1-h astm e1119 fire simulation facility fire test on

TSI TECHNICAL NOTE 8275-1

ENGINEERING TEST REPORT

ONE HOUR ASTM E119 FIRE SIMULATION FACILITY FIRE TEST

ON A CLASS 1E CABLE CONDUIT TEST ASSEMBLY

PROTECTED WITH

THERMO-LAG 330-1 SUBLIMING COATING ENVELOPE SYSTEM

JUNE 1981

iso 5 ~vo>~'tINC.

3260 BRANNON AVE. ~ ST. LOUIS. MISSOURI 63138

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ON A CLASS lE CABLE CONDUIT TEST ASSEMBLY

PROTECTED WITH


JUNE 1981

TSI, INC. 3260 BRANNON AVE. 4 ST. LOUIS, MO. 63139 4 (314) 352-8422 4 Telex: 44-2384

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TABLE OF CONTENTS

SECTION TITLE PAGE NUMBER

INTRODUCTION

IV

V

VI

VII

VIII

'TEST FACILITY

TEST MATERIALS

MATERIAL APPLICATION

TEST SPECIMEN.

TEST PROCEDURES

TEST INSTRUMENTATION

VERIFICATION OF THERMO-LAG 330-1. SUBLIMING COATING ENVELOPE .SYSTEMTHICKNESS

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RESULTS OF FIRE TEST

CONCLUSIONS

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LIST OF TABLES

TABLE NO. 1ITLE , PAGE NUMBER

. Il IDENTIFICATION OF'CABLES INCABLE CONDUIT TEST ASSEMBLY

II IDENTIFICATION OF TEST THERMOCOUPLES 16

LIST OF FIGURES

FIGURE NUMBER TITLE PAGE NUMBER

3-1

3-2

4

TESTING FURNACE FOR HEAT RESISTANCE

A.:TYPICAL CLOSEUP VIEW OF THE CABLE CONDUITTEST ASSEMBLY PROTECTED WITH THE THERMO-LAG330-'1 SUBLIMING COATING ENVELOPE SYSTEM

SCHEMATIC 'OF THE CABLE CONDUIT TEST ASSEMBLYAFTER INSTALLATION OF THE THERMO-LAG 330-1,SUBLIMING COATING 'ENVELOPE SYSTEM

A TYPICAL PHOTOGRAPH OF THE CABLE CONDUIT =

TEST 'ASSEMBLY MOUNTED ON THE FACE PLATE OF

THE TSI'STM E119 FIRE SIMULATION 'FACILITY

ASTM E-119 TEST METHOD TIME/TEMPERATURERELATIONSHIP

ASTM E119 TEST METHOD FIRE TEST SET-UPINCIDENT'EAT FLUX LEVEL AS A FUNCTIONOF FIRE DURATION/EXPOSURE TIME

CABLE CONDUIT TEST ASSEMBLYINTEGRITY MONITORING CIRCUITS

LOCATION OF TEST THERMOCOUPLES IN THECABLE CONDUIT TEST ASSEMBLY

COMPARISON OF THE REQUIRED ASTM E119 TESTMETHOD TIME/TEMPERATURE HISTORY WITH THEACTUAL MEASUREMENTS DURING THE ONE 'HOUR ASTME119 TEST ON THE THERMO-LAG 330-1 SUBL'IMING

'OATING ENVELOPE SYSTEM

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A TYPICAL PHOTOGRAPH OF THE THERMO-LAG 330-1SUBLIMING COATING ENVELOPE SYSTEM PROTECTED CABLECONDUIT WITH TEST INSTRUMENTATION AND MOUNTED FORINSERTION INTO THE TSI ASTM E119. TEST FACILITY 19

TSI ASTM E119 FIRE SIMULATION FACILITY — RESPONSE OF SURFACE CABLE TAG'ERATURES-CONDUIT — TESTS CONDUCTED ON 27 APRIL 1982:

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LOCATION 1

LOCATION'.

LOCATION 3

LOCATION 4

LOCATION 5

LOCATION 6

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ON A CLASS 1E CABLE CONDUIT TEST ASSEMBLY

PROTECTED WITH


INTRODUCTION

The purpose of this report is to present and discuss the experimentalresults obtained from performing a "one hour" ASTM 'E119 Fire Teston THERMO-LAG 330-1 Subliming Coating Envelope System for a Nuclear

'lantClass 1E electrical circuits installed in a Cable. Conduit Assembly.

