ML20235R373
| ML20235R373 | |
| Person / Time | |
|---|---|
| Site: | Quad Cities  |
| Issue date: | 09/30/1987 |
| From: | Holahan G Office of Nuclear Reactor Regulation |
| To: | Miller H NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION III) |
| Shared Package | |
| ML20235R377 | List: |
| References | |
| TAC-65789, TAC-65790, NUDOCS 8710080027 | |
| Download: ML20235R373 (38) | |
Text
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ATTACHMENT 1 c uay'o UNITED STATES g
NUCLEAR REGULATORY COMMISSION o
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W ASHINGTON, D. C. 20555 i
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Docket Nos. 50-254 September 30,1987 and 30-265 MEMORANDUM FOR: Hubert J. Miller, Acting Director l
Division of Reactor Safety, Region III FROM:
Gary Holahan, Assistant Director Division of Reactor Projects III, IV, V and Special Projects, NRR
SUBJECT:
REQUEST FOR NRR ASSISTANCE - ENVIRONMENTAL QUALIFICATION (EQ) 0F SIMPLEX ELECTRICAL CABLES INSTALLED AT QUAD CITIES,
)
UNITS 1and2,(AITSF03022987),TIA#111-87-10 TAC NOS.
6S789 AND 65790 This memorandum is in response to your July 15, 1987 memorandum requesting NRR assistance to determine the environmental qualification status of cables manufactured by SIMPLEX and installed in 4160VAC, 480VAC, 208VAC,120VAC and 125VDC applications at Quad Cities, Units 1 and 2.
1987, at Quad As a result of the Region III EQ inspection on June 8-13,(Rev. 5) dated Cities, NRR was requested to review EQ Binder CDQ-014973 June 29, 1987 and the enhanced CECO EQ submittal dated July 17, 1987. We have completed our review of the referenced reports with.the following EQ findings and recommendations.
The documentation submitted by Ceco was developed to environmentally qualify SIMPLEX 5 KV power (Butyl Rubber /PVC jacket), 600 V power and ' control (Butyl Rubber /PVC jacket) and instrumentation (polyethylene /PVC jacket) cables for I
use outside the drywell at Quad Cities, Units 1 and 2.
The EQ documentation states that the testing protocol would be as specified in IEEE Std.. 383-1974 even though the vintage of the Quad Cities plant would dictate testing under the less restrictive 00R (Division of Operating Reactors) Guidelines.
Subsequently, the acceptance criteria were changed to be.that specified in the D0R Guidelines. The EQ documentation was evaluated against the I
D0R Guidelines dated November 13, 1979 and Category II requirements in i
NUREG-0588 dated July, 1981.
QUALIFICATION OF SIMPLEX BUTYL INSULATED 5 KV POWER CABLES Section 5.2.3 of the D0R Guidelines requires that if the component -to',be tested contains any materials which are known to be susceptible to signi-ficantradiationdamageattheservice~conditionlevels(suchasButylRubber),
the radiation dose should be applied prior to or concurrent with exposure to.
the elevated temperature and pressure steam / air environment.
The Wyle test conducted for CECO in February,1984 did not fully meet this D0R Guideline NDA N g, OCT. 5 1987 1l'_.
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Mr. H. J. Miller 2
requirement.
The deviation consisted of not complying to the radiation guide-3 lines in that the cable test samples had undergone 10 years of natural aging at the plant site before being subjected to accelerated radiation, thermal and steam exposures.
Furthermore, even though the EQ documentation stated that the test would b'e conducted as specified in IEEE Std. 383-1974, the Wyle test was not conducted in strict accordance with that standard.
l Test deviations involving radiation dose rate, not testing the thinnest insulation product, not measuring leakage current, and not including traditional conservatism (mandrel bend not followed by an 80 V / MIL hipot test) have been identified. Whilethesedeviationsareconsist8btwiththe 00R Guideline requirements, the Wyle test does not represent the more conservative qualification test (IEEE Std. 383-1974) that had originally been specified.
Nevertheless, since Quad Cities is required to meet the 00R Guidelines, we conclude that the natural aging deviation is not significant and the test qualifies the 5 KV cable.
We feel, however, that it was not prudent to test the cables to the less stringent D0R Guidelines in view of Butyl Rubber's known poor performance daring radiation environments.
QUALIFICATION OF SIMPLEX BUTYL RUBBER INSULATED 600 V0LTS POWER AND CONTROL CABLES At Quad, Cities, 600 V cables are used for low voltage power and control circuits which consist of 480 VAC, 208 VAC, 120 VAC and 125 VDC sources.
In lieu of a 1
test, Ceco proposes to environmentally qualify these cables based on a similarity analysis.
The referenced Wyle test was that performed on the 5 KV Butyl Rubber insulated, PVC jacketed cable as described above.
Based on industry testing, Butyl Rubber is known to be a degradable material susceptible to radiation 6
7 damage between 5 x 10 and 10 rads.
The600vcablesatQuadCitfesmust-7 withstand a radiation dose (normal plus accident) between 1.8 x 10 and 1.3 x 10 rads.
The similarity analysis contained in the EQ binder between the 5 KV cables and the 600 volt cables does not adequately account for the large difference in insulation / jacket thickness between these cables.
The SKV insulation thickness is 171.875 mils with a jacket thickness of 125 mils.
The 600v cables have an insulation thickness of 46.875 mils with a jacket thickness of 62.5 mils.
In addition, the Wyle qualification test (1) was not performed on the thinnest insulation product, (2) did not account for oxidation degradation of polymer materials in the aging analysis, (3) may not envelope the natural aging conditions of the 600 v cable since the 5 KV radiation dose rate is 2 orders of magnitude less than the 600 v cable dose rate.
