ML20245A913
| ML20245A913 | |
| Person / Time | |
|---|---|
| Site: | Browns Ferry  |
| Issue date: | 04/13/1989 |
| From: | Wormsley J TENNESSEE VALLEY AUTHORITY |
| To: | |
| Shared Package | |
| ML18033A712 | List: |
| References | |
| NUDOCS 8904250442 | |
| Download: ML20245A913 (40) | |
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EIS 8 9.0 4 1 4 146 TEST TO DETERMINE THE AMPACITY DE-RATING EFFECTS OF-CABLE COATINGS AND TO CONFIRM THE PRINCIPLE OF LOAD DIVERSITY 4
- i Job Number 88-6254 Revision 2 '
l April 13, 1989 lR2 CUSTOMER: DIVISION OF NUCLEAR ENGINEERING BROWNS FERRY NUCLEAR PLANT OFFICE OF POWER OPERATIONS SUPPORT CENTRAL LABORATORIES SERVICES fnntA k. m r ect Engineer /-
[Pr[A.Wormsley J.
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/ Duality Adsurarfce J. B. Ragsdale
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Manager R. L. Morley 4
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TABLE OF CONTENTS 1.0 Objectives 2.0 Scope 3.0 Discussion 4.0 References 5.0 Quality Assurance 6.0 Attachments
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J SLHMARY REPORT REVISION LOG JOB NUMBER 88-6254 l REVISION PAGES l DATE AFFECTED l DESCRIPTION OF CHANGE PREPARED BY l RO l l APPROVED 1 l l
] 03/15/89 I All l Initial issue l J. A. Wormsley l 1
l l R1 l l l l 03/16/89 l Cover l Changed title. I J. A. Wormsley l 1 l l
l 1 l 1 1 l I i i Changed Section 3.0 title l J. A. Wormsley l I
l l l l Replaced Paragraphs 1.0 and 2.1.3; l l l l l l Replaced and renumbered Paragraph l l l l l l 2.1.1.4 as Paragraph 2.2; Changed l l l l l l Section 3 title; Deleted Paragraphs l l l l l l 3.1 and 3.2 and renumbered the l l l l l 1 and 2 l remainder of Section 3. I J. A. Wormsley l l I I l l l 1 l 3 1
1 Added R5 to Test Plan designation. l J. A. Wo rmsley l l l l Attachment l l 1 l l l 6.1 l Revised Test Plan 88-6254 to RS. I J. A. Wormsley l l l l l Sec. 6.2; Revised Table 1 to l l l l l l include measurement units, group l l l l l ] data by cable number, and in l l R2 l l l l descending order of ampacity after j l 4/13/89 l Table 1 l l j l l Test 1110.
l Section 6.2; Revised Table 2 to I J. A. Worm:lley l M l l Table 2 l 1 I l l
l l l include measurement units.
l Section 6.2; Revised Table 3 column l I J. A. Wormsley l 1(( l l / l l l l headings and included measurement l l l l Table 3 I units. I J. A. Wormsley l Nb l
l 1 I I I I I l l/ I I I I I I I I ! I I I I I I I I I I I I I I I I I I i l l 1 1 I I I I I I I 1 I I
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l'. 0 OBJECTIVES The purpose of these tests w s to determine the de-rating effects of cable coatings manufactured by the Flamemaster Corporation when applied in various thicknesses and to confirm the principle of load diversity.
2.0 SCOPE 2.1 This test was conducted in order to gather data on cable ampacities and to determine the effect, if any, of Flamemastic 71A and/o'r Flamemastic 77 on cable ampacities with the following consideraticas:
2.1.1 Cather data on the de-rating effects on ampacity in filled cable trays coated with various thickness layers of Flamemastic 17.
2.1.2 Gather data for a comparison of the thermal conductivity of the two Flamemastic types.
2.1.3 Gather data to determine the combined de-rating effects of Flamemastic 77 and tray covers.
2.2 In addition, selected cable groupings within a filled tray were energized at various loads and the resulting temperatures recorded.
3.0 DISCUSSION 3.1 Two test trays were constructed from TVA MK// ZGA (18" x 4") cable tray. The trays were mounted approximately four feet off the floor for free air convection and ease of access. The cable tray to support interface was made of wood to minimize heat flow down the support. Unconted trays had a layer of polyethylene applied to the bottom to prevent air flow upward through the tray.
3.1.2 All cables were tightly packed in the trays. The tray used for tests with m"1tiple power icvels in cables was arranged for ease in changing the cable groups powered and the power in each cable group prior to the initial test on that tray. All cable connections were made with lugs designed for good electrical connection.
3.1.3 A test chamber was constructed to maintain the ambient temper ature around the tray section to within i 2*C of a nominal 40*C temperature requirement. Adequate control of the temperatures outside the test section, but still inside the tray, required separate heat supplies for each overhang.
3.1.4 Thermocouple were installed in direct contact with the copper conductors in the test trays. All thermocouple were installed
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on the top side of the conductor and glass insulating tape was used to close the slit in the conductor insul& tion. Bare thermocouple were used to monitor the ambient; temperatures. All l
thermocouple were type "T" and were currently calibrated.
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'3.1.5 Baseline ampacity tests were made for'three cases; (1) Tray I l with no Flamemastic (polyethylene sheet under bottom), (2) Tray 2 with polyethylene sheet under bottom, and (3) Tray 2 with top and-bottom covers.
3.1.6 The measured current in each of these three tests was corrected for the difference between nominal and observed room ambient average temperature and the difference between the desired and actual cable temperatures. This. corrected current has been called the adjusted ampacity. More than one way to determine these averages exists and several were recorded for Tray 1.
