ML20084E542

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Emergency Diesel Generator Engine & Auxiliary Module Wiring & Termination Qualification to IEEE-383-1974
ML20084E542
Person / Time
Site: 05000000, Shoreham
Issue date: 04/30/1984
From:
STONE & WEBSTER ENGINEERING CORP.
To:
Shared Package
ML20084E531 List:
References
NUDOCS 8405020332
Download: ML20084E542 (22)


Text

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APRIL 1984

O EMERGENCY DIESEL GENERATOR ENGINE AND AUXILIARY MODULE WIRING AND TERMINATION QUALIFICATION TO IEEE-383-1974 Prepared for:

O- TDI OWNERS GROUP l

)

Prepared by:

Stone & Webster Engineering Corporation 8405020332 840424 DR ADOCK 05000

'o EMERGENCY DIESEL GENERATOh AUXILIARY MODULE CONTROL WIRING AND TERMINATION QUALIFICATION REVIEW Prepared for TDI EMERGENCY DIESEL GENERATOP OWNERS GROUP April, 1984 Prepared by STONE & WEBSTER ENGINEERING COPPORATION 1

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TABLE OF CONTENTS j Section Title Pago l

i 1 Applicability i l 2 Executive Summary 2 i

! 3 Objectives 4 i

I 4 Summary of Service Conditions 5 i i

5 Methods of Analysis 6 f'

t 5.1 Determination of Circuit Electrical ,

Requirements 0 1

i a 5.2 Determination of Wire Insulation Pating 6 l'

5.3 Determination of Termination Type 6 1

j 5.4 Determination of Wiring and Termination

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1 - Acceptability i

l 6 Discussion of Results 8 7 Conclusions 12 Table A Emergency Diesel Generator Auxiliary

Module Control Wiring and Termination i Material List i i Table B Emergency Diesel Generator Auxiliary l- Module Component List ,

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! Sketch A ' Emergency Diesel Generator Auxiliary

! Module Locations and Typical Raceway ,

Routing l

i Appendix A Task' Description l

[ Appendix B References t

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t i SECTION 1 j .

t .

APPLICABILITY i i This report is applicable to the TDI diesel generatorr ( n r. '.

I j the engine auxiliary module control wiring and terr.inations,)

utilized at the Shcrehat Nuclear Power Station. Diesel gen <rator.4 utilized at other plants will be evaluated separately. This revw included identification of the specific vire/cabic ar.d ter.m *i--

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types used for connecting auxiliary module class IE skic act:n:< .

devices.

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,, SECTION 2

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V EXECUTIVE

SUMMARY

An overall evaluation of all electrical cable and uire su; -

plied with the emergency diesel generators at Shorehar wcs under-taken as a result of Transamerica Delaval Inc.'s Service Inferrc-tion Memo (SIM) 361, Rev. 1. This memo notified LILCO of tvr potentially defective engine mounted cabler associated with the:

Woodward governor / actuator and the Air-Pax magnetic pick-up.

A field survey was conducted of all class IE auxiliary .codule wiring and terminations presently installed on the engines. Each circuit's service characteristics were identified and compared te

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the service ratings of the cable and termination types used. The evaluation of wiring also addressed flame retardancy of the insu-lation, qualification to industry standards, routing in conduit, and the need for special requirements, such as shielding.

Additionally, although there are no specifications er licensing requirements that Shoreham's emergency diesel enginc mounted wire and cable meet the qualification requirements of IEEE 383-1974, surveyed wire and cable was reviewed fcr qualifict.tior ic this standard.

As a result of this investigation, it is recommended.that r e:te wiring associated with the crankcase vacuum fan and the- two A

V ,

. starting air supply solenoid valves be replaced, because tr...

temperature rating of the wire insulation system is not compat bh with expected ambient temperatures. The investigation alse cc. -

firmed that qualified replacement cable was provided by TDI a r.d installed by LILCO in accordance with SIM 361, Rev. 1.

