Halogen Free Cables for Nuclear Power Plants Lukas VON LAUE

IEEE/ICC Fall 2007 meeting Scottsdale (Arizona) Educational Session

Technical contact:

Commercial contact:

Lukas von Laue

Tristan Cerosky

Nexans France 41 rue Maurice Gorse F-18100 Mehun-sur-Yèvre France [email protected]

IEEE-ICC Fall 2007 meetin

Nexans France 4-10 rue Mozart F 92587 Clichy France [email protected] Scottsdale - L. von Laue(Nexans) : Halogen Free Cables for Nuclear Power Plants

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Abstract Halogen free or FRNC (Fire Retardant Non Corrosive) NPP qualified cables according to Canadian, US and international specifications have been successfully used since many years in NPPs, mainly in Asia and Europe. In case of fire, the major advantages of FRNC cables over halogen containing cables are to avoid the corrosive and toxic hydrochloric acid and dense black smoke. This allows easier fire fighting (visibility, toxicity) and limits corrosion damage on metallic material in the vicinity of the fire. Experience and technical properties with this proven and well established technology shall be reported, regarding the full cable range of NPP cables (power (LV&MV), control, instrument and others). IEEE-ICC Fall 2007 meetin Scottsdale - L. von Laue(Nexans) : Halogen Free Cables for Nuclear Power Plants

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Outline ¾ Introduction ¾ Nexans NPP cable

experience with Halogen Free (FRNC) cables ¾ Review FRNC NPP cable

properties ¾ Fire properties ¾ General properties ¾ Nuclear typical properties:

Lifetime, Radiation, Loca resistance

¾ Nexans Nuclear Cable

Qualifications ¾ Conclusion

IEEE-ICC Fall 2007 meetin Scottsdale - L. von Laue(Nexans) : Halogen Free Cables for Nuclear Power Plants

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Introduction – Questions to answer

Why Halogen Free cables ? ¾ Advantages in case of fire ? ¾

1) Not fire propagating 2) Low Smoke 3) Low Toxicity 4) Low Corrosivity FRNC means Fire Retardant Non Corrosive Synonyms :

HFFR (Halogen Free Fire Retardant) ZH (Zero Halogene)

¾ These cables are different. Difficult to use ? Properties ? Experience feedback ? IEEE-ICC Fall 2007 meetin Scottsdale - L. von Laue(Nexans) : Halogen Free Cables for Nuclear Power Plants

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Daya Bay (left) and Ling Ao 1+2 (behind) close to Hong Kong, China, Areva PWR Nexans FRNC cables 1991-1993 (DB) and 1999-2001(LA) IEEE-ICC Fall 2007 meetin Scottsdale - L. von Laue(Nexans) : Halogen Free Cables for Nuclear Power Plants

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Chooz, North East of France, Areva PWR - Nexans FRNC cables 1995

IEEE-ICC Fall 2007 meetin Scottsdale - L. von Laue(Nexans) : Halogen Free Cables for Nuclear Power Plants

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Qinshan III, next to Shanghai, China, Candu from AECL (CAN), FRNC cables from Nexans 1999 - 2002 IEEE-ICC Fall 2007 meetin Scottsdale - L. von Laue(Nexans) : Halogen Free Cables for Nuclear Power Plants

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TIANWAN 1 & 2, North of Shanghai, China, VVER from Russia K2, K1 and K0 FRNC cables from Nexans 20022005 K3 FRNC cables from Chinese supplier IEEE-ICC Fall 2007 meetin Scottsdale - L. von Laue(Nexans) : Halogen Free Cables for Nuclear Power Plants

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Lungmen 1&2, Taiwan, BWR from GE (USA) FRNC Power and control cables from Nexans 20042006 IEEE-ICC Fall 2007 meetin Scottsdale - L. von Laue(Nexans) : Halogen Free Cables for Nuclear Power Plants

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Cernavoda 2, Romania Candu from AECL (CAN) FRNC cables from Nexans 2003 - 2006

IEEE-ICC Fall 2007 meetin Scottsdale - L. von Laue(Nexans) : Halogen Free Cables for Nuclear Power Plants

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Ling Ao 3+4 China, Areva copy PWR FRNC K1cables and K3 power cables from Nexans 2007 - 2009 Other FRNC K3 and NC cables from Chinese suppliers IEEE-ICC Fall 2007 meetin Scottsdale - L. von Laue(Nexans) : Halogen Free Cables for Nuclear Power Plants

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Oulkiluoto 3, Finland, EPR Areva FRNC cables specified

