ML051230078

Attachment 11, Sensors in the String Assembly Before & After Installation, Test Procedure, GE Report 26A6484, Revision 2, April 22, 2005

ML051230078
Person / Time
Site:	Quad Cities
Issue date:	04/22/2005
From:	David Chan General Electric Co
To:	Office of Nuclear Reactor Regulation
References
B13-D001 26A6484, Rev 2
Download: ML051230078 (20)

Text

ATTACHMENT 11 "Sensors in the String Assembly Before & After Installation," Test Procedure, GE Report 26A6484, Revision 2, dated April 22, 2005 .

26A6484 SH NO. I wY GENuclearEneiry REV. 2 OF 19 IDENT:

REVISION STATUS SHEET DOCUMENT TITLE SENSORS IN THE STRING ASSEMBLY BEFORE & AFTER INSTALLATION LEGEND OR DESCRIPTION OF GROUPS TYPE: TEST PROCEDURE FMF: QUAD CITIES 2 I - DENOTES CHANGE

-MPLNO: B13-DOOI SAFETY-RELATED CLASSIFICATION CODE_Q REVISION IC FEB 07 2005 0 RMCN05622 I V AP 0ZIZI RJA RMCN06058 ENGR: V RAMANI

. APR 22 2005 T 2 JC LAW RJA RMCN06089 ENGR: JC LAW

._ PRINTS TO MADE BY APPROVALS GENERAL ELECTRIC COMPANY 11/08/04 02/07/05 175 CURTNER AVENUE DH CHAN V RAMANI SAN JOSE CALIFORNIA 95125 CHKD BY: ISSUED 26A6484 FEB 07 2005 NA RJ AHMANN CONT ON SHEET 2 MS WORD (2000)

26A6484 SH NO. 2 GENuclearEnetry REV.2 OF19 Table of Contents

1. SCOPE .................................................. 3

2. REFERENCE DOCUMENTS .3

3. ACCESSORIES REQUIRED .3

4. SENSOR TEST PROCEDURE PRIOR TO INSTALLATION 4

5. SENSOR TEST PROCEDURE AFTER INSTALLATION ............................................................... ;.8

6. SENSOR RESISTANCE MEASUREMENT AFTER VESSEL HEAD CLOSURE .0 List of Figures Figure 1. Strain Gage connection................................................................................................................ 11 Figure 2. Strain gage test box .12 Figure 3. Accelerometer/Pressure Transducer Connection .13 Figure 4. Strain gage connection for sensor response test .14 List of Tables Table 1. Resistance Measurement Test Pre-Installation Data Collection Form .15 Table 2. Resistance Measurement Test Post-Installation Data Collection Form .16 Table 3. Strain Gage Post-Installation Functional Test Data Collection Form .17 Table 4. Accelerometer/Pressure Transducer Pre-Installation Functional Test Data Collection Form . 18 Table 5. Accelerometer/Pressure Transducer Post-Installation Functional Test Data Collection Form .... 19

26A6484 SH NO. 3 V GENuclearEnerjy lREV. 2 OF 19 l

1. SCOPE This specification describes the procedures for testing the strain gages, pressure transducers and accelerometers to be used on the Quad Cities instrumented steam dryer. When the sensor strings are received at the steam dryer final assembly facility for installation, the sensors will be tested for insulation resistance, sensor element resistance and functionality. Similar testing will be performed after completion of the sensor installation and the insulation resistance and sensor element resistance tests will again be performed after the dryer is installed in the RPV and the vessel head is closed.

Work step sequences in this procedure can be changed or altered at the discretion of the GE Project Manager or Responsible Engineer, provided they do not affect quality or violate any approved specifications.

2. REFERENCE DOCUMENTS

a. Penetration Bolt A Sensor Strings, 352B2191

b. Penetration Bolt B Sensor Strings, 352132192

c. Penetration Bolt C Sensor Strings, 352132193

d. Instruction Manual for Kyowa Signal conditioner model MCD-16A.

e. Instruction manuals for Vibro-meter (VM) signal conditioner UVC689, Charge converter IPC629 and Galvanic separator GSI 130.

f. Sensor data sheets provided with sensor strings.

