ML20095E553
| ML20095E553 | |
| Person / Time | |
|---|---|
| Site: | Hope Creek  |
| Issue date: | 07/16/1971 |
| From: | Public Service Enterprise Group |
| To: | |
| Shared Package | |
| ML20095E524 | List: |
| References | |
| NUDOCS 8408240288 | |
| Download: ML20095E553 (80) | |
Text
{{#Wiki_filter:. _ _ ._ _ __ _ __ t t l i j BASIS FOR O I CABLE SYSTEM DESIGN POWER GENERATING STATIONS i l l h i l Public Service Electric and Gas Company Newark, New Jersey July 16, 1971 i f
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INDEX Page I. Introduction 1 II. Cable Construction - 3 III. Fire Testing 9 IV. Cable Inspection 17
-V. Cable Application and Installation 19-VI. Summary 26 J
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1 I. INTRODUCTION For over 50 years we have followed a consistent approach in the- design of cable systems for power generating stations. We have used high grade ru'ober insulated cable purchased from relia-ble manuf acturers and have installed it following conservative de-sign and installation practices. This approach has resulted in a sound cable system with a proven 40 year minimum life. We have realized that the cable system is a very impor-tant factor in the overall reliability of operation in generating stations. Although the cable system is a relatively small part of the total cost of a generating station, cable f ailures can result in costly repairs and outages. Cable insulation is the foundation of the cable system. It must be a good dielectric material capable of withstanding it the is rigors of installation in a power generating station where subjected to high temperatures, water, surf ace contamination, fire, and in nuclear stations, radiation. High grade rubber insulation has been proven to be capable of 40 years life under such condi- ' tions. Although we have followed a consistent basic policy for 50 years, we have made many improvements in our cable design during those years. We have participated actively in changes in the cable insulation field and in 1966, after extensive testing in our own laboratory, we became one of the first utilities to use ethylene [ propylene rubber (EPR) insulation. EPR was found to be superior to t the natural rubber insulation that we had been using and also superi-l or to the other thermosetting and thermoplastic insulations tested. l Recently, we have made changes in our overall cable construction to i obtain greater fire resistance. Until the 1940's most utilities used high grade rubber insulation. From 1940 to 1965 many utilities switched to the newer insulations: PVC, polyethylene, butyl, and cross-linked polyethy-lene. These utilities changed not because of poor service with the l high grade rubber insulation, but rather for short term economic Since 1965, gains. The newer insulations had a lower initial cost. [ with the greater concern for fire and radiation resistance, manyDuring utilities have switched back to high grade rubber insulation. the time that the newer insulations were being used in generating stations, a number of failures were reported in technical magazines and surveys. In 1964 as an owner in Keystone Generating Station we tried to convince the other owners that the additional cost for high grade rubber insulated cable was worthwhile becauseNone of its of excellent the other char-acteristics, which included flame resistance. L owners agreed with us and polyethylene-PVC cable was purchased for l the Keystone Generating Station. l
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2 In 1967, after the utility industry had experienced a number of. serious fires, we had no trouble convincing the other own-era of Conemaugh Generating Station that it was worthwhile to buy a superior cable. After extensive fire tests and evaluation of cable characteristics, the owners of Conemaugh Generating Station decided on EPR insulated cable as we had recommended. Although the cable construction is of prime importance in cable system design, there are other factors which must be considered in order to design a sound, trouble-free cable system. These factors are cable inspection, cable derating, cable overload protection, cable run design, and cable identification and installation control. These factors, together with cable construction, will be discussed in detail in the remainder of this report. i l l 6
II. CABLE CONSTRUCTION 3 Rubber .was first used as an insulation in 1811. Since that time many improvements have been made in rubber technology. In the early 1920's, with new chemicals, particularly antioxidants and organic accelerators, improvements were made in rubber insula-tion to the point where it had excellent electrical characteris-tics as well as good physical properties. Neoprene was introduced in 1931 as a jacketing material for rubber insulation to provide protection from flame, oil, and chemicals. The combination of Neo-prene jackets and rubber insulated cables became the industry's standard. Polyvinyl chloride, the first modern thermoplastic wire insulation, was introduced in 1930. It has been used for interior wire, control cable, and as a jacket for rubber insulated power c able s . It provided adequate electrical characteristics for indoor applications, but it does not have the characteristics required for a high grade insulation for use in generating station applications. Polyethylene was developed in 1933 and was first used as insulation for high frequency cables. It has been used in recent years for communication wire, medium voltage cable, and control cable. Polyethylene has excellent electrical characteristics and low water absorption, but it lacks flame resistance and has a low melting point. A popular control cable design during the 1960's has been the polyethylene-PVC cable. It was thought that for control cable applications, the low melting point of PVC and polyethylene would not be a f actor and that the PVC would provide adequate flame pro-tection for the polyethylene. After several serious fires, it was demonstrated that the PVC did not provide the required flame pro-tection for. polyethylene because it melted when subjected to flame; thereby, exposing the polyethylene to the flame. Butyl was offered as a cable insulation in 1946. Its prime characteristie was its 90oC rating. Many utilities switched to butyl insulated power cables in order to obtain the higher am-
- pacity ratings that were available because of the 90 C insulation rating. Testing that had been done by the manufacturers failed to discover that butyl reverted to a soft compound when subjected to high temperatures, as occurred during short circuits. Also, butyl was found to be a very difficult material to manufacture.
I j In the 1960's cross-linked polyethylene was developed as j a cable insulation and provided almost the same electrical charac-teristics as polyethylene, but was a thermosetting compound rated at 90 0C. It, like polyethylene, has a very poor fire resistance. L Cross-linked polyethylene has been used mainly as a power cable in-l sulation. 1 In 1965, when the utility industry became concerned about I I fire resistance, a flame retardant cross-linked polyethylene was
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4 developed. It was thought that this type of insulation, which did not' require a jacket for flame resistance, would be superior to high grade rubber insulation with Neoprene jackets. The flame re-tardant cross-linked polyethylene is compounded by adding antimony oxide to regular cross-linked polyethylene. This addition changes the electrical and water absorption characteristics of the insula-tion. It no longer has the excellent characteristics of polyethy-lene. In 1966 ethylene propylene insulation was first offered as a replacement for the high grade natural rubber insulation, which was in short supply. EPR insulation like rubber insulations is a compound of elastomers, antioxidant, and stabilizers. The compound that was offered for cable insulation was the result of 10 years of laboratory investigation. EPR insulation' offers excellent electri-cal and water absorption characteristics and, in addition, has a l 90 C rating. Although EPR will burn, it can be protected by a thermosetting Neoprene jacket and has passed all known flame tests. Although up until 1966 we use'd natural rubber insulation, we did analyze new insulations as they were introduced; we found ne reason to switch from the high grade rubber insulation with which we had had an excellent service record. In 1966 ve instituted an ex-tensive testing program in our own laboratory in order to analyze the characteristics of various commercially available cable insula-tions. In addition to testing new insulations, we also tested the natural rubber insulation of which we had been using for 45 years. l We used the characteristics of the natural rubber insulation as a l . benchmark. To our knowledge no one in the cable industry has been l able to determine any single characteristic of an insulation which l can be used to project long service life. Therefore, we considered l the overall balance of characteristics to be of prime importance. l Both standard and special tests were used. The standard tests were basically ASTM tests with modifications to use the same test condi-tions for thermosetting and thermoplastic compounds. The special tests were developed to simulate possible field conditions which were not hiequately covered by standard tests and to determine the long time aging characteristics of the insulations. Following is a list of the tests that were performed: i Tests Test Methods l Dimensions ASTM D 470 l Tensile Strength ASTM D 470 Elongation ASTM D 470 Aging Test Air Oven-121C, 168 hrs. ASTM D 573 Air Pressure-121C, 48 hrs., 80 psi ASTM D 454 0xygen Pressure-700, 96 hrs., 300 psi ASTM D 572 Oil Immersion-ASTM #2, 121C, 18 hrs. ASTM D 470 l l Ultraviolet Aging ASTM D 2244 i
5 Tests Test Methods Heat Distortion-121C, 1 hr. ASTM D 2633 ASTM D 2633 Heat Shock ASTM D 2633 Cold Bend Water' Absorption Electrical Method ASTM D 470 Gravimetric Method ASTM D 470 Electrical Characteristics ASTM D 150 Dielectric Constant ASTM D 150 Power Factor Insulation Resistance ASTM D 257 Insulation Resistance Constant ASTM D 149 Dielectric Strength Alternating AC-DC Test (see below) Ozone Resistance ASTM D 1149 Compression Cut Test (see below) Flame Tests ASTM D 470 Horizontal ' ASTM D 2633 Vertical Electroendosmosis Test (see below) Thermal Endurance (see below) Alternating AC-DC Test Ten foot specimens of the control cables were immersed in tap water at ambient tempera-ture for 16 hours. A potential of 3500 Volts AC was applied to the conductors and main-tained for 5 minutes, followed immediately by a potential of 9000 Volts DC, maintained for 10 minutes. If the cables withstood these potentials, the AC was increased in increments of 1000 Volts and the DC in increments of 2500 ! Volts and maintained for 5 and 10 minutes re-spectively. The test was terminated when the insulation f ailed electrically or a potential of 19,500 Volts AC and 49,000 Volts DC was attained. Compression Cut Test A twelve inch specimen of cable was formed into a loop with the ends twisted to-gether. A 2.5 pound weight was suspended on the looped cable with a short section of #20 AWG bare copper wire. The assembly was placed l ! in an air oven and maintained at an elevated i 1
6 i temperature for 24 hours. The specimen.was allowed to cool to ambient temperature and then electrically proof tested with a poten-tial of 5 0 kV for 5 minutes between the ; cable conductor and the #20 AWG bare copper wire with the weight still attached. If the cables sustained the 5 0 kV for 5 minutes, they were then tested to electrical failure. Each type of cable was subjected to several diff erent elevated temperatures. Electroendosmosis Test , Ten foot specimens of the cables were immersed in tap water maintained at 750. A negative 600 Volt direct current potential was maintained on the cables continuously, except when the following tests were conducted:
- 1. Maintain 5 kV AC for'5 minutes
' 2. Power factor, 60 Hertz 3 Dielectric Constant, 60 Hertz The tests values were determined at the start of immersion and weekly thereafter for three months. i Thermal Endurance Thermal endurance of the cable insula-tions was determined by aging the insulation at various temperatures until a loss of 40% elongation was determined. l The insulations tested, in addition to natural rubber, were ethylene propylene rubber, two flame retardant Since 1966 cross-linked we have polyethylenes, and two polyvinyl chlorides. also performed tests on silicone and teflon insulation and addi-tional tests on different suppliers of EPR,Polyethylene flame retardant cross-was not linked polyethylene, and PVC insulations. tested because of its poor fire resistance and low melting point, and butyl insulation was not tested because of its reversion at high temperatures. EPR insulation was found to be the best insula-tion of all those we have tested. It has the excellent balance of characteristics which natural rubber has and, Theinonly addition, a much characteristic improved long time aging characteristic. l
7 where EPR is inferior to natural rubber is in initial tensile strength, but since it was found to be very stable during lonc time aging tests, this characteristic was not considered a serious deficiency. In addition, the Neoprene jacket provides the mechanical strength required for installation. Our tests substantiated the deficiencies which were mentioned earlier concerning PVC and flame retardant cross-linked polyethylene. These insulations do not remain stable when immersed in water for long periods of time. Since wet conditions are found in generating stations, we considered this characteristic to be important. In the last few years cable manufacturers supplying EPR insulation have performed extensive radiation tests. EPR insula-tion has been proven to be serviceable after bging subjected to a l pre-aging equivalent to a 40 year life, 1 X 10 RADS radiation, and i then 350 F in a steam autoclave at 60 psig for 10 hours. In the last 5 years many utilities who had switched away !. from high grade rubber insulation are changing back to high grade insulation and are using EPR insulation. The use of PVC-polyethy-lene cable has virtually disappeared in the utility industry. Most utilities are now using either flame retardant cross-linked poly- t ethylene or EPR insulation. Those who favor flame retardant cross-linked polyethylene do so because it offers a smaller size cable since a jacket is not required on single conductors. EPR insulated cables, although larger in size, have superior electrical and water absorption characteristics. For power cables, EPR and regular cross-l j linked polyethylene are the insulations used in most generating l st ations . For power cable applications, EPR offers much better corona resistance, higher physical strength at . operating temperature, l and it is more flexible and easier to handle. , I The overall cable construction is important because it protects the insulation during installation and provides fire, oil, and chemical protection. Until 1957 we used lead outer covering on control cables. At that time we changed the outer covering to in-corporate a 5 mil corrugated bronze tape and a PVC outer jacket, which we felt offered the same protection as the lead but at a lower cost. In 1968, after performing many fire tests, we decided to change the PVC outer jacket to Neoprene to provide improved fire resistance. In 1970 we added an asbestos mylar tape under the cor-rugated bronze tape to provide additional fire protection. The add'i-j tional fire resistance added by changing the outer covering of the ' cable in no way changes the excellent electrical and water absorption characteristics of the insulation.
