ML20212J624
| ML20212J624 | |
| Person / Time | |
|---|---|
| Site: | Sequoyah  |
| Issue date: | 02/27/1987 |
| From: | Gridley R TENNESSEE VALLEY AUTHORITY |
| To: | Youngblood B NRC OFFICE OF INFORMATION RESOURCES MANAGEMENT (IRM), Office of Nuclear Reactor Regulation |
| References | |
| NUDOCS 8703090072 | |
| Download: ML20212J624 (16) | |
Text
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TENNESSEE VALLEY AUTHORITY CHATTANOOGA. TENNESSEE 37401 SN 157B Lookout Place FEB 271987 U.S. Nuclear Regulatory Commission Attn: Document Control Desk Office of Nuclear Reactor Regulation Washington, D.C.
20555 Attention:
Mr. B. J. Youngblood In the Matter of
)
Docket Nos. 50-327 Tennessee Valley Authority
)
50-328 SEQUOYAH NUCLEAR PLANT -
SUMMARY
OF CABLE AMPACITY SAMPLINC PROCRAM
Reference:
TVA letter from me to you dated December 23, 1986, "Sequoyah Nuclear Plant (SQN) Units 1 and 2 - Cable An'pacity Information" In the referenced letter TVA provided information to NRC regarding the program to resolve the concerns on electrical cable ampacity.
In particular, this submittal documented the history of the problem, outlined the program for resolution, and provided the implementing procedures for a sampling program and as-built raceway verification, as well as the corrected electrical design standard. This information and the preliminary results of the sampling program were discussed with NRC in a presentation at their Bethesda, Maryland office on January 30, 1987. The purpose of this letter is to document the results and dispositions of the sampling program and to provide additional information which was requested in the referenced meeting.
The ampacity evaluation program at sequoyah, which began as a result of the generic concern identified in Problem Identification Report (PIR) CENBEB8605, is now concluded. As of February 20, 1987, 125 cables must be reworked, or doenergised if not required to support operation, before restart of unit 2.
Corrective actions are in progress, and 108 cables are currently being reworked.
Inclosure 1 contains a complete description of the ampacity evaluation program and the results of the evaluation. contains a list of the commitments made in this submittal.
Very truly yours, TENNESSEE VAL
.Y AUTH011TY 670 k
PDR p
R. Cridley, D ector P
Nuclear Safety and Licensing Enclosures cc: see page 2 U j I \\
i An Equal Opportunity Employer
h ~U.S.-Nuclear Regulatory Cosuaission cc (Enclosures):
U.S. Nuclear Regulatory Commission Region II Attn:
Dr. J. Nelson Grace, Regional Administrator 101 Marietta Street, NW, Suite 2900 Atlanta, Georgia 30323 Mr. J. J. Holonich Sequoyah Project Manager i
U.S. Nuclear Regulatory Commission 7920 Norfolk Avenue Bethesda, Maryland 20814 Mr. G. G. Zech, Director TVA Projects U.S. Nuclear Regulatory Commission Region II i
101 Marietta Street, NW, Suite 2900 1
Atlanta, Georgia 30323 Sequoyah Resident Inspector Sequoyah Nuclear Plant 2600 Igou Ferry Road i
Soddy Daisy, Tennessee 37379 1
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I ENCLOSURE 1 SEQUOYAH NUCLEAR PLANT AMPACITY EVALUATION PROGRAM I.
TVA DESIGN STANDARD FOR CABLE SIZING - AMPACITY The electrical design standard recently developed by TVA for sizing cables with regard to ampacity, DS-E12.6.3, was developed in accordance with recognized industry standards. The complete basis for the design standard is documented in TVA calculation EEB-CSTF-0001. A summary of the industry standard basis is detailed below:
The Basis for the Ampacities For Cables Installed In In DS-E12.6.3 Conduit IPCEA P-46-426 NEC Article 310 (1987)
Tray (Randomly Filled V3 and V4 Level)
ICEA P-54-440 IEEE 70TP 557 PWR Tray (Maintained Spacing VS Level)
IPCEA P-46-426 The medium voltage (6.9 kV) shielded power cables are installed at Sequoyah Nuclear Plant (SQN) with the shields grounded at both ends or short circuited. The ampacities for these single-conductor cables in DS-E12.6.3 are based on those for triplexed cables from IPCEA P-46-426.
This is due to the fact that the IPCEA Standard does not provide values for singin-conductor cables in conduits and that TVA allows triangular grouping (triplexing) of the three single-conductor power circuits in V5-level tray. As stated in IPCEA P-46-426, the ampacities for triplexed cables have already been calculated for short-circuited shields.
II.
