Search NASA⌕ Search

SEARCH · Search NASA

Results for “Cable aging”

Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

Quote a phrase for an exact phrase match. Source license links do not imply unrestricted reuse.

At least 55 records · Page 3
All sourcesNASA NTRSDOE OSTI
DOE OSTI2024

Evaluation of Clamshell Current Coupler for Online Frequency Domain and Spread Spectrum Time Domain Reflectometry to Detect Anomalies in Energized Cables

This document describes adaptation and evaluation of a clamshell inductive current coupler for online reflectometry testing (both frequency domain reflectometry and spread spectrum time domain reflectometry) to evaluate cable insulation degradation and anomalies. Safety-critical nuclear power plant cables were initially qualified for 40 years. However, as plants extend their operating licenses to 60 and 80 years, justification for continued safe operation includes test and monitoring programs. These will become more important as the industry moves to condition based qualification programs. Cable test programs traditionally involve manual interventions to disconnect cables, perform one or several tests, then reconnect the systems, usually during refueling outages occurring only every 18 to 24 months. This poses an operational burden that can be minimized by online testing or periodic connection to a coupler that may remain on the cable of interest or be clamped onto the cable without de-termination. This work investigates the adaptation of a clamshell inductive current coupler for either frequency domain reflectometry or spread-spectrum time domain reflectometry. The reflectometry test instrument injects a broad-band chirp or pseudo-noise signal onto a cable conductor and monitors for a reflected signal indicative of an impedance change caused by a damage condition. The instrument maximum input signal levels are typically 10 to 30 volts or less and the instruments will be damaged if subjected to 60 Hz power line voltages of 110, 220, or 480 VAC. One commercial spread-spectrum time domain reflectometry system has circuitry suitable for voltages up to 1 kV, but typical reflectometry tests are performed on de-energized cables. The clamshell inductive coupler provides >60 dB of 60 Hz attenuation with less than 10 dB loss in the 1-500 MHz test bandwidth of interest. An energized cable was successfully tested up to 6.7 kVp-p and frequency response plots imply that the tests could be extended to 10 kV or higher energized levels.

36 MATERIALS SCIENCE↗
DOE OSTI2024

SSTDR and FDR Detection of Un-Energized and Energized Cable Anomalies Including Thermal Degradation Using Machine Learning

Historically, cables are initially qualified for nuclear power plant use for 40 years. As plants extend their operating license to 60 and 80 years, continued use of these cables must shift to a performance-based approach since it is cost prohibitive to completely replace cables that are likely still capable of performing their design function. A variety of cable tests are available and are commonly applied during outages when the cables can be taken out of service. Frequency domain reflectometry (FDR) is one of these test methods that is being more broadly accepted and used because it not only detects anomalies along the cable with a low-voltage signal that does not stress the cable insulation, but the technique also locates the anomalies. This supports follow-up local inspection and local repair or partial replacement of a damaged cable segment. Currently, FDR testing is only applied to cables that are taken out of service since the test instrument would be damaged by operational voltages. A related technology that has found some acceptance in the aircraft and rail industry is spread spectrum time domain reflectometry (SSTDR). This technology has been implemented with a custom commercial instrument by LiveWire Innovation that is designed to operate on live cables up to 1000 volts and with a bandwidth of 48 MHz. Initial evaluation by the Pacific Northwest National Laboratory (PNNL) of the Live Wire system indicated that a broader bandwidth (BW) SSTDR may be better for many kinds of flaws. This led PNNL to develop an SSTDR laboratory instrument suitable for tests up to 500 MHz bandwidth. Testing on energized cables is also desirable for online monitoring systems so an inductive clamshell coupler was developed that allows energized cables to be tested up to at least 5 kV and likely higher voltage levels. Dielectric spectroscopy and tan delta testing plus various laboratory destructive tests were included in this data acquisition campaign directed to feed a machine learning (ML) study. With these kinds of developments, online energized cable tests may be possible with industrial adoption of such hardware advances but it will be completely impractical to have highly skilled data analysts continually examine these complex signals for indications of damage or compromised conditions. If online testing is to be implemented in new test hardware, it must be accompanied by software that can interpret the signals and alert plant operators of changing or degraded conditions. The thermally aged, shielded cable investigated here was separately treated for ML analysis. Visual analysis of electrical data showed generally increasing peaks where the cable entered and exited the oven. These peaks were not exactly aligned with expected locations, but these differences were attributed to velocity of propagation calibration errors. Only supervised ML was applied to the thermally aged data as this data was only available shortly before the committed publication date of this report. The supervised ML was structured to divide the 0 to 70-day responses as ‘normal’ from 0 to 35 days or ‘anomalous’ from 36 to 70 days, based on cable tensile elongation at break (EAB) insulation characterization. Using 80% of the data for training and 20% for testing, the supervised ML predicted normal versus anomalous was 70% accurate. Important conclusions include: • Accuracy to predict the presence of cable damage is improved from the 2023 effort by more training data. Weighted accuracies for comparisons among the instruments ranged from 67 to 89 % for unsupervised ML and 71 to 99% for supervised ML. • Based on the synthetic data tests, the unsupervised models are more generalizable to unseen anomalies. The Multi-Layer Perceptron classifier (MLP) model reported as high as 99.7% accuracy on the test data, but this dropped to 58.3% when tested on the synthetic data. In contrast, the unsupervised Pointwise model only achieved 89.7% accuracy on the experimental data but reported 78.3% accuracy on the synthetic data. • The best anomaly indicators are higher frequency (400 MHz BW) FDR data. Other tests may be interesting but for this study, this was the best predicter.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗
DOE OSTI2023