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- In our 5 kV power cables until 1970 we used a non-shielded construction. From 1966 to 1969 we used an EPR insulation with oil added, which provided greater corona resistance. We experienced problems with this insulation in areas where the cable was alter-nately wet and dry. We worked closely with the cable manufacturer and discovered that the problem _could not be corrected. We then started using straight EPR cables for 5 kV applications and decided to use a shielded construction with Neoprene outer jackets. We decided after a careful analysis that the shielded construction, terminated properly, would offer a safer installation than non-shielded cable and would also have greater fire resistance.
The changes mentioned previously in overall cable con-struction to effect greater fire resistance were made after perform-ing an extensive amount of fire . testing. A. separate section of this report will discuss in detail the fire testing which we have per-formed. The cable construction for the 5 kV power, 600 Volt power, and 600 Volt control cables for nuclear generating stations are similar to those we have used for past stations. The following is a brief description of each type of cable.
- 1. 5 kV Power Cable Copper conductor Strand shielding Ethylene Propylene Rubber Insulation Semi-conducting shielding l
Flat copper shielding tape Neoprene jacket
- 2. 600 Volt Power Cable Copper conductor Ethylene Propylene Rubber Insulation Neoprene jacket l 3. 600 Volt Control Cable Copper conductor l
Ethylene Propylene Rubber Insulation ! Neoprene jacket l Outer coverings:- ' Asbestos-Neoprene tapes Asbestos Mylar tape Corrugated bronze tape Neoprene jacket l-i
III. FIRE TESTING 9 Since no industry test exists for determining acceptabla degrees of fire resistance for completed cables, a number of fire tests have been developed by utility companies and manufacturers. The greatest cable fire hazard in the generating stations exists in exposed tray systems, and a vertical tray fire propagation test has been accepted by many companies. The vertical tray runs repre-sent the greatest hazard because " chimney" action will spread the products of combustion to a large area. In 1968 we suggested that the owners of Conemaugh Generating Station form a task force to establish criteria for acceptable fire resistant control cable. Criteria established specified that the cable had to be fire resistant and also maintain circuit continuity without short circuiting during the fire test. In addition, the electrical, mechanical,.and water absorption characteristics of the cable had to be suitable for a 40 year life in a generating station. The vertical tray fire propagation test was chosen by the task force as the test to use to evaluate differ-ent cable constructions. The test procedure used was as follows:
- 1. Erect an 8 foot high, 6 inches wide metal tray vertically.
Protect tray from wind by installing in an enclosure.
- 2. Load tray with one level of test cable, of one type, allowing one-half diameter space between cables.
3 Make electrical connections to check continuity and energize circuit.
- 4. Insert crumpled 2 foot x 2 foot burlap previously soaked in transil oil, into vertical tray appro tmately one foot above lower cable ends. Hold burlap in place with loose metal band.
5 Ignite the oil-soaked burlap. The cable fails this test if a self-sustaining, propa-gating fire results or one electrical circuit breaks down during the fire. Each supplier on the bidders' list was requested to submit 100 foot samples of 7 conductor, #12 control cable before the due date for proposals. By requesting all samples to be the same size and number of conductors , the possibility of conductor size affecting the test results was eliminated. All fire resistance testing was performed at Public Service Electric and Gas Company's Maplewood Testing Laboratory.
10 The task force decided, based on consideration of ' insulation characteristics and our experience in many installations, to specify a control cable construction consisting of EPR insulation and Neoprene jacket on single conductors, cabled together with an asbestos tape and an overall jacket of Neoprene. Since the task force realized that all the manufacturers could not. conform to this spe-cified construction, alternate constructions were invited. All manufacturers were requested to send data on insulation character-istics in. addition to samples for fire resistance testing. In addition to the specified construction, four other constructions were submitted for the task force's consideration.
- 1. EPR-Neoprene on 1/C, Asbestos Tape, and PVC overall.
- 2. Hypalon on 1/C, Asbestos Tape, and Neoprene overall.
3 XLPE on 1/C-Silicone Glass Tape, Asbestos Tape, and Neoprene overall. 4 PVC-Nylon on 1/C, Asbestos Tape, and Neoprene overall. All the above censtructions passed the fire propagation part of the test but alternate constructions No. 1 and Figures 4 failed on14 electrical continuity by shorting between conductors. show a typical sequence of before, during, and after the test for cables that passed the five propagation part of the test. The polyethylene-PVC control cable construction used at Keystone was also subjected to the test. It failed both criteria and continued to burn until all the polyethylene-PVC was burned off the wires for the entire length of the sample (Figure 5).
- As a result of all the fire tests, the task force con-cluded that PVC was not acceptable as an insulation on single i
conductors because it flowed from the wires and exposed a greater length of conductor. During the test, the wires shorted. It was also decided that even though cables with an overall PVC jacket passed the fire propagation part of the test, PVC was not acceptable as an overall Jacket because the cables with PVC jackets burned for
- a greater length and emitted more smoke during the test than corresponding cables with Neoprene jackets. Therefore, alternate 1 with the overall PVC jacket and alternate 4 with the PVC insulation were eliminated.
Since it was decided at the beginning of the investigation that an acceptable control cable construction had to be not only fire resistant but also had to have characteristics suitable for a forty-year life in a generating station where it may be subjected a
11 to water and heat, each manufacturer was asked to state that his cable could operate satisfactorily in this environment. The manufacturers who offered cable constructions with Hypalon insulation did not recommend using it in a wet environment. Hypalon was therefore considered unacceptable and alternate 2 was eliminated. Based on fire resistance testing and consideration of electrical, mechanical, and water absorption characteristics, the task force concluded that two of the cable constructions submitted were acceptable for use in open trays in generating stations, the specified construction and alternate 3:
- 1. EPR-Neoprene on 1/C, Asbestos Tape, Neoprene overall.
- 2. XLPE on 1/C-Silicone Glass Tape,. Asbestos Tape, Neoprene overall.
EPR was preferred over XLPE because of its superior elec-trical characteristics; bids were received on both constructions and EPR was selected. . The task force did not agree that a corrugated bronze tape was recuired on control cable in the generating station. They felt that the overall Neoprene jacket was more important for fire resis-tance than the bronze tape. As a result of our participation in these tests, we changed the outer jacket of our control cable to Neoprene but retained the use of the corrugated bronze tape. This tape offers additional fire resistance and also provides excellent mechanical protection to the single conductors. Our power and control cables have passed both the Bureau of Mines and the UL Vertical Flame Test for single conductors. The results of the vertical tray flame propagation test were given to NEPIA for their consideration in our appeal to their requirements for a water spray system over cable trays. NEPIA felt the vertical i tray fire propagation test in partly loaded trays was not sufficient and they suggested a test be made to check fire propagation between j horizontally stacked trays filled with cables. In order to test our cables in fully loaded trays stacked one above another, we developed a test procedure and had tests l performed by the Okonite Company at their Fire Test Building in l Passaic, New Jersey. Several tests were performed to determine the l effectiveness of tray spacing in preventing propagation between trays. i l
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12 The test procedure, results,tand conclusions are as follows: Test Procedure
- 1. Erect two 6' long by 24" wide ladder-type aluminum cable trays horizontally with provisions to space the trays at 12" and 18", tray bottom to tray bottom.
- 2. Three tray tests are to be performed:
A. Trays separated 12" and no asbestos barrier. B. Trays separated 12" and an asbestos barrier in the bottom of the upper tray. C. Trays separated 18" and no asbestos barrier. 3 Load each tray with six cables of each type of control cable supplied by Public Service. This loading will result in 4Q% fill by cross sectional a area. The cable lengths shall be 10' long, 6' of which is in the tray with 2' overhanging on each end for connection to test leads. Connect conduc-tors in every other cable in the lower layer of each tray to a 120/240 Volt 3 wire test circuit as follows: A. Connect center conductor, bronze shielding tape, and tray to neutral of test circuit. B. Group conductors into two groups with alter-nate conductors in each group. Connect groups to test circuit with a lamp in each circuit to indicate conductor shorting. 4 Locate six thermocouples as follows: At the bottom of the lower tray, at the center of the fire, and to the side - 12" and 18" from the center of the fire and at the bottom of the upper tray directly above the center of the fire and 12" and 24" to the side. 5 An Ellipse wheel gas burner with a 14" outer diameter shall be used as the source of fire. The burner shall be located below the center point lower tray and shall be adjusted to pro-duce a temperature of 1500 F at the point of impingement with the cables. (See Fig. 6)
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- 6. The burner shall be ignited for 15 minutes.
