Design and Testing of Commercial vs Nuclear Qualified Cable · • IEEE 383-1974 vs. IEEE 383-2003...

Design and Testing of Commercial vs

Nuclear Qualified Cable

Jim FitzgeraldThe Okonite Company

Established 1947

ICC Fall 2007 Scottsdale Az

Education Subcommittee

COLLEAGUES

John Cancelosi

Carl Zuidema

ICC Fall 2006Subcommittee D

Jacket

Integrally color coded

insulation

CHARACTERISTICSCOMMERCIAL

• WET ELECTRICALS• MECHANICALS• PRODUCTION

TESTING

NUCLEAR

40 YEAR LIFE ANALYSIS• THERMAL AGING• RADIATION AGING• WET ELECTRICALS• MECHANICALS• PRODUCTION

TESTING

COMMERCIAL LOW VOLTAGE POWER and CONTROL CABLES

INDUSTRY STANDARDS

• NATIONAL ELECTRICAL CODE• UNDERWRITERS LABORATORY• ICEA• AEIC

NATIONAL ELECTRICAL CODE

• THHN/THWN• XHHW

• RHH/RHW

PVC/NYLONXLPEEPR

Jacket

Integrally color coded

insulation

COMMERCIAL XHHW-2 or RHH/RHW-2

• DimensionsPhysicals

– 7d at 121C– 4d in oil at 100C– 720hr weatherometer

• Conductor Corrosion• Cold Bend• Deformation Resistance• Crush Test

• Long Term IR at 90C and 600v– Capacitance– SIC– Pf Stability

• Horizontal Flame test• VW-1 Flame Test• Dielectric Withstand

– ACBD after Glancing Impact

– ACBD after Limited Scoring

SINGLE PASS INSULATION

OR INSULATION + JACKET

CONDUCTOR

USUALLY COPPER

COMPRESSED OR COMPACT

SMALL WIRE TESTING

WATER TANK

TESTING

? QUESTION ?

Is There a Short Term

Test That can Predict

Long Term Performance

Compounding Objectives

• New Base Polymer• 1 - Compound with XHHW Properties• 2 - Flexible-Low Set Compound• 3 – New Flame Test IEEE 1202• 4 – Plant Life Extension to 60 years

Compound Development

• Survey Experiments– Broad Evaluation of Numerous Variables and Levels

• Mixture Designs– Valuable for Predicting Response within Design

Space• Factorial Designs

– High Reliabiltiy Requires Numerous Trials • Optimizations

– For Fine Tuning – Can be of Various Designs

EPR-N Physical Properties

Tensile Properties

EPR-N

Stress @ 100%, psi

ICEA0

500

1000

1500

2000

2500

Psi o

r % E

long

.

EPR-N

ICEAType II EPR

EPR-N

ICEAType IIEPR

Tensile Strength, psi

Elongation, %

Fluid Resistance, 100 Hour Immersions

IRM 902 Oil150°C

IRM 902 Oil

150°C

IRM 902 Oil

150°C

Diesel Fuel60°C

Diesel Fuel60°C

Diesel Fuel60°C

0.0

10.0

20.0

30.0

40.0

50.0

60.0

70.0

80.0

90.0

EPR-N EPR Type II XLPE

XHHW

% S

wel

l

EPR-N

Accelerated Aging

Original21Days @

150° 14 Days @165°

Hardness

% Elongation Ret.

% Tensile Strth Ret.

0

20

40

60

80

100

120

VW-1 Flame Test Performance

1st A

pp

2nd

App

3rd

App

p

4th

App

5th

App

Flag

EPR-II

EPR-N

0

10

20

30

40

50

60

Bur

n Ti

me

afte

r Fla

me

App

licat

ion

EPR-N Electrical Properties

•

SIR MΩ

–

1000ft

6910000•

Dielectric Const. 40V/mil

2.77

•

Dielectric Const. 80 V/mil

2.77•

DF 40 V/mil

0.0020

•

DF 80 V/mil

0.0020

EPR-N Dissipation Factor after Water Immersion

0.00

0.10

0.20

0.30

0.40

0.50

0.60

0.70

0.80

0.90

0 50 100 150 200 250 300 350 400

Days Immersion

DF

x 10

0

Unique IEEE 383 Requirements

• Type Testing– Simulate Significant Aging Mechanisms– Simulate Specific Service Conditions

• Characterize Aging Performance• Test After Characteristic Aging

– Thermal Aging– Radiation Aging– Aging Sequence?