AMPACITY EVALUATION PROCRAM Samplina Proaram The sampling program was developed utilizing Military Standard 105D,
" Sampling Procedures and Tables for Inspection by Attributes." This publication establishes sampling plans and procedures for inspection by attributes. These plans are specifically applicable to inspection of end items or installed cables as applied by TVA.
An acceptable quality level of 4.0, defined as the maximum number of defects per 100 units, was established as a satisfactory result. This is in line with sample programs previously performed by TVA.
Individual inspection lots were created to sort all of the cables of concern into batches which consisted, as far as practicable, of cables of a single type with regard to the cable selection criteria. As the discrepancies in the superseded
J-I p 4
ampacity' standards centered on the failure to address.the various installed raceway configurations, the lots were specifically oriented to focus on the known problem areas. The inspection lots created are 1 -
identified in section 4.4 of SQN Project Procedure SQEP-47, " Sampling for Cable Ampacity," (enclosure 4 of the referenced letter). This, procedure detailed the overall requirements of the sampling evaluation.
V3-Level Evaluation j
Inspection lots 1, 2, and 3 were established to determine the adequacy, with respect to ampacity, of cables routed in voltage level 3 (V3) i raceways.
This voltage level is restricted to control cables operating
]
at a voltage up to 277 volts and a current of less than 30 amps. The 4
great majority of cables in a V3-level raceway carry. low-level (less-l than five amps) and/or intermittent signals for which the ampacity rating of the cable is of no concern (No. 14 AWG is the smallest conductor size utilized in these applications). However, due to the i
allowable ampacity range in V3-level raceways (less that 30 amps), some cable sizes could produce sufficient heat to warrant specific
[
consideration of the. conductor rating with regard to ampacity. In order i
to readily separate those V3-level cables which require consideration for ampacity, which are referred to as " control power cables," from those utilized for controlling the operating status of equipment,
}
referred to as " control function cables," the definitions provided in j
section 1.0 of DS-E12.6.3 (enclosure 5 of the referenced letter) were
]
established. The basis for these definitions is included as Appendix A i
to calculation EEB-CSTF-001 and is included as attachment 1 to this l
enclosure. The purpose of the sampling program for these inspection lots, therefore, was to verify the adequacy of the control power cables.
j The total number of units (Class 1E cables or nonclass lE cables routed 1
with Class lE cables) in inspection lots 1 and 2 exceeded 9,200.
This included both control power and control function. cables. In accordance with the requirements of the military standard and SQEP-47, the sample should consist of 102 control power cables, assuming all of the cables l
were conservatively assumed to be control power.
Following a detailed analysis of 1,072 randomly selected cables from these two lots, only five cables which carried sufficient current to be considered control power cables were found. All five of these cables were found to be adequately sized in accordance with DS-E12.6.3.
Lot 3 contained only l
three cables, all of which were analyzed. None of these cables had a load current sufficient enough to be considered a control po.%e cable.
{
V3-Level Results l
l The analysis in these inspection lots evaluated more than 10 percent of l-the total quantity of cables, far in excess of that required by the i
sampling program and standards. Of the cables evaluated, less than l
one-half percent met the requirements to mandate further ampacity j
consideration. All of these were found acceptable when analyzed.
I i
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______.____.._.___...,1.-____-.._.a.-_,,.-._
t TVA determined that the required number of 102 sample cables would not be achieved even with a 100-percent inspection, since only five control power cables were found through an inspection of almost 12 percent of the total number of cables. More importantly, it became obvious that the load current of cables routed in V3-level raceways at SON was substantially below the previously established maximum limit.
Accordingly, the sampling program in inspection lots 1, 2, and 3 was concluded at this point.
The results are documented in calculation SQN-EPS-006.
V4-and VS-Level Evaluation Inspection lots 4 and 5 were established to verify the adequacy of 600-volt power cables routed in various cable tray configuration. The initial sampling of cables in these lots, 975 in total, indicated a quality level below that initially established as acceptable.
Subsequently, 100 percent of the cables in these lots were individually analyzed for their adequacy with respect to ampacity, resulting in 429 cables which failed the sizing criteria.
Similarly, lots 6 and 7 were developed to determine the adequacy of 6.9-kV power cables in tray.
Lot 6, which contained 29 cables, exhibited an unacceptable quality level in the initial sampling and was therefore subjected to a 100-percent review. This review yielded eight failures.
During the examination of lots 4, 5, and 6, the evaluation of the failures indicated a single generic root cause.
Many of the 10 CFR 50.49 cables have a qualified insulation temperature rating of 60 degrees centigrade, which is substantially below their design rating (generally 90 degrees centigrade). The resulting reduced allowable ampacity of these cables as well as those that are routed with them is significant.
