ML16127A595: Difference between revisions
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State: NY NRC Notified by: PATRICK SHAW Notifications: FRED BOWER R1DO HQ Ops Officer: DONG HWA PARK MIKE ERNSTES R2DO Emergency Class: NON EMERGENCY NICKVALOS R3DO 10 CFR Section: JOHN KRAMER R4DO 21.21 (d)(3)(i) DEFECTS AND NONCOMPLIANCE PART 21/50.55 REACTORS EMAIL PART 21 -ANOMALY RELATED TO MICRO SWITCHES The following report was received via email: | State: NY NRC Notified by: PATRICK SHAW Notifications: FRED BOWER R1DO HQ Ops Officer: DONG HWA PARK MIKE ERNSTES R2DO Emergency Class: NON EMERGENCY NICKVALOS R3DO 10 CFR Section: JOHN KRAMER R4DO 21.21 (d)(3)(i) DEFECTS AND NONCOMPLIANCE PART 21/50.55 REACTORS EMAIL PART 21 -ANOMALY RELATED TO MICRO SWITCHES The following report was received via email: | ||
"Based on test data, Rotork believes an unsafe condition may exist as defined under 10CFR21. The adhesive formulation used for the construction of V12 and K5 safety related micro switches was altered by the switch maker's sub-supplier. K5 switches have no reported failures, but are affected because of construction. The altered adhesive formulation outgases an insulating material at elevated temperatures, which coats the switch.contacts as it cools, and can prevent the conduction of electricity." | "Based on test data, Rotork believes an unsafe condition may exist as defined under 10CFR21. The adhesive formulation used for the construction of V12 and K5 safety related micro switches was altered by the switch maker's sub-supplier. K5 switches have no reported failures, but are affected because of construction. The altered adhesive formulation outgases an insulating material at elevated temperatures, which coats the switch.contacts as it cools, and can prevent the conduction of electricity." | ||
FAX rotor.. | FAX rotor.. | ||
| Line 225: | Line 224: | ||
c-..r1.... | c-..r1.... | ||
o....- | o....- | ||
lltS a.. | lltS a.. | ||
lfl;~-"1 1X2MJU1-*1 C...-rl..._ | lfl;~-"1 1X2MJU1-*1 C...-rl..._ | ||
o.i.,..,.o fr" | o.i.,..,.o fr" | ||
:.. ttlOli- x !tU15-y '41Gl- "41Q..,., | :.. ttlOli- x !tU15-y '41Gl- "41Q..,., | ||
l us- l us- | l us- l us-01'0'9-"1 4il'lif-"1 "llh'i-.-, | ||
01'0'9-"1 | |||
4il'lif-"1 | |||
Figure 3: Air volume inside actuator electricol enclosure Figure 4: 245ml enclosure | Figure 3: Air volume inside actuator electricol enclosure Figure 4: 245ml enclosure | ||
| Line 371: | Line 362: | ||
The best fit of data was obtained by plotting temperature (T) against time (t) with a correction factor applied to time (t) that represented the difference between the actuator "switch to air volume" ratio and the metallic test enclosure "switch to air volume" ratio. Smaller than actuator enclosure test volumes were used to increase the " switch to air volume" ratio and accelerate the onset of the anomaly. The term concentration factor (Cf) was thus developed and multiplied the experiment duration time, measured in seconds (T versus t | The best fit of data was obtained by plotting temperature (T) against time (t) with a correction factor applied to time (t) that represented the difference between the actuator "switch to air volume" ratio and the metallic test enclosure "switch to air volume" ratio. Smaller than actuator enclosure test volumes were used to increase the " switch to air volume" ratio and accelerate the onset of the anomaly. The term concentration factor (Cf) was thus developed and multiplied the experiment duration time, measured in seconds (T versus t | ||
* Cf). The electrical enclosure volume in the Rotork NA actuator is slightly different for each model size. To be conservative the smallest NA actuator enclosure volume was used to develop the best fit equation. The line displayed in Figure 19 is the estimated boundary at which the anomaly onset would be observed . Above the line both open and closed contact anomalies were observed . Below the line anomalies were not observed. | * Cf). The electrical enclosure volume in the Rotork NA actuator is slightly different for each model size. To be conservative the smallest NA actuator enclosure volume was used to develop the best fit equation. The line displayed in Figure 19 is the estimated boundary at which the anomaly onset would be observed . Above the line both open and closed contact anomalies were observed . Below the line anomalies were not observed. | ||
Open Contact Anomaly 200 | Open Contact Anomaly 200 150 y = -20.4 lln(x) + 380.88 | ||
y = -20.4 lln(x) + 380.88 | |||
~ R2 =0.9497 | ~ R2 =0.9497 | ||
~ | ~ | ||
~ 100 Q) c.. | ~ 100 Q) c.. | ||
E Q) | E Q) | ||
| Line 401: | Line 386: | ||
* Open & Closed Contact Anomaly | * Open & Closed Contact Anomaly | ||
.. No anomaly | .. No anomaly | ||
- Log. !Anomaly Onset Boundary) 150 | - Log. !Anomaly Onset Boundary) 150 50 No reported switch anomalies by industry under mormal operating temperatures (48C max) 0 0 500000 1000000 1500000 2000000 2500000 3000000 3500000 4000000 4500000 Tlrne*Cf (sec) | ||
Figure 20 9.3. Switch performance under accident profiles The figures in the following pages show a number of temperature time profiles applicable to nuclear power plants that use Rotork NA actuators that use Rotork NA actuators. Each test was performed using eight new test switches placed in a new metallic enclosure having a volume of one US gallon. | Figure 20 9.3. Switch performance under accident profiles The figures in the following pages show a number of temperature time profiles applicable to nuclear power plants that use Rotork NA actuators that use Rotork NA actuators. Each test was performed using eight new test switches placed in a new metallic enclosure having a volume of one US gallon. | ||
The enclosure volume and number of switches provided a concentration factor of 1.125 thus assuring margin in the testing. In all cases the switches operated after the test and met the industry acceptance criteria of 500m0 or less. A large proportion of the switches met the supplier acceptance criteria of | The enclosure volume and number of switches provided a concentration factor of 1.125 thus assuring margin in the testing. In all cases the switches operated after the test and met the industry acceptance criteria of 500m0 or less. A large proportion of the switches met the supplier acceptance criteria of | ||
| Line 412: | Line 396: | ||
rotor11- Page 26 of 48 Rotork Controls Lim ited Approved by Engineering Nuclear Engineering Report No. ER857 Issue 1 Date: 3 rd May 2016 Priori ty 1 | rotor11- Page 26 of 48 Rotork Controls Lim ited Approved by Engineering Nuclear Engineering Report No. ER857 Issue 1 Date: 3 rd May 2016 Priori ty 1 | ||
__.,_ TiW 40 0 5000 10000 15000 lOOO'l l11ne(~c) | __.,_ TiW 40 0 5000 10000 15000 lOOO'l l11ne(~c) | ||
Figure 21 a Measured at 20C 4/15/16 Priorityl test data As provided resistance data mJH ohms Sample No-> .. 4/15-1 " 4/15 -2 4/15-3 4/15-4 4/15 -S 4/15-6 4/15-7 4/15 -8 NC NO NC NO NC NO NC NO NC NO NC NO NC NO NC NO 5.8 4.2 4.0 3.3 3.3 4.0 2.4 5.2 3.4 3.6 4.8 3.4 3.2 4.2 3.0 3.0 5.1 3.4 4.7 2.8 4.0 3.5 2.8 3.6 3.7 3.5 3.5 3.2 3.8 3.9 2.9 3.0 4.4 2.9 4.4 3.0 3.9 3.3 2.9 3.2 3.1 3.0 3.9 3.2 3.6 3.6 2.9 2.8 4.1 2.8 4.0 2.9 3.6 3.4 2.9 3.4 3.0 3.2 4.7 3.1 3.9 3.9 2.9 2.8 4.2 2.8 4.0 2.8 3.6 3.3 3.0 3.2 3.3 3.5 4.1 3.1 3.8 4.0 3.0 2.8 4.2 2.8 4.0 2.6 3.1 2.8 3.0 3.1 3.4 3.0 4.1 3.0 4.1 3.7 3.0 2.7 | Figure 21 a Measured at 20C 4/15/16 Priorityl test data As provided resistance data mJH ohms Sample No-> .. 4/15-1 " 4/15 -2 4/15-3 4/15-4 4/15 -S 4/15-6 4/15-7 4/15 -8 NC NO NC NO NC NO NC NO NC NO NC NO NC NO NC NO 5.8 4.2 4.0 3.3 3.3 4.0 2.4 5.2 3.4 3.6 4.8 3.4 3.2 4.2 3.0 3.0 5.1 3.4 4.7 2.8 4.0 3.5 2.8 3.6 3.7 3.5 3.5 3.2 3.8 3.9 2.9 3.0 4.4 2.9 4.4 3.0 3.9 3.3 2.9 3.2 3.1 3.0 3.9 3.2 3.6 3.6 2.9 2.8 4.1 2.8 4.0 2.9 3.6 3.4 2.9 3.4 3.0 3.2 4.7 3.1 3.9 3.9 2.9 2.8 4.2 2.8 4.0 2.8 3.6 3.3 3.0 3.2 3.3 3.5 4.1 3.1 3.8 4.0 3.0 2.8 4.2 2.8 4.0 2.6 3.1 2.8 3.0 3.1 3.4 3.0 4.1 3.0 4.1 3.7 3.0 2.7 Std 3.9 4.5 0.7 2.7 3.1 0.5 4.3 4.2 0.3 2.5 2.8 | ||
Std 3.9 4.5 0.7 2.7 3.1 0.5 4.3 4.2 0.3 2.5 2.8 | |||
: 0. 3 3.5 3.6 0.3 3.0 3.3 0.4 3.0 2.9 0.2 3.0 3.5 0.8 3.4 H | : 0. 3 3.5 3.6 0.3 3.0 3.3 0.4 3.0 2.9 0.2 3.0 3.5 0.8 3.4 H | ||
0.2 2.9 3.2 0.3 4.6 4.2 0.5 2.9 3.1 0.2 4.4 3.8 0.4 3.3 3.8 0.3 3.2 3.0 0.1 2.7 2.8 0.1 Measured at 60C (140f) 4/18/16 Post thermal aging using Priority l temp time profile Sample No-> ,,. 4/15-1 ' 4/15-2 ' 4/15-3 4/15-4 4/15 -5 4/15-6 4/15 -7 4/15 -8 NC NO NC NO NC NO NC NO NC NO NC NO NC NO NC NO 2.2 3.9 2.3 4.2 2.6 3.9 2.6 4.1 2.4 2.3 3.3 2.3 4.7 2.2 7.2 Measured at 20C 4/19/16 Post the rmal aging usi ng Priority l temp time profile Sample No -> ,. 4/15-1 .. 4/15-2 ,,. 4/15-3 4/15-4 4/15 -S 4/15-6 4/15 -7 4/15 -8 NC NO NC NO NC NO NC NO NC NO NC NO NC NO NC NO 2.6 iO 3.0 14.0 3.4 6.2 3.3 5.0 2.8 'DO 3.3 3.8 3.4 5.3 2.8 6.0 2.9 12.0 3.0 5.5 3.8 6.0 3.0 5.2 3.1 3.2 3.9 3.6 4.0 3.1 4.3 3.0 6.0 3.0 4.8 4.1 7.3 3.6 5.9 3.0 eo.11 3.2 3.2 3.6 4.1 3.2 3.6 2.9 3.3 3.0 5.2 4.2 7.6 4.1 4.0 3.1 ~ 3.6 3.0 3.6 4.0 3.3 4.0 3.0 3.4 2.9 3.9 4.4 7.0 4.9 3.5 3.0 so.o 3.0 2.9 3.7 4.1 3.3 3.4 3.1 3.0 2.8 3.7 4.2 10.2 4.1 3.2 3.3 ao.o 3.0 2.7 3.8 3.9 3.2 3.2 Ave Std 3.1 2.9 0.2 3.1 8.7 9.9 2.9 2.9 | 0.2 2.9 3.2 0.3 4.6 4.2 0.5 2.9 3.1 0.2 4.4 3.8 0.4 3.3 3.8 0.3 3.2 3.0 0.1 2.7 2.8 0.1 Measured at 60C (140f) 4/18/16 Post thermal aging using Priority l temp time profile Sample No-> ,,. 4/15-1 ' 4/15-2 ' 4/15-3 4/15-4 4/15 -5 4/15-6 4/15 -7 4/15 -8 NC NO NC NO NC NO NC NO NC NO NC NO NC NO NC NO 2.2 3.9 2.3 4.2 2.6 3.9 2.6 4.1 2.4 2.3 3.3 2.3 4.7 2.2 7.2 Measured at 20C 4/19/16 Post the rmal aging usi ng Priority l temp time profile Sample No -> ,. 4/15-1 .. 4/15-2 ,,. 4/15-3 4/15-4 4/15 -S 4/15-6 4/15 -7 4/15 -8 NC NO NC NO NC NO NC NO NC NO NC NO NC NO NC NO 2.6 iO 3.0 14.0 3.4 6.2 3.3 5.0 2.8 'DO 3.3 3.8 3.4 5.3 2.8 6.0 2.9 12.0 3.0 5.5 3.8 6.0 3.0 5.2 3.1 3.2 3.9 3.6 4.0 3.1 4.3 3.0 6.0 3.0 4.8 4.1 7.3 3.6 5.9 3.0 eo.11 3.2 3.2 3.6 4.1 3.2 3.6 2.9 3.3 3.0 5.2 4.2 7.6 4.1 4.0 3.1 ~ 3.6 3.0 3.6 4.0 3.3 4.0 3.0 3.4 2.9 3.9 4.4 7.0 4.9 3.5 3.0 so.o 3.0 2.9 3.7 4.1 3.3 3.4 3.1 3.0 2.8 3.7 4.2 10.2 4.1 3.2 3.3 ao.o 3.0 2.7 3.8 3.9 3.2 3.2 Ave Std 3.1 2.9 0.2 3.1 8.7 9.9 2.9 2.9 | ||
: 0. 1 3.1 | : 0. 1 3.1 | ||
: 5. 7 3.7 5.0 | : 5. 7 3.7 5.0 | ||
: 4. 2 0.5 6.6 7.3 1.4 | : 4. 2 0.5 6.6 7.3 1.4 4.0 O.ti 3.1 4.3 1.1 2.9 3.0 0.2 C'jS.0 53.6 19.5 3.1 3.2 0.2 2.8 3.2 0.5 3.8 3.6 0.1 4.1 4.2 0.5 3.3 3.2 0.2 3.1 3.9 1.0 | ||
4.0 O.ti 3.1 4.3 1.1 2.9 3.0 0.2 C'jS.0 53.6 19.5 3.1 3.2 0.2 2.8 3.2 0.5 3.8 3.6 0.1 4.1 4.2 0.5 3.3 3.2 0.2 3.1 3.9 1.0 | |||
~the contac1 resistance meets the industry accep tan~ wtena of 5CO mili ohms memo: the contact resistance mel!!ts the supplier accep tan ce criteria of <25 mill ohms Figure 21b | ~the contac1 resistance meets the industry accep tan~ wtena of 5CO mili ohms memo: the contact resistance mel!!ts the supplier accep tan ce criteria of <25 mill ohms Figure 21b | ||
| Line 429: | Line 408: | ||
!COO | !COO | ||
~ | ~ | ||
~ | ~ | ||
800 | 800 | ||
| Line 450: | Line 428: | ||
rotor11- Page 28 of 48 Rotork Controls Limited Approved by Engineering Nuclear Engineering Report No. ER857 Issue 1 Date : 3 rd May 2016 Pr io r ity 3 100 | rotor11- Page 28 of 48 Rotork Controls Limited Approved by Engineering Nuclear Engineering Report No. ER857 Issue 1 Date : 3 rd May 2016 Pr io r ity 3 100 | ||
"° 70 memo: for this test the oven profile temperatures between h(\ the start and end point were | "° 70 memo: for this test the oven profile temperatures between h(\ the start and end point were | ||
£ elevated 3 centlarade to assure temperature maralne. | £ elevated 3 centlarade to assure temperature maralne. | ||
| Line 457: | Line 434: | ||
- Taop1nt | - Taop1nt | ||
- - Ta1r I | - - Ta1r I | ||
40 | 40 20 10 20000 40000 60000 1()00)() | ||
20 10 20000 40000 60000 1()00)() | |||
r1me(sec. 1 Figure 23a Menu*ed1120C 4/2S/'l016 Priority3tu1du1 A*p!'Ovidedreslu1nced11tamlllohm* | r1me(sec. 1 Figure 23a Menu*ed1120C 4/2S/'l016 Priority3tu1du1 A*p!'Ovidedreslu1nced11tamlllohm* | ||
Sample No -> ' 4/25-1 NC | Sample No -> ' 4/25-1 NC | ||
!1.0 9.4 | !1.0 9.4 | ||
'4/25 | '4/25 | ||
* 2 NC 1.S | * 2 NC 1.S NO 12 | ||
NO 12 | |||
* ..,,JS . ) | * ..,,JS . ) | ||
NC NO | NC NO | ||
' 4/2S | ' 4/2S | ||
* 4 NC | * 4 NC NO | ||
' 4/2S -S NC NO | |||
NO | |||
' 4/2S -S | |||
NC NO | |||
' 4/2S | ' 4/2S | ||
* 6 NC l .6 NO u | * 6 NC l .6 NO u | ||
' 4/2S | ' 4/2S | ||
* 7 | * 7 NO | ||
' 412s -1 NO u 4.7 u | |||
NO | |||
' 412s -1 NO | |||
u 4.7 u | |||
..*1* 12 u | ..*1* 12 u | ||
<1 | <1 | ||
,, 17 | ,, 17 17 u | ||
17 u | |||
.. ..*... .,"u u | .. ..*... .,"u u | ||
31 31 17 .. . u | |||
31 31 | |||
17 .. . u | |||
... ...'*' u | ... ...'*' u | ||
" u | " u | ||
*~ | *~ | ||
u u | u u | ||
"' 1'2 Menu1ed1t60C( l40f l *126'2016 Post thermil iglng using Prior ity) temp time pro Ille 5-lmpleNo -> "*12s-1 NO 5.1 | "' 1'2 Menu1ed1t60C( l40f l *126'2016 Post thermil iglng using Prior ity) temp time pro Ille 5-lmpleNo -> "*12s-1 NO 5.1 | ||
**12s -2 4/27/1016 NO u | **12s -2 4/27/1016 NO u | ||
| Line 514: | Line 467: | ||
*4/2S *6 NO u | *4/2S *6 NO u | ||
' 4/25 *1 Postthe1m1l1gingusingPrioritylttmptimep<ofile S...mpleNo * > | ' 4/25 *1 Postthe1m1l1gingusingPrioritylttmptimep<ofile S...mpleNo * > | ||
"412s.1 NC | "412s.1 NC | ||
*u. | *u. | ||
NO | NO | ||
*412s -2 u | *412s -2 u | ||
NO s.1 "41zs .1 NO u | |||
NO | |||
s.1 "41zs .1 NO u | |||
' 4125 .4 NC u | ' 4125 .4 NC u | ||
*O | *O | ||
*4/2S -S NC 17 | *4/2S -S NC 17 | ||
' 411s -6 u | ' 411s -6 u | ||
NO 10 | NO 10 | ||
' 412s -1 | ' 412s -1 NO NC NO u | ||
NO NC NO u | |||
u | u | ||
*4/2S *I | *4/2S *I NC NO 1U 17 u | ||
NC NO 1U | |||
17 u | |||
.,u ...... | .,u ...... | ||
u u | |||
u | u | ||
.,u l .0 J.1 | |||
.,u | |||
l .0 J.1 | |||
* .1 u | * .1 u | ||
u u ...., | u u ...., | ||
u u | u u | ||
*.1 { | *.1 { | ||
u | u u | ||
u | |||
7.* | 7.* | ||
u 17 | u 17 31 | ||
*.", l .7 l.1 | |||
31 | |||
*.", l .7 | |||
l.1 | |||
~:~ | ~:~ | ||
'3.t | '3.t | ||
| Line 600: | Line 526: | ||
95 - | 95 - | ||
1\\ | 1\\ | ||
~ | ~ | ||
94 - 1650 | 94 - 1650 | ||
| Line 607: | Line 531: | ||
4000 3000 2000 1000 Wavenumbers (cm -1) | 4000 3000 2000 1000 Wavenumbers (cm -1) | ||
Fig ure 24: Infrared spectra of residue on NO contact rivets 9s :PoLYM5053: residue from bottom contact rivet of Switch s (2007) - 4 d;iys ;it 125"C | Fig ure 24: Infrared spectra of residue on NO contact rivets 9s :PoLYM5053: residue from bottom contact rivet of Switch s (2007) - 4 d;iys ;it 125"C | ||
:POLYM3246: Araldite Gl ue (24hrs;it WC) an;ilysed i n 2011 | :POLYM3246: Araldite Gl ue (24hrs;it WC) an;ilysed i n 2011 I- | ||
I- | |||
~ | ~ | ||
93 : | 93 : | ||
| Line 620: | Line 542: | ||
rotor11- Page 32 of 48 Rotork Controls Limited Approved by Engineering Nuclear Engineering Report No. ER857 Issue 1 Date : 3 rd May 2016 98-POLYM!i053: residue from bottom contact nvet of Switch S (2007) - 4 days at 125"C | rotor11- Page 32 of 48 Rotork Controls Limited Approved by Engineering Nuclear Engineering Report No. ER857 Issue 1 Date : 3 rd May 2016 98-POLYM!i053: residue from bottom contact nvet of Switch S (2007) - 4 days at 125"C | ||
:POLYM3210: new OAP C3Se an:ilysed in 2011 97 ~.-..J.,J, 96-96- | :POLYM3210: new OAP C3Se an:ilysed in 2011 97 ~.-..J.,J, 96-96-0~ | ||
0~ | |||
94-93-92 - | 94-93-92 - | ||
91-so: | 91-so: | ||
| Line 676: | Line 596: | ||
* OPERATING BUTION MAY BE DEPRESS ED FLUSH WITH CASE APPROVED SW ITCHES - | * OPERATING BUTION MAY BE DEPRESS ED FLUSH WITH CASE APPROVED SW ITCHES - | ||
c BURGESS REF NO 3252 tV1213252) | c BURGESS REF NO 3252 tV1213252) | ||
Ooti,...,I VIZCG::t Hc¥0ng Oiall)ll.Pll"1o!olt a>.Plli.1t | |||
Ooti,...,I | |||
VIZCG::t Hc¥0ng Oiall)ll.Pll"1o!olt a>.Plli.1t | |||
...11l V12t* C"'11XI lhr.:.,ti'l;lll'lrd1if1911"'*..,.*~lt -::o:.,.a*fd. | ...11l V12t* C"'11XI lhr.:.,ti'l;lll'lrd1if1911"'*..,.*~lt -::o:.,.a*fd. | ||
tor:btteb.-. - Sto:.:. l t1.:lldte:trotin~CCll'l!Olt mt1-Sd>trC~0.t>0tlwle*l'l:ln.rcl B | tor:btteb.-. - Sto:.:. l t1.:lldte:trotin~CCll'l!Olt mt1-Sd>trC~0.t>0tlwle*l'l:ln.rcl B | ||
| Line 702: | Line 617: | ||
A A """' | A A """' | ||
"'""' KStcu~ | "'""' KStcu~ | ||
J.Stic--.t.on.i OollJl. Prltld.clrrllU'lll.lr | J.Stic--.t.on.i OollJl. Prltld.clrrllU'lll.lr HS12e'H ltttatn;i ~ | ||
HS12e'H ltttatn;i ~ | |||
Olc.117\ Ptltnal.art DAPl!lur Zyt!l liln:s ttlt<JNyl.on D-.1 T Qll~t ~Wrt:I Sll.ll!!'Dltay B ''"""' T ermnit~adlr !lr ~ fJicrlllllf:.ral | Olc.117\ Ptltnal.art DAPl!lur Zyt!l liln:s ttlt<JNyl.on D-.1 T Qll~t ~Wrt:I Sll.ll!!'Dltay B ''"""' T ermnit~adlr !lr ~ fJicrlllllf:.ral | ||
"""122 Tttltll'Ol. ;.arw !.l2 Hlld $ftd,flll!ll | """122 Tttltll'Ol. ;.arw !.l2 Hlld $ftd,flll!ll | ||
""""tt | """"tt | ||
~toiloct: | ~toiloct: | ||
lktrolnJ fru9t | lktrolnJ fru9t | ||
~hrtzrlnlSil~ | ~hrtzrlnlSil~ | ||
PtlQ.;p:u lhnzt loltmc!tM ~per' ~~ | PtlQ.;p:u lhnzt loltmc!tM ~per' ~~ | ||
5m:.: wrin stwr c:da, | 5m:.: wrin stwr c:da, l<.'670 lctfn[cnfGCI Rrn.rn ~11'"11'9 Stmrtr~ Sitt!. W'n A | ||
l<.'670 lctfn[cnfGCI Rrn.rn ~11'"11'9 Stmrtr~ Sitt!. W'n A | |||
K>12f.51 Utercit11:un;i ~taft.!:.s ~lttl. ifn, fft=n na.V'Ol ~ | K>12f.51 Utercit11:un;i ~taft.!:.s ~lttl. ifn, fft=n na.V'Ol ~ | ||
SECTION A-A 1 160906 JC 1 EC Fwst Issue | SECTION A-A 1 160906 JC 1 EC Fwst Issue | ||
.._ - - .c.. .... | .._ - - .c.. .... | ||
~::- II!! ,_:_:_7_CH _c_~_'c;_;_'ON_*_o_*_M_1c_RO_.SW~l-TC_H_K_S-32_5_2-A2 | ~::- II!! ,_:_:_7_CH _c_~_'c;_;_'ON_*_o_*_M_1c_RO_.SW~l-TC_H_K_S-32_5_2-A2 | ||
| Line 737: | Line 644: | ||
z | z | ||
"'Q | "'Q | ||
~~ | ~~ | ||
B | B | ||
| Line 800: | Line 706: | ||
State: NY NRC Notified by: PATRICK SHAW Notifications: FRED BOWER R1DO HQ Ops Officer: DONG HWA PARK MIKE ERNSTES R2DO Emergency Class: NON EMERGENCY NICKVALOS R3DO 10 CFR Section: JOHN KRAMER R4DO 21.21 (d)(3)(i) DEFECTS AND NONCOMPLIANCE PART 21/50.55 REACTORS EMAIL PART 21 -ANOMALY RELATED TO MICRO SWITCHES The following report was received via email: | State: NY NRC Notified by: PATRICK SHAW Notifications: FRED BOWER R1DO HQ Ops Officer: DONG HWA PARK MIKE ERNSTES R2DO Emergency Class: NON EMERGENCY NICKVALOS R3DO 10 CFR Section: JOHN KRAMER R4DO 21.21 (d)(3)(i) DEFECTS AND NONCOMPLIANCE PART 21/50.55 REACTORS EMAIL PART 21 -ANOMALY RELATED TO MICRO SWITCHES The following report was received via email: | ||
"Based on test data, Rotork believes an unsafe condition may exist as defined under 10CFR21. The adhesive formulation used for the construction of V12 and K5 safety related micro switches was altered by the switch maker's sub-supplier. K5 switches have no reported failures, but are affected because of construction. The altered adhesive formulation outgases an insulating material at elevated temperatures, which coats the switch.contacts as it cools, and can prevent the conduction of electricity." | "Based on test data, Rotork believes an unsafe condition may exist as defined under 10CFR21. The adhesive formulation used for the construction of V12 and K5 safety related micro switches was altered by the switch maker's sub-supplier. K5 switches have no reported failures, but are affected because of construction. The altered adhesive formulation outgases an insulating material at elevated temperatures, which coats the switch.contacts as it cools, and can prevent the conduction of electricity." | ||
FAX rotor.. | FAX rotor.. | ||
| Line 1,004: | Line 909: | ||
c-..r1.... | c-..r1.... | ||
o....- | o....- | ||
lltS a.. | lltS a.. | ||
lfl;~-"1 1X2MJU1-*1 C...-rl..._ | lfl;~-"1 1X2MJU1-*1 C...-rl..._ | ||
o.i.,..,.o fr" | o.i.,..,.o fr" | ||
:.. ttlOli- x !tU15-y '41Gl- "41Q..,., | :.. ttlOli- x !tU15-y '41Gl- "41Q..,., | ||
l us- l us- | l us- l us-01'0'9-"1 4il'lif-"1 "llh'i-.-, | ||
01'0'9-"1 | |||
4il'lif-"1 | |||
Figure 3: Air volume inside actuator electricol enclosure Figure 4: 245ml enclosure | Figure 3: Air volume inside actuator electricol enclosure Figure 4: 245ml enclosure | ||
| Line 1,150: | Line 1,047: | ||