Record all thermocouple readings every 2 minutes. Note propagation of fire and observe lamps for conductor shorting. Time shall be recorded.for any cables which short. After completion of the tests, the damaged area of cable in each tray shall be measured. 7 During the test, photographs shall be taken at 2 minute intervals. After the test, close-up photo-graphs shall be taken of the damaged areas.
- 8. The above test procedures shall be followed for each of the 3 tests required.
Public Service provided one 2,000 foot reel of each of the follow ing cable constructions for the tests: T-201, T-401, T-901, T-214, T 414, T-914, T-1914. Also provided were four aluminum trays and two asbestos boards. Test Results General The complete test data for all the tests is given in tables attached to this section. The0 gas burner was adjusted prior to the tests to 1500 F at the hottest part of the flame. It was-noted that when the thermo-couple was moved away from the hottest part of the flame, the temperature dropped off rapidly. During the tests the thermocguple directly above the burner never read above 1060 F because it was not possible to position the thermocouple in the hottest spot. During the test the temperature decreased because of movement i of the cables and tray caused by the extreme heat. Test No.'l - 12" Separation, No Barrier Prior to the start of the test the set-up was checked and even though the tray was filled with cables, there were spacings between the cables (See l Fig. 8-12). At 11.5 minutes conductors in a T-201 cable shorted. Two minutes later it was observed that the flame had surrounded the bottom tray along the Leeral edges. At 15 minutes conductors in a T-214 cable chorted 'See Fig. 13-15). At this time the burner was turned off. Most of the flame extinguished immediately,
.but a small flame continued to burn until 7.5 minutes after the burner was turned off (See Fig. 16-18). The
-cables in the upper tray with stood the entire test without a failure. The burned area in the cables in the lower tray was no greater than the area that the
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14 burner flame contacted. There was no horizontal or vertical propagation of the fire. Test No. 2- 12" Separation, Asbestos Barrier This test was cancelled because the results of Test No. 1 proved that flame propagation between trays with a 12 inch separation was negligible without a barrier. The asbestos barrier would have completely t blocked both flame and heat from the upper tray, i It was decided to perform Test No. 3 in order to , compare temperatures at the bottom of the upper tray j for 12 and 18 inch separation. Test No. 3 - 18" Separation, No Barrier Prior to the start of the test, the test set-up l was inspected and spaces were observed between the cables in both fully loaded trays (See Fig. 19). About 7.5 minutes after the flame was applied conduc-tors in a T-214 appeared to short, but then the indicating lamp turned off, indicating that the short had cleared. At 10 minutes the flame broke around the edges of the lower tray. At 12.5 minutes conductors in both a T 414 and a T-214 cable shorted. Since the flame had not broken through the cables in the lower tray at the end of 15 minutes, the test was continued ' for 5 more minutes (See Fig. 20-23). The burner was turned off at 20 minutes and there was no major afterburn (See Fig. 24). l } Close inspection after the test revealed the cables I in the lower tray had swelled during the test and bonded together to form a tight barrier which prevented f the main flame from breaking through the cables. The maximum temperature of the cables in the upper tray was 190oF (See Fig. 20). The " bonded" cables in the lower tray were separ-ated to allow air to circulate andThe theflame test was broke through continued for 10 more minutes. i- immediately towards the upper tray. Five more cables failed in the lower tray during this additional test, But there were no cable f ailures in the upper tray. Flame concentration was within twelve inches above the 3 lower tray with the cables in the upper tray subjected to flame intermittently (See Fig. 26-29).
15 This additional test of 10 minutes added to the original test of 20 minutes subjected the same cables to 30 minutes of flame. This combined test was much more severe than any test that we or Okonite were aware of. Test No. k i-A special test using oil as a source of flame in place of gas was performed because we felt that since NEPIA is used to fire testing with oil, they might want to be able to compare the results of an oil fire with the resu3ts of a gas-fire. In order to save time and expense, it was decided to use the same cables that were used in Test No. 2. Since the cables in the upper tray were not damaged in that test, the oil fire was set up under that tray. An oil pan with a quarter of an inch of turbine lubricating oil was
.l used. The oil was added to the pan by pouring it over the cables to simulate an oil spray.
The oil was very difficult to ignite, but once !' ignited it burned readily. Again, as in Test No. 3, the cables in the tray blocked the flame from going
- through, and the flame went around the sides of the tray. The fire lasted about 10 minutes. Three minutes There
' after no were thefailures oil was consumed,(all of cables See flames were out. Fig. 30-32). ! Conclusions l , 1. There was no propagation of the fire from the lower to the upper tray with either 12" or 18" spacing I with no barriers used in either tray. At the start of each test there were spacings between the
. randomly laid cables, but af ter the fire started the cables expanded and closed the openings, thereby restricting the fire from breaking through the cables. In the first test the fire broke through in 7 minutes-and in the second test there was no breakthrough after 20 minutes of burning.
The cable damage was primarily limited to the lower cables in the bottom tray.
- 2. There was no propagation of the fire horizontally outside the immediate area of the gas burner in any of the tests. The main part of the fire exting-uished immediately when the gas burner was shut off. In several tests a small flame continued to burn.sfter the burner was shut off. The maximum after burn time was 7 minutes.
16 3, The 18 inch separation provided greater protection than the 12 inch separation for the cables in the upper tray, although the cables in the upper tray were not damaged in either case. The maximum temperature at the bottom of the upper 0 tray was 1900F for 18 inch separation and 520 F for 12 inch separation.
- 4. The vertical tray fire propagation test with a partially loaded tray appears to be more severe than a horizontal test with fully loaded trays. The vertical tray test is also simpler and less expensive to perform and therefore is much better suited as a qualification test than the horizontal test.
- 5. There were no conductor shorts during the first 11 minutes, after which there were several shorts in the lower cables in the bottom tray. This time is more than adeguate to allow proper operation of the control circuits.
- 6. The fire produced by the gas burner was more severe than that produced by the oil fire. No circuits shorted during the oil fire.
7 The test result of the horizontal tray fire propagation tests confirm our findings from previous fire tests that our control cable construction does not propagate fire either vertically or horizontally and does provide adequate circuit integrity. The [ test results also prove that 18 inch vertical I separation between trays provides adequate protec-tion from fire propagation when fire resistant l cables are used. 1 i { l i
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- r. 4 PUBLIC SERVICE ELE IC AND GAS COMPANY ELECTRIC ENGINEEhiNG DEPARTMENT TABLE 1 HORIZONTAL TRAY FIRE PROPAGATION TEST 12" SEPARATION - No BARRIER 2 12'71
/
' THERMOCOUPLE READING F TIME 1 2 3 4 5 6 NOTES 1 1000 80 70 130 90 70 -
2 1050 80 70 120 90 80 3 970 80 70 120 100 80 4 960 . 100 80 120 100 80 5 950 13o 80 130 100 80 6 940 150 80 140 100 80 7 910 150 80 200 120 80 Flame broke through lower tray 8 900 140 80 350 140 90 9 900 130 80 440 160 100 10 910 130 80 460 180 100 11 900 140 80 480 180 100 T-201 failed at 11' 30" 12 900 140 80 500 200 llo 13 930 14o 80 510 220 120 , Flame broke around tray front and back 14 930 150 90 54o 220 120 15 920 160 90 520 220 120 T-214 failed at 15' Flame out at 15' 18 650 120 80 240 160 llo 20 610 120 80 210 150 llo 22 590 llo 80 200 150 llo Final flame out at 22' 35" 24 570 llo 80 200 140 loo 26 540 110 80 180 140 100 28 500 llo 80 180 . 140 100 30 480 llo 80 170 140 100 THERMOCOUPLE LOCATIONS Upper Center of Tray 12" 12" Tray 44 --
>S<. M Lover Center of Tray 12" 12" Tray if . >2< . - - - - -
>3 _
PUBLIC SERVICE ELE,QTRIC AND GAS COMPANY ,*
- ELECTRIC ENGII ' RING DEPARTMENT TABLE 2 CONTROL CABLE 1 '
HORIZONTAL TRAY FIRE PRCPAGATION TEST
#. 'Ss '18" SEPARATION - No. BARRIER. 's
, </ ;'s 2'17/71 i
THERMOCOUPLE READINGS OF M' ' TIME 1 2 3 4 5 6 - NOTES '
- 1 1360 80 80 00~ 80 ~ 80 .s W
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2 - 1350 90 90 90' 80 - - 3 1280 loo ' - 100.~ c110 100 80 , 4' .'f 260 120 . _100 '~ 126' ~100' 80 w'
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' 1200 130 - 100 120,. -loo 80 6 _1130 _ 140 -
110 c-130 ' 200 '90 . 7' '110c? ' 150 ' // 11s~N .11o7 5 1)of 80' T-214 failed at 7' 30" ,P 8 1060 140 . n110 -r "140 . 110.' 80 9 1030, ~ 1 10 . 410 ; - 160 120 80 Flame broke around tray front'and back lo 1020 . lo6 llo 160 120 80 11 - - 1000 '160 llo 160 120 90 d 12 920 180 120 180 130 100 ' T-914 failed at 12' 25" and T-414 failed at 12' 35" J 13 900 180 120 180 130 100 14 900 180 120 200 140 100 , 15 940 200 120 190. 140 x 100 s 16 960 21o 12o 200 140 loo . 18 940 240 120 200 140 100 19 940 ' 260 130 100 - 140 100 l 20 960 220 130< 1900 '- 140 ~. 100 Flame turned off - No major afterburn 21 680 200 120 150 120 100 . i 22 580 200 120 130 120 loo 23 520 190 120 120 llo 90 24 480 180 120 120 100 90 l 26 430 180 120 110 - 100 90 I 28 390 170 120 100 100 80 30 360 160 120 100 100 80 THERMOCOUPLE LOCATIONS Center of Tray 12" 12" . Upper 4' .
