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I. 7. L. REPORT NO 84-10-5

ENCIIJEERING REPORT ON AN AMPACITY TEST FOR 600 VOLT POWE CABLES

INSTALLED IN A FIVE FOOT LDNGTB OF TWO INCH CO!qDUIT

• " PROTECTED WITH A

THREE HOUR FIRE RATED DESIGN OF TlEE

THERKO-LAG 330 FIRE ]BARRIER SYSTD{

ISSUI•: OCTOBER 1984

• | NDUSTRZAL.TEF;T| NC

Inc,

I. T. L. REPORT HO. 84-10-5

TEST DATE: 29 SEPTEMBER 1984

TEST:

A3PFROVE• BY :

AKPACITY TEST FOR 600 VOLT POWER CABLESINSTALLED Thq A FiVrE FOOT LENGTH OF'NO 11NCR CONDUIT PROTECTED W"ITH ATHRLEt HOUR FIRE RATED DESIGN OF THEETKERXO-LAG 330 FiRE BARRIER SYSTEM

ALLAiN H. SIEGEL, P.E. ,._DIRECTOR

INDUSTRLAIL TESTING LABORATORIES , INC.2350 SEVEHTH BOUTLEVARDST. LOUIS, KISSOUKI 63104

OCTOBER 1984

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Z~NDUBTRdALT1E5T1 NO

LABORATOJ]gS

I. 7. 1.. EDORT Xo 84-10-5

Test Date: 29 September 1984

Superviaing tbe teat for Industrial Testing Laboratories., Inc.

Donald L. SEorment, P.E.

Witnessing the test..for Thermal Science, Inc.

Rubin Feldmaao President

Operating the test equipment for Thermal Science, Tnc.

Wilbur Paddock, Vice President of Operations

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• NDU8TRIA1oLABO•ATORI ES

I.T.L. REPORT NO. t•-I0-5

TABLE OF CONTNS

:CTION -ZT

• 0 • L'TROSE

.0 TEST LOCATION

n ~TEST SET U'P

SE PACE ?O.

I

2 a

12J i •+a

3.13.2

.3.2,3.5.

~4.1

CONDUIT TRAY ASSD'IL!POWER CABLEP OWE._R SOURCEflLXT LOSS REDUJCTIONI NSTRUIE'TATION '- "l '

TEST PROCI~b"RE

UNPROTECTED COND3UIT TEST ASS D{BLYPROTECTED) CONDUIT TEST ASSEMBLY

ANALYSIS OF TEST R•ESULTS

UNPFROTECTED CONDUIT TEST ASSEYILYPROTECTS) CONTDUIT TEST AZSDI•LY

CONCLUS IONS

ADDE2'TA

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22255

5.0 Il

11115.1

5.2

126.0

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•A INDUSTRIALTESTING

LA•ORATO•I EB

I.T.L. REPORT NO. B4-10-5

LIST OF FIGURES

FIGURE NO. TITLE PACE .NUMBER

LOCATION OF TEST ASSEMLT ANDAMB 1ENT TEMPERATURE ThZERMOCOULESIN TEST CEABER

SCltEMATIC CIRCUIT DI.AGRAM

LOCATION OF TrIXRMOCOU5E W~lTBTF.SI ASSE•L!

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2 14

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••b NrWSTR!AL

A•ORAORIEInc.

I.T.L. REPOR~T NO. 84-10-5

LIST OF TABLES

ABLE NO. TITLE

1 BASE LINE TEST DATA

TJ PAGCE NO.

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TEST DATA FOR A FIVE FOOT LENGTH OFTWO INCH CON•DUIT PROTECTED VrITh ATHREE BOUR FIRE RATED •DESIGN OF TEEThERXO-LAC 330 FI.RE BAP.RIER SYSTEMI

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,,•J-- INpUSTRIAI..""....""":::TESTI NG C ll};'l:

ABORATORI ES

I. T. L. RE PORT NO 84-10--5

ENGIN'EERING REPORT ON AN A2!PACITY TEST FOR 600 VOLT POWER CABLES

I•STALLE) IN A FIVE FOOT LENGTh OF TWO INCH CON'DUIT

PROTECTED IJITE A

THREE HOUR YIPI RATED DESIGN OF THE

THERMCO-LAC 330 FIRE BARRIE1. SYSTEX

1.0 PUJPYOSE

The purpose of the test was to determine the effect of the applicationof a t~hree hour fire rated design (one inch (1") uinimium dry filmthickness) of the THERI{O-LAG 330 Fire Barrier System, on the temperaturerise and ampacity of a 600 volt #00 AWO power cable0 installed in a fivefoot length of rvo inch conduit. This test yas conducted in accordancev'ith A.IEE Publication No. 5-1135-2, IPCE.A Pub. ?h.. P-d•6-426 (1962)entitled: "Power Cable Ampacities."

