ML15134A018
| ML15134A018 | |
| Person / Time | |
|---|---|
| Site: | Salem, Hope Creek  |
| Issue date: | 05/07/2015 |
| From: | Franchuk T Qualtech NP |
| To: | Office of Nuclear Reactor Regulation, NRC/RGN-III |
| References | |
| Download: ML15134A018 (34) | |
Text
0510712015 U.S. Nuclear Regulator Commission Operations Center Event Report Pa-ve I Part 21 (PAR)
Event#
51053 Rep Org: QUALTECH NP Notification Date I Time: 05/07/2015 14:31 (EDT)
Supplier: QUALTECH NP Event Date I Time: 05/07/2015 (EDT)
Last Modification: 05/07/2015 Region:
3 Docket #:
City:
CINCINNATI Agreement State:
Yes County:
License #:
State: OH NRC Notified by: TIM FRANCHUK Notifications: DAN SCHROEDER R1DO HQ Ops Officer: STEVE SANDIN SHANE SANDAL R2DO Emergency Class: NON EMERGENCY RICHARD SKOKOWSKI R3DO 10 CFR Section:
GREG PICK R4DO 21.21(d)(3)(i)
DEFECTS AND NONCOMPLIANCE PART 21/50.55 REACTORS EMAIL POTENTIAL PART 21 INVOLVING STRUTHERS DUNN RELAYS WITH CONTACT RESISTANCE GREATER THAN ONE OHM The following is excerpted from a report submitted by QualTech NP, Nuclear Division, Curtiss-Wright Corporation:
Subject:
"PSEG reported failures for Struthers Dunn 219BBX200 relays related to greater than 1 ohm contact resistance.
Two relays were evaluated by Exelon Power Labs. Of these, one had a failure consisting of a contact resistance greater than one ohm. Struthers Dunn has also provided an evaluation in this regard and does not agree with the failure mode as inferred in the Exelon Power Labs report.
"Lab and OEM report key difference:
"The Power Labs' Report(s) shows fiberglass fiber(s) embedded into gold plated contacts on one relay believed to result in a contact resistance greater than one Ohm (1.7 Ohm Max). The second relay, from stock, had evidence of fiberglass present but was not considered to have affected functionality.
"The Struthers Dunn evaluation suggests that the fiber embedded on the gold contact is not at the mating point of the contacts and should not impact operability. Struthers Dunn also indicates that the relay's application is operating below their minimum current.
"Discussion:
"The actuator board on the evaluated relays is manufactured from a printed circuit board (PCB) type fiber board.
05/07/2015 U.S. Nuclear Regulatory Commission Operations Center Event Report Pa~e 2 The fibers from the edges of the board could become airborne. [... ] this specific board material was utilized beginning in March 2010. Since there have been no prior reports of this issue, it is possible that the 2010 material change introduced a foreign materials exclusion (FME) concern. Since then, and solely for those relays manufactured in the USA, the material changed again in November 2014 and was incorporated into the products starting January 2015. The newest version of the actuator board is a molded material that does not contain fiberglass fibers.
"Struthers Dunn relays with base part numbers 219, 236, 237, and 255 have the common PCB type fiber board.
This fiber board was used in relays with date code 1009 through 1452 with or without letter suffix (where the letter indicates made outside of the USA).
"Customer Input:
"1st 219 series relay failed due to contact issue, considered a random failure & discarded. 2nd 219 series relay failed due to contact resistance & sent to Exelon Power Labs. Five parts from inventory bench tested. One had high resistance and it was sent to Power Labs "Note: All parts provided were 100% functionally tested for contact resistance during dedication process and passed testing at QTNP.
'Vendor Input:
"Struthers Dunn has, since 2010, experienced only one field complaint (PSE&G) on continuity issues related to fiberglass on these 219 relays. The material change to ULTEM 2300 was considered an ongoing quality/process improvement process to reduce potential defects proactively. Over the four years using this PCB type material, 13,000 relays were sold.
"Struthers Dunn has also questioned the application having current below the manufacturer's recommended value of 50mA, requiring bifurcated contacts. Please see their attached report and current product catalog for details.
"Recommendation:
"The root cause of the failure is inconclusive. Exelon Power Labs said 'The irregular contact surface patterns in conjunction with the presence of the embedded fiberglass fibers are the most likely cause of the excessive resistance. This finding is considered to be a manufacturing defect.' While the manufacturer sees the failure as a misapplication of its product and that the fiber 'was not located at the 'mating point' of the 2 contacts so therefore has no effect on the performance of the contacts or relay.'
"QualTech NP recommends an application review for the named relays. A review of the Exelon Power Labs reports and the vendor's report should also be completed by the utility to evaluate the impact on the safety function."
CUR TISS" CONTRACT W qG DOCUMENT N/A WRIGHT TRANS MITTAL QualTech NP, Nuclear Division Curtiss-Wright Corporation P.O. NUMBER 4600 East Tech Drive, Cincinnati, OH 45245 QTNP560 N/A T: 513.528.7900 1 F: 513.528.4537 1
TO:
NRC'S DOCUMENT CONTROL DESK ACTION LEGEND STATUS U.S. REGULATORY COMMISSION WASHINEGULTON, DC20555-0001.
For Approval A. Approved-Released for WASHINGTON, DC 20555-0001
- 2. Final Documents for Construction ATTN:
HEADQUARTERS OPERATIONS OFFICER Record B. Approved as noted-hoo.hoc@nrc.gov
- 3. For Information Only Resubmit-Construction Phone: (301) 816-5100; Fax: (301) 816-5151
- 4. For Preliminary Use may proceed Phone__(301)__16-5100;__ax:
__301) __1_-5151
- 5. For Your Use C. Not approved-Resubmit PROJECT:
- 6. Revised as Requested D.