All of the fire tested THERMO-LAG 330-1 Subliming Coating Envelope SystemMaterials were manufactured in accordance with the procedures set forth inTSI's Quality Assurance and Quality Control Operating Procedures.

The THERMO-LAG 330-1 Subliming Coating Envelope System materials wereapplied in accordance with TSI's Quality Assurance and Quality ControlOperating Procedures and TSI's Technical Note 80181 entitled:"THERMO-LAG 330-1 Subliming Coating Envelope System Application Procedures."

The Nuclear Plant Class IE Cable Conduit assembly successfully passed allof the applicable Design, Performance and Operation Criteria specifiedin applicable sections of ANI/MAERP Standard Fire Endurance Test Methodto Qualify a Protective Envelope For Class 1E Electrical Circuits andthe Nuclear Regulatory Commission, 10CFR, Part 50, (Fire ProtectionProgram for Operating Nuclear Power Plants, dated 19 November 1980)Final Rule.

TSI INC. 4 3260 BRANNON AVE. 4 ST. LOUIS, MO. 63139 4 (314} 352-8422 4 Telex:.44-2384

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II TEST FACILITY

~ TSI's ASTM E119 Fire Simulation Facility consis. s of an enclosed hightemperature furance and the necessary supporting equipment vhich isinstalled in a special test room at the Company The furnace isconstructed of steel plate lined vith high temperature insulative materialand has exterior dimensions of 49 1/2 inches in vidth, 49 3/8 inches indepth and 66 3/4 inches in height. The bottom section of the furnace ismade of 1/4 inch steel plate and is lined with a 4 7/8 inch layer ofMoucolite VL, and a 4 1/8 inch layer of Monocast 50 ' The top and vali

'ectionsof the furnace are constructed of 1/8 inch steel plate and arelined with a 3 inch layer of Fibergax Durablock and a 5 inch layer wfthree different types of Piberfax Durablanket.

The furnace interior is 36 inches vide by 3& inches deep by 48 inches high.The top and bottom sections are further insulated vith approximately4 inches of calcined flint clay in order to protect the test specimenfrom upper and lower end temperature effects The entire furnace assemblyis aaunted on five 4 inch "8" beam supports

Twelve (12) gas burners are arranged in groups of three's per side and .'re staggered to provide more uniform flaming in the vicinity of thetest assembly The furnace air temperature is monitored by six (6)chromel/alumel thermocouples vhich are enclosed in protective tubes sothat the time constant of the protected thermocouple assembly liesvithin the range of 1 to 2 minutes Th'ese sDr,'6) thermocouples arelocated in groups of tvo's on three of the four walls at distancesof 18 inches and 34 inches above the floor

Visual observations are facilitated through the use of view portswhich are mounted in each of the four walls k schematic of TSZ'sASTH Z119 Pire Simulation Facility is shown in Pigure 1

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III. TEST MATERIALS

The THERMO-LAG 330-1 Subliming Coating Envelope System as testedconsisted of the following materials:

A. - THERMO-LAG STRESS SKIN TYPE 330-69

This material provides an outer protective cover. It is an openweave, stiffened steel mesh with a 0.019 inch strand diameter, *

a 64 minimum mesh size and a weight per square yard, of 1.75 pounds.

B. THERMO-LAG 330-1 -SUBLIMING COATING

This material provides the required one hour level of fire endurance.It is a water based, subliming, thermally activated, fire resistivecoating which volatilizes at a fixed temperature —exhibits a smallvolume increase through the formation of a multi-cellular matrix,and absorbs and 'blocks heat to protect. the substrate material.

lV- MATERIAL APPLICATION

Suggested test specimen layouts are presented in ANI/MAERP Fire EnduranceTest Method to +alify a Protective Envelope For Class lE ElectricalCircuits. The following will summarize the preparation of the cableconduit test assembly, protected with the THERMO-LAG 330-1 SublimingCoating Envelope System applied in accordance with details describedin TSI's Technical Note 81081.

A. The protective envelope consisted of a wrap around — "clam shell"arrangement which completely covered the cable, conduit assembly'sexterior surface.