2.0 TEST LOCATION

The test was conducted at the laboratory facilities of Thermal Science,Inc. ("T751") in St. Louis, Missouri, on 29 September 1984, and witnessedby a representative of Industrial Testing L~aboratories, Inc, inSt. Louis, Missouri. The duration of the ampacity derating test wesone hour. The data from this test vas compared to the base linetest data obtained from the test conducted at T~r.'s laboratory on23 October 1981, on the sane unprotected test assembly.

3.0 TEST SET UP

For test purposes, the conduit test assembly vas placed on two 2"x:'"wooden blocks with 5 /' by 5' wide by 29½" deep test chamber constructedof 3/G8" plyvood. The test chamber, in turn, was placed on the surface of.a laboratory bench..

The desired level of ambient temperature yam provided within the tentchamber by means of three heat lamps located in the top of the enclosurea nd tv hot plates located at tbe bottom of the enclosure. The entranceand e.xit openings for t' • power nableu, at one end of the test enclosure•were szealed by means of a 2" shroud of ceramic tool. Likewrise, theentire surface of all power cables, enterin~g the test enclosure from thejunction with their power aupply and power cables leaving the testenclosure all the way to the energizing varilic, were coerted with a 2"ceramic wool shroud in order to minimize heat losses.

3.1 Conduit Test A~ssembly,

The conduit test •asem=bly vas constructed of a five foot section of2" schedule 40 rigid steel conduit. The in•ide diameter of the rigidsteel conduit was 2.10 inches and the cross-sectional area of the conduitwas 3.46 square inches. The test assembly ~an used for the unprotectedbase line conduit teats. A separate but identical conduit asoeibly wasprotected with a three hour fire rated design of the ?HXRMG-LAG 330 FireBarrier System Preshaped Conduit Sections.

3.2 Power Cables

A 21 foot length of #00 AWG cable van folded into tvo loops and theninstalled in each five foot length of two inch conduit. The power cablewas appronimately 0.562 inches in diameter, had 0.23 square inches in thecross-sectional area, and was made of 19 strands of 0.0827 inch diametercopper wire.

A schem~atic which shovi the conduit test section outed in the testchamber together with the location of the ambient temperaturethermocouples within the test chamber is nbovna in Figure 1,

3.3 Power Source

A 200 volt, single phase power source was used to energize the #00 AWCpower cable conduit. The power source was equipped with a variac anda current transformer as shown in Figure 2.

See addenda for eitplanation of 5 foot length.

2

FI1lW.E 1

LWCAION Op' TEsT ASSDLY A• AXWT :Tzfl, UR

-T--

4TC 2-FT19

I

2" THICIZ CERAMIlC WOOL 3LA1•E

CONUI~VT TEST ASSI•LYMAOUNTED ON WOODEN BLOCKSIN TEE TEST CBIMB1R

#~oo AWJGPOW'ER CAZLJ

"3 LINES

3

FIGURE 2

SCHflKATIC CIP.CUIT DIAGRAM

3 SECTIONS .oF #00 AWG POWER CABLEEACH SECTION 7 FEET LONG - ALL flN SERIES

KCURR.EN'I ThANSFO•~

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3./. Heat Los,. Reduction

The tvn ends of the conduit, together vi~th the cables emerging from theconduit ends, were wrapped with a 2 inch thick piece of ceramic wiooi.The cera~mic blsnk~et wrap was then secured to the conduit and the cablesby wrapping it vith duct tape. This step was taken to reduce the amountof heat loss from within the conduit section and from the cable lengthsthat were not located with the conduit section.

3.5 Inet rum~entation

The test instruments and devices used during the auzpacity test consistedof three thermocouples, a thermocouple temperature recorder, an ammeter,a digital readout and a current transformer.

3.5.1 Thermocouples

Three (3) Thermocouples vere installed in the center of the 2" conduitsection. The first two thermocouples were located six inches on eachside of the midpoint along the length of the conduit and the third waslocated an additional six inches away from the midpoint. They wereembedded in slits made in the cable insulation.

The location of the three thermocouples with the test assembly is shownin Figure. 3.

3.5.2 Thermocouple Temperature Recorder

A Brown MuJiripoint Thermocouple Temperature Recorder was used to recordthe temperature of the pover cable circuit at the locations previouslydescribed.

Calibration of each thermocouple was checked againzt a standardthermometer by comparing the thermocouple readings at room temperatureand in boiling water. The deviation was less than lC from the knowntemperature in each case.