Accordingly, while the initial sampling for the 47 cables in lot 7 was successful, this lot was further subjected to a 100-percent evaluation of the 10 CFR 50.49 cables and those associated with them in tray. All of the 28 cables evaluated in this lot were adequately sized.
Cables in conduits were evaluated in inspection lots 8 and 9.
While inspection lot 8, with a total of 384 cables, passed the initial sampling in accordance with the established procedure, a further 100-percent evaluation of the 10 CFR 50.49 and associated cables in conduit identified 18 cable failures.
Lot 9 received a 100-percent inspection of its 11 cables due to its limited size. This inspection yielded two cable failures.
V4-and VS-Level Results Inspection lots 4 through 9 consisted of approximately 1,446 cables.
Lots 4, 5, 6, and 9 received a 100-percent inspection of their 1,015 cables, which resulted in 439 identified cables which did not meet the
4 i )
- sizing criteria.
Inspection lots 7 and 8 each passed the initial 4
sampling-in accordance with the established pr6:edure. However, a further 100-percent inspection of the portion of these lots which consisted of 10 CFR 50.49 cables or those associated with them in the raceway. configuration in concern yielded an additional 18 failures, E
bringing.the total to 457.
2 i
The results of the calculations.for V4-and VS-level raceways are documented in calculations SQN-EPS-007 and SQN-EPS-008,.respectively.
i These calculations document two unverified assumptions which were utilized.
The assumptions relate to the,accurack of the SQN cable schedule data base and the installed thickness of the fire protective cable coating. Thesa two items will be vosolved before unit 2 resthet j
-by resolution of Employee Concern Progrks Element Reports 238.01, 238.03, 239.00, and 240.00.
The evaluation plans and corrective actions are currently being developed for these element reports.
It should be noted that at the time of the presentation in Bethesda, Maryland, it was believed that inspection lots 7 and 8 had received a 100-percent evaluation of the corresponding cables.
During the recesit l
review for signout of the calculations, it was identified that the 100-percent review was limited to the 10 CFR 50.49 cnd associated cables l
while the remainder of the lot was subjected to a sampling approach.
This sample was conducted and was successful in %ccordance with the initially established sampling progran and acceptance criteria.
III. CORRECTIVE ACTIONS The cables identified by the above evaluation are documented on Significant Condition Report (SCR) SQWEEB86178.
This initial avalua'ti'on t
I was, however, performed utilizing conservativ( assumptions. As an example, all trays were assumed to be fully loaded to their maximum i
limit, and all distribution equipment was assurned to be loaded to the equipment rating.
l Following the identification of the 457 cables which did not meet the j
sizing criteria, an individual evaluation was performed to determine the exact installed configuration and the possibility of modifications to.
fully justify the acceptability of the installed. cable. The i
installation of tray covers and/or bottoms was revievsd and those not required for personnel or cable protection or to meet licensing commitments were removed. The allowable cable ampacity was recalculated l
based on the existing, if less than 30 percent, tray fill..The actual i
load current was determined based on the existing connected loads. If credit was taken for reduced tray fill or load current, the fill or load I
was frozen, administratively, to prevent future additions without engineering review and approval. Finally, the load-type multiplierJ for l.
ampacity margin were reviewed to remove any excess conaepvatism.
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% rough individusi evaluation of the 457 cables and use of one or more-of tha above appi.*cet.hes, 332 of the cables were justified as technically c
acceptable. Thrhveraining 125 (as of February 20, 1987) cables will be reworked, op de' Energized if not required to support operation, before.
restart of unit 9 at SQN. The results and basis of this final portion of the ampacity evaluation are documented on the ErIgineering Report for
, SCR SQWEEB86178.' Currently, 108 cablos are being reworked.
The espacity evaluat. ion progran at SQN, which began as a result of the
' i concerns identified in '?Ih[CENEEBS605, is now concluded. All corrective action twill be c;ce,31sted t fore rectart of SQN unit 2.
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e u.,e yf5_ w, 12-22-gg APPCMDix A - Documsaranssi AND Jusnp/CArisA/ of cogrgou
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pai:aorafer.s o/N4ed bi dese/opk fAe. dead lt>A-, of aofro/
9 power cod /cs. 7d~e ascer/> ik /As/- dos fo fAe.,a//awa6/e ompaosfp/e sdes wXprMeerwge. Li V3-/ eve / r~~ ray some cad
. ss/Abb.<st //aat ib saarra.<>r
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table J.s ofiss wcern l'hs'. /4. AW4 J.s t4e sma//est-aedsefar-siee </4Med a pas-r y76Lar< ras). A dear was.dd%', is reguired 6 read /, sepscafe. Mose. V3-/evet <.as/es.ul<k6 regabe 4.<>sl6t>/7s' rGr mps<.lfp, adsb4 siO/ de. raderred fa as 'Confro/ power caddes" frort fdsse-se}Ndedfor an/rs/
sparsfros, sida,4 n// 4e referred fo as "essfro/ rGe^L> t. aves."