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. SECTION 3 i I

OBJECTIVES i

!. I J The objective of this review was to evaluate the f u nc t i or.a 1 i i

attributes of the electrical wiring and terminations supplied wit).

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} the emergency diesel generators as detailed in the Componer.t Desig:.

i i Review Task Description. The wiring and terminations conside. red

j. were those shown on Reference and task description details inclurb : ,

j

1. Review of wiring insulation for compatibility with- circuit t

1

requirements.

i j 2. Determine whether insulating material is kncwn t.o have corerie I

fire retardant characteristics and is qualified to IEEE-3E2 or some other industry standard.

3. Review the wiring inctallation methoo for routing in orcer *c l

determine the actual physical environment for each cable.

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i Evaluate any special circuit requirements to determine ::

special cable construction is required (i.e., s his_ I d o.. cat . . ) . l l 5. Compare the termination type, material, si: e and insulatic: '

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i ratings with characteristics required for applicatter..

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! . SECTION 4 i

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SUMMARY

OF SERVICE CONDITIONS 1

The electrical metallic tubing (EMT) installed on the skid a d i

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] supported away from the engine was considered to be at the san (su temperature as the maximum room ambient of 140'F. (60'C.)

j Reference). The junction box, EMT.and cable which are directly 1 attached to the engine block may be exposed to temperatures great-r .

l j than 140*F. (60*C.). The engine block surface temperature, during i

full load operation, was conservatively assumed to be equel to ths 1.

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jacket water and lube oil maximum normal operating temperature of I
180'F. (82.2*C.) (see Reference). The jacket water and lube cil l

l temperaturg were based on actual field readings during start up

! V testing. ,

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I Typical installation configurations are shown on Sketch 7..

j This sketch identifies those components at the maximu:r rcce an ie:.:

1 f' anri those which may experience a temperature of 180'F. (62.:"C.).

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, Electrical requirements for cables and terminatient are

provided in Table B.

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.,- SECTION 5 O

METl!ODS OF ANALYS:E 5.1 Determination of Circuit Electrical Requirements Each component listed in Table B was inspects;d fcr porti:.<r*

nameplate data. Manufacturer's catalog information contained in Reference was also reviewed. This review established-th<

circuit requirements for each component which cre listed it.

Table B.

5.: Determination of Wire Insulation Rating Each wire and cable was inspected for manufacturer information on the insulation or jacket. An investigation was then j performed for each cable to determine its insulation prep-l()

4 erties, flame retardancy, and electrical' rating ~. These J

results are listed ir. Table A.

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j 5.3 Determination of Termination Tvpe All terminations and terminal blockc were inspected to i ,

! identify manufacturer, type and model number. Additienci j design and vendor documents were utilized as' required te determine the model or rating of each component. This infor-l mation is listed in Table A. A comparison war made tc the l circuit requirements in Table B.

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, 5.4 Determination of Wiring and Termination Acceptabiliti

() The evaluation for the acceptability of cable and wire-included reviews for the following:

1. Voltage rating for the insulation system as compare:  ;.

the service voltage.

2. The maximum allowable operating temperature a: the w;rt as compare 6 to the sum of the expected aml.ir.nt and t N expected conductor temperature rise.

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3. The insulation system characteristics relative- tc f::-

retardancy and industry standards.

4. Routing.

Additionally, a review was made of cable manuf acturer dat , f: r evidence of qualification to IEEE 383-1974. These results are

/~'\ listed in Table A.