Dose Rate Effects on Degradation of Nuclear Power Plant Electrical Cable Insulation at a Common Dose

The intent of this report is to address an identified knowledge gap in relating accelerated aging of nuclear electrical cables to service aging: dose rate effects (DRE). Here, DRE refer to gamma radiation-induced polymer degradation being a function of dose rate in addition to total absorbed dose. The concern raised is that historical qualification conducted at higher dose rates to simulate service lifetime may underestimate insulation degradation that occurs at lower dose rates in service. In the work described herein, common nuclear cable insulation materials—cross-linked polyethylene (XLPE) and ethylene propylene diene elastomer (EPDM)—were subjected to accelerated aging at ambient temperature (26°C) at different gamma dose rates of 100, 200 and 1800 Gy/h for select exposure durations to achieve constant total doses of 170, 210 and 300 kGy to evaluate DRE. First, the cable insulation material types investigated are described. Then, the accelerated aging experimental process involving gamma irradiation applied to the insulation specimens at room temperature and different dose rates is discussed. Then, the experimental characterization techniques used to perform this work are elucidated. These include elongation at break (EAB), mass change, yellowness index (YI), carbonyl index (CI), density, indenter modulus (IM), and relaxation constant (t). Theory of polymer degradation is discussed, and characterization results and discussion are provided. Finally, concluding remarks are made. The findings from this work and cited prior work reveal that DRE are material dependent, even between similar material categories (e.g., XLPE). In the case of the EPDM studied, degradation of ductility was observed to be greater at higher dose rate for the same total dose, indicating accelerated gamma aging to be more conservative than extended aging. Thus, conclusions regarding the conservatism of historical qualification likely require additional consideration for specific materials and conditions in question. The results of this study support the contention that, due to inherent limitations and uncertainties associated with prediction of cable remaining useful life from accelerated aging experiments, trending of installed cable insulation health status will be more practical and useful for safe and efficient cable aging management repair and replace decisions than lifetime prediction from historical qualification. The combination of material robustness demonstrated by the qualification process and ongoing monitoring of cable health status combine to provide confidence in continued safe use of existing nuclear cables. Additional research into effective and efficient condition monitoring methods for non-destructive evaluation of installed cables is needed to support aging cable management, including material studies to inform interpretation of measured results.

