ML20235X599
| ML20235X599 | |
| Person / Time | |
|---|---|
| Site: | Comanche Peak  |
| Issue date: | 02/09/1989 |
| From: | Hilaman S, Khanna K, Parker W STONE & WEBSTER ENGINEERING CORP. |
| To: | |
| Shared Package | |
| ML20235X559 | List: |
| References | |
| PTR-04, PTR-04-R00, PTR-4, PTR-4-R, NUDOCS 8903130542 | |
| Download: ML20235X599 (22) | |
Text
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TU ELECTRIC COMANCHE PEAX STEAM ELECTRIC STATION UNIT 1 PROJECT TECHNICAL REPORT NUMBER -04 REVISION NO. O APPLICATION OF XAPTON CABLE INSUIATION Sc<n 6 2Ak R
ponsible Engineer Dath KN KHAMA/
2h/M, Lead Discipline Engineer Date Mww am uo-sk/n Division Chief Enginear Date' Nfde 2hArs Projtet Engineer Date Stone & Webster Engineering Corporation l
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PTR-04, Rev. O Page 2 of 22 l
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TABLE OF CONTENTS P.AES EL.
3 Sunnary 1.0 Purpose and Scopa 5
2.0 Kapton Applications at CPSES 6
3.0 Xapton 7
4.0 Description of Installed Kapton 9
Applications 4.1 Electrical Conductor Seal 9
Assemblies (ECSA) 4.2 Electrical Containment Penetrations 10 4.3 Gammanetric System Cables 12 4.4 Borg Warner Teedwater Isolation 12 Valve solenoids 4.5 Electric Hydrogen Recombiner 13 4.6 Incore Thermocouple 13 5.0 Conclusions 14 6.0 Typical Installation Sketches 15 7.0 References 21 0
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SUMMARY
l Nuclear Regulatory Commission (NRC) IE Notice 67-08, l
Ref. 7.1) IN-88-89 (Ref. 7.18) and recent newspaper articles on military aircraft (Ref. 7.2) have heightened concern over potential failure mechanisms of Kapton insulated wire used in Kapton is a DuPont tradename nuclear generating stations.
for a translucent polyimide insulation tape in varied thickness, with or without coatings applied over the po yimide.
The reported failure mechanisms of Kapton are bi hlighted as follows:
Chafing and abrasion in vibration areas Cut-through due to impact with sharp edges Cracks due to the synergy of the simultaneous application of elongation stress, produced by cable bending, and total immersion in hot water This report identifies and reviews the installed applications of Kapton at Comanche Peak Steam Electric Station (CPSES)
CPSES with respect to the above failure mechanisms.
installation procedures, quality control inspections, and tests prevant exceeding manufacturers recommendations during installation and minimizes undetected problems.
Therefore, only items occurring after initial installation need to be addressed in this report.
A review of class 1E Equipment Qualification binders has identified the following equipment either inside or outside of the Reactor Containment Building as the only application of Kapton insulated wire:
Electrical Conductor Seal Assemblies (ECSA)
Containment Electrical Penetrations Gammanstric Neutron Flux Monitoring System Cables Borg Warner Feedwater Isolation valve Solenoids Electric Hydrogen Recombiner Incore Thermocouple The design of the cable as described in IE Notice 87-08 is significantly dif ferent than CPSES application.
There are no The IE Notice motor leads at CPSES utilizing Kapton.
reference motor leads had one-third the insulation thickness, one-third the number of moisture barrier layers and had no outer covering, e.gi1 cations found at CPSES. polyolefin tubing or glass braid wh compared to the app The installed configuration prevents chafing, abrasion, and cut-through and the synergism for cracking has been analyzed and shown not to exist at CPSES therefore, the potential for are tracking and explosion is eliminated.
0 PTR-04, Rev. O Page 4 of 22
)
Rapid decomposition in an electric arc, resulting in an are
" explosion" appears unique to aircraft wiring applications due to differences in environments (i.e., altitude and ter.perature) and cable installation design.
