NUREG/CR-7000 

BNL-NUREG-90318-2009 

Essential Elements of an 

Electric Cable Condition 

Monitoring Program

Office of Nuclear Regulatory Research 
NUREG/CR-7000 

BNL-NUREG-90318-2009 

Essential Elements of an 

Electric Cable Condition 

Monitoring Program 

Manuscript Completed: April 2009 

Date Published: January 2010 

Prepared by 

M. Villaran and R. Lofaro 

Brookhaven National Laboratory 

Upton, NY 11973-5000 

S. Aggarwal and D. Murdock, NRC Project Managers 

NRC Job Code N6744 

Office of Nuclear Regulatory Research 
iii

ABSTRACT 

For more than 20 years the NRC has sponsored research studying the aging degradation, 

condition monitoring and environmental qualification, and testing practices for electric cables 

and cable accessories used in nuclear power plants. The essential elements for an effective 

cable condition monitoring program presented in this report are based upon the results of the 

NRC’s electric cable and equipment research programs, industry guidance and standards, and 

the experience and observations of others who have studied or conducted electric cable 

condition monitoring and qualification testing. The program methodology presented herein 

provides guidance on the selection of cables to be included in the program, characterization and 

monitoring of cable operating environments and stressors, selection of the most effective and 

practical condition monitoring techniques, documentation and review of cable condition 

monitoring testing and inspection results, and the periodic review and assessment of cable 

condition and operating environments. 

v

FOREWORD 

Electric cables are one of the most important components in a nuclear plant because they 

provide the power needed to operate safety-related equipment and to transmit signals to and 

from the various controllers used to perform safety operations in the plant. In spite of their 

importance, cables typically receive little attention because they are considered passive, longlived components that have proven to be very reliable over the years. 

The integrity of electric cables is monitored, to some extent, through periodic testing of the 

equipment to which they are attached; however, this testing does not specifically focus on the 

cables and may not be sufficient to detect all of the aging mechanisms to which a particular 

cable is susceptible. If aging mechanisms remain undetected, they can eventually lead to a 

deterioration of cable performance and possibly cable failure. In response to Generic Letter 

2007-01, licensees provided data showing that the number of cable failures is increasing with 

plant age and that cable failures are occurring within the plants’ 40-year licensing periods. 

These cable failures have resulted in plant transients and shutdowns, loss of safety redundancy, 

entries into limiting conditions for operation, and challenges to plant operators. The data also 

show that as many unanticipated (in-service) cable failures occur as do testing failures. Based 

on this information and the fact that licensees are now considering license extension to 60 years 

and more NRC is considering the need to monitor the condition of electric cables throughout 

their installed life through the implementation of a cable condition monitoring program. 

Condition monitoring (CM) is a useful means of determining the condition of installed electric 

cables, and a great deal of research has been performed to identify effective CM techniques. 

Plants undergoing license renewal have agreed to a cable-testing program for a limited number 

of cables that are within the scope of licensee renewal; however, plants not undergoing license 

renewal have not committed to any cable testing. In addition, most plants do not have a cable 

diagnostic condition monitoring program in place. 

In light of the above issues, the Office of Nuclear Regulatory Research (RES) sponsored the 

research reported herein to evaluate the various aging mechanisms and failure modes 

associated with electrical cables along with condition monitoring techniques that may be useful 

for monitoring degradation of power, control, and instrumentation cables. Based on these 

evaluations, the essential elements of an effective cable condition monitoring program have 

been identified. These results will provide the technical basis for the staff to use in developing 

appropriate regulatory guidance on monitoring of electric cables. 

TABLE OF CONTENTS 

Page No.

ABSTRACT.................................................................................................................................. iii 

FOREWORD................................................................................................................................. v 

TABLE OF CONTENTS.............................................................................................................. vii 

LIST OF FIGURES ...................................................................................................................... ix 

LIST OF TABLES.......................................................................................................................... x 

EXECUTIVE SUMMARY ............................................................................................................. xi 

ACKNOWLEDGMENTS ............................................................................................................. xv 

ABBREVIATIONS ......................................................................................................................xvii

1. INTRODUCTION ................................................................................................................1-1

1.1 Background........................................................................................................1-1 

1.2 Objective...........................................................................................1-2 

1.3 Scope................................................................................................1-2 

1.4 Organization of the Report....................................................................1-3 

2.0 OVERVIEW OF CABLE SYSTEM AGING..........................................................2-1 

2.1 Electric Cable Construction....................................................................2-1 

2.2 Cable Systems Failure Modes, Stressors, and Aging Mechanisms.................2-2 

 2.2.1 Cable Systems Failure Modes....................................................2-2 

 2.2.2 Cable System Aging and Degradation Stressors............................2-3 

 2.2.3 Cable System Aging and Degradation Mechanisms......................2-14 

2.3 Applicable Regulatory Requirements....................................................2-15 

2.4 Increasing Trend of Undetected Early Cable Failures................................2-16 

3.0 COMMONLY USED CABLE CM TECHNIQUES..................................................3-1 

3.1 Desired Attributes of an Effective Condition Monitoring Technique...............3-1 

3.2 In Situ CM Techniques.......................................................................3-2 

3.2.1 Visual Inspection.....................................................................3-2 

 3.2.2 Compressive Modulus (Indenter).................................................3-3 

 3.2.3 Dielectric Loss (Dissipation Factor/Power Factor)...........................3-4 

 3.2.4 Insulation Resistance and Polarization Index.................................3-7 

 3.2.5 AC Voltage Withstand Test.........................................................3-7 

 3.2.6 Partial Discharge Test...............................................................3-8 

 3.2.7 DC High Potential Test..............................................................3-8 

3.2.8 Step Voltage Test...................................................................3-8 

3.2.9 Time Domain Reflectometry .....................................................3-9 

3.2.10 Infrared (IR) Thermography......................................................3-9 

3.2.11 Illuminated Borescope............................................................3-10 

3.2.12 Line Resonance Analysis (LIRA)..............................................3-10 

3.3 Laboratory CM Techniques...............................................................3-10 

3.3.1 Elongation-at-Break...............................................................3-11 

3.3.2 Oxidation Induction Time/Temperature......................................3-11 

vii
viii

 3.3.3 Fourier Transform Infrared Spectroscopy....................................3-12 

 3.3.4 Density................................................................................3-13 

3.4 Factors to be Considered in Selecting CM Techniques.............................3-20 

 3.4.1 Intrusiveness.........................................................................3-20 

 3.4.2 Cable Characteristics .............................................................3-20 

4.0 ESSENTIAL ELEMENTS OF A CABLE CONDITION MONITORING PROGRAM.....4-1 

 4.1 Selection of Cables to be Monitored Program............................................4-1 

4.2 Database of Monitored Cables...............................................................4-5 

4.3 Characterize and Monitor Environments...................................................4-7 

4.3.1 Characterizing Cable Operating Environments.................................4-7 

4.3.2 Monitoring Cable Operating Environments....................................4-15 

4.3.3 Monitoring Inaccessible/Underground Cable Circuits.......................4-16 

4.3.4 Managing Cable Operating Environments.....................................4-19 

4.4 Identification of Cable Stressors and Aging Mechanisms...........................4-20 

4.5 Selection of CM Techniques................................................................4-22 

4.6 Establish Baseline Cable Condition.......................................................4-24 

 4.6.1 Baseline Visual CM Inspection...................................................4-25 

4.6.2 Baseline CM Tests..................................................................4-27 

4.7 Perform Cable CM Inspection and Testing.............................................4-28 

4.8 Operating Experience........................................................................4-29 

4.9 Periodic Review and Assessment of Cable Condition...............................4-31 

4.9.1 Periodic Review and Assessment...............................................4-31 

4.9.2 Managing Cable Operating Environments and Degradation Effects...4-32 

5.0 CONCLUSIONS AND RECCOMENDATIONS.....................................................5-1 

5.1 Conclusions........................................................................................5-1 

 5.2 Recommendations.................................................................................5-2 

6.0 REFERENCES..........................................................................................6-1 

Appendix A Fiber Optic Cables............................................................................A-1 

Appendix B Definitions.......................................................................................B-1 

 
ix

LIST OF FIGURES 

Figure 

No. Page No. 

2.1 Number of failures per ten-year service intervals, GL 2007-01 [Ref. 8] .......................2-17 

3.1 Insulation power factor relationship .....................................................................3-4 

4.1 Block diagram of the elements of a cable CM program and their interactions................4-2 

4.2 Cable cross-section illustrating water tree formation [Ref. 3]....................................4-18
x

LIST OF TABLES 

Page No.

Table ES.1 Recommended Nine Essential Elements of a Cable Condition 

 Monitoring Program.............................................................................. xiii 

Table 2.1 Summary of Stressors and Potential Aging Mechanisms for MV Power, 

 LV Power, and I&C Cables....................................................................2-4 

Table 2.2 Summary of Stressors and Potential Aging Mechanisms for MV Power, 

 LV Power, and I&C Cable Splices and Termination Connections.....................2-9 

Table 3.1 Summary of Cable Condition Monitoring Techniques... .............................3-14 

Table 3.2 Cable Condition Monitoring Technique Selection Matrix.............................3-20 

Table 4.1 Recommended Categories of Information to be Included in a 

 Cable CM Database............................................................................4-8 

Table 5.1 Recommended Nine Essential Elements of a Cable Condition 

 Monitoring Program..............................................................................5.3
xi

EXECUTIVE SUMMARY 

The polymers used for the insulation and jacket materials for electric cables, cable splices, and 

terminations are susceptible to aging and degradation mechanisms caused by exposure to 

many of the stressors encountered in nuclear power plant service environments. Longer cable 

circuits may pass through several different operating environments over the length of their 

routing throughout the plant. Portions of a cable circuit may pass through areas experiencing 

more harsh environmental conditions, such as high temperature, high radiation, high humidity, 

or flooding of underground cables. There has been concern that such local adverse 

environmental stressors can cause excessive aging and degradation in the exposed sections of 

a cable that could significantly shorten its effective service life and cause unexpected early 

failures. 

The integrity and function of power and instrumentation and control (I&C) cables are monitored 

indirectly through the performance of in-service testing of safety-related systems and 

components. These tests can demonstrate the function of the cables under test conditions. 

However, they do not provide assurance that they will continue to perform successfully when 

they are called upon to operate fully loaded for extended periods as they would under normal 

service operating conditions or under design basis conditions. In-service testing of a cable does 

not provide specific information on the status of cable aging degradation processes nor the 

physical integrity and dielectric strength of its insulation and jacket materials. Consequently, a 

cable circuit with undetected damaged or degraded insulation could pass an in-service 

functional test, but still fail unexpectedly when called upon to operate under anticipated 

environmental conditions or the severe stresses encountered during a design basis event (i.e., 

fully loaded equipment, more extreme environmental conditions, extended operation in a heavily 

loaded state). 

The 10 CFR Part 50 regulations require licensees to assess the condition of their components, 

to monitor the performance or condition of structures, systems, and components in a manner 

sufficient to provide reasonable assurance that they are capable of fulfilling their intended 

functions, and to establish a test program to ensure that all testing required to demonstrate that 

components will perform satisfactorily in service is identified and performed. Recent incidents 

involving early failures of electric cables and cable failures leading to multiple equipment 

failures, as cited in IN 2002-12, “Submerged Safety-Related Cables,” and Generic Letter 2007-

01, “Inaccessible or Underground Power Cable Failures That Disable Accident Mitigation 

Systems or Cause Plant Transients,” suggest that licensee approaches to cable testing, such as 

in-service testing, surveillance testing, preventive maintenance, maintenance rule, etc., do not 

fully characterize the condition of cable insulation nor provide information on the extent of aging 

and degradation mechanisms that can lead to cable failure. Analysis of the summary of 

licensee responses to GL 2007-01 inquiries on licensees’ experiences regarding cable failures 

and cable CM activities, revealed wide variations to the approaches and comprehensiveness of 

cable testing activities. Analysis of the reported cable failures also indicated a trend toward 

early cable failures occurring prior to the end of the original 40-year license period. These data 

prompted the NRC to consider whether “...licensees should have a program for using available 

diagnostic cable testing methods to assess cable condition.” 

This research study developed recommendations for a comprehensive cable condition 

monitoring program consisting of nine essential elements. These nine elements consolidate a 

core program of periodic cable CM inspections and tests, together with the results of in-service 

testing, cable operating environment monitoring and management activities, and the 
xii

incorporation of cable-related operating experience. The recommended nine essential 

elements of the cable CM program are listed in Table ES.1 with a summary of the purpose and 

expected result for each element of the program. 

Condition monitoring inspections and tests can provide the means for evaluating the level of 

aging degradation of electric cables. The cables are exposed to a variety of environmental and 

operational stressors throughout their service life. Environmental stressors can include elevated 

temperatures, high radiation, high humidity, moisture intrusion, accumulation of dirt and dust, 

and exposure to chemicals or other reactive contaminants. Operational stressors can include 

external interference, installation and maintenance damage, high voltage stress, materials 

defects, water treeing, and electrical transients. Over time, the aging and degradation 

mechanisms caused by these stressors can eventually lead to early failure of the cable. These 

failures can result in multiple equipment failures as described in the example incidents cited in 

Generic Letter 2007-01. It is therefore important that the cable condition status information that 

can be provided by periodic condition monitoring inspection and testing of electric cables be 

considered in the assessment of cable aging and degradation. Severely damaged or degraded 

cable insulation can then be identified and repaired or replaced to prevent unexpected early 

failures while in service. 

In addition, the benefits of periodic cable condition monitoring inspections and testing can be 

further complemented by addressing cable operating environments. Environmental stressors, 

especially temperature, moisture/flooding, and radiation, can be responsible for causing 

significant aging and degradation of electric cable insulation and jacket materials. Monitoring 

and management of the environmental conditions in which cables are operated can help 

licensees to identify adverse stressors so that measures can be taken to control or reduce aging 

and degradation. 

Finally, the review of cable-related operating experience can play an important role in the 

assessment and management of electric cable aging and degradation. Industry-wide operating 

experience can alert licensees to cable manufacturing defects, inadequate installation practices, 

misapplication of cable types, and other environmental and operation factors. Regular review 

and analysis of in-plant cable failures or cable-related problems can sometimes reveal adverse 

performance trends or otherwise point to emerging problem areas that can be monitored more 

closely and/or corrected in a timely fashion before the occurrence of an early cable failure. 
xiii

Table ES.1 Recommended Nine Essential Elements of a Cable Condition Monitoring Program 

Program Element Purpose Expected Result 

1. Selection of Cables to 

be Monitored 

To identify and select electric cables that 

are candidates for inclusion in the cable 

condition monitoring program. 

A listing of the most important cables in the 

plant whose condition should be 

periodically monitored and evaluated to 

provide assurance that they are capable of 

performing their intended function 

2. Develop Database of 

Monitored Cables 

To provide a single centralized source of 

information for all the cables in the 

program that can be used by the cable 

engineer as a tool to access, analyze, and 

evaluate the data and documentation 

necessary to make cable condition 

assessments and to guide the direction of 

program decisions and activities 

A database that will provide essential 

information to support the implementation 

of the cable CM testing and inspection 

activities, and the periodic review and 

assessment of the condition of individual 

cables 

3. Characterize and 

Monitor Cable Operating 

Environments 

To verify the baseline design operating 

environment for a cable, to periodically 

verify actual environmental conditions and 

identify local adverse environments (e.g., 

high temperature or radiation, moisture, 

submergence) that may have developed, 

and to manage environmental conditions 

to mitigate the effects on cables 

Baseline environmental operating 

conditions measurements and inspection 

results, periodic environmental condition 

monitoring and verification measurements 

and results, identification and description 

of local adverse environments, and 

activities for managing operating 

environments to mitigate adverse effects 

on cables 

4. Identify Stressors and 

Aging Mechanism 

Affecting Cables in the 

Program 

To identify the stressors and determine the 

aging mechanisms affecting cables in the 

program 

Listing of the stressors and aging 

mechanisms affecting the condition of 

each cable in the program to be used in 

program element 5 to select the most 

effective CM inspection and testing 

techniques for each cable 

5. Select CM Inspection 

and Testing Techniques 

To determine the most effective CM 

inspection and testing techniques to detect 

and monitor the anticipated aging/failure 

mechanisms for each cable 

An initial listing of cable CM inspection and 

testing techniques and periodic 

performance frequency for each cable 

6. Establish Baseline 

Condition of Cables in 

the Program 

To measure and document the baseline 

condition of each cable in the program 

using the selected cable CM inspection 

and testing methods identified in program 

element 5 

Baseline cable condition measurements 

and inspection results for the techniques 

selected in program element 5 

7. Perform periodic CM 

Inspection and Testing 

To periodically measure and document the 

condition of each cable in the program 

using the selected cable CM inspection 

and testing methods identified in program 

element 5 

Periodic record of cable condition 

measurements and inspection results for 

the techniques selected in program 

element 5 

8. Review and 

Incorporate CableRelated Operating 

Experience 

To review industry-wide and in-plant cablerelated operating experience and 

incorporate changes to the cable CM 

program as required to address applicable 

issues and trends 

Incorporate changes to the cable CM 

program based on review of applicable 

operating experience 

9. Periodic Review and 

Assessment of Cable 

Condition 

To perform a periodic review of the current 

cable condition CM inspection and testing 

results, operating environments CM 

results, trends of cable properties and 

condition measurements, and applicable 

operating experience to establish an up-todate assessment of cable condition, 

expected service life, and program 

changes and activities to manage aging 

degradation of each cable in the program 

A formal periodic assessment of cable 

condition, expected service life, and 

program changes and activities to manage 

aging degradation of each cable in the 

program 

 

xv

ACKNOWLEDGMENTS 

The research program described in this report was sponsored by the Office of Nuclear 

Regulatory Research of the U.S. Nuclear Regulatory Commission. The authors would like to 

express their gratitude to NRC Project Managers Satish Aggarwal and Darrell Murdock for the 

technical and administrative support they have provided in performing this study. 

The authors also acknowledge and thank Charles Hofmayer, Kenneth Sullivan, and Edward 

Grove of the Brookhaven National Laboratory staff for their administrative support, technical 

guidance, and comments. 

The authors also express special thanks to Lynda Fitz and Maryann Julian for their secretarial 

help and assistance throughout this program and in the preparation of this report. 

xvii

ABBREVIATIONS 

AAC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Alternate ac (power source) 

ASTM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .American Society for Testing and Materials 

ATWS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Anticipated Transient Without Scram 

AWG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . American Wire Gauge 

BNL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Brookhaven National Laboratory 

CM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Condition Monitoring 

CRT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Cathode Ray Tube (Display) 

CSPE . . . . . . . . . . . . . . . . . . Chloro-Sulfonated Polyethylene (also known as Hypalon®) 

DBE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Design Basis Event 

DSC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Differential Scanning Calorimeter 

EAB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Elongation-at-Break 

EMI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Electromagnetic Interference 

EPDM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ethylene Propylene Diene Monomer 

EPR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ethylene Propylene Rubber 

EPRI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Electric Power Research Institute 

EPIX . . . . . . . . . . . . . . . . . . .Equipment Performance and Information Exchange System 

EQ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Environmental Qualification 

ESF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engineered Safety Feature 

FMEA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Failure Modes and Effects Analysis 

FTIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Fourier Transform Infrared Spectroscopy 

I&C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Instrumentation and Control 

IEEE . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Institute of Electrical and Electronics Engineers 

INPO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Institute for Nuclear Power Operations 

IR (1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Insulation Resistance 

IR (2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Infrared (imaging thermography) 

LCD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Liquid Crystal Display 

LER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Licensee Event Report 

LIRA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Line Resonance Analysis 

LOCA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Loss of Coolant Accident 

LV. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Low Voltage 

MV. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Medium Voltage 

NPRDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Nuclear Plant Reliability Data System 

NRC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Nuclear Regulatory Commission 

OITM .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Oxidation Induction Time 

OITP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Oxidation Induction Temperature 

OTDR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Optical Time Domain Reflectometry 

PE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Polyethylene 

PI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Polarization Index 

PM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Preventive Maintenance 

PVC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Polyvinyl Chloride 

QA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Quality Assurance 

RES . . . . . . . . . . . . . . . . . . . . . . . . . . U.S. NRC, Office of Nuclear Regulatory Research 

SBO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Station Blackout 

SR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Silicone Rubber

SSC(s) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Structures, Systems, and Components 

TDR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Time Domain Reflectometry 

XLPE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Cross-Linked Polyethylene 

XLPO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cross-Linked Polyolefin 

1-1 

1. INTRODUCTION 

1.1 Background 

The structures, systems, and components (SSCs) operating in nuclear power plants will 

routinely be exposed to a variety of environmental and operational stressors that can 

produce aging and degradation mechanisms. Over time, the aging and degradation 

mechanisms caused by exposure to these stressors can result in degradation of the 

SSCs. 

Electric cables are important nuclear power plant components that are used to supply 

electric power to safety-related systems and to interconnect the systems with their 

instruments and controls. The polymer materials used for the insulation and jacket 

materials for electric cables, cable splices, and terminations are susceptible to aging and 

degradation mechanisms caused by exposure to many of the stressors encountered in 

nuclear power plant service. 

The integrity and function of power and instrumentation and control (I&C) cables are 

monitored indirectly through the performance of in-service testing of the safety-related 

systems and components. Unfortunately, while these tests can demonstrate the function 

of the cables under test conditions, they do not verify their continued successful 

performance when they are called upon to operate fully loaded for extended periods as 

they would under normal service operating conditions or under design basis conditions. 

The results of instrument and control system calibration and functional surveillance tests, 

system and equipment performance tests, or other related technical specification 

surveillance testing and preventive maintenance program testing, can provide useful 

information and trends regarding the functional performance of a cable. However, 

specific information on the physical integrity and dielectric strength of the cable 

insulation and jacket materials is not revealed by this type of testing. Consequently, a 

cable with undetected damaged or degraded insulation could fail unexpectedly when 

called upon to operate under the severe stresses encountered during an emergency 

(i.e., fully loaded equipment, more extreme environmental conditions, extended 

operation in a heavily loaded state) or extended normal service operation at high load. 

Condition monitoring inspections and tests can provide the means for evaluating the 

level of aging degradation of electric cables. The cables are exposed to a variety of 

environmental and operational stressors throughout their service life. Over time, the 

aging and degradation mechanisms caused by these stressors can eventually lead to 

early failure of the cable. These failures can result in multiple equipment failures, as 

described in Generic Letter 2007-01 [Ref. 1]. It is therefore important that periodic 

condition monitoring inspection and testing of electric cables be considered. Severely 

damaged or degraded cable insulation can then be identified and repaired or replaced to 

prevent unexpected early failures while in service. 

In addition, the benefits of periodic cable condition monitoring inspections and testing 

can be further complemented by addressing cable operating environments. 

Environmental stressors, especially temperature, moisture/flooding, and radiation, can 

be responsible for causing significant aging and degradation of electric cable insulation 
1-2 

and jacket materials. Monitoring and management of the environmental conditions in 

which cables are operated can help to control or reduce aging stressors. 

Finally, the review of cable-related operating experience can play an important role in 

the assessment and management of electric cable aging and degradation. Industrywide operating experience can alert licensees to cable manufacturing defects, 

inadequate installation practices, misapplication of cable types, and other environmental 

and operation factors. Regular review and analysis of in-plant cable failures or cablerelated problems can sometimes reveal adverse performance trends or otherwise point 

to emerging problem areas that can be monitored more closely and/or corrected in a 

timely fashion before the occurrence of an early cable failure. 

1.2 Objective 

The objective of this research study is to propose a comprehensive electric cable 

condition monitoring (CM) program that will consolidate a core program of periodic CM 

inspections and tests, together with the results of in-service testing, environmental 

monitoring and management activities, and the incorporation of cable-related operating 

experience. This study develops the background and technical basis for regulatory 

guidance pertaining to the essential elements of a cable monitoring program. 

1.3 Scope 

This study includes nuclear power plant electric cable systems used for low-voltage (less 

than 1000Vac and 240Vdc) power and instrumentation and controls applications, and 

medium-voltage power cables up to about 38kV. Most nuclear power plants utilize 

overhead transmission lines for circuits operating at voltages higher than this, however, 

it is noted that a few nuclear power plant distribution systems utilize higher voltage 

power cables that should also be included in a cable condition monitoring program. The 

boundaries of the cable systems that are to be monitored in the cable CM program will 

include the electric cable, cable splices, and insulated connectors from their source 

terminals, electrical connectors, bushings, terminal blocks, or other electrical connection 

devices to their load terminals, electrical connectors, bushings, terminal blocks, or other 

electrical connection devices. Cables, wiring, splices, and connections contained within 

electrical power equipment, instrumentation, and controls enclosures or equipment 

cabinets are considered internal wiring that should be addressed under inspection, 

testing, and maintenance activities for that equipment. 

Discussions, examples, and guidance regarding condition monitoring inspection and 

testing techniques, and the essential elements of the cable CM program are based on 

the assumptions that the cable electrical conductors are constructed from copper or 

aluminum, and the cable insulation and jacket materials are polymers, such as crosslinked polyethylene (XLPE), ethylene propylene rubber (EPR), silicone rubber (SR), and 

polyethylene (PE). These assumptions encompass nearly all of the cable conductors 

and more than 80 per cent of the polymer-insulated cables in nuclear plant service [Ref. 

2]. With minor variations, the guidance and discussions presented herein are also 

applicable to the other polymers used in nuclear plant cable insulation and jackets. 
1-3 

Discussions and guidance regarding medium-voltage power cables are based on cables 

designed for operation below 38kV. Much of the medium-voltage cable information in 

this report can be adapted to higher voltage polymer-insulated power cables. However, 

due to the special construction, application, and hazards involved with higher voltage 

power cables, the aging and degradation mechanisms, inspection methods, condition 

monitoring techniques, and controlling procedures for these cables must be uniquely 

developed on an application-specific basis. 

Another category of cables that should be considered for incorporation into the cable CM 

program activities is fiber-optic cables used to provide signal transmission 

interconnections for digital I&C systems that have safety-related or accident mitigation 

functions. Since optical fibers serve as the conducting medium in these cables, the 

aging and degradation mechanisms are unique to these cables as compared to electric 

cables utilizing copper and aluminum conductors. The outer jacket material for a fiber 

optic cable is usually a polymer so aging and degradation mechanisms would be similar 

to those experienced by polymer insulated and jacketed electric cables. However, the 

jacket on a fiber optic cable serves as a protective layer for the internal optical 

conductors and has no dielectric insulating function. As a result of these significant 

differences, the failure modes, failure mechanisms, and CM inspection and testing 

techniques are unique to these cables. Analysis and discussions for the aging, 

degradation, and CM testing of fiber-optic cables are presented in Appendix A. 

Discussion and guidance on the selection and incorporation of fiber optic digital I&C 

cables into the plant cable CM program are presented in the appendix. 

1.4 Organization of the Report

Section 2 of the report presents a basic overview of the aging of electric cable systems. 

A brief general description of the construction of electric cables is followed by a 

discussion and analysis of the failure modes for power and I&C cables. The most 

common stressors for medium-voltage power cables and low-voltage power and I&C 

cables are tabulated. Similarly, discussion and analysis of failure modes for cable 

splices and connectors are followed by a tabulation of the most common stressors for 

medium-voltage cable splices and terminations and low-voltage cable splices and 

terminations. The regulations requiring demonstration of the capability of cable systems 

to perform their safety function are presented along with a discussion on why a program 

specifically focused on cable condition monitoring is needed. 

Section 3 of this report describes many of the common CM testing methods available for 

measuring the performance parameters and properties of electric cables. A brief 

description for each method is provided along with a table listing the applicability, 

features, advantages and disadvantages for each technique. A CM technique selection 

matrix is provided linking the various common techniques with the stressors and aging 

mechanisms they are best suited to detect and monitor. 

Section 4 presents nine recommended essential elements for an effective cable CM 

program. The purpose for each element of the program is presented in turn along with 

discussion and guidance for implementing each element. Finally, the expected results 

from each program element are presented together with a discussion on how each 

element supports and interacts with the other cable CM program elements. 
1-4 

Observations on the condition monitoring of electric cables are summarized in Section 5 

of the report. A table summarizing the nine essential elements of an effective cable 

condition monitoring program is presented. Important features of the program 

methodology are highlighted. 
2-1 

2. OVERVIEW OF CABLE SYSTEM AGING 

This section provides a brief description of electric cable construction. Discussion and analysis 

on the failure modes, stressors, and aging mechanisms for medium-voltage power cables, lowvoltage power and I&C cables, medium-voltage splices and terminations, and low-voltage 

splices and terminations are presented. Finally, applicable regulations requiring demonstration 

of the capability of cable systems to perform their safety function are listed followed by a 

discussion on why a program specifically focused on cable condition monitoring is needed. 

2.1 Electric Cable Construction 

The construction of a typical electric cable consists of a polymer insulating material covering a 

metallic copper or aluminum electrical conductor. The metallic conductor may be a single 

strand of solid wire or a bundled group of smaller diameter wires. The insulating material of 

individual cable conductors is often covered by a layer of polymer jacket material to protect the 

integrity of the insulating material from physical damage; multiple conductor cables will typically 

include an overall polymer jacket to protect the individual insulated cables that make up the 

cable. 

Cables are qualified by their manufacturers to provide a specified service life (e.g., 40 years for 

nuclear power plants) for a specified voltage class (based on the qualified dielectric strength of 

the polymer insulation) operating continuously at or below a specified maximum ambient 

temperature (e.g., 90o

C). If the insulation and outer jacket material are undamaged, most 

cables can tolerate occasional wetting, but are not qualified for extended operation in a 

submerged state. 

Electric cables operating in nuclear power plant service can be exposed to a variety of 

environmental and operational stressors. Environmental stressors can include elevated 

temperature, high radiation, high humidity, submersion, (note that cables are not qualified for 

submerged operation unless they have been specifically procured as submarine cables) and 

exposure to dust, dirt, and corrosive contaminants. Operational stressors can include high 

voltage, electrical transients, internal ohmic heating, vibration, installation damage, 

manufacturing defects, and damage inflicted by operating and maintenance activity. Over time, 

these stressors, and combinations of these stressors, can cause aging and degradation 

mechanisms that will result in a gradual degradation of the cable insulation and jacket materials. 

A nuclear power plant may contain more than 50,000 electric cable circuits, of which about 60% 

are control circuits, 20% are instrumentation, 13% are ac power, 1% are dc power, and the 

remainder are miscellaneous communications circuits [Ref. 2]. Most of these electric cable 

circuits are located in dry, mild operating environments that are well within their qualified 

operating limits, and therefore perform reliably throughout their qualified service life. Many 

cable circuits, however, may normally be exposed to one or more of the stressors described 

above and must be qualified to operate under more harsh operating environments. Electric 

equipment important to safety, including electric cables, that are required to continue to 

successfully perform their safety function in the harsh environment throughout the duration of 

and following design basis events occurring at the end of their qualified life, must be 

environmentally qualified in accordance with the requirements of 10 CFR 50.49. 
2-2 

2.2 Cable Systems Failure Modes, Stressors, and Aging Mechanisms 

The reliability engineer typically uses the failure modes and effects analysis (FMEA) tool to 

identify the manner or state in which a structure, system, or component (SSC) fails and the 

resulting effect that the failure mode will have on the function of the SSC. The piece-parts and 

subcomponents of the SSC are each analyzed in turn to identify the sub-component materials, 

stressors, potential aging mechanisms, and the potential effect(s) of the stressors and 

associated degradation/aging mechanisms on the function and operation of the subcomponent, 

i.e., will the mechanisms result in the subcomponent’s failure. 

By identifying these stressors, and quantifying their severity, the cable engineer can determine 

the aging and failure mechanisms that will cause degradation or other damage that, over time, 

could lead to the ultimate failure of a cable system. This information can then be used to select 

the most effective CM inspection and testing techniques for detecting and monitoring the 

anticipated aging/failure mechanisms. 