The best fit of data was obtained by plotting temperature (T) against time (t) with a correction factor applied to time (t) that represented the difference between the actuator "switch to air volume" ratio and the metallic test enclosure "switch to air volume" ratio. Smaller than actuator enclosure test volumes were used to increase the " switch to air volume" ratio and accelerate the onset of the anomaly. The term concentration factor (Cf) was thus developed and multiplied the experiment duration time, measured in seconds (T versus t | The best fit of data was obtained by plotting temperature (T) against time (t) with a correction factor applied to time (t) that represented the difference between the actuator "switch to air volume" ratio and the metallic test enclosure "switch to air volume" ratio. Smaller than actuator enclosure test volumes were used to increase the " switch to air volume" ratio and accelerate the onset of the anomaly. The term concentration factor (Cf) was thus developed and multiplied the experiment duration time, measured in seconds (T versus t | ||
* Cf). The electrical enclosure volume in the Rotork NA actuator is slightly different for each model size. To be conservative the smallest NA actuator enclosure volume was used to develop the best fit equation. The line displayed in Figure 19 is the estimated boundary at which the anomaly onset would be observed . Above the line both open and closed contact anomalies were observed . Below the line anomalies were not observed. | * Cf). The electrical enclosure volume in the Rotork NA actuator is slightly different for each model size. To be conservative the smallest NA actuator enclosure volume was used to develop the best fit equation. The line displayed in Figure 19 is the estimated boundary at which the anomaly onset would be observed . Above the line both open and closed contact anomalies were observed . Below the line anomalies were not observed. | ||
Open Contact Anomaly 200 | Open Contact Anomaly 200 150 y = -20.4 lln(x) + 380.88 | ||
y = -20.4 lln(x) + 380.88 | |||
~ R2 =0.9497 | ~ R2 =0.9497 | ||
~ | ~ | ||
~ 100 Q) c.. | ~ 100 Q) c.. | ||
E Q) | E Q) | ||
| Line 1,180: | Line 1,071: | ||
* Open & Closed Contact Anomaly | * Open & Closed Contact Anomaly | ||
.. No anomaly | .. No anomaly | ||
- Log. !Anomaly Onset Boundary) 150 | - Log. !Anomaly Onset Boundary) 150 50 No reported switch anomalies by industry under mormal operating temperatures (48C max) 0 0 500000 1000000 1500000 2000000 2500000 3000000 3500000 4000000 4500000 Tlrne*Cf (sec) | ||
Figure 20 9.3. Switch performance under accident profiles The figures in the following pages show a number of temperature time profiles applicable to nuclear power plants that use Rotork NA actuators that use Rotork NA actuators. Each test was performed using eight new test switches placed in a new metallic enclosure having a volume of one US gallon. | Figure 20 9.3. Switch performance under accident profiles The figures in the following pages show a number of temperature time profiles applicable to nuclear power plants that use Rotork NA actuators that use Rotork NA actuators. Each test was performed using eight new test switches placed in a new metallic enclosure having a volume of one US gallon. | ||
The enclosure volume and number of switches provided a concentration factor of 1.125 thus assuring margin in the testing. In all cases the switches operated after the test and met the industry acceptance criteria of 500m0 or less. A large proportion of the switches met the supplier acceptance criteria of | The enclosure volume and number of switches provided a concentration factor of 1.125 thus assuring margin in the testing. In all cases the switches operated after the test and met the industry acceptance criteria of 500m0 or less. A large proportion of the switches met the supplier acceptance criteria of | ||
| Line 1,191: | Line 1,081: | ||
rotor11- Page 26 of 48 Rotork Controls Lim ited Approved by Engineering Nuclear Engineering Report No. ER857 Issue 1 Date: 3 rd May 2016 Priori ty 1 | rotor11- Page 26 of 48 Rotork Controls Lim ited Approved by Engineering Nuclear Engineering Report No. ER857 Issue 1 Date: 3 rd May 2016 Priori ty 1 | ||
__.,_ TiW 40 0 5000 10000 15000 lOOO'l l11ne(~c) | __.,_ TiW 40 0 5000 10000 15000 lOOO'l l11ne(~c) | ||
Figure 21 a Measured at 20C 4/15/16 Priorityl test data As provided resistance data mJH ohms Sample No-> .. 4/15-1 " 4/15 -2 4/15-3 4/15-4 4/15 -S 4/15-6 4/15-7 4/15 -8 NC NO NC NO NC NO NC NO NC NO NC NO NC NO NC NO 5.8 4.2 4.0 3.3 3.3 4.0 2.4 5.2 3.4 3.6 4.8 3.4 3.2 4.2 3.0 3.0 5.1 3.4 4.7 2.8 4.0 3.5 2.8 3.6 3.7 3.5 3.5 3.2 3.8 3.9 2.9 3.0 4.4 2.9 4.4 3.0 3.9 3.3 2.9 3.2 3.1 3.0 3.9 3.2 3.6 3.6 2.9 2.8 4.1 2.8 4.0 2.9 3.6 3.4 2.9 3.4 3.0 3.2 4.7 3.1 3.9 3.9 2.9 2.8 4.2 2.8 4.0 2.8 3.6 3.3 3.0 3.2 3.3 3.5 4.1 3.1 3.8 4.0 3.0 2.8 4.2 2.8 4.0 2.6 3.1 2.8 3.0 3.1 3.4 3.0 4.1 3.0 4.1 3.7 3.0 2.7 | Figure 21 a Measured at 20C 4/15/16 Priorityl test data As provided resistance data mJH ohms Sample No-> .. 4/15-1 " 4/15 -2 4/15-3 4/15-4 4/15 -S 4/15-6 4/15-7 4/15 -8 NC NO NC NO NC NO NC NO NC NO NC NO NC NO NC NO 5.8 4.2 4.0 3.3 3.3 4.0 2.4 5.2 3.4 3.6 4.8 3.4 3.2 4.2 3.0 3.0 5.1 3.4 4.7 2.8 4.0 3.5 2.8 3.6 3.7 3.5 3.5 3.2 3.8 3.9 2.9 3.0 4.4 2.9 4.4 3.0 3.9 3.3 2.9 3.2 3.1 3.0 3.9 3.2 3.6 3.6 2.9 2.8 4.1 2.8 4.0 2.9 3.6 3.4 2.9 3.4 3.0 3.2 4.7 3.1 3.9 3.9 2.9 2.8 4.2 2.8 4.0 2.8 3.6 3.3 3.0 3.2 3.3 3.5 4.1 3.1 3.8 4.0 3.0 2.8 4.2 2.8 4.0 2.6 3.1 2.8 3.0 3.1 3.4 3.0 4.1 3.0 4.1 3.7 3.0 2.7 Std 3.9 4.5 0.7 2.7 3.1 0.5 4.3 4.2 0.3 2.5 2.8 | ||
Std 3.9 4.5 0.7 2.7 3.1 0.5 4.3 4.2 0.3 2.5 2.8 | |||
: 0. 3 3.5 3.6 0.3 3.0 3.3 0.4 3.0 2.9 0.2 3.0 3.5 0.8 3.4 H | : 0. 3 3.5 3.6 0.3 3.0 3.3 0.4 3.0 2.9 0.2 3.0 3.5 0.8 3.4 H | ||
0.2 2.9 3.2 0.3 4.6 4.2 0.5 2.9 3.1 0.2 4.4 3.8 0.4 3.3 3.8 0.3 3.2 3.0 0.1 2.7 2.8 0.1 Measured at 60C (140f) 4/18/16 Post thermal aging using Priority l temp time profile Sample No-> ,,. 4/15-1 ' 4/15-2 ' 4/15-3 4/15-4 4/15 -5 4/15-6 4/15 -7 4/15 -8 NC NO NC NO NC NO NC NO NC NO NC NO NC NO NC NO 2.2 3.9 2.3 4.2 2.6 3.9 2.6 4.1 2.4 2.3 3.3 2.3 4.7 2.2 7.2 Measured at 20C 4/19/16 Post the rmal aging usi ng Priority l temp time profile Sample No -> ,. 4/15-1 .. 4/15-2 ,,. 4/15-3 4/15-4 4/15 -S 4/15-6 4/15 -7 4/15 -8 NC NO NC NO NC NO NC NO NC NO NC NO NC NO NC NO 2.6 iO 3.0 14.0 3.4 6.2 3.3 5.0 2.8 'DO 3.3 3.8 3.4 5.3 2.8 6.0 2.9 12.0 3.0 5.5 3.8 6.0 3.0 5.2 3.1 3.2 3.9 3.6 4.0 3.1 4.3 3.0 6.0 3.0 4.8 4.1 7.3 3.6 5.9 3.0 eo.11 3.2 3.2 3.6 4.1 3.2 3.6 2.9 3.3 3.0 5.2 4.2 7.6 4.1 4.0 3.1 ~ 3.6 3.0 3.6 4.0 3.3 4.0 3.0 3.4 2.9 3.9 4.4 7.0 4.9 3.5 3.0 so.o 3.0 2.9 3.7 4.1 3.3 3.4 3.1 3.0 2.8 3.7 4.2 10.2 4.1 3.2 3.3 ao.o 3.0 2.7 3.8 3.9 3.2 3.2 Ave Std 3.1 2.9 0.2 3.1 8.7 9.9 2.9 2.9 | 0.2 2.9 3.2 0.3 4.6 4.2 0.5 2.9 3.1 0.2 4.4 3.8 0.4 3.3 3.8 0.3 3.2 3.0 0.1 2.7 2.8 0.1 Measured at 60C (140f) 4/18/16 Post thermal aging using Priority l temp time profile Sample No-> ,,. 4/15-1 ' 4/15-2 ' 4/15-3 4/15-4 4/15 -5 4/15-6 4/15 -7 4/15 -8 NC NO NC NO NC NO NC NO NC NO NC NO NC NO NC NO 2.2 3.9 2.3 4.2 2.6 3.9 2.6 4.1 2.4 2.3 3.3 2.3 4.7 2.2 7.2 Measured at 20C 4/19/16 Post the rmal aging usi ng Priority l temp time profile Sample No -> ,. 4/15-1 .. 4/15-2 ,,. 4/15-3 4/15-4 4/15 -S 4/15-6 4/15 -7 4/15 -8 NC NO NC NO NC NO NC NO NC NO NC NO NC NO NC NO 2.6 iO 3.0 14.0 3.4 6.2 3.3 5.0 2.8 'DO 3.3 3.8 3.4 5.3 2.8 6.0 2.9 12.0 3.0 5.5 3.8 6.0 3.0 5.2 3.1 3.2 3.9 3.6 4.0 3.1 4.3 3.0 6.0 3.0 4.8 4.1 7.3 3.6 5.9 3.0 eo.11 3.2 3.2 3.6 4.1 3.2 3.6 2.9 3.3 3.0 5.2 4.2 7.6 4.1 4.0 3.1 ~ 3.6 3.0 3.6 4.0 3.3 4.0 3.0 3.4 2.9 3.9 4.4 7.0 4.9 3.5 3.0 so.o 3.0 2.9 3.7 4.1 3.3 3.4 3.1 3.0 2.8 3.7 4.2 10.2 4.1 3.2 3.3 ao.o 3.0 2.7 3.8 3.9 3.2 3.2 Ave Std 3.1 2.9 0.2 3.1 8.7 9.9 2.9 2.9 | ||
: 0. 1 3.1 | : 0. 1 3.1 | ||
: 5. 7 3.7 5.0 | : 5. 7 3.7 5.0 | ||
: 4. 2 0.5 6.6 7.3 1.4 | : 4. 2 0.5 6.6 7.3 1.4 4.0 O.ti 3.1 4.3 1.1 2.9 3.0 0.2 C'jS.0 53.6 19.5 3.1 3.2 0.2 2.8 3.2 0.5 3.8 3.6 0.1 4.1 4.2 0.5 3.3 3.2 0.2 3.1 3.9 1.0 | ||
4.0 O.ti 3.1 4.3 1.1 2.9 3.0 0.2 C'jS.0 53.6 19.5 3.1 3.2 0.2 2.8 3.2 0.5 3.8 3.6 0.1 4.1 4.2 0.5 3.3 3.2 0.2 3.1 3.9 1.0 | |||
~the contac1 resistance meets the industry accep tan~ wtena of 5CO mili ohms memo: the contact resistance mel!!ts the supplier accep tan ce criteria of <25 mill ohms Figure 21b | ~the contac1 resistance meets the industry accep tan~ wtena of 5CO mili ohms memo: the contact resistance mel!!ts the supplier accep tan ce criteria of <25 mill ohms Figure 21b | ||
| Line 1,208: | Line 1,093: | ||
!COO | !COO | ||
~ | ~ | ||
~ | ~ | ||
800 | 800 | ||
| Line 1,229: | Line 1,113: | ||
rotor11- Page 28 of 48 Rotork Controls Limited Approved by Engineering Nuclear Engineering Report No. ER857 Issue 1 Date : 3 rd May 2016 Pr io r ity 3 100 | rotor11- Page 28 of 48 Rotork Controls Limited Approved by Engineering Nuclear Engineering Report No. ER857 Issue 1 Date : 3 rd May 2016 Pr io r ity 3 100 | ||
"° 70 memo: for this test the oven profile temperatures between h(\ the start and end point were | "° 70 memo: for this test the oven profile temperatures between h(\ the start and end point were | ||
£ elevated 3 centlarade to assure temperature maralne. | £ elevated 3 centlarade to assure temperature maralne. | ||
| Line 1,236: | Line 1,119: | ||
- Taop1nt | - Taop1nt | ||
- - Ta1r I | - - Ta1r I | ||
40 | 40 20 10 20000 40000 60000 1()00)() | ||
20 10 20000 40000 60000 1()00)() | |||
r1me(sec. 1 Figure 23a Menu*ed1120C 4/2S/'l016 Priority3tu1du1 A*p!'Ovidedreslu1nced11tamlllohm* | r1me(sec. 1 Figure 23a Menu*ed1120C 4/2S/'l016 Priority3tu1du1 A*p!'Ovidedreslu1nced11tamlllohm* | ||
Sample No -> ' 4/25-1 NC | Sample No -> ' 4/25-1 NC | ||
!1.0 9.4 | !1.0 9.4 | ||
'4/25 | '4/25 | ||
* 2 NC 1.S | * 2 NC 1.S NO 12 | ||
NO 12 | |||
* ..,,JS . ) | * ..,,JS . ) | ||
NC NO | NC NO | ||
' 4/2S | ' 4/2S | ||
* 4 NC | * 4 NC NO | ||
' 4/2S -S NC NO | |||
NO | |||
' 4/2S -S | |||
NC NO | |||
' 4/2S | ' 4/2S | ||
* 6 NC l .6 NO u | * 6 NC l .6 NO u | ||
' 4/2S | ' 4/2S | ||
* 7 | * 7 NO | ||
' 412s -1 NO u 4.7 u | |||
NO | |||
' 412s -1 NO | |||
u 4.7 u | |||
..*1* 12 u | ..*1* 12 u | ||
<1 | <1 | ||
,, 17 | ,, 17 17 u | ||
17 u | |||
.. ..*... .,"u u | .. ..*... .,"u u | ||
31 31 17 .. . u | |||
31 31 | |||
17 .. . u | |||
... ...'*' u | ... ...'*' u | ||
" u | " u | ||
*~ | *~ | ||
u u | u u | ||
"' 1'2 Menu1ed1t60C( l40f l *126'2016 Post thermil iglng using Prior ity) temp time pro Ille 5-lmpleNo -> "*12s-1 NO 5.1 | "' 1'2 Menu1ed1t60C( l40f l *126'2016 Post thermil iglng using Prior ity) temp time pro Ille 5-lmpleNo -> "*12s-1 NO 5.1 | ||
**12s -2 4/27/1016 NO u | **12s -2 4/27/1016 NO u | ||
| Line 1,293: | Line 1,152: | ||
*4/2S *6 NO u | *4/2S *6 NO u | ||
' 4/25 *1 Postthe1m1l1gingusingPrioritylttmptimep<ofile S...mpleNo * > | ' 4/25 *1 Postthe1m1l1gingusingPrioritylttmptimep<ofile S...mpleNo * > | ||
"412s.1 NC | "412s.1 NC | ||
*u. | *u. | ||
NO | NO | ||
*412s -2 u | *412s -2 u | ||
NO s.1 "41zs .1 NO u | |||
NO | |||
s.1 "41zs .1 NO u | |||
' 4125 .4 NC u | ' 4125 .4 NC u | ||
*O | *O | ||
*4/2S -S NC 17 | *4/2S -S NC 17 | ||
' 411s -6 u | ' 411s -6 u | ||
NO 10 | NO 10 | ||
' 412s -1 | ' 412s -1 NO NC NO u | ||
NO NC NO u | |||
u | u | ||
*4/2S *I | *4/2S *I NC NO 1U 17 u | ||
NC NO 1U | |||
17 u | |||
.,u ...... | .,u ...... | ||
u u | |||
u | u | ||
.,u l .0 J.1 | |||
.,u | |||
l .0 J.1 | |||
* .1 u | * .1 u | ||
u u ...., | u u ...., | ||
u u | u u | ||
*.1 { | *.1 { | ||
u | u u | ||
u | |||
7.* | 7.* | ||
u 17 | u 17 31 | ||
*.", l .7 l.1 | |||
31 | |||
*.", l .7 | |||
l.1 | |||
~:~ | ~:~ | ||
'3.t | '3.t | ||
| Line 1,379: | Line 1,211: | ||
95 - | 95 - | ||
1\\ | 1\\ | ||
~ | ~ | ||
94 - 1650 | 94 - 1650 | ||
| Line 1,386: | Line 1,216: | ||
4000 3000 2000 1000 Wavenumbers (cm -1) | 4000 3000 2000 1000 Wavenumbers (cm -1) | ||
Fig ure 24: Infrared spectra of residue on NO contact rivets 9s :PoLYM5053: residue from bottom contact rivet of Switch s (2007) - 4 d;iys ;it 125"C | Fig ure 24: Infrared spectra of residue on NO contact rivets 9s :PoLYM5053: residue from bottom contact rivet of Switch s (2007) - 4 d;iys ;it 125"C | ||
:POLYM3246: Araldite Gl ue (24hrs;it WC) an;ilysed i n 2011 | :POLYM3246: Araldite Gl ue (24hrs;it WC) an;ilysed i n 2011 I- | ||
I- | |||
~ | ~ | ||
93 : | 93 : | ||
| Line 1,399: | Line 1,227: | ||
rotor11- Page 32 of 48 Rotork Controls Limited Approved by Engineering Nuclear Engineering Report No. ER857 Issue 1 Date : 3 rd May 2016 98-POLYM!i053: residue from bottom contact nvet of Switch S (2007) - 4 days at 125"C | rotor11- Page 32 of 48 Rotork Controls Limited Approved by Engineering Nuclear Engineering Report No. ER857 Issue 1 Date : 3 rd May 2016 98-POLYM!i053: residue from bottom contact nvet of Switch S (2007) - 4 days at 125"C | ||
:POLYM3210: new OAP C3Se an:ilysed in 2011 97 ~.-..J.,J, 96-96- | :POLYM3210: new OAP C3Se an:ilysed in 2011 97 ~.-..J.,J, 96-96-0~ | ||
0~ | |||
94-93-92 - | 94-93-92 - | ||
91-so: | 91-so: | ||
| Line 1,455: | Line 1,281: | ||
* OPERATING BUTION MAY BE DEPRESS ED FLUSH WITH CASE APPROVED SW ITCHES - | * OPERATING BUTION MAY BE DEPRESS ED FLUSH WITH CASE APPROVED SW ITCHES - | ||
c BURGESS REF NO 3252 tV1213252) | c BURGESS REF NO 3252 tV1213252) | ||
Ooti,...,I VIZCG::t Hc¥0ng Oiall)ll.Pll"1o!olt a>.Plli.1t | |||
Ooti,...,I | |||
VIZCG::t Hc¥0ng Oiall)ll.Pll"1o!olt a>.Plli.1t | |||
...11l V12t* C"'11XI lhr.:.,ti'l;lll'lrd1if1911"'*..,.*~lt -::o:.,.a*fd. | ...11l V12t* C"'11XI lhr.:.,ti'l;lll'lrd1if1911"'*..,.*~lt -::o:.,.a*fd. | ||
tor:btteb.-. - Sto:.:. l t1.:lldte:trotin~CCll'l!Olt mt1-Sd>trC~0.t>0tlwle*l'l:ln.rcl B | tor:btteb.-. - Sto:.:. l t1.:lldte:trotin~CCll'l!Olt mt1-Sd>trC~0.t>0tlwle*l'l:ln.rcl B | ||
| Line 1,481: | Line 1,302: | ||
A A """' | A A """' | ||
"'""' KStcu~ | "'""' KStcu~ | ||
J.Stic--.t.on.i OollJl. Prltld.clrrllU'lll.lr | J.Stic--.t.on.i OollJl. Prltld.clrrllU'lll.lr HS12e'H ltttatn;i ~ | ||
HS12e'H ltttatn;i ~ | |||
Olc.117\ Ptltnal.art DAPl!lur Zyt!l liln:s ttlt<JNyl.on D-.1 T Qll~t ~Wrt:I Sll.ll!!'Dltay B ''"""' T ermnit~adlr !lr ~ fJicrlllllf:.ral | Olc.117\ Ptltnal.art DAPl!lur Zyt!l liln:s ttlt<JNyl.on D-.1 T Qll~t ~Wrt:I Sll.ll!!'Dltay B ''"""' T ermnit~adlr !lr ~ fJicrlllllf:.ral | ||
"""122 Tttltll'Ol. ;.arw !.l2 Hlld $ftd,flll!ll | """122 Tttltll'Ol. ;.arw !.l2 Hlld $ftd,flll!ll | ||
""""tt | """"tt | ||
~toiloct: | ~toiloct: | ||
lktrolnJ fru9t | lktrolnJ fru9t | ||
~hrtzrlnlSil~ | ~hrtzrlnlSil~ | ||
PtlQ.;p:u lhnzt loltmc!tM ~per' ~~ | PtlQ.;p:u lhnzt loltmc!tM ~per' ~~ | ||
5m:.: wrin stwr c:da, | 5m:.: wrin stwr c:da, l<.'670 lctfn[cnfGCI Rrn.rn ~11'"11'9 Stmrtr~ Sitt!. W'n A | ||
l<.'670 lctfn[cnfGCI Rrn.rn ~11'"11'9 Stmrtr~ Sitt!. W'n A | |||
K>12f.51 Utercit11:un;i ~taft.!:.s ~lttl. ifn, fft=n na.V'Ol ~ | K>12f.51 Utercit11:un;i ~taft.!:.s ~lttl. ifn, fft=n na.V'Ol ~ | ||
SECTION A-A 1 160906 JC 1 EC Fwst Issue | SECTION A-A 1 160906 JC 1 EC Fwst Issue | ||
.._ - - .c.. .... | .._ - - .c.. .... | ||
~::- II!! ,_:_:_7_CH _c_~_'c;_;_'ON_*_o_*_M_1c_RO_.SW~l-TC_H_K_S-32_5_2-A2 | ~::- II!! ,_:_:_7_CH _c_~_'c;_;_'ON_*_o_*_M_1c_RO_.SW~l-TC_H_K_S-32_5_2-A2 | ||
| Line 1,516: | Line 1,329: | ||
z | z | ||
"'Q | "'Q | ||
~~ | ~~ | ||
B | B | ||
Latest revision as of 03:50, 5 February 2020
| ML16127A595 | |
| Person / Time | |
|---|---|
| Site: | Mcguire, Catawba, Summer, Seabrook, McGuire  |
| Issue date: | 05/04/2016 |
| From: | Arnold R, Shaw P Rotork Controls |
| To: | Office of Nuclear Reactor Regulation |
| References | |
| Download: ML16127A595 (62) | |
Text
0510412016' U.S. Nuclear Regulatory Commission Operations Center Event Report Pagel Part 21 (PAR) Event# 51907 Rep Org: ROTORK CONTROLS, INC. Notification Date I Time: 05/04/2016 14:56 (EDT}
Supplier: JOHNSON ELECTRIC Event Date I Time: 01/25/2016 (EDT}
Last Modification: 05/04/2016 Region: 1 Docket#:
City: ROCHESTER Agreement State: Yes County: License#:
State: NY NRC Notified by: PATRICK SHAW Notifications: FRED BOWER R1DO HQ Ops Officer: DONG HWA PARK MIKE ERNSTES R2DO Emergency Class: NON EMERGENCY NICKVALOS R3DO 10 CFR Section: JOHN KRAMER R4DO 21.21 (d)(3)(i) DEFECTS AND NONCOMPLIANCE PART 21/50.55 REACTORS EMAIL PART 21 -ANOMALY RELATED TO MICRO SWITCHES The following report was received via email:
"Based on test data, Rotork believes an unsafe condition may exist as defined under 10CFR21. The adhesive formulation used for the construction of V12 and K5 safety related micro switches was altered by the switch maker's sub-supplier. K5 switches have no reported failures, but are affected because of construction. The altered adhesive formulation outgases an insulating material at elevated temperatures, which coats the switch.contacts as it cools, and can prevent the conduction of electricity."
FAX rotor..
Contro~s G75 Mile Cro.1sin11 Blvd Hocht*stl'r, New Yo1k 14G:/.4 trl: *t*l 585 247 2304 f;nr +1585 2'17 230.'l
~v,uotnrk.com 111fo@lrotork.uim Far. {301) "315° - Pages: (Including Cover Page}
Date: oS/o4j2o/6 Re: CC:
D Urgent 0 For Review 0 Please Comment 0 Please Reply 0 Please Recycle
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1
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!1)6"1- <63'1 .I k5/12 ~ 2 - /.lZ
rotorlf Controls Rotork Controls Inc.
675 Mile Crossing Blvd Rochester. New York 14624 U.S. Nuclear Re,bJUlatory Commission, tel: +1 585 247 2304 Washington, DC 20555~0001 fax: +1 585 247 2308 wwvv.rotork.com From: Patrick A. Shaw, P.E info@rotork.com To: NRC Operations Center Date: May 4111 2016
Subject:
Rotork Controls Inc. Part 21 Notification, concerning V12 [Pt No N69-921] and KS [N69-838 & N69*926] safety related micro switches
Dear Sir/Madwne,
On January 25111 2016 Rotork Controls Inc. opened a fonnal Part 21 investigation into an anomaly reported by Duke Energy from testing conducted at Kinectrics in Canada. The anomaly related to Basic micro switches incorpomtcd within Rotork safety related NA 1E range electric actuators; also referred to as electric Valve Operators. The anomaly description was "switches failed to change state [Pt No N69-921 ]"and was observed after ten ( l 0) days of thennal aging at 125 Centigrade (25 7 Fahrenheit).
On March 18111 2016 Rotork wrote to the U.S. NRC requesting a 40 day extension to the 60 day investigation period permitted under 10CFR21 (Ref. Event No MLI 6088A087).
Based on test data, Rotork believes an unsafe condition may exist as defined under 10CFR21. The adhesive fonnu]ation used for the construction of Vl 2 and KS safety related micro switches was altered by the switch maker's sub-supplier. KS switches have no reported failures, but are affected because of construction. The altered adhesive formulation outgases an insulating material at elevated temperatures, which coats the switch contacts as it cools, and can prevent the conduction of electricity.
The anomaly onset is a function of temperature and time. The anomaly may occur when a switch is maintained above 90°C (194°F) for an extended period of time, and then subsequently cooled below 65°C (150)°F (see Rotork Engineering Report ER857 for details). Based on Rotork's NCR data this anomaly has not been reported by any U.S. NRC licensed operator. The anomaly is not observed at normal operating temperatures. Furthennore, all switches are expected to function nonnally whi1e at elevated temperatures (i.e. above 65°C (l 50°F)). The concern is limited to accident design based events that include heating above 90°C (194°F) and subsequent cooling below 65°C (150°F). Tests described within report ER857 suggests the anomaly has a lower limit of 90°C (194°F) (i.e. the switch is expected to function normally if the temperature is maintained below 90°C (194°F)). To assist the industry with risk assessment, the report includes tests performed using temperature time accident Page 1of12
rotorlf Controls profiles provided by the industry. The extent of condition affects switches manufactured from 2007 to 2015, inclusive. Product supplied prior to this date was tested and did not exhibit the anomaly.
Below is a summary in accordance with 10CFR Part 21 .21 (d)(4), which includes a list of all supplied actuators and spare components containing V 12 and K5 switches affected by this notification.