These differences do not allow the postu-lated aging, oxidation, and subsequent surface cracking of the lower voltage cables to be adequately addressed, and thus we conclude that qualification by similarity has not been established.
We recommend CECO be informed of our conclusion regarding qualification of the 600 volt cables.
Finally, it is our judgment that the only feasible manner in which the 600 volt cables can be qualified is by testing, using techniques to simulate both natural aging conditions and LOCA conditions and thus demonstrate environmental qualification.
The vintage of the Quad Cities Plant would dictate
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Mr. H. J. Miller 3
that the qualification testing be as specified in the D0R Guidelines. However, the uncertainty of Butyl Rubber regarding its radiation and high temperature tolerance, and the numerous safety.related circuits (700,000 feet of cable per q
Unit) in which these 600 y cables are used, justify that Ceco be urged to j
consider that it specify the more stringent IEEE Std. 383-1974 qualification q
test.
QUALIFICATION OF GIMPLEX INSTRUMENTATION CABLES'(PE/PVC JACKET)
The above referenced Wyle report was also used to qualify SIMPLEX instrumen-Category II requirements of NUREG-0588 (DOR guidelines)yvinyl chloride jacket tation cables with polyethylene (PE) insulation and pol state that performance.
characteristics of equipment should be verified before, after, and periodically -
j during testing throughout'its range of required operability.
Leakage current and IR measurements were not monitored during the high-energy-line-break (HELB) simulation test. These cables are used for pressure and flow transmitters that are required to function in the post LOCA environment to comply with the guide-lines of R.G. 1.97. While these transmitters do not provide a trip function, accurate readings of the parameters they measure are vital to enable an operator to diagnose the accident.
Inaccuracies, nevertheless,- cannot be predicted :since cable leakage current was not monitored during the HELB simulation. The accuracy error range of 10-20% (ANS4.5) deemed acceptable by CECO for these transmitters cannot be verified. By not verifying the performance characteris-tics of these cables during the HELB simulation, the qualification test is con-sidered to be invalid. We recommend that these cables'be retested with leakage current and IR measurements monitored and recorded during the HELB simulation.
l In addition, further justification and explanation should be provided to sub-stantiate the assumption that during the DBE, the 100% relative humidity will i
be non-condensing.
In addition, synergistic effects in the presence of oxygen are known to. occur in PE insulation and PVC jacketed material even when the radiation dose rate is low and the plant is operating under normal conditions. CECO states that the existing maintenance and surveillance program allows for early visual detection of any serious degradation of the PVC cable insulation system. Since outside' drywell cables will be inspected every 10-years for age related visual degra-dation on a sampling basis (less than 100% of the cables will be inspected),
identification of such problems may go undetected throughout the life of the 1
plant. We recommend that the maintenance, surveillance and inspection program l
to identify any synergistic related cable deterioration he enhanced since synergistic effects have been shown to occur at 2.5 x 10j rads between-PE and PVC and the Quad Cities maximum radiation dose is 1 x 10 rads.
CONCLUSION Based on our review of the CECO EQ documentation for SIMPLEX electrical cables, we conclude that adequate justification presented in the enhanced EQ package.
has not been provided by CECO to demonstrate the environmental qualification of the Simplex 600'v and instrumentation cables outside the'drywell at Quad Cities l
Units 1 and 2.
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1 Although we believe this issue should be handled promptly, we do 'not believe it warrants more direct action regarding continued operation of-Quad Cities
. since' cable deterioration is progressive'and the~ Quad Cities units-are at~less i
than half.of their : forty-year design life.
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V Gary Holahan,4ssistant Director
-Division of Reactor Projects III, IV, V.
and Special. Projects, NRR l
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D. Crutchfield i
N. Chrissotimos, RIII l
J. J. Harrison, RIII
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R.'Gardner, RIII i
'A. Gautam, R1II 1
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Shao-1 A. Thadani I
J. Craig
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H.' Walker 3
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.1 PURPOSE 1
TE PURPOSE OF THIS EETING IS TO ADDRESS NRR CONCERNS-REGARDING TE APPLICABILITY OF EDIS0N'S SIMPLE BUTYL RUBBER CABLE TESTS TO EDIS0N'S 600V SIMPLE ITIL RUBBER CABLES, (HOLAHAN TO MILLER EM0, DATED 9/30/87),
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SIMPLEX BUTYL RUBBER I
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CABLE QUALIFICATION QUAD CITIES STATION 1
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INTRODUCTION AND BACKGROUND II.
CABLE SPECIFICATION, MATERIAL', CONSTRUCTION AND.
DEGRADATION
-III.
CABLE TESTS I
1 IV.
APPLICABILITY OF TEST RESULTS V.
INDEPENDENT REVIEW OF TEST RESULTS VI.
DDRCOMPLIANCE Vi1.
NRR CONCERNS IN SEPTEMBER 30,1987 LETTER-VIII.
SUMMARY
AND CONCLUSIONS
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-BACKGROUND J
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D0R GUIDELINES FOR ORIGINAL EQUIPMENT.
