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Frequency Domain Reflectometry NDE for Aging Cables in Nuclear Power Plants
Cable insulation polymers are among the more susceptible materials to age-related degradation within a nuclear power plant. This is recognized by both regulators and utilities, so all plants have developed cable aging management programs to detect damage before critical component failure in compliance with regulatory guidelines. Although a wide range of tools are available to evaluate cables and cable systems, cable aging management programs vary in how condition monitoring and nondestructive examinations are conducted as utilities search for the most reliable and cost-effective ways to assess cable system condition. Frequency domain reflectometry (FDR) is emerging as one valuable tool to locate and assess damaged portions of a cable system with minimal cost and only requires access in most cases to one of the cable terminal ends. Since laboratory studies to evaluate the use of FDR for inspection of aged cables can be expensive and data interpretation may be confounded by multiple factors which influence results, a model-based approach is desired to parametrically investigate the effect of insulation material damage in a controlled manner. This work describes development of a physics-based FDR model which uses finite element simulations of cable segments in conjunction with cascaded circuit element simulations to efficiently study a cable system. One or more segments of the cable system model have altered physical or electrical properties which represent the degree of damage and the location of the damage in the system. This circuit model is then subjected to a simulated FDR examination. The modeling approach is verified using several experimental cases and by comparing it to a commercial simulator suitable for simulation of some cable configurations. The model is used to examine a broad range of parameters including defect length, defect profile, degree of degradation, number and location of defects, FDR bandwidth, and addition of impedance-matched extensions to minimize the end-shadow effect.
Application of Cable Condition Monitoring Technologies to Assess Age-Related Degradation of Industrial Cables Installed in Harsh Environments
The aging of electrical cables has been the subject of substantial research and development (R&D) projects performed by national and international laboratories, universities, and private organizations for many years. This R&D was conducted to develop guidance, equipment, and techniques to support aging management of in-service cables in industrial facilities such as nuclear power plants, research reactors, waste facilities, and fuel fabrication plants. Through these research efforts, condition monitoring technologies have been developed that can determine the severity of age-related degradation that occurs in industrial cables and insulation polymers during service. This paper summarizes the results of aging assessments that were performed for cables installed in two U.S. nuclear power plants, one a pressurized water reactor and one a boiling water reactor. These cables had been in service for over 40 years and during plant operation were exposed to harsh environmental conditions including elevated temperatures and radiation. For these assessments, a comprehensive series of measurements was performed to assess the aged condition of the cables. These cables came from different manufacturers, were manufactured in different years, and were constructed with a variety of jacket and insulation polymers including chloro-sulfonated polyethylene (CSPE), cross-linked polyethylene (XLPE)/cross-linked polyolefin (XLPO), neoprene, and ethylene propylene rubber (EPR). The goal of these assessments was to determine the current aged condition of the cable polymers and provide an estimate of how long the cable insulation materials could remain exposed to their in-service environmental conditions before reaching their end-of-life condition. Both nuclear power plants have received license renewals to extend their operation from 40 to 60 years, and the utilities need objective evidence to show that critical components such as cables will be able to function safely and reliably during the extended operating period. Furthermore, the results of these assessments showed that the cables exhibited different aged conditions depending on the type of polymers they were constructed with and the environment they were exposed to during service. Some of the cables and insulation polymers showed signs of significant age-related degradation and were estimated to have approximately 5 years of remaining service life. Other cables exhibited no signs of significant age-related degradation and were estimated to have 50 years or more of remaining service life. Using the results of these cable aging assessments, plant personnel were able to (1) determine the overall aged condition of cables and insulation polymers using objective test results, (2) identify aged or degraded cables before they caused operability issues, and (3) avoid unnecessary and costly replacement of cables that can continue to operate safely and reliably.
