Text

Units 1 & 2 Suppl 1 to Response to NRC Concern 7
	ML20247E452
Person / Time
Site:	Braidwood
Issue date:	07/13/1989
From:	Behera A; SARGENT & LUNDY, INC.
To:	;
Shared Package
ML20247A248	List: ML20247A244; ML20247E445; ML20247E452; ML20247E467; ML20247E481;
References
	NUDOCS 8909150288
	Download: ML20247E452 (50)
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BRAIDWOOD STATION - UNITS 182 SUPPLEMEN" 1 TO RESPCNSE TO NRC CONCERN NO. 7 l~

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Preparer: A. K . Behera Date: July 13, 1989 L

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Y DISPOSITION OF ANAMOLY #2 (WYLE TEST 17961-01)

[l' l-During the Post-DBE exposure, Specimen Splice 1A, 21A and 21C exhibited leakage in excess of 1 amp and were necessarily removed from their respective circuits. The

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Specimen Splices lA, 21A and 21C had the following lead wires:

Specimen First Lead Second Lead 1A Note 1 Note 2 21A Note 1 Note 1 21C Note 1 Note 1 Notes

1. Reliance Thermafit Specification 4024-6CM (Nomex) No. 14 AWG

2. Okonite EPR insulation, Okolen Jacket No. 14 AWG The above splices had braided Nomex lead wires and a burned /

darkened area on the braided material of these lead wires on each specimen.

Additional hi-pot testing verified that the burned / darkened area (s) on the braided material of the lead wire (s) were the weakest points of the specimen splices. Specimen 21C had come into physical contact with the enclosure in':ernal 1

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to the Thermocouple No. 4 during the accident simulation.

This contact was the cause of the excessive leakage exhibited through the lead wire to ground for Specimen 21C. The Specimens lA and 21A were partially submerged in water during the accident simulation. This allowed leakage path to ground through the burned / darkened areas of the Nomex. lead wire '(see Page VI-!O for Specimen 21A and Page VI-14'for Specimen lA).

The above failures are attributed to the Nomex lead wire and not to the Okonite splice. Hence, this anomaly has no impact (n1 the qualification of the Okonite splice.

In addition, since Nomex insulation is not used as a cable insulation at Braidwood Station, the above f ailure has no' safety significance at Braidwood Station.

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h-COMMONWEALTH EDISON COMPANY BRAIDWOOD STATION - UNITS 1 & 2 SUPPLEMENT 2 TO RESPONSE TO NRC CONCERN NO. 7

1. NUCLEAR EQ REPORT FOR OK0 GUARD INSULATED CABLES AND T-95 &

NO. 35 SPLICING TAPES (REPORT #NQRN-3).

2. OKONITE ENGINEERING RE"0RT NO. 407 LOCA QUALIFICATION OF 600 VOLT SPLICES.

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NUCLEAR ENVIROWDRAL QUALIFICATION REPORT for -

010 GUARD INSULATED CABLES and L

T-95-6 NO. 35 SPLICING TAPES OKONITE REPORT NO. NQRN-3

/ This report 1s The Okonite Company's nuclear qualification document for Okoguard insulated cables and splicing tapes. It coaiolies with each para-graph.'in'IEEE Standard 383-1974, Section 1.4 " Documentation". Section J 4 dtv,-nts the parameters specified in Section 1.3, " Type Tests as Qaal-'

ification Method."'

Included in this report are appendices which serve to further clarify Okonite's test procedures and results. These appendices are as follows:

Appendix

. iffy 1 --Straight Splice .-- 1/C Rubber Insulated, Shielded, Jacketed

. Nuclear Station Cable D-11489 2 40-Year Life Detail Document-3- Radiation Certification 4' Okonite's W 3 Test Profile 5 LOCA Autoclave Drawing 6' List of Equipment 7 Elevated Temperature Moisture Absorption 8 Vertical Tray Flame Test R3 9 Insulation Resistance R3 10 Anomalies Rev. 1 6/30/82

" Rev. 2 - 2/16/84 Rev. 3 - 3/31/87

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The necessary data to document satisfactory compliance as specified in i Section 2.6 of IEEE 383, " Documentation of Type Testing" is provided in i

- this report. The following cross-reference table illt.strates where this information can be found.

Section Title Section in Report 2.3.1 Temperature and Moisture Appendix 7 2.3.2 Long-term Physical Aging Properties Appendix 2 2.3.3 Thermal and Radiation Exposure Paragraph 1.4.1.3 (Pre-aging and Irradiation-and Appendix 3).

2.4 Testing for Operation During Paragraph 1.4 and specif-DSE-LOCA ically 1. 4. 2, 1.4. 3, and 1.4.4 2.5.1 Vertical Tray Flame Test Appendix 8 j

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,' Documentation of Test Procedures -- IEEE 383, Section 1.4 1.4 documentation 1.4.1.1

Description:

SkV, #6, 7X BC, extruded semicon, .090" Okoguard, extruded semicon, .005" x 1" BC shielding tape, 121% lap, no jacket. Two 15 ft. samples: 1-non-aged, 1-thermally aged.

1.4.1.2 Description of hand-wrapped filled splice: Per attached drawing D-11489, Appendix 1, with the following exceptions:

(1) The cable tested had no jacket. However, jacketing tape (No. 35) was applied over the splice.

J) Grounding straps and tinned copper perforated strips were not utilized.

(3) A compression connector was used instead of a solder connec-tor.

1.4.1.3 Identification of environmental featuros:

Listed below are the environmental parameters which the samples were subjected to. A temperature-pressure profile is given in Appendix 4.

,{L"#; Preaging: Aged sample was aged for 3 weeks @ 150*C in a forced draft circulating air even. Temperature was monitored continuously by a chart recorder. Appendix 2 is a ,

detailed discussion of 40 year life simulations. 1 Radiation: The samples received a minimum dose of 200M rads of gamma radiation at a rate of less than 1 megarad per hour. See attached certification (Appendix 3).

Temperature: 2 peaks at 345"F for 3 hrs, each 3 brs. at 335*F 4 hrs. at 315*F 3 days 9 hrs. at 265*F 126 days at 212*F Pressure: 2 peaks at 114 psi for 3 hrs, each 3 hrs. at 95 psi 4 hrs, at 69 psi 3 days 9 hrs. at 24 psi 126 days at 0 psi Relative Humidity: Saturated steam conditions throughout profile. i Chemistry of Spray Solution: per IEEE 323, Appendix A Table A-1

.28 molar H 3B03 !

.064 molar Na773 S0 NaOH approx. .59% to make a pH of 10.5 at 77"F dissolved in tap water ,

Spray rate of minimum .15 (gal / min)/ft.' of surface area of the test vessel.

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('n,! ) 1.4.1.4 Specific performance requirements (Acceptance Criteria)

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(a) Cable and splice must maintain electrical load throughout entire LOCA profile.

(b) Cable and splice must withstand the 30 day and 130 day 1:ost-LOCA withstand tests (40 x OD at 80 V/ mil, 5 min.)

(c) Test sequence must provide a margin of assurance.

1.4.1.5 Test Program (a) Sample selection

(b) Pre-test electrical and physical (mechanical) characteristics

-- to determine if samples are representative samples; capacitance, % PF, and 1R.

(c) Prepare splices

(d) Electrical characteristics after splices -- to determine if splices were made correctly.

(c) Thermal aging of one sample: 3 weeks at 150*C followed by electrical characteristics *

(f) Irradiation of sanples: 200M rads f

(g) Pre-LOCA electrical characteristics -- to determine the con-dition of samples prior to LOCA (h) Jnsta11ation of samples into LOCA vessel

(i) Pre-LOCA insulation resistance measurements and 5 min.

80 V/ mil ac withstand test, to determine if samples were damaged during installation.

(j ) Chemical solution sprayed into vessel.

(k) Initiation of LDCA simulation (see Profile-Appendix 4).

(1) Maintenance of LOCA profile thru 30 days with IR measure-ments* taken as shown in profile.

(m) 30 t y Post-LOCA withstand test (40 x OD bend, 80 V/ mil ac, 5 minutes)

(n) Reinstallation of samples into vessel for additional 100 days at 212 F. 1R measurements

taken once every two weeks.

(o) 130 day Post-LOCA withstand test (40 x OD bend, 80 V/ mil ac, 5 minutes) I

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(q) Dielectric strength.