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗
DOE OSTI2025

Return on Investment and Sustainability of HVDC Links: Role of Diagnostics, Condition Monitoring, and Material Innovations

HVDC cable systems are becoming an upscaled technical option, compared to AC, because of various factors, including easier interconnections, lower losses, and longer transmission distances. In addition, renewables providing direct DC energy, electrified transportation, and aerospace where DC can be favored because of higher carried specific power all point in the direction of broad future usage of HV and MV DC links. However, contrary to AC, there is little return from on-field installation as regards long-term cable reliability and aging processes. This gap must be covered by intensive research, and contributing to this research is the purpose of this paper. The focus is on key points for HVDC (and MVDC) cable reliability and sustainability, from design modeling able to account for voltage transients and extrinsic aging (such as that caused by partial discharges) to the impact of aging on insulation conductivity (which rules the electric field distribution, thus aging rate). Also, recyclable and nanostructured materials, as well as health conditions, are considered. It is shown how cable design can account for accelerated aging due to voltage transients, as well as for aging-time dependence of conductivity, and how design can be free of extrinsic aging caused by PDs. Algorithms for health condition evaluations, which have additional value in a relatively new technology such as HVDC polymeric cables, are applied to insulation system aging under partial discharges, showing how they can provide an indication of insulation degradation globally or locally (weak spots) and of possible maintenance times. All of this can effectively contribute to reducing the risk of major cable breakdown and damage under operation, which would significantly affect the return on investment (ROI).

Montanari, Gian Carlo (ORCID:0000000320258693)↗
DOE OSTI2021

Aging mechanisms of filled cross-linked polyethylene (XLPE) cable insulation material exposed to simultaneous thermal and gamma radiation

Thermal and simultaneous thermal and gamma radiation aging experiments were conducted on an industry grade cross-linked polyethylene (XLPE) cable insulation material, which is a composite material with XLPE as polymer matrix and various additives and fillers. Reverse engineering was conducted to identify and quantify the material composition given that this information was not revealed by the cable manufacture. Samples were then aged at temperatures of 60, 90, and 115 °C, exposed to gamma radiation for total doses of 0 to 324 kGy, and at dose rates of 0 to 540 Gy/h. Aging mechanisms were studied using various materials characterization techniques including pyrolysis gas chromatography mass spectrometry (Py-GCMS), differential scanning calorimetry (DSC), nuclear magnetic resonance spectroscopy (NMR), and gel-fraction tests. Results show that the flame-retardant components were decomposed into smaller molecules when the material was exposed to gamma radiation, while no changes were observed when the samples were aged thermally without gamma radiation. With exposure to gamma radiation, the crystalline phase of the XLPE were damaged by gamma radiation introducing defects in the crystals, resulting in smaller and less perfect crystals. The dominance of chain scission or chain reformation process largely depends on the chain mobility, which is decided by the aging temperature. Chain scission was seen to dominate when the material was exposed to gamma radiation at 60 °C. Chain cross-linking slightly dominated when the material was exposed to gamma radiation at 90 °C and became more dominant with exposure to gamma radiation at 115 °C. No significant change to the XLPE polymer matrix was observed when the samples were exposed to thermal aging without gamma radiation. Finally, antioxidant is more effective in protecting the XLPE polymer matrix under thermal aging, but less effective with sample exposure to gamma radiation.

38 RADIATION CHEMISTRY, RADIOCHEMISTRY, AND NUCLEA↗
DOE OSTI2023

A Reconfigurable Planar Capacitor Sensor for Thru the Jacket Dielectric Constant Measurement of Cable Insulation

Planar capacitor sensors have been proposed to measure the aging-related dielectric constant variation of the jacket or insulation materials of cables. Although capacitor sensors have been used to monitor the aging of cable insulation by removing the jacket, through the jacket measurement of cable insulation dielectric constant variation is difficult because once the sensor is placed on the jacket it would either measure the aging of the jacket or that of the jacket and insulation together. A reconfigurable sensor along with innovative cable-specific models could be used to determine the jacket and insulation aging using the same sensor. For the proposed novel reconfigurable sensor, the electric field penetration depth is changed by activating and deactivating PIN diode switches. In one instance, the sensor measures the dielectric constant variation of the jacket, while in the next, it measures the dielectric constant variation of both the jacket and the insulation. Here, by leveraging previously developed capacitance estimation models from large-scale finite element simulations for a specific cable, these two sets of measurement data are used to evaluate the aging-related dielectric constant variation of the insulation. Experimental data from aged cable specimens are presented to demonstrate the operation of the sensor.