Sincerely a~t;J.jl_
Patrick A. Shaw, P.E Robert Arnold, P.E Quality Assurance Manager President Tel (585) 770-1019 Patrick.Shaw@rotork.com Page 2of12
rotorlf Controls Required information as per 10CFR Part 21.21(d)(4) follows~
(i) Name and address ofthe individual or individuals i11formi11g tlte Commission.
Patrick A. Shaw, P.E.
Rotork Controls Inc, 675 Mile Crossing Blvd, Rochester, New York 14624 (ii) Identification ofthe facility, the activity, or the basic component suppliedfor such facility or such activity within the United States which fails to comply or contains a defect.
Rotork part number N69-921 Micro-Switch Vl.2/3252 (RS104) and N69-926 Micro-Switch KS/3252 (RS378) and N69-838 Micro-Switch K5/3252-A2 (RS366) manufactured by Johnson Electric (Fonnerly Burgess) from 2007 to 2015.
(iii) Identification ofthe firm conslrocJing the facility or supplying the basic component which fails to comply or contains a defect.
Rotork Controls Ltd Brassmill Lane Bath, England BAJ 3JQ (iv) Nature of the defect or failure to comply and the safety hazard which is created or could be created by such defect or failure to comply.
The supplier (Johnson Electric) incorporates a small amount of adhesive in each switch's construction to secure the two halves of the switch housing together. The specified adhesive & hardener are AYl03 & HY951, respectively. Both are provided to Johnson Electric by Huntsman. To comply with legislation concerning toxicity, Huntsman altered the formulation and renamed the adhesive A YI 03-1; the HY95 l is unaltered. This change was not formally communicated by Huntsman and the modified adhesive name was not noticed by Johnson Electric.
The altered adhesive fonnulation outgases at elevated temperatures and deposits an insulating material layer onto the switch internal electrical contacts as it cools (see Rotork Engineering Report ER857 for specifics). The deposit of insulation material results in contact resistances exceeding the supplier acceptance criteria of 25mQ max, the industry SOOm!l max acceptance criteria and in some cases causes an open circuit.
Page 3of12
rotorlf Controls (v) 111e date 011 which the it!formation ~fsuch defect or.failure to comply was obtained.
January 25 111 2016 b'i) Jn tile case of a basic component which contains a defect or fails to comply, tile number and location of these components in use at, supplied for, being supplied for, or may be supplied for, manufactured, or bei11g ma11ufact11red for one or more .facilities or activities subject to the regulations in this part.
Vt 2 switch list Onlrr Part Qly DCKrlpllon Cuscomrr_PO Project 3SS818 NA/3SS8180l I 14NA IEFAl4A N Wnl2021VNO RSP358 I 8 (RCI CATAWBA limnally SERVICE)/
8409930 I030l 001118308 (DUKE) 8311669 NA/83866901 I 16NA I fAl4A N Wnl2023VNO 001151126 MCGUIRE 638773 NA/83877301 3 30NAX I FAl6A N Wnl2023VNO 00078626 CATAWBA 838786 NA/83878601 I 16NA I FAl4A N WTU202JVNO 00079069 MCGUIRE 8311854 NA/83885401 I 90NA I l'AJOA N WfU2021VNO 00080357 MCGUIRE 838854 NA/83885402 I 7NA I FAIOA N WTU2023VNO 00080357 MCGUIRE 838945 NA/83894501 3 16NA I FAl4A N WTU2023VNO 00081992 MCGUIRE B38945 NA/83894502 5 7NA I FAIOA N WTU2023VNO 00081992 MCGUIRE 838963 NA/83896301 6 1INA I FAIOA N WI1J 2023VNO 00082321 MCGUIRE B39003 NA/83900301 2 90NA I FAJOA N Wnl2021VNO 00083027 CATAWBA B39315 NA/83931501 I 70NAX I FA25A N WTIJ2021VNO 00087663 CATAWBA 839400 NA/83940001 I 40NA I FA2SA N Wl"U2023VNO 00088722 MCGUIRE 839435 NA/83943501 I 14NA I FAl4A N WTU2021VNO 00089037 CATAWBA 839475 NA/83947501 I JONA I FAl6A N Wnl2023VNO 00089808 MCGUIRE 839693 NA/B3969301' 6 16NA IEFAl4A N Wnl2023VNO 00092438 MCGUIRE 839725 NA/B3972SOI 4 JONAX IEFAIM N WTU2023VNO 40726 (CRANE) MCGUIRE 839765 NA/B3976501 I 14NA I FAl4A N WI1J 2021 VNO 00093385 CATAWBA 839836 NA/83983601 2 1INA I FAIOA N WTU2021VNO 00094314 CATAWBA 839970 NA/83997001 I JONAX IEFAl6A N WTU2023VNO 00096162 CATAWBA 839974 NA/83997401 I 1INA IEFAIOA N WTU2021VNO 00096233 MCGUIRE 839974 NA/83997402 I 30NAX IEFA16A N WTU2023VNO 00096233 MCGUIRE 839975 NA/83997501 2 llNA IEFAIOA N WTU2021VNO 00096222 CATAWBA 839977 NA/8399770 l 2 14NA IEFAl4A N WfU2021VNO 00096249 CATAWBA 840076 NA/84007601 2 40NAX l FA25A N WTU2021VNO 00097864 CATAWBA 840243 NA/84024301 2 IJNA I FAIOA N WTU2023VNO 00099808 MCGUIRE 840243 NA/84024302 I 70NA I FA25A N Wl1J2023VNO 00099808 MCGUIRE 840312 NA/84031201 I 30NA IEFA16A N WTU2023VNO 00099864 MCGUIRE Page4of12
rotor Controls If Onlrr l'nrl Qly Drurlpllon Customu_PO Proj~I B4031J NA/IJ403130 I 2 14NA IU'Al4A N Wl112023VNO ODll'J'Jll(15 MCGUIRl:.
R404SI NNR4114511ll 2 16NA IF.f/\14/\ N WI112023VNO ()(11()2329 MCGUIRi-!
R411!!77 NNB40117701 2 llNA IEFAIOA N WI11202 I VNO OlllOt1558 CATAWBA 841ll!77 NNB41187702 I 16NAX IEFA14A N wru21121VNO ()(}106558 CATAWBA 840993 NNB411993111 4 14NA IHAl4A N WfU2021VNO 001011308 CATAWBA 8411129 NNR411121JOI I JONAX I F.FAl6A N WfU202.WNO 436114 (CRANE) MCGUIRF.
841560 NA/B41.5600I 3 16NA 1EFAl4A N WI112023VNO 00115319 MCGUIRE 841573 NA/84157301 2 1INA IEFAIOA N wrLI202JVNO 00115417 MCGUIRE 841573 NAIB4157302 2 40NA IEFA2SA N wru 2023 VNO 00115417 MCGUIRE B41609 NNB4l6090I I llNA I l'AIOA N WllJ 2023 VNO 00115991 MCGUIRE 841bl7 NNB4161701 I 14NA IEFAl4A N WfU202JVNO !10116103 MCGUIRE B4178S NA/B4178SOI I llNA I FAIOA N WfU2023VNO OOl 18959 MCGUIRE 841910 NA/B41910<ll 2 16NA IEfAl4A N WTU202JVNO 0111211513 MCGUIRE 841981 NNB4198101 I 14NA IEFAl4A N WI11202JVNO 00121598 MCGUIRE B419KI NNR41911102 I 40NA IF.FA25A N WTU2023VNO 00121598 MCGUIRE 8420(,g NNB4206801 I 14NA IEFA14A N WTU2021VNO 00123289 CATAWflA 842078 NA/84207801 I 90NA I FA30A N wru2021VNO 00123469 MCGUIRE 8422}4 NA/8422.1401 2 16NA IF.FAl4A N WTU202.WNO 0111261185 MCGUIRE 842279 NAIB4227?01 2 70NA IEFA2SA N WTU2023VNO 00127067 MCGUIRE 842279 NA/84227902 2 I INA IEFAIOA N Wl112023VNO 00127067 MCGUIRE 842353 NNB423531ll 2 14NA IEfAl4A N WfU2021VNO 00128249 CATAWBA 84237.3 NA/84237301 l 90NA I FAJOA N WTU2023VNO 00128425 MCGUIRE 842457 NA/84245701 I 40NA IEFA2SA N WTU2023VNO 00130114 MCGUIRE 84252.S NA/84252501 l lbNAX IEFAl4A N WfU2021VNO OOIJ 1141 CATAWBA 842525 NA/84252502 I 30NAX IEFAl6A N WI112021VNO 00!31141 CATAWBA 842525 NA/84252503 I 1INA IEFAIOA N WTU2021VNO 00131141 CATAWBA 842585 NA/84258501 I 40NA IEFA25A N WTU2023VNO OOl32277 MCGUIRE 842696 NA/84269601 I I INA IEFAIOA N WfU2023VNO 00133938 MCGUIRE 842831 NNB4283l01 2 14NA 1EFAl4A N WTIJ 2021 VNO 00135938 CATAWBA 842855 NA/B4285SOI 6 40NA lffA25A N WfU2029VNO 97567 LUNG MEN (FLOWSERVE) 842868 NA/84286.~0I 2 1INA IEFAIOA N WTU2023VNO 00136550 MCGUIRE 842871 NA/84287101 l 40NA lEFA25A N WTIJ2023VNO 00136593 MCGUIRE 842918 NNB4291801 I 70NA IEFA2.5A N WTU2023VNO 00137202 CATAWBA 842918 NA/84291802 I 40NAX IEFA25A N WfU2023VNO 00137202 CATAWBA 842922 NA/84292201 I 16NAX IEFA14A N WTU202JVNO 00137242 CATAWBA 842922 NA/84292202 l 30NAX I EFA16A N WfU2021VNO 00137242 CATAWBA 842953 NAIB4295301 I 14NA IEFAl4A N WTU2023VNO 00137763 MCGUIRE 843608 NA/84360801 I 1 INA IEFAIOA N WTU2023VNO 00142102 MCGUIRE Page5of12
rotormt*
Controls Onkr P11rt Qt)' Drscrlpllun Customrr_ 1'0 Projl:'Ct B436bl WNK23 1)K 3 NAllS~ 12SW Vl2 AOPI 00142224 MCGUIRE B431J46 WNK2398 12 NAl/5E 12SW Vl2 AOl'I RSP.181114 OC*KF.
MCGUIRE 844151 NA1844151111 2 14NA I F.FAl4A N WTU2021VNO 00143556 DUKE CATAWBA 844269 NNB4426901 I l6NA IEFAl4A N Wl'U2023VNO OOl43880 MCGUIRE 84S067 NA/84506705 2 MODJA 40NAI C-WISESW.MF.CH !04962 OPG ASSV.
B4S067 NA/84506706 2 MOOSA 12 SW wru 2029VNO AOPI 104962 OPG ASSV.
845074 NA/84507401 2 1INA U.FAIOA N WfU202JVNO OOl45KKI MCGUIRE 846016 NA/84601601 I 14NA IEFA14A N WTU2023VNO 1111147120 MCGUIRE 846021 NA/84602201 I llNA IEFAIOA N WfU2023VNO 00147790 MCGUIRE B4602li WN82395 5 NAl/SE 6SW V12 AOPI 00147787 CATAWBA B46724 NNB4672401 I 90NA IEF A30A N WTU2023VNO 00148800 MCGUIRE 846724 NA/84672402 2 l6NA IEFA14A N WTU202JVNO 00148800 MCGUIRE 84728.8 WN82398 9 NAl15E 12SW Vl2 AOPI RSP39208 (RC! MCGUIRE SERVICE) I 00147756 {DUKE) 847352 NA/84735201 I I INA IF.FAIOA N WTU202JVNO 001500311 MCGUIRE 847745 NA-03-102 5 NAl/5 SWITCH MECH 011208N (RCC) I OPG 110208959 (OPG) 848378 NA/84837801 8 JINA 5EFI0841WNJ wru Cl4284SR ECU NOT KNOWN 2021VNO CORPORATION 848687 NA/B4K68701 I llNA IEFAIOA N WTU2023VNO 00152920 MCGUIRE 848811 NA/84881 IOI I l6NA IEFAl4A N WTU2023VNO 00153320 MCGUIRE 848925 NA/84892501 2 JINA IEFAIOA N WTU2021VNO 00153564 CATAWBA 849264 NA/84926401 I 14NA IEFA14A N WTU2021VNO 00154397 CATAWBA 849369 NA/84936901 2 I INA IEFAIOA N WTU2021VNO 00155275 DUKE CATAWBA 849459 NA/8494590 I I 14NA IEFAl4A N WnJ2021VNO 00155653 CATAWBA 849620 NA/84%2001 I MOD8A6 SWWTU 2021VNO AOPI 205435 AK NUCLEAR I ASSV.
849770 NA/84977001 I 14NA IEFAl4A N WnJ2023VNO 00156719 MCGUIRE 849774 WN80262 4 MODllA 7/llNAl/4COMPKITPOST78 RSP41188 (RCI SEABROOK SERVICE) 0230945 (SEABROOK) fWJ774 NA-03-102 I NAli5 SWITCH MECH RSP41188 (RCI SEABROOK SERVICE) 0230945 (SEABROOK) 849777 WN82398 6 NAl/5E 12SWV12AOPI RSP41660 (RCI MCGUIRE SERVICE)/
00155079 (DUKE) 349779 WN80262 2 MODI IA 7/llNAl/4COMPK!T POST78 RSP4 I l 89 (RCI SEABROOK SERVICE);
02302948 (SEABROOK) 849779 NA/8497791 l I 7NA I FAIOA N WTU2021VNO RSP41 I 89 (RCI SEABROOK SERVICE)/
02302948 (SEABROOK)
Page6of12
rotorlf Controls Order Pul Q1y lle$cripllon Costumer_ PO Project
()49779 NNB4lJ77'Jl2 I 7NA I fAIOA N WfU2021VNO RSP41189(RCI SEABROOK SERVICE)/
02302948 (SEABROOK) 849781 NA/B4<J7810l l 14NA IEFA14A N WTU202JVNO RSE39823 (RC! CATAWBA SERVICE)/
00155773 (DUKE) 84911!3 NA/84978301 I 14NA IEFAl4A N WTU202lVNO RSE394 IO (RCI MCGUIRE SERVICE)!
0015S086(DUKE) 8491!42 NNB4984201 I 90NA lEFAJOA N WTU2023VNO 00156967 MCGUIRE 849890 WN80334 I MODID 14/16NA5 CJCASE MAINT KIT 012171N (RCC)/ OPG POST78 00214820 (OPG) 850131 NA-03*102 2 NAl/5 SWITCH MECH 00158579 MCGUIRE 850641 NNB5064101 l llNA JEFAIOA N WfU2023VNO 00159726 MCGUIRE 85066.~ WN!12398 8 NAl/.~E 12SW VIZ AOPI NCRI 14367 (RCI) I MCGUIRE 0015751 I {DUKE) 850775 WN81509 5 MOD38 Vl2 NA'E' SIM 00160864 MCGUIRE 851199 NNB5119901 I l4NA IEFAl4A N WTU2023VNO 00162285 MCGUIRE 851201 NA/85120101 I I INA IEFAIOA N WTU2023VNO 00162286 MCGUIRE 851470 NA/85!47001 1 90NA I FAJOA N WTU2023VNO 00163632 MCGUIRE 851625 NA*03-I02 4 NAl/5 SWITCH MECH NU02SR748437 VCSUMMER ST 851684 NN8Sl68401 1 16NA IEFAl4A N WTU2023VNO 00164715 MCGUIRE 851902 NA185190201 2 JONAX IEFAl6A N WfU2023VNO 00165981 MCGUIRE 852307 NA/8523070 I I 14NA IEFAl4A N WfU2021VNO RSE41495 (RCI CATAWBA SERVICE)/
00164457 (DUKE) 852439 NAJBS243901 I 90NA I EFAJOA N WnJ2023VNO 00168826 MCGUIRE B52790 NNB5279001 I 16NA IEFAl4A N WTU2023VNO 00170740 MCGUIRE 85280! NA/85280101 2 JONAX IEFAl6A N WTU2023VNO 57081 DUKE CRANE NUKE 853470 NNB5347001 ;J 7 NA IEFAIOB4 IWN3 wru 8907060N DUKE 2023VNO MCGUIRE 853613 NAfBS361301 I 14NA IEFAl4A N WTU2021VNO 00172853 (DUKE) CATAWBA 854087 NNB5408701 2 30NAX IEFAl6A N WTU2023VNO 58666 CRANE NUKE B54177 NN85417701 I 14NA IEFAl4A N WTUZ021VNO RSP46290 (RCI DUKE SERVICE) CATAWBA 8441510101 854177 NNB5417704 l 14NA IEFAl4A N WTU2021VNO RSP46290 (RCI CATAWBA SERVICE)/
00174477(DUKE) 85433{) NAIBS433001 I 14NA IEFAl4A N Wl"U202lVNO 00177225 DUKE CATAWBA 854444 WN8239.5 I NAl/SE6SW VIZ AOPI NCR136918 (RCI) i MCGUIRE 00176305 (DUKE)
Page7of12
rotortf Controls Order Parl Qty Deseripllon Customer_ PO Project 854444 WN823'1K IO NAl/SE 12SW Vl2 AOPI NCRl361JIK (RCl)1 MCGUIRE 00176305 (DUKE)
BS4727 NAJBS47270 I 2 14NA IEFA14A N WTU2021VNO 001791<15 DUKE CATAWBA BS4727 NAJBS472702 2 14NA IEFAl4A N WTU2021VNO 00179165 DUKE CATAWBA 8.54842 NA*OJ-102 6 NA l/.'i SWITCH MECH OUl79h39 CATAWBA 856398 NA!B5639801 2 14NA IF.FAl4A N WTU2021VNO 00186461 CATAWBA BS6437 NAJB5643706 I I INA IEFAIOA N WllJ 2023VNO RSP4K672 DUKE MCGURIE 856515 NAIB56SISOI I 1INA IEFAIOA N WTU2023VNO 00186989 DUKE MCGUIRE BS723S NA/BS723SO I I 90NA IEFA30A N WTU2023VNO 00189572 DUKE-MCGUIRE 857239 NAJB5723901 3 l6NA IEFA14A N WfU2023VNO 00189629 DUKE-MCGUIRE 857239 NNBS723902 I 9DNA IEFAJOA N WTU2023VNO 00189629 DUKE-MCGUIRE B57239 NA/85723903 I 90NA IEFA30A N WTU2023VNO 00189629 DUKE-MCGUIRE 857443 NA/B5i' 4430 I 3 7 NA 5EFAIOB4 IWN3 wru 1193547 OPGESWSTRA 2220VNO 857603 NNB5760301 I 70NAX I FA2SA N WTU2021VNO 00191051 CATAWBA 857687 WNSOJ.14 I MODI D 14!16NAS GIC ASE MAINT KIT P002240-4 (RCC)/ OPG POST78 0028620 I (OPG) 857722 NA/85772201 I 40NA IEFA25A N WTU2023VNO 00191584 MCGUIRE 858332 NNBS833201 2 14NA IEFA14A N WTU2023VNO 00193561 DUKE-MCGUIRE B589tll NN85890101 I I INA IEFAIOA N WTU2023VNO 00195572 DUKE MCGUIRE 859205 NN85920501 4 16NA IEFAl4A N WTU2023VNO 00196629 DUKE-OCONEE B592(15 NA/85920502 I 16NA IEFAJ4A N WTU2023VNO 00196629 DUKE**
OCONEE 859319 NA/8593190 I I 16NA IEFAl4A N WTU202JVNO 00197087 CATAWBA 859392 NA/8593920 I I 70NA JEFA25A N WTU2023VNO 00197274 DUKE MCGUIRE 859392 NA/85939202 I JINA IEFAIOA N WTU2023VNO 00197274 DUKE MCGUIRE 859879 NA/85987901 I IJNA JEFAIOA N WTU2021VNO 00199184 DUKE CATAWBA B602n NA/86021301 I 7 NA SEFAIOA N WTC 2i}ZIVNO Pfl06139 (RCI)/ OPG Pl500268 (NEWMAN HATTERS LEY) 860896 NA/86089601 2 JINA IEFAIOA N WTU2023VNO 03003170 MCGUIRE 861560 WN81S09 2 MODJB Vl2 NA'E' SIM 03007832 CATAWBA 861721 N69-921 6 SWITCH*M Vl2/3252 RSP54951 / 013962010301)
NCRJ64927 (RCI OPG SERVICE 861721 NA/B617l!Ol j 7 NA 5EFAIOA N WTCZ021VNO RSP54951 ! 01396201030! -
NCRl64927 (RCI OPG SERVICE)
Page 8of12
rotorlf Controls Order l'arl QI)" Descripllon Cuslomcr_PO l'rojeel 061721 WN!llSO'J I MODJB Vl2 NA'E' SIM RSPS4951 f OIJ"62010JOI -
NCRl64927(RCI NEWMl\N SERVICE) Hl\TIERSLEY -
Ol'G 012CJ89 NAJDl291!<JOI 2 JONA I FAl6A N WfCWDI8016 00153869 OPG DBl40 NNDD 141Kll 2 JONA I FAl6A N WfCWDl8016 00159480 OPG D131:'il NArDl:\l.'ilOI I 411NA I FA2SZ N wrc woo3142 llOISSS90 OPG OIOCJ71} NA/OI0971JOI I lliNA IEFAl4A N WTC2029VNO Pl 100211 CF.RNAVODA NEWMAN HATIERSLEY-013JS1J NAIOl33S90I I 7 NA IEFAl084 IWNJ WTC Pl200360{NEWMAN EMBALSENPP 2024VNO HATIERSLEY)
OIJJS9 NAJ01335902 I 7 NA IEFAIOB4 JWN3 wrc Pl200360(NEWMAN FMBALSE NPP 2024VNO llA1"rERSLEY)
OIJJll:'i NA/01338501 I 7NA SEFALOB4 IWN3 wrc 12-12079 (RITEf'ROl F.MBl\LSE NPP 2020VNO 013%2 NA/01396201 J 7NA SEFAIOA N WTC2021VNO PIJ002U2 (NEWMAN OPG HATIERSLEYJ Sl)l))\l3 NAISD939302 ] MOD3A 90NAI C -WISE SM.MECH 216341, ENTERGY ASSY. REPLACMENT FOR 10156515
<ENTERGY)
WE2984 NA-03-102 J NAl!5 SWITCH MECH 114800 PALO VERDE CURTIS WRIGHT -
ENERTECH, WE3110 NA-03-102 s NAl/5 SWITCH MECH ESD8468N (RCC) I OPG 00151524 (OPG)
WEJl67 NA*Ri-102 I NAl/5 SWITCH MECH ESD86JON (RCC) I OPCi OOIS4615(0PG)
WEJ267 NNW82670 I N00.()3-020 NAI SWITCH MECH 4500362690 f'SOO I
WE3747 NA.()l-102 J NAl/S SWITCH MECH ESD9023N (RCC)/ OPG 0016228 (OPG)
WE381J NA*03-102 I NAli5 SWITCH MECH ESD9070N ( RCC) i OPG 00163571 (OPG)
WE3907 NA..00-102 2 NAl/5 SWITCH MECH 4500428140 PSEG WE3910 NA-OJ-102 2 NAl/S SW ITCH MECH ED13239R (RCC) OPG TRAINING PURPOSES PER PO, WE4022 NA-03-102 i NAl/5 SWITCH MECH ESD9135N (RCC)/ OPG 00158829 (OPG)
WE4037 NA-03-102 2 NA 115 SWITCH MECH 00098888 MCGUIRE WE4246 NA-03-102 I NAl/5 SWITCH MECH SJl5871 ENTERGY Page9of 12
rotorlf Controls Onlrr 11,HI Qt)" Drscrlpllon Cus1an111r_ l'O l'rajrd W~l'lb NA-0)-102 I NAl/S SWllCll MECll ESD'l2711N (RCC)/ Ol'G llOlt.!!401 (OPG)
WE41161J NA-ll3-I02 2 NAl/5 SWITCH MECH ESD94'>1 N ( RCC) I OPG 110173259 (OPG)
W~5621 NA~JJ-102 Ii NA II.~ SWITCll MECll ESD1JllOIN (RCC)/ OPG 11018111011 (OPG)
WE6060 NA-Ol-102 6 NAl/S SWITCll MECll L'i ll00211N/REV2 Ol'G (RCC)I 001116517 (OPG)
WE6152 NA-IU-102 l NA!/S SWITCll MECll ESD0092N (RCC) I OPG 001118202 (OPG)
WE6660 NA-03-IOZ I NAl/S swrrc11 MECH 500546062 APS- PALO VERDE WE6822 NA-08-706 I lllAI 6SW VJ2 AOPI ASS RSP35818 (RCI RCISERVICEi SERVICE)/ CATAWBA 110132331 (DUKE)
WE6904 WN112395 . NAl/SE6SW VIZ AOPI 00136411 CATAWBA WF.7023 WN82395 5 NAl/SF.6SW Vl2 AOPI 00137764 CATAWBA WE70llS WN82398 IS NAl/SE 12SW Vl2 AOPI 00138769 MCGUIRE WE.7139 WN80262 I MODI IA 7ll INAl/4 COMP KITPOS'r711 02263)79 SEABROOK WE7247 WN82398 l NAl/!iE 12SW VIZ AOPI 0014043:'i MCGUIRE Page 10of12
rotormt*
Controls KS switch list Onlcr l'art Qty Dettrlptlon Customer PO Projet I 84641102 N564114 2 NAI SWITCH MECH SPF.C 010634N (RCC)/ HVDROQUBEC 4503054188 (I lydro ICENTRALE Quebec) GENTILLY II 8494511 WNl<06S3 II NAI SW MECll KS-3252*A2 Ol 196SN (RCC) I BRUCE POWER 0017!079 (BRUCE POWER)
B4977'J NASll3B* 2 NAl/S SWITCH MECH KS RSP41189(RCI SEABROOK OIHl4 SERVICE)/
02302948 (SEABROOK) 134'>524 N564K4 3 NAI SWITCll MECll SPEC Ol 1998N (RCC) I MOBIL VALVE 1065218 (MOBILE /NEW VALVE)/ BRUNSWICK 4500370878 (NEW POWER BRUNSWICK POWER) 850333 WN80653 b NAI SW MECH K5*32S2-A2 012410N (RCC)/ OPG 00216597 (OPG) 851532 WN806SJ 8 NAI SW MECH K5*3252*A2 012969N (RCCJ f BRUCE POWER 00177514 (BRUCE POWER) 852075 N564K4 J NAI SWITCH Ml'.Cil SP£C 013329N (RCC) I BRUCE POWER OOl796116(BRUCE POWER) 853208 NASOJB- I SWITCH MECH NAI KS OAP. ANNEALED 013968N (RCC) I OPG 0005 RYTON 00226962 (OPG)
BSJS75 N56484 I NAI SWITCH MECH SPEC 013877N (RCC)/ BRUCE POWER 00183812 (BRUCE POWER) 854843 NS6484 J NAI SWITCH MECH SPEC 014684N (RCCJ I BRUNSWICK 1177461 (MOBILE POWER VALVE)/
4500398343 (NEW BRUNSWICK POWER)
B55380 NS6483 I NA l SWITCH BANK SPEC P000623-I (RCC)/ OPG 00232427 (OPG) 856689 NS6484 I NAI SWITCH MECH SPEC NCRl4877S NCR SPARES B56643 NA/BS664301 s MODJA 90NAI C-WISESW.MECH ASSY. P002330*1 (RCC)/ Ol'G 00235579 (OPG) 855572 NASOJB- I SWITCH MECH NAI KS DAP. ANNEALED P000918*1 (RCC)/ OPG 0005 RYfON 00233354 (OPG)
Oi20(iU NA/0!209001 3 7 NA 5EFAIOB4 IWN3 WTC2040-NO 202546 (BRAVJ BRAY, BRUCE POWER 014002 NA/01400201 I 14NA I FA14A N WTC2024-NO 00183784 (BRUCE BRUCE POWER POWER)
Page 11of12
rotor1f Controls (vii) 11ie corrective actioll which has bee11, i.f bei11g, or will be take11; the name ofthe individual or organization responsible for the action; and the length of time that /ms been or will be tt1ke11 to complete the action.
By this notification Rotork is infonning al] Utilities and listing affected customer orders.
Utilities may contact their local Rotork office or the undersigned for support relating to their specific units. Rotork recommends the replacement of switches in the affected orders.
Rotork is currently evaluating options regarding replacement switches with the supply chain. The switch assembly's design will be changed by Johnson Electric so that the adhesive AY 103-1 is no longer used.
