Cables and Penetrations

1.0 Introduction

Normally in any power plant, cabling assumes no significance and it is only

required to connect the load to the feeder through an appropriate size of cable.
But in a PLANT, because of the importance to Safety and adherence to the
relevant standard practices and stipulations, cabling and associated activities
assume a lot of significance.

In PLANT following aspects are considered

• Segregation
• Standard recommended practices
• Cabling – design aspects
• Cable carriers/trays
• Fire protection with regard to cables
• Hermetic cable penetration

Class 1E circuits: the safety classification of circuits those are essential to

emergency plant shutdown, containment isolation, plant cooling, and
containment and plant heat removal or otherwise essential in preventing a
significant release of pollute material to the environment.

1.1 Electrical segregation:

The requirements for the electrical segregation of the cable systems for Class 1E
circuits, according to voltage levels, signal levels and vulnerability to electrical
noise are as follows.

1.1.1 MV Power cables

Designed to supply power to utilization devices of plant auxiliary systems rated

between 601 to 15000 Volts. MV power cables shall be installed with respect to
LV cables.

1.1.2 LV Power cables

Designed to supply power to utilization devices of plant auxiliary systems rated at

600 Volts or less.

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1.1.3 Control cables

Applied at relatively low current levels or used for intermittent operation to

change the operating status of a utilization device of the plant auxiliary system.

1.1.4 Instrumentation cables

Used for transmitting variable current or voltage signals (analog) or those used
for transmitting coded information (digital). Instrumentation cables shall be
installed to minimize unacceptable noise pickup from adjacent circuits and
equipments.

1.2 Physical separation and electrical isolation

Physical separation and electrical isolation is provided to maintain the

independence of the Class 1E circuits and equipment so that the safety functions
required during and following any DBA can be accomplished.

Physical separation is achieved by

• Use of safety class structures

• Separation distance or barriers
• Combination of both

Electrical isolation is achieved by:

• Isolation devices
• Separation distances
• Shielding and wiring techniques
• Combination of any

2.0 Cables and cable trays

Classification of areas where Class 1E and associated circuits are routed.

• Non-hazard areas
• No high energy equipment
• Limited to C&I functions, power circuits for which are in enclosed trays
• Control & limiting of introduction of potential hazards the area-possible
• Limited hazard areas

Plant areas from which potential hazards such as missiles, non-electrically

induced fires and pipe failures are excluded.

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2.1 Hazard areas

Independence of redundant class 1E systems is maintained by cable routing

restrictions, or physical separation or both. Redundant standby generating units,
batteries, battery chargers, distribution S/G, are placed in separate safety class
structures. Containment electrical penetrations are widely dispersed around the
circumference of the containment.

Minimum separation distances are specified to meet the following criteria:

• All cables meet fire propagation requirements

• Non combustible cable trays
• Fire resistance rating of fire barriers be commensurate with fire hazards
• Identification of the exposed 1E circuit cable trays is done in a distinct
manner at interval not exceeding 4.5M.

2.2 Shielding and Shield grounding (for MV and instrumentation cables for
1E)

2.2.1 Cable shield: A non-magnetic material applied over the insulation of the
conductor or conductors to confine the electrical field of the cable to the
insulation of the conductor or conductors. It is required that cables rated above 5
kV shall be shielded, except for special applications or cable designs as per IEEE
690.Shielding can also be used in cables rated less than 5kV to monitor or test
cable installation for additional assurance of insulation integrity.

The purpose of an insulation shield is:

• To provided a uniform voltage stress over a relatively rough stranded

conductor surface
• A close bonding between the conductor and the insulation
• To avoid interspersed voids that may constitute sources of partial
discharge
• The outer shield being grounded also protects the cable against any
potential that may be induced extraneously.