(79-01B) i e
QUAD CITIES IS A DOR PLANT o
BUTYL. RUBBER CABLES AT QUAD CITIES ARE ORIGINAL EQUIPMENT INSTALLED PRIOR TO THE ISSUE OF D0R GUIDELINES e
QUAD CITIES MEETS THE.REOUIREPINTS OF THE l
D0R GUIDELINES j
(TRIS IS DISCUSSED IN DETAIL IN A LATER 4
SECTION)
I e
SINCEQUADCITIES! SAD 0RPLANE' EQUIPMENT INSTALLED PRIOR TO D0R GUIDELINES79-01B 1
IS NOT REQUIRED TO COMPLY WITH IEEE STD'383-1974) l
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a BACKGROUND e ALL CABLE OUTSIDE PRIMARY CONTAINENT
- NO CABLES IN 5 X 10 RADS AND ELB CONDITIONS (MAXIM 1,8X10 RADS) q e5KVSIMPLEBUTYLRUBBERCABLESARE LOCATEDINHIGHRADIATION-NONCOEESING HUMIDITYZONES.(DRY)
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- 600 SIMPLE BUTYL RUBBER POER & CONTROL 1
CABLESAREINQUADCITIES j
e HIGH MIDITY, HIGH TEMPERATURE, MODERATE RADIATION (ET) - 5%
e HIGH RADIATION - N0N C0EENSING M IDITY (DRY) -.10%
l LOCA - RADIATION ONLY.
- PE/PVC INSTRUENT CABLES ARE NOT REQUIRED TO MCTION DURING A ELB AND ARE ONLY:
EXPOSEDTOHIGHRADIATION-NONCONDENSINGENVIRONMET
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j CABLESPECIFICATIONSLMATERIAL-
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. CONSTRUCTION AND: DEGRADATION I
o CECO CABLE SPECIFICATIONS-IPCEA
'S-19-81 CABLE" CECO SPEC.*
INSUL~.-
JACK.--
CLASS SERVICE N0 ~.
~INSUL/ JACK. -
600V 120VAC EM-29115 BR/PVC SEC3'.i5SEC4','13.5l 125VDC 600V 208VAC EM-29105 BR/PVC
'SEC 3.15SEC 4.13.5 480VAC 5000V 4160VAC EM-29116' BR/PVC SEC 3.15 SEC 4.13.5
- ALL SPECS CONTAINED SIMILAR REQUIREMENTS FOR THE--
1 INSULATION AND JACKET COMP 0UNDS
]
o BUTYL RUBBER INSULATION MATERIAL o
SKV AND.600V CABLE SPECIFIED AND~ MANUFACTURED IN SAME TIME FRAME o
BUTYL RUBBER SPECIFIED TO MEET SAME REQUIREMENTS FOR EACH CABLE CLASS 1
o BUTYL RUBBER CABLE MANUFACTURED BY SIMPLEX T0 CECO i
SPECIFICATIONS-BUTYL RUBBER FOR SKV AND 600V SAME 4
i
4 CABLE SPECIFICATIONS, ETC. (CONTINUED) l o
CABLE CONSTRUCTION o
SINGLE-CONDUCTOR - BR INSUL., PVC JACK.
o MULTI-CONDUCTOR -
BR INSUL., PVC COND. JACK..
PVC OVERALL JACK.
o INSULATION / JACKET THICKNESS 1
THICKNESS
. VOLTAGE STRESS IN INSULATION CABLE INSUL JACK.
V/ MIL
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CLASS MILS MILS' NOMINAL 4160V 480V-120V J
5000V 171.8 47/125 14?54 7' 0 600V 46.8 16/62.5 4.8 2'. 2 0.96
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DIELECTRIC STRENGTH OF BUTYL RUBBER (47' MILS INSUL.)*
RADIATION DOSE DIELECTRIC STRENGTH i
'R D-V/ MIL-O 564 5iO5 618 5.'106 542
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7 5.10 129
- IEEE TRANS. PAS-88', N0'. S', MAY 1969', P. 535
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1 CABLE SPECIFICATIONS (CONTINUED) o DEGRADATION FACTORS o
VOLTAGE STRESS, V/ MIL u
TEMPERATURE o
RELATIVE HUMIDITY o
RADIATION o
0XIDATION l
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MOST SEVERE COMBINATIONS OF ACCIDENT AND NORMAL CONDITIONS-VOLT.
REL.l*
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ENVIRONMENT CABLE STRESS TEN HUM.
RADIATION OUTSIDE DRYWELL CLASS V/Mll.
'F
-RAD.
HELB 600V 4.8 304 100(C) 1.8.'106-
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STEAM TUNNEL SIMIM) 6 OTHER HELB 600V 4.8 285 100(C) 1.6.10 i
d tMIN)
LOCA 5000V 12.09 104 100(NC) 39.106 6
RADIATION ONLY 600V 4.8 135 95(NC) -13.10
- C - CONDENSING NC - NON-CONDENSING
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- CABLE SPECIFICATIONS,-ETC (CONTINUED) i f
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o-HISTORICAL PERFORMANCE OF BUTYL RUBBER CABLE.AT QUAD CITIES o
SERVICE LIFE TO DATE
- 16 YEARS o
IN-SERVICE FAILURES'
. - NONE T0 DATE TO DATE DUE TO MATERIALS 1
OR INSTALLATION o
0XIDATION INSULATION LOSS-
- NONE APPARENT (SAMPLE FROM PLANT) l 1
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-l CABLE SPECIFICATIONS, ETC. (CONTINUED o
CONCLUSIONS o
BUTYL RUBBER CABLE AT QUAD CITIES SPECIFIED AND J
MANUFACTURED IN SAME TIME FRAME BY SIMPLEX o
SAME MATERIAL FOR SKV AND 600V CABLE-o DEGRADATION FACTORS MORE SEVERE FOR SKV CABLE NO IN-SERVICE FAILURES TO DATE-DUE TO MATERIAL u
OR INSTALLATION o
NO EVIDENCE OF INSULATION LOSS DUE T0.0XIDATION j
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i CABLE TESTS 1
o PURPOSE OF TESTS q
j o
SHOW THAT THE RUTYL RUBBER AND POLYETHYLENE INSULATING MATERIALS USED IN THE SIMPLEX CABLES AT QUAD-7 CITIES ARE QUALIFIED FOR THE ENVIRONMENTS T0-WHICH THEY WILL j
BE EXPOSED-AT-QUAD CITIES, 4
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.:j CABLE'TESTSL(CONTINUED) j a
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o CABLES TESTED
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o IG-YEAR-OLD' CABLES TAKEN FROM QUAD CITIES.