Tray 1 results are tabulated in Table 1.
3.2 An additional test (No. 1110) was performed on Tray 1 with two inches and .75 inches of Flamemastic applied to the top and bottom respectively, and a top cover installed. This test result is also shown in Table 1.
3.2.1 De-rating factors as measured on Tray 1 are shown in Table 1 as a function of the baseline ampacity. This column is a result of assigning 100 percent to the baseline ampacity and considering an increase in adjusted ampacity as above 100 percent and decreases in adjusted ampacity as less than 100 percent by direct ratio.
The multiplication factor was determined by reduction of the de-rating factor to unity.
3.3 Tests en Tray 2 involved randomly assigning the paired conductor circuits (supply and return) to one of four load groups. The currents on the four groups were varied and conductor temperatures recorded. Both load currents and measured temperatures are shown in Table 2.
3.4 In order to provide data for a comparison of the thermal properties of the two Flamemastic types, temperature measurements were made at the surface of two heated metal plates, within layers of Flamemastic applied to these plates, and at the surface of the Flamemastic layers. These Flamemastic layers were of type 71A on one plate and were type 77 on the other. The results of these measurements are in Table 3.
3.5 One anomaly was written for this program as a result of a broken thermocouple. The thermocouple, which broke between tests, was replaced and had no effect on the results,
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4 .'O REFERENCES 4.1 CLS-QAP .4, " Qualification Laboratory Program" 4.2 ANSI N45.2-197~., Section 12. " Test Control" 4.3 10 CFR 50/ Appendix B. " Quality Assurance Criteria for Nuclear Power plant and Fuel Reprocessing Plants" 4.4 10 CFR 21. " Reporting of Defects or Noncompliance" 4.5 IEEE p848, " Procedure for Determination of the Ampacity De-rating of Fire Protected Cables." - Draft 7, November 12, 1987.
5.0 OUALITY ASSURANCE COA) 5.1 All test equipment and instrumentation to be used in the performance of this test program was calibrated in accordance with applicable TVA standards and QA procedures and conforms to applicable portions of ANSI N45.2,10CFR50 Appendix B, and 10 CFR21. Standards used in performing all calibrations are traceable to the National Institute of Standards and Technology (NIST), natural physical constants, or commercially accepted practices.
5.2 All personnel, procedures, and instructions used in the performance of this test program complied with the applicable requirements of the CLS QA program.
6.0 ATTACHMENTS 6.1 Test plan 88-6254 6.2 Tables 6.3 Anomaly Report l
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6.1 TEST PLAN 88-6254 R5 lR1 O %. 4
. TEST PLAN TEST TO DETERMINE THE AMPACITY FFECT OF DE-RAT l
CABLE COATING 3 AND TO CONFIRM THE PR t
- R5 0F LOAD DIVERSITY I
l Revision 5 March 16, 1989 Job Number 84-6234 0FFIC3 0F POWER DIVISION OF CP3AATIONS St/PPORT CENTRAL LABORATORIES SERVICES di~ A.
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TEST PLAN g TEST TO DETERMINE THE AMPACITY DE-RATING EF/ECT OF l l-CABLE COATINGS AND TO CONFIRM THE PRINCIPLE lRS I !
CF. LOAD DIVERSITY l Revision 5 March 16, 1989 Job Number 88-6254 0FFICE OF POWER DIVISION OF OPERATIONS SUPPORT CENTRAL LABORATORIES SERVICES
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l 4 * . j TEST PLAN REVISION LOG ]
JOB NUHBER 88-6254
~ REVISION PAGES l DATE AFFECTED DESCRIPTION OF CHANGE PREPARED BY APPROVED l Rsv. 0 l l l l l
2/29/88 l All l Initial Issue l J. A. Wormsley l I l Paragraphs 1.1;1.1.1 and 2.1; l l l l
l l changed Flamemastic 71A to 77 be- l l l Rev. 1 l Title Page l cause sufficient quantity of 11A l l l 4/29/88 l and 4 I was unavailable to conduct test. I J. A. Wormsley l l l l Paragraph 1.1.3; previous paragraph l l l l l 1.1.3 deleted and subsequent para- l l l l l graphs renumbered. Deleted stair- l l l l 4 I step shape. I J. A. Wormsley l l l l Paragraph 5.1.1; changed from 8 to l l l l 5 l 3 tray configuration. I J. A. Wormsley l l l l Paragraph 5.1.1.1; added last l l l l l sentence describing the "se of a l l l l polyethylene sheet to prevent up- l l l l
l l ward airflow through the tray. 1 J. A. Wormsley I l l l Paragraph 5.1.1.2; added clarifica-l l l l l tion statement concerning bending l l l l l at the cable. I J. A. Wormsley l l 8
l Paragraph 5.1.1.3; removed tray l 1 l
l l numbers due to change in test l l l 1 l requirements. l J. A. Wormsley l l l l Paragraph 5.1.1.4; clarified l l l l l insulation requirements. I J. A. Wormsley l l l l Paragraph 5.1.1.5; clarified the l l l l l application of electric heat and l l l l l defined temperature requirements. l J. A. Wormsley l l l l l Paragraph 5.1.1.6.2; redefined l l l l l 6 l temperature requireme nts . l J. A. Wormsley l l l l l Paragraph 5.1.1.7; deleted thick- l l l I l I ness requirement for insulation. l J. A. Wormsley l l l l l Paragraph 5.1.1.8; clarified l l l l l l temperature specifications. l J. A. Wormsley l l l l l Paragraph 5.2.1; changed Reference l l l l l l 1 to Section 3.5 to correct. l l l l l l Changed 1.1*C to 1.0*C to l l l l 7 l correct. Clarified ampacity. 1 J. A. Wormsley l l l l Paragraph 5.2.1.9; changed data l l l l l l recording requirements to include l l l l l l all thermocouple readings and l l l l l l average, not room, temperature. 1 J. A. Wormsley l l l l l Paragraph 5.2.1.10; clarified l l l
! l l current increase and deleted 90*C l l l l l 8 l requirement. I J. A. Wormsley l l
} l l Paragraph 5.2.1.11; clarified data l l l I l l to be recorded, l J. A. Wormsley l l i
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TEST PLAN REVISION LOG JOB NUKBER 88-6254 l REVISION PAGES l DATE AFFECTED l DESCRIPTION OF CifANCE PREPARED BY l Rev. 1 l l Paragraph 5.2.1.12; added word APPROVED l l 4/29/88 l 8 I " chamber".