>54 --
>6 Tray Center of Tray 12" 12" Lover p' >24- >3 Tray Center of Burner
PUBLIC SERVICE EL' 'IC AND GAS C@MPANY ELECTRIC ENGINE. ING DEPARTMENT TABLE 3 HORIZONTAL TRAY FIRE PROPAGATION TEST 18" SEPARATION - No BARRIER 2/17/71 TEST CONTINUATION AFTER CABLE SEPARATION O THERMOCOUPLE READING F 4 5 6 NOTE 3 TIME __ 1 2 3 1 450 140 180 360 160 loo 140 80 51o 200 llo 2 580 120 3 600 170 80 630 240 190 90 63o 280 140 4 730 140 5 760 240 100 620 330 6 760 260 100 510 320 140 7 740 320 100 510 320 150 8 760 340 100 500 340 160 T-914 failed at 8' o" 780 340 llo 520 330 160 9 lo 780 340 110 540 360 170 T-901 failed at 11' o" 12 790 270 llo 380 280 150 Flame out at 11' 30" 14 780 200 100 320 280 140 - 17 740 160 90 250 200 130 - 20 700 140 90 220 180 120 130 80 19o 170 120 23 690 120 26 620 140 80 200 170 30 600 120 80 190 150 120 T-1914 f ailed at 27' o" THERMOCOUPLE LOCATIONS Center of Tray 12" 12" Upper 4' ;54 26 Tray Center of Tray 12" .12" ' Lover if ;2< >3 Tray i . Center of Burner R WM 'vh
PUBLIC SERVICE ELL IC AND GAS COMPANY ' ELECTRIC ENGINEL .ING DEPARTMENT TABLE 4 CONTROL CABLE HORIZONTAL TRAY FIRE PROPAGATION TEST OIL FIRE TEST 2 17'71
/
4 6 NOTES TIME 1 2 3 5 1 400 140 loo
, 4 480 140 100 5 1160 220 120 6 114o 320 120 1080 300 130 Flame surround cable tray at 7'
- 7 8 1020 300 130 990 360 140 9 Fire out in oil pan at 10' 10 1000 300 140 11 960 360 140 850 240 130 All flames out at 12' 12 ,
THERMoCO'/SLE LOCATIONS 12" 12" Upper Center ex ? ray ,
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IV. CABLE INSPECTION 17 As has been our long standing policy all cable for generating stations is checked by one of our qualified cable inspectors in the factory for compliance with our specifications. The cable manufacturer is required to provide certified test reports of all tests required in our specifications and the IPCEA Standards. Our inspectors check that all reouired tests are performed and verify that the test results meet the characteristics required in our specifications. Detailed inspection reports are issued by our inspectors for each inspection. Control cable inspection reports contain the following information: Our inspector's report on single conductors includes the following: 1 - Test report number 2 - Date , 3 - station name 4 - Reel number 5 - Conductor size 6 - Length on reel 7 - Conductor outer diameter 8 - Insulation thickness 9 - Jacket thickness 10 - Centering of conddctor 11 - AC and DC tests - record voltage, time and pass or fail 12 - Insulation Resistance 13 - Conductor Resistance 14 - Indicate quantity accepted and rejected 15 - Inspector's signature o
18 For Items 7-13 the specified and the observed values are included in the report. The inspector also takes one three foot sample from each reel of single conductor Each backsampleto the laboratory is tagged with for testing of physical characteristics. the reel number, date, station name and test report number. Our inspector's report on finished cables includes the following: 1 - Test report number 2 - Date 3 - Station name 4 - Reel number of finished cable 5 - Reel numbers of single conductor which made up finished cable , 6 - Type of cable 7 - Length on reel 8 - Cable outer diameter 9 - Painting on single conductors for numbering and readability 10 - Footage marker tape 11 - Bedding Tapes (2' - thickness and lap 12 - Asbestos Mylar Tape - thickness and lap 13 - Corrugated Metal Tape - thickness and lap 14 - Outer jacket thickness 15 - AC and DC tests - record voltage, time and pass or fail 16 - Indicate quantity accepted and rejected 17 - Inspector's signature For Items 8 and 11-15 the specified and the observed values are included in the report. The inspector also takes one, one foot sample of finished cable from every other Each reel back to is sample thetagged laboratory with for testing of physical characteristics. the reel number, date, station name and test report number. Inspection reports similar to the above are also issued for power cables.
V. C ABLE APPLIC ATION AND INST ALLATION 19 Cable Derating The normal current rating assigned to power cables is limited to that continuous value which does Thenot causeratings current excessivelisted in insulation deterioration from heating.
" Power Cable Ampacities," published by the Insulated Power Cable Engineers Association (IPCEA-IEEEi are derated for the specific application of grouped conductors in tray or conduit It and then is further derated 10% to provide a margin of safety. is assumed in these calculations that all conductors are carrying rated current continuously. We believe this method of calculating current ratings is conservative because the number of different conductor sizes is limited and the chance that a group of conductors will all be carrying full normal rated current is remote.
The following table and notes indicate the step by step procedure used in calculating the normal current ratings for generating station power cable applications. Voltage Cond. Normal In Tray _ In Conduit , Rating Class Size Note 2 Note 3 Note 4
- Note 5 JJote 1 2/0 257 211 221 189 5 kV 344 350M 467 383 387 500 578 474 473 425 750 728 596 579 520 12 27 30 24 600 36 60 l 6 69 66 75 2 158 117 130 105 l
2/0 247 183 204 165 l 308 l 350M 464 342 384 ! 500 580 430 477 387 750 747 552 598 497 Note 1 The figures indicated in this column are from the published IPCEA ampacities for 90oC total temperature, three single 5 kV shielded and 600 V. to 5 kV non-shielded conductors in air. Note 2 The figures indicated in this column have been obtained by multiplying the figures in the column under Note 1 by the following derating factors: (a) For 5 kV cables a derating factor of 0.82 which l represents the derating factor to be applied per l IPCEA for a single, spaced layer of cable in tray. l
20 (b) For 600/1000 Volt cables a derating f actor of 0.74 which represents the standard derating f actor to be applied per IPCEA for two layers of cable in tray. Note 3 The figures indicated in this column are from the pub-lished IPCEA ampacities for three single conductors in j 9 one isolated conduit. ! Note 4 The figures indicate'd in this column have been obtained by multiplying the lowest of the ampacity figures in the columns under Note 2 and Note 3, by an additional derat-ing factor of 0 90. These final ampacity figures are used to determine conductor sizes for all generating ! station power cable applications. Note 5 The minimum cable size to be used for each application !. is 2/0 for 4160 Volt, #6 for 460 Volt and #12 for 230 - Volt. These cable sizes are the smallest that can carry i the available short circuit current without overstress-1 ing the insulation. Cable Overload Protection All power cable circuits are protected by circuit breakers with thermal or magnetic overload devices. The current-time inter-rupting characteristic settings for these protective devices are chosen for each cable size so as not to exceed the published allow-able short circuit current duration for the associated cables. The selection of the settings is subject to independent review to assure
- the proper setting is selected.
Prior to installation, breakers are tested at the generat-ing station to assure that the settings are correct. Periodic main-tenance checks are also made. Cable Rur Design The design of cable runs within nuclear generating stations follow our long established practices for fossil stations which are:
- 1. No intermixing of 4160 Volt cables with 460 Volt cables.
Separate tray systems are used for each of these voltages.
- 2. No intermixing of above power cables with 230 volt power control and instrumentation cables.
- 3. Tray loadings in trays are limited to: one layer for 4160V power cables, two layers for 460V power cables and 50% fill by cross-sectional area for 230V power, control and instrumentation cables. .
- 4. Physical separation, routing or barriers are used to assure
- 21 isolation between 4160 Volt, 460 Volt and other cable trays.
5 Where physical limitations prevent the above, rigid con-duit is used.
- 6. Where vertical shafts are used between elevations, the In addition, same philosophy of separation is followed.
all cable openings between elevations are sealed.
- 7. All cables entering the relay room and control room areas and interconnecting cables between these two rooms are sealed to insure the integrity of each area.
In addition to the above practices, the following separa-tion requirements are followed for Class I Electrical Systems cable runs:
- 1. Physical separation of cable runs is provided for redun-dant cables so that no single credible event can damage cables or redundant counterparts.
- 2. Large distr nces or alternate routing, and the utilization of walls and other natural barriers inherent in the station design, are used as means of providing physical separation of redundant cables. The routing of redundant cables in a
' tiered tray arrangement is avoided. l
- 3. If situations occur which involve crossing redundant trays or short runs of tiered redundant trays in non-hostile
! areas, a minimum vertical separation of 18" is provided. Where trays containing redundant cables have less than l 18" vertical separation, a fire resistant barrier is pro-I vided.
- 4. The minimum horizontal distance between trays containing redundant counterparts is 12". If this is unattainable, a fire resistant barrier is provided.
5 When non-Class I electrical cables are run with Class I electrical cables, the cable run will not violate the above four requirements.
- 6. The grouping of penetrations at the containment wall follow the above requirements.
A
22 Cable Identification and Installation Control 4' A computer assisted cable control system is used by en-gineering, design, and field personnel as an aid for assuring proper separation of redundant circuits and to monitor and document the 4 installation of these circuits. All cables are assigned an identi-fying mark consisting of a combination of letters and numbers. These marks appear on permanent cable identification tags. All cables associated with Class I Electrical Systems have marks indicating l their safety-related group. For example, power cable marks are a series of alphanumeric digits indicating in order: unit number, i bus letter or equipment letters,' number or position, and voltage i (D-4160V, X-460V, Y-230V). A cable identified with-the mark 1A4D-A originates at the No.1 mdt, A bus, 4th position, 4160V and is in the A separation group. All trays, shafts, and conduits are also assigned an identifying mark consisting of letters and numbers. All wireways j containing safety related cables are distinctly identified as such. ] These designations are used by designers when routing cables. This
- routing information is provided as input to the computer system which
! controls the generation of cable pulling and connecting cards. These cards and the appropriate reference drawings are used by the field as specific instructions and become documentation for all cable instal-lation work.
