ML20100G371
| ML20100G371 | |
| Person / Time | |
|---|---|
| Site: | North Anna  |
| Issue date: | 02/07/1985 |
| From: | Hight G, Faith Johnson, Mcmicken S WYLE LABORATORIES |
| To: | |
| Shared Package | |
| ML20100G362 | List: |
| References | |
| 47193-1, NUDOCS 8504080226 | |
| Download: ML20100G371 (325) | |
Text
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1 2 34 XEQ NUCLEAR ENVIRONMENTAL QUALIFICATION 9504000226 850329 PDR ADOCK 05000338 p PDR 1@M :$ CU
i TEST PROGRAM TO DETERMINE THE EFFECTS OF CONTINUOUS 120 PERCENT RATED CURRENT ON MOTOR CONTROL CENTER CONTACTORS DURING NORMAL AND EXTREME SERVICE CONDITIONS 1
for Virginia Electric Power Company 700 East Franklin Street Richmond, Virginia 23219
NEQ 3 Test Report REPORT NO. 47193-1 )
,y *, WYLE JOB NO. 47193
,j ~, . CUSTOMER 739705 4
P.O.NO.
JL.
' y y s .J PAGE i OF 318 PAGE REPORT
!;29 7 s
- CT ' fj DATE February 7,1985
- bi
, V s
SPECIFICATION (S)
"!; See Paragraph 5.0 l
0 CUSTOMER Virstinia Electric Power Company ADDRESS 700 East Franklin Street, Richmond, Virstinia 23219 0 TEST SPECIMEN Motor Control Center Contactor Coils O MANUFACTURER Klockner-Moeller Corporation 0
SUMMARY
Motor Control Center contactor coils, described in Paragraph 6.0, were subjected to an extreme service conditions test after receiving thermal equivalent lives of 10 , 20 , and 40 ', cars.
This test program was performed to determine the ability of contactor coils rated at 115 VAC (+10 percent) to operate continuously at 138 VAC (120 percent rated voltage).
Testing was performed to determine contactor operability on specimens having thermal eges ranging from 10 through 40 years, depending on application.
(DN330) .
BTATE oF ALA8AMA t "- Alabama Professional Eng' '
comim uamse : Reg. No. 13475 E Y 01 85 meseee : The in ya y,,j,,me'D., ,,, doo,,.eAPFROVED B ~1 I '
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'. R. JalXnson -
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- r d 9 WYLE G. A. 0 le]64M N # tb2 llA)Qll(
g' ]o'e gme ** (18 Jti--- G. Wayne Ifigtit '
Nots y RIAHo in and for the State of Alabeme et large, u, - .. Le
. , 27 LABORATORIES SCIENTIFIC SERVICES & SYSTEMS GROUP HUf.78VILLE, ALABAMA
4 Page No.11 Test Report No. 47193-1 i 4.0
SUMMARY
(Continuad)
- The test program was performed as specified in References 5.1 through 5.6. The test results are presented in the appropriate sections of this report.
-o Section I Temperature Rise Measurement
- o. Section II Baseline Functional Tests o Section III Thermal Aging o Section IV Post-Thermal Aging Functional Tests (Ten-Year Specimens) o Section V Extreme Service Conditions Test (Ten-Year Specimens) o Section VI Post-Extreme Service Conditions Functional Tests (10-Year
- Specimens) o Section VII Post-Thermal Aging Functional Tests (20- and 40-Year Specimens) o Section VIII Extreme Service Conditions Test (20- and 40-Year Specimens) o Section IX Post-Extreme Service Conditions Functional Tests (20- and 4
40-Year Specimens) o Section X Wyle Laboratories' Test Procedure No. 47193, Rev C ,
o Section XI Thermogravimetric Analysis of Four Nonmetallic l'
Components j Five anomalies occurred during this test program. Detaus of these' !
j anomalies are included in the appropriate sections of this report and are
, briefly described below.
