NRC Information Notice No. 92-01: Cable damage caused by inadequate cable installation procedures and controls

In June 1989, the Tennessee Valley Authority (TVA) removed the cables from a conduit in the reactor protection system of the Watts Bar Nuclear Plant, Unit 2, to inspect for damage. TVA selected this conduit in response to an employee's concern that a welding arc that struck the conduit in response to an employee's concern that a welding arc that struck the conduit during construction may have damaged cables in the conduit. When the cables were removed, TVA found significant damage in the insulation of some cables. This damage was not attributed to heat generated by the alleged welding arc. The damage was principally attributed to the pulling stresses exerted during the initial installation of the cables. Some of the cables had insulation removed down to the conductors. To assess the extent of cable damage and determine the scope of its investigation, TVA removed more cables from conduits that constituted the most difficult pulls (worst case) and found varying degrees of damage that it attributed to pulling stresses. To fill a conduit at Watts Bar, personnel used pull cords to pull more cables through the conduits over the top of existing cables. This practice is called ''pull-by.'' This practice can cause damage to the existing cables from the sawing action of the pull cords and the friction of cables as they are pulled over existing cables. TVA instituted programs to assess the adequacy of cable installation at all its nuclear facilities and take appropriate corrective actions. At Watts Bar, TVA replaced cables in conduits which exceeded a calculated threshold value of side wall bearing pressure (SWBP) and performed a high-potential (hi-pot) tests on a number of other cables in conduits with SWBP below the calculated threshold value