l l J. A. Wormsley l l l l l l l Paragraph 5.2.2; changed from eightl
} [ l to three trays in test. I J. A. Wormsley l l l l l l l Paragraph 5.2.3; added top cover, l l l l l bottom cover and both top and l l
} l l bottom cover tests for tray one. I J. A. Wormsicy l l l l l l l Paragraph 5.3 and 5.3.1; changed l l J l l l Flamemastic 71A to 77. I J. A. Wormsley l l l l Paragraph 5.3.2; clarified l l l
l l l l
l Flamemastic thickness requirement. I J. A. Wormsley l 1 l
l Paragraph 5.3.3; delete references l l l l l to width. Changed "shall" to l l l
l l l "may". Deleted references to tray l l
} l I numbers. l l l
l J. A. Wormsley l l l l Paragraph 6.1; changed from eight l l l 9 l to three trays in test. I J. A. Wormsley l l l l l l l
l Paragraph 8.1; changed Flamemastic l l l 10 l 71A to 77 in Ip__ equation. l l
I J. A. Wormsley l l l l Paragraph 10.1; deleted number of l l l l l pages due to change in test l l
l l l requirements. l J. A. Wormsley l l l l l l l Paragraph 10.1.1 and 10,1,2; moved l l l l l
l l to section 11.0 as paragraph 11.1.1l l l
l and 11.1.2. respectively. l J. A. Wormsley l l !
l l l l Paragraph 11.0; separated Cable l l l l l l
l List from Attachments and renumber l J. A. Wormsley l l l l Paragraph 11.1.3; added wire de- l l l l l scription for change in test re- l l
l l l quirements. '
l J. A. Wormsley l l l l l l
l l Paragraph 5.1.1.6.2; revised per l l l l l
l Instruction and authorization l l l 6 l of Brian Reagan on 5/12/88, l J. A. Wormsley l l l l l
l Deleted requirements of paragraph l l l l l 5.1.1.11 per instruction and l l
l l l l
l l authorization of Brian Reagan on l l l 7 l 5/12/88. I J. A. Wormsley l l
l l l
l l Deleted requirements of paragraph l l l l 1 l
l 5.2.3 per instruction and authori- l l l l
1 zation of Brian Reagan on 5/12/88. I J. A. Wormsley l l l Renumbered paragraph 5.2.5 to l l
l l l 8 1 5.2.4 l J. A. Wormsley l l l
'*.e 6 11
I TEST PLAN i l
l REVISION LOC '
- JOB NUMBER 88-6254 l REVISION PAGES l l DATE AFFECTED DESCRIPTION OF CHANGE l
Rev. 2 l PREPARED BY APPROVED l l l Added additional page for Revision l l l 7/25/88 1 4 l Log and renumbered pages. l J. A. Wormsley l l
l l l l Paragraph 1.1.2; deleted previous l l l l l l paragraph 1.1.2 requiring test l l l
l l l l with top tray cover and renumbered l l l J l 5 l paragraph 1.1.3 to paragraph 1.1. 2.1 J. A. Wormslay l l l l l Paragraph 1.1.3; removed flame- l l l l l l mastic requirement for diversity ofl l l l l l power level tests in previous para-l l l l l l graph 1.1.4 and renumbered to para-l l I l I graph 1.1.3. l l
I J. A. Wormsley l l l l Paragraph 5.1.1.3; changed from "a l l l
} l l single" to " appropriate" power l l l l 6 I supply. l l J. A. Wormsley l l l l l Paragraph 5.1.1.5; clarified tem- l l l l l l perature requirement outside test l l l l l section. l J. A. Wormsley l l
l l l l Paragraph 5.2.1.2; previously this l l l l l l 8 l number was not used. Renumbered tol l l l 1 5. 2.1. 2 f rom pa rag raph 5. 2.1. 3. l J. A. Wormsley l l l l l Paragraph 5.2.1.3; removed previous l l l l l l paragraph 5.2.1.4 requiring pre- l l l l l l liminary data record and renumbered l l l l l paragraph 5.2.1.5 to 5.2.1.3. 1 J. A. Wormsley l l
l l l l Paragraph 5.2.1.4; removed inter- l l l l l l mediate data record requirement andl l l l l renumbered paragraph 5.2.1.6 l l l l l l to paragraph 5.2.1.4. Renumbered l l
l l l l l remainder of Section 5.2.1. l J. A. Wormsley l l l
l l l Paragraph 5.2.1.7; clarified heat l l l l l block monitors and added "when l l l l
l l l stability and temperature require- l l l l l ments have been met." l J. A. Wormsley l l l l l Paragraph 5.2.3; paragraph 5.2.4 l l l l l
l l of interim revision dated 5/12/88 l l l l l renumbered to paragraph 5.2.3 for l l l l 9 l continuity. I J. A. Wormsley l l l
l l l Paragraph 5.3.2; changed to thin l l l l l layers (for drying) and included l l l
l l l all test thickness coverage. l J. A. Wormsley I l l l l l Paragraph 5.3.6; deleted paragraph l l l l l l in previous revision that referred l l l l l to tray 5< tests and renumbered l l