- The Cable Control System was developed as an extension of the computerized Cable and Conduit List used for previous generating
! station projects. Modifications were made to this system to simplify l the input procedure, provide additional information on each cable (route, reel, number, etc.), assure tighter administrative control over the system, provide additional reporting functions'such as installation reports, cost reports, etc., and utilize the data base l to control and check field installation. r The following is a description of how the system operates. f l A comprehensive operating manual is given to the field and engineering coordinators covering card loading, filing, error routines, etc. Design Input Four stages of design input are made to the system: Termination and cable data - from, to, cable . type, wiring diagram information, etc., is prepared from controls wiring diagrams and entered onto termination in-put sheets. This information is checked l
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's' by the Design Division ' coordinator and forwarded to the Electrical Division coordinator for , entry into the computer.
s Priortohh$ptringthecablepulling schensti),for an area, the responsible desig,nfr? prepares a traymark ordering sheet .NV tgit sheet lists the vital and non-vit al tray identifications which are usedjy9aparticulararea. Rout)ng data - the cable mark, estimated len,gtdd 'and route of all cables is to be s ertared..onto routing input, sheets by each Idf rigner at the time the cable pulling schem'atic is being prepared. These sheets
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.Opdating - the Design Division coordina-f tor checYs each issue of the Cable Con-
, g<l'. trol Report, notes the required'thanges i, > on the, master copy and forward's it to the Electra cal Division coordinator for up-
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t s .' s' ' Field Operation J[}i g' ' A, The assigned field coordinator is responsible ! s' , l for ass 2 ring that all cpble installation docusedpatios operatiottu are performed in f accordarce widn* chis document and related field directives. The field portion of the ss llowing manner:
,s,ystem operates in the fo t
Each chble reel containing permanent power, I ' control and instrumentation cable will be Assigned a reel number at the time of de-livery. This reel number, the type and amount of cable, and the' manuf acturers col 14 number will be recorded on a* cable stock card and filed in the cable stock file. i Before any cable is pulled in an area, all trays and shafts must be marked with tray identification. markers. ' 1
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24 l r l' The field coordinator will distribute pulling and connecting cards at the beginning of each working day. He then assembles all cards which were distributed the previous day. The cards which show work completed are placed in the card transport box and sent to the Electrical Division j coordinator in Newark. The remain- , ing cards are returned to the appro-priate working card file. Cards re-ceived from the Electrical Division coordinator each day are to be filed in the appropriate card file immediately. The foreman of each pulling or connect-ing gang is responsible for assuring , that all work is performed in accordance e with cable pulling schematics and the pulling or connecting cards and referenced documents. After the pull is completed, the foreman fills in the required in-formation on the card and signs his name, the cable is then identified at frequent and significant intervals along its route. At the completion of the days work, the foreman returns all cards to the field coordinator for filing. t I Electrical Division Operation Each day the Electrical Division coordina-
- tor keypunches any design' input and the
! previous day's field input. He then loads this input into the local terminal. The program updates the file and generates new pulling and connecting cards (two copies). 3 Two security tapes are made of the entire i data and program files and notification ! is received on the terminal that all opera-tions have been completed successfully.
- After running the program, the operator
!~ files all design input cards and the dupli-cates of the new pulling and connecting i- cards. The originals of the pulling and connecting cards are placed in a transport i I
e' 25 box and sent to the field coordinator. Cable , Control Reports The program which generates the major Cable Control Reports will be run by the Electrical Division coordinator on a weekly basis. The reports will be printed on the 1108 high speed printer and to the site and Newark by messenger. Special reports such as file searches, installation reports, and system reportp can be generated by the Electrical Divi-sion coordinator on demand. The method of running these programs will be simi-lar to'the running of the daily report program, i. e. , the necessary input will be keypunched, placed bet, ween the control cards, and loaded into the terminal. During the running of any of these pro -
, grams, the security tapes.will be in a
" read only" mode to prevent damage to the mail file. Specific instructions cover-ing the necessary input for these func-tions will be added to the operating manual as the functions are developed.
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VI.
SUMMARY
26 We have followed a consistent basic policy for over 50 years in the design of cable systems for power generating stations. High grade rubber insulation has been the foundation of our cable system. Fire resistance is obtained by protecting the insulated conductors with coverings rather than changing the insulation. Extensive fire testing has been performed which prove that 18 inch vertical separation between trays provides adequate protection from fire when fire resistant cables are used. In addition to using high grade rubber insulated cable with proven fire resistance, we follow conservative application and instal-lation practices. This approach has resulted in a sound cable system with a proven 40 year minimum life. l l i i i
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4 4O ' FFICE F;L5 )d a/>-r
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Salem /d 4 Electrical Division /
. . ' File f it m i September it, 1971
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Memorsadun to the Chief Electrical Engineer 600 70LT P0wEm CAsLa 30aIEczTAL TnAY FIEE PROPASATION TESTS OE0EITE TEST BUILDING = PASSAIC, NEW JERSEY BALEN NUCLEAR GENERATIE0 STATION AUGUST 3, 1971 INTRODUCTION In a memorandum to the Chief.Ilectrical.Engiater. dated.^ ' *
'Septlember 24 19716 we reported' 'on' .the restits .of' 'a horisontal- -
c tray fire propsigstion test with trays filled with 600 Yelt power -
., cables with 12" vertical separation between trays. Stase thes have performed the same test with 600 Volt power embles with 1$"we vertical separation between trays. The results of this test is reported in this memorandas.
TEST PROCEDURE
- 1. Ereet two 6' long by 24" wide ladder type aluminum cable trays horisontally with a 18" spacing from tray bottom to tray bct-tom. The trays are erected is a building free from drafts and wind.
- 2. Load each tray with cables supplied by PSEAG to a 40.5 fill by cross-sectional area. The cable lengths shall be approxi-
- mately 7 feet. Twenty three test circuits shall be used
- 20 sets
! of 120/2h0 Volt 3-wire leads, and 3 sets of 220/4%O Volt 3-wire ! leads. (See Table r1 for emble type and test lead set.up).
- 3. Leeste six thermoeouples as follows: At the bottom of the lower trey, at the oester of the fire, and to the side - 12" and 18' from the center of the fire and at the bottom of the upper r
I tray directly above the oester of the fire and 12" and 24" to the l side (See Fig. 1).
- 4. An Illipse wheel gas burner with a 14" outer diameter shall be used as the source of fire. The burner shall be loested below the center point lower tray and shall be adjusted to produce a temperature of 1400 F at the point of impingement with the cables.
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meme to the Shter S&se.. Begr. 3= 9/33/71 l Sei" l$ 'sha&& he ignited for 15 minutes. aseord all t eveer atente. Note propagettom of fire med eteeswD e m 8 meter aborties. Time shall be steerted for sheet. W ee W ien of the test any schlee the damaged area of eeble la each tsey shall to anaeused.
- 6. During the test 3hetographe shall he taken at one minute latervale. After the test, elese-up photographs shall he taken of the damaged areas.
PSE&g provided the following sable seastructions for the test Triplemed 500 M8M, 350 mm, da AWS, d8/0 awe e sad e6 AVO, sad 3/C dia Ave eekle. TEST RESULTS The complete test data is given la Tables 1 and 2 attached to this memorandum. The gas burner was enlibrated prior to the test to 14000F at the hottest part of the flame. The sable construsticas sad sises used in th$a test were the same.as those used la the f . previous test arespt! ~ 3/C'i-12 AMG. eable ,veis ,used'is.' place of tr'i. -- plemed fit AWOg 3/C 412 AWS is our standard constreeties for ilt emble. The flames did met break through the embles immediately as in the previous test. At 4'30" into the test a i 6 AWG emble in the lower tray failed. Abest 45" Inter the flames broke through the embles in the lower tray. At 7' 45" a #2 AWG emble in the lower tray failed. The flames were shout the same latensity as they were in the previous test with it' separation, but the flames 414 act touch the embles la the upper tray with 18" separation. The maximum temperature of thermoeouple Ib, which was loosted directly above the burner under the apper tray, was 280*F. At 15' the Ellipse Burner was turned aff. Within 15" after the burner was extinguished, all flames vent out, but l' 30" later they suddenly re-ignited. The flames were only a fraction of the flames which occurred when the burner was on. At 20' two 350 ucu embles la the lower tray failed. At 32' a 500 McN emble la the lower tray failed. At 49' the two re-malaing small flames went out and then re-ignited 2' later. Finally at 65' all flames were out. A visual inspection was then made which revealed that no damage occurred to the cables in the upper tray (See Figures 3 - 17). CONCLUSIONS
- 1. There was ao propagation of the fire from the lower to the upper tray. The nazians temperature in the upper tray was 110007
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lever ses test with 18' separaties, The trays were fillee 90' eposs.sestiemal area as speetfied nad the sables provideo greater h1aaketing of the flames 4 arias the first 5' et the test, se emble was damaged la the upper trag, S. There was ne peepasaties of the fire horisontally est. side of the inas41ste area of the gas termer. The mata part of the fire estinguished immediately when the gas burner was sket off, I small flames contiated to bara for 50' after the hermer was shut off. The afterbara was 30' longer than the previets test with it' separation. We believe the longer afterburn was the result of the blanketing which oceurred during the first 5' of the test. When the burner was shut off at 19r there was a larger emosat of insula-tion that had set burned. The heat retained la the sepper eenenators was hot enough to re-ignite the fire. l l 3. The only cables that failed during the 15' that the burner was turned on were a 66 AWG and a ilt eetle. The $12 enkle disk had failed within a few miantes.in the previous , test did, met.fm14,.' . during this tost".because: it's ~ een'strue41ea. was change'd fron'~a: traw. '
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plex to a 3-conductor cable. In order to assure that 600 Telt power- ! cabl. viu hav. sh. same d.gr.e of fire resistanee u eenteel eelo, the Neoprene jacket thioksess should be ineressed 15 mils for single conductor and triplex embles, and for the smallen size embles G.2, ;6, i12) a three consuetor cable constructica should "Je used with a 15 mil increase in Neoprene jacket on individual conductors ! and a minimum 60 mil overall Esopreme jacket. 4 This test proves that 18 inch vertical separation between l trays provides adetuate protection from fire propagation when fire I resistant cables are used. l l 5 Additional fire tests will be performed when samples .f the new 600 Volt power cable constructions are available. GL hRJK/vh Afff. 1 i
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228 PUBLIC SERVICE ELECTRIC AND GAS COMPANY ELECTRIC ENGINEERING DEPARTMENT TABLE NO. 1 TEST LEAD SET-UP AND CABLE TYPE Set No.* Position Cable 1 Top-end 3/C #12 AWG 2 Bottom-end #6 AWG 3 Bottcm-end 350 MCM 4 Bottom-center 350 MCM 5 Bottom-end #2 AWG 6 Bottom-end #2/O AWG 7 Bottom-end #6 AWG 8 Bottom-center 500 MCM 9 Top-center #2 AWG 10 Top-end #2/O AWG 11 Top-center #2 AWG 12 Top-center 3/C #12 AWG 13 Top-end #2 AWG , 14 ~
. Top-end -
. #2'.AWG
^ 15 Top-end- -
#2 AWG 16 Top-center #2 AWG 17 Top-center 500 MCM 18 Top-center 500 MCM 19 ,
Top-end #2/0 AWG 20 Top-end 3/C #12 AWG 1A' 1B' Bottom-center 500 MCM 2A' 2B' Top-end #2/0 AWG 3A' 3B' Bottom-center 500 MCM l r i
- NOTE: Set 1 120/240V l Set 1A' 1B' -
220/440V 2A' 2B' - 220/h40V 3A' 3B' - 220/440V i l l RJK/vh , l 9 /22/71 l l l e
PUBUIC SERVICE ELECTRIC AND GAS COMPANY ELECTRIC ENGINEERING DEPARTMENT TABLE NO. 2 C able s installed in trays in- triplex configuration Upper and lower tray contain the following:
.i ~3 /c .#12' AW6, 2 - #6 AWG 2 - #2 AVG 3 - #2/0 AWG 4 - 350 MCM 4 - 500 MCM RJK/vh 9/22/71
PUBLIC SERVICE ELECTRIC AND GAS COMPANY ELECTRIC ENGINEERIhG DEPARTMENT TABLE No. 3 HORIZONTAL TRAY FIRE PROPAGATION TEST 18" SEPARATION - No BARRIER AUGUST 3, 1971 , Thermocouple Readings C1 Time 1 2 3 4 5 6 Notes
- 1 1480 18o 90 260 loo loo 2 1500 190 90 230 loo 100 3 1520 380 80 220 loo 100 4 1550 400 60 210 llo 100 #2 failed @ 4'30" 5 1540 390 60 210 llo 100 Flame Brake Through
@ 5'15" 6 1520 400 21o 120 100 7 1520 420 Ther- alo 120 100 #5 failed @ 7'45" 8 1460 420 mocou- 220 120 llo 9 1400 430 pie 240 120 120
- lo 1390 430 insert-240 120 120. . -
440ed w'rong' 2'60 ' J12'o ' -' .