L NO.
NO.
[] DRAWINGS L REPORTS E
DCMN/OF G
DOCUMENT/
OF U SPECIFICATION II PROCEDURE E
DRAWING NUMBER REV.
PRINTS/
SEPIAS
[
OTHER N
COPIES D
N/A N/A I
INVESTIGATION FOR POTENTIAL PART 21 FOR 2
STRUTHERS DUNN RELAYS PLEASE ACKNOWLEDGE RECEIPT BELOW AND REMARKS RETURN A SIGNED COPY RECEIVED BY DATED BY 9v/argie g*f/Oer DATE:
5/7/2015 DOCUMENT CONTROL In order to avoid delays in the project PAGE:
1 of I these documents must be returned by:
020-07-91, REV.4
QualTech NP CURTISS Nuclear Division 4600 East Tech Dr.. Cincinnati, OH 45245 WRAIGHT Phone: 513.528.7900
- Fax: 513.528.9292 www.qualtechnp.cwfc.com May 7, 2014 Document Control Desk U.S. Nuclear Regulatory Commission Washington, DC 20555-0001
Subject:
Potential 10CFR Part 21 Notification on Struthers Dunn Relays
Dear Sir or Madam:
This letter provides notification of a potential 10CFR Part 21 with Struthers -Dunn relays as described in the attached report. QualTech, NP offers recommendations to the industry within the body of the report. We have notified our customers that this 1OCRF21 report will be issued.
If you have any questions or wish to discuss this further, please call me at 513-528-7900 x 2176 Respectfully, Tim Fracl Director of Quality Assurance 4600 East Tech Drive, Cincinnati Ohio 45245 Phone: 513.528.7900 x 2176 Fax: 513.528.9292
Investigation for Potential Part 21 for Struthers Dunn Relays
Subject:
PSEG reported failures for Struthers Dunn 219BBX200 relays related to greater than 1 ohm contact resistance. Two relays were evaluated by Exelon Power Labs. Of these, one had a failure consisting of a contact resistance greater than one ohm. Struthers Dunn has also provided an evaluation in this regard and does not agree with the failure mode as inferred in the Exelon Power Labs report.
Lab and OEM report key difference:
The Power Labs' Report(s) shows fiberglass fiber(s) embedded into gold plated contacts on one relay believed to result in a contact resistance greater than one Ohm (1.7 Ohm Max). The second relay, from stock, had evidence of fiberglass present but was not considered to have affected functionality.
The Struthers Dunn evaluation suggests that the fiber embedded on the gold contact is not at the mating point of the contacts and should not impact operability.
Struthers Dunn also indicates that the relay's application is operating below their minimum current.
Discussion:
The actuator board on the evaluated relays is manufactured from a printed circuit board (PCB) type fiber board. The fibers from the edges of the board could become airborne. The attached design drawing and Struthers Dunn letter indicates that this specific board material was utilized beginning in March 2010.
Since there have been no prior reports of this issue, it is possible that the 2010 material change introduced a foreign materials exclusion (FME) concern.
Since then, and solely for those relays manufactured in the USA, the material changed again in November 2014 and was incorporated into the products starting January 2015. The newest version of the actuator board is a molded material that does not contain fiberglass fibers.
Struthers Dunn relays with base part numbers 219, 236, 237, and 255 have the common PCB type fiber board. This fiber board (per the attached Struthers Dunn drawing) was used in relays with date code 1009 through 1452 with or without letter suffix (where the letter indicates made outside of the USA).
PaPp 11 of 30 Mav 7. 2015 Pare 1 nf 30 May 7.2015
Investigation for Potential Part 21 for Struthers Dunn Relays 2010-2014 material USA Manufactured Material starting 2015 t
ULTEM 2300 material Fiberglass Fiber shown in the box Paaa I nf qf ay7 21 Mav 7. 2015
Investigation for Potential Part 21 for Struthers Dunn Relays Customer Input:
1" 219 series relay failed due to contact issue, considered a random failure & discarded.
2 nd 219 series relay failed due to contact resistance & sent to Exelon Power Labs Five parts from inventory bench tested. One had high resistance & it was sent to Power Labs Note: All parts provided were 100% functionally tested for contact resistance during dedication process and passed testing at QTNP.
Exelon Power Labs reports on the tested parts are attached herein.
Vendor Input:
Struthers Dunn has, since 2010, experienced only one field complaint (PSE&G) on continuity issues related to fiberglass on these 219 relays. The material change to ULTEM 2300 was considered an ongoing quality/process improvement process to reduce potential defects proactively. Over the four years using this PCB type material, 13,000 relays were sold.
Struthers Dunn has also questioned the application having current below the manufacturer's recommended value of 50mA, requiring bifurcated contacts. Please see their attached report and current product catalog for details.
Recommendation:
The root cause of the failure is inconclusive.
Exelon Power Labs said "The irregular contact surface patterns in conjunction with the presence of the embedded fiberglass fibers are the most likely cause of the excessive resistance. This finding is considered to be a manufacturing defect."
While the manufacturer sees the failure as a misapplication of its product and that the fiber "was not located at the
'mating point' of the 2 contacts so therefore has no effect on the performance of the contacts or relay".
