General Cable develops cable for nuclear applications

INDIANAPOLIS—General Cable Corp. continues to invest in new compounds and as a result has developed a new cable for nuclear applications.

The Ultrol 60+ low-voltage cable, released in 2014 after four years of development, meets the most rigorous GEN III+ reactor requirements for a 60 year operating life. That includes:

• 60 years of life expectancy confirmed through Arrhenius aging tests;

• Exposure to gamma radiation of more than 300 MRads total integrated dose or more than 300 MRads total integrated dose of beta radiation;

• Surpasses nuclear industry requirements for existing pressurized water reactor and boiling water reactor facilities to the Institute of Electrical and Electronics Engineers Standards Association 323 and 383 requirements;

• Meeting reactor manufacturer requirements for design basis event temperature and pressure profiles; and

• Completion of one-year post-DBE submergence requirements for some GE III+ reactor profiles in hot boric acid solution.

Srini Siripurapu, vice president of research and development, said designing Ultrol 60+ was one of the toughest projects the firm's Indianapolis research and development center initiated.

“After Fukushima happened, the requirements for the new generation reactors that are being built in South Carolina and Georgia have increased,” Siripurapu said. “The old cables had to survive for 40 years; the new cables have to survive for 60 years.”

General Cable's research and development centers produce compounds used in the insulation and jacketing applications of the cable, which include elastomers. Siripurapu said the firm deals mainly in polyolefinic elastomers and EPDM.

The Indianapolis facility had to custom-design a compound for its nuclear line of cables. Siripurapu said it is the largest in the company and is the main center for compounds. It spans about 50,000 square feet and employs about 45.

The facility designs compounds for utility, medium voltage, industrial and specialty applications such as transit, oil and gas, nuclear and mining, among others.

The operation has a full array of testing applications—physical, chemical, thermal, flame, electrical and recently added capabilities to test for innovation in metals.

“All of these applications use rubber and elastomeric compounds. We've really committed a lot of our resources over the last 25 years to bringing up the latest and greatest products in these areas,” Siripurapu said.

“If you look at our Indy compounding facility, we can actually run insulation tests for medium and high voltage. It's a top class, super clean facility. It's a different kind of a setup than just a run-of-the-mill compounder, if you will. Wire and cable insulations, you need them to be really, really clean.”

The firm recently named Michael T. McDonnell as its new president and CEO. He replaces Gregory B. Kenny, who led the company since 2001 and retired on July 1.

John E. Welsh will remain chairman of the board, and Kenny will remain with the firm as an adviser through the end of 2015.

McDonnell previously was chairman, president and CEO of TPC Group. Prior to joining TPC Group in 2011, he was president, CEO and executive director of Pregis Corp.

“I am honored and excited to join General Cable,” McDonnell said in a news release.

“I'm leaving a great company at TPC Group, which I have had the fortune of leading over the past four years where together with the board and the management team, we have built a stronger organization and delivered long-term value for all stakeholders. I expect to do the same at General Cable.”

General Cable develops, designs, manufactures, markets and distributes aluminum, copper and fiber optic wire and cable products for a variety of industries, including energy, industrial, specialty and communications.

The firm's annual revenues exceed $6 billion. It operates 57 manufacturing facilities in 26 countries with about 14,000 employees.