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'u ORIGINAL EQUIPMENT.
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~o SAME' INSULATION. MATERIAL AS INSTALLED:
CABLES 1
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CABLE TESTS'(CONTINUED 1 I
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-TEST PROCEDURES-
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RADIATION BEFORE THERMAL AGING TO REFLECT-
? SYNERGISTIC EFFECTS:
c DURING END OF' LIFE TESTS CABLES ENERGIZED AT
NOMINAL VOLTAGE AND CARRYING NORMAL LOAD RATED.
CURRENT POST TEST HI-P0T. TEST FOR 5 MIN. IN TAP' WATER o
. BUTYL RUBBER 5000Vi 2 TIMES SERVICE.
j POLYETHYLENE 3840V 69: TIMES SERVICE o
POST TEST FUNCTIONAL TESTS
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CABLETESTS(CONT'D).
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TESTPARAMETERSVS,SERVICEDEGRADATIONFACTORSFORB!JTYLRUBBER-CABLE j
EVIRdNET V0LTI REL..
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STESS IEMP. F lE RADIATION DRYELL LV/ MIL TIME I;.
RADL ii 16-o HELB T,EST 12.09 304-100ic)". 5,5x10 STEAM
<30 MIL l i
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TUNNEL SERVICE 4,43Q 304 100(c) 1,8x10
<5" MIN,
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RADIATION.TESI-14.54 1
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. SERVICE 7.0 a -
135*
95(nc)-
39,0x10
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?-G - 600 V CABLE W
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INSULATION + JACKET Y 1135L F FOR ONE YEAR THICKNESS:62,5 MILS.
- 4DURINGTHERMALAGING:
a-5KVCA.Bd.
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INSULATION + JACKET
-(c)
CONDENSING
' ' THICKESS : 344 MILS.
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i CABLE TESTS-(CONTINUED) d 1
o TEST RESULTS 1
o SIMPLEX BUTYL RUBBER CABLE PASSED-HI-P0i. ' TEST (LEAKAGE CURRENT-2 MA)
)
FUNCTIONAL TESTS IR TEST-4
-o POLYETHYLENE 1DNBLE PASSED HI-P0T TEST-(LEAKAGE CURRENT 0 MA)'
FUNCTIONAL TESTS l
IR TEST o
CONCLUSIONS o
SIMPLEX BUTYL RUBBER INSULATING MATERIAL IS QUALIFIED FOR THE ENVIRONMENlALLCONDITIONS.
AT QUAD CITIES o
POLYETHYLENE INSULATING MATERIAL-IS QUALIFIED-FOR THE ENVIRONMENTAL CONDITIONS AT QUAD CITIES
I APPLICABILITY OF TEST RESULTS l
J e'
TEST. PARAMETERS e
EXCEEDED ENVIRONMENTAL CONDITIONS TO WHICH ALL SIMPLEX BUTYL RUBBER CABLES'AT QUAD CITIES WILL-BE EXPOSED.
e DEMONSTRATED THAT SIMPLEX BUTYL RUBBER MATERIAL IS 0UALIFIED AS A' CABLE INSULATION AT QUAD CITIES, a
600V POWER AND CONTROL SIMPLEX BUTYL RUBBER CABLES e
SERVICE REQUIREMENTS LESS SEVERE THAN 5xV CABLES TESTED-SPECIFICALLY-VOLTAGE STRESS.
RADIATION i
QUALIFICATION OF 600 SIMPLEX BUTYL RUBBER CABLE' j
e e
TEST RESULTS QUALIFIED SIMPLEX BUTYL RUBBER-CABLE l
FOR QUAD CITIES ENVIRONMENT.
e TEST PARAMETERS ENVELOPE THE SERVICE CONDITIONS-0F o
THE 600V CABLE BY A WIDE MARGIN.-
1
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.n APPLICABILITY OF TEST 'ESULT3 (CONTINUED)
R o
CONCLUSIONS o
TEST RESULT 3 ON SIMPLEX BUTYL ' RUBBER CABLE-QUALIEY. BOTH SKV AND '600V ' CABLE FOR THE ENVIRONMENTAL CONDITOIN3 Al-QUAD CITIES.-.
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INDEPENDENT REVIEW 0FTAPPLICABILITY GF -TEST RESULTS o
BECAUSE THE NRR RAISED QUESTIONS ABOUT CECO'S j
JUSTIFICATION OF TiiE APPLICABILITY OF TiiE TEST l
RESULTS FOR THE 5xV SIMPLEX BUTYL RUBBER CABLES TO THE 600V SIMPLEX BUTYL RUBBER CABLES CECu ASKED FOR AN INDPENDENT REVIEW 0F ITS. CONCLUSIONS.
4 TiiREE INDEPENDENT REVIEWS WERE PERFORMED.
MAJOR CABLE MANUFACTURER (UK0HITE) o REVIEWED APPLICABILITY DOCUMENTATION AND CONCURRED o
WITH CECO'S JUSilFICATION.
o INDEPENDENT TEST LABORATORY (WYLE) o REVIEWED RESULTS OF TESTS IT PERFORMED d
o PREPARED AN ASSESSMENT REPORT ON THE APPLICABILITY 0F SKV RESULTS TO 600V CABLE o
CONCURRED WITH CECO's JUSTIFICATION l
o CONSULTING FIRM'(WESTEC) o REVIEWED APPLICABILITY CONCURRED WITH CECO /2 JUSTIFICATION u
is
);.