QualTech NP recommends an application review for the named relays. A review of the Exelon Power Labs reports and the vendor's report should also be completed by the utility to evaluate the impact on the safety function.
roJutner Date Tim Franchuk Date General Manager Director of Quality Assurance / Safety QualTech NP, Nuclear Division Curtiss-Wright Corporation Pnaa* 2 nf %tn Mav 7. 2015 P2aD ~ of ~fl May 7. 2015
Investigation for Potential Part 21 for Struthers Dunn Relays Relay Sub-component with material changes D-arn A,4 f 2nl M y.
0 Mav 7. 2015
Investigation for Potential Part 21 for Struthers Dunn Relays b STRUTHERS-DUNN Material Change Struthers-Dunn is committed to ensure quality products through its continuous Improvement efforts. Therefore the following products have undergone changes to two parts currently used in the following relay series: 219, 236, 237 and 255.
The material change will take affect for all the mentioned relay series that are made In the USA starting January 1" 2015.
A environmental analysis qualification has been done by an accredited company In compliance with I OCFR Part 21, 10 CFR Part 50 Appendix B, ASME NAQA-I, ANSI/ASME N45.2-1977 and IEEE Std. 323-1974.
Pi~niel Holder Engineering Manager Struthers-Dunn, LLC a 407 E. Smith Street, Suite B @ Timmonsvllle, SC 29161 a Phone: (843)346-4427 Fax: (843)346-4460 Pacp r% nf qn Mav 7. 2015 Paap ~ nf :~n May 7.2015
Investigation for Potential Part 21 for Struthers Dunn Relays j STRUTHERS-DUNN 407B E Smith Street, Timmonsville, SC 29161 Phone: 843-346-4427 Fax: 843-346-4465 Date: April 30, 2015 To: Curtis Wright
Subject:
Root Cause Analysis of a 219 Series Relay Referenced Documents:
Exelon PowerLabs PSE-83022, PSE-72352; S-D Relay Type 219BBXP200 Date code: 1233 To Whom It May Concern, After further review of the Exelon PowerLabs report, PSE-83022 and PSE-72352, Struthers-Dunn feels it is necessary to clarify any concerns with current and future customers.
Struthers-Dunn can make the following systematic conclusions of the failure analysis by Exelon PowerLabs' mentioned reports regarding the failure of a 219 series relay:
Although the situation addressed in this report was the fiber on the contact, Struthers-Dunn cannot agree with the failure mode due to the fact that Struthers-Dunn wasn't able to verify the relay had all the required adjustments (contact pressure, over-travel, etc.) after the incident happened. This is also the first time Struthers-Dunn was notified by any customer of a failed 219 relay with a claimed failure due to fiberglass on the contacts.
The exact root cause In this report points to the fiber being embedded in the contact. However, without knowing whether this fiber being embedded happened while being manufactured or was introduced while the relay was in operation, we cannot give an exact root cause. Although a fiberglass fiber was found on the contact it was not located at the "mating point" of the 2 contacts so therefore has had no effect on the performance of the contacts or relay.
Dica rs nf qIn Mav 7. 2015 9; Af ~fl May 7. 2015
Investigation for Potential Part 21 for Struthers Dunn Relays Struthers-Dunn believes this fiber could be from the previous actuator card material. Due to our continuous process improvement done to the 219/236/237/255 production line from 2012 to 2014, we added a new ionized air gun to clean the relays and neutralize any static charge, which can attract dust and particles that could possibly adhere to the relay blades and contacts. The last step of our improvement efforts was the elimination of any potential source contamination inside the relay which resulted in producing the actuator card with a different material.
The actuator card had been previously constructed from a fiberglass composite material (between March 2010 and December 2014). But now we have switched to a new and better material, ULTEM 2300. On the previous material the actuator card was stamped out of a fiberglass sheet. Where the current actuator card is being injection molded and does not have any edges that could have potential fibers breaking off. In order to keep our nuclear grade rating of this relay family series we contracted Curtiss-Wright to do an environmental analysis qualification in compliance with 10 CFR Part 50 Appendix B, ASME NAQA-1, ANSI/ASME N45.2-1977 and IEEE Std. 323-1974. As of January V 2015 all U.S.
manufactured 219 family relays are manufactured with the upgraded actuator card.
Furthermore, the PSEG application described in which the 219 relay was used had a load between 16 to 20mA @ 125VDC. This indicates the current being switched is below our specified minimum of SOmA for non-bifurcated contacts. Struthers-Dunn advises any customer to use bifurcated contacts to switch any current below the mentioned 50mA level. At this time Struthers-Dunn is testing to find out the exact minimum load level for bifurcated contacts, however it would certainly handle PSEG's stated load of 16 to 20mA @ 125VDC. Our current estimation is 10mA@48VDC but we will not publish that Information until the testing confirms our findings.
In conclusion, Struthers-Dunn cannot pinpoint the exact mode of failure of this relay, due to the fact that there were various fundamental errors in the application by the customer and in the failure analysis by PowerLabs.
t Dan el Helder David Mioduski Engineering Manager President Product Marketing Manager Pnop 7 nf q.n Mav 7. 2015 P~a~ 7 nf ~fl May 7. 2015
Investigation for Potential Part 21 for Struthers Dunn Relays 219 Series - Industrial Relays DPDT, up to 6PST, 10 Amps IPIN411224 10 Versatile Rugged. Proven These are but a few words used by customers to describe the 219 series.
When long life and cost of down time I service are important the 219 solves the problem It's a standard throughout industrial applications which many other relays are measured against. Capable of up to four poles double throw or six poles single throw Contact arrangements are easily customized for special applications. NUCLEAR versions are available that utilize special platings and materials to minimize wear All 219s are built with materials that meet the UL 94-VO requirements, GENERAL SPECIFICATIONS (@ 25' C)
Contmts:
Contact Configuration Contact Material Contact Rating 120 / 240VAC Resistive 28VDC Resistive Contact Resistance, Initial Coil.