EPR-N Oven Aging Performance

0

20

40

60

80

100

120

1 10 100 1000 10000

Hours Oven Aging

% R

eten

tion

of E

long

atio

n

180°C165°C

150°C136°C

Arrhenius Treatment

EPR-N

Butyl

Neoprene

Natural

90°C

EPR II

Silicone

120°C150°C180°C

Hypalon

10.0

100.0

1000.0

10000.0

0.0020 0.0022 0.0024 0.0026 0.00281/T°K

Hou

rs O

ven

Agi

ng

EPR-N

ButylEPR II

136°C150°C180°C10.0

100.0

1000.0

10000.0

0.00205 0.00215 0.00225 0.00235 0.00245 0.00255 0.00265 0.00275

1/T°K

Hou

rs O

ven

Agi

ng

Analysis of Arrhenius Data

X 3.1

X 7.1

Accelerated Aging Conculsions

• From Past Experience– EPR II Aged 21Days @ 150°C Simulates 40

Year Service• Arrhenius Chart

– EPR-N ~3 x Improvement over EPR II– EPR-N Aged 14 Days @165°C, (~3x EPRII)

to Simulate 60 Years Service is Conservative

Unique IEEE 383 Requirements

• Type Testing– Simulate Significant Aging Mechanisms– Simulate Specific Service Conditions

• Characterize Aging Performance• Test After Characteristic Aging

– Thermal Aging– Radiation Aging– Aging Sequence?

Sequential Aging, Design Matrix

Test X X X

Test X X X X X

150 M Rads 150 M Rads 150 M Rads 150 M Rads 150 M RadsTest X X X X X

14 days @ 165°C

21 days @ 150°C

None 21 days @ 150°C

14 days @ 165°C

50 M Rads 50 M Rads

Aging Sequence N/A Thermal-1

Radiation-Thermal-1 Radiation-

Radiation-1 Thermal-

Radiation-1 Thermal-

Radiation Aging 50 M Rads

Step 1, Thermal Aging

Step 2, Aging sequence

Step 3, Final Radiation

50 M Rads

Thermal Aging

50 M Rads

None21 days @

150°C14 days @

165°C

Thermal Aging

No

Ove

n A

ging

21 D

ay 1

50°

Ove

n Fi

rst

14 D

ay16

5°O

ven

Firs

t

21 D

ay 1

50°

Rad

firs

t

14 D

ay 1

65°

Rad

Firs

t

+ 150 MRads50 MRads

No radiation0

20

40

60

80

100

120

% R

eten

tion

EPR-N, Effect of Aging Sequence

Summary

•

New Compound, Very Superior Properties:– Dielectric– Flame Resistance– Aging– Physicals – Lab & Prototype Tests Gives High

Confidence– UL Ratings: XHHW-2, RHW-2

Overview• History of Class 1E Testing• IEEE 383-1974 vs. IEEE 383-2003

– DBE LOCA Test– Vertical Tray Flame Test

• Qualification Test Program– Specimen Selection– Aging– LOCA & HELB– Flame Tests

Early Cable Qualification Tests (Pre IEEE 383-1974)

• Early 1960’s - Effects of radiation• ’60s – early ’70s

– Thermal aging to ICEA requirements• 1 week @ 121 C

– Radiation: 100 Mrads gamma– Mild LOCA profile

Early Cable Qualification Tests

Pre IEEE 383-1974

IEEE Standards

••IEEE 323IEEE 323--19741974 –– Std for Qualifying Class Std for Qualifying Class 1E Equipment for Nuclear Power 1E Equipment for Nuclear Power Generating StationsGenerating Stations

••IEEE 383IEEE 383--19741974 –– Std for Type Test of Std for Type Test of Class 1E Electric Cables, Field Splices and Class 1E Electric Cables, Field Splices and Connections for Nuclear Power Connections for Nuclear Power Generating StationsGenerating Stations

••Tests to Qualify for Normal OperationTests to Qualify for Normal Operation

••Tests to Qualify for Design Basis Event Tests to Qualify for Design Basis Event

•• LOCA LOCA

•• HELB / MSLBHELB / MSLB

••Tests to Qualify for Design Basis Event Tests to Qualify for Design Basis Event –– FireFire

IEEE 383-1974Qualification (Type) Tests

IEEE 383-1974Tests to Qualify for Tests to Qualify for NormalNormal OperationOperation