NOA Report i t Report Date Description Section 1 8/14/84 Documents the fauure of a Size 1 coll, -III Specimen 11.2, with 115 percent of rated voltage applied during thermal aging at 1200C. Failure was caused by excessive current flow in and overheating of the coll. This occurred when the bobbin material deformed due to the high ther-4 mal aging temperature, preventing the contactor from being pulled in by the cou.
The specimen was removed from testing, 4 and testing was continued. This anomaly is judged to have no impact on the test program because the con was exposed to ,
temperatures that exceeded normal ser-vice conditions and coil design limita-tions. ;
MLE Mm Huntsville Fac611ty
O-Page No.111 Test Report No. 47193-1 4.0
SUMMARY
(Continued)
NOA Report Report Date Description Section 2 8/17/84 Documents the failure of a second Size 1 III coil, Specimen 41.1, with 115 percent of rated voltage applied to the coil during thermal aging at 1200C. The specimen failed because the magnet wire insulation in the coil broke down and allowed excessive current flow due to the reduced resistance. The client was contacted, and it was stipulated that, should a third Size 1 coil fail, all Size 1 coils were to be removed from aging and the thermal equivalent life to that point be calculated. This anomaly is judged to have no impact on the test program because the Size 1 coil was exposed to temperatures that exceeded normal service conditions and coil design limitations.
3 9/10/84 Documents the failure of a third Size 1 III coil, Specimen 41.2, with 115 percent of rated voltage applied to the coil during thermal aging at 1200C. The specimen failed because the coil shorted and allowed excessive current flow and overheating. All Size i specimens were removed from thermal aging and their equi'calant lives were calculated as spec'fied in Notice of Anomaly 2. This ano aaly resulted in the removal of all Size 1 coils from thermal aging, thus limlOrg the maximum age to be given to the s; icimens.
4 10/19/84 Dt < . tents the failure of three Size 1 VIII cods, Specimens 41.3, 41.4, and 41.5, and one She 4 coil, Specimen 44.6, during Extrer.te Service Conditions testing with Size 1 coils being powered with 115 percent of rated voltage and Size 4 coils powered with 117 percent of rated voltage. Failure of the specimens was caused by overheating from excessive current flow due to reduction in coil resistance. All four specimens were removed from the test program and WYLE LABORATORIES Huntsville Facmty
l i
Page No. iv Test Report No. 47193-1
- 4.0-
SUMMARY
(Continsamd) l NOA Report
- Report Date _ Description Section i
testing continued. As a result of this i anomaly, only coils with a 10-year or less
! equivalent life could be qualified due to repeated failures of coils with equivalent lives in excess of 10 years. The failure of Specimen 44.6 limited qualification of Size 4 coils to those with an equivalent ,
life of 35.08 yests or less.
5 10/23/84 Documents the failure of a seventh Size i VIII coil, Specimen 41.6, with 115 percent of rated voltage applied to the coil during Extreme Service Conditions testing. This anomaly affected the test program in that '
l It limited qualification of Size 1 coils to 10.03 years.
Size 1 coils having a 13.54 year or more equivalent life eyhibited repeated failures (see Notices of Anomaly 4 and 5). Therefore, the Size 1 coils could not be qualified for 13.54 years or greater since it was judged that the failures of the Size i specimens were common mode. The Size 1 coils .did demonstrate sufficient integrity to perform their safety-related functions up to and including the 13.15 year equivalent life point with voltages up to and including 117 percent of rated voltage at a 100 percent duty . cycle in the environment specified in Paragraph 2.0 of Section X.-
The Size 4 coils exhibited sufficient integrity to perform their safety-related functions up to and including a 35.08 year equivalent life at voltages up to and including 117 percent of rated and 100 percent duty cycle in the environment :
specified in Paragraph 2.0 of Section X. It was judged that the failure of the Size 4 coil, Specimen 44.6, was a common mode failure. Therefore, qualification of Size 4 coils is limited to 35.08 years.
The following table presents a breakdown of the test spae: mens and their
,- equivalent lives at 20 percent,50 percent, and 100 percent duty cycles and coil status at the end of the test program as to whether it passed or failed.