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TICUIIE 3

LOCATION OF T1IIMCOULES WITE T1• TEST ARTICLE

RIGID STEEL CONDUITDIAMETERS

#00 AWG P01,CABLES 3 LI

%%- 2 INCE DIAMETER SCHEULE 40IIGID STEEL CONDUIT

THRIJZqqCOUPLE S

2.

.J

* 00"DRY FIU'

Th{ERMO-LAC 330 TIRE BARRIER SYSTEM~

PRESIAPED WNhDLUIT DESIGN

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3.5.3 A=~eter

The amecer used to measure current in the paver cable circuit wco placedin series with the power cable and one of the output lines from thecurrent transformer. The ameter vas a General Electric Unit0 withreadout range from 0-300 amperes. The current transformer was aWestinghouse Unit with a maximi.m output of 400 amperes.

3.5.4 Ambient Temperature Digital Readout

An Omega engineering Unit wan used to prowide a dl.gital readout of theambient temperature during the test.

4.0 TEST PROCEDURE

The anpacity test was conducted in two separate but inter-related phases.The first phase consisted of e~stablishing a base line ampaciry for thepower cables when installed in the unprotected conduit teat assembly.The second phase consisted of determining the amperage derating whichoccurs when the conduit test assembly is enclosed by a three hour rateddesign of the TEERNO-LAC 330 Fire Barrier System Preshaped ConduitSections.

During both test phases, the ambient temperature was maintained at40 +/- 2C, and the m~aximum conductor temperatures were tmaintained at90 +/- 20. These two test phases are described in more detail in thefollowring paragraphs.

4.1 Unprotected Conduit Test Assembly

The base line ampacity test was conducted on the tw inch conduit testassembly prior to enclosure with the protective fire barrier at thelaboratory facilities of TSI in St. Louis, M~issouri on 23 Oct. 1981.

The base line ampacity rest was started by energizin~g the power sourcesto produce an initial amperage of 160 amperes in the C00 AWG power cablecircuit. This amperage level was then maintained in the pavder circuituntil one of the thermocouple temperatures stabilized within thedesignated temperature band of 194 +1- 3F (90+÷/- 2C). The elapsed timefor the pre-ceac period was circa (our hours,

Throughout this and the subsequent one bour test phase6 the ambienttemperature w-ithin the test enclosure was maintained at 104 +1- 3F(40 +I- 20).

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Once the base line test vas initiated, it vao continued for one hour.Durin~g the test, the amperages in the power cable, the hot spot cablether~ocouple temperature, and the eabien; temperature, wera recordedat 5 ainute intervals.

The recorded base line amperage of 152 amperes was tben corrected toreflect a 40C ambient temperature test condition and a 90C conductortemperature, using the correction formula presented in IPCF.A Pub.No. P-46-426 (1962), Page III, Equation (5).

•After correction, the base line amperage became 153.S2amperes. The baseline test &amperage and temperature., together wilth the amperage correctioncalculations are shown in Table 1.

4.2 Protected Conduit Test Assembly

A three hour fire rated designa of the TKKRM0--LAC 330 Fire Barrier SystemPreshaped Conduit Section was installed on the t• inch conduit testassembly. Insalnlarion of the System involved cuttiug and mounting 3 footlong presahped conduit sections on the test assembly, using approvedstainles a teel tie wires.

The preshaped conduit section design was installed on the test assembly inaccordance with procedures net out in TSI'a Technical Note 20684 entitled:"TBIEXO-LAG 330 Fire Barrier System, Installation Procedures Manual,Nuclear Plant Applications", Revision II, April 1984.

The test was started with the current flov established at 155 amp~eres inthe power cable circuit. This current level, which was developed in thefirst phase, was naintained until the temperature limgit of 194F (90C) wasreaiched by the hottest cable thermocouple. At this point, the amperagewas gradually reduced until the hottest cable thermocouple stabiliizedvitbhin the design~ated temperature band of 194 +/- JF (90 +/- 2C).

Alter the temperature had stabilized for one hour, the test run waninitiated and continued for another hour. During the teat rui, thecircuit amperages, the hot spot cable tharmocouple temperature andthe ambient temperature were recorded at 5 minute intarvals,

The test amperage of 140 amperes was then corrected to reflect a 0CCambient, temperature condition and a 90C conductor temperature testcondition using the correction formula presened in the IPCLA Pub.No. 46-426 (1962), Page III, Equation (5)°

Aftet correction, the test amperage became 138.60 amperes, Thetest amperages and temperatures, together with the amperagecondition factors are shown in Table 2,

