can u rn M m. ' Tn en c+%
pan go, _ See Receiving Inspection
~
g aw POST VISUAL EXAMINATION - (continued) Test No. 6 Fiberfrax sleeving was used on pair "h". Some of the highest temperatures were achieved in this test (2385.5 0F). There were some areas of discoloration and sone white areas of deterioration. The barrier material would fall away displaying a hole in the material when the white area was handled. The ty-raps melted allowing the pairs to separate for about 3 feet on the horizontal. Pair "a" exhibited local blistering, charring, and melting. There was no conductor showing'through the melted insulation. Test No. 7 Plyarc tape was used on cable pair "a". Approximately 5 seconds before failure of cable pair "b", flame erupted over one-half the barrier material. The flame lasted for 1 minute, 17 seconds. Melting and charring occurred on the material where it was held next to pair "b". Pair "a" _ showed no visible signs of physical damage. Test No. 8 Plyarc tape was used on cable pair "b". The barrier material was charred and melted at various points. There was no flame. Cable pair "a" exhibited local discoloration in a few spots but no charring or melting of insulation. Test No. 9 The barrier material for this test was Supra flexible conduit applied to cable pair "a". Flame erupted on pair "b" after failure and burned for 57 seconds. The flame was extinguished by wind gusts. The e::ternal surface of the barrier was blackened. No other physical damage was noted. Cable pair "a" exhibited no evidence of deterioration or deformation. Test No. 10 Supra flexible conduit was used on cable pair "b". No flame was observed during the test. The barrier material was blackened at one end and had a small hole, approximatJd 1/16 inch in one spot. Cable pair "a" exhibited blackening at one end but no other evidence of damage. Test No, 11 Supra flexible conduit on pair "a", plus 1-inch separation between pair "a" and pair "b" was used. Flame erupted on pair "b", 7 seconds prict to failure. Only one-half of pair
."b" had flame. The flame lasted for 57 seconds and self-extinguished. There was no evidence of physical damage to the barrier material. Cable pair "a" had some blackening at one end, but no other evidence of damage.
EQ l
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QC Form AppewalM . $HEET OF
l Report No. 56669 WY L E L ADOR ATO RIE3 DATA SHEET Page No. 27 ' , ,,, CUSTOM E A Dechtel Power Corporation Test Titlei TSOLATION BAPRIER sp.g. , See Receiving Inspection job No. O'
$fg See F.eceiving inspect.lon Port No. See Receiving Inspection g 4-18-80 POST VISUAL EXMiINATION.(continued)
Test No. 12 Supra flexible conduit on cable pair "b" plus 1-inch separation between pair "a" and pair "b" was used. Flame-erupted over the entire barrier material surface 6 seconds before failure. The flame lasted for 55 seconds, then self extinguished. Damage was evidenced by dark spots in areas of high internal heat, and small holes in 4 areas over a 2-foot section of the barrier material. Melting occurred but was limited to the inner folds in the convoluted construction of the barrier except in one area. In this area a 1/8-inch hole was visible in the outer folds of the barrier material. Cable pair."a" suffered blackening and was covered with soot (from flame) along its entire length. Test No. 13. Siltemp sleeving was used on cable pair "a". Flame erupted on pair "b", 7 ' seconds before failure covering one-half of the cable pair. The flame lasted for 1 minute,14 seconds and then self-extinguished. Areas along the length of the a barrier material were discolored and showed dark spots. Cable pair "a" had small sections of the insulation fused together. There was also general meltir.g and softening of the insulation. No conductor was visible through the damaged insulation. Test No. 14 Siltemp sleeving was used on cable pair "b". Barrier material exhibited seme local discoloration in spots, but no other damage was evident. Cable pair "a" suffered local discoloration, fusing of insulation, and charring. There was no flame.
- Test No. 17 Siltemp sleeving was used on cable pair "a". There was some local discoloration of the barrier material, but no other evidence of damage. There was no flame. Cable pair "a" exhibited no signs of deterieration or deformation.
Test No. 18 Siltemp sleeving was used on cable pair "b". There was general discoloration the entire length of the barrier material. No evidence of physical da'nage was noted. There was no flame. Cable pair "a" showed local blackening in a few spots. Q,
. .u .
OC Form App,vvofM $HEET OF
1 1 M/YL E LAOCR ATORIED Report No. 56669 DATA SHEET Page No. 28 l 5.k.s CUSTOM E R Bechtel Power corporatien Test DHei - TSCLATION BAPRIER Spedm enSee Receiving Inspection Job Nm 56669 l
$/N See Receiving Inspectica i Pod No. See Receiving Inspection Ode 4-18-80 )
POST VISUAL EXAMINATION (continued) Test No. 20 Fiberfrax tape was used on a bundle of 10 conductors of #8 AWO wire designated as pair "a". Flame erupted on cable pair "b" j and burned for 1 minute,12 seconds, then self-extinguished. The barrier material showed discoloration along its length with no l other visible damage. Pair "a" exhibited blistering and ) blackening at two points. l Test No. 21 Fiberfrax tape was used on a bundle of 10 conductors of
#8 AWG wire designared as pair "b". The barrier material exhibited discoloration along its length, but no other signs of physical damage. Cable pair "a" suf#ered extensive charring and melting of the insulation.