IEEE-ICC Fall 2007 meetin Scottsdale - L. von Laue(Nexans) : Halogen Free Cables for Nuclear Power Plants

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Flammenville 3, Normandie, France, EPR Areva FRNC specified IEEE-ICC Fall 2007 meetin Scottsdale - L. von Laue(Nexans) : Halogen Free Cables for Nuclear Power Plants

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Hongyanhe 1-6, North of China, PWR Areva copy FRNC cables specified

Sanmen 1+2, South of Shanghai, China Westinghouse AP1000

IEEE-ICC Fall 2007 meetin Scottsdale - L. von Laue(Nexans) : Halogen Free Cables for Nuclear Power Plants

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Yiangjiang, South of China, probably Areva type IEEE-ICC Fall 2007 meetin Scottsdale - L. von Laue(Nexans) : Halogen Free Cables for Nuclear Power Plants

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Nexans supplied NPP cables since 1975 Halogen Free / FRNC since 1991 ¾ France : latest NPP with FRNC, before halogenated ¾ Russia :

Kalinine in 1995 and 2003

¾ Czech Republic : Temelin & Dukovany ¾ Ukraine :

Khmelnitsky, Zaporozhe & South-Ukraine

¾ Slovaquia : Bohunice ¾ Bulgaria :

Kozloduy

¾ Romania :

Cernavoda 1 and 2 (Candu)

¾ China :

Daya Bay 1+2 and Ling Ao 1+2, Tianwan 1+2, Qinshan III (Candu), Qinshan II 3+4, Ling Ao 3+4

¾ Taiwan : Lungmen (GE-BWR) IEEE-ICC Fall 2007 meetin Scottsdale - L. von Laue(Nexans) : Halogen Free Cables for Nuclear Power Plants

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Fire properties of FRNC cables IEEE-ICC Fall 2007 meetin Scottsdale - L. von Laue(Nexans) : Halogen Free Cables for Nuclear Power Plants

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Fire Properties : 1) Non propatation of fire IEC 60332-3 9 Test on bunched cables 9 High performances of Halogen Free and Fire Retardant Cables 9 Temperature: approx. 800 °C Cat A: 7l/m of burning material Cat B: 3.5l/m Cat C: 1.5l/m 9 Test duration Cat A: 40 mn Cat B: 40 mn Cat C: 20 mn 9 Results: no burning over 2.5m height from the burner. IEEE-ICC Fall 2007 meetin Scottsdale - L. von Laue(Nexans) : Halogen Free Cables for Nuclear Power Plants

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What is this?

Footprints after the airport fire in Düsseldorf 1996

Smoke and combustion gases go everywhere ⇒ Bad visibility for evacuation and fire fighting ⇒ Dirt and acid deposition everywhere

⇒ metal corrosion everywhere

IEEE-ICC Fall 2007 meetin Scottsdale - L. von Laue(Nexans) : Halogen Free Cables for Nuclear Power Plants

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Fire Properties : 2) Smoke

Underground fire Korea 2/2003

Cable with bad smoke performance

IEEE-ICC Fall 2007 meetin Scottsdale - L. von Laue(Nexans) : Halogen Free Cables for Nuclear Power Plants

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Smoke Emission ASTM E662 / NES 711 Famous NBS chamber : Smoke density measured on compound plates With or without flame Dm and VOF4 values Very low smoke thanks to Halogen Free material IEEE-ICC Fall 2007 meetin Scottsdale - L. von Laue(Nexans) : Halogen Free Cables for Nuclear Power Plants

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Smoke Emission IEC 61034-1 / IEC 61034-2

9

Cable burnt in 3m x 3m x 3m chamber

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Measurement of light transmittance

9

Smoke opacity very low thanks to Halogen Free material

Low smoke = easier evacuation and easier fire fighting IEEE-ICC Fall 2007 meetin Scottsdale - L. von Laue(Nexans) : Halogen Free Cables for Nuclear Power Plants

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Fire Properties : 3) Toxicity

Toxicity ponderation IEC 60684-2 and NES 713 (scaled for CO = 1)

160,00

Phosgene

40,00

Hydrogen fluoride

9 9

Comparison of 30 min. lethal doses for men in ppm Inverse of dose = ponderation factor for toxicity index

Hydrogen bromide

26,67

Hydrogen cyanide

26,67

Phenol

16,00

We see:

Nitrogen oxides

16,00

HCl gas is 8 times as toxic as CO.

Sulphur dioxide

10,00

HF gas is 40 times as toxic as CO.