1 1 l l I paragraph 5. 3. 7 to paragraph 5. 3.6.1 J. A. Wormsley l l
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TEST PLAN REVISION LOC JOB NUMBER 88-6254 l REVISION PAGES l l DATE AFFECTED DESCRIPTION OF CHANGE PREPARED BY APPROVED I l Rev. 3 l l Added page for revision log and l l l l 10/15/88 l iv l renumbered pages l J. A. Wormsley l l l l l Paragraph 1.1.4; Added requirement l l l l l 1 I for test with tray cover at Test l J. A. Wormsley l l l l l 1110 only. l l l J l I l l L l l l Paragraph 5.2.1. 7.1; Added require- l l l l l 4 I ment to measure surface temper- l J. A. Wormsley l l l l l atures from Test 1108 onward. l l l 1 l 1 I l 1 l l l Paragraph 7.1; Added heated plate l l l l l 6 l tests for comparing Flamemastic l J. A. Wormeley l l l l l 71A to 77. . l l l l 1 1 I I I l l l Paragraph 10.2; Added reference to l l l l l 7 l as-constructed drawings made by 1 J. A. Wormsley l l l l l Central Lab for heated plate test l l l l l l referenced in Paragraph 7.1. l l l l Rev. 4 l l l l l l 1/12/89 I iv l Add Revision 4 information. 1 J. A. Wormsley l l l l l Complete re-write to make specific l l l l l l and correct with most recent re- l l l l l l quirements incorporated. Combined l l l l l l and renumbered most sections for l J. A. Wormsley l l l l l clarity. l l l l 1 l i I I l Rev. 5 l l l l l l 3/16/89 I Cover l Revised title l J. A. Wormsley l $j/I- l l l l Paragraph 1.1.3; Added " combined". l l /' l l l l Paragraph 1.1.4; Renumbered Para. l l l l l l 1.2 to separate diversity test. l l l l l l Para. 2.0 rewritten to include l l l 1 l 1 1 diversity. 1 J. A. Wormsley I (NSbI- l l l l Paragraph 5.1.1.1; Spelling l l /~ l l l l " polyethylene". Para. 4.2; Removed l l l l l 2 l branch status for CLS. 1 J. A. Wormsley l $6'L
/ l l l l Paragraph 5.1.1.5; Spelling l l # l l l 3 l " polyethylene" Paragraph 5 .6 11 l l l l l Changed to new name for National l l l l
l l l Bureau of Standards, l J. A. Wormsley I (Id/#- 1 l } l Paragraph 5.2.1; Spelling l l/ l l l 4 l " polyethylene" l J. A. Wormsley l //d,'d l l l l Paragraph 5.3.1; Spelling l l / l l l 5 l " polyethylene" I J. A. Wormsley l $D[d- l l l l Paragraph 5.3.1.7; Changed " insure"l l / l l l 6 I to " ensure" l J. A. Wormsley I (Id?(2 - 1 e
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TEST PLAN REVISION LOC JOB NUMBER 88-6254 I REVISION PAGES I j DATE AFFECTED DESCRIPTION OF CHANGE PREPARED BY APPROVED l l Rav. 5 I I Paragraph 6.1.1; Replaced for l l l l 3/16/89 I I clearer descripi:.lon. Paragraph l l l l l l 6.2.1; Changed " insure" to " ensure"I 1 l l l 1 Paragraph 6.3.1; Spelling i l I I I I " aperture". Paragraph 6.3.2; I l l l l 7 l Added thermocouple installation. 1 J. A. Wormsley l Ys l l l 1 1 I I I I I I I I l l l l l l J l I I I I I I I I I I I I I I I ._1.
l l l l l l l 1 I I I l l l l l 1 1 I I I I I I I I I l l l 1 1 I I I I l l l l l l I I I I I I I I I I I I I I I I I l l l l l l l l l l l l l
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l l l I l l I I I I I I I I I I I I I i i I I I, 1
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1.0 SCOPE 1.1 This test shall gather data on cable ampacities and the effect of Flamemastic 71A and/or Flamesmastic 77 on cable ampacities with the following considerations:
i 1.1.1 The decating effects on ampacity in filled cable trays coated with various thickness layers of Flamemastic 77.
i 1.1.2 The derating effects on ampacity in filled cable trays coated .i j
with Flamemastic 71A or at least a comparison of the thermal i
resistivity / thermal conductivity of the two Flamemastic types.
1.1.3 The combined effects of Flamemastic 77 and tray covers.
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lRS 1.2 The ampacity of a cable tray with various power levels in selected lRS cables to provide data for confirmation that the principle of diversity has been accurately modeled.
2.0 OBJECTIVES The purpose of these tests was to determine the de-rating effects l of cable coatings manufactured by the Flamemaster Corporation when j R5 applied in various thicknesses and to confirm the principle of l lotsd diversity.