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TAiL! 1

DbASE LIE TEST DXAA

Time

3:00 PM3:05 P,

3:103:153:203:253:30

PH

PM

PH

Average AmbientTemperature

F

106106

105105105105105

104

105105

104104104104

Maxim,-, CableTempe rat ure

P

194194

194193193193193

'93

193193

193 •.193193193

*00 AWC Pover Cable_ Ampe rage

152152

152152152152152

152

152152

152152152152

3:35 PM

3:40 P3:45 P

3:50 P3:55 PM.4:00 PM4:05 P

Average Ambient Temperature:

Average Cable Temperature:

Temperature Correlation PerIPCLA Pub. No. P-46-426:

104.79F (40.44C)

193.21F (89.56C)

90 - 4089.56 - 40.44 '

I - 152 234.5 + 89.56234.5 ÷ 90

I * 152 (1.01) - 153.52, Amperes

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5.0 ANALYSIS OF TEST RESULTS

The hottest cable thermocouple temperature, together with the ambienttemperatures and pover cable amperage readings, were recorded at5 m•nute intervals during each of the test phases. These test results,which are shown in Tables 1 and 2, are analyzed and discussed in thefollowing8 paragraphs.

5.1 Unprote~cted Conduit Test Assembly

The temperature readings for the hot spot ther~ocouple remauined writhinthe 194 ÷/- 37 (90 +/- 2C) temperature range during the one hour testperiod. The temperature ranged between l93 and 1947 during the test.

The power cable current remained constant at 152 amperes throughoutthe one hour test. The ambient temerature within the test enclosureaverage 104.79F writh all temperature readings falling wilthin theprescribed test range of 104 +/- 37 (40 +/- 2C) during the test.

5.2 Protected Conduit Teat Assembly

The tempersture reading for the hottest thermocouple rose to 194F (90C)when the powei cable circuit was energized at the 155 amperages levelestablished in the bane line test. The power cable current was thenreduced to 140 amperes and the temperature readings from this thermocouplestabilized between 196 and 1977 prior to the start of the test.

The power cable current remained at 140 amperes throughout the one hourtest. The ambient temperature with the test chamber averaged 1057 withinthe prescribed test range of 104 +/- 37 (40 +/- 2C) during the test.

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THER.MO-LAG STRESS SKIN TYPE 330-69

6.0 CONCLU5IOflS

The test results indicate that the mapacity of three lengths of 900 AMCpower cable installed in a tvo inch diameter rigid steel conduit, shouldbe derated by 9.722 vhen the conduit is protected vith a i~hree hourfire rated desipn of the Ti•M-L&G 330 Fire 5arriEtt System PreshapedConduit Section.

This derating factor van calculated by subtracting the test eapacity of138.60 amperes frou the base line amperage of 153.52, dividing the baseline value of 153.52, and then multiplying by 100. On this basis, thederating factor wau determined to be 9.722.

The derating I actor applies to the thickness of the TKEIRMO-LAG 330 Fireharrier System Naterial as tested, and tolerances employed in this testprogram which was 1,250" 4-1- 0.250', dry.

The test results obtained for derating the #00 AuG power cable may beused for all sizes of cable wiLth similar material. This is based on3. Stolpe's work which indicates that derating should be independentof cable size.

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ADDENDA

Recene IZE£ draft bulletins for ampacity dernting tests suggest the use ofracevay sections larger than the 5 foot section used for this tast. Since thebase line teat yas conducted in October of 1981. the IEEE raceway length couldnot be anticipated. Dovever, tbe 5 foot raceway used in this test witll not iiiany vay invalidate the test results.

The length of the raceway vii]. affect two parameters;

1) The temperature oscillations in both the cable conductor and thethe surrounding ambient air in the test box.

2) End effects vhere the cable enters and exits the teat box.

Each of these parameters wrill be considered below:

1) .Temperature Oscillations

The temperature oscillations are a function (among other things) of theair volume between the raceway and the test box, and the total ares offire barriers on •he raceway - both of which are a linear function ofthe raceway length. During the tests, the temperature variations forboth the conductor temperature and the ambient test box temperature werewell within the allowable +/- 2C during the one hour test period. Inaddition, the average value for conductor temperature and test boxambient teaperature were normalized to the base 90C/d&OC using thecurrent correction formu~la given in IPCE•A Publication No. P-46-426(1962) on page Ill, equation (5).

2) End Effects

A short racevay viii be vulnerable to end effects which are caused bythe localized hot spots vhe~.e the raceway enters and exits the testbox. These hot spots are caused by the cearmic fiber packing, and aretypically in the range of 5C temperature rise. The hot spots willcause a temperature gradient in both the inward and outward direction.The temperature gradient will exist f or only several inches into thetest box, not enough to effect the test results, since the conductorthermocouple locations are well into the test box.

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