In addition, the salt surface contamination associated with aircraft wiring does not exist at CPSES.
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PTR-04, Rev. O Page 5 of 22 1.0 Pureose RDA SCOPE The purpose of this report is to document the applications of Kapton insulated cable at CPSES and to compara the potential failure modes outlined in the following references with the installation at CPSES:
IE Notice 87-08 (Ref. 7.1)
IN-88-89 (Ref. 7.18)
Newspaper articles in Fort Worth Star Telegran (Ref.
7.2, 7.3)
This report is not intended to supersede the environmental qualification reports and analysis for the equipment supplied with Kapton (Refs. 7.4 thru 7.12).
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t PTR-04, Rev. O Page 6 of 22 1
2.0 Kanten Arolications 11 CPSES In order to identify Class lE e pipment which uses Kapton insulated wire, Impell Corporation reviewed Equipment Environmental Qualification Binders (Refs.
7.4-7.12).
An integral part of environmental qualification of Class lE equipment is the identification of all sub-components and materials.
It is in this way that uses of Kapton have been determined.
The specific construction details of the insulated wire and its installed configuration are discussed in Section 4.0.
The applications are summarized below:
Class II Eculement y_ith Kanton Eir.g Electrical conductor seal assemblies (ECSA); EQ binders: EEQSP-ES-28-01, EEQSP-ESE-7-01 (Conax RTDs),
EIQSP-ESE-7-01 (Westinghouse IE1 fast response RTDs)
Electrical containment penetrations, and isolation valve tank penetrations; EQ binders:
EEQSP-ES-12A-01 and 02, EEQSP-M-622-01 (Conax Airlocks)
Coaxial cables in Gammametric Instrument System; EQ binder:
EEQSP-TNES-042-01 Internal wiring pigtails in Borg Warner Feedwater Isolation Valve Solenoid; EQ binder:
IEQSP-MS-20B.1-01 Electric Hydrogen Recombiner; EQ binder:
EEQSP-SP-1-02 Incore Thermocouple; EQ binder:
EEQSP-ESE 43B, G The above Class lE epipment is installed in a harsh environmental area and is required to operate before, during, and after a Design Basis Event (DBE).
The normal ambient temperature is 50 C (122 F), relative humidity 1004.
During a DBE, the environment extreme conditions are:
temperature of 150 F to 340 F, 100% humidity, boric acid spray, total radiation (accident plus background) 200 Mrads-gamma plus beta,ide is not applicable to CPSES.PH level of sodium hydroxide 8.5 to 10.0; sodium chlor None of the equipment is submerged in water before, during, and after an accident.
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l 3.0 Kaeten Xapten is manufactured by DuPont Corp ny and is a tradename for aromatic polyimide, poly p,p',-d1 henyloxide pyromellitimide.
Xapton can be suppl ed in a variety of forms and thicknesses.
Containment penetration pigtails and ECSA pigtails use a Xapton tape which is 1 mil thick polyimide with one-half mils thickness of Teflon-TEP coating on both sides.
The Xapton tape is then applied in two half lapped reverse direction s;piral layers on the copper conductor for a total thic:< ness of 4 mils of Kapton and 2 mils of Teflon TEP.
The insulated wire then passes through a high temperature ring, melting the Teflon coating to form a moisture impervious barrier between the tape layers.
In this case, three moisture barriers are present.
The size of the conductor varies with the application and ranges from 16 AWG to 500 MCM fer containment penetration pigtails and 22 AWG to 12 AWG for ECSA pigtails.
In contrast, the Xapton insulated cable used on motor lead wire in IE Notice 87-08, had only one half-lapped layer of Xapton/ Teflon TEP of 1.2 mil thickness resulting in only a combined thickness of 2.4 mils with one resulting moisture barrier.