Coils Avail able Nominal Coil Power Input olvtage Tolerance - AC Input VIoltage Tolerance - DC Drop-out voitge Duty lmkw.
Operate Time (max)
Release Time (max)
Dsciriac stWntft Across Open Contacts Between mutually Insulated point Insulation resistance Temperatum:
Operating Storage Up to 4PDT or 6PST Sliver Alloy-Gold Diffused 10Amp/5Amp 10Amp 50 milllohms max @ 6vdc AC and DC AC bVA DC 1I 8-25W 85% to 110% of nominal 80% to 110% of nominal 10% of nominal Continuous 26 mS 20 mS 500Vrms 1500Vrms 1,000 Mohms min @ 500VDC AC = -20 to 60°C (-4 to 140°F)
DC = -20 to 70*C (-4 to 158°F)
-40 to 105°C (-40 to 221°F)
Optional Manual Aduator L b Expectny:
Electrical (full load)
Mechanical (no load)
M/leftneous:
Mourting Position Enclosure Weight Mating socket sted when used) 100,000 10,000,000 Any Clear Polycarbonate 8.5oz (241 grams) 12 PIN: 27390 (D) 14 PIN: 33377 (D)
(D) Is option for DIN Rail Mount www.struthers-dunn.com (843) 346-4427 Paup= s nf qtn Mav 7. 2015
Investigation for Potential Part 21 for Struthers Dunn Rel 219 Conact An*angrtent XBX (DPDT)
ABA (1 Pole N.O. + DPDT + 1 Pole N.C.)
BBX (2 Pole NO & DPDT)
XDX(4PDT)
FXX (6 Pole-NO)
DXB (4 Pole - NO & 2 Pole-NC)
Optional Features Permanent Magnet Blowout - CODE 69 Polycarbonate covers - CODE P Indicator Lamp - CODE L Manual Actuator - CODE M Bifurcated Contacts - CODE 33 UL Contact Load Ratings Table Contat Curre Load Load Frequency pe of Load lOAmp 1213VAC 60!618" RESISIV SAmp 240 VAC SG0Oz RESISTIVE ANWs Amp 2VDC DC RESISTIVE EXET,Amp 125 VOC DC RESISTIVE Codeo33 3Amp
- 12) VAC 8WSi INDUCTIVE IAmp 240 VAC 6W(r3-lz INDUCTIVE 3Amp 28 VDC DC INDUCTIVE 10.1AmpI 125VC I
DC IINDUCTIVE Use Code "69" for blowout magnet when switching voltages above 4OVDC. (NOT UL OR CSA APPROVED)
Contae Current Load Load Frequency Ty o
Cordpi*al Voltage Vohta Ty____o_
SiaMae
.5Amp 12VDC DC RESISTIVE Double~elk.
4 Amp 12WVDC DC RESISTIVE Slkgle Maka 0.5 Azp 26WOVC DC RESISTIVE DoubleMkel 11.1AMP 2WVDC DC RESISTIVE Skia make 0.5 Amp, iarvOc DC INDUCTIVE Double MakI 1.6 Amp 125VDC DC INDUCTIVE SaMaiMMO ISO mA 2OVDC DC INOUCTIVE Double Moe 0.Ap 26V0C DC INDUCTIVE Use Code "33" for bifurcated contacts when switching low level current below 5OmA.
AC: 12 24,120, 240, (Add VAC)
DC: 6, 12,24/28, 32, 48, 115/125, 250 (Add VDC)
Coil voltages and frequencies must be specified 219 Coil Specifications AC Coils, 50DCoHZ Nominal Resistance Milliamperes Impedance Nominal Resistance voltage ohms Cold Hot ohms voltage ohms I10%
o10%
6 1.1 1500 840 7.2 6
15.5 12 4.2 750 410 27 12 83&5 24 15.5 375 200 120 24t28*
250 120 640 75 40 2,700 32 375 240 2100 32 17 13,400 37.5 375 48 975 115/125*
e2=0 250 27777 Milliamperes Cold Hot 385 304 189 147 96 77 86 62 100 80 49 39 20 16 9
7 Note: Stock 24VDC and 115VAC relays have nameplates stamped 24128VDC and 115/125VAC respectively. These relays operate at 80% of the lower voltages and operate within allowable temperature rises at higher voltages.
www.struthers-dunn.com (843) 34.4427 A
PA17 q nf an Mav 7. 2015 p~p 9 nf 30 May 7. 2015
Investigation for Potential Part 21 for Struthers Dunn Relays 219 Series - Industrial Relays DPDT, Up To 6PST, 10 Amps Outline Dimensions ohnwudu showi h In=we £ (mi=hl ms,)
12 Pin Plug-In Optlomil muirnl actuator 0.26 2.5263) 111 6
27)211 II t
14 Pin Plug-In 0011n01 manun mWuMut 025 2Am 1 (7. 14)
- 2,1!
uokk du )
Locidtgp
_li I
1.46 (36.A)
I J AS (38-8)
-T
-F
.t x.43 92.1 x
) DIA. Typlic of a pin Imonwons
/
.10 x.43(2.6 xll.)DIA. Typicd of d pin 9imni6ne A
www.struthers-dunn.com ()
34644a7 0)a,- In nf M
7n Mav 7. 2015
Investigation for Potential Part 21 for Struthers Dunn Relavs 219 Wire Diagram (Top View) 12-Pin 219ABX 219ABA (SPST-N.O. + DPDT)
(DPDT46P-NOIP-NC) 6 5 4 3 21 6 5 4 3 2 1
- "I, i
j-1 lf Fj
.0 L44 7 8 91011 12 78 910 11 12 219BBX 219BXB (DPDT+2P-N.O.)