3. ACCESSORIES REQUIRED

a. Digital Multi Meter, HP3478A or equivalent

b. Strain gage test box for resistance measurement

c. Pressure transducer/accelerometer test box for resistance measurement

d. Signal conditioner for pressure transducer/accelerometer (for 2-channels), Vibro-meter UVC 689 and ABE-022 with input/output cables, transducer interconnecting cable, Galvanic separation unit GSI-130 and Charge converter IPC629.

26A6484 SH NO. 4 W .GENuclearEnergy REV. 2 OF 19

e. Strain gage signal conditioner (for 2-channels), Kyowa MCD-16A with monitor DPE-71A, strain gage amplifier DPM-71A, bridge completion board and input/output cables and transducer interconnecting cables.

f. Oscilloscope, dual channel

4. SENSOR TEST PROCEDURE PRIOR TO INSTALLATION

4.1 General

Take precautions not to damage the sensors, sensor leads or conduits while performing these tests. Remove the sensor protective covers carefully before testing and re-install them when done. Inspect the sensors and cables for any sign of mechanical damage before and after installation.

4.2 Strain Gage Test Procedure: The strain gages on the sensor string assembly are half bridge type which contains a 120-ohm active gage element and a 120-ohm dummy gage element enclosed within a single sealed housing. These elements are electrically connected as shown in Figure 1. When the strain gage is flexed, the electrical resistance of the active element changes slightly; the electrical resistance of the dummy element, however, remains essentially constant. The sensor leads run through a three-conductor mineral insulated (MI) cable and terminate to LEMO size-1 connector with three contacts. First, the resistances of the active and dummy elements will be measured and then the insulation resistance between the strain gage leads and the outer shield will be measured. In order to avoid potential damage to the delicate sensing element due to handling, no other tests will be performed on the strain gages prior to installation.

4.2.1 Resistance measurement:

a. Connect LEMO connector of the strain gage test box (Figure 2) to the LEMO connector of the strain gage. Alternatively, if a LEMO connector adapter is available to expose all three the strain gage leads from the LEMO connector (pin1 wired to Red lead, pin2 wired to White lead and pin3 wired to Black lead), it can be used instead of the strain gage test box.

b. Connect the Digital Multi-Meter (DMM) between Test Point (TP)-1 (pin I -

Red) and TP-2 (pin 2 - White) to measure the resistance across the active element and record the values (Table I or similar format).

26A6484 SH NO. 5 W GENucearEneiry REV. 2 OF 19

c. Connect the DMM between TP-2 and TP-3 (pin 3 - Black) and measure to get the resistance values across the dummy gage and record the values.

d. Measure the resistance between TPl and TP3 to measure the combined active and dummy gage resistances and record the values.

e. Connect the DMM.between the Shield (MI cable outer housing) and any one of the 3 test points to measure the insulation resistance. The measured value shall be greater than 1000 MegOhm. If the DMM does not have sufficient range, a Meg Ohm Meter may be used, making sure not to apply more than lOVolt +/-IV dc. Alternatively, the DMM can be used in the conductance measurement (nanoSiemens) setting if the IR measurement reading is over the range.

f. Compare the resistance readings with the measurement taken prior to sensor string shipment. If the readings deviate by more than 10%, contact the Responsible Engineer for direction on how to proceed.

4.3 Accelerometer Test Procedure The piezoelectric accelerometers on the sensor string assembly are Vibro-meter model CA 901 with a charge sensitivity of :-I-0 pC/g. They are charge type devices consisting of a crystal and twin conductor mineral insulated cable. The twin leads terminate to a LEMO size- I connector with two contacts.