~ , . ' ' ' ' ~ 11 1'320- ~120 < ,
12 1300 450 260 130 120 13 1310 46o 260 130 120 14 1340 47o 270 130 130 15 1320 480 . 290 14o 120 16 920 460 250 140 120 18 820 42o 220 140 120 #4 failed @ 19' 15" 20 840 410 210 140 120 #3 failed @ 21' 35" 22 860 400 220 140 120 24 880 400 240 140 120 26 850 390 270 140 120 28 840 39o 280 140 120 30 830 39o 280 140 120 32 780 400 280 140 120 #1A' failed @ 33' 34 740 42o 280 140 120 36 680 42o 260 140 130 38 600 42o 240 140 13o 40 560 430 230 140 130 42 520 430 240 140 130 44 490 43o 260 140 130 . 45 460 44o 300 150 130 48 420 44o 260 150 130 t h r u 65 All flames out RJK/vh 9 /22/71
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.bi,4J 6 ,. File d' Ib.n # g,,g,,g , g,g97g 12 3Poo Memorandum to the Chief Electrical Engineer l
600 YOLT POWER CABLE i ECRIZONTAL TRAY FIRE FROPAGATION TESTS OKONITE TEST BUILDING - PASSAIC, IEW JEESBY SALIM EUCLEAR GENERATING STATION JULY 28, 1971 IETRODUCTION In a memorandumn to the Chief Electrical Engineer de%ed ' a Jussi 21s '1971, we. report'ed on:the ,results 'offhorisesstWtray fits I f. p'ropagation todts with trays filled with control entlas. Siase h s we have performed the same tests with trays filled with 600 Telt " power emble. The results of a test with 12" vertical separaties be-tween trays is reported in this memorandum. TEST PROCEDURE
- 1. Ereet two 6' long by 24" vide laddor type aluminum cable trays horisontally with a 12" syneing from tray bottom to tray bottom.
The trays are erected is a building free from drafts and wind.
- 2. Load each tray with embles supplied by Publie Service Electric and Gas Company to a 405 fill by eross-sectional area. The cable lengths i
shall be approximately 7 feet long. Twenty-three test circuits shall be used: 20 sets of 120/240 Volt 3-wire leads end 3 sets of 220/440 Volt 3-wire leads. (See Table 71 for cable type and test lead set-up. )
- 3. Leeste s'ix thermeestyles as follows: At the bottom of the lower tray, at the center of the fire, and to the side - 12" and 18" from the center of the fire,and at the bottom of the upper tray directly
- above the oester of the fire and 12" and 24" to the side (See Fig. 1).
- 4. An Ellipse wheel gas burner with a 14" outer diameter shall be used as the source of fire. The burner shall be loested below the center point lower tray and shall be adjusted to produee a temperature 1 of 1400*F at the point of impingement with the embles.
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m et to the W EM6e aesh -8= g/so/n to asetted few as =*==a==. seeeed all asesy atashe. Sen et fire med sensester eheettas. I to teserted for any echase insam sheet. span eenpaalt et the test, the damages seen et sente tm eesh tWay senti he asesures.
- 4. Serias the test phetsgraphe sha11 he tehen e4 ese ainete ,
interrels. After the test, elsee up photographe eta 11 he takea of the essaged areas. Public Serpies provided the fe11ewsag tripanz emble sea = strusticas for the teste 500 men. 350 mom, #2 Awe, et/0 AWS, #6 AWG, l ame die AWS. TM T.DESTAT8 . ! . The complete test data is given in the tables attaebed to l this memorassus. The ses burner was salibratet prior to the test to j 1400'r at the hottest part of the flame. The flemme broke t M . .
- the sables 'isone41stelys - Withia a few aimetes. thai dit triples 1emana
~ in tho' lower tray shorted. ' 'The' instreme heet deeleered the relettroly .
this jaaket and insulaties. As the test osatissee, the f1emas eee= stantly lopped the upper tray. At 10' 15' a de Ase eeble la the lower tray failed ame 20 seconds later, a ilt AWS emble failed in the upper tray. The flames had see propagated to the upper tray. At 15 minutes the Ellipse burner was turned off. Just prior to enti ehing the burner. a f2/O AWG failed la the bottom trer. About of the visible flame went out when the burner was extinguishes..Jtt: 16 minutes, during afttrbara, two more sensueters failed in the lower tray. At 23' a da AWG in the upper trer failed. Finally, at 35' 10" into the test the last flame went out, mas a visual inspectica was made of the damaged area (See Figures 3 = 17). CONCLUB10E5
- 1. There was propagation of the fire from the lower tray to the j upper tray with 12" tray spacing. During installation of the triplex onkle, it was metteed that there was a large amount of space between the sektes. Also the trays were not filled to 405 fill by eross-sec- t tional area es specified. Due to the triplea construction ama spaces between eebles,- the fire broke through immediately after the buraer was '
ignited. There was ao blanketing effect as noted during the same test with control embles. Cable was damaged in both trays.
- 2. There was no propagation of the fire horisontally outside f the immediate area of the gas burner. The asia part of the fire ex-tinguished immediately when the gas burner was shut off. Small flames eastimmed to bara until 20 minutes after the harmer was shut off. The afterburn was longer them for control embles due to the larger amount of insulation.
l
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meme to the Chief Blee. Bagr. *3 9/80/71 3r ., sees at all 4hermeeouple leeations were hotter than test estag control embles. Figure a presente a e stures at each thermeeouple leesttoa.
- 4. In ereer to asegre that 600 Telt power emble will have the same degree of fire resistance as sentral enkle, the Weepreme Jacket thiekasse should be ineressee 15 mils for eingle eesameter ama tri.
piez embles. For smaller sised embles (dt, de, dis AWG), a three coa. duetor enkle construction shea14 he used. This seastreetion shou 14 imelude a 15 mil ineresse la Neopreme Jaeket on indiviaani eonductors mad a mininas 60 mil overall seeprese Jacket.
- 5. on August 3, 1971. we will conteet a horisostal tray fire propagation test using 600 Volt power enkles with 18" separaties.
l . Ot aJx/v - , l l I .
218 PUBLIC SERVICE ELECTRIC AND GAS COMPANY ELECTRIC ENGINEERING DEPARTMENT TABLE NO. 1 TEST LEAD SET-UP AND CABLE TYPE Set No.*- Position Cable 1 Top-center. #2 AWG 2 Top-end 500 mcm 3 Top-end #2 AWG 4' Top-end #2/0 AWG 5 Top-center #2/0 AWG 6 Top-center #12 AWG 7_ Top-center 500 mem 8 Top-center #2 AWG 9 Top-center #2/0 AWG 10 Top-end 500 mcm 11 Bottom-end #2 AWG 12 Bottom-end 500 mcm 13 Bottom-center #6 AWG 14 Botton-end #2/0 AWG*
, 15 Bottom-end. - ,
. #12, AWG- -
~ '
~
16 Bottom-center - 500 mem-17 Bottom-center 500 mcm 18 Bottom-end 350 mem 19 Top-center #2 AWG 20 Top-center #12 AWG 1A' 1B' Bottom-end #2/0 AWG 2A' 2B' Bottom-end . 500 mcm 3A' 3B' Top-end #2/0 AWG NOTE: Set 1- 20-120/240V Set lA' 1B' - 220/440V 2A' 2B' - 220/440V 3A' 3B' - 220 /440V RJK/vh 9 /7 /71
MI PUBLIC SERVICE ELECTRIC AND CAP. COMPANY ELECTRIC ENGINEEliTIR: DEPARTMEI:T
. TABLE NO. 2 CABLES INSTALLED IN TRAYS IN TRIPLEX CONFIGURATION Lower Tray Upper Tray
'4 -
-500 mcm 3 -
500 mem 2 - 350 mem- 2 -
#12 AWG 1 - #12 AWG- l' -
#6 AWG 3 -
#6 AWG 4 -
#2/O AWG
. 2' .f2 0,AWG
/ . . ,
J , -#2.AWG,. . 1 -
#2 AWG
'EJE'vh f
9'7'71 P t I r
NM PUBLIC SEH"[CE ILECTR]C AND CAC Cot!PANY ELECTHIC ENGINEERIUG DEPART! TENT TABLE No. 3 HORIZONTAL TRAY FIRE PROPACATION TEST 12" SEPARATION - No BARRIER JULY 26, 1971 Thermocouple Readings OF Time 1 2 3 4 5 6 Notes
- 1 143o llo 100 420 130 100 2 1430 130 llo 530 150 #15 failed at 2' 3 1440 140 110 490 160 100 4 1420 150' 120 510 170 llo 5 1430 180 120 640 200 110 6 1500 210 130 700 220 120 7 1500 240 140 740 240 120 8 1490 270 140 710 260 120 9 146o 290 150 750 260 130 lo 1470 320 160 900 290 130 #11A failed at lo' 15 11 1460 330 170 1000 320 140 #20AB failed at.lo' 3
.. .12 .