As V3-level ess/es are., b a's.Alirro's, /iml/sd sn kss Ms.<>
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y 3o pmpares, -& sosti<russ.s. current-ref>4 s fsr-v3-/e/e/
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an p//s. wad /a. sur/Syses s.mpac.if, /ess fils.n Jo arszys.res 9
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toMDUC7DR $RE hatt HumBdC hig/MGM dd77ddeJS (AWG) tuenwr RAnN4 Ao.I4-WHB -)
lo Amperes 7
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/lo. B WDD-2.
22 Anspares l
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4I M ln. T/4 E/d'W hp _Sihv2alwd sEB-Asnc--oaos
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ME.sseet added fg w,,e_ges,ue 11-13 -8 9_
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e ec.co TMS en, 12-22-86 The. cad /e a,'ya, sejec h. J Ja ye.,o,,,'sdays; Go*C (see DS-E/2.4 5, ceser,/ 6te.spg,,,,,4,,,,agf of2+ /e.ast ne s,aimm aansie ~, sac;+, >< we aerass )M&
rs c
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aruf Hese hbrsh, are Nerefore seesrad ayp/kas/e /s 3//
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dereL Me. ege/e.asdd Assk aga*1.,*rn/-Je deAerm'oed -
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& = Inkitj teospe.rarbre jnke ib 2 current edage.
T = Ga/ %,ersikre or/ee a corrsat adasp p
c t = Time ),, Ares K = Therors/ b' a wrsfambr., doors m
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as Te = To + (fr + crx -ra)(5/ra)*)-ro) x (1-e *)
a Eephakg Ts EfA To yia/ds l Te = To + (Tx -To)(Tx/Za)* X l1-e'*)
Te d//de hbsfed 7b Ts, N.s arms / /saa&& andNr.w/>his rs/d temper.o/ure. Hsa rep /sciy 7s.wj/A 75 nd %.cl/4 9
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m 4 4, os;g s h a s/a :
Tc = 7. + ((ro + (rs -r,){rx/ ray) -ro.) x (>- e~*)
ausca,a tAe. seem re-serasa wse asin,est.Ja.<w hr order th aga's emegize He essductor -rSe 2Dorisefes a+ is' anpares. To tAe sswe. g> fan, soh & r, Ne-inl/b/ tempera &ra yAc fo 7%a s>J/e Jeln9 eis yh <. Te h limded to Me uvidocfar insdahki 7%iperafure rah.by andis set egua/ fo Tx. Ta is again assomad to de lo *c /awer r
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r(([Tx-io)+lru-(fx-'o)))(Ex/TxY)-Tob O-e4)
Tx = ro C
b = 20 mt ufe3 = Y3 bour ped X 2,S pgg g,,,p),
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, _.DS-E/2.4.3 71ds sAcetadded 6,_
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a- >c8 we !!-'3-st-Ee hiin I.
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Ts = l5 amperes I d = 4 a n;o s.r e s 7 4 = To + ((D-to) e 4z.5-To)(o.12s)
Ta = Ti t(o.izs ra t-4. S4 3 e,sz s 22; )
o.975 Ts = 0.B *?S To t-4.S%3 7o~ = G - 2, S If Ass nou) Aees1 de d's ibeof N27'- /S'Anjaesac.s n2y de.
opphe'd pb a 4 nnpare. radedassdac.+<- & zo mu'wrks sddat eumfm'y Me. ksdandr koar%e radd pronae'd /de. w6A/ /s.wperar' ore-- 's ~7 S *C b u k y'?le-7 RI sorsy/p);o '
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y To is set ee02/ fo Me isss/sfio's femers7ure. r. ash7s~,
t 2;d 7,'e egaa/s (& -Jo), Sods /1Nfinj Asrb 7% fa//sws'oj e f D a f r o /r sj i k / d s 7e = 5 ' + ( 7,~e - Ti) x (I-e ~*'k) re-,.s = rs + ((ra.io)- rx) x (i-e-**)
74 -7.S = D t ((-lo)(/- e/*))
D if = l-e* *
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=
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Mes%sWo99 Used as Esds for faWe 4rgrac.irkhs_
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ENCLOSURE 2 SEQUOYAH NUCLEAR PLANT AMPACITY EVALUATION PROCRAM LIST OF COMMITMENTS 1.
As a result of the ampacity evaluation program, 125 (as of 2-20-87) cables must be reworked, or deenergized if not required to support operation, before restart of unit 2.
2.
Unverified assumption used in the ampacity evaluation program associated with the cable schedule data base and installed thickness of fire protective cable coatings will be resolved before restart of unit 2.
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