~
wvts Lamonatosuus Huntsville Facility
1 l
Page No. v Test Report No. 47193-1 4.0
SUMMARY
(Continued) 1 Equivalent Equivalent Equivalent Specimen Specimen Life (20% Life (50% Life (100% (Passed No. Duty Cycle) Duty Cycle) Duty Cycle) or Failed)
SIZE 1 COILS 11.1 43.04 18.29 10.03 Passed
- Failed 1 11.2 N/A N/A 21.1 55.91 24.34 13.78 Passed 21.2 55.28 23.71 13.15 Passed
- Failed 2 41.1 N/A N/A 41.2
- Failed 3 N/A N/A 41.3 59.70 28.13 17.57 Failed 4 41.4 55.67 24.10 13.54 Failed 4 41.5 55.91 24.34 13.78 Failed 4 41.6 55.91 24.34 13.78 Failed 5 SIZE 4 COILS 14.1 39.52 17.45 10.02 Passed 14.2 39.52 17.45 10.02 Passed 24.1 79.91 35.08 20.01 Passed 24.2 79.91 35.08 20.01 Passed 44.1 87.59 40.42 24.55 Passed 44.2 87.59 40.42 24.55 Passed 44.3 110.30 49.88 29.57 Passed 44.4 145.48 62.90 35.08 Passed 44.5 174.37 73.84 40.02 Passed 44.6 178.90 74.98 40.03 Failed 4 Specimen failed during thermal aging. See discussion in Section III.
1 See Notice of Anomaly 1.
2 See Notice of Anomaly 2.
3 See Notice of Anomaly 3. (
4 See Notice of Anomaly 4.
5 See Notice of Anomaly 5.
WYLE LABORATORIES Huntsville Facility
t Page No. vi l Test Report No. 47193-1 l
9.0 REFERENCES
'. 5.1 Virginia Electric Power Company Purchase Order No. 739705.
- 5.2 Wyle Laboratories' Quotation No. 543/1782/WB. ;
- 5.3 Wyle Laboratories' Test Procedure 47193, Rev C.
! 5.4 Wyle Laboratories'(Eastern Operations) Quality Assurance Program Manual.
5.5 U.L. Standard 508, " Industrial Control Equipment."
5.6 IEEE Standard 649-1980, "lEEE Standard for Qualifying Class 1E Equipment for Nuclear Power Generating Stations."
6.0 TEST SPECIMEN DESCRIPTION l The equipment to be qualified is Motor Control Center Contactor Coils consisting of 10 Size 1 coils,10 Size 4 coils, and 1 Size 6 coil (Temperature Rise Measurement Test only). Each specimen was installed in the appropriate size Klockner-Moeller contactor for all testing in accordance with Paragraph 1.3 of l Section X of this report.
Test Specimen No. Part No. Description 11.1 J-DIL Oa-NA Size 1 coil,10-year specimen 11.2 J-DIL Oa-NA Size 1 coil,10 year specimen 21.1 J-DIL Oa-NA Size 1 coil, 20-year specimen -
21.2 J-DIL Oa-NA Size 1 coil, 20-year specimen 41.1 J-DIL Oa-NA Size 1 coil,40 year specimen i
41.2 J-DIL Oa-NA . Size 1 coil, 40-year specimen 41.3 J-DIL Oa-NA Size 1 coil, 40-year specimen 41.4 J-DIL Oa-NA Size 1 coil, 40-year specimen Size 1 coil,40-year specimen 41.5 J-DIL Oa-NA '
41.6 J-DIL Oa-NA Size 1 coil,40-year specimen 14.1 J-DIL 4-NA Size 4 coil,10-year specimen 14.2 J-DIL 4-NA Size 4 coil,10-year specimen 24.1 J-DIL 4-NA Size 4 coil,20-year specimen 24.2 J-DIL 4-NA Size 4 coll,20-year specimen
- 44.1 J-DIL 4-NA Size 4 coil,40-year specimen 44.2 J-DIL 4-NA Size 4 coil,40-year specimen 44.3 J-DIL 4-NA Size 4 coil,40-year specimen 44.4 J-DIL 4-NA Size 4 coil,40 year specimen 44.5 J-DIL 4-NA Size 4 coil,40-year specimen 44.6 J-DIL 4-NA Size 4 coil,40-year specimen
~ 6.1 J-DIL 6-NA _ Size 6 coil ,
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WYLE LABORATOINES Huntsville Faciuty i,
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Page No. vii Test Report No. 47193-1 l6.0 TEST SPECIMEN DESCRIPTION (Continued) l All test specimens were permanently marked with the complete specimen l
number for identification throughout the test program. The specimen number i
consisted of a 2-digit number to identify the specimen as to thermal age and coil size and a decimal 1-digit number to identify the specimen among others of the same size and age (e.g., Specimen 44.2, 40-year specimen, Size 4 coil number 2 of 6). The specimens were also tagged with Quality Assurance " Test Specimen" tags upon receipt at Wyle Laboratories.