Acrylonitrile

10,00

9

For clean fire conditions, halogens, sulfur and nitrogen containing material should be avoided.

⇒ Nexans FRNC

Hydrogen chloride

8,00

Formaldehyde

8,00

Ammonia

5,33

Hydrogen sulphide

5,33 1,00

Carbon monoxide

material has very low toxicity index

Carbon dioxide 0,01

0,04 0,1

1

10

IEEE-ICC Fall 2007 meetin Scottsdale - L. von Laue(Nexans) : Halogen Free Cables for Nuclear Power Plants

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1000 23

Fire Properties : 3) Toxicity

Gases & Smoke Toxicity NFX 70100 NES 713 IEC 60684-2

9 quantitative analysis of different toxic combustion gases produced by the material 9 Ponderated addition (according to toxicity) of these quantities

⇒ Toxicity index

IEEE-ICC Fall 2007 meetin Scottsdale - L. von Laue(Nexans) : Halogen Free Cables for Nuclear Power Plants

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Fire Properties : 4) Corrosivity Halogen free cable in fire means: 9

No HCl gas production

9

Avoid hydrochloric acid formation

9

Avoid corrosion on metallic equipment (metallic structures, conducts and pipes, engines, electronics, … )

IEEE-ICC Fall 2007 meetin Scottsdale - L. von Laue(Nexans) : Halogen Free Cables for Nuclear Power Plants

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Corrosivity of combustion gas

Fire Properties : 4) Corrosivity

IEC 60754 -1 & IEC 60754 -2

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Material combustion in oven

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Combustion gases trapped in water

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Measurement of acid quantity, pH and Conductivity

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FRNC cables : HCl acid gases < 0,5% pH > 4,3 conductivity < 10μS/mm

(Reminder : 1 kG of PVC burnt produces about 2 liter of Hydrochloric Acid of “Xi” concentration) IEEE-ICC Fall 2007 meetin Scottsdale - L. von Laue(Nexans) : Halogen Free Cables for Nuclear Power Plants

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He says it is only a cabling problem IEEE-ICC Fall 2007 meetin Scottsdale - L. von Laue(Nexans) : Halogen Free Cables for Nuclear Power Plants

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General properties

Low Voltage Cables

Examples of cable constructions and Standards references

Low Voltage 1. Conductor IEC 60228 ASTME B3, B8 3. Halogen Free Low Voltage Insulation IEC 60502 - 1 types EPR & HEPR IEC 60502 - 1 types XLPE IEC 60092-351 type HF EPR IECA S-68-516 type EPR 7

6

3

1

6. Fire retardant Halogen Free Inner Sheath 7. Fire Retardant Halogen Free Outer Sheath: IEC 60092-359 type SHF1 IEC 60502 - 1 types ST8 ICEA T-33-655 types thermoset I & II CSA 22.2 n°38 BTS 74 C 068

IEEE-ICC Fall 2007 meetin Scottsdale - L. von Laue(Nexans) : Halogen Free Cables for Nuclear Power Plants

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Medium Voltage Cables

General properties

Examples of cable constructions and Standards references

Medium Voltage 1. Conductor IEC 60228 ASTME B3, B8

7

6

4

2

1

7. Fire Retardant Halogen Free Outer Sheath: IEC 60092-359 type SHF1 IEC 60502 - 1 types ST8 ICEA T-33-65 types thermoset I & II CSA 22.2 n°38 BTS 74 C 068

2. Halogen Free Medium Voltage Insulation IEC 60502 - 2 types EPR & HEPR IEC 60092-351 type HF EPR ICEA S-68-516 type EPR ICEA S-94-649 / AEIC CS 6/8 4. Medium Voltage semi conducting & metallic screens IEC 60502 ICEA S-94-649 / AEIC CS 6/8 6. Fire retardant Halogen Free Inner Sheath

IEEE-ICC Fall 2007 meetin Scottsdale - L. von Laue(Nexans) : Halogen Free Cables for Nuclear Power Plants

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Control & Instrumentation Cables:

General properties

Examples of cable constructions and Standards references

Control & Instrumentation

1. Conductor IEC 60228 ASTME B3, B8 3. Halogen Free Low Voltage Insulation IEC 60502 - 1 types EPR & HEPR IEC 60502 - 1 types XLPE IEC 60092-351 type HF EPR IECA S-68-516 type EPR 5. Instrumentation cable Screen