Test No. 22 Greenfield flexible conduit was used on cable pair "a". Flame erupted on approximately one-third of pair "b", 4 seconds prior to failure. The flame burned for 1 ' ( tinute, 51 seconds, then'self-extinguished. The barrier l material exhibited discoloration in spots, but no other physical damage was noted. Cable pair "a" showed no signs ) of deterioration or deformation. Test No. 23 Greenfield flexible conduit was used on cable pair "b". The barrier material showed no signs of deterioration or deformation. There was no flame. Cable pair "a" showed no signs of physical damage. Test No. 24 ICO-Rally sleeving was used on cable pair "a". Flame erupted on approximately one-third of pair "b", approximately 3 l seconds before failure and burned for 1 minute, 30 seconds. Ther'e was no flame on the barrier material itself. There was discoloration along most of the barrier material, but no other visible damage. Cable pair "a" showed local charring and blistering at several points. Test No. 25 ICO-Rally sleeving was used on cable pair "b". Flame erupted over the entire surface of the barrier material at the moment of failure and burned for 1 minute, 40 seconds. The barrier material had a general sooty appearance along its entire length with white, ash colored spots. There was no physical damage noted. Pair "a" showed local charring, blistering, and melting along its length where it came in clost contact with the barrier.
. . . -'<x ,
oc p.,, App,,,tg 5HEET OF
Rsport No. 56669 wYLE LADOR ATORIEO DATA SHEET Page No. 29
- :( Bechtel Power Corporation
~ s
- 1 I CUSTOMUL Test TiHes ISOLATION BARRIER Spedmen See Receiving Inspection Jd N $6664 s/N eem nnee<u4nn' t remorH nn Pod No. See Receiving Inspection Ode 4-19-80 POST VISUAL EXAMINATION (continued)
Test No. 26 Siltemp sleeve was used on cable pair "b". Flame erupted on barrier material at moment of failure. The flame appeared to be coming through the barrier material webbing. There was no visible damage noted except for two spots on the barrier where high temperature turned the area black. Cable pair "a" exhibited blistering and blackening of the insulation in one spot. No other visible damage, was noted. Test No. 27 Fiberfrax tape was used on cable pair "b". At the moment of failure, flame erupted with explosive force at the end of the pair connected to the power supply leads. The flame burned for 4 minutes, 42 seconds. In the last few minutes of burning the flame was being fed by melting ty-rap material. The barrier material exhibited local discoloration along its length. The largest area of discoloration was approximately 8 inches long. Pair "a" showed local melting, and charring
.. l . .
of the insulation in a few spots. Test No. 29 There was neither a barrier material, nor a pair "a" (rated current) specimen used in this test. A bundle of 20 conductors of #14 AWG wire was designated as pair "b". The center-most pair of this bundle was short-circuited. The worst-case of the pairs nearest the short-circuited pair was selected and examined. There was no flame,, and very little smoke. The selected pair exhibited general melting of insulation ulong the entire length of the pair. At various points along te length, conductor material was exposed through the insulation. Test No. 30 Siltemp sleeve was used on cable pair "b". There was no flame. The barrier material was discolored and burned in some spots. Cable pair "a" exhibited local charring and melting. There was no conductor wire showing through the melted insulation. Test No. 31 ICO-Rally sleeving was used on cable pair "b". There was flame on the exposed insulation of pair "b" near the shunt end. The flame lasted for 23 seconds and self-extinguished. There was no flame on the barrier material. Cable pair "a" showed no visible signs of deformation or deterioration. k, or QC Form QrovolM $HEET OF
l WY L E L ACOR ATOC2t GO Rsport No. 56669 i I l DATA SHEET Page No. 30 l p.,.
- f. s
. CUSTOM < Bechtel Power Corporation Test Titte: ISOLATION BARRIER
$pecimen See Receiving Inspection 56669
$/N See Receivinj Inspection P e No. See Receiving Anspect.lon Dde 4-18-80 e--
9 POST VISUAL EXAMINATION (continued) Test No. 33 Supra flexible conduit was used on cable pair "b". Pair j "a" and pair "b" were also separated 1 inch. There was I flame at the shunt end of pair "b". "lhe flame lasted for ! 1 minute, and then self-extinguished. There was no visible damage to the barrier material. Pair "a" showed local charring at one end. I T..- 4.o w cia e QC Fs,rm /pprovag 5HEET OF
a-Report No. 56669
-WYL E LADO R ATORIED
, DATA SHEET Page No. al i s ST Bechtel Power' Corporation Lwunua EIuvuER Specimeo See Receiving Inspection Job No.See Receivine Tnewct inn S/N 56669
-Part No. See Receivina Inspection Det, 4-18-80 1
THERMOCOUPLE LOCATIONS l Thermocouple No. Incations Tl Mounted directly on copper conductor, power supply end of cable pair.
- T2 On conductor insulation, power supply end of cable pair.
T3 On conductor insulation, under barrier material, if applicable, one foot from bracket Bl. T4 On conductor insulation, under barrier material, if 1 applicable, one foot from bracket B2.
,.' T5 On conduccor insulation, under barrier material if
, applicable, one foot from bracket E3.
T6 on conductor insulation, shunt end of cable pair. T7 Mounted directly on copper conductor, shunt end of cable pair. T8 Ambient air tenperature, near shunt and of cable pair. T9 Ambient air temperature, bracket B1 corner of backing plate. 3 4 g y $HEET OF
Report No. 56669 Page No. 32 [
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- ELAPSED TIME: Schedule 'Ao.1 Elapsed Time is the time interval from setting current on pair "b". Schedule No. 2, Elapsed Time is the interval from the beginning of the current rise on pair "b" to the failure of pair "b".
' TABLE NO. 1
'M N ISOLATION BARRIER MATERIAL TESTS
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