Survey of Aging and Monitoring Concerns for Cables and Splices Due to Cable Repair and Replacement
The purpose of this report is to survey aging and monitoring concerns for electrical cable splices in nuclear power plants (NPPs) in long term operation. As portions of existing electrical cable runs in nuclear are replaced over time due to localized events, the total number of splices in NPPs is expected to increase. Relative to cables, the body of knowledge regarding aging of splices and splices in combination with aging cables in nuclear service environments in long-term operations is low. A few reports have considered the aging of cable system components other than cables (Jacobus 1990; Nelson 1998; Villaran and Lofaro 2002), but the nuclear industry has two decades of operating experience since these were published to further enlighten this issue. Herein we discuss electrical cables and splices commonly found in U.S. nuclear power plants, their qualification in safety-related application, and methods for monitoring their health condition. Common environmental stresses that can give rise to cable and splice failure are discussed. The Nuclear Regulatory Commission (NRC) Licensee Event Reports (LER) database was used to identify documented issues of cable and splice failure. The trend in the resultant data over time is considered to see if failures are increasing as plants age. Observations and conclusions of this work include: 1. Cables and splices are highly reliable components. Occurrence rates for events of interest were low and nearly constant over the last 20 years. 2. Common-cause failure for evaluated cable events of interest was observed to primarily be associated with loose connections, which may manifest associated with workmanship issues, thermal cycling, and/or vibration. 3. Replacement of cables is more common than repair, leading to an increase in proportion of new generation cables in the plant over time. 4. Splices on degraded cables have been observed to be problematic. Due to aging NPP infrastructure, including electrical cables, it is expected that such issues will continue to increase. 5. Condition monitoring approaches, while shown to be fruitful for cables, have been shown to be insensitive to degradation of splice sleeves, which are critical to the continued performance of splices. Additional condition monitoring (CM) work is needed to evaluate methods which are sensitive to the degradation of splice components. 6. Extended Material Degradation Assessment (EMDA) knowledge gaps for electrical cables (Bernstein et al. 2014) have not been investigated for splices but may represent similar concerns such as for the accelerated aging process historically used in environmental qualification.
Mechanical and Chemical Properties of Harvested Hypalon Cable Jacket Subjected to Accelerated Thermal Aging
For nuclear power plants (NPPs) that are considering second license renewal for their operation beyond 60 years, knowledge of long-term operation, condition monitoring, and viability for the reactor components including reactor pressure vessel, concrete structures, and cable systems is essential. Such knowledge will provide NPPs with a game plan to predict performance and to estimate costs that are associated with monitoring or replacement programs for the affected systems. For cable systems that encompass a wide variety of materials, manufacturers, and in-plant location, accelerated aging of harvested cable jacket and insulation can provide insight as to remaining useful life and methods for monitoring. Accelerated thermal aging in air at temperatures between 80°C and 120°C was carried out on a multi-conductor control rod cable that had been in-service for over 30 years and was made by Boston Insulated Wire with Hypalon cable jacket and ethylene-propylene rubber insulation. From elongation at break (EAB) measurements and supporting Arrhenius analysis of the jacket material, an activation energy of 97.84 kJ/mol was estimated and the time to degradation, as represented by 50% EAB at the expected maximum operating temperature of 45°C, was estimated as consistent with 80 years. These values were slightly below previous measurements and could either be attributed to in-service degradation or variations in material properties from a given manufacturer. In addition, results from indenter modulus measurements and Fourier transform infrared spectroscopy suggest possible markers that could be beneficial to monitor cable conditions.
Bulk Electrical Cable Non-Destructive Examination Methods for Nuclear Power Plant Cable Aging Management Programs
This Pacific Northwest National Laboratory milestone report describes progress to date on the investigation of nondestructive test methods focusing particularly on bulk electrical test methods that provide key indicators of cable aging and damage. The work includes a review of relevant literature as well as hands-on experimental verification of inspection capabilities. As nuclear power plants consider applying for second, or subsequent, license renewal to extend their operating period from 60 years to 80 years, it is important to understand how the materials installed in plant systems and components will age during that time and develop aging management programs to assure continued safe operation under normal and design basis events (DBE). Normal component and system tests typically confirm the cables can perform their normal operational function. The focus of the cable test program, however, is directed toward the more demanding challenge of assuring the cable function under accident or DBE. The industry has adopted 50% elongation at break (EAB) relative to the un-aged cable condition as the acceptability standard. All tests are benchmarked against the cable EAB test. EAB, however, is a destructive test so the test programs must apply an array of other nondestructive examination (NDE) tests to assure or infer the overall set of cable’s system integrity. Assessment of cable integrity is further complicated in many cases by vendor’s use of dissimilar material for jacket and insulation. Frequently the jacket will degrade more rapidly than the underlying insulation. Although this can serve as an early alert to cable damage, direct test of the cable insulation without violating the protective jacket becomes problematic. This report addresses the range of bulk electrical NDE cable tests that are or could be practically implemented in a field-test situation with a particular focus on frequency domain reflectometry (FDR). The FDR test method offers numerous advantages over many other bulk electrical tests. Two commercial FDR systems plus a laboratory vector network analyzer are used to test an array of aged and un-aged cables under identical conditions. Several conclusions are set forth, and a number of knowledge gaps are identified.