Ikko ~3.5 0 180 ;104.0. . . 360- 140.. ' r#14a. &
- IIB ,fiirede ,ar 1430 1160 400 f50 13' 376 200 ,
14 1420 410 210 1120 400 150 .. 15 1420 420 220 1120 390 160 Flame out at 15' 16 1000 430 220 1120 400 160 #13A & 19AB failed at 15' 35" 17 904 kho 22o 1300 400 160 #4B failed at 17' 18 900 460 230 1370 390 160 #4A & 5A failed at 18' 30" 19 890 460 230 1380 390 160 #1B & 3A f ailed at 19 20 860 470 230 1380 390 16o 21 840 470 230 890 390 160 22 810 480 230 860 380 160 23 780 490 240 820 390 160 #3B railed at 23' 40" 24 750 500 240 810 400 160 25 730 Slo 240 790 440 170 26 710 530 240 76o 41o 17o 27 680 530-240 730 390 170 28 660 520 240 710 380 170 29 640 520 230 680 380 170 30 620 500 230 640 370 170 31 590 500 23o 620 360 170 32 570 490 230 600 360 170 33 55o 490 230 57o 360 170 ? 34 540 47o 230 540 36o 170 35 520 470 230 520 350 17o All ria=oc out at 35' lo"
- Refer to Tahic No. 1 for cahic type.
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Decsmbar 14, 1976 THE OKONITE COMPANY Ramsey, New Jersey ENGINEERING REPORT NO. 289 Public Service Electric and Gas Horizontal Cable Tray Fire Tests INTRODUCTION Fully loaded horizontal cable tray fire tests were conducted for Public Service Electric and Gas Co. of New Jersey. These tests were designed by PSEkG to determine the fire characteristics of various cable con-4 structions in horizontal fire tests. PSEkG also investigated the spacinr4 required between trays and conduits to prevent propagation. Propagation for these tests was defined as causing the cable in the upper tray or conduit to burn to short circuit.
SUMMARY
A twelve inch spacing between horizontal trays did prevent propagation during the fire test designed by PSEkG when 600V, 7 C #12 EPR-Hypalon control cable was exclusively utilized for testing. An eighteen inch spacing did not prevent propagation from one tray to the next when 600V, 7/C, #12 polyethylene-polyviny1 chloride (non-flame retardant) control cable was utilized for testing. , The coaxial and instrumentation cable tested created a large enough fire in ( the bottom tray to propagate the fire to the lower row of EPR-Hypalon cable in the upper tray. An asbestos thermal blanket prevent damage to the EPR-Hypalon cables during a twelve inch spacing fire test. Without the blanket, some damage occurred. The thermal blanket is effective, but it reduces the inside volume of the cable tray. PROCEDURE Tests 1-6, 9-11: Two 12 x 2-1/2 inch horizontal trays were utilized for these tests. The bottom tray was placed three inches above the 105,000 BTU /hr. (calcu-lated value),13-1/4 inch commercial gas burner. The top tray was spaced 18iinches above the top of the bottom tray for Tests 1-6 and 9. The spacing was reduced to 12 inches for Tests 10 and.)G(f. Il
December 14, 1976 Engineering Report No. 289 Each tray was loaded with two tightly packed regimented rows of cables. Each cable was approximately 68 inches long. The lower row of the top tray was electrified (120/240 volts) to determine time to short circuit should the fire propagate to the top tray. Cable construction varied. Table 111sts the constructions utilized. t A temperature profile of the fire was recorded throughout each test. - Thermocouples were located as shown in Rt.1. Copper mirrors were hung approximately two feet above the top tray to determine the presence of corrosive off gases. This procedure was discontinued after the fourth test. Tests 7 and 8: The bottom tray was kept identical to the bottom tray described in the procedure above. The top tray was removed. Two 2-inch steel ,' conduits were placed above the bottom tray. Both conduits were 66 inches long. One conduit was placed three inches above the top of the cable tray. The remaining conduit was placed six inches above the cable tray. A temperature profile was obtained throughout the test, also. (See E1. 2) Test 7 EPR-Hypalon cable was used in the bottom tray for both tests. l I had one electrified length of EPR-Hypalon cable in each of the conduits. An electrified coaxial and instrumentation cable were placed in each of the conduits for Test 8. The burner application time for each test was fifty minutes. Tests 1-12: Time to short circuit, afterburn, and maximum jacket damage were recorded for each test. Films were taken of each test by PSE&G personnel. DISCUSSION These objectives Initially, the PSELG test program had four objectives. were (1) comparison of various materials, (2) performance of fire-proof l- coatings on cables, (3) performance of thermal blankets inside trays, ' and (4) performance of cable inside conduit in horizontal tests. Tests 1 through 6 were designed to compare the various cable materials. The fire source was applied for twenty minutes during Tests 1, 2, and 3 at a rate of 105,000 BTU /hr. The first three constructions did not l demonstrate fire propagation. However, the polyethylene /PVC construc-tion was beginning to propagate the fire when the burner was extinguished. l
)
December 14, 1976 Engineering Report No. 289 If the fire source was allowed to burn longer, the polyethylene /PVC would have propagated the fire to the upper tray. The 105,000 BTU / hour burn applied for twenty minutes is considered to be a severe fire. However, twenty minutes was not long enough time period to differentiate the various cable methods when the samples were tightly packed in the tray. Therefore, PSEkG decided to increase the - length of time until they felt the fire in the lower tray had reached its maximum intensity. Tests 4 and 5 are an example of different fire characteristics encountered. Test 4 had EPR-Hypalon control cable in the bottom tray and coaxial and instrumentation cable in the top tray. Throughout the 46 minute fire source However, application to the EPR-Hypalon cable, propagation did not occur. when the trays were reversed, the coaxial and instrumentation cable created a large enough fire to propagate to the EPR-Hypalon cable in the . top tray.
'The CMO construction (Test 6) performed similar to the EPR-Hypalon tests. A longer afterburn was experienced due to the greater amount of The helically wrapped fuel (EPR) and the corrugated bronze shield tape. Pressure tape did not allow the gases from the core to escape easily.
This characteristic of was created and caused a more intense fire. helically wrapped metallic tape constructions has been observed in vertical cable tray fire tests, as well. Test 9 illustrated the flamability of polyethylene /polyviny1 chloride control cable. The PVC was not the flame retardant type. This construction does not burn similar to EPR-Hypalon. The PVC does not swell as does the Hypalon. When the Hypalon swells as it ashes, it acts as a heat shield to the remaining unburned portion. The polyethylene /PVC melts then flows and burns. As it burns, it exposes more flammables. l The cables in the upper tray began to melt due to the heat generated from Several short circuits occurred prior to ignition of the i the lower cables. The top tray took only five minutes before it was top tray of cables. The preheating and melting totally engulfed with flames on the bottom row. ' of the top tray of cables caused the rapid propagation of fire. Tests 7 and 8 were designed to determine the performance The EPR-Hypalon of cables in in the conduit in close proximity of cable tray fires. bottom tray did not create as severe a fire as would polyethylene /PVC. Therefore, the cables in the conduit did not experience the worst conditions. However, this test was designed to simulate a possible cable tray / conduit arrangement PSEkG would encounter in their nuclear stations where they using EPR-Hypalon or neoprene cables, not polyethylene /PVC.
, . - , . . , . - - . , .-,_,......,,,.,_.-_w .,...,,_,..,.-,_,,m.. , . e,_,, .,-,m~_.,,-,. ___,,._.__e_.
Decsmbar 14, 1976 Engineering Report No. 289 Maximum jacket The samples in the conduits were slightly damaged. The cores of all the test samples damage is shown in Table H. No short circuits occurred. It experienced minimal surface damage. was unknown which cables, if any, ignited since they could not be seen while inside the conduit. Testa 10 and 11 were designed to determine the performance of thermal blankets inside trays. A 0.1 inch thick woven : asbestos blanket Testwas 10 was placed in the bottom and up the sides of the tray in Test 11.The blanket r identical to Test 11 except for the blanket. Tray spacing was reduced t capacity by two samples. (Thermal typify PSEkG cable tray spacings where cable trays cross. blankets are being used at these crossings.) l The thermal blanket did prevent damage to tlie upper No tray shortincircuits Test 11. ) Fourteen inches of damage was measured in Test 10.It is impor occurred in either test. tray spacings, EPR-Hypalon still did not propagate the fire in Test 10 This decision was based PSEkG decided not to test fire-proof coatings. on the good performance of the EPR-Hypalon and CMO constructions tested. Slight traces of Copper mirrors were utilized during the first four tests. I copper remained on the glass after completion of the first two After Test 3, no copper remained. The disappearance of copper signified the emission of a halogen compo
~
(H C1) from the burning cable. 'The disappearance was expected'sinc Hypalon and PVC have chlorine atoms in them and a great deal of
~
is generated durin'g the lengthy tests. The PSEkG fully loaded horizontal cable tray fire tests were not the wo Tightly reigmented samples in cable trays will not burn case conditions. as quickly or with the same intensity as randomly placed samples. ble A except for the coaxial and instrumentation cable tests, homogeneous constructions were used for each test.' however, they felt that the cable selection and placement in the test trays best typified their present nuclear installations. i Approved , , A~'- Prepared by:~ h
'R. G. Feller J. R. flacelosi JRC/ row
/
December 14, 1976 Engineering Report No. 289 DISTRIBUTION: Messrs. J. S. Lasky R. G. Feller M. B. Masiarz . R. A. Guba G. T. Dobrowolski E. E. McIlveen J. S. Pirrong - PSE8cG J. E. Hogan T. A. Kommers I l l l [ l I t l l l l I
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. s Decembe r 14, 1976 Engineering Report No. 289 o ,
, s y TABLE 'I CABLE _ CONSTRUCTIONS ;
)
EPR-Hypal'on (Okonite)' FO-70651 - 7/C (12 7 X TC,' . 030" Okonite, . 015" Okolon,
. 020" extruded fill, ,; 065" Okolon jackst OD = 0. 760"
, n, FMR X-Olene; Flame and moisture resi tan'tlcrosslink polyethylene (Okonite)
EO 96517, 7/C, #12 7 X TC, .*035" FMR X-Olene, . 035"
' extruded fill, .065" Okolon jacket ' OD = 0. 700"
.P-30; Polyethylene-Polyvinylebloride (Okonite)' i i' SO 3-175?9 - 7/C, #12 7 X BC, . 020" Olcolene, .010" Okoseal,
.012" binder tape, . 065" Okoseal jacket OD = 0. 650" f ,
Coaxial (Boston Insulated Wire) .