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-,. DISCUSSION m OF 14ESULTS i

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! i i I. Terminati'on v

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All termination componentsc.and ' terminal blocks arr- acceptable, j as demonstrated in Ta'blo$ A and P'. '

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II. Wiring and Cables ,

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l A. Cable Ampacity and Temperature Rating

!t (1) Even though PVC is rated at 90'C in a dry location b;-

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- U.L., ICEA Publication S-61-402 rates it at 75'C in wet i

i or dry locations. The ICEA temperature ratir.g ir mcrn f

appropriate for nuclear-grade installations and there-I fore, a 75'C rating for MTW PVC materials it- assumed for i

! the purposes of conservatism, i '

! The type MTW insulated wirer associated with tho 2

l crankcase vacuum fans (lR43*FN081A, B, C) must be re- ,

I placed because the operating. temperatures are expected is i

j e):ceed the rated temperature of.the e>:i sting wiri . The i

i electrical metallic tubing enclosing the wire is dire-etl2 in contact with the engine block. During enoine f

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operation, the crankcase vacuum fan is operating cor.tinu-

-) ously to remove vapors and gases from the crankcare. At rated loads and speed, this fan maintains vacuum of 0.2 to 0.5 in. - H 2 O in the crankcase. It should be noted that these fans are rated at 6.0 full Joad amp.. The j selected replacement wire (E&DCR F-27380A) ir Okonite 1/C#12-19X copper cable Black Okozel (Tetzel Insulation) type ZW rated at 125'C. This selected wire ir acceptablo since the 12 R temperature rise of the wire under fu :

load condition is 5'C. This will result in a final  !

operating temperature of 87.2*C. (82.2'C. ambient plur i I

5'C. rise).

(2) The Starting Air Supply Solenoid Valves (IR43*SOVO46A, E,

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fs C and SOVO47A, B, C) are required to operate during engine starting only. These solenoid valves, one fcr each of two separate independent air supply system, arc l connected to the ends of the starting air header on each diesel generator. To start the engine, starting air is admitted to the air header via the scienoid valver ard, in turn, to the starting air valves fer the cy li r.de r e , as 4

well as two starting air distributors. During ncrmal 1

operation, these solenoid valves are closed (deenergized).

The insulated cables' associated with-the starting air supply solenoid valves are of the type MTW. These ca!les

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sgst be replaced because the operating temperaturet, arc g-~()

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\~' expected to exceed the temperature rating of the existing cables. Existing cables will be replaced by Okonite, Okozel wire described in (1) above.

(3) Replacement cables pro'vided by TDI per SIM 361 Rev. I are acceptable for expected ampacities and temperature.

(4) Existing cables associated with the D.C. motor driver Fuel Oil Booster Pump and Motor Starter (IR43*P109A, B, C;.1R43*MST03A, B, C) are considered acceptable for temperature and ampacity. Operation of the fuel cil booster pump is controlled by pressure switch. Thir rump operates during engine start up and when the engine

\~/ driven fuel oil pump and the associated fuel oil strainer fuel oil header pressure falls below the minimum leve'..

During normal operation this pump will not be runnina, therefore the temperature during this conditicr will net exceed 140*F. The wires will not be carrying curr..rt.

Therefore, q wire rating of 75'C. or 90*C. are acceptable.

(5)* All other wiring in Table B has a rating of 90 C. and-associated components operate either intermittently cr draw currents which do not appreciably. affect conducte:

temperature rise. Therefore, the use of 90*C. ratei wire

~~ in a maximum room ambient' of 60'C. is acceptable.

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  • Cable / Wire Routing B.

All cable was routed in EMT or flexible conduit, except as noted for the cable going from the engine mounted junction box to the governor.

C. Special Considerations Shielded cable, when required, was provided by TDI or :1-field. Reference Table A items 5 and 7.

D. Cable Insulation System Upon replacement of the Carol type MTW wire (Iter ; cf

\ Table A), for the crankcase vacuum fans and the starting air supply solenoids valves all wire and cable types usar are of an acceptable flame retardant construction fc:

their application. Except for the D.C. . motor driver :tel oil booster pumps and their motor starters, all wire and

- cable used in qualified to IEEE-383-1974 (se. Table B).

The wire used internal to the motor starter and fe.d::.g the D.C. motor driven booster pump motor is accertabh .

based on the fact that it is self contained in raccu.e.

and has no way of propagating a flane to any other clasr IE components.