Electrical or phys 2 cal tests are not requirements of IEEE 323 or 383.

NOTE: Test program and results of the vertical tray flame test are contained in Appendix 8.

1.4.1.6 Test Resu _lts (a) The unaged specimen maintained the electrical load as i.

given in paragraph 1.4.2.4 throughout the entire profile.

The electrical load on the aged specimen was interrupted R3 from the first day at 265'F through the 30th day due to a termination failure. (See Appendia 10, items 3 and 4).

(b) 150t h samples (cables and spli ces) pa . sed the 30 and 130 da.s s Post-LOCA withstand tests (40 x OD bend, 80 V/ mil ac, for 5 minutes immersion in water).

(c) A margin of assurance was demonstrated by:

(1) Each sample passed the Post-LOCA withstand test twice,

@e,;. y once at the 30 day point and again at the 130 day point.

%,s .r (2) The cables passed all withstand tests as described in paragraph 1.4.1.5.

(3) Satisfactory Post-LOCA electrical measurement values.

(4) The insulating materials maintained flexibility.

(3) Adhesion remained between cable and splice.

(6) The cable maintained dielectric strength. Post-LOCA breakdowns were greater than 8 times rated voltage.

Margin may also be demonstrated when the environmental para-meters of this test are compared to the postulated LOCA parameters of a p:trticular nuclear station.

Test data to justify the above are available for cudit by the purchaser c.r his authorized designates.

1.4 2 Test Program Outlined 1.4.2.1 Ecch sample was colled into approximately a 22-inch coil. The ends were terminat ed for t esting. One of the samples was thermally aged pr:;or to irradiation, both sampics were irradinted m-ir this configuration. An epoxy-type terminril was installed on each end. The sanples were then installed in t'3e LOC A vessel .

Tae samples were mounted around a vertical ma Crel which was made out of 1" x }" expanded st eel . Thc nhysf.c n arrangement is shown ,

in Appen:lix 5. Test equipment uti,4:ed is included in Appendi < 6.

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. _ ,) ' 1.4.2.2 The test program and sequence of environmental factors is out-lined in Section 1.4.1.5 above.

1.4.2.3 Type & Location of all environmental and cable monitoring sensors for each variable.

Radiation: See attached 1somedix, Inc. cer tification, Appendix 3.

Thermal Aging: Forced draft circulating air oven monitored by thermocouple in rear of the oven connected to a continuous readout chart recorder.

Temperature during LOCA: Monitored by mercury thermometer and thermocapillary inside the vessel connected to the Taylor Instrument panel consisting of pressure gauges and a tem-perature-pressure chart recorder.

Pressure: Monitored by Taylor Instrument panel.

Spray Soluctioni pH monitored initially with pH test paper and test liquid. Flow rate monitored by flowmeter made by Okonite. (Pressure measured before and after an orifice.)

Itclative Humidity: A one to two inch reservoir of liquid was get maintained within the test vessel. (IEEE 323, Appendix C.)

(kg/ Steam pressure was allowed to conform to saturated condi- l tions. (100% relative humidity.)

1.4.2.4 Rated voltage, 5kV, was applied to each sample. 80 amps were opplied initially. As the temperature profile changed the current was re-adjusted to 80 amps. Voltage and current were applied to '

the ends of the samples which protruded thru the vessel. j 1.4.2.5 During environmental exposure, insulation resistance measurements r are taken periodically. (See Appendix 9.) lR3 1.4.2.6 The following tests are performed after environmental exposure:

(a) Post LOCA AC Withstand Tests: These tests were performed per IEEE 383, Se :t ion 2.4.4.

Charging current is measured by a mil 11 ammet er..

(b) Capacitance and Dissipation Factor (% PF): These measurements j were taken with the sample at room temperature in air.

Measurements were taken at 40 and 80 V/ mil of insulation.

(c) Dielectric Stregh Tests: An ac rapid rise breakdowr, test pe r ASTM D149, p ua. 15(a) is performed on each sample after completion of all electrical tests.

(d) Mechanical Tests: Tensile strength and % elongation measute-ments are taken as indicated in the test program outline. k Measureirents were performed on dumbbell shaped samples taken from thc mim all section of the cable insulation. The ASTM D470 test pracedurt is follewed.

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1.4.3 Test Results 1.4.3.1- The intended environmental sequences were achieved. . Thermal aging.was perfomed with the' temperature recorded on the chart recorder. The radiation requirements were met ac shown in Appendix 3. The temperature-pressure profile as shown in IEEE 323, Appendix.A - Fig.'A-1 was achieved except'for the anomalies (1) and (2) described 'in Appendix 10. Actual tem- R3 perature and pressure.; are shown on the LOCA profile in

. Appendix 4 of this report.

1.4.3.2' The samples were capable of perfoming their intended Cunction as evidenced by:

(a) Electri~al e load was maintained during W CA except during g3 periods described in Appendix 10, items (3) and (4).

(b)' Both sampics withstood the 30 and.130 day Post-LOCA

. withstand. tests.

(c) A margin of assurance was demonstrated. See Section R

1.4.1.6(c) above.

. ,s jyg 1.4.4 Test Evaluation - Evaluation of Data The 130 day Post-WCA withstand test demonstrated that the samples were in good condition. Charging currents of less than 3mA were- ,

measured. Electrical characteristics demonstrated that the cable had degraded, yet was still in good condition when considering the severity and length of the test. Capacitance went from approxi-mately 1100 picofarads to 1000 picofatads. The % PF increased from approximately 0.50 to 0.92% at 80 V/ mil. The insulation resistance decreased from an average.of 40,000 megohms-1000 ft, to approximately 5,000 megohms-1000 ft. AC dielectric breakdown for both samples was greater than 40kV (or 8 times the rated value of the cabic). Percent rotention of tensile strength and elongation were 103 and 41, and 95 and 52 for the unaged and aged samples, respectively.

The cable and splices are considered to have passed the DBE-IACA qualification test :ince they at the requirements specified in IEEE 'iS3 and $23 for Class 1E cables, and provided a margin of .

l assurance which is deuenstrated in the above data,

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-APPENDIX 2 L.::

DEMONSTRATION'OF 40 YEAR LIFE FOR MATERIALS

This. document.is designed to present Th'e Okonite. Company's

. position on the subject of demonstration of 40. year life at 90 C for materials, as required by < the nuclear industry, industry specifications, and various government _ regulatory

, WA agencies. We hope that this presentation'will clarify our si%hf approach, aid..our. customers in their contacts with1 reg-latory agencies, and demonstrate the pitfalls involved in extrapolation of experimental 1' data.

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Appendir 2, Page 2 Thermal Aging

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To demonstrate 40 year life at 90*C, the approach used most :fre- .}

quently is the familiar Arrhenius technique. Data'obtained on aging of materials at various elevated temperatures is collected and analyzed via this technique.

Some comments on the method and the scope and limitations of the method are in order.

It should be recognized that the Arrhenius equation is valid only if the data represents a single discreet chemical reaction and the activation energy of that single reaction is within the tem-perature limits of the data. This equation can be derived from collision theory and has been experimentally verified. It serves to defint the temperature coefficient of a discreet chemical re-action and the activation energy of that reaction only within the temperature limits of the experimental data. TEd"equ a t ion is :

k = Ac fE k = specific rate constant, A = frequency factor or collision frequency, AE = activation energy - the difference in the fl'4 energy of a chemical species in the ground 17 The

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state and its activation state.

activated state is not isolabic and has a very short life time (in the order of nano or picoseconds) and collapses either to the original ground state or reactants or to the ground state of the products, R = gas content T = absolute temperature i

The specific reaction rate constant k reprsents a singic discreet chemical reaction. In the case of a simple uni-molecular first order reaction A >B, the following describes the rate where C = concentration:

-dC A kC,o yg- = n that is -- the change in concentration of reactant A with time is proportional to the initial concentration of A. The dif fe rential equation is solved and k determined from experimental measare- !

ments of concentration vs. time. Distinct values of K must be determined at various temperatures and must be constant ov:r a considerable range of conversion in the reaction, say from 20 to l

v 807, for the data to be considered valid. It ca a be used correct ly );'

l only when there are discreet chemical reactions whose rate can be 1

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. Appendix 2, Page~3 pfecisely' measured, and described by sol'vable differential equa- !

tion. 14 straight.line.will result from a plot of the logarithm j of the reaction rate k'vs. 1/T provided there is no change.in the reaction mechanism.