>~
7 strands of #21.BC, .120" insulation, . 008" BC braid,
.,001" heat barrier tape, . 005" asbestos-glass tape, 0}0" BC braid, .001" Mylar tape, .045" thermost jacket OD= 0.500"
,s N, .,
- ?.
Instrumentation (American Insylated s. Wire) , 7 pair #16 7 X . 020" EPR, . 017" neoprene, !18 7 X TC drain wire, .002" al'uminum Mylar shield, cabled with .008" asbestos-gla'sa tape, .002F Mylar tape, .095" neoprene l OD = 0. 910" jacket , I x CMO (Okonite) 4/C, #10 19 X TC, . 055" Okonite, .021" Okoprene, 5 rubber
.015" Okoprene tapes. 006" glass reinforced i fille rs , 2 asbestos Mylar, .005" corrugated bronze shield, .110" i
OD = 0. 930"
- Okoprene jacket t ,
O f. b - _ - - _ - _ _ _ -
Engineering Report No. 289 Decembe r 14. 1976
- TABLE U TABLE OF RESULTS Burner Trey or Maximum Damage Time to Application Conduit Cons truction Bottom Tray Top Tray Conduit Short Circuit Afterburr Test # (min) SpacInr Bottom Trar Top Trar Conduit (in. ) (In. ) (in.) Propa gation (min) (min e sec 1 20 18 EPR-Hypalon EPR-Hypalon --- 35/24(II. None --- No None 1230 2 20 18 FMR X-Olene FMR X-Olene --- 36/26 None --- No None None 3 20 18 Poly /PVC Poly / PVC --- 46/32 15/None --- No None Not record 4 46 18 EPR-Hypalon Coax. . Instr. --- 36/29 Coax. Blisters --- No None 10 30 5 35 18 Coax. Ins tr. EPR-Hypalon --- 38/29 28/None --- Yes 28 (3) 12 : 30 6 50 18 CMO CMO --- 33/27 17/None --- No None 32 : 20 3: 6(2) EPR-Hypalon EPR-Hypalon 48/33 --- 8: 7(2) No None 12 00 7 50 ---
50 3; 6 EPR-Hypalon Coax. Ins tr. 47/33 ---- 6: 2 No None 10300 8 --- Poly /PVC 48/45 Yes 34 (4) 46 : 15 9 50 18 Poly / PVC --- f8/68 --- utotalt 10 50 12 EPR-Hypalon EPR-Hypalon -- 47/35 14/None --- No None 8 : 10 11 50 12 EPR-Hypalon EPR-Hypalon --- 46/35 None --- No None 11 : 40 w/ asbestos thermal blanket (1) Bottom 1ayer of cable /toplayer of cable (3) Tour of fifteen cables short circuited (2) Lower conduit; upper conduit . (4) All Afteen cables short circuited
I May 2, 1977
' THE OKONITE COMPANY
-Ramsey New Jersey SE(X)ND ADDENDUM TO ENGINEERING REPORT NO. 289
SUBJECT:
Public Service Electric and Gas Company, Horizontal Cable Tray Fire Tev.ts . u ,
, e An additional fire test was performed at the request of PSE&G. PSE&G utilizes asbestos blankets in horizontal trays which are spaced less than 18" from each other.:
It becomes necessary to slit the blankets in order to secure,them to the trays. The NRC had questioned PSE&G i oncthe possibility of propagation of fire from one ~ l horizontal tray to the next through these s11ts. s Two horizontal trays PSE&G designed the following test:The bottom tray was filled were. placed 12 inches apart. The top tray
' with two layers of 4/C #919X CHO-E cable.
had a thermalon. blanket placed in the bottom of the tray with four 4 to 5 inch slits cut in it. Dio elits were direccly above the burner and two were juse outside the The bottom layer of the top perimeter of the burner. The tray was filled with CMO-E cables and electrified. As in all top layer was filled with CHO-E cables.100,000 BTU /hr. . , _ , i previous horizontal PSE&G tests, theThe burner was applied for circular burner was utilized. Temperatures at six locations were moni- j l fifty minutes.
)
tored and photographs were taken. Short At no time were flames observed in the top tray.
- s. circuits did not occur to any of the cables in the top tray. However, the bottom layer did experience some The slits f, .'
jacket damage. The core was in good condition. in the thermalon blanket probably allowed more hot air to Damage was not concentrated filter through the top tray.The entire area on the bottom directly above the slits. of the lower layer of cable above the burner was damaged.
SUMMARY
OF RESULTS
~
i 50 Burner Application (min) 18 i Tray Spacing (inches) CMO-E j t.'
Construction No Propagation No Shorts f
i Time to Short Circuit (min) 39 Afterburn-(min)- ' i 4 l
/
- Gefchfd ___
I l J. R. Cancelosi JRC/jsg . . f - - _
,)
" vets CBMENW873 CCBMpANY mmmm Work Parformad - Mcy 1977 Work Reported - March 27,1979 THIRD ADDENDUM to ENGINEERING REPORT NO. 289 P. S. E. & G. HORIZONTAL CABLE TRAY FIRE TESTS ~
Four additional fire tests were designed by and performed for P.S. E. & G. P.S.E. & G. 's purpose for these tests was to justify their cable construc-tion selection and cable system design. These tests also allowed for motion picture filming by a professional film crew. The first two tests were repeats of Tests 6 and 9 of Engineering Report No. 289. These two tests were performed mainly to demonstrate a good flame retardant construction versus a poor flame retardant construction in P.S.E.
& G. 's cable system. As expected, the CMO-E construction (Test #14) did not propagate the fire to the upper tray. The polyethylene-polyvinylchloride construction (Test #15) did pro agate the fire. Short circuits in the upper tray occurred approximately 3a minutes prior to visual observance of flames in the tray. This indicated that the polyethylene and PVC materials were melting due to the heat generated in the lower cable tray. The fire did not have to propagate from the lower tray to the upper tray in order to interrupt elec-trical integrity.
i Since these two tests were performed for motion picture filming and are repeats of Tests 6 and 9, actuallength of damage measurements were not recorded but can be seen in the movie. Damage to the CMO-E construction wasy very similar to the damage observed in Test #6. Damage to the poly- ' ethylene - PVC construction was severe, however, the entire upper tray was l- not completely damaged as in Test #9. A summary of these two tests appear j- in Table 1. l The last two tests requested by P. S. E. k G. involved an elaborate cable tray configuration as shown in the attached diagram. The cable trays were of the same type as used in Ahe previous tests. Rungs were spaced 9" apart center to center. The bends in the "S" trays were closed on the inside The of the tray. burner was The two horizontal trays were in contact with the "S" trays. l centered directly beneath the lower "S" tray as shown in the diagram. The , li l_ burner was applied for 50 minutes. Ten cables in the upper "S" tray and five in the lower horizontal tray were energized to measure time to short circuit. L,' Temperatures were measured at various locations as indicated on the diagram. l! Each cable tray was filled with two layers of the cables described below: l
March 17,1979 Third Addendum to Page2 Engineering Report #289 "S" Trays Test #16 7/C #12 (7 X) BC, . 020" Okolene, . 020" Okoseal,
. 012" binder tape, . 065" Okoseal jacket OD - 0. 650" Test #17 4/C #9 '(19 X) TC, . 055" Okonite, . 020" Okoprene, 5 rubber finers, 2 . 015" Okoprene tapes, . 006" ,
glass reinforced asbestos-Mylar, . 005" corrugated bronze shield, .110" Okoprene jacket OD = 0. 930" Horizontal Trays Tests #16 and 17 - 7/C #12 (7 X) TC, . 030" Okonite, . 015" OD = 0. 760" Okolon, . 020" extruded fin, . 065" Okolon jacket During the first 40 minutes of the Poly /PVC test, the fire in the lower horizontal section of the "5" tray continued to spread. At approximately 40 minutes the fire creeped around the corner of the tray and during the next three minutes propagated up the vertical section of the tray. At the 60 minute mark (10 minutes after the burner was turned off), the fire spread to the upper horizontal section of the lower "S" tray. The first short circuit in the upper "S" tray occurred at approximately 61} minutes. Flaming ashes fen into the horizontal trays but extinguished within ten minutes. No shorts were observed in the two horizontal EPR-Hypalon trays. At the 100 minute mark the test was discontinued and the fire was extinguished with water. The CMO-E test (Test #17) had completely different results. Damage was confined to only the lower horizontal section of the lower "S" tray. Overan damage was less than 40 inches. No short circuits occurred in any of the - cables energized. Afterburn lasted for 35 minutes. A comparison of Tests 16 and 17 are shown in Table 1. l L ' After the above test was completed and the cables cooled down to room temperature, the burner was moved to the left so that the Sames impinged on the cable just as they entered the lower curve of the "S" tray. The name was reapplied for 50 minutes. The fire did not burn past approximately two-thirds the way through the bend. Afterburn lasted 34 minutes. Ir This additional fire application was not photographed or witnessed by lj~ P.S.E. & G. but was done by Okonite to determine if the cable would { ' propagate up the vertical section if the flame source was applied close to it. i
Me.rch 27,1979 Third Addandum to Engineering Report #289 Page 3 TABLE #1 Summary of Results 14 15 Test Number Burner Application, minutes 50 50 Tray Spacing, inches 18 18 ' Construction - Bottom Tray CMO-E Poly /PVC Top Tray CMO-E Poly /PVC "S" Tray Fire Spread to: Upper. Horizontal Tray No 25:00 Propagation No Yes Time to Short Circuit, min : see No Shorts 21:20 Afterburn, minutes 28 49 16 17 Test Number Burner Application, minutes 50 50 Tray Spacing, inches See Diagram Construction - "S" Trays Poly /PVC CMO-E Horizontal Trays EPR-Hypalon Fire Spread to: Upper "S" Tray, minutes 60:00 No Lower Horiz. Tray, min. Slight Damage No Propagation Yes No Time to Short Circuit, min: sec, "S" 61:20 No Shorts Horiz. No Shorts No Shorts Afterburn, Ext.with Water 35
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