7.0 QUALITY ASSURANCE All work performed on this test program was conducted in accordance with Wyle Laboratories' Quality Assurance Program which complies with the applicable requirements of 10 CFR 50 Appendix B, ANSI N 45.2, and the " daughter" standards. Defects are reported in accordance with the requirements of 10 CFR 21.
8,0 TEST EQUIPMENT AND INSTRUMENTATION All instrumentation, measuring, and test equipment used in the performance of this test program were calibrated in accordance with Wyle Laboratories' Quality Assurance Program which complies with the requirements of Military Specification MIL-STD-45662. Standards used in performing all calibrations are traceable to the National Bureau of Standards by report number and date. When no nationt.1 standards exist, the standards are traceable to international standards cr the basis for calibration is otherwise documented and auditable.
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WYLE LABORATORIES Huntsvule Factitty
Page No.1-1 Test Report No. 47193-1 SECTION I TEMPERATURE RISE MEASUREMENT 1.0 REQUIREMENTS Coil temperature rise shall be measured on one of each of the following sizes of !
contactors: 1, 4, and 6. Temperature rise shall be measured per U.L. STD 508 with 110 percent,112.5 percent,115 percent,117 percent, and 120 percent of rated voltage (115 VAC) applied to the coil.
210 PROCEDURE 1
L1 Test Specimen Identification An inspection was performed upon receipt of the test specimens at Wyle Laboratories. This inspection verified that the equipment was as described in Paragraph 6.0 of the introduction section. The test specimens were tagged with Quality Assurance " Test Specimen" tags and permanently marked with a specimen number to facilitate identification throughout the test program.
2,2 Test Setup The three test specimens (Item 21.1, Item 24.1, and Item 6.1) were wired for temperature rise measurement as shown in Figure 1 of Section X.
2.3 Temperature Rise' Measurement The test specimen coils were installed in the appropriate contactors and three thermocouples were mounted within three to six feet of the specimens.
Temperature rise was then measured using the following procedure.
- 1. Using a DMM (digital multimeter), the coil resistance of each of the three contactor coils was measured and recorded on Data Sheets.
- 2. Contactors were connected as shown in Figure 1 of Section X.
- 3. 120 VAC power was applied to the circuit.
- 4. Voltage was adjusted to 126.5 (10.5 percent) VAC (110 percent rated).
S. Monitoring and recording of ambient temperature on the datalogger l commenced. !
- 6. The three " Start /Stop" switches were closed, timing on the coils commenced, and voltage was readjusted to 126.5 (10.5 percent) VAC.
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l WYLE e annaaTOMES Huntsville Facility
.. . .. - _ , . . o
Page No. I-2 Test Report No. 47193-1 2.0 PROCEDURE (Continued) 2.3 Temperature Rise Measurement (Continued)
- 7. Coil current at intervals of 10 percent of the previously elapsed duration of the test but not less than 10-minute intervals was measured and recorded.
- 8. At I hour of test duration and continuing throughout the test, the last 3 successive current values were compared. If the 3 values were within +1 -
percent of the mid-value current, step 10 was performed; if not, step 7 was continued.
- 9. A stopwatch was prepared to start timing w. hen the " Start /Stop" switch associated with the particular coil in question was opened.