Thel 0konite Company-in applying this Arrhenius analysis to the aging data utilizes the' time to 40% retention of elongat' ion plot-

. ted on semilog paper against a reciprocal of-absolute temperature i i

in degrees Kelvin. Parameters other than 40% retention of elonga-i tion can be utilized and have been utilized. Some have used electrical failure in water after-subjecting the material to high temperature aging for~different times and bending around a 10 or a 20X mandrel. It should be-recognized that times obtained from this latter type of test are far longer than those obtained from a 40% retention of elongation type plot since the electrica in-tegrity really depends on the insulation not cracking-and the elongations obtained in these bend tests are on the order of 50%

Thus, it is emphasized that a 40% retention of elonga-or less.

tion time is a very long way from an electrical failure. It is a very conservative measure of life and as such provides a very large margin of safety in terms of circuit integrity in use if one can show that such a parameter can indeed demonstrate 40 years of service before 40%. retention of clongation time is reached.

In examining the validity of the Arrhenius treatment as applied

[$h to thermal aging, it should be noted that there are at least 40 / four simultaneous reactions going on -- (1) oxidative. cleavage,

-(2). oxidative crosslinking. (3) thermal cleavage, (4) thermal crosslinking. The first two of these reactions are at least sec-ond order kinetically in that their rate law must depend at a minimum.on the concentration of oxygen and the concentration of reacting chemical bonds. Since vulcanized rubber is a compicx mixture of many chemical bond species, there are a multiple of in-dividual rate constants that must be measured. This is an impossibility or at best'beyond the scope of current technical expertise. From the above, it is apparent that the occurrence-of a linear plot in an Arrhenius treatment of aging data is indeed a fcrtuitous event.

Since this .is so, i.e., a straight line is really a fo rtuitous event, and if careful work is done, it can be shown that there are slope changes. occurring in the Arrhenius plot indicating mechanism changes. At lower temperatures: oxygen diffusion rates may be the rate controlling phenomena. These two among other possibilities have differing activation energy, i.e. the slope of the log k vs. 1/T'in a chemical reaction study is the activation energy SE in the Arrhenius equation. Other complications can and undoubtedly do arise leading to variations in slope. At The Okor,ite Company , we recognize these pitfalls and complications, but.we take our time to 40% retention of elongation, plce it vs.

1/T and construct via at least square method the best straight b line through the experimental data points.

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E :peratures beyond the measured experimental-points.is atLlest-a' l Very' risky matter and is indeed not; valid, and should not.bc.done, L and.will, if.done, lead,to. errors. In'our. experience in terms of' aging, i..e. loss of elongation, extrapolation'to' temperatures' beyond those experimentally: measured leads to very considerable L

errorsLin terms,of life. We have-consistently found extrapola '

tions to give lifetimes, i.e., timesEto: 40%'re'tention of clonga-tion, far shorter than experimentally observed _when older, well established' materials are measured and treated by the Arrhenius technique. To demonstrate this, reference is'made to the curves of charts 1, 2.and 3.

On chart #1, the lowest curve labelled Okolite is tha Arrhenius plot-of aging data to 40% retention of elongation of this in-sulation with data collected at temperatures between 75*C and 136 C. . Temperatures below 75 are extrapolated. Utilizing this curve, one would predict that Okolite-(a natural rubber. oil based insulation manufactured by The.0konite-Company in the past) would.have a life, i.e., a time to 40% retention of clongation, of-17 years at 20 C and-7.5 years at 30*c. This latter is say-ing that if Okolite insulation were left at 30"C for 71 years, the sample after that time would have retained 40% of its original =

clongation..

$8 A-sample of this' insulation that has been in service.at Hagood ]

' Station of the South Carolina Electric 6 Gas Co. for 25 years

-at an ambient temperature between 20 and 30 C had 50% retention of its original elongation after the 25 year service period.

Referring to chart #2, the-Arrhenius plot for neoprene is con-structed from data collected between 75 C and 136 C. .The line is extrapolated to-lower' temperatures. This line would predict ~

.that at 13 C continuous, neoprene would have 40% retention of elongation after 14.7 years. An actual sample of neoprene jacketed cable has bcon-exposed on the roof of The Okonite Company Passaic Research Laboratories since 1934. This cabic sample has been examined every five years since then. The time to 40%

retention of elongation of'this sample was 35 years. The average temperature is 13 C on an annualiicd basis in New Jersey.

Also shown on chart #2 is a curve of time to 10% retention of clongation of natural rubber insulation of the type manufactured '!

in the late 1920's. Data collected between 75 C and 121*C has been plot ted from old Okonite records to establish the slope of the line. Temperatures below 75 C are extrapolated. From this plot, one would predict that this natural rubber type insulation would have retained 10% of its original clongation after approximately 61 years at 43 C. An actual sanple of natural rubber insulation u s obtained from the Duke power Company This sample had been installed in 1926 and has been i.n service for ',9 years. The }

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sample after thi: service period had 50% absoiute elongation rhich is approximately 10% retent ion of the original elongation of natural rubber type insulation manufattr. red in the late 1920's.

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Appendix 2, Page 5 ff[h' With reference to chart #3, there is shown the curve for the time to 80%' retention of elongation for butyl rubber. Data was col-1ected between 136*C and 75*C for this material with extrapola- ;

tion to lower temperatures. From this extrapolation, one predicts a life of approximately 41 years at 50 C. A sample of butyl in-sulation returned from the Southern California Edison Company -

Los Alamitos Station which served as a fan cable has been eval-uated. The load on the cable as well as its installation condi-tion was available and the calculations considering the ambient temperature showed that the cable operated with its insulation for 7 years at 50 C and for 3 years at 40*C. As noted above, the projected life at 50 C is 41 years.

The data presented on charts 1, 2 and 3 and the allied unambig- .

uous demonstration that extrapolation of accelerated aging data treated via the Arrhenius technique leads to lifetimes lower than actually observed on real materials that have been in service clearly points out the major pitfalls of extrapolation of Arrhenius type treatments.

Recognizing this pitfall and recognizing the above demonstrated a low life projections obtained by extrapolation of Arrhenius plots, j it is not at all surprising nor mysterious that the Arrhenius treatment plot of accelerated thermal aging data of EP and poly-ethylene shown on chart #1 as the center curve does not, if j?; extrapolated, go through 40 years at 90 C.

m The curve shown for EP and PE is a masterplot of the accelerated aging data of four different EP compounds and two different cross-linked polyethylene compounds. Data was collected on all of these materials between 135 C and 180 C. Very recently data on two EP's for time to 40% retention of elongation at 121 C were obtained.

The life to 40% retention at 121 C was in excess of 5000 hours0.0579 days 1.389 hours 0.00827 weeks 0.0019 months whereas the masterplot constructed by least squares treatment of data as noted above predicts a life of a littic more than 4000 hours0.0463 days 1.111 hours 0.00661 weeks 0.00152 months . This 121 C point is not included in the least squares treatment for obtaining the slope but does indicate that the slope of the line is bending upward as long term aging data at lower temperatures is obtained.

We have thus far shown that extrapolation of Arrhenius typc plots beyond the temperatures where experimental data has been collected leads to low predicted lives for insulations. We have further pointed out that it is therefore not surprising that the extrapola- '

tion of a plot of EP or polyethylene to 90*C does not go through 40 years but indeed predicts values between 7 and 8 years life to d

40% retention. It should be remenbered as pointed out before that 40% retention of elongation is not an end point.

On chart A1, there is shown a line that is labelled 40 years at 90 C. This line is constructed by taking the point of 40 years at 90 C and drawing a line parallel to ite experimentally deter-mined line. This hypothetical line reprcsents a material that would have times to 40% retention of elongation that when extrap-olated to 90' gives a point at 40 years. The construction of this

{

~

Appendix 2, Page 6 i<

~

line parallel to the experimental EP polyethylene line is justified g, l

' ')

on the basis that in general the various mechanisms leading to loss 1{ i of elongation in materials, particularly of the EP and polyethylene type are very similar and it is our experience that various EP's and various polyethylene of rather different compound formulations do indeed give essentially identical slopes. . 1 The experimental line, i.e., that one on chart #1 labelled EP and PE was constructed from data collected on single conductor #12 or

14 coated copper wire with 30 and/or 47 mils of the various in-sulations. These samples were aged at the temperatures indicated previously in forced draft ovens.