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SECTION 7 CONCLUS ION / RECO.VJiENDATI ONS Item 2 of Table A will be replaced with Item 1 dn all threr cn_r-gency diesel generat or skids as indicated in Table P. Upcn re-placement, all functional attributes of this component desig:.

review will be satisfied.

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TABLE A EMERGENCY DIESEL GENERATOR Al'XII.I APY MODt.ILE CONTROI. WIRING AND TERMINATION MATERIAL LIST

' Item Description TDI Part No. Manu fact u re r Technical Data Reference

1. 14 AWG SIS Wire N/A Rockbestos 600V, 25 amps, Operating Temperature 90*C. 10,'12 Cross-linked Synthetic Polymer Insulation Quilified to IEEE-383-1974
2. 14 AWG Type TITW F-509-104 Carol-C 600V, Operating Temperature 75'C. Flame 17, 19 er TW or AWM Wire Retardant Moisture Idesistant Thermoplastic Insulation
3. 14 AWG Type SIS. N/A Continental 600V, 90*C. Operating Temperature Ifeat 17

-Wire Wire and Resistant Rubber Insulation (UL)

Cable

4. 12-AWG Type MTW N/A G.E. 600V, (10*C. Operating Temperature Flame- 17 Retardant, Moisture, Ifeat and Oil Resistant Insulation, Nylon .Tacket (UL) 5158110
5. Cable F-509-494 RIW Cable Part No. 13292-11-002, 2/C, 16 AWG, 8, 9 Systems Shielded 600V., Inst. 90*C. XLPE Insulat ion CSPE .Tacket. Qualified to TEEE-383-1974 6 ~ Cable F '109-495 HIW Cable Part No. 13258-II-0G;' 2/C, 14AWG 600V, 8, o Systems rentrol, 90*C. XI.PE Insulation CSPI:

.Tacket . Qualified to I Erl:-383- l o'4 7 r,1b l e. N/A f>ockbes t on SWEC Mark No. NFP-44, 2 /t ". 16 AWG, 6 Shielded 90T., 300V, Inst. X I.I'I:

Innulat ion. ('uali f i d t o !!:11'-183-1974

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3 s Item Description' TDI Part No. f tanu fact u re r Technical Data Reference R. Cable N/A Rockbeston SWEC flark No. NI'P-20, I/C, 14 AWG, 6 600V., 90*C. cont. XLPE Insulation.

Quali fied to IEFI{-3FH-1974

~9. Terminal Bleck N/A G.E. Cat. No. CR15102, 600v., 30 amps 14

10. Terminal filock N/A TRW Cinch Series 141 1100V., 20 amps /
11. Terminal Lug N/A AMP Special Nuclear PIDG terminal pre-insulated 13 Industries ring tongue lug, 150'C.
12. Terminal Lug N/A Burndy Type TN, Nylon Insulated Ring-Tongue terninal
13. Connector Plug Part of ITT Cannon No, MS3108E-1R-15 MIL-C-5015, 11, 4 74010-110 1750 VDC, 1250 VAC, 22 amps Environmental Resistant Construction
14. Connector Plug Part of Amphanol MS3106A-10SL-4S MIL-C-5015, 700 VDC, 13 15 r.A-004-000 amps, solid shell construction
15. Cable flatfield Permolene, 10 AWG, XIlifW, XP 600V (UI,)
16. Cable Okonite X-olene, XIIIIW, 10 AWG Copper 600V (UL) 17 Cable Okonite 1/C #12-19X Copper cable, black okozel (Tefzel insulation) type 7.W rated 125"C.

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l TABLE B EMERCENCY DIESEL CENERATOR AUXILIARY MODULE COMPONENT LIST TERMINATION IDENTIFICATION NO. DESCRIPTION CIRCUIT REOUIREMENTS WIRE / CABLE TYPE TYPE C0fetENTS/RECOpetENDATIONS REF.