B. This envelope consisted of an inner layer of THERMO-LAG Stress SkinType 330-69 and'a 0.625 inch wet (0.469 inch dry, 25% shrinkagein airless sprayed wet THERMO-LAG 330-1 coating) covering, of theTHERMO-LAG 330-1 Subliming Coating Material.

C. A typical closeup view of the finished THERMO-LAG 330-1 Subliming~ Coating Envelope System for an electrical cable conduit assembly

is presented in Figure 2. As shown, the THERMO-LAG 330-1 SublimingCoating Envelope System conforms quite closely to the contour ofthe cable conduit, even at the mitered 90'oints and gives arelatively smooth final finish.

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FIGURE 2: A TYPICAL CLOSE-UP VIEW OF THE CABLE CONDUIT TEST ASSEMBLY

PROTECTED WITH THE THERMO-LAG 330-1'UBLIMING COATING

ENVELOPE SYSTEM

V. TEST SPECIMEN

The Cable Conduit, Test Assembly consisted of a standard electricalcable conduit section fabricated in the form of a "U" bend. TheU bend dimensions are 5Q inches outside diameter, 36 inches long by32 inches high. A total of eight (8) electrical cables wereincorporated in the test assembly. Table I presents a listing of theindividual electrical cables.

A schematic of the cable conduit test assembly after the installation ofthe THERMO-LAG 330-1 Subliming Coating Envelope System is presentedin Figure 3-1. Figure 3-2 presents a typical photograph of the cableconduit test assembly mounted on the face plate of the TSI ASTM E119Fire Simulation Facility.

VI. TEST PROCEDURES

A. One Hour Fire Test

The fire testing procedures are specified in Paragraph 3.4.1 ofANI/MAERP Standard Fire Endurance Test Method to Qualify AProtective Envelope for Class '1E Electrical Circuits. Basically,this one hour fire test is a one hour exposure to the 'time/temperaturecurve of ASTM E119-76 (ANSI A2.1). For ease of reference, Figure 4presents this ASTM E119-76 time/temperature curve for the exposureperiod.

As shown in Figure 4, the Test Set-Up Internal Air Temperature startsat the prevailing ambient air temperature (test room temperature),reaches a temperature of circa 1000'F after 5 minutes, a temperatureof circa 1500'F after 30 minutes and a temperature of. circa 1700'Fafter 1 hour. Based upon widely 'accepted criteria, this variationin the time/temperature curve also means a;,variation in the incidentheat flux upon any "target" exposed to this time/temperaturerelationship. As shown in Figure 5, it is commonly accepted thatthe ASTM E119 Test Method produces a "time averaged incident heat'flux" of circa:

24,500 BTU/HR-FT2

34,500 BTU/HR-FT2

42,000 BTU/HR-FT

for

for

for

One Hour's Exposure

Two Hour's Exposure

Three Hour's Exposure

TABLE I

IDENTIFICATION OF ELECTRICAL CABLES

IN THE CABLE CONDUIT TEST ASSEMBLY

CABLE NUMBER ELECTRICAL CABLE IDENTIFICATION

23

24

3C W023.5 ADD7530 - ADD7438

12C W045-15 — 07054 — 07004

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26

27

28

29

30

2C .W121 — 0000078 — 0000228 Brown & Root

3C W023.5 ADD7530 — ADD7438

12C W045-15 — 07054 — 07004

'C W121 — 0000078 — 0000228 Brown & Root

3C W023.5 — ADD7530 — ADD7438

SUMMARY: Two (2) No. 2C Cables

Three '(3) No. 3C Cables

Three (3) No. 12C Cables

Total: Eight (8) Electrical Cables in Conduit Assembly

18" 8ll

'8

30

16"

425 26

32

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'.364NOTE: Not to Scale

'IGURE

3-1: SCHEMATIC OF THE CABLE CONDUIT TEST ASSEMBLYAFTER INSTALLATION OF THE THERMO-LAG 330-1SUBLIMING COATING ENVELOPE SYSTEM

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TSI ASTM" E119 FIRESIMULATION FACILITY

CABLE CONDUIT TEST ASSEMBLY,'READY FOR INSERTION INTO TEST

FACILITY FOR ONE HOUR FIREP

FIGURE 3-2: A TYPICAL PHOTOGRAPH OF THE CABLE CONDUIT TEST'SSEMBLY MOUNTED ON THE 'FACE PLATE OF THE TSI'STM E119 FIRE SIMULATION FACILITY