Samples of these insulated conductors with the various EP and ;

polyethylene insulations applied at 30 and/or 47 mils have been prepared as multiple conductor cables with an overall jacket. The samples in jacketed form are as they would be installed in a nuclear plant, i.e. a finished cable. These cables were then placed in forced draft ovens at 150, 165 and 180 C for times determined by the 40' year at 90 C. This is, at 180*, the samples were in the oven for 360 hours0.00417 days 0.1 hours 5.952381e-4 weeks 1.3698e-4 months , at 165 , they were in the oven for 960 hours0.0111 days 0.267 hours 0.00159 weeks 3.6528e-4 months and at 150 C, they were in the oven for 2500 hours0.0289 days 0.694 hours 0.00413 weeks 9.5125e-4 months .

After the above mentioned aging times in jacketed form, the samples were removed and tested. The % retention of elongation obtained from the single conductors af ter aging for the long times indicated above at the elevated temperatures were all in my excess of 40% retention. The actual retention values ranged )

depending upon the specific sample and temperature between 60 and 90% retention of elongation. It is to be emphasized that the aging conditions in jacketed form simulate the installation condi-tions.

Thus, it has been shown that polyethylene and EP agcd for times as derived from a line consistent with the aging mechanism of the materials and drawn through 40 years at 90 C do retain better than 40% of their elongation, the parameter used by The Okonite Company for its measure of life.

However, it is The Okonite Company's conviction that a more con- l vincing aspect of the argument for demonstration of 40 year life resides in the comparison of the behavior of EP and crcisslinked polyethylene to butyl and to Okolite, a natural rubber insula-tion. By examining chart #1 at temperatures where actual exper- ,

imental data were gathered, one can see that EP and crosslinked polyethylene exceed the life of butyl when measured in terms of 40% retention of elongation by a factor of between 6 and 10 in terms of comparison with the Okolite natural rubber insulation by even larger factors.

Since Okolite and butyl have performed satisfactorily in power plants and butyl in nuclear power plants, (40 years + in the case of the natural rubber type insulations, and at Icast 15 years for buty) in a nuclear plant) it is clear that the much improved )

behavior of the modern EP and crosslinked polyethylene materials

., g, ,

,.n.-

. Appendix 2, Page 7 h- in acceleratedutests, when compared at temperatures where actuali )

, data were gathered, on each of the materials, indicates that-the l polyethylene land EP's will outperform the older insulations or at the.very worst at least equal their performance.

It is The Okonite Company's conviction that-comparison of accel-erated aging behavior of modern insulations with those of well established insulations having exec 11ent service records is a more reliable and better method of demonstrating useful life for long time periods than the utilization of extrapolations. It is also better and more convincing from an. engineering view that-the .

utilization of the 40 year at 90 C line method described above i even-though the 40 year at 90*C line method described-above is acceptable.

The next requirement in qualification of materials for use in a nuclear plant is the preaging to simulate 40 year life followed by irradiation and LOCA simulatien per IEEE 323 and 383. The Okonite Company has presented data where preaging was performed for.three weeks-at.121*C and has stated that this aging period is adequate to demonstrate the point on the basis of the relative performance of EP's and crosslinked polyethylene vs. buty1.'There has been considerable criticism that this aging period not fell <

on our experimental aging line for*EP and polyethylene. The !

4 rationale for utilizing the 3 weeks at 121 C preaging for EP was Ed/ that this is the time to 40% retention of butyl at 121 C. We have shown the superiority of EP and polyethylene vs. butyl and have pointed out the satisfactory service of butyl so:that we feel the above pre-conditioning is adequate. In any event radia-tion and LOCA simulations are being performed on single conductor ,

cables with 30 mils and 45 mil walls of insulation aged for 3 ]

weeks at 150*C which is a point a little above the experimentally determined Arrhenius aging line.

It has been shown above that aging single conductors without :

jacket for 3 weeks at 150 C is more severe than aging for the j times-determined by the 40 year at 90 C line in jacketed form.

We, therefore, maintain that the aging of 3 weeks at 150 C is more than adequate and more severe aging than is required prior to the irradiation and LOCA simulation. i It is of interest to note that aging of three weeks at 150 C in i j acketed form are less severe giving between 95 and 100% reten-tion of clonga? ion on EP's and crosslinked polyethylene than ;

agings of the same insulations in unjacketed form, i.e., as bare '

single conductors for 3 weeks at 121"C which gave between 90 and 95% retention of elongation. Indeed aging to the 40 years at 90 C line jacketed give retention of elongation only somewhat I more severe than the 3 weeks at 121 C.

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-()

APPENDIX 3, P g7'l'af i f

ISOMEDIX Decenber 27, 1976 Mr. George Dobrousky The Okonite Co.

Canal & Jefferson Street Passaic, New Jcrsey 07055

Dear 'ir. Dobrowsky:

'-'his will summarize parameters pertinent to the irradiation of electric cable samples and splices for the Okonite Company, per your Order 9-76-509, dated December 10, 1976. A listing of samples exposed to irradiation is attached.

Samples were placed in a Cobalt-60 gamma field ranging in intensity from 0.50 to 0.50 megarads per hour, for a period of 400 hours0.00463 days 0.111 hours 6.613757e-4 weeks 1.522e-4 months . Cables received a ninimum dose of 200 Mrad.

- Maximum overdose to any cable was 1.16 times the dose p .h D # pecified, or 232 Mrad.

The samples, mounted on flat boards, were rotated and turned during exposure to obtain the dose distribution described.

Irradiation was conducted in air at ambient temperature and pressure. Radiant heat from the source heated the samples somewhat, but the temperature did not exceed 100cP, as indicated by previous measurements on an oil solution in the same relative position.

Dosimetry was performed using a Victoreen Model 555 Integrating Dose Rate Meter and Probe. 'I'he unit was calibrated on October 16, 1975 by the Victorcen Instrument Company, using

. Cobalt-60 and Cesium-137 sources whose calibrations are traceable to the U.S. National Dureau of Standards. A-copy of the calibration certificate is available. Backup dosimetry using a Red Perspex System confirmed the Victoreen readings.

Irradiation was comoleted on December 15, 1976. Samples were piched up by your personnel and transported back to Ohonite on Decn:,ber 16, 1976.

Very truly yours,

(

';corge R. Dietz C Manancr, 2ad iation c.crvices Att.

GP.D::n isomedix inc.

2S Eastrnans Road. Parsippany, New Jersey (201) 887-4700 v v.r , soma rw on,ee v:. '-r V.w no s. s J"m C%'

CHICAGO DIVISION

w 'are me uw Gm.' - n 'v % W 9-5 "O

&' J APPENDIX 3, Page 2 of 2 g

Okonite Sarples for irradiation 200 *1 rads s

)

nepairs 2 factory repairs per sanple

1) #12 7x .030" Okonite............... unaged 2

& thermally aged unaged, 2 thcrnally aged

2) #12 7:: .030" FMR X-Olene..........

3) 46 7x .05.5" Okonite, 030" Okolon.. Unaged & aged

4) #6 7x senicon, .090" Okoguard, senicen, .005" ccpper shield.... Unaged & aged

!?ew Compounds

1) #12 7x .030" Firmer Ohonite .015"CPE...... Unaged "

& thermally aged"

2) #12 7x .030" Firmer Okonite............... " " * "

3) #12 7x .030" Flame Retardant Okonite...... " " " "

4) #12 7% .030" Flame Retardant Okonite...... " " " "

5) #12 7x .030" FMR X-Olene tyne............. " " " "

6) #12 7x .030" FMP, X-Olene type............. " " " "

7) # 12 7x . 0 3 0 " F!!n X-Olene type. . . . . . . . . . . . .

Field Splice l SXV #6 Okoguard Field Splice _for LOCA.........Unaced & thermally aged

" 51'V #6 Okoguard Field Splice for test af ter " " " "

)-

irradiation............

Plus various short samples of the above compounds and others for physical property tests after irradiation.,

i s

i 25 Eastmans Rosd. Parsippany. New Jersey (201) 887-4700 Isomedix inc.

n ; e,1,.a av o n os m r., m e, v. un ' . -

Y"" ' '"'

*"*n A- "on'* Gn *'

CHICAGO DIVISION

p_--__--_-____.__________..._. __ _ _ _ _

I 4

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TR. DR AWING NO.