•• Made, tested and qualified to Industry Made, tested and qualified to Industry Standards ICEA Standards ICEA -- AEIC AEIC -- NEMANEMA

•• Long Term Physical Aging PropertiesLong Term Physical Aging Properties•• Thermal & Radiation ExposureThermal & Radiation Exposure

1)1) Aging to Aging to ““End of LifeEnd of Life”” conditioncondition2)2) Radiation Exposure Radiation Exposure (50 (50 MRadsMRads))3)3) Mechanical & Electrical WithstandMechanical & Electrical Withstand

IEEE 383IEEE 383--19741974Tests to Qualify for DBE Tests to Qualify for DBE --LOCALOCA

•• Thermal & Radiation ExposureThermal & Radiation Exposure•• Aging to Aging to ““End of LifeEnd of Life”” conditioncondition•• Radiation ExposureRadiation Exposure

•• Normal Life Dosage (50 MRads)Normal Life Dosage (50 MRads)•• One accident dose (150 MRads)One accident dose (150 MRads)

•• LLoss oss oof f CCoolant oolant AAccident simulationccident simulation•• Temperature, Pressure & Temperature, Pressure & ChemChem sprayspray

•• Post Post LOCALOCA Simulation testSimulation test•• Mechanical & Electrical WithstandMechanical & Electrical Withstand

IEEE 383IEEE 383--19741974

Tests to Qualify for DBE Tests to Qualify for DBE -- FlameFlame

•• Vertical wire flame testVertical wire flame test•• Vertical tray flame testVertical tray flame test

•8 ft ladder type tray•12” wide•Gas burner placed 3” behind tray and 2 ft off the floor•Theoretical Heat Input 70,000 BTU/hr•Specimens fill at least center 6” of tray width•Specimens spaced ½ OD apart•Flame Exposure 20 minutes•Allow cable to burn until self-extinguished

IEEE 383 VTFT ProcedureIEEE 383 VTFT Procedure

Cable cannot propagate to the top of the tray.

(< 6 feet damage)

IEEE 383 VTFT Requirement

1974 to 2003

•• Additional issues, Additional issues, such assuch as

•• Synergistic effectsSynergistic effects•• Factory SplicesFactory Splices•• Fire Resistance Fire Resistance •• Multiconductor qualificationMulticonductor qualification

IEEE 383-2003•• Not intended to require reNot intended to require re--qualificationqualification•• Type Testing still preferredType Testing still preferred•• Emphasizes other methods of Emphasizes other methods of

qualificationqualification•• Past operating experiencePast operating experience•• Ongoing qualificationOngoing qualification•• Qualification by analysisQualification by analysis

IEEE 383-2003 - Changes•• Vertical Tray Flame Test procedure Vertical Tray Flame Test procedure

removed and refers to IEEE 1202removed and refers to IEEE 1202--19911991•• Synergistic effectsSynergistic effects•• Factory splice qualificationFactory splice qualification•• Multiconductor qualificationMulticonductor qualification•• Class 1E qualification for Class 1E qualification for normalnormal

serviceservice must be demonstrated must be demonstrated separately from separately from DBEDBE qualificationqualification

1202 vs. 3831202 vs. 383--1974 VTFT 1974 VTFT ComparisonComparison

••Both 70k BTU/hrBoth 70k BTU/hr••IEEE 1202 IEEE 1202

Increased Tray loadingIncreased Tray loadingDecreased spacing (> 1Decreased spacing (> 1”” cables)cables)Bundled small diameter cables (< 0.5Bundled small diameter cables (< 0.5””))Less damage allowed (4.9 ft Less damage allowed (4.9 ft vsvs 6 ft)6 ft)Burner angle (20Burner angle (20°°))Test EnclosureTest EnclosureForced VentilationForced Ventilation

Tray Loading and Spacing

6” min.

12”

~8.5” to 11”

1.2” diameter4 cables0.6” spacing

1.2” diameter5 cables0.5” spacing

383

1202

6”

12”

~9” to 11”

0.3” diameter

14 cables

0.3” diameter 10 groups of 3 30 cables

383

1202

Tray Loading and Spacing

383-74 5 cables

Tray Loading OD = 0.97”

1202 7 cables

Cable OD 0.31”

1202 30 cables fill = 9.7”

Sketch from IEEE 1202-20061202 Test

Enclosure

1202383

4545””

5959”” P/FP/F

7272””