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FIGURE 5'STM E-119 TEST METHOD FIRE TEST SET-UPINCIDENT HEAT PLUX LEVEL AS A FUNCTIONOF PIRE DURATION/EXPOSURE TIME

50

40

30

20

10

TIME AVERAGED INCIDENT HEAT PLUXES

ONE HOUR,EXPOSURE> 24,500 BTU/hr-ft2

TWO HOUR EXPOSURES 34/500

THREE HOUR EXPOSURES 42 000 "

00 60 120 180

TIME-MINUTES

B. Electrical Circuit Continuit Tests

Paragraph 3.5 of ANI/MAERP Standard Fire Endurance Test Method toQualify a Protective Envelope for'lass lE Electrical Circuitsrequires that the following criteria be met for the 1 hour fire test:

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"3.5 — The tests shall be constituted a failure if any of thefollowing occur:

1. Circuits fail or fault during the fire test as .required in Test 1 ASTM E119-76 one hour exposuretest."

Thus, one of the required test conditions is to continuously monitor,a sufficient number of electrical circuits in the, test specimen to"detect failure circuit to,circuit (conductor t'o conductor shortcircuits); circuit to system (conductor continuity); and circuit toground (short circuits, conductors to ground).

Selected cables in the cable conduit test assembly were instrumentedto monitor each of the following three parameters:

1. Two cables, one power and one control cable in the cable 'conduit'est assembly were connected to a short'circuit detectioncircuit as shown in Figure 6A.

2. Two cables as, identified above, were also connected to acontinuity monitoring circuit as shown in Figure 6B.

3. Two cables, as identified above, were connected to a groundshort circuit detection circuit as shown in Figure 6C.

This procedure gives a total of six (6) instrumented cables in the cabletray test assembly for monitoring of cable integrity during the onehour fire test.

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FIGURE 6: CABLE CONDUIT TEST ASSEMBLYINTEGRITY MONITORING CIRCUITS

VII. TEST INSTRUMENTATION

The test instrumentation consisted of the following:

A. Twelve (12) chromel/alumel thermocouples for measurement of electricalcable surface temperatures. The locations of the thermocouples areshown schematically in Figure 7. Table II presents a listing of thetemperature measurements for each of the twelve (12) test thermocouples.

B. The twelve (12) electrical cable test thermcouple readings. wereautomatically recorded throughout the duration .of the fire test ona multi-point Honeywell-Brown Chart Type Recorder.

C. Six (6) chromel/alumel thermcouples were used for the air temperaturemeasurements inside TSI's ASTM E119 Fire Simulation Facility." Thesethexmocouple readings were continuously monitored on a second Honeywell-Brown Chart Recorder for the duration of the fixe test.

D. For manual control of the ASTM E119 Fire Simulation Facilitytime/temperature xelationship,'wo (2) Omega Digital TemperatureRecorders were also used. A visual reading was taken every five (5)minutes from these digital recorders for use in the control of theASTM E119 Fire Simulation Facility.

Figure 8 presents a comparison of the ASTM E119 Test Method requiredTime/Temperature Curve with the "maximum thermocouple readings" and theoverall average of the thermocouple readings for the thermocoupleslocated in the immediate vacinity of the cable conduit test assembly.

Figure 9 presents a typical photograph of the instrumented cable conduittest assembly ready for insertion into TSI's ASTM E119 Fire SimulationFacility. This photograph was made just prior to the start of theOne Hour Fire Test.

VIII. VERIFICATION OF THERMO-LAG 330-1SUBLIMING COATING ENVELOPE SYSTEM THICKNESS

Using a non-destructive magnetic flux device, the thickness of theTHERMO-LAG 330-1 Subliming Coating Envelope System was verified. Thethickness varied (dry film thickness) from a low of 0.500 inches to ahigh of 0.625 inches.

The- cured surface of the THERMO-LAG 330-1 Subliming Coating EnvelopeSystem had not cracked, spalled or flaked.'he appearance was thatof a conventional finish for this type of fireproofing material.