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APPENDIX 6 LIST OF EOU.vMENT l

The Okonite Company's Quality Assurance Department mainta ins a program which includes as found condi-tions, frequency status identification, and the use of calibration standards traceable to NBS. The ;

electrical equipment used in Okonite LOCA tests has !

been calibrated and certified by either Electrical Testing Laboratories or Electrical Calibration j"W o Laboratories on a yearly basis. Tolerances for each instrumn.nt were determined by The Okonite Company.

The test equipment accuracies are in Okonite's Mariuf acturing Fta;tdard, Section 8.11.02 (7/17/79)

" Equipment Calibration Accuracy and Requirements."

Section 8.11.02 and calibration reports written by the above testing laboratories are available for audit by the purchaser or his authorized designates. j

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__,,' Phmsey NtrwJrvury 0%4G A PPENDIX 6 , page 2

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LIST OF EQUIPMENT 1 Power Supplies A. 100 kVA Testing Transformer General Electric 0-50 kV Serial #D938528 B. 10 kVA Trt.nsformer General IClec tric 0-50 kV Serial #2833724 C. 200 kVA Transformer Westinghouse 0-200 kV r Serial #235. 230 D. 20 kVA Transformer i

Nothelfer Winding Labs. , Inc. , 0-100 kV l Model ID 7-67 E. 4 kVA Transformer )

Hipotronics 0-20 kV Model 720-2 F. Current Transformers - (2) f Scientific Ele.ctric G. 2. 5 kVA Transforme r Power Suppli es - (5)

Nothelfer Winding Labs. , Inc. 0-5 kV Model NWL 19082 - Units No. I through 5 H. Powerstat 0-230 volts Superior Electric Co.

Model No. MZ 1256-2P i 2. Measurement Equipment A. Ammetern 1 Weston Multiscale Clip on AC Ammeter 0-100 amps Model 633

2. AC Milliammeter (-I amp Simpson Model 288 I l _ _ _ _ _ _ __-_ ____ - _ O

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1. . Leeds & Northrup Insuh;. tion Resistance Test Set

. Catalog #2100 Galvanometer Catalog #2500F 1

2. Hipotronics Megohmmeter 1 to 107 MDModel HM 6 B

Unit #1 - Serial #3810-1028 Unit #2 '- Serial #3813-1080

3. Associated Research, inc.

1 M ' ohm to 1 T ohm Unit #2 - Serial #534

4. General Radio Megohmmeter .

Model 1862

- ' Serial #3323 ti "

^S C. Capacitance & Dissipation Factor Equipment

1. High Voltage Schering Bridge F & G Neptun F #150255 MF01

2. Capacitance & Loss Factor Bridge Hartmann and Braun Model EH/G16 Serial #25151

3. Gas Filled Standard Capacitor - 100 picofarada Ger:eral Electric Serial #HV-1M-63-107-A

4. Oil Filled Standard Capacitor - 100 picofarads R. Jahre Berlin W35 F. No. 6918

5. Gas Filled Standard Capacitor - 205 picofarads Lapp Serial 39.16

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MISCELLANEOUS EQUIPMENT _

Okonite Flowmeter .150" orifice, 0-200 psig - Pressure Gauge .

Cranford Sectional Oven with Honeywell Temperature Indicator 0-200 C, Model No.18IC, Serial #678672001 Scott Tester, Scott Tester, Inc. , Model L3, Serial D 4260 LOCA Chamber 24" ID,- N. .Y. Engineering Co. , Manufactur e #57003 NB #650

' Pressure & Temperature Monitoring Equipment Taylor Instruments, Serial #D251R2231-613 -

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2o'-B25mm'cabie okon'te APPENDIX 7

! MOIST 1JRE RESISTANCE Long term moisture stability is one of the essential factors in the selection of an insulation for many applications. It is not unusual for a power cable to be required to operate in an environment alter-nately wet and dry. To determine the long term water stability of a cable, a sample insulated with a thin wall dielectric is immersed in water at an elevated temperature to accelerate the deteriorating effects of moisture. Monitcring the electrical properties provides an indication of long term behavior. Based upon actual experience with installed cables over many years, insulations which have the capability of withstanding total water immersion at 90C should be capable of a life in excess of a generating station's designed life in an environment of 100% humidity.

Ff gure I shows long term 90C water' immersion on a 1/C #14 AWG Okoguard

.,3 insulated cable, and Figure I-A shows comparable data on a 1/C #4/0 jy AWG Okoguard insulated power cable.

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LONG TERM 10ISTURE RESISTANCE Method: ICEA S-68-516, Section 6.21.2 except (1) water temperature at 90*C, (2) test t ime extended, (3) ac withstand at 110 volts ac/ mil at 90*C hfter electrical measurements, and (4) 600 volts de continuous stress applied.

Sample: 1/C #14 AWG Solid Copper, 0.045" Okoguard Measurements shown below are average of three samples.

Immersion Stress Time Volts / mil (de) SIC % PF SIR

1 day 40 2.81 1.89 849 80 2.81 1.92 1 week 40 2.85 1.45 1220 1 80 2.85 1.61 2 weeks 40 2.89 1.40 1314

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80 2.89 1.43

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1 month 40 2.93 1.29 2276 80 2.94 1.31 2 months 40 2.99 1.27 2186 80 2.99 1.42 3 months 40 3.04 1.21 2498 80 3.04 1.24 4 months 40 3.08 1.06 3388 80 3.09 1.09 5 months 40 3.12 0.98 2612 80 3.13 1.03 6 months 40 3.17 1.01 4132 80 3.18 1.04 Sped

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. Sample: 1/C #4/0 AWG (19 x .1055) bare copper, 0.025" EP Semicon,

.175 wall of Okoguard 3 sample with 14.0 kV ac (80V/ mil)continuousstress(E003-96548)

Measurements at 900C Time. Stress P.F. SIC SIR Period V/ Mil -% Constant (meg. ohms)

'3 days. 40 2.09 -

k.99 505 80 2.12 2.99 -

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I week 40 1.85 2.97 673 80 1.94 2,97 -

2 weeks 40 1.71 -

2.98 932 80' 1.80 2.98 m

c.-s 1 month 40 1.88 2.95 1475 80 2.03 2.95 -

2 months 46 1.71 3.13 1545

'80 1,77 - 3.13 -

4 months 40 1.37' " . 3.06 2881 80 1.42 3.07 -

6 nonths 40 1.48 3.07 3858 80 1.61 3.07 -

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.)J APPENDIX 8 FLAME TEST QUALIFICATION for OKOGUARD INSULATED OKOLON JACKETED MEDIUM VOLTAGE POWER CABLE The attached flame test summary sheets dem-onstrate that Okoguard insulated - Okolon jacketed medium voltage power cables are capable of meeting the flame test require-

' ments of IEEE Standard 383-1974, Section 2.5.

Several tests have been performed to dem- )

onstrate compliance to the IEEE flame test requirements for a wide variety of Okoga3rd-Okolon constructions.

4

THE OKONITE COMPANY Awruw NeuJwvey ame APPENDIX & (Page 2)

.h iO VERTICAL TRAY FLAME TEST 1EEE STANDARD 383-1974 C rite ria: The fle.me test should demonstrate that the cable does not propagate fire even if its outer covering and insulation have been destroyed in the area of flame impingement.

Test Specimens: Test specimens are specified in the attached table.

Fire Test Fa,cility and Frocedure: The test should be conducted in a naturally ventilated room or enclosure free from excessive drafts and spurious air currents. The tray is *a vertical, metal, ladder type tray, 3" -

deep,12" wide, and 8' high. Multiple lengths of cable are arranged in a single layer filling at le:.t 3 the center six inch portion of the tray with a separation of approximately 1/2 the cable diameter between each cable.

The flame source is a gas ribbon burner manufactured by the American Gas Furnace Company -- 10" wide, 11-15 drilling ribbon type Cat. No.

10 X11-55 with a Venturi mixer Cat. No. ? 4-18 (2 psig max. ). The

,; burner is mounted horizontally such that t'ae flame impinges on the specimen midway between the tray rungs and so that the burner face ,

is 3" behind and approximately 2' above the bottom of the vertical tray. Due to its uniform heat content, natural grade propane is preferred to commercial gas.

Under dynamic conditions, the propane pressure is -2. 6 0. 3 cm of water at the supply side of the Venturi mixer. The air pressure it, set at 4. 310. 5 cm of water. If commercial gas is used the gas and air pressures shall be -0. 9 0.1 c.nd 5. 6 0. 5 cm of water, respectively. In practice the flame length is approximately 15 inches long when measured along its path.