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3.0 REFERENCES
3.1 CLS-QAP-4.4 " Qualification Laboratory Program" 3.2 ANSI N45.2-1971, Section 12 " Test Control" 3.3 10 CFR 50/ Appendix B, " Quality Assurance Criteria for Nuclear Power Plant and Fuel Reprocessing Plants" 3.4 10 CFR 21. " Reporting of Defects or Noncompliance" 3.5 ICEA P54-440, "Ampacities - Cable in Open Top Cable Trays" 3.6 IEEE P848, " Procedure for Determination of the Ampacity Dorating of Fire Protected Cables." - Draft 7, November 12, 1987.
4.0 QUALITY ASSURANCE 4.1 All test equipment and instrumentation to be used in the performance of this test program shall be calibrated in accordance with applicable TVA standards and QA procedures and will conform to applicable portions of ANSI N45.2,10CFR50 Appendix B, and,10 CFR21. Standards used in performing all calibrations are traceable to the National Bureau of Standardo, natural physical constants, or commercially accepted practices.
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, 4.2 All personnel, procedures, and instructions used in the performance of this test program shall comply with the Central
' Laboratories Services (CLS) Quality Assurance program. lRS
-5.0 TEST PROCEDURE 5.1 Initial Tray Setup 5.1.1 Details of tray construction and setup are as outlined in the following steps.
5.1.1.1 Construct a test section from TVA MK// ZGA cable tray or equivalent with length as needed for instrumented cable test section plus any necessary lead and thermal isolation requirements (see Figures 1 and 3). The tray should be mounted approximately four feet off the floor for free air convection and ease of access. Cable tray mounts shall be made of wood or a ;
non-heat conducting material at points of contact with the cable tray. Cable trays without Flamemastic coatings on the bottom shall have a polyethylene sheet applied to the tray bottom to lRS prevent air flow upward through the tray.
5.1.1.2 Install cables as shown on Figures 2 and 4 All cables must be tightly packed for all tests. Adequate overhang shall be provided on the power supply end to facilitate connections. '
overhanging cable ends shall be heavily insulated thermally to prevent hest loss as much as possible. Lugs shall be installed on each cable at opposite ends of the tray to facilitate connection to its return path cable. Cable overhang on the ends shall be minimumlzed but shall be adequate to facilitate connection without causing intercable or cable to tray short j circuits. This approach (eliminating long cable bend radii which act as heat sink outside the tray test section) allows convenient thermal insulation of each end of the cable tray. The lugged connections then provide a slight heat rise thus helping prevent heat loss through the end of the tray, j
5.1.1.3 portions of the cable overhang including lugs may have electric heat applied as necessary to meet temperature requirements.
Adequate control of the temperatures outside the test section, but still inside the tray, (see Figure sections FF and GG as needed) may require separate heat supplies for each overhang.
The temperatures outside the test section, but still inside the tray, shall be maintained to within + 2*C of the test section temperature. Thermocouple mounted in these areas measure this temperature on each end and verify that axial heat flow is maintained within acceptable icvols. These thermocouple shall i be numbered TCpL __994 through TCpL __999 with the blank being occupied by the. tray number. These are shown in sections FF and GG in the Figures.
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5.1 1.4 1
Thermocouple shall be installed in direct contact with the copper conductor. The insulation and/or jacket must be slit axially on the top of each cable to allow for this. Class reinforced electrical insulating tape shall be applied at each j thermocouple to conductor juncture to close the slit. l l
5.1.1.5 Each cable with thermocouple in the test section shall have a 1
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minimum of five thermocouple as shown in Figures 1 and 3. lR5 5.1.1.6 All thermocouple shall be currently calibrated per CLS !
calibration procedure and shall have proper documentation traceable to the National Institute of Standards and lRS Technology (NIST). The accuracy of the calibration shall bc l included on the thermocouple data sheet.
5.1.1.7 .All thermocouple shall be of a type T, or equivalent.
5.1.1.8 Environment ambient temperature thermocouple shall be located near each test tray at a distance of one foot from the top center, bottum center, and each end of the tray. These shall be numbered TCPL 990 thru TCpL 993 with the blank being occupied by the tray number.
5.1.1.9 Each test tray shall be located in a test enclosure capable of maintaining an average ambient temperature of 40*C throughout its entire volume. An average ambient temperature of 40*C i 2*C shall be maintained for each test. The top center thermocouple referred to in 5.1.1.8 may exceed 40 degrees C 12 due to convection directly above the tray. A minimum of forced air shall be used for control of average ambient temperature. No forced air shall be directed at the test trays.
5.1.1.10 Connect the leads of each cable to be energized to its respective power supply. Ensure (by cutting cables, locating power supply connections at the same elevation as the tray, etc.) that the leads are as short as possible.
5.1.1.11 All tests shall follow the following pattern where (1) the initial current shall be established at 80% of the estimated final value (2) the curent shall be maintained for sufficient time to allow all temperatures to stabilize (3) adjust the current, ambient temperature, or heaters, as needed, until the required current or required maximum steady-state conductor temperature is achieved, the environment temperature is achieved, and the temperature between the test section and tray end verifies acceptable heat flow. (Steady-state shall be defined as j temperatures not increasing or decreasing by more than 1*C in 30 )
minutes.) (4) record test section temperatures, ambient )
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J temperatures, temperatures for heat flow and test currents at intervals for sufficient time to determine that stability is present (include any surface temperature measurements required) i (6) increase only the applied current by a small step and again record the test section temperatures, ambient temperatures, temperatures for heat flow and the new test current for i sufficient time to verify an increase in the test section i i
temperature.