(11iii) Any ad11ice related to the defect or failure to comply about the facility, activity, or basic component that has been, is being, or will he given to purchasers or licensees.
U.S. Licensees with installed or in storage actuators, switch mechanisms or Add-On-Pak (AOP) spares modules containing V12 and K5 switches identified in section (v1) should evaluate the impact of a high contact resistance or open circuit condition on safety related systems.
(ix) In the case ofan early site permit, the entities to whom an early site permit was transferred Not Applicable Page 12of12
rotor11- Page 1of48 Rotork Controls Limited Approved by Engineering Nuclear Engineering Report No. ER857 Issue 1 Date: 3rd May 2016 REVISION SHEET ORIGIN Priyang Jadav & Patrick Shaw DATE OF ISSUE 03/05/2016 TITLE Part 21 Investigation. Anomaly of V12 Micro-Switch N69-921.
Prepared Checked Approved Priyang Jadav Patrick Shaw Kevin Sweet Product Engineer - Quality Assurance Engineering Manager Nuclear 'Manager -Nuclear Issue No Date Revision By 1 03/05/16 Original PUJ
rotor11- Page 2 of 48 Rotork Controls Limited Approved by Engineering Nuclear Engineering Report No. ER857 Issue 1 Date: 3rd May 2016 CONTENTS
- 1. Summary .............*............................................................................................................................ 3
- 2. Deviation description ............................................................................................*.......................... 3
- 3. Micro-switch function ..................................................................................................................... 4
- 4. Review of orders affected ............................................................................................................... 4
- 5. Summary of tests performed .......................................................................................................... 7 5.1. Air volume of actuator electrical enclosure ............................................................................ 9
- 6. Tests replicating the anomaly ....................................................................................................... 11 6.1. Procedure for thermal aging switches inside an enclosure .................................................. 11 6.2. Test 1-125°C (257°F) aging of V12 switches manufactured in 2015 .................................. 12 6.3. Test 2 -Volt ramp on aged switches from Test 1.. ............................................................... 14 6.4. Test 3 -125°C (257°F) aging of V12 switches manufactured in 2007 .................................. 14 6.5. Test 4 -125°C (257°F) aging of V12 contacts only ............................................................... 14
- 7. Supporting information and post-curing ...................................................................................... 16 7.1. Procedure for post-curing tests ............................................................................................ 17 7.2. Test 5 - Post-curing ............................................................................................................... 17 7.3. Test 6 -125°C (257°F) aging of KS switches manufactured in 2012 ..................................... 18
- 8. Tests of unglued and glued switches using different adhesives ................................................... 19 8.1. Test 7 -125°C (257°F) aging of a switch without adhesive .................................................. 19 8.2. Test 8 -125°C (257°F) aging of switch assembled with Duralco 4525 ................................. 19 8.3. Test 9 -125°C (257°F) aging of switches assembled with AY105-1/HY991 ......................... 20 8.4. Test 10 -125°C (257°F) aging of switch assembled with Raychem S1264 ........................... 21 8.5. Test 11-125°C (257°F) aging of switch assembled with X60 .............................................. 21
- 9. Anomaly effect upon switch operation ........................................................................................ 22 9.1. Factors Causing Anomaly ...................................................................................................... 22 9.2. Estimated Anomaly Onset .................................................................................................... 23 9.3. Switch performance under accident profiles ........................................................................ 25
- 10. Results from independent test lab ........................................................................................... 30
- 11. Conclusion ................................................................................................................................. 35
- 12. References ................................................................................................................................ 36
rotor11- Page 3 of 48 Rotork Controls Limited Approved by Engineering Nuclear Engineering Report No. ER857 Issue 1 Date: 3rd May 2016
- 1. Summary This report documents work performed to support a Part 21 investigation opened by Rotork Controls Inc. ref. tracking number NCR173472. Measurements and tests were performed to establish the operational reliability of Rotork safety related micro-switches. Non-compliant switches were identified from a batch manufactured in 201S against Rotork purchase order P01284S9. The investigation has confirmed that the defect is only attributed to batches received in 2007 and later.
The switch supplier (Johnson Electric) incorporates a small amount of adhesive in each switch's construction to secure the two halves of the switch housing together. The adhesive formulation was altered in 2003 by the adhesive supplier (Huntsman). Tests detailed in this report show that the altered formulation outgases at elevated temperatures and deposits an insulating material layer onto the switch internal electrical contacts as it cools.
- 2. Deviation description On January 2S, 2016 Rotork Controls Inc. opened a formal Part 21 investigation into an anomaly relating to a Basic micro-switch - Part No. N69-921 (RS104), description "V12". The anomaly is high resistance or loss of electrical continuity and was first observed following a customer thermal aging test of Rotork Safety Related NA Range electric Actuators; also referred to as an electric Valve Operator. Following 10 days at 12S°C (2S7°F) a significant percentage of micro-switches in the test actuators exhibited open circuit.
Subsequent in-house testing has revealed that the anomaly also relates to Basic micro-switches with the following Part Nos. as they are constructed using the same adhesive.
N69-838 (RS366), description "KS" (screw terminals)
N69-926 (RS378), description "KS" (fast-on terminals)
Drawings of the three switches can be found in Appendix A.
rotor11- Page 4 of 48 Rotork Controls Limited Approved by Engineering Nuclear Engineering Report No. ER857 Issue 1 Date: 3rd May 2016
- 3. Micro-switch function The micro-switch has four functions:
- Rotork actuators can be set to operate to a maximum torque level of opening or closing a valve. When the torque sensing mechanism in the actuator registers this maximum torque, the micro-switch will be tripped to turn off the motor.
- Rotork actuators can also be set to operate to a maximum travel limit. The mechanism inside the actuator will register when the maximum travel in the open or close direction is reached and the micro-switch will be tripped to turn off the motor.
- In the Add-on-Pak (AOP) the switch is intended for indication purposes but can also be used for interlocks and permissives to start other equipment such as pumps and valves. AOP switches can be set to trip at any point during valve travel. The AOP can also be used for torque switch bypass. If the circuit is "open" then the MOV could stop before achieving "end of travel".
- Switches must be "closed" to initiate travel.
- 4. Review of orders affected The following are details of the affected switches.
- 11000 V12 switches N69-921 supplied to Rotork against the following purchase orders.
Purchase order no. Quantity Rotork Lot reference Manufacture Year P0081139 700 LC006383 2007 1050 LC006391 1500 LC006398 725 LC006399 2025 LC006402 P0128459 183 LC010448 2015 500 LC010464 700 LC010483 483 LC010509 612 LC010539 1 LC010540 639 LC010547 640 LC010566 640 LC010570 448 LC010576 154 LC010638 11000
rotor11- Page S of 48 Rotork Controls Limited Approved by Engineering Nuclear Engineering Report No. ER857 Issue 1 Date: 3rd May 2016
- 1900 KS switches N69-838 supplied to Rotork against the following purchase orders.
Purchase order no. Quantity Rotork Lot reference Manufacture Year P0084220 200 LC006390 2007 P0086172 100 LC006S39 P00870S7 100 LC006603 2008 P00892Sl 200 LC007024 P0090778 100 LC00713S P0092646 20 LC0072S4 2009 80 LC0072SS P009S664 100 LC0074SO P0100333 100 LC007682 2010 200 LC007693 240 LC008194 2011 183 LC0082SO 2012 277 LC008271 1900
- 1S03 KS switches N69-926 supplied to Rotork against the following purchase order.
Purchase order no. Quantity Rotork Lot reference Manufacture Year P010661S 17S LC008192 2011 32S LC008193 2012 476 LC008203 149 LC008207 2S3 LC008233 12S LC0082S3 1S03
rotor11- Page 6 of 48 Rotork Controls Limited Approved by Engineering Nuclear Engineering Report No. ER857 Issue 1 Date : 3 rd May 2016
- Suspect V12 and KS switches have date code ending with 07K to lSK stamped at the location shown below. The code refers to week (43) and year (2015).
Figure 1: Location of date code on V12 switch Figure 2: Location of date code on KS switch N69-838
rotor11- Page 7 of 48 Rotork Controls Limited Approved by Engineering Nuclear Engineering Report No. ER857 Issue 1 Date: 3 rd May 2016
- 5. Summary of tests performed A range of tests were conducted as part of the investigation in order to :
- a. Replicate the anomaly
- b. Identify root cause
- c. Evaluate switches from previously supplied batches
- d. Attempt salvaging defect switches
- e. Experiment with alternative adhesives
- f. Evaluate the effect of the anomaly on switch operation Table 1 provides a summary of tests performed to cover points a toe above. Further details on each test are provided in subsequent sections which are referenced within the table itself. The experiments were performed using two programmable test ovens. Test switches were placed in metallic enclosures and heated to a fixed temperature for a defined time (thermal aging). The testing was destructive, and new switches and metallic enclosures were used for every test. Prior to use, the metallic enclosures were thermally cleaned to remove any volatile materials remaining from their manufacture. The metallic enclosure construction does not incorporate any non-metallic seals or non-metallic coatings .
Part f is a study of the 1) factors causing the anomaly, 2) estimated anomaly onset, and 3) switch performance under accident profiles. This work is detailed in section 9.
Test Test No. of Test Concentra- Result Full no. description switches parameters tion factor test tested (Cf) details 1 Thermal aging 5 switches, 5.75 days at 1680cm 3 Switch anomaly occurs See of V12 date code 125* c (257°F) . test even when the switch is Section switches 3715K, in a container. aged in isolation, 6.2 manufactured metal 336cm 3 therefore cause lies within in 2015 . container per switch . the switch itself.
of volume Cf= 1.78 Contamination is present 1680cm 3 . on NO and NC contact rivets. UV images suggest it may be coming from adhesive .
2 Volt ramp on 2 aged Volt ramp up N/A Volt ramp up to 60VDC, See aged switches switches to 60VDC 14mA does not reliably Section from Test 1. taken from across the NO clean the contacts. 6.3 Test 1. contact with 4.3k0 fixed resistor in series (14mA max across contacts) .
rotor11- Page 8 of 48 Rotork Controls Limited Approved by Engineering Nuclear Engineering Report No. ER857 Issue 1 Date : 3 rd May 2016 Test Test No. of Test Concentra- Result Full no. description switches parameters tion factor test tested (Cf) details 3 Thermal aging 4 switches, 3.93 days at 1680cm3 The 2007 manufactu red See ofV12 date code 12s*c (2S7°F) . test switches exhibit the same Section switches 2807K . container. anomaly as the 201S 6.4 manufactured 420cm 3 switches .
in 2007 . per switch .
Cf= 1.42 4 Thermal aging 3 switches, 6 days at 2SS2cm 3 There is no issue with the See of V12 date code 12s*c (2S7°F) . test silver plating process of Section contacts only . 3613K, had container. the rivets. 6.S their NO, 8Slcm 3 NC and per switch.
moving Cf =0 .70 contacts removed to be aged .
s Post-curing of 6 switches, Post-cu red at 24Scm 3 After 8 days of post- See V12 switches date code 12s* c (2S7°F) test curing, outgassing still Section manufactured 431SK . forupto8 container. occurs causing the switch 7.2 in 20 1S. days . Then 1 switch to exhibit the anomaly.
aged inside per container for container.
3.77 days. Cf =2.44 6 Thermal aging 2 switches, 6 days at 1680cm 3 The KS switch N69-838 See of KS switches date code 12s* c (2S7°F) . test exhibits the same anomaly Section N69-838 0612K . container. as the Vl2. KS N69-926 is 7.3 manufactured 840cm 3 constructed of the same in 2012 . per switch . glue thus is also affected .
Cf= 0.71 7 Thermal aging 1 switch, 7 days at 24Scm 3 Switch performance is See of a switch assembled 12s* c (2S7°F) . test acceptable if no adhesive Section without without container. is present. 8.1 adhesive. adhesive 1 switch applied . per container.
Cf =2.44 8 The rmal aging 1 switch 10 days at 24Scm 3 Duralco 4S2S outgasses to See of switch 12s* c (2S7°F) . test an extent that the switch Section assembled container. will exhibit the anomaly. 8.2 with Duralco 1 switch 4S2S . per container.
Cf =2.44
rotor1- Page 9 of 48 Rotork Controls Limited Approved by Engineering Nuclear Engineering Report No. ER857 Issue 1 Date : 3 rd May 2016 Test Test No. of Test Concentra- Result Full no. description switches parameters tion factor test tested (Cf) details 9 Thermal aging 3 switches Up to 14.2 245cm 3 Switch performance is See of switches days at 12s* c test acceptable if assembled Section assembled (257"F) . container. using a small quantity of 8.3 with AYlOS- 1 switch AY105-1/HY991.
1/HY991. per container.
Cf =2 .44 10 Thermal aging 1 switch 10 days at 245cm 3 Switch performance is See of switch 12s* c (257"F) . test acceptable if assembled Section assembled container. using a small quantity of 8.4 with Raychem 1 switch Raychem S1264.
S1264. per container.
Cf =2 .44 11 Thermal aging 1 switch 10 days at 245cm 3 X60 outgasses to an extent See of switches 12s* c (2S7" F) . test that the switch will exhibit Section assembled conta iner. the anomaly. 8.5 with X60. 1 swit ch per container.
Cf =2.44 Table 1: Summary of tests performed 5.1. Air volume of actuator electrical enclosure During the investigation it was observed that the air volume per switch is an important factor which needs to be considered in aging tests since it can influence the length of aging time before onset of the anomaly. Experimental data demonstrated, for a given temperature, the anomaly would manifest itself in a shorter time period when switches were placed in a smaller enclosure. This is further discussed in section 9. It is necessary to know the air volume in the actuator electrical enclosure in order to relate the test results to the application . To be conservative a small size actuator was used for the calculation, giving a worse switch to air volume ratio . Using CAD the air volume in an empty electrical enclosure was estimated to be 11960cm 3 (Figure 3).
Similarly, the volume of the switch mechanism and AOP were estimated 594cm 3 from CAD (5 % of enclosure volume). It is assumed another 5% of enclosure volume is consumed by the heater, looms and other components within the enclosure. The air volume to which a small actuator fitted with a switch mechanism and 12 switch AOP would outgas to is :
11960 - 594 - 594 = 10772cm 3 The maximum number of switches available in an actuator are 18. Therefore the estimated volume of air per switch is:
10772/18 = 598cm 3
rotor11- Page 10 of 48 Rotork Controls Limited Approved by Engineering Nuclear Engineering Report No. ER857 Issue 1 Date : 3 rd May 2016 Different sizes of encl osures were utilised . Most of the tests listed in Table 1 were performed using 3
245ml (=245cm ) enclosures (Figure 4) . The term concentration factor (Cf) is introduced to relate the actuator air volume per switch to the test enclosure volume per switch:
actuator air v olume per switch 598cm 3 Cf= test enclosure volume per switch = 245cm 3 = Z.4 4 The concentration factor for each test is also specified in Table 1.
c-..r1....
o....-
lltS a..
lfl;~-"1 1X2MJU1-*1 C...-rl..._
o.i.,..,.o fr"
- .. ttlOli- x !tU15-y '41Gl- "41Q..,.,
l us- l us-01'0'9-"1 4il'lif-"1 "llh'i-.-,
Figure 3: Air volume inside actuator electricol enclosure Figure 4: 245ml enclosure
rotor11- Page 11of48 Rotork Controls Limited Approved by Engineering Nuclear Engineering Report No. ER857 Issue 1 Date : 3 rd May 2016
- 6. Tests replicating the anomaly 6.1. Procedure for thermal aging switches inside an enclosure In-house thermal aging tests were performed to replicate the anomaly. The tests were performed according to the following procedure.
a) Remove screw terminals.
b) Using milliohm meter, record resistance across NC contacts . (Meter used applied 9V, SmA max. Figure 5). Manufacturer's end -of-line acceptance level is 25m0 max.
Figure 5: Milliohm meter c) Operate and hold switch plunger.
d) Record resistance across NO contacts.
e) Release plunger.
f) Repeat steps b - e until 3 NC and 3 NO measurements are obtained for each switch.
g) Fasten screw terminals h) Place switches inside a metallic container.
i) Thermally age the container at 125°C (257°F). (Total aging time varied for each test and is stated in subsequent sections of the report) j) Once thermal aging complete, remove container from oven and allow to cool. It is important that the container remains closed until cooled so that any outgassing can condense .
k) Remove switches and repeat resistance check following steps a - g
rotor11- Page 12 of 48 Rotork Controls Limited Approved by Engineering Nuclear Engineering Report No. ER857 Issue 1 Date : 3rd May 2016 6.2. Test 1 - 125°C (257°F) aging of V12 switches manufactured in 2015 5 switches, Rotork part no. N69-921, date code 3715K, labelled F - J, were tested following the procedure in section 6.1. A drawing of switch N69-921 is shown in Appendix A. Thermal aging time was 138 hrs (5.75 days).
Results are shown in Appendix B. Before aging, the switches were within the manufacturer's 25m0 acceptance. After aging, the NO contacts exhibited open circuit, indicated by a dash in the result field.
Switch H recovered on the second operation post-aging. A
- in the result field indicates that the resistance value was fluctuating between several ohms, to hundreds of ohms, to open circuit.
Green cells identify readings below the 25m0 manufacturer's end-of-line acceptance.
Yellow cells identify readings below the 500m0 industry acceptance.
Red cells identify unacceptable reading.
Switch F was opened for examination of the contacts (Figure 6 - Figure 9). Blue plastic particles were formed only as a result of breaking the switch apart. A pale yellow layer appears to have formed on the surface of the NC and NO contact rivets, Figure 6 and Figure 8. At the very centre of the NC and NO rivet, i.e. the point of contact, the layer has broken away and the normal silver appearance of the rivet is visible. The white powder on the moving contact, Figure 7 and Figure 9, indicates that there was transfer of the broken layer from the stationary contacts to the moving contact.
Contacts from aged switches were observed under UV light. Figure 10 indicates the contamination is formed only on the NC and NO stationary contacts . Under UV light the contamination is a similar colour to the residue in the area where adhesive is applied, Figure 11. The conjecture for this is that the NC and NO contact tabs extend outside of the switch housing where the surrounding temperature is lower than the temperature inside the switch. Thus through loss of heat by conduction, the NO and NC contacts would cool quicker than other components enclosed within the switch housing. This would mean that the NO and NC contacts act as heat sinks causing vapours released from the adhesive to condense onto the contacts . The NC and NO stationary contacts are made from Silver-Cadmium-Oxide (AgCdO) which provides the best known performance for switching off electrical current quickly and cleanly (Ref 1).
An independent investigation was performed by an external laboratory Exova in an effort to identify the source of contamination (Section 10). However, due to differences in chemical composition between the non -metallics and the contaminant, the source could not be confirmed by analysis.
Nevertheless, literature (section 7), test results of an unglued switch (section 8.1) and UV images identify the adhesive being the root cause.
Summary
- The V12 switch anomaly occurs even when the switch is aged in isolation, therefore the cause lies within the switch itself.
- Contamination is present on the NO and NC contact rivets, and UV images suggest it may be coming from the adhesive.
rotor11- Page 13 of 48 Rotork Controls Limited Approved by Engineering Nuclear Engineering Report No. ER857 Issue 1 Date : 3 rd May 2016 Figure 6: Switch F, NC contact rivet Figure 7: Switch F, NC side of moving contact Figure 8: Switch F, NO contact rivet Figure 9: Switch F, NO side of moving contact Figure 10: Contact rivets under UV light Figure 11 : Separated switch housing under UV light
rotor11- Page 14 of 48 Rotork Controls Limited Approved by Engineering Nuclear Engineering Report No. ER857 Issue 1 Date : 3rd May 2016 6.3. Test 2 -Volt ramp on aged switches from Test 1 A volt ramp up to 60VDC was performed across the NO contact of switch G, using a 4.3k0 fixed resistor in series. Switch G maintained open circu it.
60 V 430011
= 14mA max across contacts.
The volt ramp was repeated across the NO contact of sw itch I. At 60VDC the switch started to conduct.
The plunger was released for 5 mins before repeating the test. During the second volt ramp switch I began to conduct at 27VDC.
Summary
- Volt ramp up to 60VDC, 14mA does not reliably clean the contacts.
6.4. Test 3 -125°C (257°F) aging of V12 switches manufactured in 2007 4 switches N69-921, date code 2807K, labelled P, Q, Sand T, were tested following the procedure in section 6.1. Thermal aging time was 94.25 hrs (3.93 days).
Results are shown in Appendix B. Before aging, the sw itches were within the manufacturer' s 25m0 acceptance. After aging, the NO contacts exhibited high resistance or open circuit. Resistance readings up to 500m0 are generally acceptable in the industry.
Summary
- The 2007 manufactured switches exhibit the same anomaly as the 2015 switches.
6.5. Test 4 - 125°C (257°F) aging of V12 contacts only UV images of switch internals post-aging (Figure 10) showed that the contamination is deposited only on the NO and NC contact rivets. It was thus thought that the contamination may be related to the silver plating process of the rivets.
3 switches N69-921, date code 3613K, had their NO, NC and moving contacts removed to be aged in isolation inside a metal container. The contacts were resistance checked (Figure 12) pre and post-aging. Thermal aging time was 144 hrs (6 days).
rotor11- Page 15 of 48 Rotork Controls Limited Approved by Engineering Nuclear Engineering Report No. ER857 Issue 1 Date : 3 rd May 2016 Figure 12: Resistance checks of contacts removed from switches Thermal aging the contacts in isolation did not influence their ability to conduct current. Pre and post-aging contact resistances were 3 to 4m0.
The contacts were also observed under an optica l microscope but there were no signs of contamination . The rivets were similar in appearance pre-aging (Figure 13) and post-aging (Figure 14).
Figure 13: Contact rivet pre-aging Figure 14: Contact rivet post-aging Summary
- The results indicate there is no issue with the silver plating process of the rivets .
rotor11- Page 16 of 48 Rotork Controls Limited Approved by Engineering Nuclea r Engineering Report No. ER857 Issue 1 Date: 3rd May 2016
- 7. Supporting information and post-curing A technical report on an adhesive related issue (Ref 2) in the Large Hadron Collider {LHC) provides information supporting this Part 21 investigation. Araldite AY103-1 was used in the construction of a LHC component. The component shows an outgassing effect which has been tracked back to the adhesive. Different adhesives were investigated using a setup for measuring the amount of outgassing after 24hrs aging at 125°C {25 7° F). The two part epoxy AY103 -1 with its hardener HY951 is also used in construction of the V12 switch.
In summary the technical report states the following :
- AY103-1 is a replacement of AY103 which is no longer manufactured .
- Adhesive AY103 did not outgas but AY103-1 does.
- Higher ambient temperatures accelerate the outgassing.
- 68% of the outgas is water but the remainder isn't identified.
- Curing at 40°C {104°F) for two weeks and extracting the condensate reduces the effect.
The adhesive manufacturer, Huntsman, confirmed that AY103 was indeed withdrawn in February 2003 and replaced by AY103-1. In accordance with the 28th adaptation of the EU Dangerous Substances Directive (Directive 2001/59/EC), all products containing >0.5% DBP (Dibutyl phthalate) are to be cla ssed tox ic. AY103 would have fallen into this category therefore its formulation was changed. AY103-1 is free of DBP and phthalate esters.
Another technical paper (Ref 3) identifies the plastifiers present in the chemical makeup of the two epoxies. The report states:
- AY103 contained the plastifier dibutyl-phthalate (DBP) which is toxic.
- In the AY103 -1 formulation, DBP was replaced with plastifier di-isopropyl-naphthalene {DIPN)
- The plastifier DIPN does not take part in the curing process with the hardener and is expected to remain volatile close to the surface of the hardened epoxy.
- AYlOS -1 is another epoxy but without any plastifier. See section 8.3 for thermal aging test results with this adhesive.
Based on technical literature, the following conjecture was formed to explain the mechanism which leads to the anomaly. The adhesive is thought to outgas at temperature releasing water vapour, and with it the gaseous plastifier. The water vapour is the carrier of the contaminating material. After thermal aging the NO and NC contacts are thought to cool first (as explained in section 6.2) . The contacts thus act as a heat sink enabling water vapour to condense onto them and deposit the contam inating material.
rotor11- Page 17 of 48 Rotork Controls Limited Approved by Engineering Nuclear Engineering Report No. ER857 Issue 1 Date: 3rd May 2016 7 .1. Procedure for post-curing tests It has been confirmed from literature that the adhesive AY103-1 used in the construction of the V12 switch outgasses. The literature also indicates that a post-curing process where the condensate is extracted during thermal aging may solve the issue. The following test procedures describes the tests performed to investigate post-curing.
a) Remove screw terminals.
b) Using milliohm meter, record resistance across NC contacts. (Meter used applied 9V, 5mA max. Figure 5). Manufacturer's end-of-line acceptance level is 25m0 max.
c) Operate and hold switch plunger.
d) Record resistance across NO contacts.
e) Release plunger.
f) Repeat steps b - e until 3 NC and 3 NO measurements are obtained for each switch.
g) Fasten screw terminals h) Place all switches freely in a fan assisted oven and thermally cure at 125°C (257°F). Post-curing time for each switch is different as shown in Table 2.
i) Remove each switch when its post-curing time is complete and allow to cool.
j) Repeat resistance check following steps a - g.
k) Place each switch in its own aluminium container and perform subsequent aging at 125°C (257°F) as shown in Table 2.
Post-curing time at Subsequent aging inside Switch Identification Date code 12s c (2s1°F) 0 container at 125°C (257°F}
1 1 day 2 4 days 3 5 days 4315K 90.5 hrs (3 .77 days) 4 6 days 5 7 days 6 8 days Table 2: Post-curing time I) Repeat resistance check following steps a - g.
7.2. Test 5 - Post-curing 6 switches N69-921, date code 4315K, labelled 1 to 6, were tested following the procedure in section 7.1. As detailed in the procedure and in Table 2 the switches were post-cured for different number of days up to 8 days in a fan assisted oven . Following post-curing each switch was removed, resistance checked, then placed in a separate container. The containers were further aged to see if after being post-cured each switch would still outgas and exhibit the anomaly in a closed volume of air.
Results are shown in Appendix C. Before any aging the switches were all within the manufacturer's 25m0 acceptance. After post-curing, the NO contacts showed resistance values above 25m0 in most operations, however, this would not affect switch performance in the field . All switches remained
rotor11- Page 18 of 48 Rotork Controls Limited Approved by Engineering Nuclear Engineering Report No. ER857 Issue 1 Date: 3rd May 2016 functional after the post-curing process. However, after further aging in containers the switches exhibited open circuit I unacceptable high resistance across the NO contacts .
Summary
- After 8 days of post-curing, outgassing still occurs causing the switch to exhibit the anomaly.
7.3. Test 6 -125°C (257°F) aging of KS switches manufactured in 2012 2 switches N69-838, date code 0612K, labelled 16 and 17, were tested following the procedure in section 6.1. A drawing of switch N69-921 is shown in Appendix A. Thermal aging time was 6 days.
Results are shown in Appendix D. Before aging, the switches were within the SOOmO industry acceptance. After aging, the NO contacts exhibited high resistance or open circuit . Resistance readings above the SOOmO acceptance level are highlighted red.
Summary
- KS switches N69-838 exhibit the same anomaly as the Vl2 .
- The only difference between the two types of KS switches N69-838 and N69-926 are the contact terminals. Therefore, switches N69-926 also fall within the scope of this Part 21.
rotor11- Page 19 of 48 Rotork Controls Limited Approved by Engineering Nuclear Engineering Report No. ER857 Issue 1 Date : 3rd May 2016
- 8. Tests of unglued and glued switches using different adhesives 8.1. Test 7 - 125°C (257°F) aging of a switch without adhesive 1 switch N69-921, assembled in 2016 without adhesive applied, and labelled 18, was tested following the procedure in section 6.1. Results are shown in Appendix E. After aging for 2 days at 125°C (257°F) in a container the resistance readings were still below manufacturer's acceptance. The switch was placed back into the container and aged for a further 4.96 days. This made the NO resistance higher but still acceptable for in-field use. The switch was again placed back into the container and aged for a further 3.98 days. Contact resistances remained acceptable for in-field use.
Total aging of unglued switch= 2 days+ 4.96 days+ 3.98 days= 10.94 days Summary
- The switch performance is acceptable if no adhesive is present.
8.2. Test 8 -125°C (257°F) aging of switch assembled with Duralco 4525 A switch labelled 21 was assembled using Duralco 4525 (Figure 15) and cured in a fan assisted oven for 1 hour1.157407e-5 days <br />2.777778e-4 hours <br />1.653439e-6 weeks <br />3.805e-7 months <br /> at 121°C (250°F), as per the adhesive's datasheet. The switch was then left for 15 hours1.736111e-4 days <br />0.00417 hours <br />2.480159e-5 weeks <br />5.7075e-6 months <br /> before being tested to the procedure in section 6.1.