(see Table Al IR43*FNO81A,B,C. Crankcase Vac Fan 1/3 N.P. Continuous Duty, 115 1, 2 9,10,11,12 Replace Item 2 with Iten 2 VAC, 6.0 FL amps 17 Item 17 is IEEE-383 qualified 1043*SOV046A,B,C Forward and Aft Start Circle Seal Control Model 1, 2 9,10,11,12 Replace Item 2 with Item 2,3, Air Supply Solenoid SV 13532P4PE 115 VDC, .6 17; Item 17 is IEEE-383 4 Part of TDI Part No. amps maximum qualified ER 001-000 l

C/A Woodward Governor Transducer coil 0 to ".75 1, 6 1,10,11,13 Item 1 and 6 are IEEE-383 2,4 Actuator TDI Part volts 400 max. allowable qualified No. KR 001-000 current N/A Magnetic Pick-up TDI Air-Pax Output signal Average 5,.7 9,10,11,14 Item 5 and 7 are IEEE-383 1,5 j Part No. EA-004-000 50 Volts P-P qualified 1:43*MST-03A,B,C Fuel Oil Booster Pump 2.0 II.P. Continuous Duty 125 1, 2, 3, 4, 9,11,12 Item I and 8 are IEEE-383 1,5 IP43*P-109A, and Motor Starter VDC, 17 FL amps. Starter 15, 16 qualified. Itens 2, 3 and B, C Control Circuit 125 VDC, 10 4 are acceptable for this amps fused application. '1 I. l'R4 3*TS0 31 A,B,C- ' Lube Oil'and Jacket Chronalox Industries Thermostat 1 9, 11 Item I is qualified to 1,3

.IP43*TS032A,B, C Water Heater Thermo- Type AR Contacts open or close IEEE-383 stats TDI Part No. -120 VAC, 5.6 amp fused control BD-003-000 circuit IU43-TS070A,B,C High Temp. Lube Oil Contacts Open or Close 125 VDC, 1 9 Iten I ir qualified to 1,3 IR43-TSOllA,B,r High Temp. Jack. Water control circuit which energize grrr-383 IR43-TSn72A,H,C tow Temp. Jack. Water resay coils and alarm lights I P4 3-LS05 3A,B.C - Iens Level I nbe usi which draw a total of 03 amps

- I P 4 3-LS0 52 A ,11.C Low I. eve l Jack . W st e r riar inun l

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- IJBM624 ApC SUPPORTED ON ENGIPE (ASSUME 82.2T AMBIENT) plR43XFN08tA,RC IR43MMST03A.BC t/2EMT SUPPORTED ON EkiNE [-l EMT IR43MT5031 A.B.C (ASSUNE B2.2C AMBIENT) MM PG UP CABLE ,

I SUPIORTED ON ENGl E o e i -

iR43MSOVO46A C (A UME 822T AMBIENT IR43MP109A.RC i 8

~IR43x50V047A B GOVERNOR [ ACTUATOR c I

[_ - n IR43 -TS070A.B.C k T IR45-T5071A,BC -O s IR43-15072A,B.C IR43-LSC52 A BC - f  ; -

)

.__.--I 1R4V TSO32A.B.C" IJBM622 A B.C 1/2 EMT (TYP)

(A5SUME 6d'C AMBIENT)

Pow.menouttes Gnoup vettg C"<C"'*_

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l APPENDIX A . .

0... t>88D

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1 C'OMr firit~.M T Pt':1f.l; ut '.' l l . i l

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WIPING E TERMINATION t l a v ' . . t t e. i , f.
PART NO. 03-688B Complet. ion 3/9/84 i

) PRIMARY FUNCTION: The wiring and t eria i r .it 3. .re' . j r * *. e e < . r o .a . ' ' i nc

  • raent.

I control and power c'srcustsa :.n < f i et e! tia"ine t v. i. . . ' f ..<<! w :

  • e. . n c.

j eent rol pa ne l r..

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rUNCTIONA ATTRIDLITCG:

i .. s.ond uc-t or s, an ulation, a rid ttu vi n n. i t i . o i i nst.'

i . '.i- oi* o:i- r.r c;wc f ted aina rat a rig.