2.2.1 Cable System Failure Modes 

For low-voltage and medium-voltage power cables, as well as I&C cables, the basic failure 

modes are: 

 Conductor short circuit to ground 

 Conductor-to-conductor short circuit 

 Degraded insulation resistance (excessive leakage current) 

 Open circuit 

For low-voltage and medium-voltage ac power cables, the first two failure modes are electrical 

faults that would normally cause circuit protection devices to trip and result in loss of electric 

power transmitted through the affected circuit. For low-voltage dc power cables, depending on 

the operating configuration of the dc system (grounded versus ungrounded), the electrical fault 

will result in a trip of the circuit by protective devices or a degraded system alarm. The third 

failure mode above is an incipient failure for low-voltage power cables, except in the presence of 

a conductive medium (e.g., water, dirt, high humidity, chemical deposits) that could quickly 

degrade the condition into one of the other two failure modes. In medium-voltage power cables, 

the third failure mode can lead to partial discharge, or corona, phenomenon that could cause 

excessive heating and degradation of the cable insulating materials, and ionization of the air in 

the vicinity of the current leakage. If not corrected, this failure mode in medium-voltage cables 

could catastrophically degrade into one or both of the other two failure modes. The fourth 

power cable failure mode, i.e., open circuit conductor, can result from: a physical event breaking 

the conductor; vaporization of the conductor by an electrical fault (failure modes 1 & 2) that is 

not cleared by the circuit protective device; extreme corrosion breaking conductor continuity; 

electromechanical force from a short circuit transient breaking the conductor; vibration fatigue 

breaking the conductor; or disconnection of the electrical conducting joint at a splice, 

termination, or other connection accessory. 

In the case of instrumentation and control cables, the first two failure modes will interrupt 

transmission of analog or digital control signals over the affected circuit, functionally failing the 

control circuit. Similarly, analog or digital instrumentation signals will be interrupted by either of 
2-3 

the first two failure modes resulting in loss of signal throughout the affected instrumentation 

circuit. I&C circuits may experience degraded function or an increased level or rate of error, or 

may not be affected at all, by the third failure mode, degraded insulation resistance, depending 

upon the type of signal that is transmitted and the design of the receiving-end circuits and 

devices. For I&C cables, the fourth failure mode, open circuit conductor, can occur as a result

of a physical event breaking the conductor; extreme corrosion breaking conductor continuity; 

vibration fatigue breaking the conductor; or disconnection of the electrical conducting joint at a 

splice, termination, or other connection accessory. 

 

2.2.2 Cable System Aging and Degradation Stressors 

Cable systems in nuclear power plant service are subject to a variety of aging and degradation 

stressors that can produce immediate degradation or aging-related mechanisms and effects 

causing degradation of the cable components over time. Stressors can generally be 

categorized as one of two types based upon their origin: 1) environmental stressors originate 

from conditions in the environment where a cable system is located, or 2) operational stressors 

that are the result of operational factors such as cable current loading, electrical system 

transients, or operating and maintenance activities in the vicinity of the cable system. 

Using the FMEA analytical approach applied to electric cables, the piece-parts of a cable (e.g., 

insulation, jacket, conductor) are each analyzed to identify the constituent material(s). The 

stressors that can affect the material(s) in each piece-part of a particular cable, in a specific 

application and operating environment, are analyzed to determine whether they can produce a 

degradation or aging mechanism that could eventually lead to one of the failure modes for the 

cable. A general summary of stressors and associated potential aging and degradation 

mechanisms, adapted from References 3 and 4, is provided in Table 2.1 for medium-voltage 

power, low-voltage power, and I&C cables. 

Most of the environmental stressors affecting medium-voltage power cables and low-voltage 

power and I&C cables are the same for both categories. Operating stressors such as internal 

ohmic heating of power cables are normally significant only for medium-voltage power cables 

that are continuously energized and conducting higher current levels. However, some lowvoltage power cables, which can include voltages up to 1000V, could also be affected by 

internal ohmic heating if they continuously conduct higher current levels. Power cables that are 

fire wrapped or are located in heavily-loaded, random-filled cable raceways may be more 

susceptible to the long-term effects of internal ohmic heating. 

Special consideration should be given by licensees to the problem of monitoring the operating 

environment for cable circuits routed through inaccessible underground cable ducts and 

conduits, covered cable distribution trenches, and manhole vaults. These structures can 

frequently become flooded resulting in power and control cables operating in wetted and 

completely submerged conditions for extended periods of time. Unless the installed cables 

have been procured specifically for continuous submerged or submarine operation, the cables 

installed in duct banks, manholes and bunkers, and direct burial applications are susceptible to 

moisture- and submergence-related failure mechanisms as listed in Table 2-1. 

High voltage potential is normally only a factor in medium-voltage or higher cables because of 

the effect that this stressor can have on the propagation of water treeing in cable insulation, 

especially in the presence of moisture, and the occurrence of partial discharge, or corona, in 

defective or deteriorating insulation. The contribution of voltage is of lesser significance in lowvoltage power cables and most I&C circuits. However, water and moisture intrusion can drive 

insulation degradation mechanisms that can affect the dielectric strength of insulation materials 
2-4 

in both low- and medium-voltage cables, even when they are normally deenergized, as was 

observed in the summary report on licensees’ responses to GL 2007-01 [Ref. 8]. 

It should be noted that there are some specialized I&C cables, such as those used in nuclear 

instrumentation, which may incorporate low ampacity medium-voltage power conductors 

bundled together in the same cable with low-voltage instrumentation conductors. 

Direct mechanical damage, such as bending, abrasion, cutting, contact, deformation, and 

perforation resulting from installation and maintenance activities in and around the location of a 

cable, is a potential stressor that can affect both categories of cables. Electromechanical forces 

resulting from the passage of high levels of short circuit current through a power cable can 

potentially cause mechanical damage to cable jacket and insulation material and cable 

conductors. High voltage stress from lightning strikes or power system transients can also 

degrade the dielectric strength of cable insulation.A similar FMEA analytical approach can be 

applied to cable splices and to cable termination connections at terminal blocks, fuse holders, 

circuit breaker and disconnect switch terminal connectors, electric motor leads, electrical 

equipment insulating bushings, electrical bus bars, or other electrical equipment termination 

points. The piece-parts of a cable splice or termination connector are each analyzed to identify 

the constituent material(s). The stressors that can affect the material(s) in each piece-part of a 

particular splice or termination connector, in a specific application and operating environment, 

are analyzed to determine whether they can produce a degradation or aging mechanism that 

could eventually lead to one of the failure modes for the cable splice or termination connector. 

A general summary of potential stressors and associated aging and degradation mechanisms, 

adapted from References 4, 5, and 6, is provided in Table 2.2 for medium-voltage power, for 

low-voltage power, and I&C cable splices and termination connections. 

Cable splices are exposed to the same environmental and operational stressors as the cables 

on which they are installed. Since cable splices are constructed of many of the same or similar 

materials as the electric cables on which they are installed, these stressors can also cause 

aging degradation of the polymer insulating materials used in the cable splice. In addition, the 

other subcomponents that make up an electric cable splice (insulating tape, fillers, sleeves, 

insulating compounds, and compression connectors) are also susceptible to aging degradation 

due to the various stressors to which they are exposed. Connectors, in particular, are 

susceptible to stressors such as moisture, condensation, vibration, and thermal cycling that can 

lead to corrosion and loosening of the conductor compression joints or solder joints [Ref. 5]. 

When cable splices that are not qualified for wetted or continuous submersion are exposed to 

moisture, or are submerged in water, they can be affected more rapidly and more severely than 

a cable with intact insulation in the same environment. A poorly installed or designed splice can 

result in multiple penetration pathways for moisture into the interior of the splice, not only around 

the splice materials where they abut the surface of the cable insulation, but also through the 

damaged or cracked outer jacket or insulation [Ref. 5]. 

Stressors affecting cable termination connections at terminal blocks, fuse holders, circuit 

breaker and disconnect switch terminal connectors, electric motor leads, electrical equipment 

insulating bushings, insulating bushings, electrical bus bars, or other electrical equipment 

termination points are generally the same as those affecting electric cables. The resulting aging 

and degradation mechanisms acting on the terminations, however, can be very different than for 

cables and splices because of the variations in the types and designs for these cable system 

components. These are discussed in the following subsection.
2-5 

Table 2.1 Summary of Stressors and Potential Aging Mechanisms for MV Power, LV Power, and I&

Subcomponent Material Stressors Potential Aging Mechanisms Potential Aging Effects MV LV I&

• Various polymer 

materials (e.g., XLPE, EPR) 

• Elevated temperature • Elevated radiation 

fields 

• Embrittlement • Cracking 

• Decrease in dielectric 

strength 

• Increase in leakage 

currents 

• Eventual failure 

   

• Various polymer 

materials that are permeable to moisture 

• Wetting • Moisture intrusion • Decrease in dielectric 

strength 

• Increase in leakage 

currents 

• Eventual failure 

   

• Various polymer 

materials that do not contain a tree retardant additive 

• Wetting concurrent 

with voltage 

• Electrochemical 

reactions 

• Water treeing 

• Decrease in dielectric 

strength 

• Increase in leakage 

currents 

• Eventual failure 

 

• Various polymer 

materials that have voids or other imperfections 

• Voltage • Electrical transient 

• Partial discharge 

(corona) 

• Electrical treeing 

• Decrease in dielectric 

strength 

• Increase in leakage 

currents 

• Eventual failure 

 

• Various polymer 

materials (e.g., XLPE, EPR) 

• Handling, physical 

contact, or abuse during maintenance, operation, or testing activities 

• Mechanical damage 

including crushing, bending, tensile deformation 

• Decrease in dielectric 

strength 

• Increase in leakage 

currents 

• Eventual failure 

  

Insulation 

• Various polymer 

materials (e.g., XLPE, EPR) 

• Installation Damage • Mechanical damage 

including crushing, bending, tensile deformation 

• Decrease in dielectric 

strength 

• Increase in leakage 

currents 

• Eventual failure 

 
2-6 

Subcomponent Material Stressors Potential Aging Mechanisms Potential Aging Effects MV LV I&

• Various polymer 

materials (e.g., CSPE, Neoprene) 

• Elevated temperature • Elevated radiation 

fields 

• Embrittlement • Cracking 

• Loss of structural 

integrity 

• Increased intrusion of 

moisture and contaminants into the cable interior 

   

• Various polymer 

materials (e.g., CSPE, Neoprene) 

• Handling, physical 

contact, or abuse during maintenance, operation, or testing activities 

• Mechanical damage 

including crushing, bending, cutting, abrasion, gouging, tensile deformation 

• Loss of structural 

integrity 

• Increased intrusion of 

moisture and contaminants into the cable interior 

   

• Various polymer 

materials (e.g., CSPE, Neoprene) 

• Installation damage • Mechanical damage 

including crushing, bending, cutting, abrasion, gouging, tensile deformation 

• Loss of structural 

integrity 

• Increased intrusion of 

moisture and contaminants into the cable interior 

  

Jacket 

• Various polymer 

materials (e.g., CSPE, Neoprene) 

• Electromechanical 

forces due to electrical transient 

• Mechanical damage • Loss of structural 

integrity 

• Increased intrusion of 

moisture and contaminants into the cable interior 

 

• Copper • Aluminum 

• Wetting due to 

moisture intrusion 

• Condensation 

• Corrosion • Oxide formation • Loosening of 

connectors 

• Increased electrical 

resistance 

• Increased ohmic 

heating 

   

Conductor 

• Copper • Aluminum 

• Vibration 

• Metal fatigue • Loosening of 

connectors 

• Loss of structural 

integrity 

• Degraded connector 

contact 

   
2-7 

Subcomponent Material Stressors Potential Aging Mechanisms Potential Aging Effects MV LV I&

• Aluminum • Compressive forces • Cold flow 

• Loosening of 

connectors 

• Loss of contact on 

connectors 

• Increased electrical 

resistance 

• Increased ohmic 

heating 

   

• Copper • Aluminum 

• Electromechanical 

forces due to electrical transient 

• Mechanical damage 

including fatigue, bending, cracking 

• Loosening of 

connectors 

• Loss of structural 

integrity 

• Broken conductor 

strands 

 

• Copper • Aluminum 

• Handling, physical 

contact, or abuse during maintenance, operation, or testing activities 

• Mechanical damage 

including fatigue, bending, tensile deformation, cracking 

• Loosening of 

connectors 

• Loss of structural 

integrity 

• Broken conductor 

strands 

• Open circuit 

 

Conductor (continued) 

• Copper • Aluminum 

• Installation damage • Mechanical damage 

including fatigue, bending, tensile deformation, cracking 

• Loosening of 

connectors 

• Loss of structural 

integrity 

• Broken conductor 

strands 

• Open circuit 

 

• Copper tape • Copper wire 

• Wetting due to 

moisture intrusion 

• Corrosion • Oxide formation 

• Loss of structural 

integrity 

• Increased insulation 

degradation due to partial discharges 

• Decreased EMI 

protection 

  

Shield 

• Semi-conducting 

polymers 

• Elevated temperature • Elevated radiation 

fields 

• Embrittlement • Cracking 

• Loss of structural 

integrity 

• Increased insulation 

degradation due to partial discharges 

• Decreased EMI 

protection 

 
2-8 

Subcomponent Material Stressors Potential Aging Mechanisms Potential Aging Effects MV LV I&

• Copper tape • Copper wire 

• Handling, physical 

contact, or abuse during maintenance, operation, or testing activities 

• Mechanical damage 

including fatigue, bending, tensile deformation, cracking 

• Loss of structural 

integrity 

• Broken conductor 

strands 

• Decreased EMI 

protection 

  

Shield (continued) 

• Copper tape • Copper wire 

• Installation damage • Mechanical damage 

including fatigue, bending, tensile deformation, cracking 

• Loss of structural 

integrity 

• Broken conductor 

strands 

• Decreased EMI 

protection 

  

Sheath • Lead • Alkaline environment 

(e.g., free line from concrete ducts) 

• Corrosion • Loss of structural 

integrity 

• Increased intrusion of 

moisture and contaminants into cable interior 

 
2-9 

Table 2.2 Summary of Stressors and Potential Aging Mechanisms for MV Power, LV Power, I&C Ca

and Terminal Connections 

Subcomponent Material Stressors Potential Aging Mechanisms Potential Aging Effects MV LV I&

 C a b l e S p l i c e s 

• Various polymer 

materials (e.g., XLPE, EPR) 

• Elevated temperature • Elevated radiation 

fields 

• Mechanical & Thermal 

cycling 

• Vibration • Overvoltage Stress 

• Embrittlement • Cracking • Mechanical Wear • Treeing 

• Decrease in dielectric 

strength 

• Increase in leakage 

currents 

• Eventual failure 

   

• Various polymer 

materials that are permeable to moisture 

• Wetting • Condensation 

• Moisture intrusion • Decrease in dielectric 

strength 

• Increase in leakage 

currents 

• Eventual failure 

   

• Various polymer 

materials that do not contain a tree retardant additive 

• Wetting concurrent 

with voltage 

• Electrochemical 

reactions 

• Water treeing 

• Decrease in dielectric 

strength 

• Increase in leakage 

currents 

• Eventual failure 

 

• Various polymer 

materials that have voids or other imperfections 

• Voltage • Electrical transient 

• Partial discharge 

(corona) 

• Electrical treeing 

• Decrease in dielectric 

strength 

• Increase in leakage 

currents 

• Eventual failure 

 

Insulation; Shield (insulating tapes, potting and sealing compounds, insulating compounds, heat shrink insulation material, stress cones, etc.) 

• Various polymer 

materials (e.g., XLPE, EPR) 

• Electromechanical 

forces due to electrical transient 

• Mechanical damage • Loss of structural 

integrity 

• Increased intrusion of 

contaminants and moisture into the cable splice interior 

 
2-10 

Subcomponent Material Stressors Potential Aging Mechanisms Potential Aging Effects MV LV I&

• Various polymer 

materials (e.g., XLPE, EPR) 

• Handling, physical 

contact, or abuse during maintenance, operation, or testing activities 

• Mechanical damage 

including crushing, bending, cutting, abrasion, gouging, tensile deformation 

• Decrease in dielectric 

strength 

• Increase in leakage 

currents 

• Eventual failure • Decreased EMI 

protection (Shield, I&C cables) 

  

Insulation; Shield (continued) 

• Various polymer 

materials (e.g., XLPE, EPR) 

• Installation Damage • Mechanical damage 

including crushing, bending, cutting, abrasion, gouging, tensile deformation 

• Decrease in dielectric 

strength 

• Increase in leakage 

currents 

• Eventual failure • Decreased EMI 

protection (Shield, I&C cables) 

 

• Copper • Aluminum 

• Wetting due to 

moisture intrusion 

• Condensation 

• Corrosion • Oxide formation • Loosening of 

connectors 

• Increased electrical 

resistance 

• Increased ohmic 

heating 

   

• Copper • Aluminum 

• Mechanical and 

Thermal Cycling 

• Vibration 

• Metal fatigue • Loosening of 

connectors 

• Loss of structural 

integrity 

• Degraded connector 

contact 

• Decreased EMI 

protection (Shield, I&C cables) 

   

• Aluminum • Compressive forces • Cold flow 

• Loosening of 

connectors 

• Loss of contact on 

connectors 

• Increased electrical 

resistance 

• Increased ohmic 

heating 

   

Connectors (Electrical conductors and shield) 

• Copper • Aluminum 

• Electromechanical 

forces due to electrical transient 

• Mechanical damage 

including fatigue, bending, cracking 

• Loosening of 

connectors 

• Loss of structural 

integrity 

• Broken conductor 

strands 

 
2-11 

Subcomponent Material Stressors Potential Aging Mechanisms Potential Aging Effects MV LV I&

• Copper • Aluminum 

• Handling, physical 

contact, or abuse during maintenance, operation, or testing activities 

• Mechanical damage 

including fatigue, bending, tensile deformation, cracking 

• Loosening of 

connectors 

• Loss of structural 

integrity 

• Broken conductor 

strands 

• Open circuit • Decreased EMI 

protection (Shield, I&C cables) 

  

Connectors (continued) 

• Copper • Aluminum 

• Installation damage • Mechanical damage 

including fatigue, bending, tensile deformation, cracking 

• Loosening of 

connectors 

• Loss of structural 

integrity 

• Broken conductor 

strands 

• Open circuit • Decreased EMI 

protection (Shield, I&C cables) 

  

C a b l e T e r m i n a t i o n C o n n e c t i o n s

• Various polymer 

materials (e.g., XLPE, EPR) 

• Elevated temperature • Elevated radiation 

fields 

• Mechanical & Thermal 

cycling 

• Vibration • Overvoltage Stress 

• Embrittlement • Cracking • Mechanical Wear • Treeing 

• Decrease in dielectric 

strength 

• Increase in leakage 

currents 

• Eventual failure 

   

• Various polymer 

materials that are permeable to moisture 

• Wetting • Condensation 

• Moisture intrusion • Decrease in dielectric 

strength 

• Increase in leakage 

currents 

• Eventual failure 

   

Insulation; Shield (insulating tapes, potting and sealing compounds, insulating compounds, heat shrink insulation material, stress cones, insulating boot materials, etc.) 

• Various polymer 

materials that do not contain a tree retardant additive 

• Wetting concurrent 

with voltage 

• Electrochemical 

reactions 

• Water treeing 

• Decrease in dielectric 

strength 

• Increase in leakage 

currents 

• Eventual failure 

 
2-12 

Subcomponent Material Stressors Potential Aging Mechanisms Potential Aging Effects MV LV I&

• Various polymer 

materials that have voids or other imperfections 

• Voltage • Electrical transient 

• Partial discharge 

(corona) 

• Electrical treeing 

• Decrease in dielectric 

strength 

• Increase in leakage 

currents 

• Eventual failure 

 

• Various polymer 

materials that have voids or other imperfections 

• Electromechanical 

forces due to electrical transient 

• Mechanical Damage • Loss of structural 

integrity 

• Increased intrusion of 

contaminants and moisture into the cable connector interior 

 

• Various polymer 

materials (e.g., XLPE, EPR) 

• Handling, physical 

contact, or abuse during maintenance, operation, or testing activities 

• Mechanical damage 

including fatigue, bending, tensile deformation, cracking 

• Loss of structural 

integrity 

• Broken conductor 

strands 

• Decreased EMI 

protection 

  

Insulation; Shield (continued) 

• Various polymer 

materials (e.g., XLPE, EPR) 

• Installation damage • Mechanical damage 

including fatigue, bending, tensile deformation, cracking 

• Loss of structural 

integrity 

• Broken conductor 

strands 

• Decreased EMI 

protection 

  

• Copper • Aluminum 

• Wetting due to 

moisture intrusion 

• Condensation 

• Corrosion • Oxide formation • Loosening of 

connectors 

• Increased electrical 

resistance 

• Increased ohmic 

heating 

   

Connectors (MV: electrical 

equipment terminations, terminal bushing, bus bar connector, bolted and compression connectors; LV: equipment 

& instrument 

• Copper • Aluminum 

• Mechanical and 

Thermal Cycling 

• Vibration 

• Metal fatigue • Loosening of 

connectors 

• Loss of structural 

integrity 

• Degraded connector 

contact 

• Decreased EMI 

protection (Shield, I&C cables) 

   
2-13 

Subcomponent Material Stressors Potential Aging Mechanisms Potential Aging Effects MV LV I&

• Aluminum • Compressive forces • Cold flow 

• Loosening of 

connectors 

• Loss of contact on 

connectors 

• Increased electrical 

resistance 

• Increased ohmic 

heating 

   

• Copper • Aluminum 

• Electromechanical 

forces due to electrical transient 

• Mechanical damage 

including fatigue, bending, cracking 

• Loosening of 

connectors 

• Loss of structural 

integrity 

• Broken conductor 

strands 

 

• Copper • Aluminum 

• Handling, physical 

contact, or abuse during maintenance, operation, or testing activities 

• Mechanical damage 

including fatigue, bending, tensile deformation, cracking 

• Loosening of 

connectors 

• Loss of structural 

integrity 

• Broken conductor 

strands 

• Open circuit • Decreased EMI 

protection (Shield, I&C cables) 

  

terminations, screw terminals, compression connectors, terminal blocks, etc.) 

• Copper • Aluminum 

• Installation damage • Mechanical damage 

including fatigue, bending, tensile deformation, cracking 

• Loosening of 

connectors 

• Loss of structural 

integrity 

• Broken conductor 

strands 

• Open circuit • Decreased EMI 

protection (Shield, I&C cables) 

  
2.2.3 Cable System Aging and Degradation Mechanisms 

Table 2.1 indicates that elevated temperature and radiation stressors will cause embrittlement 

and cracking of the polymer materials used for cable insulation and jacket materials. These 

mechanisms will lead to a gradual decrease in the dielectric strength of the cable insulation, an 

increase in leakage current, and eventually will result in one of the failure modes described in 

subsection 2.2.1. When the stressors of wetting or, wetting combined with higher voltage 

(generally 480Vac and above), are acting on cables that are not qualified to operate in a wet or 

submerged state, moisture intrusion, electrochemical reactions, and/or water treeing will occur. 

These mechanisms will lead to a decrease in the dielectric strength of the cable insulation, an 

increase in leakage current, and eventually will result in one of the failure modes described in 

subsection 2.2.1. When continuously energized medium-voltage cables are operating in 

submerged or wetted conditions for which they are not designed, they can often fail very 

prematurely [Refs. 1 and 7]. Note that cables are not qualified for extended or continuous 

operation unless they have been specifically procured as submarine cables. In addition, the 

higher voltage stressors that exist during normal operation and during electrical system 

transients in medium-voltage cables can cause partial discharge, or corona, and electrical 

treeing to occur. These aging mechanisms can decrease dielectric strength over time and 

eventually can also lead to one of the power cable failure modes. Further details on electrical 

stressors and associated aging and degradation mechanisms can be found in Section 3.3 of 

NUREG/CR-6794, “Evaluation of Aging and Environment Qualification Practices for Power 

Cables Used in Nuclear Power Plants” [Ref. 3], and Section 4 of SAND96-0344, “Aging 

Management Guideline for Commercial Nuclear Power Plants - Electrical Cable and 

Terminations” [Ref. 2]. 

The aging mechanisms affecting cable conductors and other cable subcomponents generally 

develop more slowly and are less likely to occur than insulation failures that account for the 

majority of cable failures [Refs. 2 and 3]. Conductor failure is very rare in power cables where 

the wires are large diameter. Low-voltage power and I&C cable conductors are physically 

smaller-diameter wires and can occasionally break from metal fatigue due to long-term 

exposure to vibration or excessive handling and termination/determination. 

As seen in Table 2.2, the aging and degradation mechanisms affecting the polymer insulating 

materials used to construct and apply cable splices are similar to those affecting cables, and 

consequently over time, they can lead to one of the cable splice failure modes. When cable 

splices that are not qualified for wetted or continuous submersion are exposed to moisture or 

are submerged in water, they can be affected more rapidly and more severely than a cable with 

intact insulation in the same environment [Ref. 5]. Depending on the design of a splice, as the 

constituent materials degrade over time, multiple penetration pathways can develop that can 

introduce moisture into the interior of the splice. This can occur not only around the splice 

materials where they abut the surface of the cable insulation, but also through the interior of a 

cable via a damaged or cracked outer jacket or insulation. If these aging mechanisms progress 

on an environmentally qualified (EQ) electrical splice, it may shorten the qualified life of the 

cable splice and, as a consequence, the qualified life of the entire cable that contains the 

degraded EQ splice. 

In addition to the insulation materials, the connector that joins the electrical conductors within a 

splice can be vulnerable to aging and degradation mechanisms such as vibration, mechanical 

stress, thermal and mechanical cycling, and electrical transients. These mechanisms can result 

in metal fatigue of the conductors and/or loosening of the connector. Intrusion of moisture into 

the interior can cause corrosion and formation of oxides at the connector joint of a splice. This 

2-14 
2-15 

can cause increased electrical resistance and increased ohmic heating. More detailed 

description of the various stressors and aging mechanisms that can result in the failure of a 

cable splice can be found in Section 2.2 of NUREG/CR-6788 [Ref. 5]. 

As described in subsection 2.2.2, the stressors affecting cable termination connections at 

terminal blocks, fuse holders, circuit breaker and disconnect switch terminal connectors, electric 

motor leads, electrical equipment insulating bushings, electrical bus bars, or other electrical 

equipment termination points are generally the same as those affecting electric cables. 

However, the resulting aging and degradation mechanisms acting on the terminations can be 

very different than for cables and splices because of the variations in the types and designs for 

these cable system components. As shown in Table 2.2, the medium-voltage terminations will 

involve higher voltage connections at electric motors, electrical buses, fuse holders, circuit 

breaker and disconnect switch terminal connectors, and electrical equipment bushings. Some 

of these terminations depend on polymer insulation materials to provide the required dielectric 

strength. These polymers are exposed to the same stressors as cables and splices, and 

therefore can be affected by the same aging mechanisms, as shown in the tables. 

Similar to the cable splices, electrical terminations all involve a physical connector to join the 

electrical conductor to the termination point. The aging mechanisms of fatigue and loosening of 

these connections can be caused by the stressors listed in Table 2.2. 

2.3 Applicable Regulatory Requirements 

NRC regulations require that cables be capable of performing their function when subjected to 

anticipated environmental conditions, such as moisture or flooding. Further, the design should 

minimize the probability of power interruption when transferring power between sources. The 

cable failures that could disable risk-significant equipment are expected to have monitoring 

programs to demonstrate that the cables can perform their safety function when called on. The 

applicable regulatory requirements include the following: 

NRC regulations in 10 CFR Part 50, Appendix A, General Design Criterion (GDC) 4, state 

that, “Structures, systems, and components important to safety shall be designed to 

accommodate the effects of and to be compatible with the environmental conditions 

associated with normal operation.” 

NRC regulations in 10 CFR Part 50, Appendix A, GDC 17, state that, “Provisions shall be 

included to minimize the probability of losing electric power from any of the remaining 

supplies as a result of, or coincident with, the loss of power generated by the nuclear power 

unit, the loss of power from the transmission network, or the loss of power from the onsite 

electric power supplies.” 

NRC regulations in 10 CFR Part 50, Appendix A, GDC 18, state that, “Electric power systems 

important to safety shall be designed to permit appropriate periodic inspection and testing of 

important areas and features, such as wiring, insulation, connections, and switchboards, to 

assess the continuity of the systems and the condition of their components,” “...the operability 

and functional performance of the components of the systems,” “...and... the operability of 

the systems as a whole.” 
NRC regulations in 10 CFR 50.65(a)(1) state that, “Each holder of a license to operate a 

nuclear power plant...shall monitor the performance or condition of structures, systems, or 

components...in a manner sufficient to provide reasonable assurance that such structures, 

systems, and components...are capable of fulfilling their intended functions.” 

NRC regulations in 10 CFR Part 50, Appendix B, Criterion III, state that “...Measures shall 

also be established for the selection and review for suitability of application of materials, 

parts, equipment and processes that are essential to the safety-related functions of the 

structures, systems and components.” 

NRC regulations in 10 CFR Part 50, Appendix B, Criterion XI, “Test Control,” state that, “A 

test program shall be established to assure that all testing required to demonstrate that 

structures, systems, and components will perform satisfactorily in service is identified and 

performed.” 

NRC regulations in 10 CFR Part 50, Appendix B, Criterion XVI, “Corrective Action,” state that, 

“Measures shall be established to assure that conditions adverse to quality ...are promptly 

identified and corrected. In the case of significant conditions adverse to quality, the 

measures shall assure that the cause of the condition is determined and corrective action 

taken to preclude repetition. 

2.4 Increasing Trend of Undetected Early Cable Failures 

The integrity and function of power and instrumentation and control (I&C) cables are monitored 

indirectly through the performance of in-service testing of the safety-related systems and 

components. Unfortunately, while these tests can demonstrate the function of the cables under 

test conditions, they do not verify their continued successful performance when they are called 

upon to operate fully loaded for extended periods as they would under anticipated normal 

service operating conditions or under design basis conditions. Nor does in-service testing of a 

cable provide specific information on the status of aging degradation processes, or the physical 

integrity and dielectric strength of its insulation and jacket materials. Consequently, a cable 

circuit with undetected damaged or degraded insulation could pass an in-service functional test, 

but still fail unexpectedly when called upon to operate under anticipated environmental 

conditions, or the more severe stresses encountered in emergency operation during a design 

basis event (i.e., fully loaded equipment, more extreme environmental conditions, extended 

operation in a heavily loaded state). 

Longer cable circuits may pass through several different operating environments over the length 

of their routing throughout the plant. Portions of a cable circuit may pass through areas 

experiencing more harsh environmental conditions, such as high temperature, high radiation, 

high humidity, or submersion. There has been concern that such local adverse environmental 

stressors can cause excessive aging and degradation in the exposed sections of a cable that 

could significantly shorten its qualified life and cause unexpected early failures. 

It should be emphasized that the occurrence of cable system operating environments or locally 

adverse conditions that are unanticipated or more severe than the original plant design may 

constitute a design deficiency of the cable system, specifically, a potential violation of GDC 1, 4, 

17, and 18. NRC regulations, such as 10 CFR 50, Appendix B, (quality assurance), the 

maintenance rule (10 CFR 50.65), and environmental qualification regulations (10 CFR 50.49), 

require that programs and administrative controls be established to monitor and detect 

degraded conditions on a regular basis and to promptly implement effective corrective actions 

2-16 
and design modifications, consistent with its safety significance, so that any further cable 

degradation is minimized. A cable system must be designed to meet all applicable regulations 

and to perform its intended function in the plant environment under all anticipated operational 

occurrences and design basis events. 