3.0 Cable carrier system

Cables are normally carried on cable trays and through conduits at a few
locations. Cable trays are fixed on the existing walls/ceiling/floors of the
buildings. Exclusive walk through tunnels are used where there will be a large
number of cables from one building to another and trenches are provided when
there are less number of cables. Cable tunnels are advantageous from the point
of view of minimum interference to traffic and drainage, good physical protection,
ease of addition of cables, shielding effect of the ground mat.

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However the disadvantage lies in the high initial cost and the danger that a fire
could propagate between cable trays and along the length of the tunnel. The fire
hazard is minimized by provision of fire barriers of suitable rating at specified
intervals.

3.1 Cable Trays

Cable trays are basically cable carriers supported on cable tray supports. Cable
trays may be of ladder type, perforated type, solid type in line with the type of
cable to be carried and the importance.

3.1.1 Tray design

Cable tray design is done on the following major requisites:

• Required loading and the maximum spacing between the supports.

Loading calculations include the static weight of the cables and a
concentrated load of 100 Kgs approximately at mid-span.
• In case of a ladder type tray the rung spacing is a nominal 9 inches.
• Design should minimize the possibility of accumulation of fluids and debris
on the covers. Consideration to ventilation and ampacities of the cables is
also given.

3.1.2 Tray system design

The vertical spacing, in general is 12 inches, between the trays. Clearances of

atleast 9 inches are maintained between the top of the tray and any piping/beam,
etc. to facilitate cable laying.

When stacked cable tray configuration is used, a descending voltage level

arrangement is followed. And the structural integrity of the components and the
pullout values of support anchors and attachments is also verified.

3.1.3 Material of the cable tray

Generally hot dip galvanized cable trays are used in our plants. Wherever the
galvanized surface on the steel tray is broken the area is coated to protect
against corrosion. However, within the process rooms and corridors the cables
are laid in ducts or in pipes.

3.1.4 Grounding

Cable trays are made electrically continuous and solidly grounded and normally a
GI ground conductor is run all along the stack of trays and is connected to the
grounding grid.
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3.1.5 Identification

Cable tray sections are permanently identified with the tray section number as
required by drawings/specifications giving reference to the category, group and
the area of use.

4.0 Evolution of cable insulation

Natural rubber, which was later vulcanized by adding sulphur and heating and
maintaining the temperature to specified levels for cross linking to improve its
qualities like moisture ingression, higher tensile strength and to prevent flow
under high pressure.

Butyl rubber which is better resistant to strong acids but is sensitive to alkalis.

Ethylene propylene Rubber which is synthesized from Ethylene and Propylene.

This insulation is not used for higher voltages because of higher dielectric losses.

Silicone rubber which is used for low temperature applications because of its
flexibility and for very high temperature applications upto 250 deg Celsius.

Polyethylene which is formed on the polymerization of Ethylene C2H4 is very

popular in Electrical insulation application because of:

Low price
Process ability
Resistance to chemicals and moisture
Flexibility at low temperature
Excellent electrical properties
High density Polyethylene has enhanced properties of surface hardness, yield
strength, heat and chemical resistance.

Cross linking is a process of bonding between the individual polymer structures

and causes PE to change from a thermo plastic to a thermosetting plastic.

Cross linking is either done through a chemical process by adding peroxides at

specified temperatures or by irradiation.

4.0 Cable installation

Cables are installed in trays with supports that are qualified for the design basis
event. During storage the ends of the cables are sealed against moisture and
contamination. Other than the generally known guidelines it is also kept in mind

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that cable trays filled to the predetermined quantity (design) should not be used
for more cables till a proper inspection/analysis is made to ensure that the
(1) Ampacities (due to de-rating) does not change from the designed values
(2) The actual loadings (physical) do not exceed the design values from the point
of view of the seismic requirement.
It is also important to ensure that the vertical runs of the cables are secured
properly to avoid subjecting the terminals to any excessive tensions.