47 OTHER INSTRUMENTATION↗
DOE OSTI2024

Photovoltaic Cable Jackets: A Comparison of Representative Products Using Combined-Accelerated Stress Testing [Slides]

Photovoltaic (PV) cables facilitate the distribution of electricity collected from modules to the energy grid. Durable cabling enables continuous operation of PV installations, whereas cables with a lifetime less than the modules must be replaced - reducing electricity generation and adding to the operating expense. This study primarily focusses on the aging of the key cable types using the combined-accelerated stress testing (C-AST) protocol. Representative cables for utility, building, and control/auxiliary applications were examined. Cable jacket materials examined include: polyolefin, polyethylene, polyamide, poly(vinyl chloride), chlorinated polyethylene, thermoplastic elastomer, and ethylene propylene diene monomer rubber. Specimen characterizations applied include: optical microscopy, mechanical profilometry, instrumented indentation, scanning electron microscopy (SEM), energy-dispersive X-ray spectroscopy (EDS), Fourier-transform infrared spectroscopy (FTIR), thermogravimetric analysis (TGA), and differential scanning calorimetry (DSC). A variety of performance and durability characteristics were observed, depending on the base material, polymer formulation, and jacket color. The results from C-AST are analyzed and discussed relative to a recent industry survey on electronic balance of system components in addition to a recent study where similar cables were aged using steady state ultraviolet weathering (International Electrotechnical Commission Technical Specification 62788-7-2). Recommendations are made for the screening, industry qualification, and service life prediction of PV cable jackets.

24 POWER TRANSMISSION AND DISTRIBUTION↗
DOE OSTI2021

Quantifying Properties for a Mechanistic, Predictive Understanding of Aqueous Impact on Aging of Medium and Low Voltage AC and DC Cabling in Nuclear Power Plants