Several examples of this type have been reported in Information Notice 2002-12, “Submerged 

Safety-Related Cables” [Ref. 7], and Generic Letter 2007-01, “Inaccessible or Underground 

Power Cable Failures That Disable Accident Mitigation Systems or Cause Plant Transients” 

[Ref. 1]. In these incidents, medium-voltage power cables in inaccessible or underground cable 

ducts, cable trenches, or direct buried have been exposed to moisture or submergence for 

extended periods. Cables exposed to water while energized are susceptible to a phenomenon 

called 'water treeing' in which tree-like micro-cracks are formed in the insulation due to 

electrochemical reactions. Growth of water trees will increase with time under continued 

exposure to moisture and voltage stress eventually leading to complete electrical breakdown of 

the insulation [Ref. 3]. 

In GL 2007-01, licensees were requested to provide failure history information for power cables 

within the scope of 10 CFR 50.65 (the Maintenance Rule) and a description of inspection, 

testing, and monitoring programs to detect degradation of inaccessible or underground cables 

supporting systems within the scope of 10 CFR 50.65. The licensee responses to the 

requested information were analyzed and described by the NRC in a summary report [Ref. 8]. 

The summary report indicated that 93% of the cable failures analyzed occurred on normally 

energized power cables. More than 46% of the failures were reported to have occurred while 

the cable was in service and more than 42% were identified as "testing failures" in which cables 

failed to meet testing or inspection acceptance criteria. The failure data, as presented in Figure 

2.1 reproduced from Reference 8, showed a trend toward early cable failure, the majority 

occurring in the range of 11-20 years of service and 21-30 years of service; this is shorter than 

the plants' original 40-year licensing period. 

Figure 2.1 Number of failures per ten-year service intervals, GL 2007-01 responses [Ref. 8] 

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2-18 

In its recommendations and conclusions for the summary report on licensee responses to GL 

2007-01 [Ref. 8], the NRC stated that: 

 “Plants undergoing license renewal have agreed to a cable testing program for the extended 

period of plant operation for a limited number of cables that are within the scope of license 

renewal, but only a few have established a cable testing program for the current operating 

period. The data obtained from the GL responses show an increasing trend of cable failures. 

These cables are failing within the plants’ 40-year licensing periods. As shown by the 

January 2008 event at Point Beach Nuclear Plant, cable failures have resulted in plant 

transients and shutdowns, loss of safety redundancy, entries into limiting conditions for 

operation, and challenges to plant operators.” 

“Licensees have identified failed cables and declining insulation resistance properties through 

current testing practices; however, licensees have also reported that some failures may have 

occurred before the failed condition was discovered. Although the majority of in-service and 

testing failures have occurred on cables that are normally energized, the staff is concerned 

that additional cable failures have not been identified for cables that are not normally 

energized or tested. The NRC staff recommends that the licensees should also include 

normally deenergized cables in a cable testing program. It appears that no manufacturer or 

insulation type is immune from failure. In addition, licensees have identified failures and or 

declining performance capability for both shielded and unshielded cables.” 

The NRC further stated in its recommendations and conclusions that: 

“The 10 CFR Part 50 regulations require licensees to assess the condition of their 

components, to monitor the performance or condition of SSCs in a manner sufficient to 

provide reasonable assurance that they are capable of fulfilling their intended functions, and 

to establish a test program to ensure that all testing required to demonstrate that components 

will perform satisfactorily in service is identified and performed. The NRR staff believes that 

licensees should have a program for using available diagnostic cable testing methods to 

assess cable condition.” 

In response to these concerns, this research study develops a comprehensive electric cable 

condition monitoring (CM) program, consisting of nine recommended essential elements, that 

will consolidate a core program of periodic CM inspections and tests, together with the results of 

in-service testing, environmental monitoring and management activities, and the incorporation of 

cable-related operating experience. 
3. COMMONLY USED CABLE CM TECHNIQUES 

This Section discusses currently available cable condition monitoring techniques that can be 

included in a condition monitoring program. The attributes of an effective condition monitoring 

technique are first presented to provide a framework for evaluating the advantages and 

limitations of currently available techniques. Following this, an overview of several of the most 

commonly-used, currently available cable condition monitoring techniques is presented. 

Several new or less well-known techniques are also discussed for balance. This is not intended 

to be a comprehensive list, and no attempt has been made to make this list all-inclusive. The 

techniques discussed are categorized based upon whether they can be performed in situ, or 

whether they are laboratory techniques. At least two examples of each different type of 

technique are presented, including screening techniques, pass/fail techniques, and diagnostic 

techniques. These examples are taken from the currently available population of condition 

monitoring techniques with the understanding that research is continuing and new, more 

effective methods of monitoring cable condition will be developed in the future. The reader is 

encouraged to review the literature to identify and implement these new, more effective 

techniques as they are developed. 

Finally in this Section, guidance on the selection of a suitable cable condition monitoring 

technique is presented. This discussion focuses on the factors that should be considered in 

selecting a technique for a particular application. 

3.1 Desired Attributes of an Effective Condition Monitoring Technique

A key element of any electric cable condition monitoring program is the selection of appropriate 

condition monitoring techniques to achieve the desired result. Condition monitoring involves the 

observation, measurement and/or trending of one or more condition indicators that can be 

correlated to the physical condition or functional performance of the cable. An “ideal” condition 

monitoring technique would have the following desired attributes [Ref. 9] listed below. It should 

be understood that no single CM Technique will have all of these attributes. 

 Non-destructive and non-intrusive (i.e., does not require the cable to be disturbed or 

disconnected) 

 Capable of measuring property changes or indicators that are trendable and can be 

consistently correlated to functional performance during normal service 

 Applicable to cable types and materials commonly used in existing nuclear power plants 

 Provides reproducible results that are not affected by, or can be corrected for the test 

environment (i.e., temperature, humidity, or radiation) 

 Inexpensive and simple to perform under field conditions 

 Able to identify the location of any defects in the cable 

 Allows a well defined end condition to be established 

 Provides sufficient time prior to incipient failure to allow corrective actions to be taken 

 Available to the industry immediately 

The information obtained from condition monitoring techniques is used to determine the ability 

of a cable, in its current condition, to perform its intended function within certain acceptance 

criteria. To obtain useful information, it is important that an appropriate technique be selected 

3-1 
for the cable being monitored. An overview of currently available condition monitoring 

techniques is provided below, including their advantages and disadvantages, as well as insights 

into the applications for which they are best suited. 

3.2 In Situ CM Techniques

There are a number of condition monitoring techniques that can be performed in situ. This is 

desirable since the removal of sample cable material, which can be destructive, is not required. 

The following provides a brief description of available in situ condition monitoring techniques. 

3.2.1 Visual Inspection 

Visual inspection is one of the most commonly used and effective in situ condition monitoring 

techniques [Ref. 9]. It is performed by visually examining a cable using the naked eye, but can 

be aided with a flashlight and/or magnifying glass. If direct access is available, the cable can 

also be touched to obtain tactile information. No other special equipment is required. If 

indications of degradation are identified during visual inspection, additional more intrusive 

testing may be required. As such, visual inspection is an excellent screening technique. 

However, it should be noted that visual inspection alone cannot detect and quantify many types 

of cable degradation and aging mechanisms, and should therefore be supplemented by other 

CM techniques (See Table 3.2 and Section 4.5). 

The advantages of this technique are that it is inexpensive and relatively easy to perform, and 

requires no expensive equipment. A qualitative assessment of the cable’s condition is obtained 

that can provide useful information for determining whether additional, more intrusive testing is 

required. For best results, a standardized procedure should be utilized that identifies the 

various cable attributes to be examined. Cable attributes that can be visually inspected 

include:1) color, including changes from the original color and variations along the length of 

cable, and the degree of sheen; 2) cracks, including crack length, direction, depth, location, and 

number per unit area; and 3) visible surface contamination, including any foreign material on the 

surface. Also, the rigidity of the cable can be qualitatively determined by squeezing and gently 

flexing it. While no quantitative data are provided, it is possible to trend the results of visual 

inspections. For example, discoloration or degree of cracking can be noted and trended over 

time with supplemental photographic records. This technique is most effective when performed 

by experienced personnel with knowledge of cable aging mechanisms and effects, as well as 

familiarity in how cable aging is manifested and detected. 

Another important advantage of visual inspection is that it can reliably detect sections of cable 

exhibiting the signs of unexpectedly severe degradation that can be produced by locally adverse 

environmental conditions. 

Disadvantages of this technique are that the cable to be inspected must be accessible and 

visible. In cases where cables are inaccessible, such as those installed in closed conduits or 

heavily loaded cable trays, a sample of accessible cables can be used as a surrogate, provided 

they are representative of the cables of interest. Care must be taken in extrapolating results of 

the surrogate population to ensure that any conclusions drawn are appropriate for the 

inaccessible cables. Factors to be considered are cable type, application and environment. 

Another disadvantage is that this technique does not provide quantitative data that can be easily 

trended. Observations can be recorded and used for comparison with future inspection results; 

however, the results are subjective and may differ for different inspectors. 

3-2 
3-3 

3.2.2 Compressive Modulus (Indenter) 

The compressive modulus of a material is defined as the ratio of compressive stress to 

compressive strain below the proportional limit. Aging of the polymers used as cable insulation 

and jacket materials typically causes them to harden, resulting in an increase in compressive 

modulus. Thus, monitoring the changes in compressive modulus can be used as an indicator of 

the degradation rate of the cable material. This technique has been shown to be applicable to 

several common cable insulation and jacket materials, including ethylene propylene rubber 

(EPR), silicone rubber (SR), Neoprene®, polyvinyl chloride (PVC), cross-linked polyethylene 

(XLPE) and chlorosulfonated polyethylene (CSPE) [Refs. 9, 10, 11]. 

Compressive modulus can be measured using an Indenter Polymer Aging Monitor (Indenter). 

The indenter presses a pointed metallic probe into the material being tested under controlled 

conditions and measures the force required for the resulting displacement. These values are 

then used to calculate the compressive modulus of the material. The probe is computercontrolled, which limits the travel of the probe to prevent damage to the cable. Typically, 

measurements are taken at various lengths on the cable surface and at various circumferential 

positions to obtain an accurate representation of the bulk cable compressive modulus. This test 

is most appropriate for use on low-voltage cables in situ. 

In testing performed by Brookhaven National Laboratory [Ref. 9] compressive modulus 

measurement was found to be an effective monitoring technique, which can be used in situ or in 

the laboratory. The indenter is easy to operate and capable of producing repeatable results. It 

can be operated by one person in the laboratory, or by two people in situ in a nuclear power 

plant environment. This is generally a non-destructive test which provides trendable, repeatable 

results that can be correlated to other known measures of cable properties, and can be used as 

an indicator of cable condition. 

A disadvantage of this technique is that electrical cables are not always easily accessible in 

nuclear plants. In many cases, cables are installed under other cables in cable trays or run 

through conduits, which makes them inaccessible for indenter testing. Indenter testing is not 

always optimal even for accessible cables. For example, cables that may only be accessible for 

indenter testing on their outer jacket surface, which would provide little direct information about 

concealed inner jackets or insulation. To monitor the modulus of inner jackets or insulation, 

access might be available at a termination point; however, the termination point may be 

physically located in a different plant location and exposed to very different service conditions 

than the cable location of interest. 

The compressive modulus gives direct information only on the brittleness of the outer insulation 

or jacket polymer material but does not tell whether the insulation is weak or significantly 

degraded. Compressive modulus, measured at a specific point on a cable, is an indicator of the 

brittleness of the outer surface polymer at that particular point on the cable, and at that 

particular radial point on the circumferences of the cable. Local variations due to cable internal 

geometry and local environment are accounted for by obtaining multiple measurements at 

several linear intervals along the cable section of interest and at several radial points around the 

cable circumference at each interval. An average of these compressive modulus 

measurements can then be correlated to other direct measurements of the insulation dielectric 

strength of a cable, such as leakage current or insulation resistance/polarization index. 
Another drawback to this technique is that typical service conditions may not produce significant 

changes in compressive modulus in every material, which could make correlation of indenter 

results with thermal or radiation exposure problematic. In cases where cables are exposed to 

relatively mild service conditions, the resulting small modulus changes might be difficult to 

correlate with aging without accurate baseline measurements, which may not be available. 

Modulus response to service conditions may also vary based on cable construction and 

manufacturers’ material formulations. “Moreover, the conclusions are precisely applicable only 

to the area of the cable that was tested. This approach may be desireable to examine a cable 

section that had undergone a localized degradation.” 

3.2.3 Dielectric Loss (Dissipation Factor/Power Factor) 

Dielectric loss measurement is an electrical test that can be performed on cables as an indicator 

of their condition. It includes two related tests; the dissipation factor test and the power factor 

test. The principle of operation is based on the fact that when a steady-state ac test voltage (V) 

is applied across a cable’s insulation (i.e., conductor-to-ground), the resulting apparent total 

current (I) that flows consists of a charging current (IC) due to the capacitance of the cable 

insulation and a leakage current (IR). The relationships among the applied test voltage and the 

current components are shown in Figure 3.1. The phase angle θ between the applied test 

voltage (V) and the total current (I) flowing through the insulation is known as the dielectric 

phase angle. The compliment of the phase angle is called the dielectric loss angle δ. 

I 

IR

Figure 3.1 Insulation Power Factor Relationship 

Typically, leakage current is much smaller than charging current in electric cable insulation, and 

it is more sensitive to the condition of the insulation. Insulation that is degraded due to aging 

will allow an increased amount of leakage current, while the capacitive current remains 

approximately constant. Thus, as cable insulation degrades the ratio of leakage current (IR) to 

charging current (IC) will increase. This ratio (IR/IC) is the tangent of the dielectric loss angle (tan 

δ) and is a measure of dielectric degradation. It is called the dielectric dissipation factor and is 

commonly used as a measure of insulation condition. Similarly, another means of describing 

dielectric loss is the dielectric power factor, expressed as the cosine of the dielectric phase 

angle (cos θ). At very low power factors (<10 percent), the dielectric power factor (cos θ) is 

approximately equal to the dielectric dissipation factor (tan δ). 

3-4 
Dielectric loss measurements are performed using a waveform generator and a spectrum 

analyzer. The instrumentation is connected to the conductors of the cable under test, and 

applies a test voltage signal to the test specimen over a range of frequencies (e.g., 0.1 Hz to 

5000 Hz). Measurements are made from conductor-to-conductor, and/or from conductor-toground in all the conductor combinations. The resulting current response of the cable is 

measured and recorded for later analysis. Dissipation factor and power factor are calculated at 

specific frequencies of the applied test signal. ASTM Standard D150 [Ref. 12] and IEEE 

Standards 400 [Ref. 13] and 400.2 [Ref. 14] provide guidance on the performance of dielectric 

loss/power factor testing. 

Dielectric loss measurement is a very simple and straightforward condition monitoring technique 

that provides quantitative and repeatable results. Many of the factors that can affect the 

dielectric loss measurement can be controlled or accounted for through analysis. For example, 

the effect of cable length is very uniform and predictable, resulting in a relative increase in 

insulation power factor as the length of cable increases. This effect is most easily accounted for 

by obtaining in situ baseline measurements for each cable to be monitored for comparison with 

future measurements. Effects due to other operating electrical equipment or energized cables 

in the same tray as the cable under test are typically concentrated at the 60 Hz frequency of the 

operating equipment and can be mitigated by using an applied ac test voltage with a frequency 

below 50 Hz or above 70 Hz. The best results are obtained on cables with shielding, which 

reduces interference from nearby operating equipment. 

Another advantage of the dielectric loss technique is that the cable being tested does not have 

to be completely accessible. The test equipment can be connected to the ends of the cable, 

and the test can be performed without physically touching the length of the cable or removing 

material samples. 

A disadvantage of the dielectric loss technique is that the cable under test must be 

disconnected in order to attach the test instrument. This is undesirable since it can be cause 

other unforeseen problems or damage to the cable. In situ testing of cables with this technique 

would require the development of test procedures with independent verification steps, similar to 

those used for surveillance and maintenance procedures in nuclear power plants. 

3.2.4 Insulation Resistance and Polarization Index 

Insulation resistance is a standard industry technique that is commonly performed to determine 

the current condition of cable insulation. It involves the application of a voltage between the 

cable conductor and a ground to determine the resistance of the insulation separating them. It 

is based on the principle that when a dc voltage is applied to an insulated conductor, a small but 

measurable current will flow through the insulation to ground. The total current flowing in the 

insulation from the conductor to ground is equal to the sum of the capacitive charging current, 

the leakage current and the dielectric absorption current. 

These three component currents change with time. The capacitive charging current and the 

dielectric absorption current will initially be relatively high when the test voltage is first applied to 

the test specimen. Since the insulation behaves like a capacitor, after it is energized and 

charges have aligned across the insulation, these currents will taper off and eventually 

approach zero. However, leakage current will typically start at zero and then gradually increase. 

In high integrity insulation, leakage current will reach and maintain a steady value after a certain 

amount of time. If the insulation is badly deteriorated, wet, or contaminated, the leakage current 

will be greater than that found in good insulation and it could continue to increase over time. As 

3-5 
3-6 

a result, the total current flowing in a test specimen will start out high when a test voltage is first 

applied, and vary in different ways over the next several minutes depending on the condition of 

the insulation. To account for this behavior, insulation resistance is normally measured at one 

minute and again at ten minutes, then the ratio of the two measurements is calculated. This 

ratio is called the polarization index. IEEE Standard 400 [Ref. 13], IEEE Standard 141 [Ref. 15], 

and ASTM Standard D257 [Ref. 16] provide guidance on performing insulation resistance 

testing. 

Advantages of this test are that it is relatively easy to perform and requires inexpensive 

equipment. Insulation resistance is often regarded as a simple pass/fail test for the dielectric 

integrity of electrical equipment and cables since the results are very sensitive to environmental 

conditions, making them too irregular for trending purposes. The results can be corrected for 

environmental effects, such as temperature. Measurements are normally corrected to a single 

temperature, such as 60oF (15.6oC) for electric cables. This allows the comparison of 

measurements taken at different times when the cable might be at different temperatures. 

Polarization index provides quantitative results that can be trended over time as a measure of 

insulation condition. An advantage of using the polarization index is that it is not temperature 

dependent. 

Other factors that can affect insulation resistance include cable length, humidity or moisture 

within the cable and insulation, dirt, oil, and other surface contaminants, personnel in close 

proximity to the equipment under test, and electrical equipment operating in the vicinity of the 

test cable. The effect of length is very uniform and predictable, resulting in a relative decrease 

in insulation resistance as cable length increases. The effects of length and some of the other 

factors can be accounted for by obtaining in situ baseline measurements for each cable to be 

monitored and comparing future measurements to these baseline values. The effect of other 

operating electrical equipment or energized cables in the same tray was found to be negligible 

in test performed by BNL [Ref. 9]. 

Other advantages of this technique are that resistance measurements made with a 

megohmmeter are relatively easy to perform and require inexpensive test equipment. The 

megohmmeter is commonly used by all electrical maintenance personnel in nuclear power 

plants. To obtain meaningful results for electric cables, a megohmmeter that is capable of 

accurately measuring insulation resistance in the Teraohm range is required. 

A disadvantage of the insulation resistance and polarization index techniques is that the cable 

under test must be disconnected in order to attach the test instrument. This is undesirable since 

it requires handling of the cable, which could result in unintentional damage, particularly for 

aged cables that may be embrittled. In nuclear power plants, the performance of this test would 

have to be controlled by procedures containing independent verification steps, as are commonly 

used for surveillance and maintenance activities. 

Another disadvantage is that this test is not as sensitive to insulation degradation as other 

techniques. In some cases, such as in dry air, severe damage to the insulation may result in 

little change in insulation resistance. In addition, leakage currents are very small, and can be 

very difficult to measure accurately. They are very sensitive to surrounding environmental 

conditions and will vary considerably from the slightest change, such as someone walking by 

the cable under test. 
3.2.5 AC Voltage Withstand Test 

The AC voltage withstand test is similar to the DC High Potential test in which a cable’s 

insulation is exposed to a high test voltage to demonstrate that the insulation can withstand a 

voltage potential higher than it is expected to see during service. The principle behind the test 

is that if defects are present in the cable, the high test voltage will force them to fail. Absent any 

failures, the cable is considered to be in good condition and able to continue in service. 

However, in the AC Voltage Withstand test, the test voltage is applied at very low frequencies 

(<1Hz) to minimize potentially adverse charging effects in the insulation that are inherent to the 

DC Hi Potential test. 

The test is performed with a high potential test set that applies a relatively high test voltage 

(e.g., 2 times rated voltage) for a set period of time (e.g., 15 minutes) between each conductor 

and ground. If the cable is able to withstand the voltage for the specified period, it is deemed to 

have passed the test and is fit for continued service; therefore, this is considered a pass/fail type 

test. This test is applicable to installed cables that contain a shield that can be used as a 

ground plane. IEEE Std. 400 [Ref. 13] and IEEE Std. 400.1 [Ref. 17] provide guidance on 

performing low frequency withstand tests. 

This is a relatively simple test to perform that can provide insights into the overall condition of a 

cable’s insulation. If defects are found and result in failure during the test, it might be possible 

to repair or replace the degraded or defective section(s) of the cable and return it to service. 

A disadvantage of this test is that the high voltage used has the potential to cause a voltage 

breakdown that could permanently damage the cable insulation. Each time the test is 

performed on a cable the high voltage may cause an incremental increase in the amount of 

degradation to the dielectric integrity of the insulation. If this test is repeated excessively, the 

dielectric strength of the insulation could weaken to the point that the cable will fail due to the 

testing. 

Another disadvantage is that the cable under test must be disconnected to attach the test 

equipment. This is undesirable for the reasons stated previously for the IR test. 

3.2.6 Partial Discharge Test 

Partial discharge testing is an ac electrical technique that can be used for condition monitoring 

on medium-voltage cables. It is performed by applying a sufficiently high voltage stress (the 

inception voltage) across a cable’s insulation to induce an electrical discharge (also known as 

partial discharge or corona) in the small voids present within the insulation, or in air gaps 

between insulation and a ground plane, such as a shield in the cable. The occurrence of partial 

discharges indicates the presence of degradation sites in the insulation. This test can be 

performed at power frequency (i.e., 60Hz) or at very low frequencies (< 1Hz). Very low 

frequencies are sometimes used since they result in different partial discharge characteristics 

that may detect degradation sites that are not evident at power frequency. This test is 

potentially damaging since the discharges induced can cause degradation of the insulation over 

a period of time due to localized overheating. IEEE Std. 400-2001, “IEEE Guide for Field 

Testing and Evaluation of the Insulation of Shielded Power Cable Systems” [Ref. 13], IEEE Std. 

400.3-2006, “IEEE Guide for Partial Discharge Testing of Shielded Power Cable Systems in a 

Field Environment” [Ref.18], ASTM Standard D470, “Standard Test Methods for Crosslinked 

Insulations and Jackets for Wire and Cable” [Ref. 19] and ASTM D2633, “Standard Test 

3-7 
Methods for Thermoplastic Insulations and Jackets for Wire and Cable” [Ref.20], provide 

guidance on performing partial discharge testing. Additional information on partial discharge 

testing of low-voltage cables is provided in Reference 21. 

Partial discharges typically carry electrical charges in the range of picocoulombs (pC), and can 

be measured using an oscilloscope connected to the cable under test. Also, their location can 

be determined by measuring the time lag between direct and reflected pulses from the 

discharge site. Alternatively, the discharges can be detected using acoustic emission 

monitoring techniques [Ref. 22]. 

This test has limitations for use in the field since it requires relatively high voltages to be applied 

to the cable, which would be a concern due to the potential to damage the cable or surrounding 

equipment. Also, nearby operating electrical equipment in a plant environment could interfere 

with the test due to noise interference, so this test is most successful on shielded cables. 

3.2.7 DC High Potential Test 

The dc high potential test is similar to the ac voltage withstand test in which a cable’s insulation 

is subjected to a high voltage potential to determine if the insulation can withstand a potential 

higher than expected in service for a specific period of time. Since most cable insulating 

materials can sustain application of high dc potential without damage for very long periods, dc 

test voltages are sometimes preferred for repetitive field testing of cable insulation. Guidance 

for performing this test is provided in IEEE Std. 400.1 [Ref. 17] and IEEE Standard 141-1993 

[Ref. 15]. 

Advantages and disadvantages of this test are similar to the ac voltage withstand test, with the 

exception that the dc test voltage is less likely to adversely affect the cable insulation. Another 

advantage to this test is that the test equipment is much smaller and more portable. 

3.2.8 Step Voltage Test 

The step voltage test is similar to the high potential test in that dc test voltage is applied to a 

cable; however, in this test, the voltage starts low and is increased in steps until the desired 

maximum test voltage is achieved. Each step increase in voltage potential is followed by a hold 

period during which the leakage current through the insulation is measured. This is considered 

a diagnostic test since the leakage currents can be recorded and trended to provide insights into 

the condition of the insulation as a function of age and voltage potential. Guidance for 

performing this test is provided in IEEE Std. 400.1 [Ref. 17] and IEEE Standard 141-1993 

[Ref. 15]. 

Advantages and disadvantages of this test are similar to those of the high potential test, with the 

exception that damage to the cable can be mitigated since leakage current can be monitored 

and the test terminated upon indications of excessively high leakage currents. Nevertheless, 

this test can be destructive. 

3.2.9 Time Domain Reflectometry 

Time Domain Reflectometry (TDR) is a commonly used technique for assessing the condition of 

instrumentation, control, and power cables in inaccessible locations. The TDR works on the 

same principle as radar. A non-destructive pulse of energy is transmitted down a cable from 

one end, and is reflected back when it encounters (1) the far end of the cable, (2) a fault along 

3-8 
the cable, or (3) some other problem that causes a change in the electrical impedance of the 

cable. The time for the signal to travel to where the impedance change is located and return 

back is measured by the TDR and converted into a distance. This distance is used to locate the 

impedance change [Ref. 9]. 

The simplest form of TDR will display the distance to an impedance change, which could be a 

fault. More sophisticated TDRs can display the actual waveform or “signature” of the cable on a 

CRT or LCD, which will show the pulse transmitted down the cable from the instrument and any 

reflections that come back to the TDR from discontinuities or impedance variations along the 

length of the cable. Impedance variations can be caused by degradation due to aging. 

TDR testing can be used to monitor cable condition by first obtaining an initial in situ baseline 

cable signature for a specific cable, and then comparing future TDR signatures to the baseline 

to identify and trend in-service degradation over time. Once the characteristic velocity of 

propagation for specific insulating materials and cable configurations has been determined, an 

experienced operator can use the TDR to detect and physically locate any cable damage that 

may have occurred since the last cable inspection. 

An advantage of TDR testing is that it is a non-destructive test that can be performed in situ to 

monitor the condition of low-voltage or medium-voltage cables. It provides information that can 

be used to determine the severity and location of a discontinuity, which could represent a fault. 

In addition; the test equipment needed is only moderately expensive, and the data can be 

trended against historic baseline reflectograms. 

Disadvantages of the TDR are that the cable under test must be disconnected in order to 

perform the test. Also, training and experience are required of the testing personnel in order to 

obtain useful results, and transient conditions, such as immersion, are only detected if they are 

present during the TDR test. 

3.2.10 Infrared (IR) Thermography 

Infrared thermography is a non-destructive, non-contact inspection of electrical equipment that 

is simple to perform and is valuable in identifying potentially damaging service conditions where 

elevated temperatures are present [Ref. 23]. It is performed using a thermal detection or 

imaging system to detect, measure, and or display the infrared, or heat radiation emitted by an 

object. Depending on the sensitivity and sophistication of the infrared detector, extremely 

accurate temperature measurements, as fine as one tenth of a degree F, may be obtained. 

IR thermography can be performed with spot meters or imagers, both of which are capable of 

accurately measuring infrared radiation emitted from thermally hot electric equipment. The spot 

meter converts infrared radiation into a numeric temperature value. It is used by aiming the spot 

meter at the spot to be monitored, typically aided by a laser guided pointing device, and 

activating the device. While infrared spot meters are inexpensive and easy to operate, they 

require some skill, knowledge, and experience to obtain accurate, repeatable, and usable data. 

Imagers convert infrared radiation into a visual image or thermogram. These devices can 

identify hotspots when temperature differences are as small as one tenth of a degree F. 

Computer software packages are available that provide trending options in which several 

thermal images can be analyzed over a period of time and the associated temperature data 

graphed. 

3-9 
Infrared imaging provides a useful tool for identifying temperature hot-spots, which could lead to 

accelerated degradation of electric cable systems. The high resolution temperature detection 

capabilities of the instruments combined with image storage and analysis software make it 

possible to trend the thermal data obtained. 

3.2.11 Illuminated Borescope 

The use of an illuminated borescope to inspect inaccessible cables has proven to be a useful 

screening technique for identifying stressors that can lead to cable degradation. It can also 

detect visible cable damage. The borescope can be inserted into conduits or other locations 

containing cables that would ordinarily be inaccessible to inspection for mechanical damage that 

may have been caused during installation or service, or for indications that water has been 

present indicating submergence of the cables during service. The borescope can also detect 

the presence of other contaminants, such as dirt, sharp metal debris, or chemicals that can 

cause accelerated degradation of the cables. Based upon the results of a borescope 

inspection, a decision can be made as to whether additional, more intrusive testing is needed. 

Advantages of this technique are that it is non-destructive, simple to perform and requires little 

training to be successful. A disadvantage is that it does not provide quantitative data that can 

be trended; therefore, its main benefit is as a screening technique to determine if additional 

testing is needed. 

3.2.12 Line Resonance Analysis (LIRA) 

The Line Resonance Analysis (LIRA) test is a relatively new electrical condition monitoring 

technique that is based on the analysis of electrical test signals input to the cable under test 

using a waveform generator. The technique models a wire system using transmission line 

theory and uses narrow-band frequency domain analysis of high frequency resonance effects of 

unmatched transmission lines to detect changes in the cable insulation’s properties. The 

cumulative phase shift of the input impedance due to the permittivity change in the insulation is 

used as a condition indicator for aging and small defects. Amplitude change is used to account 

for larger effects. 

This technique is claimed to be sensitive to small changes in wire system electric parameters, 

such as the insulation permittivity, that are a significant condition indicator for aging of the cable 

insulation. In addition, it is claimed that this technique can detect and localize meaningful 

property changes for various different insulation types and geometries for both aging and nonaging related effects [Ref. 24]. Additional research is ongoing on this technique. 

An advantage of this technique is that it can be performed in situ without de-terminating the 

cable. The effects of loads attached to the cable can be accounted for in the analysis of results. 

Also, degradation is claimed to be detectable prior to a failure occurring 

A disadvantage of this technique is that it is not a simple test to perform or interpret. Training 

and experience are needed to obtain meaningful results. 

3.3 Laboratory CM Techniques

If samples of the cables to be inspected are available, there are condition monitoring techniques 

available that can be performed in a laboratory. An overview of some of the most common 

laboratory techniques is provided below.

3-10 
3.3.1 Elongation-at-Break 

An industry standard technique for measuring a polymer’s condition is elongation-at-break 

(EAB). EAB is a measure of a material's resistance to fracture under an applied tensile stress 

and is often termed the "ductility" of a material. When exposed to stressors such as elevated 

temperature and radiation levels, polymers tend to lose their ductility. As such, ductility can be 

used as a measure of polymer condition. The rate of ductility loss is determined by the material 

composition, as well as the severity of the stressors; however, in general, ductility will decrease 

with age. EAB has been shown to be a very accurate and repeatable method of monitoring 

polymer condition. 

Since many cable insulation and jacket materials are polymers, EAB has proven to be an 

excellent condition monitoring technique for electric cables [Ref. 9]. This is particularly true for 

cables in a nuclear power plant environment, in which cables are exposed to a combination of 

thermal oxidation and gamma radiation effects. 

EAB tests are typically performed using a calibrated tensile tester in accordance with ASTM 

Standard D638 [Ref. 25] and D412 [Ref. 26]. Test specimens are prepared from cable samples 

that are typically several inches long. The test specimens are commonly formed in the shape of 

a "dog bone" by stamping the cable material with an ASTM-approved die. The samples are 

then installed in the tensile tester and pulled under very specific loading conditions until they 

break. This is a destructive test for the extracted specimen from the cable. 