- 10. A DMM set to measure voltage was connected across the coil to be de-energized.
- 11. The " Start /Stop" switch on the temperature-stabilized coils was opened and the stopwatch started. The DMM was shifted to the resistance scale and the voltmeter ultage was adjusted to 126.5 (10.5 percent) VAC.
- 12. Coil resistance was measured and recorded using the DMM at 5 seconds,10 seconds, 20 seconds, 30 seconds, 40 seconds, 50 seconds,1 minute, 2 minutes,5 minutes, and 10 minutes following de-energization.
- 13. If other coils remained energized, testing returned to step 7.
- 14. Coils were allowed to cool to room temperature (coil resistance was either within +10 percent of last ambient value measured in step 1 or 16 hours1.851852e-4 days <br />0.00444 hours <br />2.645503e-5 weeks <br />6.088e-6 months <br /> had elapsed" whichever occurred first).
- 15. Steps 1 through 14 were repeated at a coil voltage of 129.38 (10.5 percent)
VAC (112.5 percent rated).
- 16. Steps 1 through 14 were repeated at a coil voltage of 132.25 (10.5 percent)
VAC (115 percent rated).
- 17. Steps 1 through 14 were repeated at a coil voltage of 134.55 (10.5 percent)
VAC (120 percent rated).
- 18. Steps 1 through 13 were repeated at a coil voltage of 138 (10.5 percent) i VAC (120 percent rated).
- 19. The measured resistance was plotted as a function of time elapsed since de-energization of the coil. The curves obtained were extrapolated l backward to obtain the coil resistance when energized (time zero).
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WYLE LABORATORIES Huntsvlue Factitty
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Page No. I-3 !
i Test Report No. 47193-1 he PROCEDURE (Continued) 2.3 - Temperature Rise Measurement (Contimed) l .
The resistance value, R, determined in step 19 was used to determine coil l 20.
heat rise, At per the following equatiom '
- At = (R/r (K + ti)) ~-(K + t2) in which, ,
R was the resistance of the coil at the end of the test in ohms, as determined in Step 19.
r was the resistance of the coil at the beginning of the test in ohms, as determined in step 1.
I t1 was the room temperature in degrees C at the beginning of the test.
t2 was the room temperature in degrees C at the end of the test.
K was 234.5 for copper.
3.0 RESULTS The test , specimens were' subjected to the temperature rise measurements of Paragraph 2.0 and the final results ace summarized below.
Voltage Rating - Heat Rise (degrees C)
(VAC) (%) Size 1 Size 4 Size 6 126.5 110 52.6 43.1 42.2 129.375 112.5~ 54.6 45.4 45.6 132.25 115 62.2 47.7 48.5 134.55 117 60.9 49.2 50.3 138.0 120' 63.9 52.0 51.8 Based ok the results of the heat rise test, the client directed that testing of the Size 6 e411s be discontinued and that their qualification be determined based on Size 4 edl testing. This was done because the Size 4 coils and Size 6 coils were similar- Tn construction and -' also demonstrated heat rises which were approximb.tely equivalent. It was also directed that the voltage requirements of 120 peredpt of rated be reduced to 117 percent of rated for all remaining tests -
since actt'.11 operating conditions never exceed 117 percent of rated voltage. .
Heat rise e;alculations are presented in Appendix I.
Resistance plots as a function of time elapsed since de-energization of coils are presented ia Appendix II.
.,.. WYLE LABORATORIES r
, Huntsvitte Facility ih
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Page No. I-4 Test Report No. 47193-1 3.0 RESULTS (Continued) l Photograph I-1 showing the temperature rise measurement setup is presented in Appendix III.
Test Specimen Inspection Sheet, Data Sheets, and the Instrumentation Equipment Sheet are presented in Appendix IV.