Figure 15: Switch 21, 4 drops of Dura/co 4525 Results are shown in Appendix F. After being aged for 10 days at 125°C (257°F) the switch exhibited open circuit mode across the NO contacts .
Summary
- Duralco 4525 outgasses to an extent that the sw itch will exh ibit the anomaly after 10 days aging at 125°C (257°F) .
rotor11- Page 20 of 48 Rotork Controls Limited Approved by Engineering Nuclear Engineering Report No. ER857 Issue 1 Date : 3rd May 2016 8.3. Test 9 -125°C (257°F) aging of switches assembled with AY105-l/HY991 The Araldite manufacturer Huntsman suggested an alternative adhesive/hardener system .
Used by switch manufacturer: AY103-1/HY951 Suggested alternative: AY105-1/HY991 AY105-1/HY991 has been found to be low outgassing in NASA tests. 2 switches labelled 19 and 20 were assembled using AY105-1/HY991 and cured in a fan assisted oven for 35 mins at 60°C (140°F), as per the adhesive's datasheet. The switches were then left for 3 hours3.472222e-5 days <br />8.333333e-4 hours <br />4.960317e-6 weeks <br />1.1415e-6 months <br /> before being tested to the procedure in section 6.1.
Results are shown in Appendix G.
Switch 19 was aged for 2 days at 125°( (257°F) and remained functional.
Switch 20 was aged for 6 days at 125°C (257°F) and remained functional.
The switches were placed back into the containers and aged further.
Switch 19 was aged for a total of 14.2 days, following which the NO contact exhibited open circuit.
Switch 20 was aged for a total of 10.1 days, following which the NO contact exhibited open circuit.
It was believed that using less adhesive would reduce the effect of outgassing. Therefore, the test was repeated with switch 50, which was assembled with just 3 small droplets of AY105-1/HY991.
Figure 16 and Figure 17 compare the quantity of adhesive applied to Switch 20 vs. Switch 50. With reduced amount of adhesive the switch passed the 125°( (257°F) 10 day aging test (results in Appendix G).
Figure 16: Switch 20, 4 drops of AY105-1/HY991 Figure 17: Switch 50, 3 small drops of AY105-1/HY991 Summary
- The extent of the anomaly is reduced by reducing the amount of adhesive used.
- AY105-1/HY991 in reduced quantity passed the 10 days aging at 125°C (257°F) .
rotor11- Page 21of48 Rotork Controls Limited Approved by Engineering Nuclear Engineering Report No. ER857 Issue 1 Date : 3 rd May 2016 8.4. Test 10 - 125°C (257°F) aging of switch assembled with Raychem 51264 A switch labelled 49 was assembled using 3 small droplets of Raychem S1264 (Figure 18) and cured in a fan assisted oven for 1 hour1.157407e-5 days <br />2.777778e-4 hours <br />1.653439e-6 weeks <br />3.805e-7 months <br /> at 85°C (185°F), as per the adhesive' s datasheet. The switch was then left for 3 hours3.472222e-5 days <br />8.333333e-4 hours <br />4.960317e-6 weeks <br />1.1415e-6 months <br /> before being tested to the procedure in section 6.1.
Figure 18: Switch 49, 3 small drops of Raychem 51264 The switch passed the 125°C (257°F) 10 day aging test. Results are shown in Appendix H.
Summary
- Raychem S1264 used in small quantity passed 10 days aging at 125°C (257°F).
8.5. Test 11-125°C (257°F) aging of switch assembled with X60 A switch labelled 59 was assembled using 3 small droplets of X60 . The adhesive has a very qu ick cure time of 2 mins at room temperature . The assembled switch was left for 2 hours2.314815e-5 days <br />5.555556e-4 hours <br />3.306878e-6 weeks <br />7.61e-7 months <br /> 40 mins before being tested to the procedure in section 6.1.
The switch did not pass 10 days aging test at 125°C (257°F). NO contacts exhibited open circuit. Results are shown in Appendix H.
Summary
- X60 outgasses to an extent that the switch will exhibit the anomaly after 10 days aging at 125*c (257°F) .
rotor11- Page 22 of 48 Rotork Controls Limited Approved by Engineering Nuclear Engineering Report No. ER857 Issue 1 Date : 3rd May 2016
- 9. Anomaly effect upon switch operation This element of the Part 21 investigation assesses 1) factors causing the anomaly, 2) estimated anomaly onset, and 3) switch performance under accident profiles.
9.1. Factors Causing Anomaly The anomaly is attributed to outgassing from the adhesive AY103-1/HY951 used in the switch construction, specifically meaning the migration of the plasticizer within the adhesive's phenol base material to the air volume contained within the actuator's electrical enclosure.
By review of published literature a number of papers were found on the subject of modelling outgassing expressed as mass flow rate. Most of the models have exponential forms that are functions of temperature and time with constant bases on material properties e.g. activation energy, gas constant, molecular mass etc. The reviewed papers all appeared to model outgassing to an infinite volume. In actuality the actuator electrical enclosure volume is finite and thus the partial pressure of outgassed material may influence the rate of outgassing. Experimental data demonstrated, for a given temperature, the anomaly would manifest itself in a shorter time period when switches were placed in a smaller enclosure. Based on the aforementioned it is determined the anomaly is a function of temperature, time, and electrical enclosure volume. A series of experiments were thus performed to assess these three factors.
The experiments were performed using three programmable test ovens and sealed metallic enclosures. Test switches were placed in sealed metallic enclosure and heated to a fixed temperature for a defined time (thermal aging). The testing was destructive, and new switches and metallic enclosures were used for every test. Prior to use, the metallic enclosures were thermally cleaned to remove any volatile materials remaining from their manufacture. The metallic enclosure construction does not incorporate any non-metallic seals or non-metallic coatings. Switch contact operation was measured using a EXTECH 380560 milliohm meter [calibrated 6/18/2015, Due 6/18/2016] which provided discrimination from lmO to 20,0000 (open circuit); alternative methods of assessing circuit continuity were assessed but dismissed . Switch contact resistance was measured prior to and post each thermal aging test (temperature x time). All resistance measurements were performed at room temperature. The switch was considered to exhibit the anomaly when the milliohm meter registered a resistance exceeding 20,0000. The switch maker's acceptance criteria is <25m0. The industry acceptance criteria is 500m0 or less.
The relationship between the three factors was assessed by varying their levels in experiments, recording the point of anomaly onset, and plotting scatter diagrams. Using regression analysis and correlation coefficient, the relation between temperature, time, enclosure volume, and anomaly onset was progressively established.
rotor11- Page 23 of 48 Rotork Controls Limited Approved by Engineering Nuclear Engineering Report No. ER857 Issue 1 Date : 3 rd May 2016 9.2. Estimated Anomaly Onset The test data reveal two forms of switch anomaly: 1) the normally open (NO) contact failed to change state, 2) the normally closed (NC) contact failed to change state. Failure to change state means the electrical contacts become sufficiently coated with outgassed material to prevent conduction of electricity. As thermal aging progresses, at any fixed temperature, the anomaly is first observed in the NO contact and then later in the NC contact when measured at room temperature . An open contact is more susceptible to the anomaly because the two contact working surfaces are fully exposed . A closed contact partly masks each working surface and requires a higher outgas concentration to become fully coated . Given the switch contacts have identical contact geometry, it is more accurate to state the anomaly occurs first in the contact that is open and later in the contact that is closed during thermal aging. Thus no distinction should be made between NO and NC contacts.
The best fit of data was obtained by plotting temperature (T) against time (t) with a correction factor applied to time (t) that represented the difference between the actuator "switch to air volume" ratio and the metallic test enclosure "switch to air volume" ratio. Smaller than actuator enclosure test volumes were used to increase the " switch to air volume" ratio and accelerate the onset of the anomaly. The term concentration factor (Cf) was thus developed and multiplied the experiment duration time, measured in seconds (T versus t
- Cf). The electrical enclosure volume in the Rotork NA actuator is slightly different for each model size. To be conservative the smallest NA actuator enclosure volume was used to develop the best fit equation. The line displayed in Figure 19 is the estimated boundary at which the anomaly onset would be observed . Above the line both open and closed contact anomalies were observed . Below the line anomalies were not observed.
Open Contact Anomaly 200 150 y = -20.4 lln(x) + 380.88
~ R2 =0.9497
~
~ 100 Q) c..
E Q)
I-50 0
0 200000 400000 600000 800000 1000000 Time Cf (sec)
Figure 19
rotor11- Page 24 of 48 Rotork Contro ls Limited Approved by Engineering Nuclear Engineering Report No. ER857 Issue 1 Date: 3rd May 2016 The boundary was found by performing a series of experiments at fixed temperatures . The duration of each experiment was progressively reduced until only the NO contacts started to exhibit the anomaly. The activity was repeated for different temperatures to develop the graph in Figure 19.
Figure 20 displays the accumulated test data from which the following can be concluded :
- 1. At time t=O all the switches functioned correctly .
- 2. Switches function correctly from t=O (sec) to any green triangles on a constant temperature line.
- 3. Switches function correctly from temperature T=0 °C (32°F) to any green triangles on a constant time line.
- 4. Switches function correctly where constant temperature and constant time lines intersect and green triangles straddle the intersection points; two blue extension lines showing one intersection example.
- 5. Based on Rotork NCR data no utility has reported unreliable switch operation, thus at 49°C (120°F) and below the switches function correctly.
- 6. The effect of temperature is non-linear upon anomaly onset.
- 7. At 175°C (347°F) the onset of open contact and closed contact anomaly is less distinguishable.
- 8. At lower temperatures the Log anomaly onset boundary overstates the anomaly onset.
- 9. At 90°C (194°F) the anomaly was not observed . However, the test for 3,300,000 seconds at 90°C (194°F) exhibited elevated contact resistance in 50% of the open contacts. The measured resistances exceeded the supplier acceptance criteria of <25m0 but did not exceeded the industry 500m0 acceptance criteria.
rotor11- Page 25 of 48 Rotork Controls Limited Approved by Engineering Nuclear Engineering Report No. ER857 Issue 1 Date : 3 rd May 2016 250 All Test Data Open Contact Anomaly Only 200
- Open & Closed Contact Anomaly
.. No anomaly
- Log. !Anomaly Onset Boundary) 150 50 No reported switch anomalies by industry under mormal operating temperatures (48C max) 0 0 500000 1000000 1500000 2000000 2500000 3000000 3500000 4000000 4500000 Tlrne*Cf (sec)
Figure 20 9.3. Switch performance under accident profiles The figures in the following pages show a number of temperature time profiles applicable to nuclear power plants that use Rotork NA actuators that use Rotork NA actuators. Each test was performed using eight new test switches placed in a new metallic enclosure having a volume of one US gallon.
The enclosure volume and number of switches provided a concentration factor of 1.125 thus assuring margin in the testing. In all cases the switches operated after the test and met the industry acceptance criteria of 500m0 or less. A large proportion of the switches met the supplier acceptance criteria of
<25m0. Switch resistances were measured before and after test at room temperature . All test instruments were calibrated under the Rotork Appendix B quality program. The data below demonstrates the test switch temperatures either exceeded the computed actuator switch temperature or equaled the oven air temperature.
Three temperature lines are displayed in each graph:
- Tao pin t is the computed temperature time profile of the switches in an actuator switch mechanism and add-on-pack, based on the environmental air temperature time profile.
- Tair is the measured environmental (oven) air temperature for the provided profile.
- T(8 t est s witches) is the measured temperature profile of 8 test switches, within the closed metallic enclosure, exposed to the Tair temperature time profile.
rotor11- Page 26 of 48 Rotork Controls Lim ited Approved by Engineering Nuclear Engineering Report No. ER857 Issue 1 Date: 3 rd May 2016 Priori ty 1
__.,_ TiW 40 0 5000 10000 15000 lOOO'l l11ne(~c)
Figure 21 a Measured at 20C 4/15/16 Priorityl test data As provided resistance data mJH ohms Sample No-> .. 4/15-1 " 4/15 -2 4/15-3 4/15-4 4/15 -S 4/15-6 4/15-7 4/15 -8 NC NO NC NO NC NO NC NO NC NO NC NO NC NO NC NO 5.8 4.2 4.0 3.3 3.3 4.0 2.4 5.2 3.4 3.6 4.8 3.4 3.2 4.2 3.0 3.0 5.1 3.4 4.7 2.8 4.0 3.5 2.8 3.6 3.7 3.5 3.5 3.2 3.8 3.9 2.9 3.0 4.4 2.9 4.4 3.0 3.9 3.3 2.9 3.2 3.1 3.0 3.9 3.2 3.6 3.6 2.9 2.8 4.1 2.8 4.0 2.9 3.6 3.4 2.9 3.4 3.0 3.2 4.7 3.1 3.9 3.9 2.9 2.8 4.2 2.8 4.0 2.8 3.6 3.3 3.0 3.2 3.3 3.5 4.1 3.1 3.8 4.0 3.0 2.8 4.2 2.8 4.0 2.6 3.1 2.8 3.0 3.1 3.4 3.0 4.1 3.0 4.1 3.7 3.0 2.7 Std 3.9 4.5 0.7 2.7 3.1 0.5 4.3 4.2 0.3 2.5 2.8
- 0. 3 3.5 3.6 0.3 3.0 3.3 0.4 3.0 2.9 0.2 3.0 3.5 0.8 3.4 H
0.2 2.9 3.2 0.3 4.6 4.2 0.5 2.9 3.1 0.2 4.4 3.8 0.4 3.3 3.8 0.3 3.2 3.0 0.1 2.7 2.8 0.1 Measured at 60C (140f) 4/18/16 Post thermal aging using Priority l temp time profile Sample No-> ,,. 4/15-1 ' 4/15-2 ' 4/15-3 4/15-4 4/15 -5 4/15-6 4/15 -7 4/15 -8 NC NO NC NO NC NO NC NO NC NO NC NO NC NO NC NO 2.2 3.9 2.3 4.2 2.6 3.9 2.6 4.1 2.4 2.3 3.3 2.3 4.7 2.2 7.2 Measured at 20C 4/19/16 Post the rmal aging usi ng Priority l temp time profile Sample No -> ,. 4/15-1 .. 4/15-2 ,,. 4/15-3 4/15-4 4/15 -S 4/15-6 4/15 -7 4/15 -8 NC NO NC NO NC NO NC NO NC NO NC NO NC NO NC NO 2.6 iO 3.0 14.0 3.4 6.2 3.3 5.0 2.8 'DO 3.3 3.8 3.4 5.3 2.8 6.0 2.9 12.0 3.0 5.5 3.8 6.0 3.0 5.2 3.1 3.2 3.9 3.6 4.0 3.1 4.3 3.0 6.0 3.0 4.8 4.1 7.3 3.6 5.9 3.0 eo.11 3.2 3.2 3.6 4.1 3.2 3.6 2.9 3.3 3.0 5.2 4.2 7.6 4.1 4.0 3.1 ~ 3.6 3.0 3.6 4.0 3.3 4.0 3.0 3.4 2.9 3.9 4.4 7.0 4.9 3.5 3.0 so.o 3.0 2.9 3.7 4.1 3.3 3.4 3.1 3.0 2.8 3.7 4.2 10.2 4.1 3.2 3.3 ao.o 3.0 2.7 3.8 3.9 3.2 3.2 Ave Std 3.1 2.9 0.2 3.1 8.7 9.9 2.9 2.9
- 0. 1 3.1
- 5. 7 3.7 5.0
- 4. 2 0.5 6.6 7.3 1.4 4.0 O.ti 3.1 4.3 1.1 2.9 3.0 0.2 C'jS.0 53.6 19.5 3.1 3.2 0.2 2.8 3.2 0.5 3.8 3.6 0.1 4.1 4.2 0.5 3.3 3.2 0.2 3.1 3.9 1.0
~the contac1 resistance meets the industry accep tan~ wtena of 5CO mili ohms memo: the contact resistance mel!!ts the supplier accep tan ce criteria of <25 mill ohms Figure 21b
rotor11- Page 27 of 48 Rotork Controls Limited Approved by Engineering Nuclear Engineering Report No. ER857 Issue 1 Date : 3 rd May 2016 Priority2 1101..
!COO
~
~
800
~ - T,111
! 70.tJ bO.O SO.Cl 40.U 150000 lWOOJ Figure 22 a Measured at 20C 4/19/1!Jl6 Priority2tHtdata As provided resistance data mili ohms Sam ple No -> ,.4/19-1 "4/19 -2 ..4/l!J-3 ' 4/19-4 ' 4/19 -5 '"4/19-6 ' 4/19 -7 ' 4/19 -8 NC NO NC NO NC NO NC NO NC NO NC NO NC NO NC NO
- 2. 5 2.8 3.6 3.8 3.3 3.7 4.4 3.3 2.5 3.2 3.4 5.3 2.5 2.7 4.3 4.9 3.6 2.7 3.7 3.4 3.3 3.7 4.2 3.4 3.3 2.8 3.1 4.4 2.8 2.7 3.9 5.9 3.4 2.6 3.8 3.4 3.4 3.1 4.2 3.4 4.6 2.8 3.9 4.2 2.9 2.6 3.6 7.0 3.2 2.6 4.0 3.1 3.4 3.1 3.9 3.4 4.6 2.7 3.3 3.9 2.9 2.5 3.4 7.5 3.2 2.S 3.6 3.3 3.2 2.8 3.3 3.1 4.0 2.9 3.1 3.6 3.0 2.5 3.0 3.6 3.3 2.S 3.4 2.9 3.0 2.9 4.0 3.1 4.2 2.7 2.9 3.3 3.1 2.5 3.3 3.1 3.1 2.6 3.5 2.9 2.9 2.8 4.0 2.9 3.9 2.7 3.1 3.3 2.8 2.5 3.1 3.3 Av* 3.2 2.6 3.7 3.3 3.2 3.2 4.0 3.2 3.9 2.8 3.3 4.0 2.9 2.6 3.S 5.0 Std 0.34 0.11 0.1!) 0.32 0.1!J 0.'19 O.'IS 0.1!J 0.75 0.18 0.33 0.71 0.19 0.10 0.46 1.80 Measured at 60C (140F) 4/23/1!Jl6 Post thermal aging using Priority 2 temp time profile Sam ple No -> "4/ ~l ,.4/19 -2 ,.4/19 -3 I' 4/19 . 4 ' 4/19 -5 ' 4/19-6
- 4/19 -7 ,. 4/J!j -8 NC NO NC NO NC NO NC NO NC NO NC NO NC NO NC NO 2.3 12.0 2.5 10.0 2.3 5.3 2.6 6.8 2.4 5.2 2.4 5.0 2.9 3.8 2.4 6.0 Measured at 20C 4/25/1!Jl6 Post thermal aging using Priority 2 temp time profile Sample No -> ,.4/19-1 "'4/ 19 -2 "4/19 -3 ..4/19*4 "4/19
- 5 ' 4/19 -6 "4/ 19 -7 "4/19
- 8 NC NO NC NO NC NO NC NO NC NO NC NO NC NO NC NO 3 8.3 4.7 S.6 4.1 4.4 5.6 13 2.4 5 3 5.3 3.3 4.6 3.1 7.9 3.6 7.1 3.3 3.9 3.7 5.2 12 2.8 4.8 3.2 4.9 3.6 3.5 4 7.7 3.9 6.2 3.9 3.7 3.3 3.7 6.3 5.6 3.2 6,3 3.5 4.6 3.8 4.5 3.8 5.9 3.8 4.9 6 4.2 5 2.7 6.5 4.4 3.1 3.4 4.3 3.7 4 4.6 4.5 4.1 4.9 3.6 3.3 5.5 3.7 6.5 5.1 3.2 3.4 3.8 4.2 2.9 4.1 4.5 3.5 3.9 5.5 3.5 4.2 3.5 6.8 5.9 3.5 4.2 3.5 39 3.1 2.8 5.2 5.1 Ave 4.2 "3.9 4
"'s.2 ...
6.6 3.6
"'3.7 4.7
'4.4 3
"'3.4 6.7
'6.3 4
"3.3 3.3
"'4 .4 3.5
"'3 .4 3.6
'4.2 3.9 "1.8 2.7 "3.4 4.4 4.4 5.3 "s.s Std 0.21 "1.26 *1.39 0.33 "o.79 *o.43 O.ss 0.41 "1.03 "0.12 O.so O.n 0.73 O.so "1.20 llWtaO: lbe contact resistance meets the mdustry acceptance cnter1a of 5CX) m1l1 ohms memo: the contilct resi stance meets the su pplie r ;1cce ptance a1t en;1 of <25 m1l1 ohms Figure 22b
rotor11- Page 28 of 48 Rotork Controls Limited Approved by Engineering Nuclear Engineering Report No. ER857 Issue 1 Date : 3 rd May 2016 Pr io r ity 3 100
"° 70 memo: for this test the oven profile temperatures between h(\ the start and end point were
£ elevated 3 centlarade to assure temperature maralne.
~
~
- Taop1nt
- - Ta1r I
40 20 10 20000 40000 60000 1()00)()
r1me(sec. 1 Figure 23a Menu*ed1120C 4/2S/'l016 Priority3tu1du1 A*p!'Ovidedreslu1nced11tamlllohm*
Sample No -> ' 4/25-1 NC
!1.0 9.4
'4/25
- 2 NC 1.S NO 12
- ..,,JS . )
NC NO
' 4/2S
- 4 NC NO
' 4/2S -S NC NO
' 4/2S
- 6 NC l .6 NO u
' 4/2S
- 7 NO
' 412s -1 NO u 4.7 u
..*1* 12 u
<1
,, 17 17 u
.. ..*... .,"u u
31 31 17 .. . u
... ...'*' u
" u
- ~
u u
"' 1'2 Menu1ed1t60C( l40f l *126'2016 Post thermil iglng using Prior ity) temp time pro Ille 5-lmpleNo -> "*12s-1 NO 5.1
- 12s -2 4/27/1016 NO u
..4/2S
- l NO 5.0 .
' 4/1S -4 NC
- 4/2S *S NC
- 4/2S *6 NO u
' 4/25 *1 Postthe1m1l1gingusingPrioritylttmptimep<ofile S...mpleNo * >
"412s.1 NC
- u.
NO
- 412s -2 u
NO s.1 "41zs .1 NO u
' 4125 .4 NC u
- O
- 4/2S -S NC 17
' 411s -6 u
NO 10
' 412s -1 NO NC NO u
u
- 4/2S *I NC NO 1U 17 u
.,u ......
u u
u
.,u l .0 J.1
- .1 u
u u ....,
u u
- .1 {
u u
7.*
u 17 31
- .", l .7 l.1
~:~
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.,, <.o "u
~~ '-u ~~
"" "0.41 Ci0914'<1 re.1Ui1n<e meet$ the 1nduUf)' le<l'l)Unu* r111em1ol '!OJ m>h ohm'
'0. 39
"" 'o.n '0.11 *2.ll me1110; tn. QOl'IU<-1 re ols11nce mee t$ the suppl ie r acu ptance uite111 o f <n mill ohm s Figure 23b
rotor11- Page 29 of 48 Rotork Controls Limited Approved by Engineering Nuclear Engineering Report No. ER857 Issue 1 Date: 3rd May 2016 Summary Three factors cause the anomaly onset namely temperature, time, and enclosure volume (concentration factor) . An equation relating the three factors to anomaly onset has been developed and is provided for information purposes only - not for prediction. The equation accuracy has not been verified against an adequate sample of design based temperature time accident profiles. The equation is not linear. Testing demonstrated anomalies were not observed at 90°C and below.
Published literature suggest that some level of outgassing always occurs.
When temperature varies with time, estimating anomaly onset is far more complicated and requires the integration of the outgassed material mass. Furthermore, it would be necessary to established if an elevated temperature for a brief period of time would then permit the outgassing of material at lower temperatures for an extended period . Given the available time, the latter could not be accomplished and verified by experimentation . Switch performance was thus evaluated by experimentation . Switches within closed metallic enclosures having an actuator representative volume were thermally aged using accident condition temperature time profiles. The test results indicate the switches, though degraded, would operate correctly after completing the thermal aging profiles displayed in Figure 21 through Figure 23.
rotor11- Page 30 of 48 Rotork Controls Limited Approved by Engineering Nuclear Engineering Report No. ER857 Issue 1 Date : 3rd May 2016
- 10. Results from independent test lab An independent test laboratory, Exova, was requested to investigate the contamination on contact rivets of micro-switches that had exhibited the anomaly after being thermally aged in-house at 125°C (257°F). Contacts were analysed by FTIR (Fourier-Transform Infra-Red) spectroscopy and by SEM-EDX (Scanning Electron Microscope/Energy Dispersive Using X-Ray) analysis.
FTIR spectroscopy is a valuable tool to study the molecular structure of organic materials.
SEM-EDX enables an elemental analysis of the contamination.
Figure 24 compares the infrared spectra of the residue collected from the NO contact of an aged switch manufactured in 2015 vs. an aged switch manufactured in 2007. Both infrared fingerprints virtually mirror each other which suggest that they appear to be the same type of contaminant. The following infrared bands were observed :
- 2915, 2850, 1415 cm -1 which are likely to relate to alkyl groups (CH2, CH3)
- 1535 cm-1 which could relate to alkyl groups (CH2, CH3) or amide (NH-C=O) groups
- 1650 cm-1 which could relate to alkene (C=C), aromatic groups ( 1 ~ 1 ), amide (NH-C=O) or amine groups (R-NH-)
- 1310 cm-1 which could relate to amine groups (R-NH -) or alcohol groups (-OH)
- 1030 cm-1 which could relate to carbonyl groups (C=O) or alcohol groups (-OH)
- 720 cm -1 which could relate to aromatic groups (V ), chlorinated compounds or methylene groups (CH2)
The infrared spectrum of the residue collected from the NO contact rivet of the 2007 switch was compared to the infrared fingerprints of the Araldite adhesive (Figure 25), the DAP case (Figure 26) and the nylon 66 operating plunger (Figure 27) as they are the only organic components and therefore the only possible direct or indirect sources of contamination. The infrared spectrum of the residue did not match any of the organic materials.
rotor11- Page 31 of48 Rotork Controls Lim ited Approved by Engineering Nuclear Engineering Report No. ER857 Issue 1 Date : 3rd May 2016
- POLYM50SO: resi due from bottom contact rivet of Sw itch J (2015! - 6 da>JS at 125"C
'POL YM5053: residue from bottom contact rivet of Switch . 2007) - 4 days at 125"C 9 7 ~"'~'~.4/r,JJll'J/I.~ ... .
96 -
- ~*-ww~~~~\ .~~:.
~* .\ ~
~ ,*
95 -
1\\
~
94 - 1650
- ~~I 10~ J 2860 1310 93 - I 2916 1635 1415 92 - 720 91 -
4000 3000 2000 1000 Wavenumbers (cm -1)
Fig ure 24: Infrared spectra of residue on NO contact rivets 9s :PoLYM5053: residue from bottom contact rivet of Switch s (2007) - 4 d;iys ;it 125"C
- POLYM3246: Araldite Gl ue (24hrs;it WC) an;ilysed i n 2011 I-
~
93 :
92:
91 :
so:
89 -
4000 3000 2000 1000 Wavenumbers (cm-1)
Figure 25: Infrared spectra of residue from NO contact rivet and Araldite adhesive
rotor11- Page 32 of 48 Rotork Controls Limited Approved by Engineering Nuclear Engineering Report No. ER857 Issue 1 Date : 3 rd May 2016 98-POLYM!i053: residue from bottom contact nvet of Switch S (2007) - 4 days at 125"C
- POLYM3210: new OAP C3Se an:ilysed in 2011 97 ~.-..J.,J, 96-96-0~
94-93-92 -
91-so:
4000 3000 2000 1000 Wavenumbers (cm-1)
Figure 26: Infrared spectra of residue from NO contact rivet and OAP case 98 *POL YM5053: residue from bottom contact rivet of Switch S (2007) - 4 days at 125"C
- POL YM5053: Latamid 66 operating plunge- of switch S (2007) - 4 days at 125"C 1440 92*
1535 1460 91
- so:
4000 3000 2000 1000 W;ivenumbers (cm-1)
Figure 27: Infrared spectra of residue from NO contact rivet and nylon 66 operating plunger
rotor11- Page 33 of 48 Rotork Controls Limited Approved by Engineering Nuclear Engineering Report No. ER857 Issue 1 Date: 3rd May 2016 SEM photographs of the NO and moving contact rivets of an unaged 2015 switch, an aged 2015 switch and an aged 2007 switch are shown in Table 3. The SEM photographs show clear contamination on both the NO and moving contact rivets of aged switches. The pattern was consistently different between the NO and moving rivets and suggests the contamination deposited on the NO contact is then transferred to the moving contact during operation. This observation is in line with the results observed from in-house tests (Figure 6 to Figure 9).