4.3.1 Accelerometer insulation resistance measurement:

a. Connect the accelerometer test box LEMO connector to the LEMO connector on the MI cable end of the accelerometer. Alternatively, if a LEMO connector adapter is available to expose the two leads of the accelerometer from the LEMO connector, it can be used instead of the test box.

b. Connect the DMM between TPl (pinl) and TP2 (pin2). Measure the insulation resistance (IR). Do not apply more than 10 Volt +1- IV dc. The resistance value shall be greater than 1000 Meg Ohms. If the DMM does not have sufficient range a Meg Ohm Meter can be used, making sure not apply

26A6484 SH NO. 6 GENucear&7&W REV. 2 OF 19 more than lOVolt +/-IV dc. Alternatively, the DMM can be used in the conductance measurement (nanoSiemens) setting if the IR measurement reading is over the range.

c. Measure insulation resistance between TPI and the Shield (MI cable outer housing).

d. Measure insulation resistance between the TP2 and Shield

e. Record all the values (Table I or similar format) and compare with previous measurements. If the readings deviate more than 10%, contact the Responsible Engineer for direction on how to proceed.

4.3.2 Accelerometer Functional Test:

a. Connect the LEMO connector on the accelerometer MI cable to the Vibro-meter signal conditioning unit consisting of charge converter, galvanic separation unit, amplifier and the rack as shown in Figure 3.

b. Set the V-M UVC 689 Signal Processor O/P Select switch to position 1, Gain switch to X 1 and Gain dial potentiometer to 1.0

c. Connect the Amplifier output to an Oscilloscope and set the oscilloscope dial to lV/ div and the sweep dial to 2ms/div. Alternatively, the amplifier output may be connected to a Data Acquisition System.

d. Grasp the accelerometer steady and tap on the top of the sensors gently with a fingernail or with the tip of a pen.

e. Each tap will produce a pulse either in the positive or negative direction. All accelerometers should respond in the same direction when tapped on the top of the sensors. Observe and record (Table 4 or similar format) whether or not a response was detected and the direction of the response. If a sensor response is not detected or if the response direction is opposite from the rest of the sensors, contact the Responsible Engineer for direction on how to proceed.

26A6484 SH NO. 7 d GENuclearEnergy REV.2 OF19 4.4 Pressure Transducer Test Procedure The dynamic pressure transducers in the sensor string assembly consist of two types of sensors. They are Vibro-meter model CP 104 and CP 211 'with a charge sensitivity of -1 90 pC/Bar and -25 pC/Bar respectively. These transducers are piezoelectric devices consisting of a crystal and twin conductor mineral insulated cable. The twin leads terminate to a LEMO connector with two contacts.

4.4.1 Pressure Transducer Insulation Resistance Measurement:

a. The pressure transducer resistance measurement procedure is identical to that of the accelerometer. Follow 4.3.1.a through 4.3.1.e for both types of pressure transducers.

4.4.2 Pressure Transducer Functional Test:

a. Connect the LEMO connector on the MI cable of the pressure transducer model CP 104 to the Vibro-meter signal conditioning unit consisting of charge converter, galvanic separation unit, amplifier and the rack as shown in Figure 3.

b. Set the V-M UVC 689 Signal Processor O/P Select switch to position 1, Gain switch to X I and Gain dial potentiometer to 1.0 (minimum setting) when testing pressure transducer model CP 104. When testing pressure transducer model CP 21 1, set the Gain dial potentiometer to 8.0.

c. Connect the Amplifier output to an Oscilloscope and set the oscilloscope dial to 0.2V/ div and the sweep dial to 2ms/div.

d. Blow a puff of air on to the transducer diaphragm. All pressure sensors response should be same direction. Observe and record (Table 4) whether or not a response was detected and the direction of the response. If a sensor response is not detected or if the response direction is opposite from the rest of the sensors, contact the Responsible Engineer for direction on how to proceed.

26A6484 SH NO. 8 S GENuclearEnetgy REV. 2 OF 19

5. SENSOR TEST PROCEDURE AFTER INSTALLATION

5.1 General

Take precaution not to hit the strain gages or other sensors as well as the sensor leads and conduits while performing these tests.

The responses for these tests can be recorded on to a magnetic tape recorder or digital storage media.