4.1 Acceptance testing of installed cables

To verify that the installed cables are free from any major cable insulation
damage during installation I) MV cables are subjected to high potential tests prior
to connection to the equipment ii) LV cables are checked for insulation resistance
and continuity prior to connection to the equipment and the records maintained.

Documentation is prepared as the work is performed and maintained to furnish

evidence of the quality of items and of activities affecting quality.

4.2 Cabling at PLANT

The main cable routes between buildings (with large number of cables) in PLANT
are provided through underground cable tunnels and cable routes with small
number of cables are through trenches. The cable routes for safety related
systems are through underground tunnels only. The cable structures of normal
operation are designed to withstand OBE and safety systems for SSE.
The following types of cables have been designed for PLANT.

• fire retardant cables for normal operation loads

• fire resistant (fire survival) cables for safety system loads including EPSS

Basic characteristics of Cables for Safety System and Normal Operation systems
are given in table -1 &2.

Table-1 Basic Characteristics of Safety System Cables

Location Inside Containment Outside containment

220
Voltage 6 kV 0.38 kV 6 kV 0.38 kV 220 V
V,110V
Type of the Not
FRHF FRHF LS FRLS FRLS
cable Envis
Class of aged
1000 V 660 V 7.2 kV 1000 V 660 V
voltage
Conductor Copper Copper Copper Copper Copper
material

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 Conductor
XLPE XLPE XLPE PVC XLPE
insulation
Cable inner Containing Containing
LS PVC FRLS PVC FRLS PVC
sheath no halogen no halogen
Cable outer Containing Containing
LS-PVC FRLS PVC FRLS PVC
sheath no halogen no halogen
Armour for Un- Un- Un- Un- Un-
the cable armoured armoured armoured armoured armoured
Oxygen
index for 35 % 35 % 35 % 35 % 35 %
the sheath
The
contents of
chlorides 0.05% 0.05% 5% 5% 5%
(halogens)
for sheath
Fire rating, Fire
90 90 90 90
min retardant
Smoke
10-12 % 10-12 % <60% <60% <60%
density

HF – Halogen Free;

FR – Fire Resistant (Fire survival);

LS – Low Smoke (fire retardant);

XLPE – Cross-linked polyethylene;

PVC – Polyvinyl chloride .

Table-2 Basic characteristics of Normal operation power and control cables

parameters

Location Inside containment Outside containment

220 V, 220 V,
Voltage 6 kV 0.38 kV 6 kV 0.38 kV
110 V 110 V
Type of the
HF HF HF LS LS LS
cable
Class of voltage 7.2 kV 1000 V 660 V 7.2 kV 1000 V 660 V
Conductor
Copper Copper Copper Copper Copper Copper
material
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Conductor
XLPE PVC PVC XLPE PVC PVC
insulation
Cable inner
HF HF HF LS PVC LS PVC LS PVC
sheath
Cable outer
HF HF HF LS-PVC LS PVC LS PVC
sheath
Un- Un-
Un- Un- Un- Un-
Armour of cable armoure armoure
armoured armoured armoured armoured
d d
Oxygen index
35 % 35 % 35 % 35 % 35 % 35 %
for the sheath
The contents of
chlorides
0.05% 0.05% 0.05% 5% 5% 5%
(halogens) for
sheath
Fire
Fire rating, min Fire Fire Fire Fire Fire
retardan
retardant retardant retardant retardant retardant
t
Smoke density 10-12 % 10-12 % 10-12 % <60 % <60 % <60 %

Routing of the cables from the basic route to the load is made through rigid/
flexible metal pipes.The cables for loads within the reactor containment are
routed through sealed penetrations designed for emergency environmental
parameters, inside the containment.

The cables cross the internal walls and floors through pipe penetrations and the
opening is to be sealed by a fire resistant sealant.
Provision of space for accommodating additional cabling, in future, to the extent
of 15 % is available. Mutually redundant cables are installed in different routes to
prevent simultaneous failure due to a common cause.