To address the gap in knowledge in understanding degradation in relevant service conditions, this project aimed to develop a mechanistic, predictive model of medium and low voltage cable failure based on the primary environmental degradation parameters of aqueous immersion time, temperature, and the oxidation extent. To do so, we took a two-fold approach toward evaluating degradation as related to the aqueous condition. First, we evaluated the chemical, mechanical, and electrical properties of polymers that comprise the cabling insulation under varied aqueous conditions at different temperatures. Secondly, we evaluated the performance of insulation materials under similar accelerated aging conditions in addition to the dielectric breakdown of the cabling under submersion conditions. Thermal oxidation and immersion of LDPE thin films were done using a Parr vessel and the extent of oxidation was monitored using the carbonyl index from ATR-FTIR spectrum, a ratio quantifying the carbonyl functionality produced on the LDPE film surface. Increasing the temperature, oxidation time, and oxygen pressure increased the water-vapor permeability and the carbonyl content. Thermogravimetric analysis of the films confirmed that there is indeed an initial weight loss of the smaller molecular weight molecules and volatiles. At higher temperatures, there is a secondary mass loss. Up to 70°C, the mass loss curves were similar until 80°C, when the aged films decreased at a much greater rate with respect to increasing temperature. This was seen in the 10, 50, 90% weight loss temperatures. The mechanical properties of sheet PP and HDPE as well as injection molded LDPE, HDPE, HDPP dog bones were plotted with respect to the time spent in the Parr vessel during thermal oxidation. For the sheet PP and HDPE, the UTS and the modulus of elasticity decreased while the elongation increased. The injection-molded LDPE, HDPE, and HDPP dog bones experienced a similar trend where the changes in the properties were within experimental uncertainty. This analysis of LDPE in dry and immersive oxygen-rich environments is an important baseline for future experiments looking at other degradation mechanisms. A predictive aging model for low-density polyethylene insulative cable housings was developed. This model revealed a combination of physical and chemical processes which lead to an increase in permeability and a decrease in strength of the insulator. In creating this predictive model, a gap of knowledge in the literature was revealed in two areas: understanding how the crystallinity of a polymer changes with time and visualizing the predicted pores formed through the insulator which leads to failure. Developing and using an adapted ATR-FTIR method, crystallinity was monitored and compared to bulk crystallinity found via DSC. Inhomogeneity in crystallinity changes were observed but the FTIR method but was found to be less reliable. Pore visualization was found utilizing electrical impedance spectroscopy saturated aged polyethylene films with synthesized citrate-capped gold nanoparticles, and chloroauric acid precursor. results indicate a decreasing impedance of the polyethylene films caused by the transport of ions through the film. SEM imaging was then performed for elemental analysis of the films and counter electrodes for the presence of ions. Chloride and gold ions were detected; however, no nanoparticles were found. This gives an estimated pore size of at least 0.3 nm through the aged film. Cyclic submergence of polyethylene and polypropylene in aqueous solutions of copper sulfate and Harrison’s solution were examined. It was discovered that aging in these mixed conditions and at 90°C did cause a small, yet significant increase to tensile strength for both unaged polyethylene and polypropylene. The PE and PP in cycled and submerged conditions did not have tensile strengths significantly different from dry-aged after 16 weeks. For both solutions, it was determined that capacitance increases with both water tree depth and cable temperature and is relatively independent of changing water tree AR. As for resistance, there is no apparent change between depth percentages of 10 and 80 for both solutions. This is because the water tree has not yet entered the conductor and thus there is no shorting current flowing through the tree yet. Between 80 and 100% water tree depth, it is observed that for both solutions there is a rapid decrease in resistance because the tree is now impacting the conductor shield and allowing shorting current to flow through it. The relationship between resistance and temperature was found to be inversed. As temperature increases, resistance decreases for both water tree solutions with distilled water having the most apparent difference across the range of temperatures simulated. With regards to water tree AR, resistance was found to be relatively independent at depth percentages of 10, 50, and 70, but there was some relationship at 100% depth for both solutions. At this depth, as water tree AR increased, resistance was found to also increase. Through the examination of voltage and electric field distribution plots, it was confirmed for EPR cables that increasing water tree depth leads to increasing distortion. The increase in shorting current at 100% depth for aqueous copper sulfate compared to distilled water was also visualized. Lastly, the relationship between shorting current and temperature for narrow water trees was visualized and validated using the distribution plots. This study has led to a better understanding of the effect of cable temperature, water tree solution, and geometry of the tree region on cable degradation. Furthermore, this study has documented simulation results of water tree degradation in EPR MV cables, which had been previously lacking in information. Future work in this area will add frequency into the mix and examine what effect it has on the rate of cable degradation as a result of water treeing. To compliment the work being carried by UMD on different polymer chemistries, harvested medium voltage (MV) cables were selected for accelerated aging study at ORNL. These medium voltage cables are representative of the vintages and materials that are currently in use at existing nuclear power plants (NPPs). These cables were immersed in water at 90°C and energized for a period of two years at elevated voltage. Partial discharge was measured during this period of time to track potential degradation. Unfortunately, due to the absence of failure, the extent of integration between the UMD techniques and the harvested MV insulation was limited. However, based on the findings and from the UMD research in the previous sections on polyethylene and polypropylene, follow-on characterization for harvested MV cable insulation should focus on sample preparation to take advantage of the UMD techniques to better understand mechanistic degradation in MV cable insulations. This would include: 1.) Utilization of solutions and impedance measurement insulation to track permeability in harvested and accelerated aging insulation samples, 2.) Adaptation of gold nanoparticle synthesis for electrical impedance spectroscopy with supporting SEM characterization to study pore formation in harvested and accelerated aged insulation samples, & 3.) ATR-FTIR crystallinity with multiple temperature dependent harvested MV cable insulation under different air and submerged accelerated aging. In addition, low voltage dielectric spectroscopy and high voltage dissipation factor, tan δ, could be implemented as a condition monitoring tool for harvested MV cable insulation in submerged environments.