5.2 Strain gage test procedure:

After the strain gages are installed on the dryer, the following procedures should be followed to confirm the integrity of the sensors.

5.2.1 Resistance measurement:

Follow the procedure outlined in steps 4.2.1.a through 4.2.1.f. Record the values (Table 2 or similar format) and compare with the previous measurement. If the readings deviate more than 10%, contact the Responsible Engineer for direction on how to proceed.

5.2.2 Strain gage response test:

a. Connect the strain gage LEMO connector to the Bridge box through an intermediate jumper cable. Connect the bridge box to Kyowa strain gage signal conditioning amplifier rack as shown in Figure 4.

b. Connect the amplifier output to an oscilloscope and set the oscilloscope to 0.2 V/div and the sweep to 2 ms/div.

c. Set the strain gage amplifier Range to 2 X 100 pe, LPF to 1 Khz.

d. Balance the bridge by pushing Balance button twice quickly.

e. Gently blow warm air to the strain gage for about 5 to 10 seconds using a hair dryer or a heat gun with low heat setting and observe the response on the oscilloscope at the same time. Take precaution not to overheat the sensor and keep the heat source at least a foot away from the sensor. The sensor should respond to the heat and the trace will deflect up or down (Table 3 or similar format).

26A6484 SH NO. 9 W GENuclearEnety REV. 2 OF 19

f. Allow the sensor to cool a few minutes and, using a medium size hammer with a soft tip, impact the dryer a foot away from the sensor location while observing the response on the oscilloscope. The trace will deflect up or down a few'divisions (Table 3 or similar format). Take precaution not to hit the strain gage or other sensors as well as the sensor leads and conduits.

g. If there is no response from the sensor in steps e or f, contact the Responsible Engineer for direction on how to proceed.

5.3 Accelerometer Test Procedure:

After the accelerometers are installed on to the dryer, the following procedures should be followed to confirm the integrity of the sensors.

5.3.1 Accelerometer insulation resistance measurement:

Follow the procedure outlined in steps 4.3.1a through 4.3.1d. Record the values (Table 2) and compare with the previous measurement. If the readings deviate more than 10%, contact the Responsible Engineer for direction on how to proceed.

5.3.2 Accelerometer Functional Test:

Follow the procedure outlined in steps 4.3.2a through 4.3.2e. In addition, perform an impact test on the dryer as described in 5.1.2f and observe and record (Table 5) whether or not a response was detected and the direction of the response. If a sensor response is not detected or if the response direction is opposite from the rest of the sensors, contact the Responsible Engineer for direction on how to proceed.

5.4 Pressure Transducer Test Procedure:

5.4.1 Pressure Transducer Insulation Resistance Measurement:

a. Pressure transducer resistance measurement procedure is identical to that of accelerometer. Follow 4.3.1.a through 4.3.1.d for both types of pressure transducers. Record the values (Table 2) and compare with the previous measurement. If the readings deviate more than 10%, contact the Responsible Engineer for direction on how to proceed.

26A6484 SH NO. 10 W GENuclearEnety REV. 2 OF 19 5.4.2 Pressure Transducer Functional Test:

Follow procedure outlined in steps 4.4.2a through 4.4.2d for all pressure sensors with the exception of the three internal sensors, P13, P14 and P23, which cannot be reached to test. Optionally, a hair dryer can be used to blow cool air to observe the sensor response.

6. SENSOR RESISTANCE MEASUREMENT AFTER VESSEL HEAD CLOSURE 6.1 General A final resistance measurement will be taken to assess the condition of all sensors after the dryer is installed in the reactor, the vessel head is in place and the sensor leads are routed through the instrumentation nozzle. The resistance measurement procedures for strain gages, accelerometers and pressure transducers are described in Section 4.2.1, Section 4.3.1 and Section 4.4.1, respectively. All data shall be recorded and if there are deviations of more than 10% from the previous measurements, inform project manager and responsible engineer.

26A6484 SHNO. 11 GENuclearEneWgy lREV.2 OF19 l Active Gage Element 2 120 Ohms RL

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RL .