Light Water Reactor Sustainability Program: Evaluation of Localized Cable Test Methods for Nuclear Power Plant Cable Aging Management Programs
This Pacific Northwest National Laboratory (PNNL) milestone report describes progress to date on the investigation of nondestructive test (NDE) methods focusing particularly on local measurements that provide key indicators of cable aging and damage. The work includes a review of relevant literature as well as hands-on experimental verification of inspection capabilities. As NPPs consider applying for second, or subsequent, license renewal (SLR) to extend their operating period from 60 years to 80 years, it important to understand how the materials installed in plant systems and components will age during that time and develop aging management programs (AMPs) to assure continued safe operation under normal and design basis events (DBE). Normal component and system tests typically confirm the cables can perform their normal operational function. The focus of the cable test program is directed toward the more demanding challenge of assuring the cable function under accident or DBE. Most utilities already have a program associated with their first life extension from 40 to 60 years. Regrettably, there is neither a clear guideline nor a single NDE that can assure cable function and integrity for all cables. Thankfully, however, practical implementation of a broad range of tests allows utilities to develop a practical program that assures cable function to a high degree. The industry has adopted 50% elongation at break (EAB) relative to the un-aged cable condition as the acceptability standard. All tests are benchmarked against the cable EAB test. EAB is a destructive test so the test programs must apply an array of other NDE tests to assure or infer the overall set of cable’s system integrity. These cable NDE programs vary in rigor and methodology. As the industry gains experience with the efficacy of these programs, it is expected that implementation practice will converge to a more common approach. This report addresses the range of local NDE cable tests that are or could be practically implemented in a field test situation. These tests include: visual, infrared thermography, interdigital capacitance, indenter, relaxation time indenter, dynamic mechanical analyzer, infrared/near-infrared spectrometry, ultrasound, and distributed fiber optic temperature measurement.
Radiation Aging of Cable Insulation Systems to Support Extension of Cable Electrical Assessment Techniques - CRADA 562 (Final Report)
Radiation aging (primarily gamma radiation) affects a small subset of the LV cable population based on a 40-year operation. Increasing plant operating life to 60 or 80 years will result in additional cables experiencing degradation, either from radiation or from combined thermal and radiation effects. Previous research work done by EPRI and other researchers focuses on electrical diagnostics of thermal effects. However, the electrical diagnostic response of the cable system to radiation aging is minimally understood. In order to study the electrical responses from XLPE and EPR cabling and correlate these responses with radiation dose and level of thermal exposure, gamma radiation testing was performed at Pacific Northwest National Laboratory (PNNL). This report covers the radiation testing performed at PNNL, which involved irradiation of 30-foot long cables and short witness samples. The cabling was irradiated, at room temperature, using cobalt-60 gamma-rays to intervals of 10 million rads (10 Mrads), for a maximum of 70 Mrads. The results can be used to determine cable conditions (extent of damage) more accurately and localize where the degradation exists along the length of the cable (axial location). These insights can provide operators with the options to focus repair, mitigation, or replacement efforts locally.
Leading/lagging cable referencing platform for monitoring the health of underground cable networks
A system for detecting water trees in branching underground electrical cables includes a pulse generator configured to inject a pulse into a first underground cable that branches into a second underground cable and a third underground cable. The system includes a first sensor associated with the first cable, a second sensor associated with the second cable, and a third sensor associated with the third cable. The system includes a control device configured to obtain a first, second, and third signal associated with the first, second and third sensors, respectively. The control device determines a lead-lag relationship between the second and third signals and determines presence of a water tree within at least one of the second and third cable based on the lead-lag relationship. When presence of a water tree is determined, the control device generates a control action associated with repairing or replacing the second and/or third cable.
Photovoltaic cable jackets A comparison of representative products using combined-accelerated stress testing
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Interstrand Coupling Properties of LARP High Gradient Quadrupole Cables in Response to Variations in Cable Design and Heat Treatment Condition
Calorimetric measurement of coupling loss versus frequency has been measured on two sets of cored and uncored large Hadron Collider Accelerator Research Program high gradient quadrupole Nb 3 Sn Rutherford cables. Studied are the responses of the resulting interstrand contact resistances (ICR) to variation of stainless-steel (SS) core width and position and to variation of reaction-heat-treatment (RHT) condition. One pair of cables (an early HQ-series type) with and without core had received RHT under 20-MPa uniaxial face-on pressure. Another set of cables (recent QXF type) furnished with SS cores of various widths had received RHT under ambient pressure. The results were displayed as cable-cross-sectional micrographs and plots of ICR versus percent core coverage (W). The HQ cables were tightly compacted and produced results consistent with a previously expected continuous ICR versus W variation. Furthermore, the QXF cables were uncompacted such that their upper and lower layers were separated by what is referred to as a full-width 'pseudocore;' as a result, their ICRs were independent of the widths of the SS cores. Compaction versus noncompaction is discussed and future research directions are suggested.