(DPDT÷2P-N.O.)
6554 3 21 65 4 3 21 10..1..7 8
9 10 11 12 Many additional contact combinations and wlring schematics are available. Contact sales with requirements.
Standard Diode Sulppression Wring (applies to relays with option N", alternative polarityiwirlng Is also available as a special)
(124Pn) 46 7-219XBX (DPDT) 0 I
7 "1 101,-1212) 219XCX (3PDT)
[ 5 4 3 2 1 7' 8 9 10 11 12 219 wire Diagram (Top View) 14-Pin (14-Pin)
+7 -.4-8-
219BXD 219CXC (2P-NO+4P-NC)
(3P-NO+3P-NC) 7 1 5 4 3
1
' (654 3*2 8 910 11112 13 14, fll 111 219DXB (4P-N0+2P-NC) 7654321"[7 (7
5 219EXA (5P-NO+IP-NC) 65 4 32 1!
9 1011 12 13 14 219FXX 219KXX 219XDX 219XJX (6P-NO)
(3PST-DM)
(4PDT)
(DPODT.OMDB) 7 6 64 32 1
765 4 32 1
76 54 3 21 7 654 32 1
.9.11.f... S14 J A_
1 e
UL LISTED when used with mating sockets 27390 for 12 pin or 33377 for 14 pin www.struthers-dunn.com (843) 346.4427 A
Paup I I nf 40*
Mav 7. 2015 P~w~11 nf 30 MaY 7. 2015
Investigation for Potential Part 21 for Struthers Dunn Relays Exelon Power Lab Report PSE-72352 (20 pages)
D2a-11 nf M
0 Mav 7. 2015
Investigation for Potential Part 21 for Struthers Dunn Relays A-Exelon Generation Exelon PowerLabs To:
Bryan Obmert, (856) 339-2949, PSEG-Nuclear From:
Lance Walls, 610-380-2309 lance.walls xelonpowerlabs.com Project:
PSE-72352
Subject:
Failure Analysis of a Relay Manufacturer: Struthers Dunn Model: 219BBX200 Stock Code/Cat ID: X400405 Purchase Order No.: 400850488-0 Quantity Received: 1 Qualtech Tag#: CJ358602-05 Date:
19 March 2015 STATION DESCRIPTION OF PROBLEM The relay had been installed in service for 6 months at the time of the failure. The failure mode was a consistently excessive (> 1 ohm) and erratic resistance on contact set 8-9. The expected resistance was < 1 ohm.
CONCLUSIONS The station observation of excessive resistance on the 8-9 contact was verified and duplicated via the testing performed at PowerLabs.
The relay was received free of any thermal, mechanical, or electrical damage, and the only deficiency identified during the functional testing was that of the excessive contact of the 8-9 contact. The 8 and 9 contacts were harvested from the relay for further examination. Both contact surfaces exhibited striation patterns that resembled scratch marks. The marks on the contact 9 surface being more widespread and conspicuous than that of the contact 8 surface.
SEM/EDS Analysis of both contacts revealed the presence of Gold, Copper, and Nickel, with the Nickel being of unknown origin. The 8 contact had the presence of the striation patterns, which are not thought to be due to normal wear through make/break operations and wiping action. The 9 contact surface was comprised of Gold and Copper and also had the striation patterns, but additionally had the presence of several fiberglass strands that were embedded into the contact surface, as opposed to being surface contamination. The fact that they were embedded suggests that they were present during the surface plating process during manufacturing. There were other cavities on the contact surface that were similar in appearance, which increases the likelihood that there were other fibers present at one time, but became disassociated via contact make/break operations. The irregular contact surface patterns in conjunction with the presence of the embedded fiberglass fibers are the most likely cause of the excessive resistance. This finding is considered to be a manufacturing defect.
The Exelon PowerLabs Quality System meets 10CFR50 Appendix B, NQA-1 (1994), ANSI N45.2, ANSI/NCSL Z540-1 and 10CFR21/10CFR50.55 (e). Exelon PowerLabs is ISO 9001:2008 Registered and ISO/IEC 17025 Accredited.
175 N. Cain Road Coatesville, PA Page 1 of 10 Paop 1 q nf %tn Mav 7. 2015
Investigation for Potential Part 21 for Struthers Dunn Relays COMMENTS AND RECOMMENDATIONS No additional comments or recommendations.
" QUTEMENTS If it is determined that a high resistance condition exists, determine the cause of the failure.
TEST PLAN
- 1. Document Nameplate Data
- 2. As Received Condition
- 3. Functional Testing
- 4. Disassembly / Analysis
- 5. Material Analysis (if necessary)
- 6. Discovery STATEMENT OF QUALITY Testing was performed with standard equipment that have accuracies traceable to nationally recognized standards, or to physical constants, by qualified personnel, and in accordance with the Exelon PowerLabs Quality Assurance Program.
Technician(s):
Lance Walls Prepared by:
Reviewed by:
Approved by:
Lance 7T. Walls 18 March 2015 Sr. Engineer Date Joseph P. Mulcahy 18March 2015 ANSI Level M Date Lance T. Walls 19March 2015 Sr. Engineer Date Project review and approval are electronically authenticated in the Exelon PowerLabs project record.