INDEPENDENT REVIEW (CONTINUED)
'~
a CONCLUSIONS
]
ED NO Oli E
SKV. CABLE TESTED, BUT ALSO THE-600V CABLE WiiOSE-
'l SERVICE REQUIREMENTS ARE ENVELOPED BY'THE 5KVL CABLESERVICEREQUIREMENTSANDTHETESTPARAMETERS.
o THREE QUALIFIED: INDEPENDENT PARTIES CONCUR WITH:
CECO'S CONCLUSIONS'.
l ALL SIMPLEX BUTYL RUBBER CABLE 'AT-QUAD-CITIES o
QUALIFIED FOR ENVIRONMENTAL CONDITIONS AT QUAD CITIES.
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i DDR COMPLIANCE I
o QUALIFICATION BY TYPE TESTING (SEC. 5.2 0F DOR)
DDR REQUIREMENT GUAD CITIES COMPLIANCE 1
1
. TEST ENVIRONMENT SHOULD ENVELOP
REFER TO WYLE SERVICE CONDITI0iiS AND DURATI0iiS TEST REPORT AND PREVIOUS FROM INITIATION OF ACCIDENT SECTIONS 0F THIS PRESENTA-UNTIL ENVIRONMENT RETURNS TION.
TO SAME LEVELS THAT EXISTED PRE-ACCIDENT.
TEST SPECIMENS SHOULD DE THE
- PREVIOUS DISCUSSION HAS l
SAME MODEL AS INSTALLED SHOWN THAT SKV SIMPLEX EQUIPMENT WITH RESPECT TO BUTYL RUBBER CABLE RESULTS DESIGN AND MATERIAL ARE APPLICABLE TO 600V SIMPLEX OF CONSTRUCTION, BUTYL CABLE, DEVIATIONS BETWEEN INSTALLED e NO DEVIATIONS.
AND TESTED EQUIPMENT SHOULD TESTED AND INSTALLED INSULATION BE EVALUATED IN THE QUALIFICA-SYSTEMS ARE IDENTICAL..
(SEE TION DOCUMENT.
PREVIOUS SECTIONS.
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- g D0R COMPLIANCE (CONTINUED)
D0R REQUIREMENT QU D CITIES COMPLIANCE
. COMPONENT SHOULD BE EXPOSED
..THE CABLES-WERE.
TO THE ENVIR0iiMEiiT lii THE WORST-CASE SYNERGISTIC SEQUEiiCE DEFINED BY ITS CONDITIONS WERE USED, j
3ERVICE CONDITI.10ii, fiAMELY, RADIATION BEFORE
-AGING AND THEN END OF LIFE y
~ TEST.
. IF COMPONENT MATERIALS NOT
. CABLE MATERIALS ARE SUSCEPTIBLE '
SUSCEPTIBLE TO SIGNIFICANT.
TO RADIATION DAMAGE. TEST j
RADIATI0ii DAMAGE AT SERVICE C0iiDUCTED WITH RADIATION BEFORE
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CONDITION LEVELS, IT (RADI-AGING TO REFLECT WORST-CASE ATION) SHOULD BE APPLIED AT SYNERGISTIC EFFECTS.
ANY TIME DURING THE TYPE R
TESTING.
y
- IF COMPONENT MATERIALS SUS-
- SEE AB0VE.,
CEPTIBLE TO RADIATION DAMAGE,-
RADIATION DOSE SHOU G BE APPLIED PRIOR TO OR CONCURRENT WITH EXPOSURE TO ELEVATED TEMPERATURE, PRESSURE, STEAM / AIR CONDITIONS.
~.
A D0R COMPLIANCE (CONTINUED) 110R REQUIREMENT QUAD CITIES COMPO ANCE-THE SAME SPECIMEN SHOULD BE eTHEY WERE,' REFER TO WYLE TEST USED THROUGHOUT THE TEST.
REPORT
- 8 DIFFEREiiT-SPECIMENS
' SEQUEliCE.
WERE"USED FOR 8-DIFFEREiiT EXPOSURES.-
. : COMPONEiiTS CONTAliilNG
- e. CABLE MATERIALS.ARE SUSCEPTIBLE MATERIALS SUSCEPTIBLE TO TO SIGNIFICANT. THERMAL / RADIATION SIGNIFICANT DEGRADATION DUE DAMAGE.
TESTS DONE:.TO MAXIMIZE a
TO THERMAL AliD RADIATION SYNERGISTIC EFFECTS BY RADIATING l
AGING. -QUALIFIED LIFE MUST-BEFORE TiiERMAL AGliiG.
3' Cil TESTS U
BE ESTABLISHED ON A CASE-WERE PERFORMED ON BUTYL RUBBER BY-CASE BASIS.
AND POLYETHYLENE MATERIALS.-
C SE-j BY-CASE FOR THREE HARSH AREAS.
j e OPERATIONAL MODES TESTED iTHEY WERE.
EACH CABLE TYPE WAS SHOULD BE REPRESEliTATIVE OPERATED DURING THE TESTS ATDIT3 0F THE ACTUAL APPLICATION SERVICE VOLTAGE-0R GREATER AND REQUIREMENT 3.
ITS EXPECTED LOAD CURRENT.IN CABLE TRAY-A3 INSTALLED ATL g
. QUAD CITIES'-
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t DDR COMPLIANCE -(CONTINUEDL D0R REQUIREMENT
-00ADLCITIESCOMPLIANCEL
- FAILURE OF A COMPONENT e.NOT APPLICABLE, AT ANY TIME DURING THE TEST,-
NEITHER' THE SIMPLEX BUTYL'RUBBERL
-THEN THE TEST SHOULD.BE CON-
.0R POLYETHYLENE CABLE FAILED, SIDEREND INCONCLUSIVE DURING OR SUBSEQUENT TO Tile)
FOR THE' ENTIRE. PERIOD. PRIOR TEST.IN THE lil-F0T. 0R:fUNC-TO THE FAILURE.