Switch NO contact rivet Unaged, manufactured in 2015 Aged, manufactured in 2015 Aged, manufactured in 2007 Table 3: SEM photographs Elemental analysis results are compiled in Table 4. Results show the presence of a significantly higher level of carbon (C) on the aged contacts relative to the unaged contacts . This suggests that the contaminant appears to be mainly organic, which is in line with FTIR results. A significantly higher level of oxygen (0) was observed on the aged contact rivets, especially the sample from 2007, which could suggest the presence of oxidative products.
rotor11- Page 34 of 48 Rotork Controls Limited Approved by Engineering Nuclear Engineering Report No. ER857 Issue 1 Date : 3 rd May 2016 Switch Contact location c 0 Mg Ag Cd Si Ca Cr Fe Ni Cu Br Unaged , NO 1 2.9 3.5 0.5 83.1 9.3 - - - - - - -
manufactured in 2015 Moving 1 2.2 1.0 0.4 94.5 1.9 - - - - - - -
1 54.1 5.4 - 28.8 11.7 - - - - - - -
NO 2 53.0 4.7 - 31.4 11.0 - - - - - - -
Aged, 31*1 7.5 2.4 - 84.2 5.9 - - - - - - -
manufactured in 2015 1 45 .2 6.5 - 42.3 6.0 - - - - - -
Moving 2 42.8 6.9 - 44.8 5.6 - - - - - - -
31*1 4.5 0.5 93.3 1.8 - - - - - -
1 19.9 13.0 - 62.0 5.1 - - - - - - -
NO 2 31.3 10.5 0.2 52.1 5.9 - - - - - - -
Aged , 31*1 2.8 2.9 0.5 89.9 3.8 - - - - - - -
manufactured in 2007 1 29.2 17.0 0.3 47.8 - 0.6 0.3 - - - - 4.9 Moving 2 32.6 12.2 0.3 47.7 - - - 1.2 4.3 0.5 - 1.3 31*1 12.l 11.1 0.3 73.2 2.9 - - - - - 0.3 -
l*l away from main contaminated area Table 4: EDX elemental analysis results indicating % of each element at spectrum location Summary
- The contaminant appears to be mainly organic. This is in agreement with literature (section 7), test results of an unglued switch (section 8.1) and UV images (Figure 10 and Figure 11) which all identify the adhesive being the root cause .
- The contaminating residue is not formed on the moving contact rivet but is transferred from the NO contact during operation.
rotor11- Page 35 of 48 Rotork Controls Limited Approved by Engineering Nuclear Engineering Report No. ER857 Issue 1 Date: 3rd May 2016
- 11. Conclusion The altered adhesive formulation outgases at elevated temperatures and deposits an insulating material layer onto the switch internal electrical contacts as it cools. The deposit of insulation material results in contact resistances exceeding the supplier acceptance criteria of 25m0 max, the industry 500m0 max acceptance criteria and in some cases causes an open circuit.
It should be noted that tests were performed at constant temperatures . The effect of varying temperature with time has not been investigated in the available time and the possibility exists that an initial high temperature for a short period could subsequently cause outgassing to continue at lower temperatures. Rotork thus recommend that the risk be assessed by testing switches under representative temperature time profiles.
In tests performed by Rotork the anomaly was not observed at temperatures 90°C (194°F) and below.
The maximum service temperature for A range and NA5/5E actuators is 70°C (158°F) thus they can be excluded from the scope of this Part 21.
Nuclear power plants that use Rotork NA actuators provided temperature profiles which also were tested . Anomalies were not observed using these profiles.
Rotork are recommending the replacement of the switches in the affected orders which are identified in the Part 21 notification letter.
rotor11- Page 36 of 48 Rotork Controls Limited Approved by Engineering Nuclear Engineering Report No. ER857 Issue 1 Date : 3rd May 2016
- 12. References
- 1) Czarnecki, N. (2012) Nema White Paper. Cadmium in Electrical Contacts [online] . Rosslyn, VA . Available from :
https ://www.google.co.uk/url?sa=t&rct=j&g=&esrc=s&source=web&cd=l&ved=OahUKEwjK SdCdt7PMAhWjBsAKHbPtBbcQFggtMAA&url=https%3A%2F%2Fwww.nema.org%2FProducts
%2FDocuments%2Fnema%2Bwhitepaper%2Bon%2Bcadmium%2Bin%2Belectrical%2Bcontac ts.pdf&usg=AFQjCNFevJ949rWGVG650efdbr4ejjT6kw&sig2=s1UgMfEIFnKDWWhowkA41g
[Accessed 29 April 2016)
- 2) Buffing, M . (2009) Outgassing of glue in the Outer Tracker of LHCb; measurements with a quadrupole mass spectrometer [online] . BSc, Vrije Universiteit Amsterdam . Available from :
http ://www.nikhef.nl/pub/experiments/bfys/lhcb/Theses/bachelor/2009 MaartenBuffing.p df [Accessed 29 Apri l 2016)
- 3) Tuning, N., et al. (2011) Ageing in the LHCb outertracker: Aromatic hydrocarbons and wire cleaning. Nuclear Instruments and Methods in Physics Research A . 656, pp. 45-50
rotor11- Page 37 of 48 Rotork Controls Limited Approved by Engineering Nuclear Engineering Report No. ER857 Issue 1 Date: 3'd May 2016 C""1'10 N I ~
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rotor11- Page 39 of 48 Rotork Controls Limited Approved by Engineering Nuclear Engineering Report No. ER857 Issue 1 Date: 3'* May 2016 SPECIFICA TIQ N MAX. ACTUATING FORCE 2.8 N MIN . RELEASE FORCE 11 N MAX FREE POSITION 197mm ITTDTll CONN ECTIO N DIAGRAM OPERA TING POSITION 18 1f l6 7mm NOTE OPERATING BUTT OH MAY 127mm BE DEPR:ESSfD R.USH WTTH CASE SEALING IP40 D
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rotor11- Page 40 of 48 Roto rk Controls Limited Approved by Engineering Nuclear Engineering Report No. ER857 Issue 1 Date: 3 May 2016 Appendix B- Pre and post-aging resistance results, Test 1 and 3 All results in Ohms.
Test 1-125' C (257'Fl aging of V12 switches manufactured in 2015 Results before ageing Into oven Out of oven Total aging Results after ageing 011eration 1 011eration 2 011eration 3 011eration 4 011eration 5 011eration 6 Date Code !:ill. WQ !:ill. WQ !:ill. WQ !:ill. WQ !:ill. WQ !:ill. WQ F 3715K 0.003 0.003 0.004 0.005 0.004 0.005 0.004 0.003 0.005 G 3715K 0.004 0.005 0.004 0.003 0.005 0.003 14:00 08:00 0.005 0.005 0.005 138 hrs H 3715K 0.004 0.005 0.004 0.004 0.004 0.004 Tue Mon 0.006 0.006 0.010 0.006 0.007 (5.75 days) 3715K 0.004 0.004 0.006 0.003 0.005 0.004 26/01/16 01/02/16 0.004 0.005 0.005 3715K 0.004 0.004 0.004 0.004 0.004 0.003 0.005 0.006 0.008 Test 3 -125'C (257'Fl aging of V12 switches manufactured in 2007 Results before ageing Into oven Out of oven Total aging Results after ageing 011eration 1 011eration 2 011eration 3 011eration 4 011eration S 011eration 6 Date Code !:ill. WQ !:ill. WQ !:ill. WQ !:ill. WQ !:ill. WQ !:ill. WQ p 2807K 0.004 0.008 0.008 0.007 0.008 0.007 0.004 0.279 0.004 184 0.004 0.124 15:45 14:00 Q 2807K 0.005 0.008 0.006 0.007 0.006 0.007 94.25 hrs 0.004 0.009 0.005 Mon Fri s 2807K 0.014 0.014 0.012 0.007 0.009 0.012 01/02/16 05/02/16
{3.93 days) 0.004 0.004 0.004 T 2807K 0.005 0.009 0.006 0.007 0.006 0.007 0.004 0.642 0.004 0.030 0.007 0.049
- indicates open circuit
- indicates that the resistance value was fluctuating between several ohms, to hundreds of ohms, to open circuit
rotor11- Page 41of48 Rot ork Co ntro ls Limited Appro ved by Engineering Nuclear Enginee ring Report No. ER85 7 Issue 1 Date : 3'd May 2016 A1rnendix C - Resistance results (!Ost-curing and subseguent agi ng, Test 5 All resu lts in Ohms.
Post-curing of each switch in a fan assisted oven Results before post-curing Into oven Out of oven Total aging Results after post-curing Oi;ieration 1 Oi;ieration 2 Oi;ieration 3 Oi;ieration 4 Oi;ieration 5 Oi;ieration 6 Date Code !:ill. ~ fil ~ fil w_g_ !:ill. ~ !:ill. ~ !:ill. ~
1 4315K 0.004 0.007 0.005 0.006 0.007 0.006 11:55 Fri 12/02/16 1.02 days 0.003 0.023 0.004 0.018 0.002 0.077 2 4315K 0.007 0.010 0.006 0.008 0.006 0.006 11:50 Mon 15/02/16 4.01 days 0.007 0.040 0.007 0.012 0.008 0.014 11:30 3 4315K 0.005 0.005 0.004 0.005 0.005 0.005 15:00 Tue 16/02/16 5.15 da ys 0.004 0.086 0.005 0.047 0.005 0.068 Thur 4 4315K 0.002 0.009 0.004 0.006 0.004 0.006 11:30 Wed 17/02/16 6 days 0.005 0.066 0.005 0.006 0.006 0.008 11/02/16 5 4315K 0.004 0.007 0.005 0.008 0.005 0.006 11:30 Thu 18/ 02/16 7 da ys 0.006 0.077 0.006 0.176 0.006 0.088 6 4315K 0.004 0.005 0.004 0.005 0.004 0.005 11:30 Fri 19/02/16 8 days 0.005 0.150 0.007 0.159 0.006 0.096 Further aging of i;iost-cured switches in metal containers Results before ageing Into oven Out of oven Total aging Resu Its after ageing Oi;ieration 1 Oi;ieration 2 Oi;ieration 3 Oi;ieration 4 Oi;ieration 5 Oi;ieration 6 Date Code !:ill. ~ fil ~ fil w_g_ !:ill. ~ !:ill. ~ !:ill. ~
1 4315K 0.010 0.024 0.011 2 4315K 0.006 4.800 0.016 0.319 0.018 0.243 Above post-c ured switches were taken and 14:30 3 4315K 90.5 hrs 0.007 0.010 0.048 each swit ch was pl aced in its own Fri 09:00 Tue 23/02/16 4 4315K (3. 77 days) 0.004 49.700 0.008 3.450 0.006 1.200 enclosure. 19/02/16 5 4315K 0.004 0.059 0. 005 0.250 0.005 0.164 6 4315K 0.009 0.028 0.040
- indicates open circ uit
- indicates that the resistance value was fluctuating between several ohms, to hundreds of ohms, to open circuit
rotor11- Page 42 of 48 Roto rk Controls Limited App roved by Engineering Nuclear Enginee ring Report No. ER857 Issue 1 Date: 3'* May 2016 Appendix D - Resistance results of KS switches, Test 6 All results in Ohm s.
Results before ageing Into oven Out of oven Total aging Results after ageing Operation 1 Operation 2 Operation 3 Operation 4 Operation 5 Operation 6 Operation 7
~ !'li..Q !'YS,. !'li..Q !'YS,. !'li..Q !'YS,. !'li..Q ~ !'li..Q ~ !'li..Q ~ !'li..Q 16 0.011 0.077 0.024 0.018 0.012 0.080 15:30 Tue 15:30 M on 0.005 0.507 0.018 0.492 0.011 0.369 0.008 0.236 6 da ys 16/02/ 16 22/ 02/ 16 17 0.007 0.054 0.020 0.038 0.017 0.020 0.036 1.423 0.054 3.230 0.022 0.720 0.016 2.170
rotor11- Page 43 of 48 Rotork Contro ls Li mited Approved by Engineering Nuclear Engineering Report No. ER857 Issue 1 Date : 3'd May 2016 Append ix E - Resistance results of switch aged w ithout adhesive, Test 7 All results in Ohms.
Results before ageing Into oven Out of oven Total aging Results after ageing Operation 1 Operation 2 Operation 3 Operation 4 Operation 5 Operation 6 Operation 7 WS,,!@WS,,!@WS,,!@ WS,,!@WS,,!@WS,,!@WS,,!@
13:55 Mon 13:55 Wed 18 0.006 0.004 0.005 0.004 0.007 0.005 29/02/ 16 02/03/16 2 days 0.004 0.020 0.004 0.012 0.004 0.018 0.004 0.005 Further aging of above switch to complete total 7 days aging Results before ageing Into oven Out of oven Total aging Results after ageing Operation 1 Operation 2 Operation 3 Operation 4 Operation 5 Operation 6 Operation 7 WS,,!@WS,,!@WS,,!@ WS,,!@WS,,!@WS,,!@WS,,!@
14:55 Wed 13:55 Mon 18 Above switch w as aged f urther 4.96 days 0.012 0.004 0.006 0.138 0.014 0.227 0.068 0.077 02/03/16 07 /03/16 Further aging of above switch to complete total 10 days aging Results before ageing Into oven Out of oven Total aging Results after ageing Operation 1 Operation 2 Operation 3 Operation 4 Operation 5 Operation 6 Operation 7 ws,_ !@ ws,_ !@ ws,_ !@ ws,_ !@ ws,_ !@ ws,_ !@ ws,_ !@
08:30 Fri 08:00 Mon 18 Above switch was aged fu rt her 3.98 days 0.007 0.117 0.082 0.006 0.174 0.015 0.006 0.017 01/04/16 04/04/16 Total aging time for switch 18 =2 + 4.96 + 3.98 =10.94 days
rotor11- Page 44 of 48 Rot ork Co ntrol s Li mited Approved by Engi neering Nuclear Enginee ring Report No. ERSS 7 Issue 1 Date : 3'* May 2016 Appendix F - Resistance results of switch aged with Duralco 4525, Test 8 All results in Ohms.
Results before ageing Into oven Out of oven Total aging Results after ageing O~eration 1 O~eration 2 O~eration 3 O~eration 4 O~eration 5 O~eration 6 O~eration 7
!:ill:. !UQ WS:. !UQ !:ill:. !UQ WS:. !UQ !:ill:. !UQ !:ill:. !UQ !:ill:. !UQ 08:30 Fri 08:30 Mon 21 0.004 0.004 0.005 0.004 0.007 0.004 10 days 0.027 0.178 0.250 0.186 01/04/16 11/04/16
- indicates o pe n ci rcuit
- indicates that the resistance value w as fluctuating between several ohm s, to hundreds of ohms, t o open circuit
rotor11- Page 45 of 48 Rotork Controls Limited Appro ved by Engineering Nu clear Engi neeri ng Re port No. ER857 Issue 1 Date : 3*d M ay 2016 Appendix G - Resistance results of switches aged w ith AY105-1/HY991, Test 9 Al l results in Ohms.
Thermal aging of switches assembled with AY105-l[HY991 Results before ageing Into oven Out of oven Total aging Results after ageing Operation 1 Operation 2 Operation 3 Operation 4 Operation 5 Operation 6 Operation 7
~ !:il.Q ~ !:il.Q ~ !:il.Q ~ !:il.Q ~ !:il.Q ~ !:il.Q ~ !:il.Q 13:10 Thu 19 0.004 0.004 0.005 0 .004 0.006 0.004 2 days 0.003 0.005 0.003 0.004 0.003 0.004 0.003 0.004 13:10Tue 08/03/16 08/ 03/16 13:10 Mon 20 0.003 0.003 0.004 0.003 0.004 0.003 6 days 0.004 0.013 0.004 0.011 0.004 0.010 0.004 0.007 14/03/16 Further thermal aging of above switches Results before ageing Into oven Out of oven Total aging Results after ageing Operation 1 Operation 2 Operation 3 Operation 4 Operation 5 Operation 6 Operation 7
~ !:il.Q ~ !:il.Q ~ !:il.Q ~ !:il.Q ~ !:il.Q ~ !:il.Q ~ !:il.Q 15:30 Tue 19 12days 5hrs 0.004 0.008 0.014 0.017 Abo ve switches were aged f urther in thei r 10:30 Thu 29/03/16 enclosures. 17/03/16 14:00 Mon 4da ys 3hrs 20 0.004 0 .181 0.096 0.010*
21/ 03/16 30mins Total aging t ime for sw itch 19 = 14 days, 5 hrs Total aging ti me fo r sw itch 20 =10 days, 3 hrs, 30 mins
- in dicat es o pen circ uit
- denotes a value that was inconsistent, i. e. the ohm value moved around the va lue recorded, it did not sett le.
rotor11- Page 46 of 48 Roto rk Contro ls Li mited Approved by Engineering Nuclear Engineering Report No. ER857 Issue 1 Date: 3'd May 2016 Thermal aging of switch assembled with reduced quantity of AY105-1/HY991 Results befo re ageing Into oven Out of oven Total aging Results after ageing Operation 1 Operation 2 Operation 3 Operation 4 Operation 5 Operation 6 Operation 7
!'fil !':![Q !'fil !':![Q !'fil !':![Q !'fil !':![Q !'fil !':![Q !'fil !':![Q !'fil !':![Q 13:00 Thu 08:00 Mon lOdays 50 0.006 0.004 0.018 0.004 0.012 0.004 0.030 0.078 0.035 0.008 0.005 0.007 0.170 0.005 14/04/16 25/04/16 19hrs
rotor11- Page 47 of 48 Rotork Controls Limited Approved by Engineering Nuclear Enginee ring Report No. ER857 Issue 1 Date: 3'd May 2016 Appendix H - Resistance results of switch aged w ith Raychem 51264, Test 10 All results in Oh ms.
Results before ageing Into oven Out of oven Total aging Results after ageing Operation 1 Operation 2 Operation 3 Operation 4 Operation 5 Operation 6 Operation 7 rill r:ilQ rill r:ilQ rill r:ilQ rill r:ilQ rill r:ilQ rill r:ilQ rill r:ilQ 13:00 Thu 08:00 Mon lOdays 49 0 .004 0 .003 0 .004 0.003 0.004 0.004 14/04/16 25/04/16 0.010 0 .024 0.007 0 .021 0 .008 0 .023 0.012 0 .009 19hrs
rotor11- Page 48 of 48 Rotor k Cont ro ls Li mited Approved by Enginee ring Nuclear Engineering Report No . ER85 7 Issue 1 Date : 3'd May 2016 Appendix I - Resistance results of switch aged with X60, Test 11 All results in Ohms.
Results before ageing Into oven Out of oven Total aging Results after ageing Operation 1 Operation 2 Operation 3 Operation 4 Operation 5 Operation 6 Operation 7 MK rllQ MK rllQ MK rllQ MK rllQ MK rllQ MK rllQ MK rllQ 14:20 Mo n 14:20 Thu 53 0.006 0.002 0.005 0.002 0.006 0.003 18/ 04/ 16 10 da ys 0.008 0.040 0.016 0.042 28/04/16
- indicates open circ uit
- indicates t hat the resistance value was fluctuating between several ohms, t o hund reds of ohms, to open circ uit
0510412016' U.S. Nuclear Regulatory Commission Operations Center Event Report Pagel Part 21 (PAR) Event# 51907 Rep Org: ROTORK CONTROLS, INC. Notification Date I Time: 05/04/2016 14:56 (EDT}
Supplier: JOHNSON ELECTRIC Event Date I Time: 01/25/2016 (EDT}
Last Modification: 05/04/2016 Region: 1 Docket#:
City: ROCHESTER Agreement State: Yes County: License#:
State: NY NRC Notified by: PATRICK SHAW Notifications: FRED BOWER R1DO HQ Ops Officer: DONG HWA PARK MIKE ERNSTES R2DO Emergency Class: NON EMERGENCY NICKVALOS R3DO 10 CFR Section: JOHN KRAMER R4DO 21.21 (d)(3)(i) DEFECTS AND NONCOMPLIANCE PART 21/50.55 REACTORS EMAIL PART 21 -ANOMALY RELATED TO MICRO SWITCHES The following report was received via email:
"Based on test data, Rotork believes an unsafe condition may exist as defined under 10CFR21. The adhesive formulation used for the construction of V12 and K5 safety related micro switches was altered by the switch maker's sub-supplier. K5 switches have no reported failures, but are affected because of construction. The altered adhesive formulation outgases an insulating material at elevated temperatures, which coats the switch.contacts as it cools, and can prevent the conduction of electricity."
FAX rotor..
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Date: oS/o4j2o/6 Re: CC:
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rotorlf Controls Rotork Controls Inc.
675 Mile Crossing Blvd Rochester. New York 14624 U.S. Nuclear Re,bJUlatory Commission, tel: +1 585 247 2304 Washington, DC 20555~0001 fax: +1 585 247 2308 wwvv.rotork.com From: Patrick A. Shaw, P.E info@rotork.com To: NRC Operations Center Date: May 4111 2016
Subject:
Rotork Controls Inc. Part 21 Notification, concerning V12 [Pt No N69-921] and KS [N69-838 & N69*926] safety related micro switches
Dear Sir/Madwne,
On January 25111 2016 Rotork Controls Inc. opened a fonnal Part 21 investigation into an anomaly reported by Duke Energy from testing conducted at Kinectrics in Canada. The anomaly related to Basic micro switches incorpomtcd within Rotork safety related NA 1E range electric actuators; also referred to as electric Valve Operators. The anomaly description was "switches failed to change state [Pt No N69-921 ]"and was observed after ten ( l 0) days of thennal aging at 125 Centigrade (25 7 Fahrenheit).
On March 18111 2016 Rotork wrote to the U.S. NRC requesting a 40 day extension to the 60 day investigation period permitted under 10CFR21 (Ref. Event No MLI 6088A087).
Based on test data, Rotork believes an unsafe condition may exist as defined under 10CFR21. The adhesive fonnu]ation used for the construction of Vl 2 and KS safety related micro switches was altered by the switch maker's sub-supplier. KS switches have no reported failures, but are affected because of construction. The altered adhesive formulation outgases an insulating material at elevated temperatures, which coats the switch contacts as it cools, and can prevent the conduction of electricity.
The anomaly onset is a function of temperature and time. The anomaly may occur when a switch is maintained above 90°C (194°F) for an extended period of time, and then subsequently cooled below 65°C (150)°F (see Rotork Engineering Report ER857 for details). Based on Rotork's NCR data this anomaly has not been reported by any U.S. NRC licensed operator. The anomaly is not observed at normal operating temperatures. Furthennore, all switches are expected to function nonnally whi1e at elevated temperatures (i.e. above 65°C (l 50°F)). The concern is limited to accident design based events that include heating above 90°C (194°F) and subsequent cooling below 65°C (150°F). Tests described within report ER857 suggests the anomaly has a lower limit of 90°C (194°F) (i.e. the switch is expected to function normally if the temperature is maintained below 90°C (194°F)). To assist the industry with risk assessment, the report includes tests performed using temperature time accident Page 1of12
rotorlf Controls profiles provided by the industry. The extent of condition affects switches manufactured from 2007 to 2015, inclusive. Product supplied prior to this date was tested and did not exhibit the anomaly.
Below is a summary in accordance with 10CFR Part 21 .21 (d)(4), which includes a list of all supplied actuators and spare components containing V 12 and K5 switches affected by this notification.
Sincerely a~t;J.jl_
Patrick A. Shaw, P.E Robert Arnold, P.E Quality Assurance Manager President Tel (585) 770-1019 Patrick.Shaw@rotork.com Page 2of12
rotorlf Controls Required information as per 10CFR Part 21.21(d)(4) follows~
(i) Name and address ofthe individual or individuals i11formi11g tlte Commission.
Patrick A. Shaw, P.E.
Rotork Controls Inc, 675 Mile Crossing Blvd, Rochester, New York 14624 (ii) Identification ofthe facility, the activity, or the basic component suppliedfor such facility or such activity within the United States which fails to comply or contains a defect.
Rotork part number N69-921 Micro-Switch Vl.2/3252 (RS104) and N69-926 Micro-Switch KS/3252 (RS378) and N69-838 Micro-Switch K5/3252-A2 (RS366) manufactured by Johnson Electric (Fonnerly Burgess) from 2007 to 2015.
(iii) Identification ofthe firm conslrocJing the facility or supplying the basic component which fails to comply or contains a defect.
Rotork Controls Ltd Brassmill Lane Bath, England BAJ 3JQ (iv) Nature of the defect or failure to comply and the safety hazard which is created or could be created by such defect or failure to comply.
The supplier (Johnson Electric) incorporates a small amount of adhesive in each switch's construction to secure the two halves of the switch housing together. The specified adhesive & hardener are AYl03 & HY951, respectively. Both are provided to Johnson Electric by Huntsman. To comply with legislation concerning toxicity, Huntsman altered the formulation and renamed the adhesive A YI 03-1; the HY95 l is unaltered. This change was not formally communicated by Huntsman and the modified adhesive name was not noticed by Johnson Electric.
The altered adhesive fonnulation outgases at elevated temperatures and deposits an insulating material layer onto the switch internal electrical contacts as it cools (see Rotork Engineering Report ER857 for specifics). The deposit of insulation material results in contact resistances exceeding the supplier acceptance criteria of 25mQ max, the industry SOOm!l max acceptance criteria and in some cases causes an open circuit.
Page 3of12
rotorlf Controls (v) 111e date 011 which the it!formation ~fsuch defect or.failure to comply was obtained.
January 25 111 2016 b'i) Jn tile case of a basic component which contains a defect or fails to comply, tile number and location of these components in use at, supplied for, being supplied for, or may be supplied for, manufactured, or bei11g ma11ufact11red for one or more .facilities or activities subject to the regulations in this part.
Vt 2 switch list Onlrr Part Qly DCKrlpllon Cuscomrr_PO Project 3SS818 NA/3SS8180l I 14NA IEFAl4A N Wnl2021VNO RSP358 I 8 (RCI CATAWBA limnally SERVICE)/
8409930 I030l 001118308 (DUKE) 8311669 NA/83866901 I 16NA I fAl4A N Wnl2023VNO 001151126 MCGUIRE 638773 NA/83877301 3 30NAX I FAl6A N Wnl2023VNO 00078626 CATAWBA 838786 NA/83878601 I 16NA I FAl4A N WTU202JVNO 00079069 MCGUIRE 8311854 NA/83885401 I 90NA I l'AJOA N WfU2021VNO 00080357 MCGUIRE 838854 NA/83885402 I 7NA I FAIOA N WTU2023VNO 00080357 MCGUIRE 838945 NA/83894501 3 16NA I FAl4A N WTU2023VNO 00081992 MCGUIRE B38945 NA/83894502 5 7NA I FAIOA N WTU2023VNO 00081992 MCGUIRE 838963 NA/83896301 6 1INA I FAIOA N WI1J 2023VNO 00082321 MCGUIRE B39003 NA/83900301 2 90NA I FAJOA N Wnl2021VNO 00083027 CATAWBA B39315 NA/83931501 I 70NAX I FA25A N WTIJ2021VNO 00087663 CATAWBA 839400 NA/83940001 I 40NA I FA2SA N Wl"U2023VNO 00088722 MCGUIRE 839435 NA/83943501 I 14NA I FAl4A N WTU2021VNO 00089037 CATAWBA 839475 NA/83947501 I JONA I FAl6A N Wnl2023VNO 00089808 MCGUIRE 839693 NA/B3969301' 6 16NA IEFAl4A N Wnl2023VNO 00092438 MCGUIRE 839725 NA/B3972SOI 4 JONAX IEFAIM N WTU2023VNO 40726 (CRANE) MCGUIRE 839765 NA/B3976501 I 14NA I FAl4A N WI1J 2021 VNO 00093385 CATAWBA 839836 NA/83983601 2 1INA I FAIOA N WTU2021VNO 00094314 CATAWBA 839970 NA/83997001 I JONAX IEFAl6A N WTU2023VNO 00096162 CATAWBA 839974 NA/83997401 I 1INA IEFAIOA N WTU2021VNO 00096233 MCGUIRE 839974 NA/83997402 I 30NAX IEFA16A N WTU2023VNO 00096233 MCGUIRE 839975 NA/83997501 2 llNA IEFAIOA N WTU2021VNO 00096222 CATAWBA 839977 NA/8399770 l 2 14NA IEFAl4A N WfU2021VNO 00096249 CATAWBA 840076 NA/84007601 2 40NAX l FA25A N WTU2021VNO 00097864 CATAWBA 840243 NA/84024301 2 IJNA I FAIOA N WTU2023VNO 00099808 MCGUIRE 840243 NA/84024302 I 70NA I FA25A N Wl1J2023VNO 00099808 MCGUIRE 840312 NA/84031201 I 30NA IEFA16A N WTU2023VNO 00099864 MCGUIRE Page4of12
rotor Controls If Onlrr l'nrl Qly Drurlpllon Customu_PO Proj~I B4031J NA/IJ403130 I 2 14NA IU'Al4A N Wl112023VNO ODll'J'Jll(15 MCGUIRl:.