Exelon PowerLabs, LLC - TECH SERVICES 175 N. Cain Road Coatesville, PA Project Number: PSE-72352 Page 2 of 10 Paorp 14 nf 301 May 7. 2015 P;~ip 14nf~fl May 7. 2015
investigation for Potential Part 21 for Struthers Dunn Relays I
OBSERVATIONS AND DATA 1.) Document Nameplate Data Photograph 1: Nameplate Data I Manufacturer: Struthers-Dunn Model#: 219BBX200 Coil Voltage: 24 - 28 VDC Contact Rating: 120 VAC, 10 A N.C. Contacts: 1-2 and 11-12 N.O. Contacts: 2-3, 4-5, 8-9, and 10-11 Date Code: 1233 (Not shown in photo)
Photograph 2: Nameplate Data H QualTech NP Tag#: CJ358602 QualTech NP S/N: 05 PSEG PO#: 4500790578 Exelon PowerLabs, LLC - TECH SERVICES 175 N. Cain Road Coatesville, PA Project Number: PSE-72352 Page 3 of 10 Dneim ic rf an Mav 7. 2015 I ~ nf 2fl May 7~ 2015
Investigation for Potential Part 21 for Struthers Dunn Relays 2.) As Received Condition Photograph 3: As Received Condition
,AV F:
- There was no outward indication of any thermal, mechanical, or electrical damage.
All soldered connections on the pins and contact block were microscopically examined and were verified as being acceptable.
" There was no indication of any arcing on any of the pins. There were only expected wear marks present that were associated with routine insertion / desertion operations.
" Manual manipulation of the assembly yielded no indication of the presence of free-moving or loose internal components or foreign materiaL There was no indication of coil outgassing on the internal surface of the case.
- There were no findings or observations that prohibit energized testing.
Intentionally Blank Exelon PowerLabs, LLC - TECH SERVICES 175 N. Caln Road Coatesville, PA Project Number. PSE-72352 Page 4 of 10 Dnoa I & nf aM'n Mav 7.2015
Investigation for Potential Part 21 for Struthers Dunn Relays 3.) Functional Testing Pre-Energization Tests (As-Received)
Measured Measurement Comment Parameter Coil Resistance 254.4 Q (Cold)
Reasonable per OEM spec. of 1.8 - 2.5 W N.C. 1-2 16.3 mnf Acceptable N.O. 2-3
> 500 M12 Expected in de-energized state N.O. 4-5
> 500 Mil Expected in de-energized state N.O. 8-9
> 500 Ma*
Expected in de-energized state N.O. 10-11
> 500 MU2 Expected in de-energized state N.C. 11-12 9.6 mil Acceptable All of the static measurements in the de-energized state were acceptable or expected.
Energized Testing Coil Characteristics Measured Measurement Comment Parameter Pickup Voltage 13.3 VDC (Cold)
Less than OEM-specified 80%
Current at Pickup 54 mA DC Not specified by OEM. For information only Sealed Current @ 24 94 mA DC Not specified by OEM. For information only VDC Sealed Current @ 28 107 mA DC Not specified by OEM. For information only VDC Coil Watts @ 24 2.26 Slightly greater than OEM-specified 1.8 W VDC Coil Watts @
3.00 Slightly greater than OEM-specified 3.0 W 28VDC Dropout Voltage 6.1 VDC Greater than OEM-Specified 10% of nominal The only reading that exceeded the OEM specification was that of dropout voltage.
Contact Resistance Measured Measurement Comment Parameter N.C. 1-2
> 500 ML2 Expected in energized state N.O. 2-3 9.4 mnQ Acceptable N.O. 4-5 9.5 mQ Acceptable N.O. 8-9 230 mrL - 1.7 C-The station observation of excessive contact resistance was verified N.O. 10-11 12.3 mi.
Acceptable N.C. 11-12
> 500 ML2 Expected in energized state The station observation of excessive contact resistance with N.O. set 8-9 was duplicated, although the excessive resistance was not radically excessive.
Exelon PowerLabs, LLC - TECH SERVICES Project Number: PSE-72352 175 N. Cain Road Coatesville, PA Page 5 of 10 Dann 17
"^-f 2ni Mav 7. 2015 O2nc. 17 w~f 2fl May 7. 2015
Investigation for Potential Part 21 for Struthers Dunn Relays Pickup Time Pickup Times (3 Iterations)
Commnent 19.6 ms, 19.3 ms, and 20.0 ms Less than OEM specified 25 ms Release Time Release Times (3 iterations)
I Comment 10.1 msa 10.1 ms, and 9.9 ms Less than OEM specified 20 ms There was no indication of binding or sluggish armature movement with either the pickup or dropout movements.
The only anomalous observation / test result gleaned through both the de-energized and energized testing was that of the excessive and erratic closed contact resistance measurement associated with normally open contact 8-9.
The focus of the balance of the analysis was placed upon N.O. contact 8-9.
4.) DIsassembly / Analysls Y
Photograph 4:8-9 Contact Connection The arrow in this photograph points to the closed 9-9 contact set. They were viewed via stereomicroscope ad there was clear surface - surface engagement in the approximate center areas, with no air gapping observed.
Contact 8 Exelon PowerLabs, LLC - TECH SERVICES 175 N. Cain Road Coatesville, PA Project Number: PSE-72352 Page 6 of 10 Dnaa I R nf M72 Mav 7. 2015
Investigation for Potential Part 21 for Struthers Dunn Relays Photograph 5: Contact 8 1 The surface of the 8 contact exhibited pronounced striations in the approximate center of the area They had the appearance of multiple scratch marks in close proximity and in parallel orientation to one another.
orient ion to one another.
I Contact 9 The surface of the 9 contact also had the striation A closer view of the boxed area of photograph 7.
marks that were observed with contact 8, although they were widespread and severe in nature. They appeared to be random and numerous scratch marks.