TIONAL TESTS, THE INSTALLATION INTERFACES-eTHE CABLES WERE INSTALLED IN:
e USED DURING THE TYPE TEST CABLE; TRAYS-IN.TiiE SAME MANNER' j
SHOULD BE REPRESENTATIVE OF AS THE ACTUAL ~ INSTALLATION.-
THE ACTUAL INSTALLATION.
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.s D0R COMPLIANCE (CONTINUED)
QUALIFICATION BY COMBINAT10ii 0F METHODS u
(TEST, EVALUAT10N AliD AliALYSIS)
D0R REQUIREMENT QUAD CITIES COMPLIANCE EQUIPMEiiT MAY BE SHOWN T0 e THE BUTYL RUBBER. INSULATING-BE QUALIFIED FOR A COMPLETE MATERIAL WAS SHOWN TO BE QUALIFIED SPECTRUM 0F SERVICE CONDITIONS, FOR THE ENVIR0iiMEi4TAL C0iiDITI0iiS u
EVEN THOUGH IT WAS ONLY TYPE AT QUAD CITIES.FOR ALL BUTYL.
l TESTED FOR HIGH TEMPERATURE, RUBBER CABLE APPLICATIONS.
f PRESSURE AND STEAM.
e QUALIFICATION FOR
- TEST RESULT APPLICABILITY, RADIATION AliD CHEMICAL SPRAY AliALYSIS USED TO QUALIFY 600V-3 i
MAY BE DEM0iiSTRATED BY AtiALY-BUTYL RUBBER CABLE.
SIS.
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i QUALIFICATION OF SIMDLEX BUTYL SKV CABLES l
I CONCERN 1:
HYLE TEST DID NOT MEET SECTION 5.2.3 0F DOP GUIDELINES WHICH STATES "RADI ATION DOSE SHOULD BE APPLIED PRIOR TO 4
OR CONCURRENT WITH EXPOSURE TO THE ELEVATED TEMPERATURE i
PRESSURE AND STEAM ENVIRONMENT" FOR MATERIALS WHICH APE KNOWN TO BE SUSCEPTIBLE TO SIGNI81 CANT RADIATION. DAMAGE j
AT THE SERVICE CONDITION LEVELS.
CABLES HAD UNDERGONE 10 YEARS NATURAL AGING AT THE I
PLANT ~ SITE BEFORE BEING SUBJECTED T0' ACCELERATED l
RADIATION, THERMAL AND STEAM EXPOSURE ~WHICH DEVIATED l
FROM THE SECTION 5.2.3 DOSE REQUIREMENTS.
1
RESPONSE
RADIATION AGING WAS FOLLOWED BY THERMAL AGING AND THEN I
BY LOCf/PELB EXPOSURE IN THE FYLE TEST PROGRAM (DAGE II OF FYLE TEST REPORT.)
- IEST SEQUENCE IS THE RECOMMENDED SEQUENCE FOR l
CABLES BY SANDIA LABS l
1
- TEST CABLES WERE TAKEN FROM PLANT SITE FOLLOWING 10 YEARS NATURAL AGING
- NO NEW CABLES AVAILABLE
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CONCERN 2:
TEST DID NOT MEET IEEE-383 RADIATION DCSE RATE I
RE0VIREMENTS.
1
RESPONSE
INDUSTRY STANDARDS REQUIRE THE.. DOSE RATE NOT TO EXCEED 1 X 105 RADS / HR (BOTH FOR NORMAL AND i
DDE DOSE),
i
- IEST RADIATION DOSE RATE WAS BETWEEN o.5 6
D 0.82.1 x 10 RADS /HR (FYLE TEST REPORT AGES V-10 THRU I/ 14, IEST GROUPS IV, V, VI, Vil, \\'ll { }
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- q QUALIFICATION OF SIMPLEX BUTYL SKV CABLES (CONT'DT CONCERN 3:
fl0T TESTING THE THINNEST INSULATION PRODUCT PER IEEE-333.
RESPONSE
THE SKV TEST SAMPLE IS A REPRESENTATIVE SAMPLE OF THE INSTALLED SKV CABLES-AT nUAD CITIES.
THIS.
MEETS THE D0R GUIDELINES.
1 VOLTAGE STRESS ON THE INSULATION IS MORE IMPORTANT1 THAN INSULATION THICKNESS.
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-CONCERN 4:
TEST.DID NOT MEASURE LEAKAGE CURRENT AS.SPECIFIED j
i IN:lEEE-383.
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RESDONSE:
- e. lEEE-383 DOES NOT RE0VIRE LEAKAGE CURRENT MEASURE-
]
' MENT DURING DDE TEST.
I o THE TEST CABLES WERE ELECTRICALLY STRESSED AT 173%
0F THEIR SERVICE REQUIREMENTS DURING THE DBE TEST.
AND LGADED WITH RATED SERVICE CURRENT 1
e PuST TEST HI-POT.
j i
5 MIN. IN TAP WATER AT 5000V i
1
),200% UF StRV1CE DUTY
)
i a POST TEST LEAKAGE CURRENT < 2 MA e POST TEST fuNCTiONALS SATISFACTORY i
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t QUALIFICATION OF SIMPLEX BUTYL SKY CAB C0dCERN 6:
TEST DID NOT INCLUDE MANDREL BEND TES 80v/Mll WITHSTAND TEST AS REQUIRED BY
RESPONSE
e WYLE TEST DID NOT INCLUDE MANDREL BY 80v/ MIL TEST. THIS IS NOT A D0R REQUIREMENT.
e EXCEPTION TO 80v/ MIL TEST NOT TO EX IN THE TEST PLAN (SECTION 3.5.5, PAGE 27 0F WYLE TEST PLAN 45916-03.)
e TEST CABLES HAD BEEN SUBJECTED TO THE ME STRESSES OF INSTALLATION WHICH IS WHAT THE MANDREL TEST SIMULATES - TEST CABLES ALSO SUDJECTED TO STRESSES OF REMOVAL AFTER 10 YEARS IN PLACE.