(This verifies that the current was producing the temperature and that an increase in current produces a higher temperature.) ;
I 5.2 Baseline Ampacity Tests
{
5.2.1 The baseline ampacity shall be determined by covering the tray bottom with the polyethylene sheet per section 5.1.1.1 and lR5 following the steps outlined in section 5.1.1.11 with the maximum allowed cable temperature in the test section being 90*C i 1*C and the proper heat flow into the tray evidenced by temperatures outside the test section that are within + 2*C of the maximum cable temperature in the test section. Subsequent tray 2 tests require the cables to be arranged in groups for varying the power level in each group. Connect the cables as groups and series the groups prior to the Baseline Ampacity Test. The baseline tests required are TEST 1100 for tray 1 and TEST 210 and 216 for tray 2.
5.2.1.1 Connect the cable lead ends to the power supply. Power supplies shall be 60 Hz Ac current for all tests.
5.2.1.2 Apply 80% of rated current to the cables.
(NOTE: This initial current may require adjustment based on the results of previous tests.)
5.2.1.3 Allow the cables to conduct the initial current for a minimum of 15 minutes.
5.2.1.4 All ammeters and thermocouple shall be currently calibrated.
5.2.1.5 Increase or decrease the current as necessary to achieve a maximum conductor temperature of 90*C i l'C.
5.2.1.6 The current that creates a steady-state maximum conductor temperature of 90*C i 1*C shall be defined as the ampacity for the cables in the configuration tested. The current will be the baseline current.
5.2.1.7 Concurrently with measuring the steady state conductor temperatures, the insulated, lugged, cable connections beyond the tray ends should be kept to a temperature that maintains the heat block monitor thermocouple to within + 2*C of the conductor {
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e temperature in the tray; i.e. , TCpL _990 thru TCpL _994 should have maximum temperatures of 90*C - 92*C for the baseline tests.
Record current and all thermocouple readings including maximum conductor temperature, heat block monitor temperatures', and average ambient temperature when stability and temperature requirements have been met.
5.2.1.8 In ordar to verify the cables' ampacity, increase the applied current by approximately 5 amperes. Conductor temperatures should rise.
5.2.1.9 Record applied currents, all thermocouple readings (including the maximum conductor temperature), and ambient air 5.emperature.
5.2.1.10 De-energize the test specimen and the temperr.ture chamber.
5.3 Tests subsequent to the Baseline Ampacity Te tt.
5.3.1 In addition to the Baseline ampacity (TEST 7190), tray 1 requires tests numbered 1101 through 1111 with Flamenastic coatings in the following amounts and locations:
TEST NO. BOTTOM Top TEST 1100 polyethylene none lR5 TEST 1101 0.25 inch 0.25 inch TEST 1102 0.50 inch 0.50 inch TEST 1103 0.75 inch 0.75 inch TEST 1104 0.75 inch 1.00 inch TEST 1106 0.75 inch 1.25 inch TEST 1108 0.75 inch 1.50 inch TEST 1109 0.75 inch 1.75 inch TEST 1110 0.75 inch 2.00 inch TEST 1110 0.15 inch- 2.00 inch and a tray cover TEST 1111 0.75 inch 2.50 inch TEST 1112 0.75 inch 3.00 inch These coatings are to be within + 1/16 of an inch and are not allowed to be under thickness. They are to be fully cured and will require several layers to reach the stated thickness requirement. Each test shall follow the steps of section 5.1.1.11.
5.3.1.1 After completion of baseline test in Section 5.2, allow all test tray cables to return to ambient temperature and begin applying Flamemastic 77 to the tecy as follows:
5.3.1.2 Flamemastic 77 shall be applied por vendor instructions.
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.. 5.3.1.3 Flamemastic shall be installed in thin layers to the thickness 1 required for each test. (
.5.3.1.4 Each layer shall be cured before the next layer is added.
5.3.1.5 Normal c' ure time is two to three days. However, curing time may be shortened by energizing the cables in the tray to a temperature 50*C and also adjusting the ambient temperature of the environment to the 50*C temperature ~ range when no personnel are in the test environment.
5.3.1.6 The Flamemastic shape above the tray edge may be constructed with the aid of forms made of either wood or angle iron. Care shall be taken to minimize damage to the Flamemastic during the removal of the forms. Allowable tolerance on shap~e width is i 1/8 inch.
5.3.1.7 Care shall be taken to ensure that all exposed cable lRS surfaces 1/4 in all Flamemastic inch thickness of Flamemastic, tests are covered with a minimum of '
5.3.1.8 i When all of the Flamemastic layers for each test have been applied and cured, each test listed in the test summary section shall be performed as in Section 5.3.1. The initially applied current shall be calculated as the product of 0.8 times the {
immediately preceding steady-state current. As an example the initial current applied to Test 1101 (i.e., the first test with Flamemastic on the cables) will be 0.8 x the baseline current.
The initial current for Test 1102 shall be 0.8 times the final value established for Test 1101.
5.3.2 in addition to the Baseline Ampacity (TEST 210) tray 2 requires several tests with different power levels in random groups of cables. No change to cable configuration shall be allowed aftet*
completion of baseline test. No layers of Flamemastic are required.
An additional baseline (TEST 216) with top and bottori covers will be obtained and TEST 217 will be based on this new baseline. The required tests are:
TEST NO. GROUP A CROUP B GROUP C CROUP D I
TEST 210 Baseline Baseline Baseline TEST 211 Baseline i Baseline &20% Decnergized Baseline Baseline-20%
TEST 212 Baseline &20% !
Deenergized Deenergized Baseline-201 TEST 213 BaselineF30% Decnergized Decnergized TEST 214 Baseline-101.
Baseline +10% Deenergized Deenergized Baseline-401.