R404SI NNR4114511ll 2 16NA IF.f/\14/\ N WI112023VNO ()(11()2329 MCGUIRi-!
R411!!77 NNB40117701 2 llNA IEFAIOA N WI11202 I VNO OlllOt1558 CATAWBA 841ll!77 NNB41187702 I 16NAX IEFA14A N wru21121VNO ()(}106558 CATAWBA 840993 NNB411993111 4 14NA IHAl4A N WfU2021VNO 001011308 CATAWBA 8411129 NNR411121JOI I JONAX I F.FAl6A N WfU202.WNO 436114 (CRANE) MCGUIRF.
841560 NA/B41.5600I 3 16NA 1EFAl4A N WI112023VNO 00115319 MCGUIRE 841573 NA/84157301 2 1INA IEFAIOA N wrLI202JVNO 00115417 MCGUIRE 841573 NAIB4157302 2 40NA IEFA2SA N wru 2023 VNO 00115417 MCGUIRE B41609 NNB4l6090I I llNA I l'AIOA N WllJ 2023 VNO 00115991 MCGUIRE 841bl7 NNB4161701 I 14NA IEFAl4A N WfU202JVNO !10116103 MCGUIRE B4178S NA/B4178SOI I llNA I FAIOA N WfU2023VNO OOl 18959 MCGUIRE 841910 NA/B41910<ll 2 16NA IEfAl4A N WTU202JVNO 0111211513 MCGUIRE 841981 NNB4198101 I 14NA IEFAl4A N WI11202JVNO 00121598 MCGUIRE B419KI NNR41911102 I 40NA IF.FA25A N WTU2023VNO 00121598 MCGUIRE 8420(,g NNB4206801 I 14NA IEFA14A N WTU2021VNO 00123289 CATAWflA 842078 NA/84207801 I 90NA I FA30A N wru2021VNO 00123469 MCGUIRE 8422}4 NA/8422.1401 2 16NA IF.FAl4A N WTU202.WNO 0111261185 MCGUIRE 842279 NAIB4227?01 2 70NA IEFA2SA N WTU2023VNO 00127067 MCGUIRE 842279 NA/84227902 2 I INA IEFAIOA N Wl112023VNO 00127067 MCGUIRE 842353 NNB423531ll 2 14NA IEfAl4A N WfU2021VNO 00128249 CATAWBA 84237.3 NA/84237301 l 90NA I FAJOA N WTU2023VNO 00128425 MCGUIRE 842457 NA/84245701 I 40NA IEFA2SA N WTU2023VNO 00130114 MCGUIRE 84252.S NA/84252501 l lbNAX IEFAl4A N WfU2021VNO OOIJ 1141 CATAWBA 842525 NA/84252502 I 30NAX IEFAl6A N WI112021VNO 00!31141 CATAWBA 842525 NA/84252503 I 1INA IEFAIOA N WTU2021VNO 00131141 CATAWBA 842585 NA/84258501 I 40NA IEFA25A N WTU2023VNO OOl32277 MCGUIRE 842696 NA/84269601 I I INA IEFAIOA N WfU2023VNO 00133938 MCGUIRE 842831 NNB4283l01 2 14NA 1EFAl4A N WTIJ 2021 VNO 00135938 CATAWBA 842855 NA/B4285SOI 6 40NA lffA25A N WfU2029VNO 97567 LUNG MEN (FLOWSERVE) 842868 NA/84286.~0I 2 1INA IEFAIOA N WTU2023VNO 00136550 MCGUIRE 842871 NA/84287101 l 40NA lEFA25A N WTIJ2023VNO 00136593 MCGUIRE 842918 NNB4291801 I 70NA IEFA2.5A N WTU2023VNO 00137202 CATAWBA 842918 NA/84291802 I 40NAX IEFA25A N WfU2023VNO 00137202 CATAWBA 842922 NA/84292201 I 16NAX IEFA14A N WTU202JVNO 00137242 CATAWBA 842922 NA/84292202 l 30NAX I EFA16A N WfU2021VNO 00137242 CATAWBA 842953 NAIB4295301 I 14NA IEFAl4A N WTU2023VNO 00137763 MCGUIRE 843608 NA/84360801 I 1 INA IEFAIOA N WTU2023VNO 00142102 MCGUIRE Page5of12
rotormt*
Controls Onkr P11rt Qt)' Drscrlpllun Customrr_ 1'0 Projl:'Ct B436bl WNK23 1)K 3 NAllS~ 12SW Vl2 AOPI 00142224 MCGUIRE B431J46 WNK2398 12 NAl/5E 12SW Vl2 AOl'I RSP.181114 OC*KF.
MCGUIRE 844151 NA1844151111 2 14NA I F.FAl4A N WTU2021VNO 00143556 DUKE CATAWBA 844269 NNB4426901 I l6NA IEFAl4A N Wl'U2023VNO OOl43880 MCGUIRE 84S067 NA/84506705 2 MODJA 40NAI C-WISESW.MF.CH !04962 OPG ASSV.
B4S067 NA/84506706 2 MOOSA 12 SW wru 2029VNO AOPI 104962 OPG ASSV.
845074 NA/84507401 2 1INA U.FAIOA N WfU202JVNO OOl45KKI MCGUIRE 846016 NA/84601601 I 14NA IEFA14A N WTU2023VNO 1111147120 MCGUIRE 846021 NA/84602201 I llNA IEFAIOA N WfU2023VNO 00147790 MCGUIRE B4602li WN82395 5 NAl/SE 6SW V12 AOPI 00147787 CATAWBA B46724 NNB4672401 I 90NA IEF A30A N WTU2023VNO 00148800 MCGUIRE 846724 NA/84672402 2 l6NA IEFA14A N WTU202JVNO 00148800 MCGUIRE 84728.8 WN82398 9 NAl15E 12SW Vl2 AOPI RSP39208 (RC! MCGUIRE SERVICE) I 00147756 {DUKE) 847352 NA/84735201 I I INA IF.FAIOA N WTU202JVNO 001500311 MCGUIRE 847745 NA-03-102 5 NAl/5 SWITCH MECH 011208N (RCC) I OPG 110208959 (OPG) 848378 NA/84837801 8 JINA 5EFI0841WNJ wru Cl4284SR ECU NOT KNOWN 2021VNO CORPORATION 848687 NA/B4K68701 I llNA IEFAIOA N WTU2023VNO 00152920 MCGUIRE 848811 NA/84881 IOI I l6NA IEFAl4A N WTU2023VNO 00153320 MCGUIRE 848925 NA/84892501 2 JINA IEFAIOA N WTU2021VNO 00153564 CATAWBA 849264 NA/84926401 I 14NA IEFA14A N WTU2021VNO 00154397 CATAWBA 849369 NA/84936901 2 I INA IEFAIOA N WTU2021VNO 00155275 DUKE CATAWBA 849459 NA/8494590 I I 14NA IEFAl4A N WnJ2021VNO 00155653 CATAWBA 849620 NA/84%2001 I MOD8A6 SWWTU 2021VNO AOPI 205435 AK NUCLEAR I ASSV.
849770 NA/84977001 I 14NA IEFAl4A N WnJ2023VNO 00156719 MCGUIRE 849774 WN80262 4 MODllA 7/llNAl/4COMPKITPOST78 RSP41188 (RCI SEABROOK SERVICE) 0230945 (SEABROOK) fWJ774 NA-03-102 I NAli5 SWITCH MECH RSP41188 (RCI SEABROOK SERVICE) 0230945 (SEABROOK) 849777 WN82398 6 NAl/5E 12SWV12AOPI RSP41660 (RCI MCGUIRE SERVICE)/
00155079 (DUKE) 349779 WN80262 2 MODI IA 7/llNAl/4COMPK!T POST78 RSP4 I l 89 (RCI SEABROOK SERVICE);
02302948 (SEABROOK) 849779 NA/8497791 l I 7NA I FAIOA N WTU2021VNO RSP41 I 89 (RCI SEABROOK SERVICE)/
02302948 (SEABROOK)
Page6of12
rotorlf Controls Order Pul Q1y lle$cripllon Costumer_ PO Project
()49779 NNB4lJ77'Jl2 I 7NA I fAIOA N WfU2021VNO RSP41189(RCI SEABROOK SERVICE)/
02302948 (SEABROOK) 849781 NA/B4<J7810l l 14NA IEFA14A N WTU202JVNO RSE39823 (RC! CATAWBA SERVICE)/
00155773 (DUKE) 84911!3 NA/84978301 I 14NA IEFAl4A N WTU202lVNO RSE394 IO (RCI MCGUIRE SERVICE)!
0015S086(DUKE) 8491!42 NNB4984201 I 90NA lEFAJOA N WTU2023VNO 00156967 MCGUIRE 849890 WN80334 I MODID 14/16NA5 CJCASE MAINT KIT 012171N (RCC)/ OPG POST78 00214820 (OPG) 850131 NA-03*102 2 NAl/5 SWITCH MECH 00158579 MCGUIRE 850641 NNB5064101 l llNA JEFAIOA N WfU2023VNO 00159726 MCGUIRE 85066.~ WN!12398 8 NAl/.~E 12SW VIZ AOPI NCRI 14367 (RCI) I MCGUIRE 0015751 I {DUKE) 850775 WN81509 5 MOD38 Vl2 NA'E' SIM 00160864 MCGUIRE 851199 NNB5119901 I l4NA IEFAl4A N WTU2023VNO 00162285 MCGUIRE 851201 NA/85120101 I I INA IEFAIOA N WTU2023VNO 00162286 MCGUIRE 851470 NA/85!47001 1 90NA I FAJOA N WTU2023VNO 00163632 MCGUIRE 851625 NA*03-I02 4 NAl/5 SWITCH MECH NU02SR748437 VCSUMMER ST 851684 NN8Sl68401 1 16NA IEFAl4A N WTU2023VNO 00164715 MCGUIRE 851902 NA185190201 2 JONAX IEFAl6A N WfU2023VNO 00165981 MCGUIRE 852307 NA/8523070 I I 14NA IEFAl4A N WfU2021VNO RSE41495 (RCI CATAWBA SERVICE)/
00164457 (DUKE) 852439 NAJBS243901 I 90NA I EFAJOA N WnJ2023VNO 00168826 MCGUIRE B52790 NNB5279001 I 16NA IEFAl4A N WTU2023VNO 00170740 MCGUIRE 85280! NA/85280101 2 JONAX IEFAl6A N WTU2023VNO 57081 DUKE CRANE NUKE 853470 NNB5347001 ;J 7 NA IEFAIOB4 IWN3 wru 8907060N DUKE 2023VNO MCGUIRE 853613 NAfBS361301 I 14NA IEFAl4A N WTU2021VNO 00172853 (DUKE) CATAWBA 854087 NNB5408701 2 30NAX IEFAl6A N WTU2023VNO 58666 CRANE NUKE B54177 NN85417701 I 14NA IEFAl4A N WTUZ021VNO RSP46290 (RCI DUKE SERVICE) CATAWBA 8441510101 854177 NNB5417704 l 14NA IEFAl4A N WTU2021VNO RSP46290 (RCI CATAWBA SERVICE)/
00174477(DUKE) 85433{) NAIBS433001 I 14NA IEFAl4A N Wl"U202lVNO 00177225 DUKE CATAWBA 854444 WN8239.5 I NAl/SE6SW VIZ AOPI NCR136918 (RCI) i MCGUIRE 00176305 (DUKE)
Page7of12
rotortf Controls Order Parl Qty Deseripllon Customer_ PO Project 854444 WN823'1K IO NAl/SE 12SW Vl2 AOPI NCRl361JIK (RCl)1 MCGUIRE 00176305 (DUKE)
BS4727 NAJBS47270 I 2 14NA IEFA14A N WTU2021VNO 001791<15 DUKE CATAWBA BS4727 NAJBS472702 2 14NA IEFAl4A N WTU2021VNO 00179165 DUKE CATAWBA 8.54842 NA*OJ-102 6 NA l/.'i SWITCH MECH OUl79h39 CATAWBA 856398 NA!B5639801 2 14NA IF.FAl4A N WTU2021VNO 00186461 CATAWBA BS6437 NAJB5643706 I I INA IEFAIOA N WllJ 2023VNO RSP4K672 DUKE MCGURIE 856515 NAIB56SISOI I 1INA IEFAIOA N WTU2023VNO 00186989 DUKE MCGUIRE BS723S NA/BS723SO I I 90NA IEFA30A N WTU2023VNO 00189572 DUKE-MCGUIRE 857239 NAJB5723901 3 l6NA IEFA14A N WfU2023VNO 00189629 DUKE-MCGUIRE 857239 NNBS723902 I 9DNA IEFAJOA N WTU2023VNO 00189629 DUKE-MCGUIRE B57239 NA/85723903 I 90NA IEFA30A N WTU2023VNO 00189629 DUKE-MCGUIRE 857443 NA/B5i' 4430 I 3 7 NA 5EFAIOB4 IWN3 wru 1193547 OPGESWSTRA 2220VNO 857603 NNB5760301 I 70NAX I FA2SA N WTU2021VNO 00191051 CATAWBA 857687 WNSOJ.14 I MODI D 14!16NAS GIC ASE MAINT KIT P002240-4 (RCC)/ OPG POST78 0028620 I (OPG) 857722 NA/85772201 I 40NA IEFA25A N WTU2023VNO 00191584 MCGUIRE 858332 NNBS833201 2 14NA IEFA14A N WTU2023VNO 00193561 DUKE-MCGUIRE B589tll NN85890101 I I INA IEFAIOA N WTU2023VNO 00195572 DUKE MCGUIRE 859205 NN85920501 4 16NA IEFAl4A N WTU2023VNO 00196629 DUKE-OCONEE B592(15 NA/85920502 I 16NA IEFAJ4A N WTU2023VNO 00196629 DUKE**
OCONEE 859319 NA/8593190 I I 16NA IEFAl4A N WTU202JVNO 00197087 CATAWBA 859392 NA/8593920 I I 70NA JEFA25A N WTU2023VNO 00197274 DUKE MCGUIRE 859392 NA/85939202 I JINA IEFAIOA N WTU2023VNO 00197274 DUKE MCGUIRE 859879 NA/85987901 I IJNA JEFAIOA N WTU2021VNO 00199184 DUKE CATAWBA B602n NA/86021301 I 7 NA SEFAIOA N WTC 2i}ZIVNO Pfl06139 (RCI)/ OPG Pl500268 (NEWMAN HATTERS LEY) 860896 NA/86089601 2 JINA IEFAIOA N WTU2023VNO 03003170 MCGUIRE 861560 WN81S09 2 MODJB Vl2 NA'E' SIM 03007832 CATAWBA 861721 N69-921 6 SWITCH*M Vl2/3252 RSP54951 / 013962010301)
NCRJ64927 (RCI OPG SERVICE 861721 NA/B617l!Ol j 7 NA 5EFAIOA N WTCZ021VNO RSP54951 ! 01396201030! -
NCRl64927 (RCI OPG SERVICE)
Page 8of12
rotorlf Controls Order l'arl QI)" Descripllon Cuslomcr_PO l'rojeel 061721 WN!llSO'J I MODJB Vl2 NA'E' SIM RSPS4951 f OIJ"62010JOI -
NCRl64927(RCI NEWMl\N SERVICE) Hl\TIERSLEY -
Ol'G 012CJ89 NAJDl291!<JOI 2 JONA I FAl6A N WfCWDI8016 00153869 OPG DBl40 NNDD 141Kll 2 JONA I FAl6A N WfCWDl8016 00159480 OPG D131:'il NArDl:\l.'ilOI I 411NA I FA2SZ N wrc woo3142 llOISSS90 OPG OIOCJ71} NA/OI0971JOI I lliNA IEFAl4A N WTC2029VNO Pl 100211 CF.RNAVODA NEWMAN HATIERSLEY-013JS1J NAIOl33S90I I 7 NA IEFAl084 IWNJ WTC Pl200360{NEWMAN EMBALSENPP 2024VNO HATIERSLEY)
OIJJS9 NAJ01335902 I 7 NA IEFAIOB4 JWN3 wrc Pl200360(NEWMAN FMBALSE NPP 2024VNO llA1"rERSLEY)
OIJJll:'i NA/01338501 I 7NA SEFALOB4 IWN3 wrc 12-12079 (RITEf'ROl F.MBl\LSE NPP 2020VNO 013%2 NA/01396201 J 7NA SEFAIOA N WTC2021VNO PIJ002U2 (NEWMAN OPG HATIERSLEYJ Sl)l))\l3 NAISD939302 ] MOD3A 90NAI C -WISE SM.MECH 216341, ENTERGY ASSY. REPLACMENT FOR 10156515
<ENTERGY)
WE2984 NA-03-102 J NAl!5 SWITCH MECH 114800 PALO VERDE CURTIS WRIGHT -
ENERTECH, WE3110 NA-03-102 s NAl/5 SWITCH MECH ESD8468N (RCC) I OPG 00151524 (OPG)
WEJl67 NA*Ri-102 I NAl/5 SWITCH MECH ESD86JON (RCC) I OPCi OOIS4615(0PG)
WEJ267 NNW82670 I N00.()3-020 NAI SWITCH MECH 4500362690 f'SOO I
WE3747 NA.()l-102 J NAl/S SWITCH MECH ESD9023N (RCC)/ OPG 0016228 (OPG)
WE381J NA*03-102 I NAli5 SWITCH MECH ESD9070N ( RCC) i OPG 00163571 (OPG)
WE3907 NA..00-102 2 NAl/5 SWITCH MECH 4500428140 PSEG WE3910 NA-OJ-102 2 NAl/S SW ITCH MECH ED13239R (RCC) OPG TRAINING PURPOSES PER PO, WE4022 NA-03-102 i NAl/5 SWITCH MECH ESD9135N (RCC)/ OPG 00158829 (OPG)
WE4037 NA-03-102 2 NA 115 SWITCH MECH 00098888 MCGUIRE WE4246 NA-03-102 I NAl/5 SWITCH MECH SJl5871 ENTERGY Page9of 12
rotorlf Controls Onlrr 11,HI Qt)" Drscrlpllon Cus1an111r_ l'O l'rajrd W~l'lb NA-0)-102 I NAl/S SWllCll MECll ESD'l2711N (RCC)/ Ol'G llOlt.!!401 (OPG)
WE41161J NA-ll3-I02 2 NAl/5 SWITCH MECH ESD94'>1 N ( RCC) I OPG 110173259 (OPG)
W~5621 NA~JJ-102 Ii NA II.~ SWITCll MECll ESD1JllOIN (RCC)/ OPG 11018111011 (OPG)
WE6060 NA-Ol-102 6 NAl/S SWITCll MECll L'i ll00211N/REV2 Ol'G (RCC)I 001116517 (OPG)
WE6152 NA-IU-102 l NA!/S SWITCll MECll ESD0092N (RCC) I OPG 001118202 (OPG)
WE6660 NA-03-IOZ I NAl/S swrrc11 MECH 500546062 APS- PALO VERDE WE6822 NA-08-706 I lllAI 6SW VJ2 AOPI ASS RSP35818 (RCI RCISERVICEi SERVICE)/ CATAWBA 110132331 (DUKE)
WE6904 WN112395 . NAl/SE6SW VIZ AOPI 00136411 CATAWBA WF.7023 WN82395 5 NAl/SF.6SW Vl2 AOPI 00137764 CATAWBA WE70llS WN82398 IS NAl/SE 12SW Vl2 AOPI 00138769 MCGUIRE WE.7139 WN80262 I MODI IA 7ll INAl/4 COMP KITPOS'r711 02263)79 SEABROOK WE7247 WN82398 l NAl/!iE 12SW VIZ AOPI 0014043:'i MCGUIRE Page 10of12
rotormt*
Controls KS switch list Onlcr l'art Qty Dettrlptlon Customer PO Projet I 84641102 N564114 2 NAI SWITCH MECH SPF.C 010634N (RCC)/ HVDROQUBEC 4503054188 (I lydro ICENTRALE Quebec) GENTILLY II 8494511 WNl<06S3 II NAI SW MECll KS-3252*A2 Ol 196SN (RCC) I BRUCE POWER 0017!079 (BRUCE POWER)
B4977'J NASll3B* 2 NAl/S SWITCH MECH KS RSP41189(RCI SEABROOK OIHl4 SERVICE)/
02302948 (SEABROOK) 134'>524 N564K4 3 NAI SWITCll MECll SPEC Ol 1998N (RCC) I MOBIL VALVE 1065218 (MOBILE /NEW VALVE)/ BRUNSWICK 4500370878 (NEW POWER BRUNSWICK POWER) 850333 WN80653 b NAI SW MECH K5*32S2-A2 012410N (RCC)/ OPG 00216597 (OPG) 851532 WN806SJ 8 NAI SW MECH K5*3252*A2 012969N (RCCJ f BRUCE POWER 00177514 (BRUCE POWER) 852075 N564K4 J NAI SWITCH Ml'.Cil SP£C 013329N (RCC) I BRUCE POWER OOl796116(BRUCE POWER) 853208 NASOJB- I SWITCH MECH NAI KS OAP. ANNEALED 013968N (RCC) I OPG 0005 RYTON 00226962 (OPG)
BSJS75 N56484 I NAI SWITCH MECH SPEC 013877N (RCC)/ BRUCE POWER 00183812 (BRUCE POWER) 854843 NS6484 J NAI SWITCH MECH SPEC 014684N (RCCJ I BRUNSWICK 1177461 (MOBILE POWER VALVE)/
4500398343 (NEW BRUNSWICK POWER)
B55380 NS6483 I NA l SWITCH BANK SPEC P000623-I (RCC)/ OPG 00232427 (OPG) 856689 NS6484 I NAI SWITCH MECH SPEC NCRl4877S NCR SPARES B56643 NA/BS664301 s MODJA 90NAI C-WISESW.MECH ASSY. P002330*1 (RCC)/ Ol'G 00235579 (OPG) 855572 NASOJB- I SWITCH MECH NAI KS DAP. ANNEALED P000918*1 (RCC)/ OPG 0005 RYfON 00233354 (OPG)
Oi20(iU NA/0!209001 3 7 NA 5EFAIOB4 IWN3 WTC2040-NO 202546 (BRAVJ BRAY, BRUCE POWER 014002 NA/01400201 I 14NA I FA14A N WTC2024-NO 00183784 (BRUCE BRUCE POWER POWER)
Page 11of12
rotor1f Controls (vii) 11ie corrective actioll which has bee11, i.f bei11g, or will be take11; the name ofthe individual or organization responsible for the action; and the length of time that /ms been or will be tt1ke11 to complete the action.
By this notification Rotork is infonning al] Utilities and listing affected customer orders.
Utilities may contact their local Rotork office or the undersigned for support relating to their specific units. Rotork recommends the replacement of switches in the affected orders.
Rotork is currently evaluating options regarding replacement switches with the supply chain. The switch assembly's design will be changed by Johnson Electric so that the adhesive AY 103-1 is no longer used.
(11iii) Any ad11ice related to the defect or failure to comply about the facility, activity, or basic component that has been, is being, or will he given to purchasers or licensees.
U.S. Licensees with installed or in storage actuators, switch mechanisms or Add-On-Pak (AOP) spares modules containing V12 and K5 switches identified in section (v1) should evaluate the impact of a high contact resistance or open circuit condition on safety related systems.
(ix) In the case ofan early site permit, the entities to whom an early site permit was transferred Not Applicable Page 12of12
rotor11- Page 1of48 Rotork Controls Limited Approved by Engineering Nuclear Engineering Report No. ER857 Issue 1 Date: 3rd May 2016 REVISION SHEET ORIGIN Priyang Jadav & Patrick Shaw DATE OF ISSUE 03/05/2016 TITLE Part 21 Investigation. Anomaly of V12 Micro-Switch N69-921.
Prepared Checked Approved Priyang Jadav Patrick Shaw Kevin Sweet Product Engineer - Quality Assurance Engineering Manager Nuclear 'Manager -Nuclear Issue No Date Revision By 1 03/05/16 Original PUJ
rotor11- Page 2 of 48 Rotork Controls Limited Approved by Engineering Nuclear Engineering Report No. ER857 Issue 1 Date: 3rd May 2016 CONTENTS
- 1. Summary .............*............................................................................................................................ 3
- 2. Deviation description ............................................................................................*.......................... 3
- 3. Micro-switch function ..................................................................................................................... 4
- 4. Review of orders affected ............................................................................................................... 4
- 5. Summary of tests performed .......................................................................................................... 7 5.1. Air volume of actuator electrical enclosure ............................................................................ 9
- 6. Tests replicating the anomaly ....................................................................................................... 11 6.1. Procedure for thermal aging switches inside an enclosure .................................................. 11 6.2. Test 1-125°C (257°F) aging of V12 switches manufactured in 2015 .................................. 12 6.3. Test 2 -Volt ramp on aged switches from Test 1.. ............................................................... 14 6.4. Test 3 -125°C (257°F) aging of V12 switches manufactured in 2007 .................................. 14 6.5. Test 4 -125°C (257°F) aging of V12 contacts only ............................................................... 14
- 7. Supporting information and post-curing ...................................................................................... 16 7.1. Procedure for post-curing tests ............................................................................................ 17 7.2. Test 5 - Post-curing ............................................................................................................... 17 7.3. Test 6 -125°C (257°F) aging of KS switches manufactured in 2012 ..................................... 18
- 8. Tests of unglued and glued switches using different adhesives ................................................... 19 8.1. Test 7 -125°C (257°F) aging of a switch without adhesive .................................................. 19 8.2. Test 8 -125°C (257°F) aging of switch assembled with Duralco 4525 ................................. 19 8.3. Test 9 -125°C (257°F) aging of switches assembled with AY105-1/HY991 ......................... 20 8.4. Test 10 -125°C (257°F) aging of switch assembled with Raychem S1264 ........................... 21 8.5. Test 11-125°C (257°F) aging of switch assembled with X60 .............................................. 21
- 9. Anomaly effect upon switch operation ........................................................................................ 22 9.1. Factors Causing Anomaly ...................................................................................................... 22 9.2. Estimated Anomaly Onset .................................................................................................... 23 9.3. Switch performance under accident profiles ........................................................................ 25
- 10. Results from independent test lab ........................................................................................... 30
- 11. Conclusion ................................................................................................................................. 35
- 12. References ................................................................................................................................ 36
rotor11- Page 3 of 48 Rotork Controls Limited Approved by Engineering Nuclear Engineering Report No. ER857 Issue 1 Date: 3rd May 2016
- 1. Summary This report documents work performed to support a Part 21 investigation opened by Rotork Controls Inc. ref. tracking number NCR173472. Measurements and tests were performed to establish the operational reliability of Rotork safety related micro-switches. Non-compliant switches were identified from a batch manufactured in 201S against Rotork purchase order P01284S9. The investigation has confirmed that the defect is only attributed to batches received in 2007 and later.
The switch supplier (Johnson Electric) incorporates a small amount of adhesive in each switch's construction to secure the two halves of the switch housing together. The adhesive formulation was altered in 2003 by the adhesive supplier (Huntsman). Tests detailed in this report show that the altered formulation outgases at elevated temperatures and deposits an insulating material layer onto the switch internal electrical contacts as it cools.
- 2. Deviation description On January 2S, 2016 Rotork Controls Inc. opened a formal Part 21 investigation into an anomaly relating to a Basic micro-switch - Part No. N69-921 (RS104), description "V12". The anomaly is high resistance or loss of electrical continuity and was first observed following a customer thermal aging test of Rotork Safety Related NA Range electric Actuators; also referred to as an electric Valve Operator. Following 10 days at 12S°C (2S7°F) a significant percentage of micro-switches in the test actuators exhibited open circuit.
Subsequent in-house testing has revealed that the anomaly also relates to Basic micro-switches with the following Part Nos. as they are constructed using the same adhesive.