24 POWER TRANSMISSION AND DISTRIBUTION↗
DOE OSTI2021

PNNL ARENA Cable Motor Test Bed Update

A major focus of the Light Water Reactor Sustainability (LWRS) Cable Nondestructive Examination (NDE) 2021 research is to acquire new equipment and integrate it with existing NDE instruments for a cable motor test bed which has been dubbed the Accelerated and Real Time Experimental Nodal Analysis or “ARENA”. All the primary components have been received and are being staged in the 2410 Stevens building on PNNL’s Richland campus. Building modifications to support a plug-in 480VAC receptacle have been completed and details of the system operating procedure (SOP) are in review. The approved SOP is required before the system is energized but is expected before July 2021. The ARENA system will support planned cable tests for 2021 and beyond that cannot conveniently be performed with on-site installations of cable test equipment including: (1) NDE Tests including Frequency Domain Reflectometry (FDR), Time Domain Reflectometry (TDR), Tan Delta (TD) Impedance measurements, Low Frequency Dielectric Spectroscopy (DS) measurements, standard multi-meter resistance checks, withstand tests and other bulk and distributed tests from the instrument panel with and without motors connected. (2) Online energized live wire tests using partial discharge instruments and LIVE-WIRE spread-spectrum TDR instruments. (3) Cable tests with partially submerged cable segments (including ability to submerge live cable segments). (4) Cable tests with partially or completely thermally aged segments (including ability to expose energized cable segments to thermal aging and use online monitoring instruments to monitor cable performance. (5) Ability to introduce low resistance simulations of connector or splice faults to off-line and on-line instrument setups.

42 ENGINEERING↗
DOE OSTI2023

The ARENA Test Bed – A Versatile Resource for I&C Development and Validation

The Accelerated and Real-time Experimental Nodal Assessment (ARENA) Test Bed at the Pacific Northwest National Laboratory (PNNL) is a versatile resource for development and validation of instrumentation and control (I&C) technologies. This capability was created to facilitate in-situ testing of nuclear electrical cables in various simulated operational environments. Using cable trays, a control box, and selected test components, low voltage cables can be staged to experience local adverse environments such as elevated temperature and water immersion. Cable condition can be continuously monitored over time to track the effect of local stresses using nondestructive assessment tools. A heads-up display (ARENA TV) plots key data in real-time for users. The ARENA Test Bed has recently been used to evaluate the potential for spread spectrum time domain reflectometry (SSTDR) to monitor thermal aging of a portion of live cable powering a three-phase motor. The arrangement provided the opportunity to directly compare the performance of the novel online SSTDR method with offline results from the more standard frequency domain reflectometry (FDR) method. The ability of SSTDR and FDR to identify the presence of water in immersed shielded and unshielded cables and to detect ground faults was also assessed. A digital twin is being developed to track and predict FDR signals from a thermally aging conceptual cable region to compare with measured signals from the ARENA physical counterpart. The test bed concept addresses an important need in nuclear I&C monitoring tool development. New tools and techniques can be developed in the test bed and validated versus known methods and physical measurements. Digital twins and machine learning engines can be populated with measured data in a controlled environment that would not be readily available in the actual nuclear power plant. Proposed monitoring strategies can be confirmed for effectiveness through objective evaluation. It is anticipated that the PNNL ARENA Test Bed will be a valuable resource in advancing nuclear plant instrumentation.

nuclear electrical cables, ARENA Test Bed, conditi↗
DOE OSTI2023

Frequency Domain Reflectometry (FDR) Simulation Techniques for Digital Twin Representation of an Electrical Cable