7

5

6 5 3 1

6. Fire retardant Halogen Free Inner Sheath 7. Fire Retardant Halogen Free Outer Sheath: IEC 60092-359 type SHF1 IEC 60502 - 1 types ST8 ICEA T-33-65 types thermoset I & II CSA 22.2 n°38 BTS 74 C 068

IEEE-ICC Fall 2007 meetin Scottsdale - L. von Laue(Nexans) : Halogen Free Cables for Nuclear Power Plants

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NPP Cables Qualifications

General Performances according to:

International and/or National standards IEC NF, BS, CSA, ASTM, ICEA, etc… BTS from EDF (Electricité de France)

Specific Nuclear Performances according to: IEEE 323 (NPP Electric Equipments) IEEE 383 (NPP Electric Cables) BTS and RCC-E EDF(Electricité de France) + specific engineering requirements

IEEE: Institute of Electrical and Electronic Engineers (USA) IEEE 323 and 383: Nuclear Power Engineering Committee of IEEE BTS : Book of Technical Specifications RCC-E : Construction and conception rules for electrical material in nuclear islands

IEEE-ICC Fall 2007 meetin Scottsdale - L. von Laue(Nexans) : Halogen Free Cables for Nuclear Power Plants

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Nuclear typical properties

IEEE Standard 383 for Type Test of Class 1E Electric cables

1

Thermal Aging

2

Radiation Aging

- To simulate the cables qualified life normal and accident irradiation

3

Test design Basis event

- To simulate the most severe postulated conditions of a design basis event and specified conditions of installation

- To simulate the cables qualified life

- Arrhenius methodology

The type testing for design basis event conditions shall involve both aged and non aged samples 1 + 2 + 3 2 + 3

2 scenariis because the design basis event may occur at any time

IEEE-ICC Fall 2007 meetin Scottsdale - L. von Laue(Nexans) : Halogen Free Cables for Nuclear Power Plants

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NPP cable Qualification Examples (1) Specification

¾ Thermal Aging

¾

¾ Simulation

¾

Radiation Exposure

¾

850 kGy

¾

(85 MRads)

¾

387 kGy

¾

(38,7 MRads)

¾

1025 kGy

¾

(102,5 MRads)

¾

2000 kGy

¾

(200 MRads)

1992 EDF ¾135°C

- 950 hours

1997 – 1998 Temelin

¾135°C

- 336 hours

1999

¾140°C

¾(40

Qinshan phase 3

2000 Huber& Suhner

¾(40

years at 60°C) - 798 hours

years at 90°C)

¾137°C

- 336 hours

Extreme accident ¾ Simulation conditions ¾

¾156°C

- 560 kPa

¾150°C

- 467 kPa

¾155°C

- 440 kPa

¾171°C

- 650 kPa

IEEE-ICC Fall 2007 meetin Scottsdale - L. von Laue(Nexans) : Halogen Free Cables for Nuclear Power Plants

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NPP cable Qualification Examples (2) Specification

2001 – 2003 Tianwan K0

2003 – 2004 Cernavoda

2003 – 2004 Lungmen

¾ Thermal Aging

¾

¾ Simulation

¾

Radiation Exposure

¾

140°C - 775 hours

¾

1000 kGy

¾

(40 years at 90°C)

¾

(100 MRads)

¾

1000 kGy

¾

(100 MRads)

¾

2000 kGy

¾

¾

(40 years at 90°C)

(40 years at 90°C)

¾135°C

2004 – 2007 EDF

– 240 hours ¾ (60 years)

¾(200 ¾

MRads)

850 kGy

Extreme accident ¾ Simulation conditions ¾

¾

250°C - 700 kPa

¾

150°C - 140 kPa

¾

171°C - 310 kPa

¾156°C

IEEE-ICC Fall 2007 meetin Scottsdale - L. von Laue(Nexans) : Halogen Free Cables for Nuclear Power Plants

- 560 kPa

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Nuclear typical properties

1) Thermal Aging

To simulate the cables qualified life. Arrhenius methodology According to: • ANSI/IEEE 101 • IEC 60216

IEEE-ICC Fall 2007 meetin Scottsdale - L. von Laue(Nexans) : Halogen Free Cables for Nuclear Power Plants

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Arrhenius ageing test NPP sheath material sheating compound at 180°C - 165°C - 150°C - 135°C 180 160

elongation at break [%]

140 120 100 80 60 40 20 0 1

10

100

1000

10000

time (hours) IEEE-ICC Fall 2007 meetin Scottsdale - L. von Laue(Nexans) : Halogen Free Cables for Nuclear Power Plants

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Arrhenius ageing test NPP sheath material