EAB measurements provide a useful quantitative assessment of the condition of cable materials 

and are widely used as a benchmark for characterizing such materials. It is a reliable technique 

for determining the condition of polymers and provides trendable data that can be directly 

correlated with material condition. In general, as EAB decreases, crack initiation and 

propagation become possible from in-service stresses. This could lead to moisture intrusion 

and current leakage. Currently, there is no standardized acceptance criterion for the minimum 

EAB for a cable material that will define the end of its useful service life for normal, mild or harsh 

environments. A conservative value of ≥50 percent has sometimes been used as an 

acceptance criterion; however, testing has shown that there is usually some useful service life 

remaining at levels well below this [Ref. 9]. 

The primary disadvantage of the EAB test is that it is a destructive test, and relatively large 

amounts of cable are required. The necessary samples can only be obtained if a cable is 

removed from service, or if surveillance-type cables are installed specifically for periodic EAB 

testing. 

3.3.2 Oxidation Induction Time/Temperature 

In formulating materials that must perform for long periods of time in an environment that 

exposes them to oxidation, such as electric cable insulation and jacket materials, antioxidants 

are commonly added as one of the ingredients. The antioxidants retard the onset of oxidation, 

which can degrade the cable materials. Over time, these antioxidants leach to the surface and 

are dissipated to the environment, thus increasing the susceptibility of the material to oxidation. 

Consequently, as the cable insulation ages, the time to oxidation decreases. By measuring the 

amount of time required for oxidation of a material sample to occur under controlled conditions, 

the level of antioxidant remaining in the material can be estimated and correlated to the 

remaining life of the material. 

3-11 
Oxidation induction time (OITM) is a measure of the time at which rapid oxidation of a test 

material occurs when exposed to a predetermined constant test temperature in a flowing 

oxygen environment. It is measured with a differential scanning calorimeter (DSC), which is 

essentially an oven with the capabilities for very precise control and measurement of the heat 

energy supplied to a test sample. In the OITM test, the DSC supplies heat to a small 

(approximately 10 mg) sample of material that is placed in a small aluminum pan. The sample 

is cut into small pieces, each less than about 1 mg in mass. An empty pan is placed in the 

heating chamber of the DSC adjacent to the pan containing the test specimen to act as a 

control. The difference in heat supplied to the two pans is measured and represents the heat 

supplied to the sample. 

At the beginning of the test, the temperature of the pans is raised to the predetermined test 

temperature in flowing nitrogen, which takes about 20 minutes. A nitrogen purge is used initially 

to prevent oxidation from occurring until the clock is started. When the temperature approaches 

the test temperature, the nitrogen is replaced by oxygen flowing at a specified rate (e.g., 50 

ml/min) and the clock is started. The OITM is the time from the start of oxygen flow to the time 

that rapid oxidation of the sample occurs. The onset of oxidation is manifested by the 

appearance of a large exothermic peak in the oxidation curve (the thermogram), which is 

monitored as the test progresses. Typically, the OITM is measured using software supplied with 

the DSC. Usually, at least two replicate samples are tested to assure reproducibility. ASTM 

Standard D3895 [Ref. 27] provides guidance on performing OIT testing. Use of this technique 

for cable condition monitoring is discussed in References 9 and 28. 

OITM is a destructive test from the standpoint of the test sample used; however, many consider 

this test to be non-destructive from the standpoint of the cable being tested since only a very 

small sample is required (i.e., 10 mg). It is possible that a sample this small can be obtained 

without damaging the cable, although the cable would have to be handled at some level. There 

are concerns that disturbing the cable at all to obtain such a material sample could cause 

problems and is undesirable. For inaccessible cables, the sample would have to be obtained 

from a remote location, which may not be representative of the location of interest. 

A variation of the OITM test is the oxidation induction temperature (OITP) test, which is also 

measured using a DSC. In this test, the test specimen is prepared in an identical way to those 

for OITM. However, instead of maintaining a constant test temperature and measuring the time 

at which oxidation initiates, the temperature of the sample is increased at a constant specified 

rate (e.g., 18oF/min (10oC/min)) in flowing oxygen and the temperature at which oxidation 

initiates is noted, which is the OITP. The onset of oxidation is usually considered to occur when 

the sample has become depleted of antioxidants, which allows the main polymer backbone to 

suffer rapid attack. 

This test has similar advantages and disadvantages to the OITM test. 

3.3.3 Fourier Transform Infrared Spectroscopy 

Fourier Transform Infrared (FTIR) Spectroscopy is a well known laboratory technique for 

studying the molecular structure of materials. It is performed using a spectroscope, in which a 

small material sample is exposed to infrared radiation. The absorbance or transmittance of this 

radiation by the material at various wavelengths is then measured. The principle behind this 

test is that, as radiation passes through a polymer, atoms absorb radiation and begin to vibrate. 

For a particular chemical bond, maximum vibration occurs for a specific wavelength of radiation. 

3-12 
By irradiating a specimen with a continuous spectrum of infrared radiation and identifying the 

wavelengths at which maximum absorbance or transmittance occurs, the chemical bonds that 

are vibrating can be identified by comparison with known characteristics for chemical bonds 

available from the open literature [Ref. 9]. 

In studying the oxidation of cable materials an important wave number in the FTIR spectrum 

occurs at 1730 cm-1, which indicates the presence of the carbonyl (C=O) peak. This peak is a 

direct indication that the polymer is undergoing oxidation and carbonyl bonds are being 

generated. 

An advantage of this technique is that samples can be obtained from very small areas of cable; 

therefore, it can be considered a non-destructive technique. In addition, quantitative results are 

provided that can be trended over time for use in tracking the condition of the cable. 

A disadvantage of the FTIR spectroscopy technique is that it is a surface examination procedure 

in which the infrared radiation passes into the surface of the specimen and is refracted back into 

the spectroscope crystal. The material’s transmittance is determined through analysis of the 

intensity of the incident and reflected rays. Under harsh environment condition (i.e., elevated 

temperatures) an oxidation gradient could develop at the specimen surface, resulting in the 

spectroscope detecting a higher amount of oxidation than the average bulk value. Correlation 

of FTIR results for such cables with results from other techniques that accurately reflect average 

bulk properties, such as EAB, could be problematic. This deviation from average bulk 

conditions would be exacerbated as aging temperatures increase. More accurate estimates of 

bulk aging would be expected for cable specimens naturally-aged at service temperatures low 

enough to mitigate the establishment of an oxidation gradient within the cable material. 

FTIR testing also has the disadvantage that, for inaccessible cables, the sample would have to 

be obtained from a remote location, which may not be representative of the location of interest. 

3.3.4 Density 

Measuring and trending the density of a cable’s insulation is another technique that has been 

used to monitor the condition of electric cables. As polymers age, oxidation typically occurs 

resulting in changes to the material structure, including cross-linking and chain scission, along 

with the generation of oxidation products. These processes can cause shrinkage of the 

material, along with an increase in density. Measuring and trending the density of a cable’s 

insulating material can, therefore, be used as a measure of cable aging [Ref. 29]. 

Density measurements can be made using a small piece of material (<1mg); therefore, this 

technique can be considered non-destructive. One method of measuring a polymer’s density is 

to place a material sample into a calibrated liquid column, which is composed of salt solutions of 

various densities, or mixtures of ethanol and water, containing a gradient in density. After 

equilibrium is reached, the density is determined using a calibration curve for the column. 

Another approach involves the use of micro-balances to measure the weight of a sample both in 

air and then in a liquid of lower density than the sample. From these weights the density of the 

sample can be calculated. ASTM Standard D792 [Ref. 30] and D1505 [Ref. 31] provide 

guidance on performing density measurements. 

Density measurements for typical cable insulating materials have shown good correlation with 

the aging of polymers as determined by other proven techniques, such as EAB. Thus, this 

technique could be useful as a monitoring technique for some cable insulating materials. 

3-13 
3-14 

A disadvantage of this technique is that a sample of the cable insulation material must be 

obtained to perform this test. This presents the same problems discussed earlier in regard to 

accessibility and disturbance of the cable while in service. In addition, this technique will only 

provide information for the localized area from which the sample is taken. 

“Caution: (1) The acceptance values for various tests discussed above need special 

considerations for the safety significance of the cable and the environment in which it is located. 

For example, an underground cable that brings power to a safety bus could potentially disable a 

train of equipment, therefore, a conservative acceptance value is desirable. (2) The acceptance 

value for cables that are located in a harsh environment and expected to function during and 

after the impact of LOCA, need to account for the potential degradation from the accident.” 
Table 3.1 Summary of Cable Condition Monitoring Techniques 

CM Technique Test Type Applicable Cable Categories and Materials Applicable Stressors Aging Mechanisms Detected Advantages 

In Situ CM techniques 

Visual Inspection Screening 

All accessible cables All insulation and jacket 

materials 

Elevated Temperature Radiation exposure Mechanical stress Voltage stress & 

Moisture exposure 

Submergence Exposure to chemicals 

and other surface contaminants 

Thermally induced 

embrittlement and cracking 

Radiation induced 

embrittlement and cracking 

Mechanical damage and 

wear 

Potential for water treeing Potential for moisture 

intrusion 

Surface Contamination 

Simple to perform Inexpensive equipment Provides useful qualitative 

information on cable conditionCan detect localized degradation 

Compressive Modulus (Indenter) 

Diagnostic Low-voltage cables Most effective for 

Ethylene-Propylene Rubber, Polyvinyl Chloride, Chlorosulfonated Polyethylene, Silicon Rubber, Cross-linked Polyethylene, and Neoprene® materials 

Elevated Temperature Radiation exposure 

Thermally induced 

embrittlement 

Radiation induced 

embrittlement 

Relatively easy to perform Provides trendable data 

on commonly used cable insulation materials 

Results can be correlated 

to known measures of cable condition 

Dielectric Loss -Dissipation Factor/ Power Factor (AC Voltage @ varying frequencies)) 

Diagnostic 

Low- and Mediumvoltage cables Best results on shielded 

cables 

All insulation and jacket 

materials 

Elevated Temperature Radiation exposure Mechanical stress Voltage stress & 

Moisture exposure 

Submergence Exposure to chemicals 

and other surface contaminants 

Thermally induced 

cracking 

Radiation induced cracking Mechanical damage Water treeing Moisture intrusion Surface Contamination 

Relatively easy to perform Provides trendable data 

on commonly used cable insulation materials 

Access to entire cable not 

required 

Can be correlated to 

known measures of cable condition 

Insulation Pass/Fail 

Low- and Mediumvoltage cables Elevated Temperature Thermally induced cracking in the presence Relatively easy to perform Access to entire cable not 

3-15 
Test Type Applicable Cable Applicable Stressors Aging Mechanisms CM Technique Advantages 

Categories and Materials Detected 

Resistance (DC Low Voltage) 

All insulation and jacket 

materials 

Radiation exposure Moisture exposure Submergence 

of moisture 

Radiation induced cracking 

in the presence of moisture 

Moisture intrusion 

required 

Can be corrected for 

environmental effects 

Polarization Index (DC High Voltage) 

Diagnostic 

Low- and Mediumvoltage cables All insulation and jacket 

materials 

Elevated Temperature Radiation exposure Moisture exposure Submergence Exposure to 

contaminants 

Thermally induced 

cracking in the presence of moisture 

Radiation induced cracking 

in the presence of moisture 

Moisture intrusion Surface contamination 

Relatively easy to perform Access to entire cable not 

required 

Does not need to be 

corrected for temperature effects 

Can provide trendable 

data 

AC Voltage Withstand Test (AC High Voltage @ very low frequency) 

Pass/Fail 

Low- and Mediumvoltage cables All insulation and jacket 

materials 

Elevated Temperature Radiation exposure Mechanical stress Voltage stress & 

Moisture exposure 

Submergence Exposure to chemicals 

and other surface contaminants 

Thermally induced 

embrittlement and cracking 

Radiation induced 

embrittlement and cracking 

Mechanical damage Water treeing Moisture intrusion Surface Contamination 

Access to entire cable not 

required 

Can detect cable defects 

prior to failure in service 

Partial Discharge Test (AC High Voltage @ 60 Hz or very low frequency) 

Diagnostic 

Low- and Mediumvoltage shielded cables All insulation and jacket 

materials; however, interpretation of results for extruded insulation and paper 

Elevated Temperature Radiation exposure Mechanical stress Voltage stress & 

Moisture exposure 

Thermally induced 

embrittlement and cracking 

Radiation induced 

embrittlement and cracking 

Mechanical damage 

Relatively easy to perform Access to entire cable not 

required 

Can detect degradation 

sites prior to failure in service 

3-16 
Test Type Applicable Cable Applicable Stressors Aging Mechanisms CM Technique Advantages 

Categories and Materials Detected 

insulated/lead covered cables may be problematic 

Water treeing 

High Potential Test (DC High Voltage) 

Pass/Fail 

Low- and Mediumvoltage cables All insulation and jacket 

materials 

Elevated Temperature Radiation exposure Mechanical stress Voltage stress & 

Moisture exposure 

Submergence Exposure to chemicals 

and other surface contaminants 

Thermally induced 

embrittlement and cracking 

Radiation induced 

embrittlement and cracking 

Mechanical damage Water treeing Moisture intrusion Surface Contamination 

Relatively easy to perform Access to entire cable not 

required 

Can detect degradation 

sites prior to failure in service 

Step Voltage Test (DC High Voltage) 

Diagnostic 

Low- and Mediumvoltage cables All insulation and jacket 

materials 

Elevated Temperature Radiation exposure Mechanical stress Voltage stress & 

Moisture exposure 

Submergence Exposure to chemicals 

and other surface contaminants 

Thermally induced 

embrittlement and cracking 

Radiation induced 

embrittlement and cracking 

Mechanical damage Water treeing Moisture intrusion Surface Contamination 

Relatively easy to perform Provides trendable data 

on commonly used cable insulation materials 

Access to entire cable not 

required 

Time Domain Reflectometry 

Pass/Fail or Diagnostic 

Low- and Mediumvoltage cables All insulation and jacket 

materials 

Elevated Temperature Radiation exposure Mechanical stress 

Thermally induced 

cracking 

Radiation induced cracking Severe mechanical 

damage 

Provides useful 

information for identifying and locating potential defects in cable 

Nondestructive 

Infrared Thermography 

Pass/Fail 

Low- and Mediumvoltage cables All insulation and jacket 

materials 

Elevated Temperature Ohmic heating 

Thermally induced 

embrittlement and cracking 

Relatively easy to perform Properly corrected data 

identifies temperature and location of hot spots 

Measurements can be 

made when circuit is 

3-17 
3-18 

CM Technique Test Type Applicable Cable Categories and Materials Applicable Stressors Aging Mechanisms Detected Advantages 

operating at full load 

Data may be stored and 

trended with appropriate software 

Non-destructive, nonintrusive, does not 

require cable to be determinated 

Illuminated Borescope 

Screening 

Inaccessible Low- and 

Medium-voltage cables 

All insulation and jacket 

materials 

Mechanical stress Submergence Exposure to chemicals 

and other surface contaminants 

Mechanical damage Potential for moisture 

intrusion 

Surface Contamination 

Relatively easy to perform Can be performed on 

inaccessible cables to detect the presence of stressors 

Line Resonance Analysis 

Diagnostic 

Low- and Mediumvoltage cables All insulation and jacket 

materials 

Elevated Temperature Radiation exposure Mechanical stress 

Thermally induced 

embrittlement and cracking 

Radiation induced 

embrittlement and cracking 

Severe mechanical 

damage 

Can be performed in situ 

without determinating the cable 

The effects of loads 

attached to the cable can be accounted for in the analysis of results. 

Can locate localized 

degradation. 

Laboratory CM Techniques 

Elongation-atBreak Diagnostic 

Low- and Mediumvoltage cables All insulation and jacket 

materials 

Elevated Temperature Radiation exposure 

Thermally induced 

embrittlement 

Radiation induced 

embrittlement 

Provides information on 

insulation condition that can be correlated with electrical performance 

Proven technique for 

monitoring material condition 

Data is trendable 

Oxidation Induction Time Oxidation Induction 

Diagnostic 

Low- and Mediumvoltage cables Most effective for 

Ethylene Propylene Rubber, Polyethylene, 

Elevated Temperature Radiation exposure 

Thermally induced 

embrittlement 

Radiation induced 

embrittlement 

Provides information on 

insulation condition that can be correlated with electrical performance 

Considered non3-19 

CM Technique Test Type Applicable Cable Categories and Materials Applicable Stressors Aging Mechanisms Detected Advantages Temperature and Cross-Linked 

Polyethylene materials 

destructive since only a small sample of insulation material is required 

Fourier Transform Infrared Spectroscopy 

Diagnostic 

Low- and Mediumvoltage cables Most effective for 

Ethylene Propylene Rubber, Polyethylene, and Cross-Linked Polyethylene materials 

Elevated Temperature Radiation exposure 

Thermally induced 

embrittlement 

Radiation induced 

embrittlement 

Provides information on 

insulation condition that can be correlated with electrical performance 

Considered nondestructive since only a 

small sample of insulation material is required 

Density Diagnostic Low- and Medium voltage cables 

Most effective for 

Ethylene-Propylene Rubber, Polyethylene, Polyvinyl Chloride, Chlorosulfonated Polyethylene, and Neoprene® materials 

Elevated Temperature Radiation exposure 

Thermally induced 

embrittlement 

Radiation induced 

embrittlement 

Provides information on 

insulation condition that can be correlated with electrical performance 

Considered nondestructive since only a 

small sample of insulation material is required 
 

3.4 Factors to be Considered in Selecting CM Techniques

There are several factors that must be considered in selecting an appropriate CM inspection or 

testing technique for the cable to be monitored. The following discussion provides guidance 

that can be used in selecting CM techniques. Section 4.5 provids additional guidance and 

information on the selection of CM inspection and testing techniques for electric cables in a 

cable CM program (element 5 of the cable CM program). It also provides a detailed description 

of the selection process and how it integrates with the other essential elements of the 

monitoring program. 

3.4.1 Intrusiveness 

The intrusiveness of the CM technique is a factor to consider in selecting a CM technique. A 

sensible approach is to start with the least intrusive technique and increase the intrusiveness 

only if it is warranted based on the results or past operating experience. As such, screening 

techniques, such as the visual inspection or illuminated borescope inspection are considered a 

good first choice to determine whether there is any evidence of cable degradation depending on 

the accessibility to the full length of the cable and its condition. A decision can then be made to 

perform more intrusive testing or not based on the results of the screening inspections. 

In their response to Generic Letter 2007, utilities listed several cable condition monitoring, 

inspection, and preventive maintenance programs that are currently used. The NRC reviewed 

these activities and concluded that, while they do not provide diagnostic information, they do 

contribute to delaying cable degradation or providing gross failure indication [Ref. 8]. Several of 

these activities can also be used as indicators for the need for more intrusive condition 

monitoring. These activities are the following: 

 Trending cable issues in the corrective action program 

 Testing cables for continuity and/or functionality 

 Ground detection systems 

 License renewal commitments 

 Visual inspections of cables, terminations and tray supports 

 Water abatement programs 

Any one or combination of these activities could provide useful information for making a 

decision to perform more intrusive CM testing. 

3.4.2 Cable Characteristics 

Once a decision is made to perform more intrusive testing, the characteristics of the cable to be 

monitored must be considered in selecting an appropriate technique. The following factors 

should be considered: 

 Cable voltage rating 

 Cable insulation/jacket material 

 Cable shielding 

 Cable location 

 Active stressors 

 Aging mechanisms to be detected 

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3-21 

The overview of condition monitoring techniques presented previously discussed the 

applicability of each technique and can be used as guidance for selecting an appropriate 

technique for a specific application. Table 3.2 presents a matrix summarizing the most common 

cable aging stressors and aging mechanisms, linked to various potential condition monitoring 

techniques that can be used to detect them.

Table 3.2 Cable Condition Monitoring Technique Selection Matrix 

Applicable Condition Monitoring Technique 

Screening Pass/Fail Diagnostic 

(Shading indicates laboratory test – sample needed) 

Stressor Aging Mechanism 

Visual Borescope 

Insulation Resistance AC Voltage withstand Hi Potential IR Thermography Time Domain Reflectometry Compressive Modulus Dielectric Loss Polarization Index Partial Discharge Step Voltage Line Resonance Analysis 

Elongation-at-Break Oxidation Induction Time/Temp IR Spectroscopy Density 

Embrittlement 

Elevated ● ● ● ● ● ● ● ● ● ● ● ● ●

Temperature Cracking ● ● ● ● ● ● ● ● ● ●

Embrittlement 

Radiation ● ● ● ● ● ● ● ● ● ● ● ●

Exposure Cracking ● ● ● ● ● ● ● ● ●

Mechanical 

Damage Mechanical ● ● ● ● ● ● ● ● ●

Stress 

Wear ● ●

Voltage Stress & 

Moisture 

Exposure 

Water Treeing 

● ● ● ● ●

Humid 

Environment 

Moisture Intrusion 

● ● ● ● ● ●

Submergence 

Moisture Intrusion ● ● ● ●

Contaminants Surface 

Contamination ● ● ● ● ● ● ● ●

Multiple CM techniques should be utilized to effectively monitor the condition of a cable since no 

single technique can completely characterize the condition of a cable and its insulation. [Ref.9] 

For cables that are exposed to several different stressors, a combination of different CM 

techniques may be warranted to ensure that all aging mechanisms are addressed. Section 4.5 

provides additional guidance and information on the selection of CM inspection and testing 

techniques for electric cables in a cable CM program (element 5 of the cable CM program). 
 

4. ESSENTIAL ELEMENTS OF A CABLE CONDITION MONITORING 

PROGRAM 

In this section of the report, nine essential elements that constitute an effective cable condition 

monitoring (CM) program are presented. 

These elements are as follows: 

1. Selection of cables to be monitored 

2. Development of database for monitored cables 

3. Characterize and monitor service environments 

4. Identify stressors and expected aging mechanisms 

5. Select CM techniques suitable to monitored cables 

6. Establish baseline condition of monitored cables 

7. Perform test & inspection activities for periodic CM of cables 

8. Periodic review & incorporation of plant & industry experience 

9. Periodic review & assessment of monitored cables condition 

Each element will be described in detail in the following subsections. The purpose for each of 

the individual elements of the cable CM program will be presented along with how the element 

fits into the overall cable CM program. Guidance will be provided for implementation of the 

important features or activities associated with the program element. Finally, the expected 

results or outcomes of each program element will be described. The guidance will also provide 

information needed to integrate each element into the overall cable CM program. Figure 4.1 

presents a block diagram showing the elements of the cable CM program and their principle 

interactions. 

4.1 Selection of Cables to be Monitored 

The purpose of the first element of the program is to identify and select electric cables that are 

candidates for inclusion in the cable condition monitoring program. Power, instrumentation, and 

control cables that have high safety significance, high plant risk significance, or are important to 

continued safe operation of the plant would form the core group of cables to be included in the 

program. Generally, these cables have either a direct safety-related function, are required to 

achieve and maintain safe shutdown, or are required to mitigate the consequences of design 

basis accidents. These would also include, computer and digital I&C cables that have a safetyrelated function or are required for mitigation of the consequences of an accident. 

Much of the cable selection process for implementing a cable CM program is already guided by 

Title 10 to the Code of Federal Regulations, Part 50 (10 CFR 50), requirements applying to the 

licensing and operation of commercial nuclear power plants. The design criteria for nuclear 

plant systems, structures, and components, which include electric power cables and 

instrumentation and controls (I&C) cables, are given in Appendix A to 10 CFR 50. 

More specifically, as related to the safety function of electric cables, 10 CFR 50, Appendix A, 

General Design Criterion 4 (GDC 4), “Environmental and Dynamic Effects Design Bases,” 

states that “structures, systems and components important to safety shall be designated to 

accommodate the effects of and to be compatible with the environmental conditions associated 

with normal operation.” GDC 17, “Electric Power Systems, “requires that onsite and offsite 

electrical power systems “be provided to facilitate the functioning of structures, systems and 

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4-2 
 

components important to safety,” and that “provisions must be included to minimize the 

probability of losing electric power from any of the remaining [electric power] supplies as a result 

of, or coincident with, the loss of power generated by the nuclear power unit, the loss of power 

from the transmission network, or the loss of power from the onsite electric power supplies.” 

Finally, GDC 18, “Inspection and Testing of Electric Power Systems,” requires that “electric 

power systems important to safety shall be designed to permit appropriate periodic inspection 

and testing of important areas and features, such as wiring, insulation, connections and 

switchboards, to assess the continuity of the systems and the condition of their components,” 

and that “... systems shall be designed with a capability to test periodically (1) the operability 

and functional performance of the components of the systems..., and (2) the operability of the 

systems as a whole..., including operation of applicable portions of the protection system, and 

the transfer of power among the nuclear power unit, the offsite power system, and the onsite 

power system. 

Other NRC regulations that would guide the selection of cables for the cable CM program are: 

fire protection (Appendix R to 10 CFR 50 and 10 CFR 50.48), environmental qualification of 

electric equipment important to safety (10 CFR 50.49), the station blackout rule (10 CFR 50.63), 

the maintenance rule (10 CFR 50.65), plant license renewal requirements (10 CFR 54), 

anticipated transients without scram (ATWS) (10 CFR 50.62), and protection against 

pressurized thermal events (10 CFR 50.61). Each of these regulations is discussed below as it 

relates to the selection of cables for a condition monitoring program. 

All licensees are required to maintain plant design control documentation, installation and 

construction records, cable systems installation, maintenance, and operating procedures, 

testing and inspection documentation, cable procurement documentation, and other quality 

control records in accordance with the requirements of Appendix B to 10 CFR 50, quality 

assurance criteria for nuclear power plants. As a result, the existing plant listing of safetyrelated electric power cables and I&C cables can serve as the core listing of cables to be 

included in the cable CM program. The licensee’s listing of environmentally qualified (EQ) 

Class 1E electric cables, as defined in 10 CFR 50.49 and IEEE Std. 323-1974 [Ref. 32], will be 

a subset of the entire listing of safety-related cables in the plant. However, since there may be 

some non-safety-related cables that are specified with environmental qualification requirements 

as a result of potential exposure to other-than-mild, or locally adverse, service environments, 

the listing of EQ cables should be reviewed to determine whether there are any cables in this 

category that should be added to the list of cables for the CM program. 

Electric power cables, circuit systems, and I&C cables that are designed to satisfy the 

requirements for loss of all alternating current power in a light-water cooled nuclear power plant 

as defined in 10 CFR 50.63 (the station blackout rule) should be identified and included in the 

cable CM program. Because of the importance of the alternate ac (AAC) power source in the 

plant’s capability to withstand station blackout, the function of all the power circuits and I&C 

circuits associated with connection, control, and monitoring of the AAC power supply to the 

plant must be ensured. This may be even more critical in a multiple unit plant with shared AAC 

power sources or shared onsite emergency power sources. Consequently, it is recommended 

that all of the power and I&C cables associated with satisfying the requirements of 10 CFR 

50.63 be included in the listing of cables to be monitored in the cable CM program. 

In compliance with the requirements of 10 CFR 50.65 (maintenance rule), licensees are 

required to implement a program for monitoring the performance or condition of all structures, 

systems, and components within the scope of the maintenance rule, against licensee–

established goals, in a manner sufficient to provide reasonable assurance that these structures, 

4-3 
 

systems, and components are capable of fulfilling their intended functions. The scope of the 

maintenance rule monitoring program, as defined for safety-related and non-safety-related 

structures, systems, and components in 10 CFR 50.65, paragraph (b), will encompass a group 

of electric power and I&C cables of high importance. It is recommended that cables in the 

scope of the maintenance rule be included in the cable CM program. 

Each licensee is required to develop and implement a plant fire protection plan and program in 

accordance with the requirements of 10 CFR 50.48 and Appendix R to 10 CFR 50. The fire 

protection program will designate the structures, systems, and components that are to be 

protected against fire damage in each fire area of the plant so that the capability to achieve and 

maintain safe shutdown is ensured in accordance with the fire protection regulations. It is 

recommended that the list of protected electric cable circuits in the station fire protection 

program necessary to satisfy the requirements of the fire protection regulations be added to the 

list of monitored electric power and I&C cables for the cable CM program. 

The scope of safety-related and non-safety-related systems, structures, and components within 

the license renewal regulation is defined in 10 CFR 54.4. These can include electric cables, 

conductor insulation material, and cable accessories. Table 6 of NUREG-1801, the GALL 

Report, Volume 1, Revision 1, and Section XI of Volume 2, Revision 1 [Ref. 33], identify several 

license renewal aging management programs (AMPs) for electrical equipment that affect 

electric cables, connections, and fuse holders. These are: 

XI.E.1 Electrical Cables and Connections Not Subject to 10 CFR 50.49 Environmental 

Qualification Requirements 

XI.E2 Electrical Cables and Connections Not Subject to 10 CFR 50.49 Environmental 

Qualification Requirements Used in Instrumentation Circuits 

XI.E3 Inaccessible Medium-Voltage Cables Not Subject to 10 CFR 50.49 

Environmental Qualification Requirements 

XI.E5 Fuse Holders 

XI.E6 Electrical Cable Connections Not Subject to 10 CFR 50.49 Environmental 

Qualification Requirements

The electric cables, connectors, and accessories that are identified as being within the scope of 

the above license renewal aging management programs are candidates for inclusion in the 

cable CM monitoring program. Cable monitoring activities under these license renewal AMPs 

may be no more than an evaluation of periodic surveillance testing results to identify the 

existence of cable aging degradation. Consequently, the cable systems and accessories within 

the scope of the license renewal evaluation could be included in the cable CM program, where 

they would be given more detailed and extensive inspections, monitoring tests, and condition 

evaluation to ensure their proper function. 

Another important source of guidance for the selection of cables to be included in the CM 

program is operating experience. This ties in with program element 8, review and incorporation 

of operating experience, discussed in subsection 4.8, and program element 9, periodic review 

and assessment of cable condition, discussed in subsection 4.9 of this report. The operating 

and failure experience with electric cable systems and accessories gathered throughout the 

nuclear industry is a valuable source of information that can alert licensees to generic problems 

that can affect the electric cables installed in nuclear power plants. These problems include 

manufacturing defects, deficient installation practices, unusual susceptibilities to service 

conditions, frequently-encountered adverse local conditions, and generic application problems. 

Adverse conditions in service environments, incompatible cable configurations, incompatible 

4-4 
 

combinations of insulating or jacket materials, improperly applied cable accessories, and other 

cable system vulnerabilities may appear over time within a single plant or throughout the 

nuclear industry. Manufacturers’ bulletins and information letters, NRC correspondence and 

information notices, NRC and industry cable aging evaluation studies, and industry databases, 

such as the Institute for Nuclear Plant Operations’ (INPO) Nuclear Plant Reliability Data System 

(NPRDS), the INPO Equipment Performance and Information Exchange (EPIX) reporting 

system, and the NRC’s Licensee Event Report (LER) database, are good sources for identifying 

generic problems in cable systems and informing licensees of problems so that corrective 

actions, such as increased cable CM, can be implemented. Operating and failure experience 

within one’s own plant, if properly identified, documented, and periodically evaluated, can also 

provide guidance on the selection of groups of cables that have common characteristics, 

materials, or applications that make them candidates for increased scrutiny within the cable CM 

program. Groups of electric cables that are exposed to and affected by similar adverse service 

environments, such as flooding of underground cable duct banks and manholes, should be 

included, along with their service environments, in the cable CM program so that the adverse 

service conditions, and the potentially increased rate of degradation of cable insulating 

materials, may be monitored more thoroughly and more frequently. 

A final category of cables that is recommended for inclusion in the cable monitoring program 

would be those cables that could cause a plant trip or transient . These are circuits that may not 

be directly credited with a nuclear safety function or support functions that are important to 

nuclear safety, however, their availability has been identified for avoiding plant transients. This 

improves overall plant stability, thereby reducing challenges to electric power safety systems 

The end result of the licensee’s cable selection process will be a listing of all the most important 

cables in the plant whose condition should be periodically monitored and evaluated to assure 

that they are capable of performing their intended function. The characteristics, application, 

operating environment, CM inspection and test data, and condition of the selected cables will be 

incorporated into the cable CM program database discussed in the following subsection. 

4.2 Database of Monitored Cables

The second element of the cable CM program is the database for the electric cables that are to 

be monitored under the program. The purpose of the cable CM program database is to provide 

a single centralized source of information for the cables in the program so that the cable 

monitoring program engineer can access, analyze, and evaluate the documentation and data 

necessary to make cable condition assessments and to guide the direction of program decisions 

and activities. The database will document: physical characteristics of cable systems in the 

program, details of installation and service environments (described in subsections 4.3 and 4.6), 

baseline CM test and inspection results (described in subsections 4.3 and 4.6), periodic CM test 

and inspection results (described in subsection 4.7), and periodic condition assessments and 

corrective actions (described in subsections 4.8 and 4.9). 

Referring to Figure 4.1, it can be seen that the monitored cables database serves as a key 

element in the CM program in that it assimilates information and data from every other element 

in the program to provide a source of documentation that can be accessed, analyzed, and 

evaluated. By bringing together information on the physical characteristics of cables in the 

program with periodic inspection and condition monitoring results, the cable engineer has a 

ready resource of relevant information for assessing the present condition of each cable in the 

program. Quantitative test measurements can be analyzed and trended against baseline 

4-5 
 

measurements to assess changes in cable parameters and track degradation of insulating 

materials. These can be combined with baseline inspection data and periodic inspection results 

to make an informed assessment of cable condition. Installation information and periodic 

environmental monitoring measurements can be reviewed to verify that operating conditions 

have remained within the environmental parameters specified in the original plant design. The 

engineer can also verify that the service conditions under which environmentally qualified cables 

and accessories are operating remain within the parameters of their qualified life. Using the 

database, the cable engineer can evaluate the cable condition, operating environment, and 

changes in condition and environment over time to determine whether corrective actions should 

be initiated to manage cable aging as well as any environmental stressors that can affect cable 

aging and performance. 

In order to achieve the aforementioned objectives for supporting the cable CM program, the 

database must contain essential information and data in a user-friendly, sortable, flexible, 

expandable, and accessible form. Sufficient storage capacity must be available to handle the 

various types of data that will be gathered and processed. Commercial database software 

programs, such as Microsoft Access, have been used successfully by the authors in cable 

condition monitoring testing programs and have proven to be versatile enough to accommodate 

CM inspection and test data storage, retrieval, and analysis. The database can be completely 

computer-based. However, a combination of computer-based information and hard-copy 

information keyed and linked to a computer-based list of cables and cable data may be 

preferred by some users. 

It is recommended that the cable systems database include the following essential categories of 

data in order to adequately support a cable CM program: 1) unique cable/circuit identifier, 2) 

cable construction and manufacturing information, 3) application information, 4) cable 

installation and environments information, 5) cable inspections and condition monitoring test 

results, 6) applicable operating experience, and 7) periodic cable evaluation and assessment 

results. Table 4.1 summarizes the recommended major categories of information to be included 

in the CM program database, including the specific items recommended within each category. 

Each item represents cable characteristics that have been shown to have an effect on the 

degradation or damage of electric cable insulation and jacket materials and the overall 

performance of a cable over time. This is summarized in the “purpose” column of Table 4.1. 

Realistically, all of the information listed in Table 4.1 may not be available for every cable in the 

cable CM program. For low-voltage power and I&C cables operating in mild, dry, indoor, abovegrade environments, it is not as critical to have all these data available in the database. 

However, for cable systems operating in harsh environments and with potential exposure to 

locally adverse stressors, these data will allow the cable engineer to access and analyze 

periodic testing and inspection data, identify problem environments or unusual performance 

degradation, and make the link to common factors that may affect other cables with similar 

characteristics, installation locations, or aging stressors. The ability to access, sort, link, trend, 

and analyze up-to-date manufacturing, application, inspection and test data, and operating 

experience is an essential element of the cable CM program. It gives the cable engineer a 

powerful tool enabling him to make informed decisions on modifying periodic testing frequency, 

adding CM tests, or implementing other corrective actions to manage cable degradation and/or 

adverse environmental factors. 

The resulting database will provide essential information to support the implementation of the 

cable CM testing and inspection activities and the periodic review and assessment of the 

condition of individual cables. The cable CM program database should be maintained and 

4-6 
 

4-7 

administratively controlled to obtain the maximum utility from the database and to optimize the 

effectiveness of the cable CM program. 

4.3 Characterize and Monitor Environments

The third element of the cable CM program is the characterization and monitoring of the service 

environments in which the cables in the CM program will be operating. By characterizing the 

conditions in a cable’s normal operating environment and identifying any sections of a cable run 

that could be exposed to potentially more severe adverse conditions, the cable engineer can 

determine the global and local stressors that could cause a significant increase in the rate of 

aging degradation or other damage to a cable (see cable CM program element 4, discussed in 

subsection 4.4). The cable engineer will also use the environmental information to determine, 

and document in the database, the frequency for the performance of periodic cable inspections 

and condition monitoring testing, the frequency for periodic monitoring and verification of global 

environmental conditions, and the frequency for monitoring the status of any adverse local 

environmental “hot spots” (local adverse stressors) that have previously been identified. 

Identifying the locations of environmental “hot spots” will also help the cable engineer to specify 

more frequent or more detailed CM inspection and testing for those cable circuits, or sections of 

the cable circuits, that are exposed to the identified local adverse stressors (see subsections 

4.6, 4.7, and 4.9). 

It should be emphasized that the occurrence of cable system operating environments or locally 

adverse conditions that are unanticipated or more severe than the original plant design may 

constitute a design deficiency of the cable system, specifically, a potential violation of GDC 1, 4, 

17, and 18. NRC regulations, such as 10 CFR 50, Appendix B, (quality assurance), the 

maintenance rule (10 CFR 50.65), and environmental qualification regulations (10 CFR 50.49), 

require that programs and administrative controls be established to monitor and detect 

degraded conditions on a regular basis and to promptly implement effective corrective actions 

and design modifications, consistent with its safety significance, so that any further cable 

degradation is minimized. A cable system must be designed to meet all applicable regulations 

and to perform its intended function in the plant environment under all anticipated operational 

occurrences and design basis events. 

This element consists of three groups of activities: 1) characterization of the cable system’s 

operating environment, 2) periodic monitoring and verification of operating environments and 

identified local adverse environmental “hot spots,” and 3) managing environmental conditions to 

mitigate the effects on cable systems. Guidance for implementing the activities in this element 

will be discussed in the following subsections. 

4.3.1 Characterizing Cable Operating Environments 

Characterization of the cable system’s operating environments is necessary to establish and 

document the actual baseline environmental conditions that the cable system will be exposed to 

during normal operations. It is accomplished by: 

 review of the design, specification, and installation documentation for the cable circuit, in 

order to locate the routing of the cable circuit throughout the plant; 
Table 4.1 Recommended Categories of Information to be Included in a Cable CM Program Data

Database Item Expected data or format PurposeUnique Electric Cable/Circuit IdentifierCable/Circuit ID Number alpha/numeric ID uniquely identifies a monitored cable Cable Construction and Manufacturing InformationManufacturer Manufacture Date Purchase Order/Date Insulation Material 

Conductor Insulation Color Activation Energy 

Jacket Material/Bonded 

Overall Jacket Color Conductor Jacket Color Activation Energy 

Filler Materials Cable Configuration 

Number of Conductors Conductor Size Conductor Stranding Conductor Material Ground Conductor/Material Shielding/Material/Type 

Temperature Rating Special Qualification/Documentation 

manufacturer name date PO number and date polymer (XLPE, EPR, SR, CSPE) color value (eV) at reference temp polymer/bonding (if applicable) color color value (eV) at reference temp polymer number of conductors AWG conductor size number of strands Cu, Al, other Cu, Al, other (if applicable) Cu, Al, other (if applicable) & type value EQ, seismic, hi-rad, hi-temp, FR 

uniquely identifies cables from a certain manufacturer used for age calculation and identifying polymer formula by daused to match cable to purchase specifications and age calcucharacteristic that can affect aging/degradation/performance characteristic that can affect aging/degradation/performance used in Arrhenius equation time-temperature calculation characteristic that can affect aging/degradation/performance characteristic that can affect aging/degradation/performance characteristic that can affect aging/degradation/performance used in Arrhenius time-temperature calculation characteristic that can affect aging/degradation/performance characteristic that can affect aging/degradation/performance characteristic that can affect aging/degradation/performance & characteristics that can affect aging/degradation/performance 

4-8 
Application Information

Function Type Voltage Safety Class EQ Required Additional Regulatory Requirements Energization Status 

power, instrumentation, control ac, dc, digital value and/or level Class 1E or non-Class 1E EQ or non-EQ SBO, FP, Maint. Rule, Lic. Renewal continuous, emergency only, control signals 

only, intermittent, etc. 

characteristic that can affect aging/degradation/performancharacteristic that can affect aging/degradation/performancharacteristic that can affect aging/degradation/performanaffects safety significance & application affects safety significance & application affects safety significance, importance, & application characteristic that can affect aging/degradation/performan

Cable Installation and EnvironmentsRouting Information 

Location(s) Drawing Reference(s) Raceway Type/ID Length in Each Type Orientation(s) 

Installation Date Terminations 

Type(s) Location(s) 

Splices/Accessories ID Number(s) 

Type(s) Location(s) Installation Date(s) EQ Req’d 

Environment(s)/Stressors 

Normal Operating Temp(s) Normal Radiation Dose Rate Adverse Local Environments 

Type(s) Location(s) CAP Number(s) Date(s) 

Adverse Local Stressors 

Type(s) Location(s) CAP Number(s) Date(s) 

bldg & plant locations drawing numbers conduit, tray, UG duct & ID numbers length horizontal, vertical date pigtails, terminal block, bushing, lug equipment/termination ID accessory type eqpt./raceway/cable ID number date yes/no temperature value radiation dose value temp,rad,steam,water,vibration,etc. eqpt./raceway/cable ID number corrective action program ref no date condition observed heat,rad,chems,water,vibration,etc. eqpt./raceway/cable ID number corrective action program ref no date condition observed 

used to characterize operating environment & adverse localused determine service age and to calculate thermal equivaused to characterize cable termination used to characterize cable splices characterize normal and adverse localized service condition

4-9 
Cable Inspections & CM Testing Results

Cable Baseline Visual Inspection 

Procedure Results Date 

Cable Baseline CM testing 

Procedure Results Date 

Periodic Visual Condition Inspection 

Procedure Frequency Results Date 

Periodic CM Baseline CM testing 

Procedure Frequency Results Date 

Applicable Surveillance Tests 

Procedure/Surv. Number Frequency Results Date 

inspection procedure number baseline inspection results date test procedure number condition measurement data date test procedure number performance frequency periodic inspection results date test procedure number performance frequency condition measurement data date test procedure/surveillance number performance frequency calibration/functional test data date 

characterize cable baseline condition & local adverse envirocharacterize cable baseline condition & local adverse enviroperiodic characterization of cable condition and service enviperiodic characterization of cable condition and service envicalibration/functional surveillance test results 

4-10 
Applicable Operating Experience

Manufacturer’s Notifications 

Type Reference Date CAP Number(s) Corr. Action(s) Implemented Date(s) 

Industry Notifications 

Type Reference Date CAP Number(s) Corr. Action(s) Implemented Date(s) 

NRC Notifications 

Type Reference Date CAP Number(s) Corr. Action(s) Implemented Date(s) 

Internal Operating/Failure Experience 

Type Date CAP Number(s) Corr. Action(s) Implemented Date(s) 

SIL, TIL, mfg’s literature document number document date corrective action program ref. no. yes/no/in review/in progress date(s) INPO Rpt, EPRI Rpt, EEI Rpt document number document date corrective action program ref. no. yes/no/in review/in progress date(s) IN, GL, GSI, NUREG Rpts document number document date corrective action program ref. no. yes/no/in review/in progress date(s) Failure, test, maint, inspection date of event corrective action program ref. no. yes/no/in review/in progress date(s) 

document applicable manufacturer’s notifications & plant codocument applicable industry notifications & plant corrective document applicable NRC notifications & plant corrective acdocument applicable in-plant cable-related failures & plant c

4-11 
4-12 

Periodic Cable Evaluation and Assessment ResultsReview Baseline Cable Condition 

Date 

Review Baseline Service Environment 

Date 

Review CM Inspection Results 

Review Frequency Review Date Actions Recommended CAP Number(s) Corr. Action(s) Implemented Date(s) 

Review CM Test Results 

Review Frequency Review Date Actions Recommended CAP Number(s) Corr. Action(s) Implemented Date(s) 

document baseline condition document service environment periodic review of cable condition frequency of review/assessment review cable/environment condition frequency of review/assessment date of review/assessment corrective action(s) corrective action program ref. no. yes/no/in review/in progress date(s) periodic review of cable CM test(s) frequency of review/assessment date of review/assessment corrective action(s) corrective action program ref. no. yes/no/in review/in progress date(s) 

establish baseline condition for comparison of future inspectverify environment within design specs; baseline for future dassess cable condition, remaining life, CM insp. frequency, rassess cable/environment condition, remaining life, CM insp 

 required actions 

assess/trend cable CM data, remaining life, CM test freq., re
 

 review of existing environmental survey information from programs such as radiation 

protection and environmental qualification in order to quantify the environmental 

conditions to which a cable circuit is exposed; 

 in situ measurements of environmental conditions; and 

 initial walkdown visual inspection of the accessible portions of the cable circuit to verify 

the actual in-plant environmental conditions and identify any localized adverse 

environmental conditions that could potentially affect the performance of the cable, 

splices, terminations, or other cable accessories. 

The initial environmental characterization walkdown inspection could be performed in 

conjunction with the baseline visual inspection conducted to establish baseline cable condition 

in support of CM program element 6, described in subsection 4.6. Both activities will make use 

of cable design, specification and installation documentation, require the review of cable circuit 

routing information, and require a physical walkdown of the same accessible sections of each 

cable circuit. Results of the walkdown inspections should be documented in the cable CM 

database. Based upon the results of the environmental walkdown inspection and the baseline 

measurements of the cable operating environment(s), the cable engineer can make a 

determination on the frequency for periodic walkdown inspection and monitoring of a cable 

circuits operating conditions and the frequency for monitoring and inspection of any localized 

adverse environments that had been identified in the initial walkdown. The initial inspection and 

CM testing frequencies for environments thus determined by the cable engineer should be 

documented in the cable CM database. 

The following environmental conditions are the most important factors to be considered when 

characterizing the operating environment of a cable system since they have been shown to 

have an effect on the aging degradation and performance of electric cables: 

 Temperature (high and low) 

 Radiation (type and dose rate) 

 High humidity 

 Moisture (wetting of cable surfaces) 

 Standing water or flooding of cables (submersion of cables) 

 Vibration 

 Dirt and dust 

 Exposure to chemicals or other reactive contaminants 

 Exposure to sunlight (ultraviolet radiation) 

In addition to identifying and documenting the aforementioned conditions during the cable 

system walkdown, the cable engineer should inspect for proximity to heat sources such as high 

temperature steam lines, large uninsulated valve bodies, unit area heaters, and high powered 

lighting fixtures. Storage tanks and piping carrying steam, borated water, hydraulic fluid, or 

other chemicals above, or in proximity to, cable circuits are potential sources of high 

temperature/pressure steam leakage, high temperature exposure, wetting or flooding, and 

exposure to reactive chemicals. Physical contact between polymer-insulated cables and 

structures, plant equipment, piping, thermal insulation, worker stepping, and other objects can 

deform, abrade, or degrade the performance of the cable insulating materials. Vibration of 

electrical cables can occur at the cable terminations to electric drive motors or at the 

terminations to instruments mounted on or near operating machinery or large pipelines. 

4-13 
 

Longer cable circuits may pass through several different operating environments over the length 

of their routing throughout the plant. Each of these variations should be documented in the 

cable CM database. Sections of the cable circuits passing through mild operating environments 

may only require periodic environmental monitoring at extended intervals to verify that operating 

conditions have remained within the expected range of the original design. Portions of the cable 

circuit that pass through areas experiencing more harsh environmental conditions, such as high 

temperature, high radiation, or high humidity, or that are exposed to any localized adverse 

environments identified in the baseline environmental walkdown inspection would be subject to 

more frequent inspection or cable CM testing to monitor and assess the effect on cable 

condition and performance. 

It may be determined during the review of the results of the environmental walkdown that the 

environmental measurements obtained from existing programs, such as radiation protection or 

environmental qualification, are not sufficient to properly quantify environmental conditions in an 

area. The cable engineer may then decide to install supplemental instrumentation and data 

loggers to obtain more accurate measurements of operating conditions. 

Continuously energized power cables located in randomly-filled, heavily loaded cable trays may 

be subjected to unexpectedly high operating temperatures due to internal ohmic heating. If 

these actual operating temperatures are significantly higher than the maximum recommended 

operating temperature for the cable, it can have an adverse effect on the expected operating life 

of the cable. If the cable is an EQ cable and the actual operating temperature exceeds the 

assumed maximum operating temperature at which the cable has been qualified, the qualified 

life may be adversely affected. In cases such as this, periodic measurements of the actual 

temperature in the heavily-loaded cable tray should be obtained to verify that critical design 

parameters have not been exceeded. Enhanced visual inspection using infrared imaging 

condition monitoring equipment may also be used to detect overheating in heavily loaded cable 

trays containing continuously energized power cables 

Many cable circuits, or portions of those circuits, may not be directly accessible for visual 

inspection during environmental characterization walkdown. Cables may be routed through 

conduits, bundled together into heavily loaded cable trays, covered cable trenches, direct 

buried, or routed through underground duct banks making it physically impossible to visually 

inspect them. The cable engineer must then make a technical judgement on how best to 

estimate the cable operating conditions or environments through the use of alternate or indirect 

methods. He may choose to walkdown the ground surface above the route of an underground 

circuit, for example, to verify that there are no potential sources of oil, greases, hydraulic fluid, or 

other chemicals that could leach into the soil along the route of a direct buried cable or into 

underground cable duct banks and cause degradation of cable insulating materials. Conditions 

in inaccessible sections may be estimated from conditions at adjacent accessible sections of a 

cable circuit. 

Further guidance on plant walkdowns that can be applied to cable systems environments can 

be found in Section 6 of IEEE Std. 1205-2000, “IEEE Guide for Assessing, Monitoring, and 

Mitigating Aging Effects on Class 1E Equipment in Nuclear Power Plants,” [Ref. 34] and EPRI 

TR-109619, “Guideline for the Management of Adverse Localized Equipment Environments,” 

Appendices A and B [Ref. 35]. Annex D.4 to IEEE Std. 1205-2000 [Ref. 34] presents an 

extremely useful description and analysis of nuclear power plant environmental conditions and 

environmental stressors as applied specifically to insulated electric cables. Section 2 of EPRI 

TR-109619 provides useful discussions on the types and causes of environmental stressors that 

can also be applied to cable systems [Ref. 35]. 

4-14 
 

The end result of the CM program element 3 characterization of cable operating environment 

activities will be baseline environmental measurements, data, inspection results, and 

identification and location of adverse operating environments for cables selected for monitoring 

in the CM program. The information for each cable circuit is documented in the CM program 

database and will be available for review by the cable engineer under CM program element 9. 

4.3.2 Monitoring Cable Operating Environments 

After the initial walkdown and characterization of a cable system’s operating environment(s), the 

cable engineer can use the results to establish a schedule for periodic monitoring and 

verification of operating environments (see subsection 4.7). The cable engineer can then 

identify those global and local stressors that could potentially cause a significant increase in the 

rate of aging degradation or other damage to a cable (see cable CM program element 4, 

discussed in subsection 4.4). The cable engineer will use the environmental information to 

determine, and document in the database, the frequency for the performance of periodic cable 

inspections and condition monitoring testing, the frequency for periodic monitoring and 

verification of global environmental conditions, and the frequency for monitoring the status of 

any adverse local environmental “hot spots” (local adverse stressors) that have previously been 

identified. 

For cable circuits, or portions of circuits, that are routed through mild environments with no 

identified localized adverse environments, the frequency for periodic walkdowns and verification 

review of the operating environment may be very low. For higher risk cable circuits that have 

exposure to identified localized adverse environments, the periodic environmental review and 

walkdown verification will be conducted on a much more frequent basis. The frequency may 

also be modified, at the discretion of the cable engineer, based on results of periodic condition 

monitoring inspections and testing (program element 7, discussed in subsection 4.7), industrywide and in-plant operating experience and failure history (program element 8, discussed in 

subsection 4.8), or other factors. 

Periodic monitoring of cable environments provides assurance that actual conditions in the field 

are as they had been specified in the original design of the plant, and that the service life of 

cables operating in these areas will be as specified. This is especially important for EQ-required 

cable circuits where the qualified life of the cable is based on testing and analysis of cable 

performance operating in a specified set of operating conditions, such as temperature and 

radiation exposure. If actual conditions vary from the limits upon which the qualification analysis 

was based, the qualified life of the cable will be affected. Localized adverse environments can 

also result in accelerated aging degradation in the locale of the exposure that could have an 

impact on the overall qualified life of the cable. 

For non-EQ cables, design life is based on the manufacturer’s maximum recommended cable 

operating temperature. The cable design life will be shortened by exposure to locally adverse 

environments such as steam lines, hi-temperature piping and valve bodies, missing or 

improperly installed thermal insulation, proximity to area space heaters, or proximity to high 

power lighting fixtures that cause accelerated aging degradation. Newly installed equipment 

and other modifications to implement plant power upgrades can sometimes add enough heat 

load to the environment that it could affect local temperature and overall building temperature. 

Consequently, cable operating environments must be monitored on a periodic basis to 

determine whether any changes have occurred that could make service conditions more severe, 

and to identify any new adverse local conditions that may have developed since the previous 

inspection. 

4-15 
 

During the review of the results of the periodic environmental walkdown, the cable engineer may 

determine that some adverse condition has developed that may require more detailed 

monitoring. The cable engineer may then decide to install supplemental instrumentation and 

data loggers to obtain more accurate measurements of operating conditions. For example, 

higher than expected operating temperatures may be occurring in heavily-loaded cable trays or 

conduits containing continuously-energized power cables as a result of internal ohmic heating. 

In order to quantify the extent and severity of the problem, the cable engineer may decide to 

add temperature monitoring instrumentation to track the actual operating temperature to which 

cables in the tray are exposed, or he may initiate periodic enhanced visual inspection using 

infrared thermal imaging to monitor the condition. 

4.3.3 Monitoring Inaccessible/Underground Cable Circuits 

Special consideration should be given by licensees to the problem of monitoring the operating 

environment for cable circuits routed through inaccessible underground cable ducts and 

conduits, covered cable distribution trenches, and manhole vaults. As discussed below, 

underground cable ducts, conduits, and vaults have proven to be a persistent problem 

throughout the nuclear industry because they can frequently become flooded resulting in power 

and control cables operating in wetted and completely submerged conditions for extended 

periods of time. Most electric cables used in nuclear power plants are designed to operate 

intermittently under high humidity or wetted conditions. However, the majority of these electric 

cables are not qualified to operate continuously in a fully submerged state unless the 

manufacturer has explicitly stated in the cable specification that they have been specifically 

designed, tested, and qualified for continuous submerged operation. 

Since most of these underground distribution systems are largely inaccessible, the wetted and 

flooding conditions remain undetected for extended periods of time. Eventually, power and 

control cables that are not designed to operate in the submerged state will experience early 

failures, often resulting in significant safety consequences. Several of these incidents have 

been brought to the attention of licensees in NRC Information Notice 2002-12, “Submerged 

Safety-Related Cables” [Ref. 7] and, more recently, in NRC Generic Letter 2007-01, 

“Inaccessible or Underground Power Cable Failures That Disable Accident Mitigation Systems 

or Cause Plant Transients” [Ref. 1]. Generic Letter 2007-01 made the observation that cable 

insulation degradation due to continuous wetting or submergence could affect multiple 

underground power cable circuits at a plant site; should one of these medium-voltage cables 

fail, the resulting high-level fault currents and transient voltages would propagate onto the 

immediate power distribution system and potentially fail other systems with degraded power 

cable insulation. 

A similar set of circumstances can arise in above-ground conduits that are susceptible to water 

intrusion but lack sufficient drainage such that the cables routed within the conduits operate in a 

submerged condition for extended periods of time. Since the cable circuits within the conduit 

are inaccessible for visual inspection, the condition can go on unnoticed until early failure of the 

cable occurs. This variation of the submerged circuits problem was brought to the attention of 

licensees in NRC Information Notice 89-63, “Possible Submergence of Electrical Circuits 

Located Above the Flood Level Because of Water Intrusion and Lack of Drainage,” [Ref. 36]. 

If the underground cable circuit includes a cable splice, long-term submergence of the splice 

can also result in unexpectedly early failure of the cable system if the splice is not specifically 

qualified for continuous submerged operation. If a splice is not installed correctly, failure could 

occur even more quickly in the presence of moisture or standing water. NUREG/CR-6788, 

4-16 
 

“Evaluation of Aging and Qualification Practices for Cable Splices Used in Nuclear Power 

Plants,” [Ref. 5] describes numerous incidents of moisture and water intrusion-related splice 

failures in nuclear power plant applications. The report also provides an informative discussion 

of the common stressors and failure mechanisms that can lead to splice failures. 

The chief failure mechanisms affecting power cables operating in the submerged state over 

extended periods of time are described in NUREG/CR-6794, “Evaluation of Aging and 

Environmental Qualification Practices for Power Cables Used in Nuclear Power Plants,” [Ref. 3] 

as follows: 

“Exposure to moisture can also degrade power cables. This can occur for cables 

installed below grade in ducts or conduits that are susceptible to water intrusion, or for 

cables buried directly in the ground. Cables exposed to water while energized are 

susceptible to a phenomenon called ‘water treeing’ in which tree-like micro-cracks are 

formed in the insulation due to electrochemical reactions. The reactions are caused by 

the presence of water and the relatively high electrical stress on the insulation at local 

imperfections within the insulating material, such as voids and contaminant sites, that 

effectively increase the voltage stress at that point in the insulation.” Figure 4.2 shows 

an illustration of a water tree formation in the insulation of a cable. 

“The occurrence of water treeing is well known in XLPE, however, it also is known to 

occur in other insulating materials, such as EPR, polypropylene, and PVC [Ref. 37]. 

Water trees increase in length with time and voltage level, and can eventually result in 

complete electrical breakdown of the cable insulation. Discharges leading to microcracks can also occur at voids and contaminants in the insulation without the presence 

of water. This is known as “electrical treeing” in which discharges occur due to 

ionization of the air or gas in voids, and the energy of the discharge causes breakdown 

of the insulation and the formation of micro-cracks also resembling trees.” 

“Moisture can also cause corrosion of the various metallic components in the cable, such 

as metallic shields or the conductor. In some applications where moisture intrusion is to 

be mitigated, cables with a lead sheath will be used. The lead sheath makes the cable 

impervious to moisture, provided it is properly sealed at splices and terminations. If such 

cable is installed in concrete ducts, free lime from the concrete can be a concern since it 

will form an alkaline environment which can corrode the lead sheath [Ref. 38].” 

Insulation

Conductor

Water Tree

Figure 4.2 Cablecross-section illustrating water tree formation [Ref. 3]

4-17 
 

EPRI TR-103834, “Effects of Moisture on the Life of Power Plant Cables” [Ref. 39], provides 

additional operating experience (pre-1994) and discussion on the effects of moisture, wetting, 

and submergence on the service life of medium-voltage and low-voltage cables. Several 

condition monitoring techniques for the detection of moisture are also presented and their 

advantages and disadvantages are discussed. 

In GL 2007-01, licensees were requested to provide failure history information for power cables 

within the scope of 10 CFR 50.65 (the Maintenance Rule) and a description of inspection, 

testing, and monitoring programs to detect degradation of inaccessible or underground cables 

supporting systems within the scope of 10 CFR 50.65. The licensee responses to the 

requested information were analyzed and described by the NRC in a summary report [Ref. 8]. 

The summary report indicated that 93% of the cable failures analyzed occurred on normally 

energized power cables. More than 46% of the failures were reported to have occurred while 

the cable was in service and more than 42% were identified as “testing failures” in which cables 

failed to meet testing or inspection acceptance criteria. The failure data showed a trend toward 

early failure, the majority occurring in the range of 11-20 years of service and 21-30 years of 

service; this is shorter than the plants’ original 40-year licensing period. The NRC staff noted in 

its conclusions that “...the predominant factor contributing to cable failures at nuclear power 

plants appears to be the presence of water/moisture or exposure to submerged conditions.” 

The data in Reference 8 also showed that more than 36% of the reported failures occurred on 

power cables of 2000Vac or less. These data indicate that long-term submergence in water and 

moisture intrusion can drive insulation degradation mechanisms that can affect the dielectric 

strength of insulation materials in both low- and medium-voltage cables, even when they are 

normally deenergized. 

In the summary report of licensee responses to GL 2007-01 [Ref. 8], the NRC further concluded 

and recommended that: 

 “Licensees have identified failed cables and declining insulation resistance properties 

 through current testing practices; however, licensees have also reported that some 

failures may have occurred before the failed condition was discovered. Although the 

majority of in-service and testing failures have occurred on cables that are normally 

energized, the staff is concerned that additional cable failures have not been identified 

for cables that are not normally energized or tested. The NRC staff recommends that 

the licensees should also include normally deenergized cables in a cable testing 

program. It appears that no manufacturer or insulation type is immune from failure. In 

addition, licensees have identified failures and/or declining performance capabiolity of 

both shielded and unshielded cables.” 

Clearly, underground cable environments needed to be monitored for the presence of moisture 

or standing water. However, due to the inaccessibility of these cable circuits, indirect methods 

for inspection and measurement must be considered. Visual inspection for moisture or standing 

water, or the signs of flooding, such as accumulations of sand, mud, and silt or flooding high 

water marks, could be performed at accessible manhole vaults or cable pull boxes along the 

length of an underground duct bank. Site survey data on the elevations of the manhole vaults 

along the underground cable duct bank can then be used to determine whether manhole 

flooding has affected connected cable ducts. If available, site hydrological data on water table 

depth and how the water table is affected by site precipitation or the water surface level in 

nearby bodies of water can also be used to determine where underground cable flooding may 

be occurring. Illuminated borescopes, such as those used for internal inspection of pipelines, 

4-18 
 

can be routed down into underground duct banks or conduits to visually inspect for standing 

water or the signs of flooding, such as accumulations of sand, mud, and silt. Cable conduits 

that are above flood level elevation, but are susceptible to moisture intrusion, such as described 

in Information Notice 89-63 [Ref. 36], can be checked for water accumulation using ultrasonic 

inspection at low points. 

Some of the condition monitoring tests for cables performed for implementation of element 7 of 

the cable CM program, described in subsection 4.7, can be used to detect and locate the 

presence of water along the length of an electric cable. Time domain reflectometry (TDR), the 

ECAD inspection system, and the newer line resonance analysis (LIRA) technique, which are 

described in Section 3 of this report, may be able to accomplish this. 

The results of electrical property measurement CM tests from program element 7 that can 

detect water treeing or the degradation of insulation dielectric strength resulting from water 

treeing could be reviewed as another indirect method for determining whether it is or has been 

operating in a submerged condition. CM measurement techniques such as insulation 

resistance/polarization index testing, dc high potential testing, and VLF withstand testing, can be 

used to check the condition of cables that may be exposed to water. Test results indicating 

weakened dielectric strength, or trends of unusually rapid deterioration of dielectric strength 

between successive testing periods, could be an indication of power cables operating in a 

submerged condition over extended periods of time. 

The output results of the CM program element 3 monitoring of cable operating environment 

activities will be periodic environmental measurements, data, and inspection results for global 

and local cable operating environments for those cables selected for monitoring in the CM 

program. The periodic environmental monitoring information for each cable circuit is 

documented in the CM program database. These data, together with the baseline 

environmental characterization information, and will be available for review by the cable 

engineer under CM program element 9, in order to make decisions on managing cable 

operating environments.

4.3.4 Managing Cable Operating Environments 

The next step for the cable engineer, performed under CM program element 9 (see subsection 

4.9), will be to review the results of the periodic cable systems environmental monitoring 

activities on a regular basis. The periodic environmental inspection and monitoring data can be 

compared to the baseline environmental data to identify any significant changes in the operating 

conditions to which cables systems are exposed, or to note the emergence of new locally 

adverse environments, not previously identified. The cable engineer will use this environmental 

information, together with CM inspection and test results (from CM program element 7), 

operating experience information (from CM program element 8), and other information in the 

database, to decide how to best manage the evolving changes in operating conditions or locally 

adverse cable environments in order to mitigate or minimize the effects that the severe 

stressors can potentially have on cable degradation, performance, and service life. 

If unanticipated or locally adverse cable system operational environments are detected through 

periodic monitoring of cable environments or other reported observations, the cable engineer 

can implement one or more of the following responses for the affected cable(s), consistent with 

its safety significance: 

4-19 
 

 perform more frequent CM testing and environmental inspections to more closely 

monitor the cable condition 

 add more CM tests that will more closely monitor the status of the specific aging 

mechanisms associated with the environmental stressors and the cable condition 

 perform more frequent periodic review and condition assessment of the affected cable’s 

condition (program element 9) and initiate corrective actions as required 

 protect the cable from the adverse environment to reduce or eliminate the effects of the 

associated stressors 

 identify the root cause of the adverse environmental condition and implement 

modifications, maintenance, or other corrective actions to address and correct the root 

cause of the adverse condition 

It should be emphasized that the occurrence of cable system operating environments or locally 

adverse conditions that are unanticipated or more severe than the original plant design may 

constitute a design deficiency of the cable system, specifically, a potential violation of GDC 1, 4, 

17, and 18. NRC regulations, such as 10 CFR 50, Appendix B, (quality assurance), the 

maintenance rule (10 CFR 50.65), and environmental qualification regulations (10 CFR 50.49), 

require that programs and administrative controls be established to monitor and detect 

degraded conditions on a regular basis and to promptly implement effective corrective actions 

and design modifications, consistent with its safety significance, so that any further cable 

degradation is minimized. A cable system must be designed to meet all applicable regulations 

and to perform its intended function in the plant environment under all anticipated operational 

occurrences and design basis events. 

Further guidance and a suggested methodology for management of adverse localized 

equipment environments that can be applied to cable systems environments can be found in 

Section 3 of EPRI TR-109619, “Guideline for the Management of Adverse Localized Equipment 

Environments” [Ref. 35]. 

4.4 Identification of Cable Stressors and Aging Mechanisms

The fourth element of the cable CM program is the identification of stressors affecting cable 

systems and their associated aging/failure mechanisms. By identifying these stressors, and 

quantifying their severity, the cable engineer can determine the primary aging and failure 

mechanisms that will affect each cable circuit. These are the processes that the cable CM 

program inspection and testing activities must be able to detect and monitor, since they can 

cause degradation or other damage that may, over time, lead to the ultimate failure of a cable 

system. This information may then be used by the cable engineer, in cable CM program 

element 5, to select the most effective CM inspection and testing techniques for detecting and 

monitoring the anticipated aging/failure mechanisms. 

Subsection 2.2.2 of this report describes the FMEA analytical approach applied to identify the 

piece-parts of an electric cable (e.g., insulation, jacket, conductor) and to analyze the stressors 

that can affect the material(s) in each piece-part of a particular type of cable in a specific 

application and operating environment. The aging and degradation mechanisms caused by 

exposure of cable materials to various stressors can cause a steady, and sometimes rapid, 

4-20 
 

degradation of the cable insulation integrity, performance, and dielectric strength. Since the 

degradation process can eventually result in one of the cable failure modes, it is essential that 

the stressors, and the aging and degradation mechanisms that they can cause, be identified 

early and periodically monitored by the cable CM program activities. Corrective actions can 

then be implemented to prevent early in-service cable failures. 

The FMEA process was applied to the common materials that make up the piece-parts of typical 

electric power cables and I&C cables used in nuclear power plants. Anticipated in-service 

environmental stressors, such as those listed in subsection 4.3.1, are analyzed to identify the 

potential aging and degradation mechanisms that can affect the common cable materials used 

to construct the piece-parts of the cable. Anticipated in-service operational stressors are 

similarly analyzed. Table 2.1 presents a general summary of the stressors and associated 

potential aging and degradation mechanisms identified in the FMEA for typical medium-voltage 

power, low-voltage power, and I&C cables used in nuclear power plants. The table should 

apply to the majority of cables in a plant, and with a minor reanalysis, can be adapted to 

accommodate most of the variations in materials, construction, and configurations that will be 

encountered in nuclear power plant cables. 

Guidance on the identification of environmental and operation stressors acting on medium- and 

low-voltage cables and I&C cables is presented in subsection 2.2.2. Discussion and guidance 

regarding the aging and degradation mechanisms affecting these cables is given in subsection 

2.2.3. 

Similarly the FMEA process was used to analyze electric cable splices and cable termination 

connections. Table 2.2 presents a general summary of the stressors and associated potential 

aging and degradation mechanisms identified in the FMEA for typical medium-voltage power, 

low-voltage power and I&C cable splices and termination connections used in nuclear power 

plants. Since there are numerous variations in types of splices, configurations, and 

applications, each group should be analyzed to identify unique failure modes, stressors, and 

degradation mechanisms. Likewise, there are so many variations in cable terminations that 

may be encountered, each group and application should be considered. 

Guidance on the identification of environmental and operation stressors affecting cable splices 

and cable termination connections for medium- and low-voltage cables and I&C cables is 

presented in subsection 2.2.2. Discussion and guidance regarding the aging and degradation 

mechanisms affecting splices and termination connections for these cables is given in 

subsection 2.2.3. 

The environmental characterization and monitoring walkdown inspections described previously 

in subsections 4.3.1 and 4.3.2 (program element 3), the cable baseline visual CM inspection 

described in subsection 4.6.1 (program element 6), and the periodic CM visual inspections 

described in subsection 4.7 (program element 7) will provide the primary means for identifying 

the environmental and operational stressors to which a cable will be exposed during its normal 

anticipated service. Tables 2.1 and 2.2 can be used to identify applicable aging and 

degradation mechanisms that are likely to affect the individual cables, splices, and termination 

connections. 

The end result of the process for identification of stressors and aging mechanisms for cable 

systems in CM program element 4 is a listing of the likely anticipated stressors and associated 

aging mechanisms that will affect each cable system that is to be monitored in the cable CM 

4-21 
 

4-22 

program. These stressors and aging mechanisms are documented in the cable CM program 

database for each cable. The information will next be used by the cable engineer to select a 

group of condition monitoring inspection and testing techniques in CM program element 5 that 

can best be used to detect and monitor anticipated stressors and associated aging 

mechanisms. These inspection and testing techniques will be used to establish the baseline 

condition of a monitored cable (program element 6) and then to periodically assess and monitor 

the status of cable condition (program element 7). 

4.5 Selection of CM Techniques

The fifth element of the cable CM program is the selection of condition monitoring inspection 

and testing techniques that can be used to detect, quantify, and monitor the status of the aging 

mechanisms that are causing the degradation of cable systems. By selecting CM techniques 

that are best suited to the detection and monitoring of the anticipated stressors and associated 

aging and degradation mechanisms identified, the cable engineer can more accurately monitor 

the condition of critical plant cables, assess their operating condition, and implement corrective 

actions to manage aging and degradation in those cables that are found to be experiencing 

stressors and aging/degradation rates beyond specified design conditions. Realistic and timely 

assessment of cable condition is the best means for managing cable degradation and avoiding 

unexpected early cable failures. 

Condition monitoring for electric cable systems involves inspection and measurement of one or 

more indicators, which can be correlated to the condition or functional performance of the 

electric cable on which it is applied. Furthermore, it is desirable to link the measured indicators 

with an independent parameter, such as time or cycles, in order to identify trends in the 

condition of the cable. Ideally, condition monitoring data and trends in cable performance 

indicators can guide the cable engineer‘s decisions to effectively manage the aging and 

degradation in electric cables, cable splices, or other accessories in a cable system before they 

reach the point of failure or degraded performance that may adversely affect the safe and 

reliable operation of the associated components and systems. 

As described in subsection 3.1, the most useful condition monitoring would provide information 

that can be used to determine the current ability of a cable system to perform within specified 

acceptance criteria, as well as to make predictions about its future functional performance and 

accident survivability. To predict future performance, it is desirable to have a trendable indicator 

and a well-defined end point. A trend curve can then be used to estimate the time remaining 

before the end point is reached. However, research and experience has shown that no single, 

non-intrusive, cost effective currently available CM method alone can be used to predict the 

survivability of electric cables under accident conditions. A plant cable circuit may traverse a 

number of different environments and localized conditions along its length. Many condition 

monitoring techniques are localized indicators of condition at the specific location along a cable 

circuit where the measurement is made. The criteria used to define cable functional condition or 

accident survivability for a particular circuit are application-specific. Consequently, engineering 

judgement concerning the integrity and soundness of an electric cable must be made by 

experienced personnel based upon the results of several condition monitoring tests, including 

visual, electrical, physical, and chemical techniques. A suite of such condition monitoring tests, 

with periodic measurements referenced to baseline values may then be used to make cable 

condition assessments and predict cable survivability [Ref. 9].
 

Section 3 of this report describes several of the most commonly used cable condition monitoring 

inspection and testing techniques available to plants for managing cable aging and degradation. 

These are summarized in Table 3.1, grouped by whether the inspection or test is performed in 

situ on electric cables in the plant or are laboratory-type tests performed on representative 

material specimens in a controlled laboratory setting. The advantages and limitations of the 

various techniques are indicated in Table. 3.1. The table also indicates the types of aging and 

degradation mechanisms that each CM technique is best suited to detect and monitor. 

These CM test techniques may be performed to measure and assess: 

 electrical properties (such as insulation resistance/polarization index, voltage withstand, 

dielectric loss/dissipation factor, time domain reflectometry, partial discharge), 

 mechanical properties (such as hardness, elongation-at-break, compressive 

modulus/polymer indenter test), 

 chemical/physical properties (such as density, OITM, OITP, and FTIR), 

 physical condition/appearance, or 

 functional performance (technical specifications calibration & functional surveillance 

tests, system/component operating tests, preventive maintenance functional tests) 

Using the environmental survey information for a given cable circuit, the cable engineer can 

establish the anticipated stressors to which the cable will be exposed during normal operation. 

The aging and degradation mechanisms that these stressors can have on the materials that are 

used in the construction of that cable and its cable accessories can then be determined in the 

evaluation process described previously in subsection 4.4 for CM program element 4. The 

cable engineer can then use his engineering judgement to establish a suite of condition 

monitoring inspection and testing techniques that can detect, quantify, and monitor the 

anticipated degradation effects for the selected cables. These inspections and tests would be 

repeated periodically, and at designated monitoring locations along the length of the selected 

cable circuit (at the point of locally adverse environments(s), for example), at a frequency 

determined by the cable engineer. The periodic inspection and test results, may then be 

compared to the baseline measurements, established for the cable circuit in CM program 

element 6 (described in subsection 4.6), to periodically review and assess the up-to-date 

condition and status of the cable circuit as described in subsection 4.9. 

Consider as an example, a safety-related, low-voltage instrumentation circuit consisting of a 2/C 

#12 AWG EPR-insulated cable with overall CSPE jacket originating at a pressure transmitter in 

the turbine-driven RCIC pump area of a BWR secondary containment and terminating at an 

analog trip system cabinet in the electrical equipment room of the control building. Baseline 

environmental survey of the cable route (CM program element 3) showed that the cable passed 

through mild, dry environments, in ladder-type cable tray or metal conduit, throughout most of its 

length with no splices, no adverse local environments, and no extreme installation stressors, 

such as long vertical runs or sharp bends, were noted. However, at the pressure transmitter in 

the RCIC pump area, elevated temperature and radiation levels were observed during normal 

operation. Vibration at the transmitter was also a possible stressor for the cable and the cable 

termination, but this occurred very infrequently during pump operation for testing or emergency 

operation of the system. Following the initial baseline cable condition visual inspection and 

environmental walkdown (cable CM elements 6 and 3), a reasonable frequency for subsequent 

visual CM inspection for the instrumentation cable circuit in this example might be once every 5 

to 10 years because of the mild environment over most of the cable’s route. However, because 

of the elevated temperature and radiation stressors at the transmitter end of the cable, the 

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4-24 

polymer insulation and jacket material in this section of the cable should be visually inspected 

as part of the quarterly or 18-month technical specification calibration and functional 

surveillance test procedure for the pressure transmitter. The results of the calibration and 

functional surveillance tests would also provide one indication of cable condition. In addition, 

the cable engineer may elect to routinely perform polymer indenter tests of the cable insulation 

and jacket at the accessible portions of the cable at the transmitter or perhaps a junction box in 

the RCIC pump area. If visual inspection, surveillance tests, or indenter/hardness tests indicate 

an unusual rate of degradation, the cable engineer could add a periodic material density test, 

OIT, or EAB to more closely monitor thermal and radiation effects on insulation condition. Note 

that these last CM techniques are destructive tests that would require removing a small piece of 

insulation from the end of the cable insulation at the transmitter terminations, or from sacrificial 

materials test specimens that had been previously placed in the RCIC pump area specifically to 

monitor polymer condition. 

The guidance provided in Table 3.1 enables the cable engineer to select those CM inspection 

and testing techniques that are best suited to the detection, assessment, and monitoring of the 

types of cable aging and degradation mechanisms that are anticipated or are occurring in the 

various types of cables and cable applications in nuclear power plants. Table 3.2 presents a 

cable CM technique selection matrix summarizing the most common cable aging stressors and 

aging mechanisms linked to the various potential CM techniques that can be used to detect 

them. Further information describing the selection and performance of many different types of 

cable CM techniques, including in situ methods as well as laboratory tests, can be found in: 

Section 3 of NUREG/CR-6704 [Ref. 9], Volume 2; Section 5 of SAND96-0344 [Ref. 2]; IEEE 

Std. 400-2001, “IEEE Guide for Field Testing and Evaluation of the Insulation of Shielded Power 

Cable Systems” [Ref. 13]; IEEE Std. 400.1-2007, “IEEE Guide for Field Testing of Laminated 

Dielectric, Shielded Power Cable Systems Rated 5 kV and Above With High Direct Current 

Voltage” [Ref. 17]; IEEE Std. 400.2-2004, “IEEE Guide for Field Testing of Shielded Power 

Cable Systems Using Very Low Frequency (VLF)” [Ref. 14]; IEEE Std. 400.3-2006, “IEEE 

Guide for Partial Discharge Testing” [Ref. 18]; and Section 6 and Annexes A, C, and D.4 of 

IEEE Std 1205-2000, “IEEE Guide for Assessing, Monitoring, and Mitigating Aging Effects on 

Class 1E Equipment Used in Nuclear Power Generating Stations” [Ref. 34]. 

Once the most suitable CM inspection and testing techniques have been selected for a 

particular cable system, the cable engineer will perform a baseline visual CM inspection of the 

cable to establish the initial installed condition of the cable along the length of its routing through 

the plant. The initial set of CM tests selected will be performed on the installed cable system 

and cable materials specimens (if available) to establish the baseline condition of the cable 

circuits selected for monitoring in the cable CM program. Baseline CM inspection and testing 

are described in subsection 4.6. 

4.6 Establish Baseline Cable Condition

The performance of baseline cable CM inspection and testing is the sixth element of the cable 

CM program. This activity establishes benchmark values for measured cable parameters, 

physical condition, and appearance at the time of installation (or the beginning of a cable 

monitoring program). The cable CM inspection and testing techniques that are used to 

establish baseline cable condition were selected in cable CM program element 5 where it was 

determined that they were the methods best suited to identify, quantify, and monitor the status 
 

of the aging mechanisms that are causing the degradation of a particular cable system. The 

results of subsequent periodic performances of these cable CM inspections and tests (cable CM 

program element 7, described in subsection 4.7) may then be compared to the baseline values 

to assess cable condition (cable CM program element 9, described in subsection 4.9). 

4.6.1 Baseline Visual CM Inspection 

The baseline visual inspection of a cable system consists of a walkdown of the entire length of a 

selected cable circuit to assess the installed physical condition of the accessible portions of a 

cable, cable splices, and cable accessories. Similar to the discussion of the cable 

environmental walkdown inspection described in subsection 4.3.1, the baseline cable CM 

inspection is accomplished by: 

 review of the design, specification, and installation documentation for the cable circuit, in 

order to locate the routing of the cable circuit throughout the plant; 

 review of existing environmental survey information from programs such as radiation 

protection and environmental qualification in order to quantify the environmental 

conditions to which a cable circuit is exposed; 

 in situ measurements of environmental conditions; and 

 initial walkdown visual inspection of the accessible portions of the cable circuit to 

document the physical installation and condition of the cable, and to identify any 

installation and construction activities damage, operating and maintenance activities 

damage, and any adverse localized installation conditions, such as sharp bends, long 

vertical rises, physical contact with SSCs, or other conditions that could potentially affect 

the performance of the cable, splices, terminations, or other cable accessories. 

Since the baseline cable CM visual inspection is so similar in purpose to the baseline cable 

environmental walkdown inspection described in subsection 4.3.1, it is recommended that these 

activities be performed at the same time and incorporated into the same procedure. Both 

activities will make use of cable design, specification and installation documentation, require the 

review of cable circuit routing information, and require a physical walkdown of the same 

accessible sections of each cable circuit. 

A procedure for baseline and periodic cable CM visual inspection should be developed so that 

the inspections are conducted in a standardized, detailed manner. Cable attributes that are to 

be documented include: 1) color, including changes from the original color and variations along 

the length of the cable route, and sheen; 2) surface damage, including cracks (location, length, 

and depth, scrapes, gouges, deformations, and indentations, 3) visible surface contamination, 

including dirt, chemical deposits, surface tracking, 4) rigidity, 5) adverse localized installation 

conditions such as sharp bends, long vertical rises, physical contact with SSCs, and 6) proximity 

to adverse localized environments and stressors. Procedural standardization of the qualitative 

observations made during a baseline CM inspection of a cable system will make them more 

useful for comparison to qualitative observations obtained during subsequent periodic cable CM 

visual inspections. 

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The observations and results from the environmental walkdown described in subsection 4.3.1 

are an important part of the assessment of the cable condition. Information on the general 

environmental conditions to which a cable is exposed can be used by the cable engineer to 

establish the frequency for subsequent periodic visual inspections. In addition, the identification 

of localized adverse environmental conditions, the proximity to sources of heat, radiation, and 

vibration, and other factors related to the installation of a cable circuit can highlight the locations 

of vulnerable sections of an otherwise mild-environment cable circuit that should be monitored 

on a more frequent basis. Items to be noted include the proximity to heat sources such as high 

temperature steam lines, large uninsulated valve bodies, unit area heaters, and high powered 

lighting fixtures. Storage tanks and piping carrying steam, borated water, hydraulic fluid, or 

other chemicals above, or in proximity to, cable circuits are potential sources of high 

temperature/pressure steam leakage, high temperature exposure, wetting or flooding, and 

exposure to reactive chemicals. Physical contact between polymer-insulated cables and 

structures, plant equipment, piping, thermal insulation, worker stepping points, and other objects 

can deform, abrade, or degrade the performance of the cable insulating materials. Vibration of 

electrical cables can occur at the cable terminations to electric drive motors or at the 

terminations to instruments mounted on or near operating machinery or large pipelines. 

As noted in subsection 4.3.1 for the environmental walkdown inspection of a cable circuit, 

accessibility issues should be noted in the baseline visual CM inspection. Many cable circuits, 

or portions of those circuits, may not be directly accessible for visual inspection during the 

environmental characterization walkdown. Cables may be routed through conduits, bundled 

together into heavily loaded cable trays, covered cable trenches, direct buried, or routed through 

underground duct banks making it physically impossible to visually inspect them. The cable 

engineer must then make a technical judgment on how best to estimate the cable operating 

conditions or environments through the use of alternate or indirect methods. He may choose to 

walkdown the ground surface above the route of an underground circuit, for example, to verify 

that there are no potential sources of oil, greases, hydraulic fluid, or other chemicals that could 

leach into the soil along the route of a direct buried cable or into underground cable duct banks 

and cause degradation of cable insulating materials. Conditions in inaccessible sections may 

be estimated from conditions at adjacent accessible sections of a cable circuit. Accessibility at 

manholes, cable pull boxes, junction boxes, or conduit elbows and fittings may provide a means 

to physically inspect portions of an otherwise inaccessible cable run. 

As discussed in the special section on inaccessible underground medium-voltage cable runs 

that could potentially be exposed to moisture or complete submergence (see subsection 4.3.2), 

the cable engineer must positively identify, either by direct visual inspection or by one or more of 

the alternative inspection methods suggested previously, those sections of an underground 

cable run that are susceptible to water intrusion or submergence. These sections of the cable 

circuit must then be monitored on a more frequent basis to detect unusual rates of cable 

degradation that could result in early failure. 

Further guidance on plant walkdowns and visual inspection that can be applied to cable 

systems and their operating environments can be found in Section 6 of IEEE Std. 1205-2000, 

“IEEE Guide for Assessing, Monitoring, and Mitigating Aging Effects on Class 1E Equipment in 

Nuclear Power Plants” [Ref. 34], and EPRI TR-109619, “Guideline for the Management of 

Adverse Localized Equipment Environments,” Appendices A and B [Ref. 35]. Annex D.4 to 

IEEE Std. 1205-2000 [Ref. 34] presents an extremely useful description and analysis of nuclear 

power plant environmental conditions and environmental stressors as applied specifically to 

insulated electric cables that can serve as useful guidance for cable CM visual inspection 

walkdowns of cable systems. 

4-26 
 

4.6.2 Baseline CM Tests 

Subsection 4.5 described the process for selection of CM tests that were best suited to detect, 

quantify, and monitor the status of aging mechanisms that may lead to the degradation of cable 

systems in the program. It also described the desirable attributes to be found in the ideal CM 

technique (listed in subsection 3.1), one of these being the capability to “...measure property 

changes or indicators that are trendable and can be consistently correlated to functional 

performance during normal service,” and another being the reproducibility of test results “...that 

are not affected by, or can be corrected for the test environment...” 

In order to fully realize the goals of trendability and reproducibility, the quantitative test results 

from the cable CM test methods that are being used to monitor the cable in the program must 

be referenced back to a reliable set of initial values representing the condition and properties of 

the cable, as installed in the plant, at the start of its normal service life or when the CM program 

was initiated. This initial set of test data is the baseline CM test data. 

For non-destructive tests and measurements, the first performance of a particular CM test 

serves as the baseline value or data set for that CM test. Preferably, these measurements are 

performed at the time that the cable system is installed or first put into service. However, if a 

cable that has already been in service is added to the cable CM program or if a new CM test 

has been added to an existing cable, the first performance of that CM test can be considered a 

baseline, and then subsequent measurements performed using that CM test technique are 

referenced against that first performance set of baseline measurements. All subsequent 

performances of that CM test may then be compared to the baseline measurement to provide a 

plot of the changes of the measured parameters or properties over time. Over time the data 

may show changes that correspond to aging or degradation of the cable materials in response 

to environmental or operational stressors. If a clear time-related trend is manifested for the 

measured cable parameter or property, these data may help the cable engineer to project future 

values of the cable parameter or property, and estimate remaining useful life for the cable 

system. 

If the CM tests selected to monitor a cable are destructive-type tests, requiring sacrificial 

materials specimens to measure the property or parameters of the cable material (e.g., the 

elongation-at-break (EAB) which requires standard “dogbone” insulation or jacket material 

specimens), the sacrificial materials testing specimens must be prepared from samples of the 

cable from the same reel, or the same purchase lot, if possible. This will ensure that the age of 

the test specimen materials since the time they were manufactured is the same as the age of 

the materials on the installed cable that is being monitored. The formulation of the materials in 

the test specimens will then be more likely to match the formulation of the materials in the 

installed specimen. The exact formulation for a polymer material is proprietary information and 

manufacturers may often change content, quantities, and additives without notice and change 

the overall trade-name for the polymer material. The best way to account for this in a CM 

testing program is to prepare sacrificial test specimens from the same reel that the installed 

cable was taken from, or if that is not possible, then at least from cable manufactured at the 

same time. 

Ideally, destructive testing would require that a sufficient quantity of sacrificial test specimens be 

prepared to allow baseline CM testing and periodic CM testing for that method throughout the 

installed life of the cable. The specimens prepared for future periodic CM testing would have to 

be placed in the plant at the most severe locally adverse environment for the selected cable or 

groups of cables using the same types of materials. By testing materials specimens that have 

4-27 
 

been exposed to the most severe plant environments in which cables of that type are located, 

the cable engineer can estimate the “extreme limit” of aging-related degradation for cables using 

that particular material. The level of degradation of the materials in other cables of that type, 

operating in less severe environments for the same amount of time, should then be less than for 

the “extreme limit” specimens. It may be possible to extrapolate the remaining life of cables in 

less severe environments using CM data from cables in the most severe environment. 

Other alternatives for obtaining baseline sacrificial materials test specimens would be: unused 

cables of the same type, purchased at the same time, from warehoused supplies of cable; spare 

cables of the same type that are located along a similar route as the cable(s) to be monitored; 

disconnected cable circuits, of the same type, that are “abandoned in place” and that are 

located along a similar route as the cable(s) to be monitored. 

The end results of the CM program element 6 baseline visual cable inspections and CM tests 

will include cable physical condition information, the locations of adverse localized 

environments, the locations of actual and/or potential physical damage to the cable, and 

quantitative baseline CM test data covering cable properties and condition measurements. The 

baseline information for each cable circuit is documented in the CM program database and will 

be available for review by the cable engineer under CM program element 9. 

4.7 Perform Cable CM Inspection and Testing

The performance of periodic cable CM inspection and testing is the seventh element of the 

cable CM program. The implementation of this program element involves the routine 

performance of inspection and testing procedures to provide a periodic assessment of the 

physical condition and appearance of a cable system, the status of the cable circuit’s operating 

environments (including locally adverse environments), and the quantitative measurement of the 

properties, operating parameters, and performance parameters that indicate the condition of the 

cable systems included in the plant’s cable CM program. The data and results obtained from 

the periodic testing and inspections are documented in the cable CM program database. 

The CM program elements described in the preceding subsections provide the background and 

foundation for the cable CM program. The cable CM inspection and testing techniques that are 

used to establish baseline cable condition were selected in cable CM program element 5 where 

it was determined that they were the methods best suited to identify, quantify, and monitor the 

status of the aging mechanisms that are causing the degradation of a particular cable system. 

Once the types of cable CM inspections and test procedures have been selected, the controlling 

procedures have been developed and put into place, and the initial baseline cable CM 

inspections and tests have been completed, what remains is the routine implementation of the 

periodic cable CM inspection and testing program. 

This activity is very similar to existing nuclear power plant programs for the performance of plant 

technical specifications surveillance testing and plant preventive maintenance (PM) activities. It 

is anticipated and recommended that the periodic performance of cable CM inspection and 

testing activities for CM program element 7 be incorporated into the existing plant preventive 

maintenance program either as new PM activities or as an expanded part of existing PM 

activities. The timely performance of the cable CM inspections and tests are ensured by 

incorporating these activities into the format of the existing plant PM program. The plant PM 

program structure thus provides for the scheduling and administrative controls to implement the 

activities for CM program element 7. 

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The performance frequency for the CM inspection and testing of each cable that is to be 

monitored under the cable CM program is initially determined by the cable engineer based upon 

experience and the results of the environmental baseline inspection and the baseline CM 

inspection and tests. Certain sections of a cable circuit may require CM inspection and testing 

at even shorter intervals than the performance frequency for the overall remainder of the cable if 

they have been identified in walkdown inspections as being exposed to locally adverse 

environmental conditions (more severe aging and degradation stressors). The normal CM 

frequency and the augmented frequency for more severely stressed cable locations should all 

be identified and documented on the cable CM program database. 

Periodically, the cable engineer will review the results of periodic CM inspections and tests for 

each cable and compare them to the baseline observations and test data as part of CM program 

element 9 (see subsection 4.9). Based on this review of test results and observations, and the 

observation of any trends in the plot of quantitative testing results data versus time, the cable 

engineer may choose to modify the performance frequency for the periodic CM tests and 

inspections for entire cables or sections of the cables exposed to more severe environmental 

stressors. The cable engineer may also elect to add (or delete, as warranted) additional CM 

tests to provide more detailed monitoring of a particular aging mechanism or cable condition 

parameter. These changes should be controlled and documented in the cable CM program 

database. 

The results of the periodic CM inspection observations and CM test data obtained under cable 

CM program element 7 are all consolidated and documented in the program database (CM 

program element). These data and information are available to the cable engineer to support 

the formalized periodic review and assessment of the condition of each cable system monitored 

under the cable CM program. The periodic review and assessment activity constitutes CM 

program element 9 and it is discussed in subsection 4.9. 

4.8 Operating Experience

The eighth element of the cable CM program is the review of cable-related operating experience 

and incorporation of applicable information into the program. By actively reviewing industrywide operating experience regarding cables, a plant can be alerted to deficiencies or defects in 

specific cable types or configurations, inadequate or damaging installation practices, testing 

techniques that can potentially damage cables, useful new testing techniques, manufacturing 

defects, or misapplications of cable types. Regular review and analysis of cable failures or 

cable-related problems in one’s own plant can sometimes reveal adverse performance trends or 

otherwise point to emerging problem areas that can be monitored more closely and/or corrected 

in a timely fashion before the occurrence of an early cable failure. 

All nuclear plants are required to have a program or other measures in place to address 

corrective actions, in accordance with 10 CFR 50, Appendix B, Criterion XVI. An effective 

corrective action program promptly identifies, corrects, and documents failures, malfunctions, 

deficiencies, deviations, defective material and equipment, nonconformances, or other 

conditions adverse to quality that occur in a nuclear power plant. The corrective actions 

program can provide the means for analyzing problems, finding root causes, developing 

corrective actions, and implementing solutions. 

The corrective action program and process can be used to provide an effective means for 

identifying and correcting cable-related problems that occur in the plant. The cable engineer 

should periodically review and analyze these cable-related failures, problems, and other 

4-29 
 

deficiencies to try to identify adverse performance trends or otherwise point to emerging 

problem areas. Corrective actions can then be developed and implemented to address cablerelated problem areas. Corrective actions in response to industry and in-plant operating 

experience may then be incorporated as modifications or additions to the cable CM program. 

These could include: more frequent monitoring of certain cable types or materials; root cause 

analysis of cable failures; augmented monitoring for unusual rates of cable system degradation 

or adverse local environments; added CM tests for certain cables and configurations that have 

experienced higher failure rates; or special tests or inspections to address specific cable-related 

problems. 

Nuclear power plants typically have industry operating experience programs in place to regularly 

review and analyze industry-wide failures, incidents, operating experience, or other events to 

determine applicability to their plant. Information regarding applicable operating experience is 

added to the corrective action program and/or directed to the responsible plant organization for 

follow-up analysis. 

Sources for current nuclear industry operating experience regarding cables would include: NRC 

information notices, generic letters, circulars, and bulletins; Licensee Event Reports (LERs); 10 

CFR Part 21 reports; the NRC website (www.nrc.gov); cable and cable splice manufacturers’ 

technical bulletins and instruction manuals; cable test equipment manufacturers’ technical 

bulletins; international cable testing standards; and technical research literature on cable 

systems. 

Historical cable-related operating experience can be obtained from the Nuclear Plant Reliability 

Data System (NPRDS) for events up through 1996, the Equipment Performance Information 

Exchange (EPIX) database for events occurring since 1997, and the LER database. Several 

NRC-sponsored research programs included sections dedicated to the assessment and 

analysis of operating experience related to cables, cable splices, and terminations. Some of 

these, which are listed in the references section of this report, include: 

 NUREG-1760 fuse holders and connections 

 NUREG/CR-6384 electric cables research, operating, and qualification experience 

 NUREG/CR-6704 electric cables research and qualification testing experience 

 NUREG/CR-6788 cable splices 

 NUREG/CR-6794 power cables 

NUREG/CR-6950 medium-voltage power cables, switchgear electrical bus 

connections, circuit breaker connections, power transformer 

terminations, instrument transformer terminations 

 SAND96-0344 electrical cables, splices, and terminations 

In addition, utility organizations such as the Electric Power Research Institute (EPRI) have 

sponsored research programs on electric cables, splices, and terminations that included 

sections dedicated to the assessment and analysis of cable-related operating experience. 

Some of these reports, which are available to member utilities, are listed in the references 

section of this report. 

The end result of the review and incorporation of industry-wide and in-plant electric cable 

operating experience would be to enhance, augment, or modify the cable CM program in order 

to address cable issues that are applicable to the plant and to identify, analyze, and implement 

corrective actions for adverse performance trends or emerging problem areas in the plant 

before the occurrence of an early cable failure. 

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4-31 

4.9 Periodic Review and Assessment of Cable Condition

The periodic review and assessment of the condition of cables that are being monitored under 

the cable CM program is the ninth element. The purpose of this element is to perform a formal 

periodic review that brings under consideration all of the inspection and CM testing results, 

inspection and testing data trends, surveillance and PM test results, applicable operating 

experience, and operating environment conditions and trends in order to establish an 

assessment of the present condition for each cable in the program. 

4.9.1 Periodic Review and Assessment 

The formal periodic review and assessment element of the cable CM program is the activity 

where the results and inputs from all the other elements of the program that are being gathered 

together and documented in the cable program database are evaluated and analyzed in order to 

make an experienced, informed, assessment of cable condition. No single CM inspection or 

test alone can provide a complete picture of cable condition, nor can successful functional 

testing, under the limited and controlled loadings and conditions of such testing, fully predict 

cable function under the more severe, demanding, extended conditions of full power or 

emergency operation. The periodic cable condition review and assessment allows the cable 

engineer to use his engineering judgment to weigh all the contributing factors (CM inspection 

and testing, functional testing, environmental factors, data trends, in-plant and industry-wide 

operating experience) to determine the condition of a cable at the time of the analysis in terms 

of material degradation, performance, and remaining service life. 

Research and experience has shown that no single, non-intrusive, cost effective currently 

available CM method alone can be used to predict the survivability of electric cables under 

accident conditions. Each plant cable circuit may traverse a number of different environments 

and localized conditions along its length. Many condition monitoring techniques (e.g., EAB, 

compressive modulus, density) are localized indicators of condition at the specific place (and 

even a specific point on the cable jacket’s surface) along a cable circuit where the measurement 

is made; cable properties measured at multiple points may show the cable to be in sound 

condition, but a measurement made only inches away at a more severely stressed section could 

show otherwise. Furthermore, the criteria used to define cable functional condition or accident 

survivability for a particular circuit are application-specific. Consequently, engineering 

judgements concerning the integrity and soundness of an electric cable must be made by 

experienced personnel based upon the results of several condition monitoring tests, including 

visual, electrical, physical, and chemical techniques. A suite of such condition monitoring tests, 

with periodic measurements referenced to baseline values may then be used to make cable 

condition assessments and predict cable survivability [Ref. 9]. Results and data from the 

periodic CM inspection and testing activities described in subsections 4.6 and 4.7 (CM program 

elements 6 and 7) provide input to the cable engineer regarding bulk cable properties, insulating 

material condition and properties, and rates of degradation.

It has also been shown that the operating environment in which a cable operates can have a 

significant effect on the performance and operating lifetime of a cable. Since a cable can 

traverse several different operating environments throughout the length of its route through the 

plant, the effect of the various environmental conditions must be considered. Of even more 

significance may be the identification and monitoring of locally adverse operating environments 

that can drive cable aging and degradation mechanisms that could end in unexpectedly early 

cable failures. Periodic monitoring inspections and measurements of cable system operating 
 

environments, described in subsections 4.3.1 and 4.3.2, provide valuable information to the 

cable engineer in his evaluation of the state of the cable operating environment, exposure to 

locally severe conditions, and the types and severity of cable stressors. 

The functional performance of a cable, as revealed by instrument and control system calibration 

and functional surveillance test, system and equipment performance tests, or other related 

technical specification surveillance testing and preventive maintenance program testing, can 

provide useful information and trends to the cable engineer as part of his overall assessment of 

a cable’s condition. Such testing alone can only tell part of the total story, since the cable circuit 

may appear to be operating normally during periodic functional testing right up until the time it 

fails, even though cable CM visual inspection and/or tests performed at the same time would 

indicate significant overall and/or localized degradation. When called upon to operate under the 

stresses encountered during an emergency, (i.e., fully loaded equipment, more extreme 

environmental conditions, extended operation in a heavily loaded state), however, such a cable 

could fail unexpectedly. 

Finally, operating experience (CM program element 8 described in subsection 4.8) can provide 

very important input to the cable engineer as part of his periodic assessment of cable condition. 

Industry-wide occurrences, application-related cable problems, commonly-encountered 

manufacturing defects, or common performance shortcomings of cables used at other plants 

must be evaluated and in-plant applicability determined so that these common problems are 

addressed in a timely manner. In-plant cable failures and other cable-related operating 

experience should be reviewed and evaluated for applicability to in-plant cable systems. From 

the experienced cable engineer’s viewpoint of the impact that various operating experience 

incidents can have on plant cable systems, his review and analysis of these cable-related 

failures, problems, and other deficiencies may reveal adverse performance trends or otherwise 

point to emerging problem areas. During the periodic cable condition assessment the cable 

engineer can fully determine the applicability and impact of operating experience on each cable 

system or groups of cables operating under similar circumstances. 

4.9.2 Managing Cable Operating Environments and Degradation Effects 

An important part of the periodic review and assessment of cable condition under CM program 

element 9 is the development of recommendations for the management of cable operating 

environments and the associated aging and degradation mechanisms that are affecting each 

cable in the program. Based upon the periodic review and assessment of present cable 

condition, the cable engineer can make an estimate of the remaining service life of a cable 

given the present condition of the cable, existing cable operating environments, and rates of 

degradation of cable properties and performance parameters. 

If the estimated remaining service life of the cable is much greater than the operating life of the 

plant, including the design bases accident conditions, the cable engineer may decide to 

continue the present environmental inspection and monitoring activities, at their present 

performance frequencies, to periodically confirm that the operating environments of the cable do 

not become more severe and that no local adverse environmental conditions have developed. 

In this case, the cable engineer would most likely continue to perform the same visual 

inspections and CM tests on the cable, at the same performance frequencies, to periodically 

confirm that the physical condition of the cable does not change significantly and to monitor for 

any adverse trends in the measured cable properties and performance parameters. 

4-32 
 

If adverse environmental changes have occurred, the more severe cable stressors and 

associated aging and degradation mechanisms could cause increased rates of degradation in 

the cable, possibly shortening its service life. Should the estimated remaining service life of a 

cable be approximately equal to, or less than the remaining operating life of the plant, the cable 

engineer must recommend and implement activities to manage cable aging degradation and 

operating environments and/or to repair or replace the degraded cables. All of the cables 

selected for monitoring in the program are important to the safe operation of the plant, so the 

timely implementation of corrective action strategies will help to avoid unexpected early cable 

failures. 

Cable aging degradation can be managed by modifying the performance frequencies for the 

cable visual inspections and CM tests. More frequent inspections and measurements will keep 

the cable engineer better informed of the recent status of cable condition and performance 

parameters. Adverse trends of measured cable parameters or increased rates of degradation 

can be monitored and detected sooner. The cable engineer may also decide to augment the 

existing CM inspections and testing with additional CM tests to provide more comprehensive 

data to monitor specific aspects of cable condition or to provide more information on critical 

cable parameters. Cables that have indicated adverse performance trends or increased rates of 

degradation will also be tagged for more frequent periodic review and condition assessment 

under CM program element 9. 

Another action available to the cable engineer for the management of cable aging is the 

management of the cable operating environments. By controlling or reducing the severity of 

environmental and operating stressors acting on a cable system, the degradation process can 

be controlled or slowed, thereby maintaining the estimated service life. 

As discussed in subsection 4.3.3, if unanticipated or locally adverse cable system operational 

environments are detected through periodic monitoring of cable environments or other reported 

observations, the cable engineer can implement one or more of the following responses for the 

affected cable(s), consistent with its safety significance: 

 perform more frequent CM testing and environmental inspections to more closely 

monitor the cable condition 

 add more CM tests that will more closely monitor the status of the specific aging 

mechanisms associated with the environmental stressors and the cable condition 

 perform more frequent periodic review and condition assessment of the affected cable’s 

condition (program element 9) and initiate corrective actions as required 

 protect the cable from the adverse environment to reduce or eliminate the effects of the 

associated stressors 

 identify the root cause of the adverse environmental condition and implement 

modifications, maintenance, or other corrective actions to address and correct the root 

cause of the adverse condition 

It should be emphasized that the occurrence of cable system operating environments or locally 

adverse conditions that are unanticipated or more severe than the original plant design may 

constitute a design deficiency of the cable system, specifically, a potential violation of GDC 1, 4, 

4-33 
 

4-34 

17, and 18. NRC regulations, such as 10 CFR 50, Appendix B, (quality assurance), the 

maintenance rule (10 CFR 50.65), and environmental qualification regulations (10 CFR 50.49), 

require that programs and administrative controls be established to monitor and detect 

degraded conditions on a regular basis and to promptly implement effective corrective actions 

and design modifications, consistent with its safety significance, so that any further cable 

degradation is minimized. A cable system must be designed to meet all applicable regulations 

and to perform its intended function in the plant environment under all anticipated operational 

occurrences and design basis events. 

 

Finally, if cable visual inspections and CM tests indicate that a monitored cable is in such a 

degraded state that it is at risk for early cable failure, the cable engineer will recommend either 

maintenance/repair or replacement. Repairs can be made to damaged sections of a cable to 

restore the dielectric strength of the cable insulation or, if access allows, damaged sections of 

the cable can be cut out and replaced with new cable sections spliced into the cable circuit. If 

degradation of the cable is widespread, the entire cable may have to be replaced with a new 

cable run or use an existing spare cable, if any are available along the same cable route. 
 

5. CONCLUSIONS AND RECOMMENDATIONS 

The important observations and recommendations from this study to evaluate cable condition 

monitoring techniques and develop the essential elements of an effective electric cable 

condition monitoring program are summarized in this section. 

5.1 Conclusions

A cable condition monitoring program is needed for the following reasons: 

 The 10 CFR Part 50 regulations require licensees to assess the condition of their 

components, to monitor the performance or condition of SSCs in a manner sufficient to 

provide reasonable assurance that they are capable of fulfilling their intended functions, 

and to establish a test program to ensure that all testing required to demonstrate that 

components will perform satisfactorily in service is identified and performed. Recent 

incidents involving early failures of electric cables and cable failures leading to multiple 

equipment failures, as cited in IN 2002-12, “Submerged Safety-Related Cables” [Ref. 7], 

and Generic Letter 2007-01, “Inaccessible or Underground Power Cable Failures That 

Disable Accident Mitigation Systems or Cause Plant Transients” [Ref. 1], may indicate 

that licensee approaches to cable testing, such as in-service testing, surveillance testing, 

preventive maintenance, maintenance rule, etc., do not fully characterize the status of 

cable insulation condition nor provide information on the extent of the aging and 

degradation mechanisms that can lead to cable failure. 

 The polymer materials used for the insulation and jacket materials for electric cables, 

cable splices, and terminations are susceptible to aging and degradation mechanisms 

caused by exposure to many of the stressors encountered in nuclear power plant 

service. Portions of a cable circuit may pass through areas experiencing more harsh 

environmental conditions, such as high temperature, high radiation, high humidity, or 

flooding of underground cables. There has been concern that such local adverse 

environmental stressors can cause excessive aging and degradation in the exposed 

sections of a cable that could significantly shorten its qualified life and cause unexpected 

early failures. 

 In-service testing of safety-related systems and components can demonstrate the 

integrity and function of associated electric cables under test conditions. However, inservice tests do not provide assurance that cables will continue to perform successfully 

when they are called upon to operate fully loaded for extended periods as they would 

under normal service operating conditions or under design basis conditions. In-service 

testing of systems and components does not provide specific information on the status 

of cable aging degradation processes and the physical integrity and dielectric strength of 

its insulation and jacket materials. 

 Analysis of the summary of licensee responses to GL 2007-01 [Ref. 8] inquiries on 

licensees’ experiences regarding cable failures and cable CM activities, revealed wide 

variations to the approaches and comprehensiveness of cable testing activities. 

Analysis of the reported cable failures also indicated a trend toward early cable failures 

occurring prior to the end of the original 40-year license period. These data prompted 

the NRC to consider whether “...licensees should have a program for using available 

diagnostic cable testing methods to assess cable condition.” 

5-1 
 

5.2 Recommendations 

This research study developed recommendations for a comprehensive cable condition 

monitoring program consisting of nine essential elements that consolidate a core program of 

periodic CM inspections and tests, together with the results of in-service testing, environmental 

monitoring and management activities, and the incorporation of cable-related operating 

experience. The recommended nine essential elements of the cable CM program are listed in 

Table 5.1 with a summary of the purpose and expected result for each element of the program. 

A comprehensive cable condition monitoring program consisting of the nine essential elements 

listed in Table 5.1 can address the shortcomings of indirectly demonstrating cable integrity and 

function through in-service testing of systems and components. Some of the features of this 

program are as follows: 

 Condition monitoring inspections and tests provide the means for evaluating the level of 

aging degradation of electric cables. Portions of a cable circuit that pass through areas 

experiencing more harsh environmental conditions or local adverse environmental 

stressors can cause excessive aging and degradation in the exposed sections of a cable 

that could significantly shorten its qualified life and cause unexpected early failures. 

Periodic cable condition monitoring inspection and testing can provide cable condition 

status information and measurements of cable insulation properties, physical integrity, 

and dielectric strength. Severely damaged or degraded cable insulation can then be 

identified and repaired or replaced to prevent unexpected early failures while in service. 

 The benefits of periodic cable condition monitoring inspections and testing can be further 

complemented by addressing cable operating environments. Environmental stressors, 

especially temperature, moisture/flooding, and radiation, can be responsible for causing 

significant aging and degradation of electric cable insulation and jacket materials. 

Monitoring and management of the environmental conditions in which cables are 

operated can help to control or reduce aging stressors. 

 Special consideration should be given the problem of monitoring the operating 

environment for cable circuits routed through inaccessible underground cable ducts and 

conduits, covered cable distribution trenches, and manhole vaults because they can 

frequently become flooded resulting in power and control cables operating in wetted and 

completely submerged conditions for extended periods of time. Unless the installed 

cables have been procured specifically for continuous submerged or submarine 

operation, the licensees should ensure that cables installed in duct banks, manholes, 

bunkers and direct burial applications, are provided with proper drains, sumps, alarms 

and other protective measures and inspection activities to ensure that they are 

monitored and maintained in a dry environment. 

 The review of cable-related operating experience can play an important role in the 

assessment and management of electric cable aging and degradation. Industry-wide 

operating experience can alert licensees to cable manufacturing defects, inadequate 

installation practices, misapplication of cable types, and other environmental and 

operation factors. Regular review and analysis of in-plant cable failures or cable-related 

problems can sometimes reveal adverse performance trends or otherwise point to 

emerging problem areas that can be monitored more closely and/or corrected in a timely 

fashion before the occurrence of an early cable failure. 

5-2 
 

Table 5.1 Recommended Nine Essential Elements of a Cable Condition Monitoring Program 

Program Element Purpose Expected Result 

1. Selection of Cables to 

be Monitored 

To identify and select electric cables that 

are candidates for inclusion in the cable 

condition monitoring program. 

A listing of the most important cables in the 

plant whose condition should be 

periodically monitored and evaluated to 

provide assurance that they are capable of 

performing their intended function 

2. Develop Database of 

Monitored Cables 

To provide a single centralized source of 

information for all the cables in the 

program that can be used by the cable 

engineer as a tool to access, analyze, and 

evaluate the data and documentation 

necessary to make cable condition 

assessments and to guide the direction of 

program decisions and activities 

A database that will provide essential 

information to support the implementation 

of the cable CM testing and inspection 

activities, and the periodic review and 

assessment of the condition of individual 

cables 

3. Characterize and 

Monitor Cable Operating 

Environments 

To verify the baseline design operating 

environment for a cable, to periodically 

verify actual environmental conditions and 

identify local adverse environments (e.g., 

high temperature or radiation, moisture, 

submergence) that may have developed, 

and to manage environmental conditions 

to mitigate the effects on cables 

Baseline environmental operating 

conditions measurements and inspection 

results, periodic environmental condition 

monitoring and verification measurements 

and results, identification and description 

of local adverse environments, and 

activities for managing operating 

environments to mitigate adverse effects 

on cables 

4. Identify Stressors and 

Aging Mechanism 

Affecting Cables in the 

Program 

To identify the stressors and determine the 

aging mechanisms affecting cables in the 

program 

Listing of the stressors and aging 

mechanisms affecting the condition of 

each cable in the program to be used in 

program element 5 to select the most 

effective CM inspection and testing 

techniques for each cable 

5. Select CM Inspection 

and Testing Techniques 

To determine the most effective CM 

inspection and testing techniques to detect 

and monitor the anticipated aging/failure 

mechanisms for each cable 

An initial listing of cable CM inspection and 

testing techniques and periodic 

performance frequency for each cable 

6. Establish Baseline 

Condition of Cables in 

the Program 

To measure and document the baseline 

condition of each cable in the program 

using the selected cable CM inspection 

and testing methods identified in program 

element 5 

Baseline cable condition measurements 

and inspection results for the techniques 

selected in program element 5 

7. Perform periodic CM 

Inspection and Testing 

To periodically measure and document the 

condition of each cable in the program 

using the selected cable CM inspection 

and testing methods identified in program 

element 5 

Periodic record of cable condition 

measurements and inspection results for 

the techniques selected in program 

element 5 

8. Review and 

Incorporate CableRelated Operating 

Experience 

To review industry-wide and in-plant cablerelated operating experience and 

incorporate changes to the cable CM 

program as required to address applicable 

issues and trends 

Incorporate changes to the cable CM 

program based on review of applicable 

operating experience 

9. Periodic Review and 

Assessment of Cable 

Condition 

To perform a periodic review of the current 

cable condition CM inspection and testing 

results, operating environments CM 

results, trends of cable properties and 

condition measurements, and applicable 

operating experience to establish an up-todate assessment of cable condition, 

expected service life, and program 

changes and activities to manage aging 

degradation of each cable in the program 

A formal periodic assessment of cable 

condition, expected service life, and 

program changes and activities to manage 

aging degradation of each cable in the 

program 

5-3 
 

5-4 

 In the periodic review and assessment element of the program, the cable engineer 

brings together all of the inspection and CM testing results, inspection and testing data 

trends, surveillance or PM test results, applicable operating experience, and operating 

environment conditions and trends in order to establish an assessment of the present 

condition for each cable in the program. Based upon the periodic review and 

assessment of present cable condition, the cable engineer can make an estimate of the 

remaining service life of a cable given the present condition of the cable, existing cable 

operating environments, and rates of degradation of cable properties and performance 

parameters. 

 The periodic review and assessment element of the program provides the opportunity for 

the cable engineer to make adjustments to the types and frequencies of CM testing and 

inspection for individual cable circuits, or specified sections of cable circuits, depending 

on the present status of the cable condition and operating environments. 

Recommendations can be made for corrective actions to manage cable aging 

degradation and environmental stressors. 
 

6. REFERENCES 

1. US NRC Generic Letter 2007-01, “Inaccessible or Underground Power Cable Failures 

That Disable Accident Mitigation Systems or Cause Plant Transients,” U.S. Nuclear 

Regulatory Commission, February 7, 2007. 

2. SAND96-0344, “Aging Management Guideline for Commercial Nuclear Power Plants - 

Electrical Cable and Terminations,” prepared by Sandia National Laboratory for US 

Department of Energy. September 1996. 

3. NUREG/CR-6794, “Evaluation of Aging and Environmental Qualification Practices for 

Power Cables Used in Nuclear Power Plants,” Brookhaven National Laboratory, January 

2003. 

4. NUREG/CR-6950, “Effects of Switchgear Aging on Energetic Faults,” Brookhaven 

National Laboratory, October 2007. 

5. NUREG/CR-6788, “Evaluation of Aging and Qualification Practices for Cable Splices 

Used in Nuclear Power Plants,” Brookhaven National Laboratory, September 2002. 

6. NUREG-1760, “Aging Assessment of Safety-Related Fuses Used in Low- and MediumVoltage Applications in Nuclear Power Plants,” Brookhaven National Laboratory, May 

2002. 

7. US NRC Information Notice 2002-12, “Submerged Safety-Related Electrical Cables,” 

U.S. Nuclear Regulatory Commission, March 21, 2002. 

8. Memorandum from G.A. Wilson, Chief, Electrical Engineering Branch to P. Hiland, 

Director, Division of Engineering, “Generic Letter 2007-01, Inaccessible or Underground 

Power Cable Failures that Disable Accident Mitigation Systems or Cause Plant 

Transients: Summary Report,” U.S. Nuclear Regulatory Commission, November 12, 

2008. 

9. NUREG/CR-6704, “Assessment of Environmental Qualification Practices and Condition 

Monitoring Techniques for Low-Voltage Electric Cables,” Brookhaven National 

Laboratory, Volume 2, February 2001. 

10. Toman, G. and Gardner, J. B., “Development of a Non-Destructive Cable Insulation 

Test,” published in NUREG/CP-0135, “Workshop on Environmental Qualification of 

Electric Equipment,” U.S. Nuclear Regulatory Commission, November 1993. 

11. NUREG/CR-5772, “Aging, Condition Monitoring, and Loss-of-Coolant Accident (LOCA) 

Tests of Class 1E Electrical Cables,” 3 volumes, Sandia National Laboratories, 1992. 

12. ASTM Standard D150, “Test Methods for AC Loss Characteristics and Permittivity 

(Dielectric Constant) of Solid Electrical Insulating Materials,” ASTM International. 

6-1 
 

13. IEEE Std. 400-2001, “IEEE Guide for Field Testing and Evaluation of the Insulation of 

Shielded Power Cable Systems” (Revision of IEEE Std. 400-1991), IEEE, New York, 

January 29, 2002. 

14. IEEE Std. 400.2-2004, “IEEE Guide for Field Testing of Shielded Power Cable Systems 

Using Very Low Frequency (VLF),” IEEE, New York, March 8, 2005. 

15. IEEE Std. 141-1993 (Red Book), “IEEE Recommended Practice for Electric Power 

Distribution for Industrial Plants,” Chapter 12, IEEE, New York, 1993. 

16. ASTM Standard D257, “Test Methods for DC Resistance or Conductance of Insulating 

Materials,” ASTM International. 

17. IEEE Std. 400.1-2007 (Active), “IEEE Guide for Field Testing of Laminated Dielectric, 

Shielded Power Cable Systems Rated 5 kV and Above With High Direct Current 

Voltage” (Revision of IEEE Std. 400-1991), IEEE, New York, September 21, 2007. 

18. IEEE Std. 400.3-2006, “IEEE Guide for Partial Discharge Testing of Shielded Power 

Cable Systems in a Field Environment,” IEEE, New York, February 5, 2007. 

19. ASTM Standard D470, “Standard Test Methods for Crosslinked Insulations and Jackets 

for Wire and Cable,” ASTM International. 

20. ASTM D2633, “Standard Test Methods for Thermoplastic Insulations and Jackets for 

Wire and Cable,” ASTM International. 

21. Steiner, J.P. and Martzloff, F.D., “Partial Discharges in Low-voltage Cables,” paper 

presented at IEEE International Symposium on Electrical Insulation, Toronto, Canada, 

June 3-6, 1990. 

22. Tian, Y. et al., “Acoustic Emission Detection of Partial Discharges in Polymeric 

Insulation,” paper presented at Eleventh International Symposium on High Voltage 

Engineering, August 23-27, 1999. 

23. Seffrin, James R., “Thermography Advances Aid Proactive Maintenance,” Energy User 

News, page 30. June 1996. 

24. Presentation to NRC, “Wire System Aging Condition Monitoring and Fault Detection 

using Line Resonance Analysis,” April 5, 2005, Paolo F. Fantoni, OECD Halden Reactor 

Project, Institutt for Energiteknikk, Halden, Norway (available from 

Paolo.Fantoni@hrp.no). 

25. ASTM D638, “Standard Test Method for Tensile Properties of Plastics,” ASTM 

International. 

26. ASTM D412, “Test Methods for Vulcanized Rubber and Thermoplastic Rubbers and 

Thermoplastic Elastomers-Tension,” ASTM International. 

27. ASTM D 3895, “Test Method for Oxidative Induction Time of Polyolefins by Thermal 

Analysis,” ASTM International. 

6-2 
 

6-3 

28. Toman, G., “Oxidation Induction Time Concepts,” published in NUREG/CP-0135, 

“Workshop on Environmental Qualification of electric Equipment,” U.S. Nuclear 

Regulatory Commission, November 1993. 

29. Gillen, K.T., et al., “Density Measurements as a Condition Monitoring Approach for 

Following the Aging of Nuclear Power Plant Cable Materials,” Radiation Physics and 

Chemistry, v56, pp 429-447, 1999 Elsevier Science Ltd, Exeter Engl. 

30. ASTM Standard D792, “Test Method for Specific Gravity (Relative Density) and Density 

of Plastics by Displacement,” ASTM International. 

31. ASTM Standard D1505, “Test Method for Density of Plastics by the Density Gradient 

Method,” ASTM International. 

32. IEEE Std. 323-1974, “IEEE Standard for Type Test of Class 1E Equipment for Nuclear 

Power Generating Stations,” IEEE, New York, 1974. 

33. NUREG-1800, “Generic Aging Lessons Learned (GALL) Report,” Volumes 1 and 2, 

Revision 1, September 2005. 

34. IEEE Std. P1205-2000, “IEEE Guide for Assessing, Monitoring, and Mitigating Aging 

Effects on Class 1E Equipment Used in Nuclear Power Generating Stations” (Revision 

of IEEE Std. 1205-1993), IEEE, New York, March 20, 2000. 

35. EPRI TR-109619, “Guideline for the Management of Adverse Localized Equipment 

Environments,” Electric Power Research Institute, Palo Alto, CA. June 1999. 

36. US NRC Information Notice 89-63, “Possible Submergence of Electrical Circuits Located 

Above the Flood Level Because of Water Intrusion and Lack of Drainage,” U.S. Nuclear 

Regulatory Commission, September 5, 1989. 

37. Moore, G. F., “Electric Cables Handbook,” Third Edition, Blackwell Science, Inc. 1999. 

38. Romanoff, M., “Underground Corrosion,” National Bureau of Standards Circular 579, 

April 1957. 

39. EPRI TR-103834-P1-2, “Effects of Moisture on the Life of Power Plant Cables,” Electric 

Power Research Institute, Palo Alto, CA. August 1994.
 
 

APPENDIX A: FIBER OPTIC CABLES 

A-1 
 
 

A. FIBER OPTIC CABLES 

With the increased availability of digital and computer-based instrumentation and control (I&C) 

systems, many existing nuclear power stations are considering the replacement of their aged 

and obsolete original analog instruments and control systems with newer digital I&C 

technologies. The next generation of nuclear plants now being developed (e.g., the 

Westinghouse AP-600 and AP-1000, the General Electric ABWR and ESBWR, the Mitsubishi 

Industries US APWR, and the Areva EPR) make more extensive use of digital controls, 

instrumentation, and computer-based systems in their original designs. Many of these new 

digital I&C systems make use of fiber optic cable systems to interconnect the diverse system 

sensors, controls, and other components. 

This section provides a brief description of fiber optic cable materials, construction, and 

configurations. Discussion and analysis on the failure modes, stressors, and aging mechanisms 

for fiber optic cables, splices and connectors is presented. Finally, some of the condition 

monitoring test methods applicable to fiber optic cables are described. 

A.1 Construction, Materials, and Configurations 

Instead of using the conventional metallic copper or aluminum conductor cables, many of the 

new digital I&C systems incorporate fiber optic cable systems to link the digital process signals 

and communications among the various subcomponents in the digital I&C channel. On the 

functional level the two types of cables are similar. However, where metal conductor-based I&C 

systems transmit information via electrical pulses or analog electrical waveforms along the 

metallic conductors in the conventional electric cable, the fiber optic-based channels use light 

pulses to transmit information along the fiber optic cables to link the various components in the 

system. 

At one end of the fiber optic system channel is a transducer/optical transmitter that translates 

the signal from its original form at the origin of the cable into a series of light pulses to be 

transmitted along the fiber optic cable to an optical receiver/transducer at the receiving end. A 

light-emitting diode (LED) or an injection-laser diode (ILD) can be used for generating the light 

pulses. Using a lens, the light pulses are funneled into the fiber-optic medium where they travel 

down the cable. The wavelength of the light source (near infrared) is most often 850nm for 

shorter transmission distances and 1,300nm for longer distances on multi-mode fiber optic 

systems. On single mode fiber optic systems, the wavelength of the light source is typically 

1,300nm for shorter transmission distances and 1,500nm is used for longer distances. The 

optical receiver translates the optical pulses into an information signal in a form compatible for 

use at the receiving end of the fiber optic channel. [Ref. A1] 

The fiber optic cable acts as an optical waveguide that transmits light within the cable by the 

principle of total internal reflection. In its most basic configuration, a fiber optic cable is 

composed of two concentric layers: the core, through which light is piped, and the cladding. 

The core and cladding have different indices of refraction with the core having n1 and the 

cladding n2. The light pulses are guided down the fiber optic cable in the core because the core 

and cladding have different indices of refraction with the index of the core, n1, always being 

greater than the index of the cladding, n2. Light rays entering the fiber optic cable core that 

strike the core-to-cladding interface at an angle greater than critical angle, Θc = arccos (n2 / n1), 

are reflected back into the core. Since the angle of incidence is always equal to the angle of 

reflection the reflected light will be reflected again and again down the entire length of the fiber 

A-3 
 

optic cable. If a light ray strikes the core-to-cladding interface at an angle less than the critical 

angle, Θc, it passes into the cladding where it is attenuated very rapidly with propagation 

distance. [Refs. A1, A2] 

Attenuation is principally caused by two physical effects: absorption and scattering. Absorption 

removes signal energy in the interaction between the propagating light (photons) and molecules 

in the core. Scattering redirects light out of the core to the cladding. When attenuation for a 

fiber optic cable is dealt with quantitatively it is referenced for operation at a particular optical 

wavelength, a window, where it is minimized [Ref. A2]. The integrity and quality of the core-tocladding interface are very important to the attenuation of light channeled along the length of a 

fiber optic cable. Stressors that could erode, physically disrupt, or chemically alter the core-tocladding interface in any way, will therefore result in greater attenuation of light, through 

scattering, when traveling from the origin to the receiving end of the fiber optic cable. 