The striation / scratch marks observed with both the 8 and 9 contact surfaces are not a normal or expected observation with contacts that have not been mechanically burnished. Mechanically burnishing will produce scratched surface marks due to the inherent cleaning process, however it is not believed that either of these contacts were burnished.
Exelon PowerLabs, LLC - TECH SERVICES 175 N. Cain Road Coatesville, PA Project Number: PSE-72352 Page 7 of 10 Pacy 19 nf 910 Mav 7. 2015 PRRP 19 of 30 May 7. 2015
Investigation for Potential Part 21 for Struthers Dunn Relays 5.) Material Analysis Both contacts were examined with high magnification and for elemental constitution via SEM / EDS analysis (Scanning Electron Microscope / Energy Dispersive x-ray Spectroscopy).
coat-ad a Photograph 10: Contact 8 Suafce - Center wtmi i.0K~
iftK V0K N.3
(
A" VA Cm.
CO A
____ p Na Elt.
Ni Cu Au 5
10 Cww.w-1 3.5 kcV 21 au ID-818h Thlb2 WO',t-5UO Wi.v O00i. 40955= 22 077.1 2 Line Intensity Cone Ka 5.21 0.877 wt.%
Ka 2.98 0.619 wt.%
La 65.36 98.503 wt.%
25:]
4 10 uMa-MM Xko r OK95 a) -FA 4 WWI PO W Vq" 260A MWviw@WS.40.955 140.216m 25v Elt Ni Cu Au Line Ka Ka La Intensity Conc 6.37 1.055 wt.%
4.77 0.976 wt.%
66.01 97.969 wt.%
Photograph 10 exhibits the striation patterns that were present on the contact 8 surface. Again, these patterns are not a typical wear pattern observed relay contact makebreak or wipe operations. Gold was primary elemental constituent in both snapshots, with similar concentrations of Nickel and Copper in both.
Comud 9 Exelon PowerLabs, LLC - TECH SERVICES 175 N. Caln Road Coatesville, PA Project Number. PSE-72352 Page 8 of 10 Poan 7nl r-f an Mav 7.201S P~a~ 7fl nf ~fl May 7. 2015
Investigation for Potential Part 21 for Struthers Dunn Relays Photograph 11: Contact 9 Surface The contact 9 surface had the striation patterns present both in the contact center area and away from the center area. Gold was the primary constituent, and the presence of Copper was also detected. No Nickel was detected. The boxed area will be better explained in photographs 12 and 13.
Elt Line Intensity Conc Units Cu Ka 2.42 0.573 wt.%
Au La 58.07 99.427 wt.%
1.OK-L OKX-Cu
,...lt Au li Pu I
Cua 5kdV 25 CM ID =Pa M Ra 15 Vef-~OOWimgiw 0 W)O
- 4(1,95' 18,6 cr 1MCIe Intentionally Blank Exelon PowerLabs, ILC - TECH SERVICES 175 N. Cain Road Coatesville, PA Project Number. PSE-72352 Page 9 of 10 D~oan 71 rf anl May 7. 2015 P200 ~11nf ~fl May 7. 2015
Investigation for Potential Part 21 for Struthers Dunn Relays C0K Al 10K-5100 Jc
-U J
Ca FA L
Cu T
Au An L'uncwl4.435 ktY 15 cut 1W - 1~r 1W, An 1a2 3
Io now OimrwA-12AI5kcV 7enr TO - Os 82 TI W Vert-1330 W~now&0.003-40.935-Je36.5cat Elt.
Line Intensity Conc The embedded fibers shown in this photograph Cu Ka 2.17 0.508 wL%
were primarily made up of Silicon, Aluminum, Au La 58.66 99.492 wt.%
and Calcium. This is consistent with Fiberglass.
The embedded fibers in the contact surface, which are exhibited in photographs 12 and13 had an elemental composition consistent with Fiberglass. The fact that they are embedded into the surface of the contact suggests that they were present at the time of manufacture when the surface was coated. The presence of other similar cavities into the contact surface may suggest that there were other fiberglass fibers present at one time, but that they became disassociated due to contact make /
break operations. The irregular patterns in the contact surfaces and the presence of the fiberglass fibers in the approximate center of contact 9 are the most likely cause of the excessive resistance.
6.) Discovery There were no additional items of discovery.
Exelon PowerLabs, LLC - TECH SERVICES 175 N. Cain Road Coatesville, PA Project Number: PSE-72352 Page 10 of 10 Paup 22 of 310 Mav 7. 2015
Investigation for Potential Part 21 for Struthers Dunn Relays Exelon Power Lab Report PSE-830222 (7 pages)
Dmao
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Investigation for Potential Part 21 for Struthers Dunn Relays O
Exeton Generation Exelon PowerLabs To:
Joseph Thanpson, (356) 339-1177, PSEG Nudear From:
Michael Minicozzi, 61"-380-2427 MlchaeLMlnlcozrinexelonpowerlabs.com Project:
PSE-83022 Subject Scanning Electron Microscope Examination of Relay Contacts Manufacturer: Struthers-Dunn Model: 219BBX200 Purchase Order No.: 4500650488-1 Quantity Received: 2 Date:
4/15/15 F
DESCRIPTION Highly Magnified Examination of All Contacts in an Effort to Determine if Foreign Material and / or Manufacturing Defects Exist Site Information:
Due to the issues identified under notification 20682668, all of the existing stock associated with X400405 Struthers Dunn relay purchased from Qualtech as part number 219BBX200 has been placed in blocked stock To provide an adequate replacement relay for the failed relay in 21CFCU, 2 of the 5 relays purchased under PO 4500850435 have been sent to power labs to assure the sample and by extrapolation the entire batch is free from FM concerns.