4.3 Cable sizing

Having decided the type of the cable the following consideration are made while
selecting the cable size.

4.3.1Continuous current rating

Continuous current rating of cables depends largely on ambient temperature and

also with the type of the installation and grouping of cables. Proper de-rating
factors are considered for the purpose of asserting the actual current carrying
capacity of the cable.
De-rating factors are applied under the following conditions:
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 • Ambient temperature
• Ground temperature
• Type of installation and grouping of cables

4.3.2 Short circuit withstanding capability

For Breaker protected feeder with relays, the minimum cable size depends on
the short circuit current of the system as well as on the duration of the short
circuit. Due consideration is given while selecting the minimum size of the cable
so that it can withstand the specified system fault current for the specified fault
duration. At times, the minimum size of the conductor is decided by the short
circuit withstanding capacity, especially when feeders are protected with
switchgear and relay (as the actuation time of the relay - instantaneous (0.2s) or
IDMT (1s) + breaker operating time + a safe margin is taken into account).

4.3.3 Voltage drop

The minimum size of the cable should be such that while carrying the normal
running or starting load, the voltage drop at the equipment terminal should not
cross the specified limits.

Flexible cables are used for mechanisms of vibration isolators.

Special consideration, while designing is also given to the areas where ambient
temperatures exceed 40-45 degree Celsius such as reactor containment, near
steam valves, equipment enclosures. During an accident condition the
atmosphere within a PWR may consist of saturated steam, air, and hydrogen. In
addition the equipment could simultaneously be exposed to a typical aqueous
spray of Boron, Boric Acid, NaOH solution.

Environmental conditions considered in design of cables are given in table- 3.

Table- 3 Environmental conditions of cables

Designed
Designed
ambient
ambient
temperature
Power Cabling -areas/locations temperature
under
during normal
emergency
operation
condition *
DG room 43 deg. C 50 deg. C
6kV & 0.38 kV switchgear / MCC room 35 deg. C 43 deg. C
Battery room 20-25 deg. C 35 deg. C
Rectifier and inverter room 35 deg. C 40 deg. C
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 Cable inside containment 40 deg. C 43 deg. C

Selection of materials for use in radiation environments is considered for short

and long term effects of radiation. Both normal radiation levels and during
accident conditions are taken into account and cables are qualified accordingly.

Ageing simulation is designed, to put a test specimen, in the end –of- life or the
plant design life service condition, whichever is earlier and this includes thermal
and radiation ageing.

The concept of defense in depth against fire and its consequences includes the
use of non-combustible materials. When the use of non-combustible materials is
not practical such as in the case of cables, lubricants, etc. their flame retarding
properties is considered.

The minimum separation distances for cables/structures are given in table-4.

Table-4 Minimum Distances for Cable Structures

Minimum dimensions, in mm,

in laying

In tunnels,
Distance
galleries,
cable floors In trenches and double floors
and on
trestles

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Height in air 1800 Not limited, but not more than
1200 mm

Horizontally in air between structures 1000 Both side structures not

when positioned side-by-side (passage envisaged
width)

Horizontally in air between structures 900 300 with depth down to 0.6 m
when positioned single-side (passage 450 with depth more than 0.6
width) down to 0.9 m
600 with depth more than 0.9 m
Vertically between horizontal structures
for power cables having voltage 200 150
under 10 kV*
Vertically between horizontal structures 100 100
for control cables and communication
cables, power cables with section up to
3 x 25 mm2 and voltage up to 1 kV*
Between support structures (cantilevers) 800 -1000 800 -1000
along the length of cable structures*
In air between single power cables with Not less Not less than a cable’s
voltage up to 35 kV** than a diameter
cable’s
diameter
Horizontally between control cables and No standard No standard
communication cables**
* Usable length of cantilever must be not more than 500 mm on the straight parts of the
route.
** The same applies to cables, laid in cable wells.