Experimental : • Measured quantity : elongation at break according to IEC60811 -1-1 • Ageing conditions : hot ai r oven according to IEC60811 -1-2 • Endpoint criteria : 50 % of initial elongation at break Test temperature [°C] 135 150 165 180

Inverse absolute temperature [1/K] 2,450E-3 2,363E-3 2,282E-3 2,207E-3

Time for 50 % of initial elongation at break Min. estimate [hours] 6520 2080 520 162

Max. estimate [hours] 9200 2510 620 189

Median time [hours] [days] 8160 340 2270 95 570 24 188 8

Fit results of median time values to Arrhenius law : • Activation energy : Ea = 1,348 eV or 130,1 kJ/mol • Correlation coefficient o f linear fit : R² = 0,9991

IEEE-ICC Fall 2007 meetin Scottsdale - L. von Laue(Nexans) : Halogen Free Cables for Nuclear Power Plants

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Arrhenius lifetime test

Followed by: Complete cable test according to IEEE 383 • Electric evaluation after bending => 40 or 60 years expected lifetime

temperature [°C] 160

140

120

100

80

1,0E+07 Nexans NPP K1 sheath material 1,0E+06

100 y 50 y

1,0E+05

10 y 5y

1,0E+04 experimental points

lifetime [years]

70 75 80 85 90 95 100

Lifetime [years] 95% confiPredence limit diction upper lower 1634 1133 1334 848 589 693 448 312 367 241 168 198 132 92 108 73 51 60 41 29 34

time for endpoint criteria [h]

Temperature [°C]

1y 0,5 y

fit curve

1,0E+03 95% confidence limits

1,0E+02 0,0022

0,0024

0,0026

0,0028

0,003

inverse temperature [1/K]

IEEE-ICC Fall 2007 meetin Scottsdale - L. von Laue(Nexans) : Halogen Free Cables for Nuclear Power Plants

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Nuclear typical properties

2) Gamma radiation

Gamma radiation Aging (from Cobalt 60) To simulate the cable qualified life normal and accident irradiation LABRA (CEA Saclay Facilities)

Nexans Cable

IEEE-ICC Fall 2007 meetin Scottsdale - L. von Laue(Nexans) : Halogen Free Cables for Nuclear Power Plants

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Nuclear typical properties

3) Loss of Coolant Accident Simulation

To simulate the most severe postulated conditions of a design basis event - thermo dynamical shocks)

Accident scenarios are plant and engineering specific.

Different equipments at disposal

Many different scenarios have been tested

IEEE-ICC Fall 2007 meetin Scottsdale - L. von Laue(Nexans) : Halogen Free Cables for Nuclear Power Plants

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Nuclear typical properties

3) Loss of Coolant Accident Simulation EDF (Electricité de France) LOCA curve (from RCC-E)

IEEE-ICC Fall 2007 meetin Scottsdale - L. von Laue(Nexans) : Halogen Free Cables for Nuclear Power Plants

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Temperature and Pressure conditions Example Tir Nexans K0 300

16

14 250 12

10

150

8

6 100 4 50 2

0 1,00E+00

5,00E+04

1,00E+05

1,50E+05

2,00E+05

0 2,50E+05

Temps (sec) IEEE-ICC Fall 2007 meetin Scottsdale - L. von Laue(Nexans) : Halogen Free Cables for Nuclear Power Plants

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Pression (bar)

Température (°C)

200

Conclusion 1 Nexans FRNC cables 1E & non1E are the Best Choice for NPP’s cabling

9 Used Inside and Outside NPP’s containment 9 Fitted to 40/60 years life time 9 Fire retardant 9 No corrosivity - No toxicity – No smoke 9 Qualification according to many standards 9 Radiation resistance up to 2.106 Gy (200 Mrads)

IEEE-ICC Fall 2007 meetin Scottsdale - L. von Laue(Nexans) : Halogen Free Cables for Nuclear Power Plants

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Conclusion 2 Nexans has been chosen by many Utilities, thank to: 9 its high quality and performance of electrical cables for Nuclear Power Plants, 9 its broad experience all over the World regarding multiple types of Nuclear Power Plants 9 its efficient Service and its Reliability

IEEE-ICC Fall 2007 meetin Scottsdale - L. von Laue(Nexans) : Halogen Free Cables for Nuclear Power Plants

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Thank you for your attention

IEEE-ICC Fall 2007 meetin Scottsdale - L. von Laue(Nexans) : Halogen Free Cables for Nuclear Power Plants

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