TEST 215 Baseline +50% Decnergized Deonergized Baseline-20%
TEST 216 (with top and bottom cover)
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New Baseline New Baseline New Baseline New Baseline TEST 217 (with top and bottom cover)
New Baseline +20% Deenergized Deonergized New Baseline-20%
(
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__ - - - - _- - - - - - - - - - --- -- A
- / . j 5.0 FLAMEKASTIC TYPE C0KPARISON l
6.1 Fixture Construction 6.1.1 The heat transfer characteristics of Flamemastic 71A and 77 will l be evaluated through the use of test fixtures shown in Figures 5 l and 6. Temperatures are then measured on the top and bottom l R5 surfaces of the metal plate at various depths within the coating l and on the coating surface. [
6.1.2 Construct and wire test fixtures as shown in Figure 5 and Figure 6. Prepare one fixture for each Flamemastic type.
Arrange the resistors for as even as possible heating of the plate. Apply a coating of thermal conducting compound between each resistor and the plate. Center and mount a type "T" thermocouple on the top and bottom of the aluminum plate with a few drops of epoxy cement. Make certain the thermocouple touch the plate. Connect the thermocouple to the data logging system. Measure and record the total resistance of each heater circuit.
6.2 Baseline Data 6.2.1 Apply power and slowly raise the voltage with the variac until the data logger indicates a stable temperature of 90'C i 1*C for the thermocouple attached to the top of the plate, then measure and record the voltage applied to the resistor heater.
Calculate the input power for each fixture. Record the thermocouple readings at intervals with the data logger and ensure temperature stability. (Stability shall be defined as lR5 changing no more than 1*C in 30 minutes.)
6.3 Flamemastic Comparisons 6.3.1 Remove power and allow fixtures to cool. Remove the insulation surrounding the fixtures and construct a form around each fixture with apertures for measuring the height of the form. lRS Apply Flamemastic in thin layers, allowing each layer to cure, to a depth of 0.25 inch. Remove the form and replace the insulation. Repeat section 6.2.1 and while the data logger is recording the temperatures measure the surface temperatures at surface temperature points 1 through 5 as shown in Figure 5.
6.3.2 Repeat section 6.3.1 as many times as needed. Install a l thermocouple in the center of the fixture before cach .25 inch l RS layer.
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7.0 ANALYSIS OF RESULTS
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The results will be presented as data only, however in order to quantify the ampacities and the doratings some calculations will be necessary. -. %
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7.1 Results shall be reported by a simple comparison of the baseline and subsequent test. specimen ampacities and calculating the derating factor as follows:
% Ampacity Derating =-(Io_- Ig) x100 Io Where: Io =- Current in amperes required to attain a temperature of 90*C for.the baseline (unprotected) system.
It= Current in amperes required to attain a
-temperature of.90*C for the system as protected by the passive fire protection system (i.e., Flamemastic 77).
7.2 In order to obtain oI and It in section 7.1, it is necessary to correct the current as measured in each test to the exact value for these currents at 90*C. Ambient temperature differences from the nominal 40*C also affect these currents, so these currents will be adjusted to nominal by the following equation:
Adjusted ampacity =
II
- N/(((Ter-Tra)/(Tem-Tma))*((234.5+ Tem)/(234.5+Ter)))
where Il = average applied current for the 30 minute test conditions T em = cable measured avg. temperature (hot spot in test section)
Tma = measured ambient temperature (avg.- 30 minute test)
T er = cable required temperature (90 degrees centrigrade)
T ra = required ambient temperature (40 degrees centigrade) 234.5 = linear inferred absolute temperature for copper 8.0 REPORT The final report shall describe the test requirements, report the results of performance tests necessary to meet test acceptance criteria and reference procedures and test instructions required to perform the testing.
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-__ _ - _ _ _ _ - - _ _ _ - _ _ - _ _ _- _ a
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9.0 ATTACHMENTS 9.1 Test configuration drawings Figures 1 through 6 prepared by the Central Laboratories.
9.2 All necessary cable number, thermocouple number, datalogger channel and thermocouple TVA number cross reference charts will be made a part of the final test report.
9.3 Interim reports of data and correspondence may be included as attachments to the final test report.
10.0 CABt.E LIST 10.1 Mark No. WDH-1, PXJ, 1/C No. 1/0 AWG, Contract 828920-1, Reel No. YC2295NC-2510. Total footage: 4652 feet. TIIC No. : BHA 150P 10.2 Mark No. WDP-2, PX, 1/C No. 500 MCM, Contract 830040-1, Reels 32537Al (2136 feet) and 32536B1 (2195 feet).