Reported modes of failure (Ref. 7.1, 7.2, 7.3) are as follows:
Chafing and abrasion in vibration areas Cut-through due to impact with sharp edges Cracks due to the synergy of the simultaneous application of elongation stress produced by cable bending and long term total immersion in hot water Kapten is an organic insulation and as such degrades under thermal aging and radiation.
These effects are addressed in the EQ binders and are not within the scope of this report.
The Xapton insulated cable construction used at CPSES is different from that used in military aircraft as reported in the references.
Aircrafts have conductors installed in tight raceways subject to vibrations (Ref. 7.2).
Also the CPSES 480 V applications have an additional covering directly over the Xapton, which is not used on aircraft wiring.
McDonnell Douglas and Naval Research Laboratories have documented that the synergy of the simultaneous application of elongation stress, produced by cable banding, and total immersion in het water will cause Xapton to hydrolize and form cracks.
High humidity does not readily initiate this phenomenon (Ref. 7.19) ion of cracks. Increase in water temperature accelerates the format The level of elongation stress also accelerates the cracking.
Since each Xapton layer cracks independently of the underlying layer,
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PTR-04, Rev. O Page 8 of 22 l
l additional layers improve reliability of the cable (Ref. 7.17).
Reference 14 indicate a minimum of 3 to 4%
strain is required to initiate this cracking (percent elongation)This translates to an approximate cable bend radius of 8 to 6 times cable diameter.
Stone & Webster Engineering Corporation's experience with Kapton has shown that exposed Kapton insulation could be more easily degraded from impact with sha n objects than other 1
insulation used at CPSES e.g., cross-linked polyethylene ethylene-propylene-rubber because of the reduced insulatlon thickness.
However, proper handling and conformance to installation instructions will prevent damage.
For example:
Testing of Kapton conductors is specified in the Electracal Installation Specification ES-100.
Typical t: cts performed are:
(1) resistance, (2) continuity, end (2) maggar test.
Quality control inspections for installation and testing were performed in accordance NQA 3.09-3.06.
QC inspections for terminations were performed in accordance with NQA 3.09-3.05.
Kapton containing cracks could result in a conductor to ground fault which could produce an electric arc.
Subsequent melting and rapid decomposition of Kapton can occur.
Reports from military aircraft applications imply that the decomposition products have " exploded" and caused additional tracking of the electric arc down to other sections of the wire (Refs. 7.2, 7.3.
DuPont in their study indicates this phenomenon is difficu)lt to create (Ref. 7.16).
Influencing factors include: presence of conducting surface contaminants (e.g. salt coverings.), voltage level, and non-track resistant outer CpSES applications of Kapton ensure a non-immersed, non
" salt-air" environment.
Coastal generating stations and aircraft applications may be more subject to salt contaminants.
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PTR-04, Rev. O Page 9 of 22 4.0 Description 21 Installed Kaeton Aeolicatiens This section describes the installed Kapton applications relative to: chafing and abrasion, cut-through from impact with sharp edges, and cracking due to the synergy of elongation stress and water immersion.
4.1 Electrical Conductor Seal Assemblies (ECSAL (Sketch 6.1)
A.
Aeolication and Installation ECSAs are used to interface the field cables to equipment and provide a hermetic seal for the equipment.
The ECSAs are manufactured by CONAX Corporation.
ECSAs are also supplied with Rosemount transmitters, but are manufactured by CONAX.
The pigtails of the ECSAs are Kapton insulated conductors, size 22-12 AWG.
On the outboard side of the ECSA, which is exposed to the environment, the Xapton pigtails have an Applied overall covering of heat shrinkable polyolefin.
The covering was installed in accordance with IPS-725 utilizing electric heat pns.
These outboard pigtails are a maximum of 20 ft in length, installed inside flexible and rigid steel conduit, and are terminated inside a metal enclosed junction box.
The inboard side pigtails, as provided, are a maximum of 36 in.
long.
In those installations in which the ECSA is connected directly to the instrument housing the Kapton has no additional covering material.