PVC jacketedPVC jacketedpower cablepower cable

Class 1E Qualification Program

for a Instrumentation, Control & LV Power EPR

Insulation

1.1. Industry Standard TestsIndustry Standard Tests2.2. LOCA TestLOCA Test3.3. Normal Operation TestNormal Operation Test4.4. HELB TestHELB Test5.5. Vertical Tray Flame TestVertical Tray Flame Test

Class 1E Qualification Program

1.1. Industry Standard testsIndustry Standard testsICEA & UL requirementsICEA & UL requirements1/C1/C: : Listed as RHWListed as RHW--2 , XHHW2 , XHHW--2, X1102, X110

VW-1 & Oil ResistantM/C: Listed as Type TC

Class 1E Qualification Program

2. 2. LOCA Test Sample selection:LOCA Test Sample selection: Single Conductors:Single Conductors:#14 AWG (7x) 0.030#14 AWG (7x) 0.030”” EPREPR--NN#16 AWG (7x) 0.025#16 AWG (7x) 0.025”” EPREPR--NN

Six Six ccoolloorrss

Class 1E Qualification Program

22. . LOCA Test Sample selection:LOCA Test Sample selection: M/CM/C•• 3/C #14 AWG 0.0303/C #14 AWG 0.030”” EPREPR--N, cabled, N, cabled,

binder tape, TSbinder tape, TS--CPE jacketCPE jacket•• 3/C #14 AWG 0.0303/C #14 AWG 0.030”” EPREPR--N, cabled, N, cabled,

binder tape, CSPE jacketbinder tape, CSPE jacket•• 1 Pr #16 AWG 0.0251 Pr #16 AWG 0.025”” EPREPR--N, #18 AWG N, #18 AWG

drain wire, Cu laminate tape, XLPO jacket.drain wire, Cu laminate tape, XLPO jacket.

Class 1E Qualification Program

2.2. LOCA TestLOCA TestNon aged specimensNon aged specimensAged specimens Aged specimens

Radiation Radiation –– 50 Mrads (gamma)50 Mrads (gamma)Thermal Thermal -- 3 weeks @ 150 C3 weeks @ 150 C

-- 2 weeks @ 165 C2 weeks @ 165 C

Class 1E Qualification Program

2.2. LOCA TestLOCA TestAccident radiation dose Accident radiation dose -- 150 Mrads 150 Mrads Current & voltage loadedCurrent & voltage loadedTempTemp--PressurePressure--ChemChem Spray profileSpray profileCharging current monitoredCharging current monitoredPeriodic IR measurementsPeriodic IR measurements

LOCA Profile

Margins• Double peak

• Voltage: ø-ø Rated voltage applied ø-grd

• Radiation • Normal aging: 50 Mrads - gamma• Accident: 150 Mrads - gamma

• Thermal Aging: 60 years

Class 1E Qualification Program

for a Instrumentation, Control & LV Power EPR

Insulation

LOCA Test EPRLOCA Test EPR--N SpecimensN Specimens•• 42 1/C wires42 1/C wires•• Six 3/C cablesSix 3/C cables•• Three 1 Pr cablesThree 1 Pr cables

LOCA EPRLOCA EPR--N Test SpecimensN Test Specimens•• 42 1/C wires42 1/C wires•• Six 3/C cablesSix 3/C cables•• Three 1 Pair cablesThree 1 Pair cables

Class 1E Qualification Program

3.3. LOCA Test ResultsLOCA Test ResultsAll samples: All samples: •• Maintained voltage & currentMaintained voltage & current•• Withstood PostWithstood Post--LOCA Simulation LOCA Simulation

TestTest•• Straighten & Recoil (40 x OD)Straighten & Recoil (40 x OD)•• 80 v/mil ac withstand80 v/mil ac withstand

Class 1E - Qualification Program

3.3. Post Post LOCA Test ResultsLOCA Test ResultsPost LOCA Long Term Moisture Resistance @90C

#16 AWG 0.025" EPR-N

0

1000

2000

3000

4000

5000

6000

7000

0 2 4 6 8 10 12 14

Time - months

IR M

ohm

s-10

00 ft

Non-Aged 3 Wks @150C 2 Wks @165C

IR values are avg of 2 specimens

Post LOCA Long Term Moisture Resistance @90C#14 AWG 0.030" EPR-N

0

1000

2000

3000

4000

5000

6000

7000

0 2 4 6 8 10 12 14

Time - months

IR M

ohm

s-10

00 ft

Non-Aged 3 Wks @150C 2 Wks @165C

IR values are avg of 2 specimens

Class 1E Qualification Program

3.3. Normal Operation TestNormal Operation TestSample selection:Sample selection: Single ConductorsSingle Conductors

#16 AWG (7x) 0.025#16 AWG (7x) 0.025”” EPREPR--NNsix specimenssix specimens

Class 1E Qualification Program

3.3. Normal Operation TestNormal Operation TestAging Aging

Radiation Radiation –– 50 Mrads (gamma)50 Mrads (gamma)Thermal Thermal –– 3 weeks @ 150 C3 weeks @ 150 C