Simulation of cable system response to frequency domain reflectometry (FDR) tests can be instrumental to understanding these tests and the nature and influence of various cable anomalies on test signatures. Reflectometry simulations are based upon a finite element representation of cable conductors and insulation to produce an S-parameter at each evaluated frequency. The aggregate collection of cable model S-parameters can simulate the influence on a test signal injected into a physical cable. Such an approach was undertaken in this work to produce a digital twin simulation of a low-voltage electrical cable. The electrical cable digital twin examined the influence of test simulation parameters and the relative influence of cable anomalies, including thermal aging, water or moisture exposure, water or moisture ingress, and other anomalies. The digital twin in this work included modeling of the conductors, insulation, jacket, and surrounding environment (air, water, etc.). The digital twin could be expanded to include cable bends, junctions and splices, branch or T systems, and termination impedances of motors or instruments. Observations and conclusions of this work include: 1. Fully 3D digital twin simulation of an electrical cable using an FDR approach is possible. However, there are tradeoffs between simulation fidelity and solution time, which must be balanced to ensure the simulation solves in an adequate amount of time (e.g., less than 20 minutes). Simulation parameters to balance include frequency bandwidth, number of frequencies, mesh density, connection impedance, and permittivity tolerance. 2. The digital twin simulation can explain FDR sensitivity to various cable anomalies, including entry and exit from an oven or water bath. 3. The digital twin simulation FDR response attenuates with distance along the cable and is further affected by the frequency bandwidth, which is similar to that observed with physical measurements. 4. The resolution of the digital twin FDR peaks increased with increasing bandwidth and with increasing number of frequencies, again similar to physical measurements. 5. The presence of multiple anomalies in the digital twin does not substantially attenuate the FDR response to anomalies located beyond the first encountered anomaly and impedance mismatch. 6. Spectral variation of the permittivity did not have a significant effect on the FDR response compared to a fixed nominal value. 7. Extension of the digital twin to 1000 ft still allowed for detection of distal anomalies near the far end of the electrical cable from the instrument connection point. 8. The ARENA test bed facilitates efficient NDE evaluations of well understood cable anomalies with various NDE methods without risking actual plant damage.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2022

Evaluation of Copper Catalytic Effects in Cable Insulation Polymers

This paper summarizes work performed to evaluate a phenomenon that occurs in electrical cable insulation polymers subjected to accelerated aging while in contact with copper metal. This effect, commonly known as the copper catalytic effect, is a result of chemical reactions that occur when copper ions diffuse into insulation polymers. This diffusion process is observed in various types of polymeric materials exposed to elevated temperatures and happens at the interface between the insulation and metallic components (e.g., conductor, shielding, etc.) in a cable. This polymer-metal interaction has only been observed in cables constructed with copper components (i.e., no interactions observed in cables with aluminum or other metal conductor/shielding) and results in a significant catalytic effect that increases the oxidation rate (e.g., aging) of the material. Under this research, the copper catalytic effects observed in cross-linked polyethylene, cross-linked polyolefin and ethylene propylene rubber insulated cables subjected to thermal accelerated aging were evaluated. These evaluations involved applying infrared spectroscopy, microscopy, and energy dispersive X-ray spectroscopy cross-sectional depth profiling to obtain an in-depth understanding of the aging characteristics of the materials under accelerated conditions. Based on the results of these assessments, the copper catalytic effect can have a significant impact on the mechanical, thermal, chemical, and electrical properties of cable insulation polymers. Here, the results acquired from this research provided the information needed to characterize the copper catalytic effects observed in these polymers, analyze how this phenomenon affected the polymer degradation process, and compare and understand the differences in the properties of the materials.

42 ENGINEERING↗
DOE OSTI2026

Hygrothermal aging effects on polyimide and acrylate-based adhesive materials in high-performance flat-flex cable assemblies