CONCLUSIONS All contacts from both relays were harvested and examined under the Scanning Electron Microscope.
Relay I displayed one contact (#2 N/0) with one piece of embedded foreign material (consistent with fiberglass). Similar to what was discovered under PowerLabs project PSE-72352. All the other contacts from Relay I did not contain any foreign material, but revealed scratches on the contact surface.
All contacts for Relay 2 revealed scratches on the contact surface, but no embedded foreign material was observed.
The Exelon PowerLabs Quality System meets 10CFR50 Appendix B, NQA-I (1994), ANSI N45.2, ANSI/NCSL Z540-1 and 10CFR21/10CFR50.55 (e). Exelon PowerLabs is ISO 9001:2008 Registered and ISO/IEC 17025 Accredited.
175 N. Cain Road Coatesville, PA Page I of 7 Paae 24 of 30 Mav 7. 2015
Investigation for Potential Part 21 for Struthers Dunn Relays TEST PLAN
- 1. Document Nameplate Data
- 2. Harvest contacts from Both Relays
- 3. Highly Magnified Examination (Scanning Electron Microscopy) of all contacts in an effort to determine if foreign material and / or manufacturing defects exist.
STATEMENT OF QUALITY Testing was performed with standard equipment that have accuracies traceable to nationally recognized standards, or to physical constants, by qualified personnel, and in accordance with the Exelon PowerLabs Quality Assurance Program.
Technician(s):
Lance Walls, Michael Minicozzi Reviewed by:
Approved by:
Lance Walls 4/15/15 ANSI Level M / Sr. Engineer Date Michael Minicozzi 4/15/15 ANSI Level III / Sr. Engineer Date Project revew and approval are electronically authenticated in the Exelon PowerLabs project record Exelon PowerLabs, LLC - TECH SERVICES 175 N. Cain Road Coatesville, PA Project Number. PSE-83022 Page 2 of 7 Dnern "2r.,,,f Mn May 7. 2015 D~aa
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Investigation for Potential Part 21 for Struthers Dunn Relays I
OBSERVATIONS AND DATA 1.) Document Nameplate Data Photo 1: Nameplate Data I - Relay 1 Manufacturer: Struthers-Dutm Modd#: 219BBX200 Coil Voltage: 24 - 28 VDC Contact Rating: 120 VAC, 10 A N.C. Contacts: 1-2 and 11-12 N.O. Contacts: 2-3, 4-5, 8-9, and 10-11 Photo 2: Nameplate Data H - Relay 1 QualTech NP Tag#: CJ471601 QualTech NP S/N: 02 PSEG PO#: 4500850435 Exelon PowerLabs, LLC - TECH SERVICES 175 N. Cain Road Coatesville, PA Project Number. PSE-S3022 Page 3 of 7 Paoa 7A nf M
0 Mav 7. 2015
Investigation for Potential Part 21 for Struthers Dunn Relays Photo 3: Nameplate Data I - Relay 2 Manufacturer: Struthers-Dunn Model#: 219BBX200 Coil Voltage: 24 - 28 VDC Contact Rating: 120 VAC, 10 A N.C. Contacts: 1-2 and 11-12 N.O. Contacts: 2-3, 4-5, 8-9, and 10-11 Photo 4: Nameplate Data II - Relay 2 QualTech NP Tag#: CJ471601 QualTech NP S/N: 03 PSEG PO#: 4500850435 Exelon PowerLabs, LLC - TECH SERVICES 175 N. Cain Road Coatesville, PA Project Number: PSE-83022 Page 4 of 7 Dna,- 77 nf qin Mav 7. 2015 D2aD 77 Af ~lfl May 7. 2015
Investigation for Potential Part 21 for Struthers Dunn Relays
- 2. and 3.) Harvest Relay Contacts and Perform Scanning Electron Microscopy of the contact surfaces Photo 5: Scanning Elect
£OUVLE% I---.. im D.t.-1 IrnMicroscope Photo 6: Magnification of Photograph 5
- Contact #2 NIO 400-300 0
200 Au SlOkeV
.,ni Embedded foreign material was observed on the #2 N/O contact surface. The embedded foreign material in the contact surface had an elemental composition consistent with fiberglass shown in the Energy Dispersive Spectroscopy spectrum shown above (Primary constituents are Si, Ca, Al, 0).
Exelon PowerLabs, LLC - TECH SERVICES 175 N. Caln Road Coatesville, PA Project Number. PSE-83022 Page 5 of 7 Pnop 7R nf My2 Mav 7. 2015
Investigation for Potential Part 21 for Struthers Dunn Relays Photo 7: SEM Photo 8: SEMim The photographs above are representative of the remaining contact surfaces examined from Relay 1, All the other contact surfaces did not contain any foreign material, but revealed scratches on the contact surface.
Exelon PowerLabs, LLC - TECH SERVICES 175 N. Caln Road Coatesville, PA Project Number: PSE-83022 Page 6 of 7 on*aa yaQ nf an Mav 7. 2015 0200 70 nf 2fl May 7. 2015
Investigation for Potential Part 21 for Struthers Dunn Relays
-T The photographs above are representative of the contact surfaces examined from Relay 2. All of the contact surfaces did not contain foreign material, but revealed scratches on the contact surface.
Exelon PowerLabs, LLC - TECH SERVICES 175 N. Caln Road Coatesville, PA Project Number: PSE-83022 Page 7 of 7 D-^n 2fl nf 2nlMyt21 May 7. 2015