Applying Diagnostics to Enhance Cable System Reliability (Cable Diagnostic Focused Initiative, Phase II)
The Cable Diagnostic Focused Initiative (CDFI) played a significant and powerful role in clarifying the concerns and understanding the benefits of performing diagnostic tests on underground power cable systems. This project focused on the medium and high voltage cable systems used in utility transmission and distribution (T&D) systems. While many of the analysis techniques and interpretations are applicable to diagnostics and cable systems outside of T&D, areas such as generating stations (nuclear, coal, wind, etc.) and other industrial environments were not the focus. Many large utilities in North America now deploy diagnostics or have changed their diagnostic testing approach as a result of this project. Previous to the CDFI, different diagnostic technology providers individually promoted their approach as the “the best” or “the only” means of detecting cable system defects.
Extension of Cable Electrical Assessment Techniques to Detect and Discriminate Radiation Aging on Cable Insulation Systems (Abstract)
The purpose of this study of the electrical responses of gamma radiation aged low voltage nuclear cables is to advance tools to determine cable condition (extent of damage) and identify degradation location along the cable length. The developed technology will provide nuclear plant operators with the options to focus cable repair, mitigation, or replacement efforts locally and avoid wholesale cable replacement.
Magnetic Properties of Cables with Meandering Wires through a Multipole-based Cable Braid Electromagnetic Penetration Model
In this paper, we employ our first principles multipole-based cable braid electromagnetic penetration model to evaluate the transfer inductance of cables exhibiting meandering wires. We concentrate on a cable structure with two wires, and consider the dependence on the transfer inductance as a function of braid angle and amplitude of the meandering. We compare the results from the first principles model to analytical estimations, confirming the accuracy and correctness of our model. In turn, this makes the multipole-based model readily available for the modeling of realistic cable geometries by accounting for the full dependence on the actual cable geometry.
Addendum to SAND2023-09604 Xyce lumped-element transmission line model verification to support Empire-Cable cable SGEMP analyses
This report supplements the Verification of Empire-Cable SAND report by expanding on the use of Xyce to simulate the coupling to a transmission line cable model. While Empire-Cable solves its governing equations on a high-order, finite-element mesh with an an implicit-in-time formulation, Xyce must use a first order graph for the circuit and explicit-in-time approach to be compatible with non-linear electrical device models. Thus, given the different solution methodologies in Xyce as compared to Empire-Cable, the convergence rates are expected to be different but the overall quality of the solution should be the same. The original four canonical problems studied in the Empire-Cable verification report are replicated here running in Xyce using transmission line modeling parameters from the verification report. Overall, agreement between the codes is excellent with Xyce’s convergence rates being limited mostly to first order due to the circuit network approximation of a transmission line being a first order approximation.
Dimensional changes of Nb 3 Sn Rutherford cables during heat treatment
In high field magnet applications, Nb 3 Sn coils undergo a heat treatment step after winding. During this stage, coils radially expand and longitudinally contract due to the Nb 3 Sn phase change. In order to prevent residual strain from altering superconducting performances, the tooling must provide the adequate space for these dimensional changes. The aim of this paper is to understand the behavior of cable dimensions during heat treatment and to provide estimates of the space to be accommodated in the tooling for coil expansion and contraction. In addition, this paper summarizes measurements of dimensional changes on strands, single Rutherford cables, cable stacks, and coils performed between 2013 and 2015. These samples and coils have been performed within a collaboration between CERN and the U.S. LHC Accelerator Research Program to develop Nb 3 Sn quadrupole magnets for the HiLumi LHC. The results are also compared with other high field magnet projects.
Laboratory evaluation of distributed coaxial cable temperature sensors for application in CO 2 sequestration well characterization: Original Research Article: Laboratory evaluation of distributed coaxial cable temperature
Downhole monitoring plays a crucial part in a geological carbon dioxide (CO 2 ) sequestration project, especially in providing early warnings of failure. However, most downhole monitoring technologies are often low in spatial resolution and time-consuming, or expensive and have system longevity issues. To address this issue, a robust and cost-effective distributed coaxial cable Fabry-Perot interferometer-based temperature sensor is proposed for real-time downhole monitoring. The coaxial cable sensor (CCS) was made in house and tested using a high pressure high temperature (HPHT) testing apparatus to study the sensor accuracy, sensitivity, stability, and crosstalk effect in simulated downhole conditions. The laboratory test results indicate that the sensor can work under simulated downhole conditions of pressures up to 1000 psia and temperatures up to 110°C. At 1 ATM, the sensor has an accuracy of about 1%. At 1000 psia, the hysteresis phenomenon is observed, but it is reduced and tends to stabilize after repeated heating and cooling treatments. The pressure crosstalk effect was observed on the flexible cable sensor and minimized on the rigid cable sensor. The temperature and pressure range of the distributed CCS allows long-term in situ monitoring for a well depth up to 2500 feet, which would prove of great value in detecting temperature change associated with wellbore leakage that may lead to groundwater contamination.