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