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1 QUALIFICATION OF 600V SIf1 PLEX BUTYL INSULATCD POWER AND CONTROL CABLES l
CONCERN 1:
INDUSTRY TESTING SHOWS BUTYL RUBBER SUSCEPTIBLE.TO DAMAGE BETWEEN 5 x 10 AND 107 6
RADS.
600V CABLES AT QUAD CITIES MUST WITHSTAND A I.I.D. sETWEEN 1.8 x 106 AND 1.3 x 107 RADS.
1
RESPONSE
INDUSTRY PUBLISHED DATA ON BUTYL RUBRER SHOWS:
l e NO CHANGE th DIELECTRIC STRENGTH (IME DIATELY AFTER IMMERSION IN WATER) UP TO 5 x 106,333, AFTER 50 x 106 RADS (IEEE TRANSACTIONS ON POWER i
i 1
APPARATUS AND SYSTEMS, VOL. PAS-88, 40. 5, MAY 1969.)
S11LL HAD DIELECTi<IC STRENGTH.OF 129 V/ MIL.
)
i e WYLE TEST EXPOSED THE BUTYL SKV CABLES TO 44.9 MEGARADS l
AND THE SPECIMtiNS SUSTAINED 5KV FOR FIVE MINUTES UNDER TAP WATER.
(14'.'54V/MILVS.SERVICEFOR600VCABLE OF 4.43 V/ MIL.)
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QUALIFICATION OF 600V SIMPLEX BUTYL INSULATED POWER AND CONTROL CABLES (CONT'D1 l
CONCERN 2:
WYLE TEST NOT PERFORMED ON THE THINNEST INSULATION PRODUCT.
-a RESP 0' HSE:
e VOLTAGE STRESS lIN V/ MIL ; IMPOSED ON ~
o i
BUTYL RUBBER INSULATION. KEY: PARAMETER --
NOT INSULATION THICKNESS.s
.l.
9 ERIMARI INSULATION AND CABLE JACXETING IDENTICAL FOR'BOTH'5KV AND 600V CABLES.
['
6 4 DURING HELB.AND LOCAtTESTS) SIMPLEX' butyl RUBBP.R INSULATION STR6SSED T0:12'.09. V/ MIL ' ' \\
VS.4.43V/MILFOR600VcABLESERVICE-Y THRi!E TIMES.
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QUALIFICATION OF 600V SIMPLEX BUTYL INSULATED POWER Afl0 CONTROL CABLES (CONT'D) s
)
CONCERN 3:
WYLE TEST DID NOT ACCOUNT FOR OXIDATION DEGRADATION OF-POLYMER MATERIALS IN THE AGING ANALYSIS.
e TO THE BEST OF OUR KNOWLEDGE THERE IS
RESPONSE
NOPUBLISHEDDATAT0VERIFYTHEOXIDATIONDEGRADATiUN.
OF SUTYL MATERIAL UNDER VARIOUS DOSE RATE AND' TEM-!
e PERATURE CONDITIONS.
9 PVC JACKET PREVENTS CONTA'CT BETWEEN BUTYL' RUBBER, AND OXYGEN - NO OXYGEN,.NO OXIDATION.
9 WYLE TEST ON SKV CABLGS HAD NO VISIBLE DEGRADATION:
]
OR DAMAGE INDICATING THAT EFFECT OF OXIDATION WAS l
MINIMAL OR NONE.
l 4
WYLE TEST WAS CONDUCTED-IN THE SANDIA RECOMMENDED i
SEQUENCE.
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i 4
i 1
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t QUALIFICATION OF 600V SIMPLEX BUTYL INSULATED POWER AND CONTROL CABLES (CONT'D)
C0iiCERii 4:
WYLE TEST MAY NOT ENVELOP THE NATURAL AGING CONDITIONS OF THE 600V CABLE! SINCE THE SKV' RADIATION DOSE RATE l
1S TWO ORDERS OF MAGNITUDE LESS THAN THE 600V CABLE l
DOSE RATE.
l RESP 0i4SE:
e THE TOTAL DOSE QUALIFIES THE CABLES.
e IT IS NOT' PRACTICAL TO TEST THE CABLES AT THE ACTUAL DOSE RATE OF 15 RADS /HR.
l e
A REVIEW 0F PUBLISHED INDUSTRY DATA SHOWS i
NO CHANGE IN PROPERTIES OF DUTYL RUBBER WITH RESPEC's TO DOSE RAIE.
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QUALIFICATION OF SIMPLEX PE/PVC If1STRUf1EiiT CABLES-(CGNT'D)L CONCERNLli
' TEST DID NOT MEET DDR GUIDELINES BECAUSE LEAKAGE CURRENT AND IR MEASUREMENTS NOT. MONITORED.DURING HELB SIMULATION.