Flat-flex assemblies are widely used across a diverse range of technologies, including consumer electronics, automotive systems, aerospace and defense applications, and medical devices, due to their compact form factor and flexibility. However, environmental stressors like temperature and humidity are known to degrade performance over time, though the main mechanisms for degradation remain unknown. Here, in this work, we examined the aging behavior of copper/polyimide/adhesive laminate systems under varying temperature and humidity conditions, focusing on material degradation and its effects on mechanical and dielectric properties. Results show that peel strength and breakdown voltage decrease with exposure time, temperature, and humidity; spectroscopic characterization revealed that the adhesive, and not the polyimide, is the weak link in the material stack-up. The adhesive, identified as a butyl acrylate-acrylonitrile (BA-AN) copolymer, exhibited age-related spectral changes that correlated with exposure severity and duration. Hydrolysis at BA ester and AN nitrile groups was identified as the primary degradation mechanism, producing amides, acids, and alcohols. We developed a mechanistic model that connects kinetic parameters for BA-AN spectral band decay to peel strength and breakdown voltage, and implicates hydrolysis at the AN moiety, not BA, in performance decrements. Modeling predictions at ambient conditions indicate faster decline in peel strength than dielectric strength at early times, followed by plateauing of both properties at longer times. These findings provide critical insights into laminate aging mechanisms and highlight the importance of addressing BA-AN degradation to improve the long-term reliability of these systems in high-humidity environments.

organic↗
DOE OSTI2025

Evaluation of Damage in Medium Voltage Cable Using Machine Learning

Developments in cable test instrumentation coupled with artificial intelligence and machine learning (ML) to aid in interpretation of cable test signals supports the feasibility for automated analysis of reflectometry tests for low voltage power cables. This work seeks to leverage prior ML work and success for low voltage cables to evaluate potential application to medium voltage (2kV to 10kV) installations. The Accelerated and Real-Time Environmental Nodal Assessment (ARENA) Cable Motor Test Bed at Pacific Northwest National Laboratory (PNNL) was used to test a medium voltage cable with several types of damage including thermal aging and low resistance conductor-to-shield faults. The cable was tested using an inductive clamshell coupler to protect the test instruments from the energized cable voltages that would damage the test instruments if coupled directly to the energized conductor.

42 ENGINEERING↗
DOE OSTI2020

Initial Radiation of Nuclear Power Plant Components (CRADA NFE-17-06892 Final Report)

As advanced reactor concepts are developed, instrumentation and control (I&C) cables and sensors will play a significant role in assuring their operation is well understood, and safety-related process information can be collected reliably over the course of their design life. As a first step to develop acceptance criteria and define the limits of currently available nuclear I&C cable and sensor technology, a collaboration between Oak Ridge National Laboratory and Analysis and Measurement Services (AMS) Corporation was initiated under the Gateway for Accelerated Innovation in Nuclear (GAIN) Program. This collaborative effort focused on providing technical information related to the combined thermal and radiation aging of nuclear power plant (NPP) cables, companion NPP cable insulation samples, and two prototype temperature and two pressure sensors. This work was carried out using the instrumented gamma irradiation system that is part of the High Flux Isotope Reactor Gamma Irradiation Facility (HFIR GIF). This system provided the opportunity for the condition of the prototype sensors to be tracked during the irradiation in order to determine their functional limits with greater granularity when compared to a simple irradiation insertion at the HFIRGIF. Experimental assemblies for sensor irradiation were successfully completed, and sensor irradiation to accumulated dose of 3000 kGy at a rate of approximately 6 kGy/hr was carried out. Two prototype temperature assemblies were continuously monitored during exposure to 3000 kGy and found to have no observable degradation from the irradiation. Two pressure sensors were first irradiated to 1000 kGy. At which point, one of the sensors was found to operate normally; however, a second sensor failed the operability test. The operable pressure sensor output was then continuously monitored from 1000 kGy to 3000 kGy. The sensor output exhibited steady trendable drift versus the accumulated radiation dose. At the conclusion of the irradiation, the four test sensors were released for laboratory calibration checks. The calibration check of the temperature sensors found no significant change after irradiation compared to baseline measurements before irradiation; however, both pressure sensors failed the post-test calibration checks and both sensors were not functioning properly. These results will help inform sensor manufacturers and I&C design engineers of potential limitations of these types of sensors for use in high radiation environments associated with the compact configuration of new Small Modular Reactors (SMRs) such as NuScale’s reactor power module. Irradiations on NPP cables and companion samples were not completed due to programmatic delays, however a path forward that was based on lessons learned from this project was defined to accommodate future, comparable instrumented gamma irradiations at the HFIR GIF.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