The gas burner is ignited and allowed to burn for 20 minutes. The impingement temperature is recorded throughout the test. Length of time the flame persists after the burner is shut off (afterburn),

jacket char distance, and insulation damage distance are measured and recorded.

Evaluation: Cables which propagate the flame and burn the total length of the Cables which self-extinguish tray above the flame source f ail the test.

when the flame source is removed pass the tet t. Cables which continue to burn after the flame source is shut off should be allowed to burn in order to determine the extent.

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15 kV Okoguard Shielded Okolon f

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Specimen: (A) 1/C250MCM(37x)BC,extrudedstrandscreen,.220Okoguard insulation, extr. insulation screen, .005 tinned copper tape,

.080 Okolon jacket (FL-141, 228)

(B) 3-1/C triplexed 250 MCM (37x) BC, extr. SS, .220 Okoguard insulation, extr. insulation screen, .005 TC tape, .080 Okolon jacket (FL-196)

(C) 3/C #4/0 (19x) BC, extr. 55 175 Okoguard insulation, extr. '

insulation screen, .005 TC tape, cabled with fillers, .110 Okolon jacket _(FL-96)

Results: A B C

96h minutes 0 0 0 Afterburn, 23 25.5 )

Jacket Damage, inches 21 Core. Damage, inches 0 0 0 No No No Propagate Avg.

of 2 tests f

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[!@ , -{C Test: .IEEE Standard'383-1974,. Paragraph 2.5-Flame Source: ' Ribbon Gas Burner Sample Construction: 1/C #4/0 (19x) CC, strand screen,:.140" Okoguard' insulation,-insulation screen, .005" TC shielding tape, cable tape .

.080" Okolon Jacket-(FL-199, 200, and 201)

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Test Test Test 1 2- 3 Results: ,

Afterburn, minutes; seconds 1:05 0 0

i. 25 26 Jacket damage, inches. 28 Core damage, inches 12 4 12 NO NO NO

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.-(r.,g 0 7 THE! ' 8OKONITE COMPANY hwv h *rSov N APPENDIX 8 (Page 5) 1/C,5 & 15kV Okoguard Constructions Construction A: 1/C #2 AWG, extruded strand screen, .125" Okoguard insulation, ,080" Okolon jacket - non-shielded Construction B: 1/C, 4/0 AWG copper, extruded strand screen, .175" Okoguard insulation, extruded insulation screen, copper tape, . 080" Okolon jacket Flame: 70,000 BTU per hour Test Time, Flame Height, (Inches)

Minutes A B 1 27 27 2 20 25 3 33 24 4 34 27 5 33 26 6 33 27

')l 1

27) 7 32 28 8 29 28 9 29 28 10 28 28 11 28 26 12 30 27 13 29 26 14 29 26 15 29 26 16 30 27

! 17 30 29 l

18 29 27 19 28 32 20 28 34 Afterburn, min : sec 3:05 1:05 Core Damage, inches No Measured 27 Jacket Char, inches 25 29 Propagate No No

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1/C SkV Okoguard Shielded Okolon -

Specimen: ' A - 1/C 750 MCM (61 X) bare copper, extruded strand screen, . 090" Okoguard, extruded insulation-screen, 085" tinned copper, cable tape, .080" Okolon jacket (FL-179)

B - 1/C 250 MGM (37 X) bare copper, extruded strand sereen, .115" Okoguard,. extruded . insulation screen, . 005" tinned copper, cable tape, .080"

. Okolon jacket (FL-132)

Flame Source: .70,000 BTU / hour - - - 20 minute application

,si$x .

s-- Results:

A -

B O

Impingement Temperature, F 1400 to 1500 1400 to 1490 Afterburn, minutes 0 -1 Jacket Damage, inches 26 26 Core Damage, inches 0 12 O

4

- - - - - - - _ _ ~ _ _ - - _ _ - .

m g THE OKONITE COMPANY Arreey Newhv oms APPENDIX 8 (Page 7)

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FLAME TEST DATA l

, Test: IEEE 383-1974, Paragraph 2.5 Flame Source: Ribbon Gas Burner, 70,000 BTU /hr. j Construction: 1/C #2/0 WG, 19X BC, SS, .115" Okoguard,

.030" Semicon, .005" Cu Tape, Cable Tape,

.080 Okolon. l Test Results:

A B C Measured BTU rate 71,051 71,051 70,116 Afterburn, min: 10 11 9

- ~'s Jacket Damage, in. 24 25 23 Core Damage, in. 14 15 14 )

No No Propagation No 1

)

n_-----_-_--______ __ _ _ _ _

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+ ~ - 4- f THE OKONIT3 COMPANY w %Wcmas APPENDIX 9

. t %. INSULATION RESISTANCE MD - 1000 ft. _

Okoguard Cable With T-95/No. 35 Splice Unaged Aged Time 6 Temperature 2.1 E4 3.0 E4 Initial 0 68 F 13.5 E4 >14.7 E4 Pre LOCA 0 60 F 1.5 EO 0.88 E0 First Peak 0 344 F

6.0 El 5.3 El Between Peaks a 208 F 7.5 El 5.1 E-1 2nd Peak 0 345 F 8.3 E-1 6.2 E-1 Plateau 6 335 F 1.05 EO 9.5 El Plateau 9 315"F 5.1 E0 <1.5 E-3 at 50V*

After 1 day, 265 F E-3 at 50V*

4.05 E0 <1.5 After 4 days, 265 F 3.6 El <1.5 E-3'at 50V*

After 11 days, 212 F I 4.5 El <1.5 E-3 at 50V*

After 17 days, 212 F 4.9 El <1.5 E-3 at 50V*

After 25 days, 212 F d After 29 days, 212 F 5.1 El <1.5 E-3 at 50V*

3.75 E3 <1.5 E-3 at 50V*

After 30 days, 80 F 5.7 El 8.4 El After 35 days, 212 F 6.0 El 9.8 El After 49 days, 212 F 7.5 El 1.1 E2 After 63 days, 212 F 9.0 El 1.3 E2 After 77 days, 212 F 7.5 El 1.1 E2 After 91 days, 212 F 9.0 El 1.3 El After 105 days, 212 F 9.8 El 1.3 El After 121 days, 212 F 9.9 El 1.4 E2

,5 After 128 days, 212 F 5.25 E3 4.99 E3 After 130 days, 80 F 4

After the sampic was removed from the test vessel it was determined that the poor IR was the result of a terminal failure. Sample was reterminated and test was continued All 1R tests were perfored at 500 volts dc unless othentise indicated.

1 Prepared by:. L CMafc4 3!2 f7 J. R. ancejosi p p j-N Approved by:

v J. 5. l.asky

P Page 1 of 2 h' THE %, OKONITO Neww crwe COMPANY APPENDIX 10 AN04ALIES Anomalies which occurred during environmental qualification test are listed below.

(1) The rise time to 280 F was approximately 30 seconds. ;

Discussion: IEEE 323-1974 Appendix A, Figure A1, suggests a 10 second rise to 280 F. This anomaly was not deemed significant since electrical cable is a passive electrical device (i.e., no moving parts). As such, rate of temperature rise is not considered significant.

(2) A temperature excursion occurred during the 79th hour. The test vessel temperature rose from 265 F to 293 F and remained at this temperature for approximately five hours.

Discussion: This event made the IDCA sequence more severe than designed.

~

No adjustment to the test was necessary.

(3) The continuous stress voltage was off for the first twelve hours at 265 F on both the aged and unaged samples.

Discussion: The twehe hour loss of voltage on both samples is less J than 0.4% of the total test time and is therefore considered in- )

significmt.

(4) The continuous stress voltage and current was disconnected from the aged sampic from the twelve hour point during the 265 F plateau until the thirty day point.

Discussion: The voltage and current load was disconnected because of a termination failure. The termination failure could not be cleared until the vessel was unloaded at the thirty day point. The aged specimen was reterminated, passed the 30 day " Post LOCA Withstand Test" and returned to the test vessel for continuation of the test.