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5/I I25 26

32'I

24

23

36"NOTE: Not to Scale

FIGURE 7: LOCATION OF TEST THERMOCOUPLES IN THE CABLE CONDUIT'EST ASSEMBLY

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TABLE II

IDENTIFICATION OF TEST THERMOCOUPLES

THERMOCOUPLENUMBER

ELECTRICAL CABLENUMBER THERMOCOUPLE LOCATION

1&2

3&4

5&6

7&8

10

12

29

30

28

27

25

26

24

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2C W121 — 0000078 — 0000228 Brown & Root

3C W023.5 ADD7530 - ADD7438

12C W045-15 — 07054 —07004

3C W023.5-15 ADD7530 — ADD7438

12C W045-15 — 07054 —07004

2C W121 — 0000078 —0000228 Brown & Root

12C W045-15 .— 07054 — 07004

3C W023.5 ADD7530 — ADD7438

NOTE: See Figure 7 for Physical Location of Test Thermocouples

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TSI ASTM E119 FIRESIMULATION FACILITY

CABLE CONDUIT TESTSPECIMEN WITH:THEPROTECTIVEENVELOPE

ELECTRICAL CABLETEST THERMOCOUPLELEADS

HONEYWELL-BROWNTEMPERATURECHART RECORDER

A TYPICALFIGURE 9: PHOTOGRAPH OF THE THERMO-'LAG 330'-.1 SUBLIMING COATING

ENVELOPE SYSTEM PROTECTED CABLE CONDUIT WITH TESTINSTRUMENTATION AND MOUNTED FOR INSERTION INTO THETSI ASTM E119 TEST FACILITY

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IX. RESULTS OF FIRE TEST

Based on the requirements of ANI/MAERP Standard Fire Endurance TestMethod to Qualify a Protective Envelope for Class lE ElectricalCircuits as shown in Section VII (B) of this report, and on the basisof the energized cable integrity as shown by Figure 6 (MonitoringCircuits), the cable conduit test assembly PAASED the One Hour FireTest requirements.

To provide additional test data for interpretation of the test results,a number of cable surface temperature measurements were recorded andare reported -in Figures 10 through 15. These figures present plots ofthe measured electrical cable surface temperature 'in the Cable ConduitTest Assembly.

CONCLUSIONS

Based upon the test results and experimental data presented herein,as well as detailed visual inspections of the cable conduit testassembly before the start of testing and after the one'hour firetest, the following conclusions are presented for consideration andevaluation purposes:

1. Based on the requirements for maintaining cable circuit integrity,as specified in ANI/MAERP Standard Fire Endurance Test Method toQualify a Protective Envelope System for Class lE Electrical Circuits,the THERMO-LAG 330-1 Subliming Coating Envelope System applied tothe cable conduit test assembly PASSED the One Hour Fire Testrequirements.

2. The recorded cable surface temperature measurements at theconclusion of the one hour fire test shows that the electricalcable surface temperatures are well below commonly acceptedindustrial standard limitations.

3. On the basis of the cable integrity monitoring, requirements andthe detailed visual inspection of the test assembly after the onehour fire test, it is concluded that the THERMO-LAG 330-1 SublimingCoating Envelope System, as tested and reported upon. herein, meetsthe specified performance criteria and is expected to provide therequired one hour of thermal protection against an ASTM E119Test Method fire environment.

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TSI ASTM E119

FIRE SIMULATION FACILITY

RESPONSE OF SURFACE CABLE TEMPERATURES

CONDUIT

TESTS CONDUCTED ON 27 APRIL 1981

LOCATION 2

FIGURE 11

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TIME - MINUTES

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TSI, INC. o 3260 BRANNON AVE. 4 ST. LOUIS, MO. 63139 o (314) 352-8422 o Telex: 44-2384

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TSI ASTM E119



CONDUIT


LOCATION 3

FIGURE 12

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TSI, INC. o 3260 BRANNON AVE. o ST, LOUIS, MO. 63139 o (314) 352-8422 o Telex:.44-2384

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TSI ASTM E119



CONDUIT


LOCATION 4

FIGURE 13

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TSI, INC. o 3260 BRANNON AVE. o ST. LOUIS, MO. 63139 o (314) 352-8422 o Telex:.44-2384

TSI ASTM E119



CONDUIT


LOCATION 6

FIGURE 15

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TIME - MINUTES

2S

TSI INC o 3260 BRANNON AVE o ST, LOUIS hhO 63}39 o (3 I4) 352.8422 o TeIex:-44-2384

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