5.0 Fire protection/Barrier

Fire protection is basically classified into

I) Active fire protection

II) Passive fire protection.

As the nomenclature conveys, an active fire protection system is which comes

into action in case of a fire, like the water spray or mulsifire system and fights to
put down the fire. A passive fire protection system is one which remains as it is
even when there is a fire and resists/attenuates propagation of fire through it.
Automatic fire detection devices are installed in areas of high cable
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concentration. And in PLANT Automatic fire detection and fire fighting system
has been provided in the cable tunnels, shafts, etc. After conducting fire hazard
analysis, fixed automatic fire-extinguishing systems are provided for high cable
concentration areas and spaces below/above false ceilings containing exposed
cables, if found required. However, if the activation of the fixed automatic water
spray discharge could cause undesirable consequences to sensitive equipment
which would negate single failure criteria, such equipments are protected from
the spray and sealed against potential water damage due to water traveling
along the cable system. If the equipment cannot be protected, an extinguishing
system utilizing another extinguishing agent is provided.

In areas where forced ventilation can circulate smoke or a gaseous extinguishing

agent, or both, to other areas, mechanical ventilation systems are shut down
prior to system actuation and fire dampers are closed by mechanical or electrical
releases prior to fire protection system discharge.

Fire barriers or fire stops are passive fire protection systems which
prevent/resist/attenuate propagation of fire from one fire zone to the other,
maintaining the required fire rating.

5.1 Design objectives of the fire barriers in cabling

To prevent/retard/attenuate flame propagation and spread of fire in cable runs.

To prevent delay and minimize the damage due to fire to the cables, preserve the
functioning and increase their resistance to fire/heat.
To segregate cable runs into compartments with a view to localize a possible
cable fire and its spread.
To ensure that a single internal fire in one safety group cable system does not
expose/affect the other safety group cable system.
To ensure that fire in NSR cable system does not affect the SR cable system.

Fire barriers of 3/1.5/0.75 hours rating are provided at

I) the openings in walls and floors where the cables cross from one building
to another, one redundant area to another, one floor to another and from
one room to another
II) at the entry and exit of cable trenches and along cable tunnels at regular
intervals (one in every 30M horizontal – 0.75 hour rating and 20M
vertical). Doors at the ends of the cable tunnels are also of 0.75 hour
rating.
III) Between groups when the required segregation cannot be adhered to.

The cables in each of the four safety channels of emergency power supply
system are installed in separate routes with building/structures having fire

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resistance of not less than three hours.In case of crossing of cable ducts of
different channels of safety systems crossing of cables of normal operation over
safety systems cables with a separation distance less than two meters, a coat of
a fire resistant compound with a fire resistance of 1.5 hours is provided on the
outer surface of the duct . Cables feeding power to the mutually redundant loads
of the same channel are also routed separately, with a partition between them
having a fire rating of not less than 0.75 hours.

Material of the fire barrier is selected with the objective of meeting the following
requirements:

• To meet the specified fire rating

• Should be completely gas tight besides being a effective fire seal
• Should not contain flammable materials
• Should be of retrofit design to facilitate addition or removal of cables
• Should not have any effect on the ampacity of the cables
• Should remain secure in its place through out the service life and should
not get dislodged during repairs/retrofit operations.
• Should not undergo shrinkage or cracking after prolonged use.
• The material should be non-hygroscopic, non-corrosive.
• Should be compatible with cable sheathing material.
• Should have a life expectancy of 30/40 years.
• Should have resistance to chemicals.
• Should be able to withstand specified radiation dosages.

Testing of the barrier is done by preparing a sample of the barrier with specified
number of cables and subjecting it to various tests like impact test, water
absorption test, ageing test, vibration conditioning test, fire rating test and hose
stream test.