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ItEPORT OF AMPACITY DE-RATING FOR FLAMEHA5 TIC COATED CABLES ADJUSTED AMPACITY BASED ON CENTER THREE THERM 0 COUPLES ADJUSTED AMPACITY FLAMEMASTIC CABLE 3 CABLE 4 DE-RATING FACTOR MULTIPLICATION-THICKNESS C101-103 AVG C6-C8 AVG % AMPACITY FACTOR TEST 1100 (BASELINE) 363.01 AMPS 100.00 1.0000 TEST 1101 0.25 INCH 365.01 AMPS 100.55 1.0054
' TEST 1102- 0.50 INCH 334.11 AMPS -92.04 0.9203 TEST 1103 0.75 1:iCH 327.51 AMPS 90.22 0.9022 TEST 1104 1.00 INCH 315.38 AMPS 86.88 0.8687 TEST 1106 1.25 INCH 310.85 AMPS B5.63 0.8563-TEST 1108 1.50 INCH 304.41 AMPS 83.86 0.8385 TEST 1109 . 1.75 INCH 302.15 AMPS 83.23 0.8323 TEST 1110 2.00 INCH 299.77 AMPS 82.58- 0.8257
. TEST 1111 2.50 INCH 293.52 AMPS 80.86 0.8086 TEST 1112 3.00 INCH 284.28 AMPS 78.31 0.7831 TEST 1110 2.00 INCH (W/ COVER) 267.07 AMPS 73.57 0.7357
. TEST 1111 2.50 INCH 293.59 AMPS 80.88 0.8088
' TEST 1112 3.00 INCH 283.66 AMPS 78.14 0.7814 TEST 1110 2.00 INCH (W/ COVER) 261.88 AMPS 12.14 0.7214 l
ADJUSTED AMPACITY BASED ON CENTER THERMOCOUPLE ADJUSTED AMPACITY FLAMEMASTIC CABLE 3 CABLE 4 DE-RATING FACTOR MULTIPLICATION THICKNESS C102 AVERAGE C7 AVERAGE % AMPACITY FACTOR l
TEST 1100 (BASELINE) 366.99 AMPS 100.00 1.0000 TEST 1101 0.25 INCH 371.51 MPS 101.23 1.0123 TEST 1102 0.50 INCH 337.40 AMPS 91.94 0.9194 TEST 1103 0.75 INCH 330.51 AMPS 90.06 0.9006 TEST 1104 1.00 INCH 318.36 AMPS 86.75 0.8675 TEST 1106 1.25 INCH 313.31 AMPS 85.37 0.8537 TEST 1108 1.50 JNCH 306.61 AMPS 83.55 0.8355 TEST 1109 1.75 INCH 304.71 MPS 83.03 0.8303 TEST 1110 2.00 INCH 301.27 AMPS 82.09 0.8209 TEST 1111 2.50 INCH 296.23 AMPS 80.72 0.8072 TEST 1112 3.00 INcn 283.59 AMPS a
77.27 0.7727 }
' TEST 1110 2.00 INCHIV/C0VER) 271.03 AMPS 73.85 0.7385 l TEST 1111 2.50 INCH 295.15 AMPS 80.42 0.8042 TEST 1112 3.00 INCH- 284.43 AMPS 77.50 0.1750 TEST 1110 2.00 INCHlW/ COVER) 268.34 AMPS 73.12 0.7312
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TABLE 1
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SUMMARY
OF DATA FOR TRAY 2 GROUP A GROUP B CROUP C CROUP D AMPS MAX. TEMP. AMPS MAX. TEMP. AMPS NAX. TEMP.
TEST 210(BASELINE) 79.21 AMPS . HAX. TEMP.
86.08 79.21 90.51 79.21 886.93 TEST 211 79.21 89.85 95.57 77.90 ZERO 77.46 79.02 876.73 63.65 18.42 TEST 212 95.04 68.73 ZERO 68.05 ZERO 866.85 62.98 68.80
' TEST 213 102.55 73.47 ZERO 72.56 ZERO 871.65 '71.36 TEST 214 73.70 87.31 62.11 ZERO 61.01 ZERO 859.44 47.75 60.96 TEST 215 119.00 81.51 ZERO 79.32 ZERO 876.51 63.70 79.47 -
TEST 216(V/C0 VERS) 53.36 90.16 53.36 90.68 53.36 889.02 53.36 90.00 TEST 217(V/ COVERS) 64.69 65.46 ZERO 64.09 ZERO 864.30. 42.81 64.73 NOTES: All temperatures are in degrees Centigrade.
-R2
- Due to random selection of cable pairs for groups, GROUP C did not have a thermocouple.
Temperatures for GROUP C obtained from hottest instrumented cable close to GROUP C.
TABLE 2
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.7 TEMPERATURE COMPARIS0NS OF FLAMEMASTIC 71A AND FLAMEMASTIC 77 FLAMEMASTIC 71A ALUM. PLATE TEMP. THERM 0 COUPLE TEMPERATURES SURFACE INPUT. AMBIENT -R2 THICKNESS,1NCHES BOTTOM TOP LAYER 1 LAYER 2 LAYER 3 TEMP. KATTS- TEMP. -R2 NONE -NA- 89.89 -NA- -NA- -NA- -NA- 65.07 25.83 0.25 .-NA- 90.20 -NA- -NA- -NA- 7?.30 57.66 .28.90 0.50 97.64 96.11 86.26 -NA- -NA- 70.06- 54.48 27.83 0.75 90.86 90.65 81.88 60,94 73.54 -NA-- 52.40 22.09 1.00 90.47 90.71 83.26 .76.09 70.46 57.47 50.14 24.02 NOTE: All temperatures are in degrees Centigrade. -R2 FLAMEMASTIC 77 ALUM, PLATE TEMP. THERMOCOUPLE TEMPERATURES SURFACE INPUT AMBIENT -R2 THICKNESS,1NCHES BOTTOM TOP LAYER 1 LAYER 2 LAYER 3 TEMP. WATTS TEMP. -R2 NONE -NA- 89.89 -NA- -NA- -IIA- -NA- 65.07 25.83 0.25 -HA- 89.60 -NA- -NA- -NA- 74.20 64.03 28.90 0.50 94.31 92.42 83.52 -NA- -NA- 67.59 53.62 27.83 0.75 91.02 90.63 81.83 74.29 -NA- 62.01 55.57 22.09 1.00 90.36 88.30 81.05 75.01 70.54 59.10 47.71 24.02 NOTE: All temperatures are in degrees Centigrade. -R2 TABLE 3
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