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WYLE LABORATORIES Huntsville Facikty
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Page No. I-5 1
Test Report No. 47193-1 l l
l APPENDIX 1 CALCULATIONS WYLE LABORATORIES Huntsville Facility
Paga No. I-6 --- --
Test Report No. 47193-1 featucz cakala% weacW;d e pn Ryu/h I.I, atp zI uca;p n. pdy[nudu :
At = f(.K+t-) -(K tt,)
Awpfe c4Afa fr fpca'm zu.t at /K5 VaC (firA):
R=tiossar adu.;,as bg A.tp t+ = 22.7'c.
22.4'c d ftas T = 92.08517/kaouud in J6p /hr#f:A1.I ti d % % fi K = 234.s Jo ceppn
///.O s T 4t = Ti~oi (f 234 5+ 22. 4 )-(2.34,5+ 22 7/
ht= S2.6 degC.
00%. lud stbe %bw #1L C0culdaL od on M k h % b.
w atsisvu
/&.5 VAC. ( \ \0kot:.0
( r t. t. At
$p@:dm
- o. _(2)_ h ("c) (oc) (degd3 2I.\ I l0.980, %.o3 12.4 12 7 52.6 24.l c).lSI9 7.8n 22.5 2t8 43.os (o.1 (5182 s.sso 22.s 223 42 2
i Pags No, I-7 Test Report No. 47193-1 M MGaibTelueadbM teh l /29.38 VMC C//2.5% sohr0 i
.34 R un ca r ts ca t2 Nn At a c. _
21.1 ///.2166 c>l.'2? 20.?_ 21.5 5%9
'24,1 a),/373 7.741 20.3 20.t. 45.45 G.1 (,.5188 5.5 51 20.( 20.0 45. S
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?.A l 9.2493 7.925 2h 23.5 47.74 fo. l 6.619 2. 5.568 23.5 22.6 16, 5) 184,55 VAc( m%atal) 21.1 113.9161 *AoS 22.5 22.6 f.o.ss 24.1 , 934W 7 818 22.6 23 7 4 9.14 4.1 6.6732 5.581 22.6 22.9 50.2.5 i
I Pcg6 No. I-8 - - -
Test Report No. 47193-1 Ca shL %t % % Lc k 6 138.0 VAC. (120%x4hd
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At Ad 21,1 115.24 % 92.'Jo 21.5 21.4 63.89 24 1 9,4135 7.6?.3 21.4 2i.9 51.98 j (o,I 6.'It2B 5.583 21.4 21.6 51.83 4
4 1
5
Page No. I-9 Test Report No. 47193-1 APPENDIX II FIGURES Figure Title I-1, 2 Resistance plot of Specimen 21.1 at 126.5 VAC (110 percent rated)
I-3, 4 Resistance plot of Specimen 24.1 at 126.5 VAC (110 percent rated)
I-5, 6 Resistance plot of Specimen 6.1 at 126.5 VAC (110 percent rated) _
I-7,8 Resistance plot of Specimen 21.1 at 129.38 VAC (112.5 percent rated)
I-9, 10 Resistance plot of Specimen 24.1 at 129.38 VAC (112.5 percent rated)
I-11,12 Resistance plot of Specimen 6.1 at 129.38 VAC (112.5 percent rated)
I-13, 14 Resistance plot of Specimen 21.1 at 132.25 VAC (115 percent rated)
I-15, 16 Resistance plot of Specimen 24.1 at 132.25 VAC (115 percent rated)
I-17, 18 Resistance plot of Specimen 6.1 at 132.25 VAC (115 percent rated)
I-19, 20 Resistance plot of Specimen 21.1 at 134.55 VAC (117 percent rated) 1-21, 22 Resistance plot of Specimen 24.1 at 134.55 VAC (117 percent rated)
I-23, 24- Resistance plot of Specimen 6.1 at 134.55 VAC (117 percent rated)
I-25, 26 Resistance plot of Specimen 21.1 at 138.0 VAC (120 percent rated)
-I-27, 28 Resistance plot of Specimen 24.1 at 138.0 VAC (120 percent rated)
I-29, 30 Resistance plot of Specimen 6.1 at 138.0 VAC (120 percent rated)
~.
WYLE LABORATORIES Huntsville Facthty
Page No. I-10 Test Report No. 47193 4 i
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