.a RL

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Dummy Gage MI Cable Element LEMO pin 120 Ohms number Strain Gage LEMO Plug Connection Figure 1. Strain Gage connection.

26A6484 SH NO. 12 w GENuclearEnergy REV. 2 OF 19 Micro-Clip Leads LEMO Mini-Gator I,-

Receptacle Clip Lead II II LI Figure 2. Strain gage test box

26A6484 SH NO. 13 S GENuclearne REV. 2 OF 19 Pressure Transducer I BNC (Optional)

Figure 3. Accelerometer/Pressure Transducer Connection

l 26A6484 SH NO. 14 w GENuclearEnergy REV. 2 OF 19 Kyowa Strain gage Signal conditioner, MCD-16A and DPM-71A Figure 4. Strain gage connection for sensor response test

26A6484 SH NO. 15 w GENulearney REV. 2 OF 19 Table 1. Resistance Measurement Test Pre-Installation Data Collection Form Resistance Measurement Test (Pre-installation)

Strain Gages Pressure Transducers I Accelerometers Sensor ID Test Points 1-2 Test Points 2-3 Test Points 1-3 Insulation TPI-TP2 Shield-TP1 Shield-TP2 Data Collected By: Signature:

Verified By: Signature:

Date Performed:

Test Equip., Serial No. & Calibration Due Date:

26A6484 SH NO. 16 w GENuclearEnergy REV. 2 OF 19 Table 2. Resistance Measurement Test Post-Installation Data Collection Form Resistance Measurement Test (Post-installation)

Strain Gages _Pressure Transducers IAccelerometers Sensor ID Test Points 1-2 Test Points 2-3 Test Points 1-3 Insulation TP1-TP2 Shield-TP1 Shield-TP2 4 4 4 4 4 4- 4-

.4 4 4 4 4 + +

4 4 4 4 1 T T 4 4 + 4 4 1* 1-

-II 4I

.444 4 - *I 4 -4 4 4 4 + I-1 4 4 4- .4- .4 44 4 4 *I

-I 4 4 4 I + +

4 4 4 4 .4 -I-

-L I 4 4 4 + +

I Io Data Collected By: Signature:

Verified By: Signature:

Date Performed:

Test Equip., Serial No. & Calibration Due Date:

26A6484 SH NO. 17 X GENuclearEnergy REV. 2 OF 19 Table 3. Strain Gage Post-Installation Functional Test Data Collection Form Strain Gage Functional Test (Post-installation)

Tester Name(s):

Date Performed:

Strain Gages Sensor ID Heat Response Detected? (Y/N) Impact Detected? (YIN) i .

I 4 I 4 I 4 I 4 I +

4

. .

.I Data Collected By: Signature:

Verified By: Signature:

Date Performed:

Test Equip., Serial No. & Calibration Due Date:

41ft, 126A6484 SHNO. 18 l GENucearEneg REv. 2 OF 19 I Table 4. Accelerometer/Pressure Transducer Pre-Installation Functional Test Data Collection Form Accelerometer I Pressure Transducer Functional Test (Pre-installation)

Accelerometers Pressure Transducers Sensor ID Response Detected? (YIN) Response Direction (pos/neg) Response Detected? (YIN) Response Direction (pos/neg)

i. ,

Data Collected By: Signature:

Verified By: Signature:

Date Performed:

Test Equip., Serial No. & Calibration Due Date:

26A6484 SH NO. 19 GENuleaarEn erjy REV. 2 OF 19 Table 5. Accelerometer/Pressure Transducer Post-Installation Functional Test Data Collection Form Acceleronieter / Pressure Transducer Functional Test (Post-installation)

Accelerometers l Pressure Transducers Response Response Direction Hammer Impact Response Direction Response Response Direction Sensor ID Detected? (YIN) (poslneg) Detected? (YIN) (poslneg) Detected? (YIN) (poslneg)

Data Collected By: Signature:

Verified By: -Signature:

Date Performed:

Test Equip., Serial No. & Calibration Due Date: