核电站用1E级K3类仪表电缆的研制

    Development of Class 1E Category K3 Instrumentation Cable for Nuclear Power Plant

    • 摘要: 为提升核电站用1E级K3类仪表电缆的性能,文中提出一种集成式抗干扰长寿命电缆结构。该电缆采用高导磁合金丝与芳纶丝复合缠绕屏蔽层,兼具电磁屏蔽与机械防护功能;绝缘与护套采用共挤分层梯度设计,以提升环境耐受性能;内置光纤传感单元,实现全线温度与振动的分布式实时监测。最后,通过智能检测功能验证、电磁兼容性试验、机械性能测试、绝缘热老化寿命预测、护套长期耐久性试验及集成光纤传感单元长期可靠性试验,验证电缆结构的可靠性和可行性。结果表明,该电缆集成光纤传感单元的温度测量误差不超过±1.5℃、振动定位精度为±1 m;在50 Hz工频下,屏蔽效能达到26.4 dB;拉伸承载力大于2200 N;在温度为90 ℃的环境下,绝缘系统的预测寿命下限为68 a;护套与光纤单元经加速热老化后的验证寿命均满足至少60 a的要求。综上,上述设计显著增强了电缆的电磁兼容性、机械强度、耐久性及智能化水平,适用于核电站高可靠性仪表与控制回路。

       

      Abstract: To enhance the performance of Class 1E Category K3 instrumentation cables for nuclear power plants, an integrated anti-interference long-life cable structure was proposed. In the developed cable, a composite shielding layer wound with high-permeability alloy wires and aramid fibers was employed, providing both electromagnetic shielding and mechanical protection functions. A co-extruded layered gradient design was adopted for the insulation and sheath to improve environmental resistance. Meanwhile, an embedded optical fiber sensing unit enables distributed real-time monitoring of temperature and vibration along the entire cable length. Finally, the reliability and feasibility of the cable structure were verified through intelligent detection function verification, electromagnetic compatibility tests, mechanical performance tests, insulation thermal aging life prediction, long-term durability tests of the sheath, and long-term reliability tests of the integrated optical fiber sensing unit. Results showed that temperature measurement error of integrated optical fiber sensing unit was kept within ±1.5 °C, and vibration localization accuracy of ±1 m was achieved, shielding effectiveness of 26.4 dB was reached at 50 Hz power frequency, tensile load-bearing capacity of over 2 200 N was obtained, predicted service life lower limit of 68 years for the insulation system at 90 °C was calculated; and the validated service lives of both the sheath and the optical fiber unit after accelerated thermal aging were proved to meet the requirement of at least 60 years. In conclusion, the electromagnetic compatibility, mechanical strength, durability, and intelligence of the cable were significantly enhanced by the proposed design, making it suitable for high-reliability instrumentation and control circuits in nuclear power plants.

       

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