-- 2 weeks @ 165 C2 weeks @ 165 C

Class 1E Qualification Program

3.3. Normal Operation TestNormal Operation TestMechanical & Voltage Withstand Mechanical & Voltage Withstand

Straighten Straighten 20 x OD bend20 x OD bend80 volt/mil ac withstand test80 volt/mil ac withstand test

Class 1E Qualification Program

4.4. HELB TestHELB TestSpecimens Specimens -- #16 AWG 0.025#16 AWG 0.025”” EPREPR--NNNonNon--aged & aged specimens aged & aged specimens Temp Temp –– Press Press –– ChemChem spray profilespray profileCurrent & voltage loadedCurrent & voltage loadedCharging current monitoredCharging current monitoredPeriodic IR measurementsPeriodic IR measurements

High Energy Line Break Test Temperature / Time Profile

HELB Temperature Profile

050

100150200250300350400450500

1 10 100 1000 10000 100000 1000000

Time (Seconds)

Tem

pera

ture

(F)

HELB EPRHELB EPR--N Test SpecimensN Test Specimens

Class 1E Qualification Program

4.4. HELB Test ResultsHELB Test ResultsAll samples: All samples: •• Maintained rated voltage & currentMaintained rated voltage & current•• Withstood PostWithstood Post--LOCA Simulation TestLOCA Simulation Test

•• Straighten & Recoil (40 x OD)Straighten & Recoil (40 x OD)•• 80 v/mil ac withstand80 v/mil ac withstand

Class 1E Qualification Program

5.5. IEEE 1202 VTFT Test ResultsIEEE 1202 VTFT Test Results600 V Constructions:600 V Constructions:•• 3/C #14 AWG 0.0303/C #14 AWG 0.030”” EPREPR--N, cabled, N, cabled,

binder tape, TSbinder tape, TS--CPE jacket CPE jacket -- PassedPassed•• 3/C #14 AWG 0.0303/C #14 AWG 0.030”” EPREPR--N, cabled, N, cabled,

binder tape, CSPE jacket binder tape, CSPE jacket -- PassedPassed•• 1 Pr #16 AWG 0.0251 Pr #16 AWG 0.025”” EPREPR--N, #18 AWG N, #18 AWG

drain wire, Cu laminate tape, XLPO drain wire, Cu laminate tape, XLPO jacket jacket -- PassedPassed

Class 1E Qualification Program

5.5. IEEE 1202 VTFT Test ResultsIEEE 1202 VTFT Test Results2 kV Constructions:2 kV Constructions:

•• 3/C #14 AWG 0.0453/C #14 AWG 0.045”” EPREPR--N, cabled, N, cabled, binder tape, TSbinder tape, TS--CPE jacket CPE jacket -- PassedPassed

•• 3/C #14 AWG 0.0453/C #14 AWG 0.045”” EPREPR--N, cabled, N, cabled, binder tape, CSPE jacket binder tape, CSPE jacket -- PassedPassed

•• 1/C #6 AWG 0.0601/C #6 AWG 0.060”” EPREPR--N N -- PassedPassed

Summary• IEEE 383-2003

– Doesn’t require re-qualification– Allows other types of qualification– Addressed ’74 to ’03 issues

• Qualification Test Program– EPR-N qualified to 383-74 & 383-03

Normal, LOCA, HELB & 1202– Qualification Report documents results

Previously Qualified Materials

• Type I EPR/CSM – LV• Type II EPR – LV• Type II FR EPR – LV• Type II EPR – MV• FR XLPE – LV• PVMQ – Silicone Rubber• ETFE – Ethylene Tetrafluoroethylene

Why Requalify

• Obsolete Materials– Base Polymers – Several EPRs– Compounds – Silicone Rubber

• New Standard – IEEE 383-2003– Only Applies to New Construction

• Offer Materials with Enhanced Properties– Improve Flame Resistance– Improve Physical Properties– Improve Aging