6.0 Cable Penetrations

Hermetically sealed special electrical penetrations are used to pass cables

through the Reactor building containment. These Penetrations are leak-tight and
thus, the integrity of the containment while crossing of electrical cables through
the same is maintained under normal and accident conditions.
A typical penetration consists of:

• Electrical conductors suitable for connection of cables inside and outside

the containment.
• Elements ensuring insulation of these conductors.

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 • Elements ensuring leak-tightness, gas tightness, thermal stability and
elements of fixation with the containment wall.
• Manometer for recording of gas leakage.

6.1General Requirements

Leak-tight cable penetrations are designed in accordance with the containment

design requirements. While designing and installing penetrations, effects of
postulated accidents and seismic events are taken into consideration.
Penetrations are qualified in accordance with the requirements of IEEE-317,
IEEE-323 and IEC-60772.
The cable penetrations are serviceable under both the normal operation mode
and in emergency conditions inside the containment.

6.2 Mechanical Requirements

Electrical penetrations are designed with decontamination capability

corresponding to the requirements for the containment. Following are the
important features.All the materials in the penetrations are qualified for radiation
resistance and do not have to be replaced while in service.

Design pressure: 5.6 bar abs.

Design temperature: 150 оС
Design gas leakage through a penetration assembly without open plugs at a
differential pressure of 1 bar is 1x10-6 cm3/s. of Helium
Admissible integrated absorbed dose of a radiant irradiation for life expectancy is
1.57.

6.3 Electrical Requirements

Cable penetrations circuits meet the following conditions of operation.

• Insulation of each conductor to withstand high voltage tests in conformity

with the applicable standards.
• Penetration of thermocouple conductors and connections are designed to
take into account credible measurement errors, stipulated by the
applicable standards
• Coaxial cable penetrations are designed to take into account the
transmission requirements

Penetrations are designed to meet the following electrical requirements( as per

IEC-60772).
• Medium voltage power conductors (above 1kV) to be free of partial
discharge (corona) when energized at rated voltage.

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 • The electrical penetrations are adopted to the required properties of the
measuring circuits so that the cable penetrations do not deteriorate the
measuring circuits
• Cable connections and splices of medium & low voltage conductors are
capable of carrying rated continuous current before and after continuous
rated short circuit currents without causing the connections and splices to
exceed the temperature design limit.
• The penetrations are designed to withstand stresses resulting from the
short circuits without changing leakage characteristics
• The electrical integrity of conductors, connections and electrical insulation
systems are designed to withstand all electrical environmental loading
without failure or loss of function.
• Fire resistance of penetrations is similar to that of the containment.
• Cables penetrations are capable of maintaining the containment integrity
even in case of a cable fire.
• Penetrations are delivered under dry nitrogen pressure that provides
visual inspection / control of leak-proofness of each penetration after its
installation.
• Penetrations have a lifetime of not less than 50 years.

6.4 Maintenance requirements

Penetrations are designed to be maintainable. Time required for replacing a

damaged feed-through / module or mounting a feed-through / module instead of
a plug, will not exceed 8 hours.

6.5 Construction

Electrical penetration assembly consists of modules installed in a steel case and

connection boxes mounted on both ends. Modules with electrical wires shall be
interchangeable. Penetrations are intended for mounting in horizontal position.
The penetration case shall be installed in an embedded pipe, in the reinforced
concrete containment wall (1200 mm thick) with steel lining on the reactor side.
The penetration is fitted with shrouds, protecting the module's sealing points from
mechanical damage. The penetration construction shall ensure the possibility of
replacing penetration modules both at the manufacturing plant and under
operating conditions.

The penetration keeps its operability under seismic conditions also.

7.0 Figures

1. 6KV cable connection to penetration in the containment

2. 6KV cable connection to penetration outside the containment

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3. Connection of two cables to penetration

4. 0.38 KV cable connection to penetration

5. Cable carrier lay out

6. 6KV hermetic penetration

7. 0.38KV & 220V AC hermetic penetration

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