When t
flexible conduit is used to connect the ECSA to the instrument, a field applied Raychem WCSF heat shrink polyolefin tubing is applied over the pigtails; (as detailed in Specification ES-100 Appendix "L").
The ECSAs provided with Rosemount transmitters have a metallic shield over the pigtails with an overall Kapton covering over the shield.
The rating of the pigtails used in these applications is 600 v.
The maximum operating voltage for these ECSAs is 120 V AC or 125 V DC.
In addition to Raychem heat shrink, the conduit also provides mechanical protection.
The possibility of water in contact with Kapton exists in the conduit section of the outboard side of certain ECSA configurations.
This is not a problem because of low elongation stress of large l
bending radius of the conduit.
Exposed Xapton in junction boxes inside the containment is not subjected to an accumulation of water because of 1
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r PTR-04, Rev. O Page 10 of 22 weep holes.
Exposed Kapton in junction boxes outside the containment may be subjected to water accumulation.
B.
Analysis There is minimum vulnerability of mechanical damage.
during installation for Kapton insulated conductor using existing site procedures.
The Kapton is further protected from chafing, abrasion, and cut-through from impact with sharp edges by a heat shrinkable tube over the Kapton insulated conductors on the outboard side of the ECSA.
The overall heat shrinkable. tubing is however removed inside the junction box to facilitate terminations.
Reference 7.17 clearly indicates that strain (percent elongation below 3 to 4% does not initiate cracks in presence o)f water.
In the conduit section of the outboard side of the ECSA which could fill with water, the resulting strain on Kapton is 24 or less, which is well below the threshold of crack formation.
Because of the installed configuration, the band radius of conductors inside the junction boxes is typically about 30 x 0.D. of conductors (14 elongation).
The junction boxes inside the containment have weep holes to prevent water accumulation.
In accordance with the above ana. lysis, the phenomena outlined in Ref. 7.17 consisting of long term water immersion combined with bending stress is non-existent at CPSES.
In addition, the operating voltage-is significantly below the rated voltage providing margin in operating voltage stress.
4.2 Electrical G2Dtainment Penetrations (Sketch 6.2)
A.
Annlication And Installation The construction of containment electrical penetrations and isolation valve tanks vary with electrical circuit applications as follows:
480 V power modules Size 2/0 and larger:
These penetrations have 18 in. Kapton insulated pigtails with polyolefin coverig on the inboard and outboard sides with the solid l
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PTR-04, Rev. 0 page 11 of 22 copper cenductor ends threaded and with lugs for splicing with the field cable.
The operating voltage is 480 V, 3 phase, 60 Hz.
Due to the short length, and size, these pigtails are rigid and do net come in contact with other pigtails or metal surfaces.
Triaxial and coaxial modules:
Xapten is used as the first and second dielectric insulation) has an overa(ll stainless steel shield. layers, but the pigtail Maximum length of pigtails is is in.
480 V power modules sizes No. 6 and No. 2 AWG:
The inboard pigtails are a maximum of 180 in.
(15 ft) long and have an individual factory applied polyolefin sleeve over each Kapton insulated conductor up to point of field splice.
The pigtails are exposed in cable trays.
splices to field cables are made in tray.
Minimum band radius provided by the manufacturer is 6 times the cable diameter.
Operating voltage is 480 V, 3 phase, 60 Hz.
Control, signal, and 120 V power modules:
Each module contains up to 55 Kapton insulated pigtails.
The pigtails have an overall factory applied polyolefin heat shrink tubing for most of their 180 in. (15 ft length.
The tubing was removed for varyin ) distances in order to splice and train the p gtails in trays.
These distances were typical y 1-3 ft, however extreme distances up to 13 ft were observed.
The pigtails for most installations are in solid bottom trays without covers.
Some installations are partially contained in ladder type trays without bottom or top covers.
Operating voltage of circuits is 120 V or less.