Environmental qualification was not jeopardized due to this un-scheduled event because of the following reasons:

(a) During the time voltage was applied, the test voltage was much higher than required. The test voltage was SkV phase to ground. IEEE 383 requires that the specimens be en-ergized to rated voltage. The cables rated voltage is 5kV phase to phase. The required test voltage is 2.89kV phase to ground (shicid). Although the test under voltage stress was reduced by approximately 29/130 or 22.3%, the voltage stress was 73% higher than required. The higher stress more than compensates for the reduction in time.

(b) If the specimen was in a marginal condition, it could be )

argued that the 29 days under an electrical load could pos-sibly have been the difference between passing or failing the test. However, this was not the case. An examination

~

.s X, y _

APPENDIX 10 (Continued)

..-- s

Eij ,'

of the electrical and physical measurements reveals that the

. sample was in good condition with plenty of margin at the .

end of the-130 day test. In particular, insulation resist-ance measurements of the unaged and aged specimens during and after IDCA were similar. At 212*F the insulation resist-ance was in the hundred megohm-1000 ft, range., Post-LOCA SIR corrected to 60 F was approximately 40,000 M chms-1000 ft.

-The guaranteed value for this insulation when new.is 50,000.

During the Post-1DCA 40x0D bend withstand test, a chstging current of only- 2.5mA was measured. This value is similar to that expected from new cable. In addition,-the rising velt-age breakdown strength for the aged specimen was 48kV, approx-imately 16 times higher than the phase to ground rating of the cable.

Physical tests also demonstrate the margin availtble at the end of the test. Both the unaged and irradiated and the thermally aged and irradiated specimens had similar tensile and clongation' values prior to IDCA (i.e., after irradiation to 2 'x 10' rads) . Tests performed after LOCA sinulation demonstrate similar changes between the unaged sample, which was continuously loaded, versus the thermally aged samples which saw the interruption of the electrical load.

Thermally

,o Unaged Aged

,Qy After 2 x 10 8 rads 113 Tensile, % Retention -121 Elongation, % Retention- 33 30 After IDCA Simulation 95 Tensile, % Retention 103 41 52

. Elongation, % Retention Prepared by: U40 $ 3)27!37 J. R. Cancelosi' /

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, m --u COMBENY- January 21,1985:

n. ess se $.l ENGINEERING REPORT NO. 407 LOCA QllALIFICATICN OF 600 VCET SPLICE _S Introduction At a client request LOCA tests were perfoned on in-line splices made to the standard Okonite instructions for 600 voit ntclear station cables. Sp11ces were hand-wrspped taped splices utilizing akanite T-95 insulating tapes.

No. 35 jackting tape and T-95 nuclear grade cement. Qualification was based on both IEEE 323-1974 and IEEE 383-1974 requirements as modified within thir, report since this was a test of splice performance and not the cable used in splicing.

Discussion

'Ite format of this report complies with each paragraph in IEEE Standard 383-1974, Section 1.4 " Documentation". Section 1,4 documents the specified in section 1.3, " Type Tests as Qualification Nethod"parsmeters.

Included in this report are six appendices which further clarify Okontte's test procedurcs and results. These appendices are as follows:

Appendix 1 Okonite Instmetions D-11485 2 40-Year Life Detail Document 3 Okonite's LOCA and Test Profile 4 Radiation Certification 5 LOCA Autoclave Drawing 6 List of Equignent Documentation of Test Procedures --

IEEE 383, Section 1.4 1.4.1 Documentation 1.4.1.1

Description:

200nV, 1/C 86, 7X AC, insulated with extruded n.055" Okonite (EPR) and .030" Okolon (CSPB , 90*C rated conductor temperature with 130*C overload ra) ting. Four 7 ft. i sampics: 2 non-aged, 2 thermally aged. '

i 1.4.1.2 Description of Splico: In-line straight splice was made per (konito Instructions and Drawing D-11485, Appendix 1 l

Exception to the instructions was that a conjression connec-f ter, TSB Sta-Kon, Catalog No. 54505 (blue), was used for the conductor connections. Ono set, consisting or one aged and one unaged sanple, was propared with penciled insulation and another set with square cut ir.sulation including a gap botveen insulation and connector.

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.. 4 vs s f Engineering Report No. 407 January 21, 1985' It should be noted that the above cable construction is a 2kV rated cable. However, the splices made are 600 volt splices. 'Iherefore, all thicknesses are based en a 600 voit cable. Tape thickness does not vary considerably between the 600V and 2kV splice. At 600 volts a 1/C #6 AWG would have a .045" of Okonite insulation and .030" of Okolon jacket vs. 055" cf Okonite insulatien and .030" of Okclon jacketfor2kV. Therefore, the tape thickness would be .150" for 600V vs. 170" for 2kV.

During LOCA testing the cable and splice were energized as a 600 volt cablo; 600 volts - 80 nmps. Cable perfonnance has been prevously cpalified.

1.4.1.3 Identification of environmental features:

Preaging: Aged snrples were aged for 3 weeks 0150*C in a forced draft circulating air oven. Tecperr.ture was manitored continuously by a chart recorder and periodically with mercury theimzleter.

The T-95 insulating tape is an EPR based thermoplastic material. Since the t:.pe is therraoplastic (not vulcanized),

it is not possible to perform the elevated temperature accelerated agir.g tests necessary to develop an Arrhenius t>Tc plot for T-95.

Since the EPR base in T-95 tape is similar to the T.PR in other Okonite insulations which are themoset materials, the aging characteristics are expected to be essentially the same and themal aging is performed in acconhnce with -

Appendix 2. ,

i Purthemore, sirce the splice is always associated with cable, it is sufficient to show that:

(1) The splice when treated to the sanc enviroiracntal factors as the cable prior to LOCA simlation per-foms satisfactorily after the LCCA.

(2) The splice does not effect the ability of the cable to perfom its regiird functinn after environmental treatment and LOCA simlation.

Therefore, to reiterate, the EFR insulating materini characteristics are known and previously qualified. Aging to the insulation life and passing this 10CA test proves rplicing tape and cable acceptability when used together.

h diation: "he samples received a minirm doso of 200M rads of garuna radiation at a rate of loss than 1 negarad per hour. See attached certir2cution (Appendix 4) .

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' 1 Intended Temperature 6 Pressure Environment - . .

Temperature:, _ 2 peaks at- 545'C for 3 hrs. each- . .

- a, 3 hrs. at 335'F 4 hrs. at 315'F

~

)

3 days 9 hrs. at 265'F- 126 days at'212'F -

Fressure: - .

2 peaks at 114 psi for 3 rs each-

. 3 hrs, at 95 psi -4 hrs. at 69 psi .

3. days 9 hrs. at 24 psi 120 days at 0 psi 1 Actual temperature and pressure achieved are:

given in Appendix 3. .

Relative knidity: Saturated steam conditions throughout profile. ,

_ Chemistry of Spray Solu _ tion: per IEEE 323, Appendix A, Table A-1 0.28 molar H BO, 0.64 molar Na:S 0 NaCH approximately. 59% to makh a pH of 10.5 at' 77'F dissolved in tap water Spray rate of minimum 0.15 (gal / min)ft2 of surface area of the test vessel 1.4.1.4 Specific Performance Requirements 9

(a) Sample must maintain electrical load throughout entire LOCA . ,

profile. ~

~

(b) Sampic raast withstand the 30 day and 130 day Post-LOCA withstand -

tests (80 V/ mil, 5 miraites).

(c) Sample rust prwide a margin of assurance.

1.4.1.5 Test Program

- (a) Sample selection

(b) Pre-tost characteristien -- to determine if samples are rep-resentative samles; 1R and voltage withstand 50 V/ mil ac-5 min.

Th mal aging of two samples: 3 weeks at 150'C followed by I

(c)

IR and electrical withstand test 80 V/mit ac - 5 mi.1utes.

(d) Irradiation of samples: 200M rads

(e) Pre-LOCA cicctrical characteristics -- to detornine the candition of samples prior to LOCA. IR and electrical withstand 80 V/ mil ac-5 ntnutes.

(f) Installation of samles into LOCA vessel.

(g) Tre-LOCA insulaticn resistance measurement and 5 minute 80 V/ mil ac withstand test, to detemine if samles are danoed during installation.

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(i) Initiation of LOCA sinulation (see Profile - Appendix 3),

(j) Wintenance of LOCA profile thru 30 days with IR meamsrements taken-as shoc in Profile. (See Appendix 3)

(k) 30 day Post-LOCA withstand test, 60 V/ mil ac - 5 minutes.

(1) Additional 100 days at 212'F. IR measurements taken periodically.