There are two basic modes of operation for fiber optic cables: single mode and multimode. A 

mode is the defined path in which light propagates through the fiber optic core. A light signal 

propagates through the fiber optic cable core on a single path in the single mode fiber and over 

many paths through the core in multimode fiber. The mode in which the light travels is dictated 

by the wavelength, core index profile, and core geometry. Single mode cable is comprised of a 

single strand of a very slender 8.3μm to 10μm diameter glass fiber through which light signals 

propagate via one mode, typically with a wavelength of 1310nm or 1550nm. Single mode fiber 

carries higher bandwidth than multimode fiber and experiences less signal attenuation, but 

requires a light source with a narrow spectral width. Multimode cable uses a larger fiber, in the 

50μm to 100μm diameter range, and can provide a high bandwidth at a high speeds over 

medium distances. Since the light is dispersed over multiple pathways through the core, signal 

attenuation and distortion at the receiving end can become unacceptable at distances greater 

than 3000 feet [Ref. A1]. 

The fiber optic cable is composed of one of three basic types of material construction: fused 

silica (glass), polymer (plastic), or polymer-clad silica (PCS). Glass fiber optic cable, consisting 

of a glass core and glass cladding, has the lowest signal attenuation characteristic (and 

therefore, the longest transmission distance without the need for optical signal repeaters) but it 

is more expensive than the other types. The core fiber may be pure silica glass or it may be 

doped with other elements such as germanium or fluorine to achieve a specified index of 

refraction (e.g., germanium or phosphorous are added to increase the index of refraction; boron 

or fluorine are added to decrease the index of refraction) or to optimized the performance 

characteristics of the glass fiber core operating in high radiation or temperature environments 

[Refs. A2, A4, A5]. 

Polymer (plastic) fiber optic cable, consisting of a polymer core and polymer cladding, has the 

highest signal attenuation characteristic (and the shortest transmission distance capability), but 

comes at the lowest cost. Plastic fiber optic cable is the largest in diameter, e.g. typical 

core/cladding dimensions are 480/500μm, 735/750μm and 980/1000μm, which also makes it 

quite rugged and capable of withstanding abuse. A typical plastic fiber optic cable consists of 

polymethylmethacrylate (PMMA) fiber core coated with a fluropolymer cladding [Ref. A2]. Poor 

performance under high temperature and radiation conditions, the limited transmission distance, 

and flammability problems make it an unlikely choice for nuclear plant applications. 

Plastic Clad Silica (PCS) fiber optic cable, consisting of a glass core fiber with a polymer 

(plastic) coating (usually of a lower index of refraction), has an attenuation characteristic falling 

between the pure silica fiber cables and the polymer fiber optic cables. The cost of PCS fiber 

A-4 
 

optic cable lies between that of pure glass fiber cables and all-plastic cables, as well. Plastic 

Clad Silica (PCS) fiber optic cable has a glass core which is often vitreous silica while the 

cladding is plastic - usually a silicone elastomer with a lower refractive index. The IEC 

standardized PCS fiber optic cable in 1984 to have the following dimensions: core 200μm, 

silicone elastomer cladding 380μm, jacket 600μm. Application of connectors on PCS fabricated 

with a silicone elastomer cladding can require a higher level of skill and training because of the 

plasticity of the cladding and other application problems [Ref. A2]. Attenuation performance and 

transmission distance limitations, together with connector application and other difficulties, make 

the PCS fiber optic cable a less desirable option for nuclear power plant service. 

A typical basic fiber optic cable has an additional coating(s) around the cladding called the 

jacket. The jacket usually consists of one or more layers of polymer. Its role is to protect the 

core and cladding from physical impacts that might affect their optical or physical properties. 

The jacket also acts as a physical shock absorber, and it provides protection for the internal 

optical fiber and cladding from abrasions, solvents, moisture, and other contaminants. The 

jacket does not have any optical properties that might affect the propagation of light within the 

fiber optic cable [Ref. A1]. 

A.2 Failure Modes, Stressors, and Aging Mechanisms 

In order to include important fiber optic cables in the electric cable condition monitoring (CM) 

program it is necessary to identify the similarities and differences between fiber optic cables and 

the conventional polymer-insulated, metal conductor I&C cables around which the essential 

elements of the program are designed. The general programmatic structure of the 

recommended nine essential elements of the cable CM program is compatible with monitoring 

and evaluation of fiber optic cables. However, the differences in construction of the fiber optic 

cable, its failure modes, the important failure mechanisms, and the types of inspection and CM 

testing techniques will be unique as compared to conventional electric cables. Therefore, some 

minor considerations and adaptations may be called for to incorporate fiber optic cables into 

program element 3, environmental monitoring, element 4, identification of stressors and aging 

degradation mechanisms, and element 5, selection of CM inspection and testing techniques. 

Some modifications may be needed to the database data fields (CM program element 2) to 

accommodate fiber optic cable characteristics information and test data. 

In conventional electric cables, the evaluation of the condition of the electrical insulation is the 

primary focus when monitoring the cable. The integrity of the conductor, cable splices, and 

cable termination connections is proven through condition monitoring activities, such as 

functional testing, visual inspection, Infrared (IR) thermography, and time domain reflectometry 

(TDR) testing. The major considerations in the evaluation of electric cables are insulation 

resistance, insulation dielectric strength, aging mechanisms, flexibility, effects of design basis 

events (DBEs), and fire resistance. In contrast, when evaluating optical fibers, the condition of 

the cable is assessed by evaluating signal transmission performance. The outer polymer buffer 

layer does not contribute to the transmission of light signals and serves as physical protection 

for the optical core and cladding material. The major considerations for evaluating fiber optic 

cables are monitoring signal attenuation, radiation dose and dose rate, and environmental 

thermal effects [Ref. A3]. 

The reliability engineer typically uses the failure modes and effects analysis (FMEA) tool to 

identify the manner or state in which a structure, system, or component (SSC) fails and the 

resulting effect that the failure mode will have on the function of the SSC. The piece-parts and 

subcomponents of the SSC are each analyzed in turn to identify the sub-component materials, 

A-5 
 

stressors, potential aging mechanisms, and the potential effect(s) of the stressors and 

associated degradation/aging mechanisms on the function and operation of the subcomponent, 

i.e., will the mechanisms result in the subcomponent’s failure. 

By identifying these stressors, and quantifying their severity, the cable engineer can determine 

the aging and failure mechanisms that will cause degradation or other damage that, over time, 

could lead to the ultimate failure of a cable system. This information can then be used to select 

the most effective CM inspection and testing techniques for detecting and monitoring the 

anticipated aging/failure mechanisms. 

Using the FMEA methodology applied to fiber optic cable systems, the failure modes, stressors, 

and significant aging mechanisms must be identified. The condition monitoring inspection and 

testing methods that are best suited for detecting and monitoring the progress or effects of the 

significant degradation mechanisms can then be selected. The failure modes for optical fibers 

include attenuation of signal to unacceptable optical power levels, distortion of the signal (time 

dispersion) causing an unacceptable bit error rate (BER), or complete loss of signal. 

Cable systems in nuclear power plant service are subject to a variety of aging and degradation 

stressors that can produce immediate degradation or aging-related mechanisms and effects 

causing degradation of the cable components over time. Stressors can generally be 

categorized as one of two types based upon their origin: 1) environmental stressors originate 

from conditions in the environment where a cable system is located or 2) operational stressors 

that are the result of operational factors such as inspections or operating and maintenance 

activities in the vicinity of the cable system. 

Using the FMEA analytical approach applied to fiber optic cable systems, the piece-parts of a 

cable (e.g., silica fiber optic core and cladding, protective fiber optic cable jacket, the precision 

silica fiber connector interface, and the fiber optic cable splice and connector hardware) are 

each analyzed to identify the constituent material(s). The stressors that can affect the 

material(s) in each piece-part of a particular cable system and operating environment, are 

analyzed to determine whether they can produce a degradation or aging mechanism that could 

eventually lead to one of the failure modes for the fiber optic cable. A general summary of 

stressors and associated potential aging and degradation mechanisms, adapted from 

information found in References A3 through A9, is provided in Table A.1 for fiber optic cables, 

splices, and connectors. 

A.3 Fiber Optic Inspection and Testing 

Condition monitoring of fiber optic cable systems will include visual inspection and testing using 

instruments and techniques specifically designed for fiber optic cable systems. Baseline visual 

inspection and periodic visual inspection for fiber optic cable systems will be quite similar to 

those described in subsections 3 and 6 for conventional electric cables. Identification of local 

adverse stressors, such as high temperature, high radiation, high humidity or flooding, is 

important since these stressors can cause the aging and degradation mechanisms summarized 

in Table A1, which could have an adverse affect on cable performance. Visual inspection can 

detect direct mechanical damage, such as physical impacts, bending, abrasion, cutting, contact, 

deformation, and perforation resulting from installation and maintenance activities in and around 

the location of a cable. As indicated in Table A.1, mechanical damage is a potential stressor 

that can affect fiber optic cable systems by direct damage to the optical fibers or, indirectly, by 

damaging the protective polymer jacket and opening a potential pathway for intrusion of 

A-6 
 

A-7 

moisture or other contaminants that could degrade the optical properties of the fiber optic core 

and cladding material. 

Testing fiber optics requires special tools and test instruments that must be selected specifically 

for monitoring the types of fiber optic components and fiber optic cables used in the particular 

installation being tested. Guidance on various types of fiber optic cable system testing 

techniques has been developed and incorporated in to testing standards, known in the industry 

as fiber optic test procedures (FOTPs), sponsored by the Electronic Industries Alliance (EIA) 

and the Telecommunications Industry Association (TIA). A list of these EIA-TIA fiber optic test 

procedures can be found on the Fiber Optics Association (FOA) internet website [Ref. A8]. 

At the time fiber optic cables are installed, spliced, and terminated, they must be baseline 

tested. In addition to a baseline visual inspection to verify the condition of the installation, 

typical fiber optic cable system measurements will include a test for continuity and polarity, endto-end insertion loss, and then troubleshooting for any problems that are identified. Long fiber 

optic cable runs that include intermediate splices should be checked using an optical time 

domain reflectometer (OTDR) to verify the location and performance of the individual splices. 

Baseline measurements of these data can be compared with subsequent periodic 

measurements of the same type to identify or trend any degradation of the fiber optic cable 

system. The aging and degradation mechanisms listed in Table A1 can degrade the 

performance of the cable’s optical fiber and intermediate optical cable splices and connectors. 

Continuity checking is accomplished using a visual fiber tracer to verify that the optical fibers are 

not broken and to trace the path of a fiber from one end to another through many connections. 

The visual fiber tracer looks like a flashlight, or a pen-light, with a simple light bulb or LED 

source that mates to a fiber optic connector. When attached to a cable, the light from the 

source will be transmitted through the core of the fiber and will be visible at the far end. If there 

is no light at the end, there are faulty intermediate connectors or splices, or broken sections of 

the fiber optic cable [Refs. A8, A9]. 

Optical power measurement is one of the most important indicators of fiber optic cable 

performance. The power output of an optical transmitter or the input to the optical receiver are 

"absolute" optical power measurements; that is, the actual value of the optical power is being 

measured. Optical power loss is a "relative" power measurement, being the difference between 

the power coupled into a component like a cable, splice, or a connector and the power that is 

transmitted through it. This difference in power level before and after the component is called 

optical loss and defines the performance of a cable, connector, splice, etc. [Refs. A8, A9]. 

“Loss testing of a cable is the difference between the power coupled into the cable at the 

transmitter end and what comes out at the receiver end. Testing for loss (also called "insertion 

loss") requires measuring the optical power lost in a cable (including fiber attenuation, connector 

loss and splice loss) with a fiber optic light source and power meter (LSPM) or optical loss test 

set (OLTS). Loss testing is done at wavelengths appropriate for the fiber and its usage. 

Generally, multimode fiber is tested at 850nm and optionally at 1300nm with LED sources. 

Single mode fiber is tested at 1310nm and optionally at 1550nm with laser sources” [Ref. A8]. 

The optical time domain reflectometer (OTDR) is typically used to measure distance and 

attenuation over the entire length of a fiber optic cable link. It is also used to identify specific 

points along the link where optical power losses occur, such as splices and connectors. 

An OTDR is an optical radar which measures time of travel and the return strength of a short 

pulse of light launched into an optical fiber. The functional principle is similar to the time domain 
Table A.1 Summary of Stressors and Potential Aging Mechanisms for Fiber Optic Cables, Splices, and 

Subcomponent Material Stressors Potential Aging Mechanisms Potential Aging Effects 

• Silica fiber (pure and 

doped) 

• Elevated temperature • Elevated radiation fields 

• Discoloration • Degradation of core to 

cladding interface 

• Increased signal 

attenuation 

• Decrease in optical power 

transmission 

• Increased signal time 

dispersion 

 Silica fiber (pure and 

doped) 

• Wetting • Humidity 

• Moisture intrusion • Degradation of core to 

cladding interface 

• Increased signal 

attenuation 

• Decrease in optical power 

transmission 

• Increased signal time 

dispersion 

Mointrintefun

 Silica fiber (pure and 

doped) 

• Corrosive chemical 

contamination 

• Chemical reactions • Discoloration • Degradation of core to 

cladding interface 

• Increased signal 

attenuation 

• Decrease in optical power 

transmission 

• Increased signal time 

dispersion 

 Silica fiber (pure and 

doped) 

• Handling, physical 

contact, or abuse during maintenance, operation, or testing activities 

• Mechanical damage 

including crushing, bending, tensile deformation, cracking 

• Increased signal 

attenuation 

• Decrease in optical power 

transmission 

• Increased signal time 

dispersion 

• Loss of signal 

Breloss 

Fiber Optic Cable Core and Cladding 

 Silica fiber (pure and 

doped) 

• Installation damage • Mechanical damage 

including crushing, bending, tensile deformation 

• Increased signal 

attenuation 

• Decrease in optical power 

transmission 

• Increased signal time 

dispersion 

• Loss of signal 

Breloss 

A-8 
Material Stressors Sub- Potential Ag component ing Mechanisms Potential Aging Effects 

• Various polymer 

materials 

• Elevated temperature • Elevated radiation fields 

• Embrittlement • Cracking 

• Loss of structural integrity • Increased intrusion of 

moisture and contaminants into the cable interior 

The cabmecabsecmitiand inte

• Various polymer 

materials 

• Handling, physical 

contact, or abuse during maintenance, operation, or testing activities 

• Mechanical damage 

including crushing, bending, cutting, abrasion, gouging, tensile deformation 

• Loss of structural integrity • Increased intrusion of 

moisture and contaminants into the cable interior 

Mointrdamand abo

Cable Jacket 

• Various polymer 

materials 

• Installation damage • Mechanical damage 

including crushing, bending, cutting, abrasion, gouging, tensile deformation 

• Loss of structural integrity • Increased intrusion of 

moisture and contaminants into the cable interior 

Mointrdamand abo

 Silica fiber (pure and 

doped) 

• Contamination by dirt or 

dust 

• Degradation of 

connection interface 

• Decrease in optical power 

transmission 

• Loss of signal 

 Silica fiber (pure and 

doped) 

• Wetting due to moisture 

intrusion 

• Humidity 

• Degradation of 

connection interface 

• Decrease in optical power 

transmission 

• Loss of signal 

Mointrintefun

 Silica fiber (pure and 

doped) 

• Vibration • Abrasion 

• Loosening of connectors 

• Decrease in optical power 

transmission 

• Loss of signal 

 Silica fiber (pure and 

doped) 

• Corrosive chemical 

contamination 

• Chemical reactions • Discoloration • Degradation of 

connection interface 

• Decrease in optical power 

transmission 

• Loss of signal 

Fiber Optic Cable Connection Interface (Splices and Connectors) 

 Silica fiber (pure and 

doped) 

• Handling, physical 

contact, or abuse during maintenance, operation, or testing activities 

• Mechanical damage to 

interface surfaces 

• Misalignment of 

connection interface 

• Decrease in optical power 

transmission 

• Loss of signal 

Can discreccon

A-9 
A-10 

Subcomponent Material Stressors Potential Aging Mechanisms Potential Aging Effects 

Connectors (continued) 

 Silica fiber (pure and 

doped) 

• Installation damage • Mechanical damage to 

interface surfaces 

• Dirt on interface surfaces • Misalignment of 

connection interface 

• Decrease in optical power 

transmission 

• Loss of signal 

Respra

• Metal connection 

assembly components 

• Plastic connection 

assembly components 

• Handling, physical 

contact, or abuse during maintenance, operation, or testing activities 

• Mechanical damage to 

interface surfaces 

• Misalignment of 

connection interface 

• Decrease in optical power 

transmission 

• Loss of signal 

Can discreccon

• Metal connection 

assembly components 

• Plastic connection 

assembly components 

• Installation damage • Mechanical damage to 

interface surfaces 

• Dirt on interface surfaces • Misalignment of 

connection interface 

• Decrease in optical power 

transmission 

• Loss of signal 

Respra

Fiber Optic Cable Connection Hardware 

• Metal connection 

assembly components 

• Plastic connection 

assembly components 

• Vibration • Mechanical damage to 

interface surfaces 

• Fatigue damage to 

connector hardware 

• Misalignment of 

connection interface 

• Loss of structural integrity • Decrease in optical power 

transmission 

• Loosening of connection • Loss of signal 
 

reflectometer (TDR), described in subsection 3.2.9, used for trouble shooting conventional 

electric cables. As a light signal propagates the length of an optical fiber, small reflections occur 

throughout the fiber, becoming weaker as power levels drop with distance. At major breaks, 

large reflections occur and appear as strong peaks on an oscilloscope display at the instrument. 

The magnitude and location of the peaks can indicate broken or damaged sections of optical 

fiber, or indicate degradation, misalignment, or other problems at the site of an optical cable 

splice or an optical cable connector. The instrument also gives the location of the problem, so 

that if the site of the problem is accessible, the degraded splice or connector can be cleaned 

and/or repaired [Refs. A8, A9]. 

Additional guidance on the use of OTDRs, optical power meters, and other fiber optic test 

instruments to perform condition monitoring measurements on fiber optic cable systems can be 

found in References A8 and A9. 

Table A.1 indicates that the interconnection joint on an optical cable splice or connector is an 

area that is susceptible to contamination, damage or misalignment that can degrade the optical 

performance of the connection. Fiber optic inspection microscopes are used to inspect 

connectors and to find faults like scratches, polishing defects, and dirt. A properly installed 

connector will have a smooth, polished, scratch-free finish and the fiber will not show any signs 

of cracks, chips, or areas where the fiber is either protruding from the end of the ferrule or 

pulling back into it. 

The magnification available on a fiber optic inspection microscope for viewing connectors can 

typically range from 30 to 400 power, so that an optimum viewing magnification can be selected. 

Some fiber optic inspection microscopes allow examination of the connector from several 

angles, either by tilting the connector or adjusting the angle of illumination to optimize the 

viewing conditions. Adaptors are provided to affix the connector in position to allow inspection. 

More advanced fiber optic inspection microscopes provide a digital video display of the optical 

connector end face and software that analyzes the surface finish [Refs. A8, A9]. 

Further guidance on the installation, inspection, cleaning, and maintenance of fiber optic cable 

splices and connectors is provided in References A8 and A9. 

A-11 
 

A-12 

References for Appendix A 

A1. “The Basics of Fiber Optic Cable,” Internet Website: www.arcelect.com/fibercable.htm , 

ARC Electronics Co., Georgetown, Texas. 

A2. Schneider, Kenneth S., “The Fiber Optic Data Communications Link for the Premises 

Environment,” Internet Website: www.telebyteusa.com/foprimer/foch2.htm#2.2, Telebyte 

Co., Hauppauge, New York. 

A3. Pirrong, Jan, “Qualification of Fiber Optic Cables for Nuclear Power Plants,” presentation to 

IEEE Nuclear Power Engineering Committee (NPEC), Subcommittee SC-1, New Orleans, 

Louisiana, 21 April 2004. 

A4. West, R. H., “A Local View of Radiation Effects in Fiber Optics,” Journal of Lightwave 

Technology, Vol. 6, No. 2, February 1988. 

A5. Ott, Melanie N., “Fiber Optic Assemblies for Spaceflight II: Thermal and Radiation Effects,” 

white paper, Component Technologies and Radiation Effects Branch, Goddard Space 

Flight Center/Swales Aerospace, Greenbelt Maryland. 

A6. Lindholm, Eric A., Li, Jie, Hokansson, Adam, Slyman, Brian, and Burgess, David, “Aging 

Behavior of Optical Fibers in Aqueous Environments,” white paper, OFS, Specialty 

Photonic Division, Avon, Connecticut. 

A7. Camlibel, I., Pinnow, D.A., and Dabby, F.W., “Optical Aging Characteristics of Borosilicate 

Clad Fused Silica Core Fiber Optical Waveguides,” Bell Laboratories, Murray Hill, New 

Jersey, November 7, 1974. 

A8. “Reference Guide to Fiber Optics - Fiber Optics Testing,” Internet Website: 

www.thefoa.org/tech/ref/basic/test.html, The Fiber Optic Association, Inc., Fallbrook, 

California. 

A9. “Tools - Fiber Optic Cable Installation,” Internet Website: 

www.belden.com/08Tools/08_FiberOpticsInstall.cfm#Testing, Belden, Inc., Richmond, 

Indiana. 
 
 

APPENDIX B: DEFINITIONS 

B-1 
 

B-2 
 

B. DEFINITIONS 

This appendix provides definitions for several of the key terms and phrases used in this report. 

Some of these are common electric cable terminology in use in the commercial nuclear and 

electric power industries. Other usages have evolved during the performance of electric cable 

manufacturing, testing, maintenance, qualification testing, and research. Many of the electric 

cable terms and phrases are defined in one or more standard industry dictionaries or glossaries 

of technical terms, such as EPRI Brochure BR-101747, “Common Aging Terminology” [Ref B1], 

and IEEE Std. 100-2000, “The Authoritative Dictionary of IEEE Standards Terms, Seventh 

Edition” [Ref B2]. Reference sources are cited as applicable. 

B.1 Definitions of Terms and Phrases 

Aging Mechanism - specific process that gradually changes characteristics of an SSC with 

time or use [Refs. B1 & B6] 

Alternate AC (AAC) Power Source - an alternating current (ac) power source that is available 

to and located at or nearby a nuclear power plant and meets the following requirements: 

(1) is connectable to but not normally connected to the offsite or onsite emergency ac 

power systems; 

(2) has minimum potential for common mode failure with offsite power or the onsite 

emergency ac power sources; 

(3) is available in a timely manner after the onset of station blackout; and 

(4) has sufficient capacity and reliability for operation of all systems required for coping 

with station blackout and for the time required to bring and maintain the plant in safe 

shutdown (non-design basis accident) [Ref B3] 

Antioxidants (cable insulation) - an oxidation inhibitor included in polymeric electric cable 

insulation to protect the main polymer compound from oxidation damage 

Cable System - an electric cable circuit or group of circuits including the electric cable, 

terminations, splices, and other accessories 

Compressive Modulus - a material property defined as the ratio of compressive stress to 

compressive strain below the proportional limit [Ref B4] 

Condition Monitoring - observation, measurement or trending of condition or functional 

indicators with respect to some independent parameter (usually time or cycles) to indicate the 

current or future ability of an SSC to function within acceptance criteria [Ref B1] 

Degradation Mechanism - specific process that causes the immediate or gradual deterioration 

of characteristics of an SSC that could impair its ability to function within acceptance criteria 

[adapted from Refs. B1 & B6] 

Design Basis Event - conditions of normal operation, including anticipated operational 

occurrences, design basis accidents, external events, and natural phenomena for which the 

plant must be designed [10 CFR 50.49] 

Dielectric Loss Angle - the angle whose tangent is the dissipation factor (See Figure 3.1) 

[Ref. B2 & B4] 

B-3 
 

B-4 

Dielectric Phase Angle - the angular difference in phase between the sinusoidal alternating 

voltage applied to a dielectric and the component of the resulting alternating current having the 

same period as the voltage (See Figure 3.1) [Ref. B2 & B4] 

Dielectric Strength - the potential gradient at which electric failure or breakdown occurs 

[Ref. B2 & B4] 

Dissipation Factor - the tangent of the dielectric loss angle, Note: For small values of dielectric 

loss angle dissipation factor is virtually equal to insulation power factor (See Figure 3.1) 

[Refs. B2 & B4] 

Dry (environment) - an operating environment in which an electric cable is generally protected 

from direct exposure to water and only occasionally may be exposed to moisture, condensation, 

or high humidity for brief intervals of time 

Environmental Conditions - ambient physical states surrounding an SSC [Ref. B1] 

Failure Mode - the manner or state in which an SSC fails [Ref. B1] 

Harsh Environment - an environment expected as a result of the postulated service conditions 

appropriate for the design basis and post-design basis accidents of the station [Ref. B2] 

Insulation (cable) - the part that is relied upon to insulate the conductor from other conductors 

or the conductor from ground [Ref. B2] 

Insulation Resistance (cable) - the resistance, measured at a specified dc voltage, between a 

specified conductor and any other conductor or ground [adapted from Refs. B2 and B4] 

Jacket (cable) - a thermoplastic or thermosetting covering, sometimes reinforced, applied over 

the insulation, core, metallic sheath, or armor of a cable [Ref. B2] 

Local Adverse Environment - a condition in a limited plant area containing an electric cable 

system that is significantly more severe than the specified service condition for the electric cable 

system; the service conditions of interest include normal, abnormal, and error-induced 

conditions prior to the start of a design basis accident or earthquake [adapted from Ref. B6] 

Low-Voltage (power cable) - those cables used on systems operating at 1000V or less 

[Ref. B2] 

Mild Environment - a mild environment is an environment that would at no time be significantly 

more severe than the environment that would occur during normal plant operation, including 

anticipated operational occurrences. [10 CFR 50.49] 

Ohmic Heating (cable) - the internal heat generated by the flow of current through the electrical 

resistance of a cable conductor 
 

Partial Discharge/Corona - an electric discharge which only partially bridges the insulation 

between conductors, and which may or may not occur adjacent to a conductor; partial 

discharges occur when the local electric-field intensity exceeds the dielectric strength of the 

dielectric involved, resulting in local ionization and breakdown; depending on intensity, partial 

discharges are often accompanied by emission of light, heat, sound, and radio influence voltage 

(with a wide frequency range). [Ref. B2] 

Polarization Index - the ratio of the insulation resistance of a cable insulation measured at 1 

minute after test voltage has been applied divided into the insulation resistance measurement at 

10 minutes. [Ref. B2 & B4]

Power Factor - the insulation power factor is equal to the cosine of the phase angle between 

the voltage and the resulting current when both the voltage and current are sinusoidal (See 

Figure 3.1) [Refs. B2 & B4] 

Qualified Life - period for which an SSC has been demonstrated, through testing, analysis, or 

experience, to be capable of functioning within acceptance criteria during specified operating 

conditions while retaining the ability to perform its safety functions in a design basis accident or 

earthquake [Ref B1] 

Sheath (cable) - a uniform and continuous covering, metallic or nonmetallic, enclosing the 

insulated conductor(s), used to protect the cable against influences from the surroundings 

(corrosion, moisture, etc.) [Ref. B2] 

Shield (instrumentation cable) - braided copper, metallic sheath, or metallic coated polyester 

tape (usually copper or aluminum), applied over the insulation of a conductor or conductors for 

the purpose of reducing electrostatic coupling between the shielded conductors and others that 

may be either susceptible to, or generators of, electrostatic fields (noise). [Ref. B2]

Stressor - an agent or stimulus that stems from pre-service and service conditions and can 

produce immediate or aging degradation of an SSC [Refs. B1 & B6] 

Submergence/Submerged (environment) - an operating environment in which an electric 

cable is submerged in water continuously or for extended periods of time 

Water Treeing - a phenomenon in which tree-like micro-cracks are formed in electric cable 

insulation due to electrochemical reactions caused by the presence of water and the relatively 

high electrical stress on the insulation at local imperfections within the insulating material, such 

as voids and contaminant sites, that effectively increase the voltage stress at that point in the 

insulation [Refs. B7 & B8] 

Wetting/Wetted (environment) - an operating environment in which an electric cable is 

exposed to moisture and high humidity for limited periods of time. 

B-5 
 

References for Appendix B 

B1. BR-101747, “Common Aging Terminology,” Electric Power Research Institute, Palo Alto, 

California. February 1993. 

B2. IEEE Std. 100-2000, “The Authoritative Dictionary of IEEE Standards Terms, Seventh 

Edition,” Institute of Electrical and Electronics Engineers, New York. March 30, 2000. 

B3. 10 CFR 50.2 “Definitions” 

B4. NUREG/CR-6704, “Assessment of Environmental Qualification Practices and Condition 

Monitoring Techniques for Low-Voltage Electric Cables,” Brookhaven National Laboratory, 

Volume 2, February 2001. 

B5. IEEE Std. 1205-2000, “IEEE Guide for Assessing, Monitoring, and Mitigating Aging Effects 

on Class 1E Equipment Used in Nuclear Power Generating Stations” (Revision of IEEE 

Std. 1205-1993), IEEE, New York, March 20, 2000. 

B6. EPRI TR-109619, “Guideline for the Management of Adverse Localized Equipment 

Environments,” Electric Power Research Institute, Palo Alto, CA. June 1999. 

B7. NUREG/CR-6794, “Evaluation of Aging and Environmental Qualification Practices for 

Power Cables Used in Nuclear Power Plants,” Brookhaven National Laboratory, January 

2003. 

B8. Moore, G. F., “Electric Cables Handbook,” Third Edition, Blackwell Science, Inc. 1999. 

B-6 
 

NRC FORM 335 U.S. NUCLEAR REGULATORY COMMISSION

(9-2004) 

NRCMD 3.7 

BIBLIOGRAPHIC DATA SHEET

1. REPORT NUMBER (Assigned by NRC, Add Vol., 

Supp., Rev., and Addendum Numbers, if any.) 

 NUREG/CR - 7000 

 BNL-NUREG-90318-2009 

3. DATE REPORT PUBLISHED 2. TITLE AND SUBTITLE 

MONTH 

January 

YEAR 

2010 

Essential Elements of an Electric Cable Condition Monitoring Program 

4. FIN OR GRANT NUMBER 

JCN: N-6744 

6. TYPE OF REPORT 

Technical 

5. AUTHOR(S) 

M. Villaran, R. Lofaro 

7. PERIOD COVERED (Inclusive Dates) 

10/01/ 2008 - 11/30/2009 

8. PERFORMING ORGANIZATION - NAME AND ADDRESS (If NRC, provide Division, Office or Region, U.S. Nuclear Regulatory Commission, and mailing address; if contractor, 

provide name and mailing address.) 

Energy Science & Technology Department 

Brookhaven National Laboratories Upton, NY 11973-5000 

9. SPONSORING ORGANIZATION - NAME AND ADDRESS (If NRC, type "Same as above"; if contractor, provide NRC Division, Office or Region, U.S. Nuclear Regulatory Commission, and mailing 

address.) 

Division of Engineering 

Office of Nuclear Regulatory Research 

 U.S. Nuclear Regulatory Commission, Washington DC 20555-0001 

10. SUPPLEMENTARY NOTES 

S. Aggarwal and D. Murdock NRC Project Managers 

11. ABSTRACT (200 words or less) 

For more than 20 years the NRC has sponsored research studying the aging degradation, condition monitoring, environmental qualification, 

and testing practices for electric cables and cable accessories used in nuclear power plants. The essential elements for an effective cable 

condition monitoring program presented in this report are based upon the results of the NRC's electric cable and equipment research 

programs, industry guidance and standards, and the experience and observations of the others who have studied or conducted electric cable 

condition monitoring and qualification testing. The program methodology presented herein provides guidance on the selection of cables to be 

included in the program, characterization and monitoring of cable operating environments and stressors, selection of the most effective and 

practical condition monitoring techniques, documentation and review of cable condition monitoring testing and inspection results, and the 

periodic review and assessment of cable condition and operating environments. 

13. AVAILABILITY STATEMENT 

 unlimited 

12. KEY WORDS/DESCRIPTORS (List words or phrases that will assist researchers in locating the report.) 

14. SECURITY CLASSIFICATION 

(This Page) 

 unclassified 

(This Report) 

 unclassified 

Condition monitoring, aging degradation, electric cables, stressors 

15. NUMBER OF PAGES 

 130 

16. PRICE