In those cases where cleaning of the penetration module, the penetration port-hole, the ECSA scal-body, or the conductors was required " Freon" TF (Trichlorotrifluorethane or Denatured Alcohol-(Isopropyl) was used in a)ccordance with manufacturer's procedures, IPS-1365 and 725.
B.
Analysis There is no possibility of immersion of pigtails in water, therefore, cracking of Kapton due to the
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Page 12 of 22 synergy of elongation stress and immersion in water is prevented.
The majority of Kapton insulation on pigtails is covered and is protected from chafing, abrasion,-and cut through from sharp edges.
Contact with sodium hydroxide in the form of mist (direct spray not applicable) inside containment does not affect the Kapton as documented in Equipment Qualification Binders.
4.3 Gammanetric Svstem Cables (Sketch 6.3)
A.
Aeolication and Installation The!ammanetricinstrumentsystemusesaKaptonIt is provided insu ated shield over coaxial cable.
with a clear plastic protective covering extruded over the outer layer of Kapton insulated shield.
The cable is installed in a tube, consisting of a glass braid / stainless steel composite flexible
- conduit, operating voltage is 1,000 v.
B.
Analysis The Kapton insulated coaxial cable is adequately protected from chafing and abrasion, and cut-through from impact with sharp edges.
There is no possibility of long term ammersion of Kapton in water, therefore, cracking of Kapton due to the synergy of elongation stress and immersion in water is prevented.
4.4 h Warner Teedwater Isolation Eglvg Solenoids (Sketch 6.4)
A.
Aeolication ADA Installation The solenoid valves are provided with two Kapton insulated pigtails.
The Kapton is painted for color coding purposes by the vendor.
The pair of pigtails is enclosed in a glass braid sleeve.
Operating voltage of the solenoid is 120 V AC.
The valve and pigtails are subject to some normal equipment vibration.
The pigtails are routed between the solenoid valve and termination housing in a rigid conduit, approximately 3 in. long.
Maximum pigtail length is j -
1 in.
B.
Analysis The Kapton insulated c~able is adequately protected from chafing and abrasion,.and cut-through from impact with sharp edges.
There is no possibility of 1
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PTR-04, Rev. O Page 13 of 22 long term immersion of cables in water, therefore, cracking of Xapton due to the synergy of elongation stress and immersion in water is prevented.
4.5 Electric Hydrocen Recombiner (Sketch 6.5)
I A.
Amelicatien ADA Installation Internal to the electric hydrogen recombiner, some 480 V power cables are insulated with Xapton.
Operating voltage is 480 V, 3 phase 60 Hz.
Each conductor has a varnish saturated giass braid applied over Kapton insulated conductors.
Thres conductors are grouped together, and an overall covering consisting of silicone rubber with a g* tass braid is then applied.
B.
Analysis The Kapton insulated power cables are adeque.tely protected from impact with sharp edge.
There is no 1
possibility of long term immersion of cab 1'es in water, therefore, cracking of Kapton due f,o the synergy of elongation stress and immersien in water is prevented.
4.6 Incore Thermoeueles (Sketch 6.6)
A.
Amelication and Installation The thermocouple wires are routed i': a mineral insulated, stainless steel sheath r;able design.
Conductors in the cable are first insulated with Xapton.
The two conductors are r,urrounded by mineral insulation between the cuter surface of the Kapton and inner surface of the, sheath.
The cable enters the thermocou compression fitting.ple junction box through a Stainir.ss steel sheath and the mineral insulation is removed leaving the Xapton s
insulated conductor exposed inside the junction box.
The wires inside the junc'aion box are terminated on a terminal board.
The outgoing wires are installed j
the same way as incoming and are spliced to a field l
run cable smaller thar. No.18 AWG conductors are used with Kapton insulation.
B.
Analysis l
The Kapton is exposed only inside the junction box with minimum vulnerability of mechanical damage.
There is no possibility of long term immersion of cables in water therefore, cracking of Kapton due 1
to synergy of' elongation stress and immersion in water is prevented.