RESPONSE
e MEASUREMENT OF LEAKAGE CURRENT AND IR)RE NOT-DDR GUIDELINE REQUIREMENTS e
IR' MEASUREMENTS WERE TAKEN.BEFORE AND AFTER RADI '
ATION TEST (SECTIONS IV AND VI'0F WYLE TEST.)
e CABLES SUSTAINED 3840 VDC: FOR FIVE MINUTES UNDER l
i TAP WATER WITH 0 MA LEAKAGE AFTER'HELB TEST.1
)
e IHE MAXIMUM APPLICATIO. VOLTAGE FORLTHESE CABLES lS j
~
55 VDC.
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QUALIFICATION OF SIMPLEX PE/PVC IHSTRUMEllT CABLES (C0ilT'D) i1 CONCERN 2:
CABLE ACCURACY CAN NOT BE PREDICTED $1NCE CABLE LEAKAGE CURRENT WAS NOT MONITORED DURING.HELB SIMULATION.-
10-20% ACCURACY USED BY CECO CANNOT BE VERIFIED.
RESPONSE
O CABLES ARE nut RE8UIRED TO PERFORM ANY FUNCTION DURING AN HELB AND ARE NOT EXPOSED TO An HELB AT QUAD CITIES.
e CABLES ARE NEEDED ONLY FOR POST LOCA RADIATION HARSH ENVIRONMENTS.
e IR MEASUREMENTS WERE TAKEN BEFORE AND AFTER. RADI ATION AGING.
8 0
e L0 west IR MEASURED = 9 x 10 n /15' AT 74 F.
e USING IEEE-43, IR OF THE CABLE AT 150 F IS 52.94 Mn'/15' i
e USING THE-WORST CASE -CABLE LENGTH, THE AB0VE IR YlELDS INSTRUMENT INACCURACY 07 LESS THAN 15s WhlCH' IS LESS' THAN THE 10-20% INACCURACY' ALLOWED BY ANS 4.5.-
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l QUALIFICATION OF SIMPLEX PE/PVC INSTRUMENT-CABLES (CONT'D)
CONCERN 3:
JUSTIFICATION AND EXPLANATION SHOULD BE PROVIDED TO SUBSTANTIATE THE ASSUMPTION THAT DURING THE DBE, THE 1001 RELATIVE HUMIDITY WILL BE-NON-CONDENSING..
RESP 0ilSE:
THESE CABLES ARE EXPOSED TO RADIATION ONLY DUE-T0 f
A LOCA INSIDE PRIMARY CONTAINMENT.
.IHESE CABLES ARE OUTSIDE PRTMARY CONTAINMENT AND NOT EXPOSED TO' LOCA HUMIDITY (APPENDIX B 0F BECHTEL SPEC. 13524-1 069-N202, REv. 03, PAGE 2).
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1 QUALIFICATION OF SIMPLEX PE/PVC INSTRUMENT CABLES (CONT'D) 1 CONCERN 4:
MAINTENANCE, SURVEILLANCE, AND INSPECTION PROGRA IDENTIFY ANY SYNERGISTIC RELATED CABLE DETERIO 1
BE ENHANCED. SINCE ' SYNERGISTIC EFFECTS HAVE TO OCCUR AT 2.5-X 106RADS BETWEEN PE & PVC AND THE q
QUAD CITIES. MAXIMUM. DOSE.IS 1 X 10 ' RADS.
7
.t I
RESPONSE
e t
ALTHOUGH A TECHNICAL ISSUE, SYNERGI'STIC EFFECTS ARE NOT PART OF D0R GUIDELINES.
l 0
THE PE' CABLES'WERE AGED-!N THE SEQUENCE
,e BY SANDIA REPORT (NUREG/CR-2158, SANb80-2149.)
WHICH MAXIMISES SYNERGISTIC EFFECTS.
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S M Y & CONCLUSIONS
- CABLES ARE OUTSIDE TiiE PRIMAfd CONTAINENT l
eINDEPENDENTREVIEW
- COMPLIED WITil 00R GUIDELIES Q_-._-___--_-__------__.-____.
7 ATTACHMENT 3 MEETING ATTENDEES NAME TITLE ORGANIZATION C. J. Paperiello Deputy Regional Administrator NRC/RIII Paul Shemanski LaSalle Project Manager NRR/PDIII-2 H. J. Miller Director, Div. of Reactor Safety NRC/RIII A. S. Gautam EQ Lead NRC/RIII U. Potapovs Chief, SPIS NRR/DRIS
- 1. Ross Project Manager NRR/PDIII-2 i
D. R. Muller Project Director NRR/PDIII-2 R. Gardner Chief, Plant Systems Section NRC/RIII Mark A. Ring Chief, Section 1C, DRP NRC/RIII j
Jack Kudrick Section Leader, PSB NRC/NRR j
Raj Anand Nuclear Engineer, PSB NRC/NRR
)
Zelig Falevits Reactor Inspector NRC/RIII
{
j Dave Butler Reactor Inspector NRC/RIII l
J. J. Harrison Chief, Engineering Branch, DRS NRC/RIII J
Mark Sievert Quad Cities EQ Engineer CECO
)
Bala Goginewi C&D Project Engineer S&L l
Anup Behera Consultant S&L J. Sinnappan Supervisor S&L J. S. Lasky Vice President, Research & Eng.
Okonite Co.
l C. J. Crane Manager, Engineering Projects WESTEC 1
G. L. DeYoung Prod. Services-Electrical Eng.
Ceco Chris Laub Prod. Services-Electrical Eng.
CECO L. Del Butterfield Nuclear Licensing Manager CECO E. R. Zebus D/QC Engineering Superintendent CECO J. E. Hausman BWR Engineering CECO
]
Z. J. Boxer BWR Engineering CECO S. C. Hunsader Nuclear Licensing CECO I. M. Johnson Nuclear Licensing Admin.
CECO I
Neil P. Smith BWR Licensing Supervisor CECO j
T. M. AcCauley Senior Elec. Project Engineer S&L l
S. L. Trubach Staff Attorney CECO i
NRC Nuclear Regulatory Commission NRR Nuclear Reactor Regulation (NRC-HQS)
Ceco Commonwealth Edison Company S&L Sargent and Lundy Engineers