2. Cor.duc't ors and insulat t .n taust br* f I cinae* co' a e clan' .
7. Mtit er i a l a nt.i a n'..n l at i on ra t a rey ..h.oile! be ' .ipin .in. s.*'. . ...o ." .nd i  ;,crierat or appl a cat i ons.
E'CC FIEr ETANDARDS
:EEE-380 t

C'.'r

  • U n ~ :.3 N .

l  :. 4eslaw wiring i nc.. la t ion for corapal ab t 1 i t s w a t. i s j c '. r e .i t ' rec;u t reraent s.

s* . '~;acae retardant irsulation:

. Det orraine whet here insulat t oia a a cusiif set; to IEEE-332, U_ or sorac other i t.c'ut.t t y .t ance r d. a
c. . Det arraine w'1et her i ns u l a t 1. o . ; c. ... sa.a t i.*r i e l
riow r, to
  • .as c gencese ia re t et urtlant i . har ac t er 4 t.t a ct..

! c. De t s.tria i nt' uhether w c i ns; ear or' ! .c. air. t. 3 1 t e.: : r, j i raf i . a c'us constu 2 i i.. ... i n i s. a .. . . , n o.i1.it 2.., ij ea.4u ,

S alua'.o any taptcsal careunt requ a rt insmt r., . o r 'a or l

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t. '. . a ' cler! ca 51.*.

/. . ~ :.:;.,a cci t ter'sc a nat 4 on type, s int er i a l , t,  : e .n c!

. e.e..: a t i.: n v'3 t . n g t with character 19Lito rtuin 1i

. . ed Ner a vs.71 i ca t i or..

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  • N ~ !< ! c".W.LYC~S: 'tes2ew i f civa I at:1..

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! "~ ~ r ".'.~ C" RC CL'I RE D :

. Tc.ble 1,;,e test c ? port s. . .e ot hs. r ' a nnro. ed unalif1

. t,o s.tet h or' fri each t..ble tvpc s u pp

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APPENDIX B - REFERENCES Reference 1: TDI Drawing 52122, Auxiliary Module Control Wiring Reference 2: TDI Drawing 52076, Engine Electrical Schematic Reference 3: TDI Drawing 52072, Panel Electrical Schematic Reference 4: Transamerica Delaval Associated Publications Manual Reference 5: S&W Drawing No. 11600.02-FE-14A, B and C External Connection Diagram Emergency Generator Control Panel 1R43*PNL-GP1, 2 and 3 Reference 6: Specification SH1-129, Rev. 3, March 9, 1983, 300V and 600V Fire Resistant Control and Instrument Cable Reference 7: IEEE Std. No. 383 1974, Standard for Type Test of Class 1E Electric Cables, Field Splices and Con-nections for Nuclear Power Generating Stations 1 Reference 8: TDI Service Information Memo (SIM). 361, Rev. 1;

Subject:

IE Nuclear Qualified Cable dated October 13, 1983 Reference 9: Boston Insulated Wire and Cable Co. Report No. B'16, J

dated April 1980 Reference 10: Rockbestos Report No. QR 1807 " Qualification of Firewall III Class IE Electric Cables" dated December 8, 1980 Reference 11: Cannon Catalog MS-21, Standard Circular Connector dated December 1978 I Reference 12: Rockbestos specification RSS-4-002 "Firewall SIS 600 Volt Switchboard Wire Specification" dated October 24, 1979 Reference 13: AMP Special Industries Catalog Nuclear Terminals and Splices l

Reference 14: General Electric Catalog GEP-1260B

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N Reference 15: Ampharol Catalog AID-5 Reference 16: Stone & Webster Letter to LILCO LIL-22805 April 11, 1983 Reference 17: The National Electric Code Handbook 1984 Table 310-13 Reference 18: TDI Instruction Manual 1R43-1 Volume 1 Reference 19: ICEA Publication S-61-402 Thermoplastic - insulated Wire and Cable for the Transmission and distribution of Electrical Energy

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