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Page 14 of 22 5.0 conclusions j
The installation and environment of each a lication at CPSES has been analyzed relative to the fo owing failure modes:
Chafing and abrasion in vibration areas Cut-through due to impact with sharp edges Cracks due to the synergy of the simultaneous application of elongation stress produced by cable bending and long term total immersion in hot water The Kapton insulated wire at CPSES has an outer covering or is otherwise installed to preclude the above failure modes.
The phenozenon expressed as " explosion" has been thoroughly researched by DuPont.
The necessary conditions to initiate these events are difficult to recreate in the laboraton and are not found in the applications at CPSES.
This phenomenon appears to be unique to our aircraft wiring.
All Class lE applications of Kapton insulation have been identified at CPSES and it is concluded that the installations are not subject to similar conditions as published by the Fort Worth Star Telegram and NRC Notices IN 87-08 and 88-89.
FTR-M, Revision 0 j
Page 15 of 22 j
i 6.0 TYPICE INSTALLATION SKETCHE$:
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P!R-04, Rev. O Page 16 of 22 4.3 EttCTRICAL CONTA!l9 TEN PEETRAT!0lls CONTAlleWIT ELEC. PtlitTRAfl0E i.
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PTR-04, Rev. 0 Page 19 of 22 6.5 HYDROGEN RECOM8!NER RIGID CONDUIT FIELD CABLE SPLICE T[KAPTONINSULATEDCONDUCTOR PO K R TERMINATION 90X OVERALL C0VERING 0F b $1LICON RUSSER AND GLASS 8AA!0.
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PTR-04, Rev. O Page 21 of 22 7.0 References 7.1 NRC, IE Notice 87-06 " Degraded Motor Leads in Limitorque DC Motor Operators" 7.2 Fort Worth Star Telegram, June 24, 1988 and June 25, 1988 " Wired for Disaster" 7.3 Ibid, June 26, 1988, "Kapton Use in Reactors Re-examined" 7.4 Equipment Qualification Report EEQSP-ES-28-01
" Electrical Conductor Seal Assemblies" 7.5 Equipment Qualification Report EEQSP-ES-12A-01 and 02 " Electrical Penetrations" 7.6 Equipment Qualification Report EEQSP-TNES-042-01 "Gammametrics Neutron Flux Monitoring System" 7.7 Equipment Qualification Report EEQSP-MS-20B.1-01 "Feedwrter Isolation Valves" a
7.8 Equipment Qualification Report EEQSP-MS-622-01 "Conax Airlocks" 7.9 Equipment Qualification Report EEQSP-ESE-7-01 "Conax RTDs" 7.10 Equipment Qualification Report EEQSP-ESE-7-01
" Westinghouse Fast Response RTDs" 7.11 Equipment Qualification Report EEQSP-SP-1-02
" Hydrogen Recombiner" 7.12 Equipment Qualification Report EEQSP-ESE-43B, G "Incore Thermocouple" 7.13 F. J. Campbell " Temperature Dependence of Hydrolysis of Polyimide Wire Insulation," IEEE Transaction on Electrical Insulation, Vol: EI-20,
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No.1, February 1988 7.14 McDonnell Douglas Paper " Durability of Electrical Wire Insulation" McDonnell Douglas, Dept. 221 7.15 Electrical Installation Specification ES-100 7.16 E.I. DuPont DeNemours & Company:
"DuPont Arc Tracking Comments" DuPont, Polymer Product Department, Wilmington, DE 7.17 C.J. Wolf and R.S. Soloman " Environment Degradation of Aromatic Polyiside Insulated Electrical Wire":
IEEE Sunnydale, PA, Vol. EI-19, No. 4 August 1984 s
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A PTR-04, Rev. O Page 22 of 22 7.18 NRC, I14-88-89 " Degradation of Kapton Electrical Insulation," November 21, 1988 7.19 DuPont Laboratory Studies on Hydrolysis of Kapton Polyinide Film