(m) 130 day Post-LOCA withstand test, 80 V/ mil ac - 5 minutes.

Electrical tests perfonned are not requirements of IEEE 323 or 383.

1.4.1.6 Test Results (a) All saJuples maintained the electrical load as given in paragraph 1.4.2.4 throughout the entire profile.

(b) All- sanples passed the 30 and 130 day Post-LOCA with-stand tests, 80 V/ mil ac for 5 minutes izutersicri in water.

(c) A margin of cssurance was demonstrated by:

(1) Each sample passed the Post-LOCA withstand test twice, once at the 30 day point and again at.the 130 day point.

(2) Each sangle passed all withstand tests as described -

in paragraph 1.4.1.5.

Margin may also be demonstrated when the enviresmental parameters of this test are compared to the postulated 1.0CA parameters of a particular nuclear station.

1.a.2 Test Program Outlined 1.4.2.1 Each sample was coiled into approximately a 22-inch coil.

Tac ends were IcIninsted for testi.ng. 'No of the samples wre t.hermally aged prior to radiation, all samples were irrcdiated in this configuration. An epoxy-type terrinal was instc11ed on each end. We sarples were then installed in the LOCA vessel. The samples were mounted around a vertical mandrel which was made out of 1" x !" expanded stec1. The physical arn.ngement is shown in the attached Test equipment utilized is included diagram,d:.x in Appen 6. Appendix 5.

1.4.2.2 The test progrrn and sequence of envitenmental factors are cutlined in Secticn 1.4.1..; above.

1.4.2.3 Type G Location of all enviro nental and cable monitoring sensors for each variable.

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Appendix 4 hermal Agingi Forced draft cinulating air _ oven .

~

monitored by a themoccuple in rear of the even ecnr.ected to a centinuous readout chart' recorder.

l Terprature during LOCA: Monitored by themocouples mounted inside the vessel connected to a pyrmeter.

Pressure: Monitored by Taylor Instrument panel'.

Spray Solutient pli monitored initially with pH test paper and test liquid. Flow rate monitomi by flow-neter made by Okonite. (Pressure measured before and after an orifice.)

Relative Ibnidity_: A one to two inch reservoir of liquid was maintained within the test vessei.. (IEEP.

323, Appendix C.) Steam pressure was allowed to confom to saturated cmditions. (100%

relativehumidity.)

1.4.2.4 600 volts was applied to each sanple, 80 nelps were applied.

initially. As temperature profile changed the current was re-adjusted to 60 anps.

' Voltage and currer.t wen applied to the ends of the camplec .

which protmded through the vessel.

1.4.2.5 During environmental exposure, insulation resistance measurcrnents uro performed periodien11y.

I 1.4.2.6 Following the 130 day LOCA exposure, all sanples were given an 80 volt / mil 5 min. ac withstand test while~ immersed in WEECr.

1.4.3 TcSt Results 1.4.3.1 The intended envirortnental sequences were achievod. Demal aging was performed with the temperature monitorod by thermo-couple. The radiation requirements were met as shown in Appendix 4 The temperature pressure profile as shown in IET.F, The initial rise to323380 Agnhendix A - 10 was within Figure A-1 The seccads. wastemperature achieved. rise to 340*F took appmximtely 2 minutes which was well within the 5 minute reg.nrcrent. Actual temperature and pressures ,re shown in Appendix 3 of this report.

The test duration wa:; extended a total of four additional days. This additional tine canpensated for spray pump dwn-l time.

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I:ngineering Report No. 407 ' Ja22ac 21,1985 ,.j q

1.4.3.2 (u) The aged and unaged sa::ples maintained the'.r elec-trical lead for the canplete test.

(b) All four caq les withstood the 30 day and 150 day j Post-14CA Withstand tests.

(c) A margin of assurance was demonstrated - See Section 1.4.1.6(c) above.

1.4.4 Test Evaluation Table I lists the results of all tests perfomed during testing.

Insulation resistance measurements were taken periodically, and five minute ac voltage withstand tests were perfoned at various i critical times during the test to check integrity of the sar.ples.

In total the splice sampics passed six 5 minute 3.75kV ac (80 V/

mil x 47 mils) voltage withstand tests. Typically insulation-resistance values decreased for all splice sa g les. However, review of Table I dna indicates that insulation resistance change fran initial to the end of 1.0CA was small. The electrical load of sectica 1.4.2.4 was maintained throughout the entire profile.

Ihorefore, tho test data demonstrates that the splice sanples were in good condition.

Conaidoring the coverity and length of this i.0FA f)mlification Test, these sami es l are considered to have passed the DBE-IACA qualificatic" te.st since they meet the requirements specified in EEE 383-1974 and 323-1974, and provide a margin of assurance.

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~ Engineering Report No. 407.. . Jamary 21, 1985 TABLE I.

1N5'JL\T10N RESISTANCE AND WI'ntSTAND TESIS 0383E . . 03a3F .

Splice to Drawing Splice to Drawing D-11485 D-11485.

Temp., Penciled Insulation Square Cut Insulation

'F E-2 _ '_h "F e-a r-3 Initial 1R-me2ches 66 6.4x10' 7.2x10' 5.8xtD' 6.ox105 3.75W ac - all pass Withstand test 80 V/ mil-5 min.

IR after 'Ihemal Aging 3 uks.150'C 74 ----

9.0x108 -- -

7.sx10s withstand test 80 V/ mil-5 mit 3.75kV ac - both pass IR after Irradiation Exposure 200M rads 5.2x105 2.0x105 4.0x105 2.6x105 Withstand test 80 V/ nil-5 min. 76 3.75kV ac - all past 70 4.8x105 2.5x10s 2,8x10s 1.9x108 IR Prior to Start of LOCA DEE 3.75kV ac - all pass Withstand test 80 V/ mil-1 min.

IR 1,0CA Profile 600V ac -- 80 mys -

Continuous Stress and Load ,

3 hours3.472222e-5 days 8.333333e-4 hours 4.960317e-6 weeks 1.1415e-6 months 345 1.45x10' 2.6x10 8 1.tx10 8 2.5x10 8 5 hours5.787037e-5 days 0.00139 hours 8.267196e-6 weeks 1.9025e-6 months 212 1.5x10' 2.8x10' .-l.exte' 2.4x10' 8 hours9.259259e-5 days 0.00222 hours 1.322751e-5 weeks 3.044e-6 months 345 1.3x102 .2.8x10 8 1.3Sx10' 2.0x10'-

11 hours1.273148e-4 days 0.00306 hours 1.818783e-5 weeks 4.1855e-6 months 335 1.6x10' 3.2x108 1.tx10' Z.2x108-315 3.5x104 6.0x108 3.oxtos 5.0x108 4 15 hours1.736111e-4 days 0.00417 hours 2.480159e-5 weeks 5.7075e-6 months 1.4xtes 3.0x10s 1 day 265 1.45x103 3.3x108 4 days 265 1.6x10' 4.0x10' 1.6x10' 3.5x108-8 days 214 1.1x10' 2.6x10- 1.7x10' 2.2x10' 1

21 days 214 1.3x10" 2.8x10' 1.5x10' 1.4x106 4

30 days 214 1.2x10* 2.4x10' 1.9x10' 1.3x10' j 2.1x10f 1.9x10s 1.6x108 30 day Post LOCA Simlation 70 1.6x105

] Withstand test 80 V/ mil-5 min, 3,,4V ac -

all pass-

. 213 1.6x10' 2.4x10* 2.0x10' 1.8x10" 36 days 2.8x10' 4

42 days 213 2.Dx10' 3.5xt0"4 2.6x104

.l 212 2.0x10' 3.0x10 3.0x10' 2.0x106

56 days s0 days 232 1.4x10' 2.cx10' 2.2x10* 1.7x106 212 1.8x10' 3.0x10' 2.5x10* 1.9x10 6

.j 84 days 2.6x10' 213 2.0x10' 4.5x10' 2.9x10' 98 days 212 2.5x10' 4.0x13' 3.0x10' 3.ox10'

' 112 days 4.0x10' 3.sx10' 126 days 212 2.3x10' 5.0x10'

212 3.5x10' 6.Sx10' 4.5x10' 3.5x10' 130 days W .- 60 2.0x10' 3.2x10' 3.5x10' 2.cx10 5

' 330 days 3.75kV ac - 5 minutes Post LOCA Simulaticu all pass 4

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