N69-838 (RS366), description "KS" (screw terminals)
N69-926 (RS378), description "KS" (fast-on terminals)
Drawings of the three switches can be found in Appendix A.
rotor11- Page 4 of 48 Rotork Controls Limited Approved by Engineering Nuclear Engineering Report No. ER857 Issue 1 Date: 3rd May 2016
- 3. Micro-switch function The micro-switch has four functions:
- Rotork actuators can be set to operate to a maximum torque level of opening or closing a valve. When the torque sensing mechanism in the actuator registers this maximum torque, the micro-switch will be tripped to turn off the motor.
- Rotork actuators can also be set to operate to a maximum travel limit. The mechanism inside the actuator will register when the maximum travel in the open or close direction is reached and the micro-switch will be tripped to turn off the motor.
- In the Add-on-Pak (AOP) the switch is intended for indication purposes but can also be used for interlocks and permissives to start other equipment such as pumps and valves. AOP switches can be set to trip at any point during valve travel. The AOP can also be used for torque switch bypass. If the circuit is "open" then the MOV could stop before achieving "end of travel".
- Switches must be "closed" to initiate travel.
- 4. Review of orders affected The following are details of the affected switches.
- 11000 V12 switches N69-921 supplied to Rotork against the following purchase orders.
Purchase order no. Quantity Rotork Lot reference Manufacture Year P0081139 700 LC006383 2007 1050 LC006391 1500 LC006398 725 LC006399 2025 LC006402 P0128459 183 LC010448 2015 500 LC010464 700 LC010483 483 LC010509 612 LC010539 1 LC010540 639 LC010547 640 LC010566 640 LC010570 448 LC010576 154 LC010638 11000
rotor11- Page S of 48 Rotork Controls Limited Approved by Engineering Nuclear Engineering Report No. ER857 Issue 1 Date: 3rd May 2016
- 1900 KS switches N69-838 supplied to Rotork against the following purchase orders.
Purchase order no. Quantity Rotork Lot reference Manufacture Year P0084220 200 LC006390 2007 P0086172 100 LC006S39 P00870S7 100 LC006603 2008 P00892Sl 200 LC007024 P0090778 100 LC00713S P0092646 20 LC0072S4 2009 80 LC0072SS P009S664 100 LC0074SO P0100333 100 LC007682 2010 200 LC007693 240 LC008194 2011 183 LC0082SO 2012 277 LC008271 1900
- 1S03 KS switches N69-926 supplied to Rotork against the following purchase order.
Purchase order no. Quantity Rotork Lot reference Manufacture Year P010661S 17S LC008192 2011 32S LC008193 2012 476 LC008203 149 LC008207 2S3 LC008233 12S LC0082S3 1S03
rotor11- Page 6 of 48 Rotork Controls Limited Approved by Engineering Nuclear Engineering Report No. ER857 Issue 1 Date : 3 rd May 2016
- Suspect V12 and KS switches have date code ending with 07K to lSK stamped at the location shown below. The code refers to week (43) and year (2015).
Figure 1: Location of date code on V12 switch Figure 2: Location of date code on KS switch N69-838
rotor11- Page 7 of 48 Rotork Controls Limited Approved by Engineering Nuclear Engineering Report No. ER857 Issue 1 Date: 3 rd May 2016
- 5. Summary of tests performed A range of tests were conducted as part of the investigation in order to :
- a. Replicate the anomaly
- b. Identify root cause
- c. Evaluate switches from previously supplied batches
- d. Attempt salvaging defect switches
- e. Experiment with alternative adhesives
- f. Evaluate the effect of the anomaly on switch operation Table 1 provides a summary of tests performed to cover points a toe above. Further details on each test are provided in subsequent sections which are referenced within the table itself. The experiments were performed using two programmable test ovens. Test switches were placed in metallic enclosures and heated to a fixed temperature for a defined time (thermal aging). The testing was destructive, and new switches and metallic enclosures were used for every test. Prior to use, the metallic enclosures were thermally cleaned to remove any volatile materials remaining from their manufacture. The metallic enclosure construction does not incorporate any non-metallic seals or non-metallic coatings .
Part f is a study of the 1) factors causing the anomaly, 2) estimated anomaly onset, and 3) switch performance under accident profiles. This work is detailed in section 9.
Test Test No. of Test Concentra- Result Full no. description switches parameters tion factor test tested (Cf) details 1 Thermal aging 5 switches, 5.75 days at 1680cm 3 Switch anomaly occurs See of V12 date code 125* c (257°F) . test even when the switch is Section switches 3715K, in a container. aged in isolation, 6.2 manufactured metal 336cm 3 therefore cause lies within in 2015 . container per switch . the switch itself.
of volume Cf= 1.78 Contamination is present 1680cm 3 . on NO and NC contact rivets. UV images suggest it may be coming from adhesive .
2 Volt ramp on 2 aged Volt ramp up N/A Volt ramp up to 60VDC, See aged switches switches to 60VDC 14mA does not reliably Section from Test 1. taken from across the NO clean the contacts. 6.3 Test 1. contact with 4.3k0 fixed resistor in series (14mA max across contacts) .
rotor11- Page 8 of 48 Rotork Controls Limited Approved by Engineering Nuclear Engineering Report No. ER857 Issue 1 Date : 3 rd May 2016 Test Test No. of Test Concentra- Result Full no. description switches parameters tion factor test tested (Cf) details 3 Thermal aging 4 switches, 3.93 days at 1680cm3 The 2007 manufactu red See ofV12 date code 12s*c (2S7°F) . test switches exhibit the same Section switches 2807K . container. anomaly as the 201S 6.4 manufactured 420cm 3 switches .
in 2007 . per switch .
Cf= 1.42 4 Thermal aging 3 switches, 6 days at 2SS2cm 3 There is no issue with the See of V12 date code 12s*c (2S7°F) . test silver plating process of Section contacts only . 3613K, had container. the rivets. 6.S their NO, 8Slcm 3 NC and per switch.
moving Cf =0 .70 contacts removed to be aged .
s Post-curing of 6 switches, Post-cu red at 24Scm 3 After 8 days of post- See V12 switches date code 12s* c (2S7°F) test curing, outgassing still Section manufactured 431SK . forupto8 container. occurs causing the switch 7.2 in 20 1S. days . Then 1 switch to exhibit the anomaly.
aged inside per container for container.
3.77 days. Cf =2.44 6 Thermal aging 2 switches, 6 days at 1680cm 3 The KS switch N69-838 See of KS switches date code 12s* c (2S7°F) . test exhibits the same anomaly Section N69-838 0612K . container. as the Vl2. KS N69-926 is 7.3 manufactured 840cm 3 constructed of the same in 2012 . per switch . glue thus is also affected .
Cf= 0.71 7 Thermal aging 1 switch, 7 days at 24Scm 3 Switch performance is See of a switch assembled 12s* c (2S7°F) . test acceptable if no adhesive Section without without container. is present. 8.1 adhesive. adhesive 1 switch applied . per container.
Cf =2.44 8 The rmal aging 1 switch 10 days at 24Scm 3 Duralco 4S2S outgasses to See of switch 12s* c (2S7°F) . test an extent that the switch Section assembled container. will exhibit the anomaly. 8.2 with Duralco 1 switch 4S2S . per container.
Cf =2.44
rotor1- Page 9 of 48 Rotork Controls Limited Approved by Engineering Nuclear Engineering Report No. ER857 Issue 1 Date : 3 rd May 2016 Test Test No. of Test Concentra- Result Full no. description switches parameters tion factor test tested (Cf) details 9 Thermal aging 3 switches Up to 14.2 245cm 3 Switch performance is See of switches days at 12s* c test acceptable if assembled Section assembled (257"F) . container. using a small quantity of 8.3 with AYlOS- 1 switch AY105-1/HY991.
1/HY991. per container.
Cf =2 .44 10 Thermal aging 1 switch 10 days at 245cm 3 Switch performance is See of switch 12s* c (257"F) . test acceptable if assembled Section assembled container. using a small quantity of 8.4 with Raychem 1 switch Raychem S1264.
S1264. per container.
Cf =2 .44 11 Thermal aging 1 switch 10 days at 245cm 3 X60 outgasses to an extent See of switches 12s* c (2S7" F) . test that the switch will exhibit Section assembled conta iner. the anomaly. 8.5 with X60. 1 swit ch per container.
Cf =2.44 Table 1: Summary of tests performed 5.1. Air volume of actuator electrical enclosure During the investigation it was observed that the air volume per switch is an important factor which needs to be considered in aging tests since it can influence the length of aging time before onset of the anomaly. Experimental data demonstrated, for a given temperature, the anomaly would manifest itself in a shorter time period when switches were placed in a smaller enclosure. This is further discussed in section 9. It is necessary to know the air volume in the actuator electrical enclosure in order to relate the test results to the application . To be conservative a small size actuator was used for the calculation, giving a worse switch to air volume ratio . Using CAD the air volume in an empty electrical enclosure was estimated to be 11960cm 3 (Figure 3).
Similarly, the volume of the switch mechanism and AOP were estimated 594cm 3 from CAD (5 % of enclosure volume). It is assumed another 5% of enclosure volume is consumed by the heater, looms and other components within the enclosure. The air volume to which a small actuator fitted with a switch mechanism and 12 switch AOP would outgas to is :
11960 - 594 - 594 = 10772cm 3 The maximum number of switches available in an actuator are 18. Therefore the estimated volume of air per switch is:
10772/18 = 598cm 3
rotor11- Page 10 of 48 Rotork Controls Limited Approved by Engineering Nuclear Engineering Report No. ER857 Issue 1 Date : 3 rd May 2016 Different sizes of encl osures were utilised . Most of the tests listed in Table 1 were performed using 3
245ml (=245cm ) enclosures (Figure 4) . The term concentration factor (Cf) is introduced to relate the actuator air volume per switch to the test enclosure volume per switch:
actuator air v olume per switch 598cm 3 Cf= test enclosure volume per switch = 245cm 3 = Z.4 4 The concentration factor for each test is also specified in Table 1.
c-..r1....
o....-
lltS a..
lfl;~-"1 1X2MJU1-*1 C...-rl..._
o.i.,..,.o fr"
- .. ttlOli- x !tU15-y '41Gl- "41Q..,.,
l us- l us-01'0'9-"1 4il'lif-"1 "llh'i-.-,
Figure 3: Air volume inside actuator electricol enclosure Figure 4: 245ml enclosure
rotor11- Page 11of48 Rotork Controls Limited Approved by Engineering Nuclear Engineering Report No. ER857 Issue 1 Date : 3 rd May 2016
- 6. Tests replicating the anomaly 6.1. Procedure for thermal aging switches inside an enclosure In-house thermal aging tests were performed to replicate the anomaly. The tests were performed according to the following procedure.
a) Remove screw terminals.
b) Using milliohm meter, record resistance across NC contacts . (Meter used applied 9V, SmA max. Figure 5). Manufacturer's end -of-line acceptance level is 25m0 max.
Figure 5: Milliohm meter c) Operate and hold switch plunger.
d) Record resistance across NO contacts.
e) Release plunger.
f) Repeat steps b - e until 3 NC and 3 NO measurements are obtained for each switch.
g) Fasten screw terminals h) Place switches inside a metallic container.
i) Thermally age the container at 125°C (257°F). (Total aging time varied for each test and is stated in subsequent sections of the report) j) Once thermal aging complete, remove container from oven and allow to cool. It is important that the container remains closed until cooled so that any outgassing can condense .
k) Remove switches and repeat resistance check following steps a - g
rotor11- Page 12 of 48 Rotork Controls Limited Approved by Engineering Nuclear Engineering Report No. ER857 Issue 1 Date : 3rd May 2016 6.2. Test 1 - 125°C (257°F) aging of V12 switches manufactured in 2015 5 switches, Rotork part no. N69-921, date code 3715K, labelled F - J, were tested following the procedure in section 6.1. A drawing of switch N69-921 is shown in Appendix A. Thermal aging time was 138 hrs (5.75 days).
Results are shown in Appendix B. Before aging, the switches were within the manufacturer's 25m0 acceptance. After aging, the NO contacts exhibited open circuit, indicated by a dash in the result field.
Switch H recovered on the second operation post-aging. A
- in the result field indicates that the resistance value was fluctuating between several ohms, to hundreds of ohms, to open circuit.
Green cells identify readings below the 25m0 manufacturer's end-of-line acceptance.
Yellow cells identify readings below the 500m0 industry acceptance.
Red cells identify unacceptable reading.
Switch F was opened for examination of the contacts (Figure 6 - Figure 9). Blue plastic particles were formed only as a result of breaking the switch apart. A pale yellow layer appears to have formed on the surface of the NC and NO contact rivets, Figure 6 and Figure 8. At the very centre of the NC and NO rivet, i.e. the point of contact, the layer has broken away and the normal silver appearance of the rivet is visible. The white powder on the moving contact, Figure 7 and Figure 9, indicates that there was transfer of the broken layer from the stationary contacts to the moving contact.
Contacts from aged switches were observed under UV light. Figure 10 indicates the contamination is formed only on the NC and NO stationary contacts . Under UV light the contamination is a similar colour to the residue in the area where adhesive is applied, Figure 11. The conjecture for this is that the NC and NO contact tabs extend outside of the switch housing where the surrounding temperature is lower than the temperature inside the switch. Thus through loss of heat by conduction, the NO and NC contacts would cool quicker than other components enclosed within the switch housing. This would mean that the NO and NC contacts act as heat sinks causing vapours released from the adhesive to condense onto the contacts . The NC and NO stationary contacts are made from Silver-Cadmium-Oxide (AgCdO) which provides the best known performance for switching off electrical current quickly and cleanly (Ref 1).
An independent investigation was performed by an external laboratory Exova in an effort to identify the source of contamination (Section 10). However, due to differences in chemical composition between the non -metallics and the contaminant, the source could not be confirmed by analysis.
Nevertheless, literature (section 7), test results of an unglued switch (section 8.1) and UV images identify the adhesive being the root cause.
Summary
- The V12 switch anomaly occurs even when the switch is aged in isolation, therefore the cause lies within the switch itself.
- Contamination is present on the NO and NC contact rivets, and UV images suggest it may be coming from the adhesive.
rotor11- Page 13 of 48 Rotork Controls Limited Approved by Engineering Nuclear Engineering Report No. ER857 Issue 1 Date : 3 rd May 2016 Figure 6: Switch F, NC contact rivet Figure 7: Switch F, NC side of moving contact Figure 8: Switch F, NO contact rivet Figure 9: Switch F, NO side of moving contact Figure 10: Contact rivets under UV light Figure 11 : Separated switch housing under UV light
rotor11- Page 14 of 48 Rotork Controls Limited Approved by Engineering Nuclear Engineering Report No. ER857 Issue 1 Date : 3rd May 2016 6.3. Test 2 -Volt ramp on aged switches from Test 1 A volt ramp up to 60VDC was performed across the NO contact of switch G, using a 4.3k0 fixed resistor in series. Switch G maintained open circu it.
60 V 430011
= 14mA max across contacts.
The volt ramp was repeated across the NO contact of sw itch I. At 60VDC the switch started to conduct.
The plunger was released for 5 mins before repeating the test. During the second volt ramp switch I began to conduct at 27VDC.
Summary
- Volt ramp up to 60VDC, 14mA does not reliably clean the contacts.
6.4. Test 3 -125°C (257°F) aging of V12 switches manufactured in 2007 4 switches N69-921, date code 2807K, labelled P, Q, Sand T, were tested following the procedure in section 6.1. Thermal aging time was 94.25 hrs (3.93 days).
Results are shown in Appendix B. Before aging, the sw itches were within the manufacturer' s 25m0 acceptance. After aging, the NO contacts exhibited high resistance or open circuit. Resistance readings up to 500m0 are generally acceptable in the industry.
Summary
- The 2007 manufactured switches exhibit the same anomaly as the 2015 switches.
6.5. Test 4 - 125°C (257°F) aging of V12 contacts only UV images of switch internals post-aging (Figure 10) showed that the contamination is deposited only on the NO and NC contact rivets. It was thus thought that the contamination may be related to the silver plating process of the rivets.
3 switches N69-921, date code 3613K, had their NO, NC and moving contacts removed to be aged in isolation inside a metal container. The contacts were resistance checked (Figure 12) pre and post-aging. Thermal aging time was 144 hrs (6 days).
rotor11- Page 15 of 48 Rotork Controls Limited Approved by Engineering Nuclear Engineering Report No. ER857 Issue 1 Date : 3 rd May 2016 Figure 12: Resistance checks of contacts removed from switches Thermal aging the contacts in isolation did not influence their ability to conduct current. Pre and post-aging contact resistances were 3 to 4m0.
The contacts were also observed under an optica l microscope but there were no signs of contamination . The rivets were similar in appearance pre-aging (Figure 13) and post-aging (Figure 14).
Figure 13: Contact rivet pre-aging Figure 14: Contact rivet post-aging Summary
- The results indicate there is no issue with the silver plating process of the rivets .
rotor11- Page 16 of 48 Rotork Controls Limited Approved by Engineering Nuclea r Engineering Report No. ER857 Issue 1 Date: 3rd May 2016
- 7. Supporting information and post-curing A technical report on an adhesive related issue (Ref 2) in the Large Hadron Collider {LHC) provides information supporting this Part 21 investigation. Araldite AY103-1 was used in the construction of a LHC component. The component shows an outgassing effect which has been tracked back to the adhesive. Different adhesives were investigated using a setup for measuring the amount of outgassing after 24hrs aging at 125°C {25 7° F). The two part epoxy AY103 -1 with its hardener HY951 is also used in construction of the V12 switch.
In summary the technical report states the following :
- AY103-1 is a replacement of AY103 which is no longer manufactured .
- Adhesive AY103 did not outgas but AY103-1 does.
- Higher ambient temperatures accelerate the outgassing.
- 68% of the outgas is water but the remainder isn't identified.
- Curing at 40°C {104°F) for two weeks and extracting the condensate reduces the effect.
The adhesive manufacturer, Huntsman, confirmed that AY103 was indeed withdrawn in February 2003 and replaced by AY103-1. In accordance with the 28th adaptation of the EU Dangerous Substances Directive (Directive 2001/59/EC), all products containing >0.5% DBP (Dibutyl phthalate) are to be cla ssed tox ic. AY103 would have fallen into this category therefore its formulation was changed. AY103-1 is free of DBP and phthalate esters.
Another technical paper (Ref 3) identifies the plastifiers present in the chemical makeup of the two epoxies. The report states:
- AY103 contained the plastifier dibutyl-phthalate (DBP) which is toxic.
- In the AY103 -1 formulation, DBP was replaced with plastifier di-isopropyl-naphthalene {DIPN)
- The plastifier DIPN does not take part in the curing process with the hardener and is expected to remain volatile close to the surface of the hardened epoxy.
- AYlOS -1 is another epoxy but without any plastifier. See section 8.3 for thermal aging test results with this adhesive.
Based on technical literature, the following conjecture was formed to explain the mechanism which leads to the anomaly. The adhesive is thought to outgas at temperature releasing water vapour, and with it the gaseous plastifier. The water vapour is the carrier of the contaminating material. After thermal aging the NO and NC contacts are thought to cool first (as explained in section 6.2) . The contacts thus act as a heat sink enabling water vapour to condense onto them and deposit the contam inating material.
rotor11- Page 17 of 48 Rotork Controls Limited Approved by Engineering Nuclear Engineering Report No. ER857 Issue 1 Date: 3rd May 2016 7 .1. Procedure for post-curing tests It has been confirmed from literature that the adhesive AY103-1 used in the construction of the V12 switch outgasses. The literature also indicates that a post-curing process where the condensate is extracted during thermal aging may solve the issue. The following test procedures describes the tests performed to investigate post-curing.
a) Remove screw terminals.
b) Using milliohm meter, record resistance across NC contacts. (Meter used applied 9V, 5mA max. Figure 5). Manufacturer's end-of-line acceptance level is 25m0 max.
c) Operate and hold switch plunger.
d) Record resistance across NO contacts.
e) Release plunger.
f) Repeat steps b - e until 3 NC and 3 NO measurements are obtained for each switch.
g) Fasten screw terminals h) Place all switches freely in a fan assisted oven and thermally cure at 125°C (257°F). Post-curing time for each switch is different as shown in Table 2.
i) Remove each switch when its post-curing time is complete and allow to cool.
j) Repeat resistance check following steps a - g.
k) Place each switch in its own aluminium container and perform subsequent aging at 125°C (257°F) as shown in Table 2.
Post-curing time at Subsequent aging inside Switch Identification Date code 12s c (2s1°F) 0 container at 125°C (257°F}
1 1 day 2 4 days 3 5 days 4315K 90.5 hrs (3 .77 days) 4 6 days 5 7 days 6 8 days Table 2: Post-curing time I) Repeat resistance check following steps a - g.
7.2. Test 5 - Post-curing 6 switches N69-921, date code 4315K, labelled 1 to 6, were tested following the procedure in section 7.1. As detailed in the procedure and in Table 2 the switches were post-cured for different number of days up to 8 days in a fan assisted oven . Following post-curing each switch was removed, resistance checked, then placed in a separate container. The containers were further aged to see if after being post-cured each switch would still outgas and exhibit the anomaly in a closed volume of air.
Results are shown in Appendix C. Before any aging the switches were all within the manufacturer's 25m0 acceptance. After post-curing, the NO contacts showed resistance values above 25m0 in most operations, however, this would not affect switch performance in the field . All switches remained
rotor11- Page 18 of 48 Rotork Controls Limited Approved by Engineering Nuclear Engineering Report No. ER857 Issue 1 Date: 3rd May 2016 functional after the post-curing process. However, after further aging in containers the switches exhibited open circuit I unacceptable high resistance across the NO contacts .
Summary
- After 8 days of post-curing, outgassing still occurs causing the switch to exhibit the anomaly.
7.3. Test 6 -125°C (257°F) aging of KS switches manufactured in 2012 2 switches N69-838, date code 0612K, labelled 16 and 17, were tested following the procedure in section 6.1. A drawing of switch N69-921 is shown in Appendix A. Thermal aging time was 6 days.
Results are shown in Appendix D. Before aging, the switches were within the SOOmO industry acceptance. After aging, the NO contacts exhibited high resistance or open circuit . Resistance readings above the SOOmO acceptance level are highlighted red.
Summary
- KS switches N69-838 exhibit the same anomaly as the Vl2 .
- The only difference between the two types of KS switches N69-838 and N69-926 are the contact terminals. Therefore, switches N69-926 also fall within the scope of this Part 21.
rotor11- Page 19 of 48 Rotork Controls Limited Approved by Engineering Nuclear Engineering Report No. ER857 Issue 1 Date : 3rd May 2016
- 8. Tests of unglued and glued switches using different adhesives 8.1. Test 7 - 125°C (257°F) aging of a switch without adhesive 1 switch N69-921, assembled in 2016 without adhesive applied, and labelled 18, was tested following the procedure in section 6.1. Results are shown in Appendix E. After aging for 2 days at 125°C (257°F) in a container the resistance readings were still below manufacturer's acceptance. The switch was placed back into the container and aged for a further 4.96 days. This made the NO resistance higher but still acceptable for in-field use. The switch was again placed back into the container and aged for a further 3.98 days. Contact resistances remained acceptable for in-field use.
Total aging of unglued switch= 2 days+ 4.96 days+ 3.98 days= 10.94 days Summary
- The switch performance is acceptable if no adhesive is present.
8.2. Test 8 -125°C (257°F) aging of switch assembled with Duralco 4525 A switch labelled 21 was assembled using Duralco 4525 (Figure 15) and cured in a fan assisted oven for 1 hour1.157407e-5 days <br />2.777778e-4 hours <br />1.653439e-6 weeks <br />3.805e-7 months <br /> at 121°C (250°F), as per the adhesive's datasheet. The switch was then left for 15 hours1.736111e-4 days <br />0.00417 hours <br />2.480159e-5 weeks <br />5.7075e-6 months <br /> before being tested to the procedure in section 6.1.
Figure 15: Switch 21, 4 drops of Dura/co 4525 Results are shown in Appendix F. After being aged for 10 days at 125°C (257°F) the switch exhibited open circuit mode across the NO contacts .
Summary
- Duralco 4525 outgasses to an extent that the sw itch will exh ibit the anomaly after 10 days aging at 125°C (257°F) .
rotor11- Page 20 of 48 Rotork Controls Limited Approved by Engineering Nuclear Engineering Report No. ER857 Issue 1 Date : 3rd May 2016 8.3. Test 9 -125°C (257°F) aging of switches assembled with AY105-l/HY991 The Araldite manufacturer Huntsman suggested an alternative adhesive/hardener system .
Used by switch manufacturer: AY103-1/HY951 Suggested alternative: AY105-1/HY991 AY105-1/HY991 has been found to be low outgassing in NASA tests. 2 switches labelled 19 and 20 were assembled using AY105-1/HY991 and cured in a fan assisted oven for 35 mins at 60°C (140°F), as per the adhesive's datasheet. The switches were then left for 3 hours3.472222e-5 days <br />8.333333e-4 hours <br />4.960317e-6 weeks <br />1.1415e-6 months <br /> before being tested to the procedure in section 6.1.
Results are shown in Appendix G.
Switch 19 was aged for 2 days at 125°( (257°F) and remained functional.
Switch 20 was aged for 6 days at 125°C (257°F) and remained functional.
The switches were placed back into the containers and aged further.
Switch 19 was aged for a total of 14.2 days, following which the NO contact exhibited open circuit.
Switch 20 was aged for a total of 10.1 days, following which the NO contact exhibited open circuit.
It was believed that using less adhesive would reduce the effect of outgassing. Therefore, the test was repeated with switch 50, which was assembled with just 3 small droplets of AY105-1/HY991.
Figure 16 and Figure 17 compare the quantity of adhesive applied to Switch 20 vs. Switch 50. With reduced amount of adhesive the switch passed the 125°( (257°F) 10 day aging test (results in Appendix G).
Figure 16: Switch 20, 4 drops of AY105-1/HY991 Figure 17: Switch 50, 3 small drops of AY105-1/HY991 Summary
- The extent of the anomaly is reduced by reducing the amount of adhesive used.
- AY105-1/HY991 in reduced quantity passed the 10 days aging at 125°C (257°F) .
rotor11- Page 21of48 Rotork Controls Limited Approved by Engineering Nuclear Engineering Report No. ER857 Issue 1 Date : 3 rd May 2016 8.4. Test 10 - 125°C (257°F) aging of switch assembled with Raychem 51264 A switch labelled 49 was assembled using 3 small droplets of Raychem S1264 (Figure 18) and cured in a fan assisted oven for 1 hour1.157407e-5 days <br />2.777778e-4 hours <br />1.653439e-6 weeks <br />3.805e-7 months <br /> at 85°C (185°F), as per the adhesive' s datasheet. The switch was then left for 3 hours3.472222e-5 days <br />8.333333e-4 hours <br />4.960317e-6 weeks <br />1.1415e-6 months <br /> before being tested to the procedure in section 6.1.
Figure 18: Switch 49, 3 small drops of Raychem 51264 The switch passed the 125°C (257°F) 10 day aging test. Results are shown in Appendix H.
Summary
- Raychem S1264 used in small quantity passed 10 days aging at 125°C (257°F).
8.5. Test 11-125°C (257°F) aging of switch assembled with X60 A switch labelled 59 was assembled using 3 small droplets of X60 . The adhesive has a very qu ick cure time of 2 mins at room temperature . The assembled switch was left for 2 hours2.314815e-5 days <br />5.555556e-4 hours <br />3.306878e-6 weeks <br />7.61e-7 months <br /> 40 mins before being tested to the procedure in section 6.1.
The switch did not pass 10 days aging test at 125°C (257°F). NO contacts exhibited open circuit. Results are shown in Appendix H.
Summary
- X60 outgasses to an extent that the switch will exhibit the anomaly after 10 days aging at 125*c (257°F) .
rotor11- Page 22 of 48 Rotork Controls Limited Approved by Engineering Nuclear Engineering Report No. ER857 Issue 1 Date : 3rd May 2016
- 9. Anomaly effect upon switch operation This element of the Part 21 investigation assesses 1) factors causing the anomaly, 2) estimated anomaly onset, and 3) switch performance under accident profiles.
9.1. Factors Causing Anomaly The anomaly is attributed to outgassing from the adhesive AY103-1/HY951 used in the switch construction, specifically meaning the migration of the plasticizer within the adhesive's phenol base material to the air volume contained within the actuator's electrical enclosure.
By review of published literature a number of papers were found on the subject of modelling outgassing expressed as mass flow rate. Most of the models have exponential forms that are functions of temperature and time with constant bases on material properties e.g. activation energy, gas constant, molecular mass etc. The reviewed papers all appeared to model outgassing to an infinite volume. In actuality the actuator electrical enclosure volume is finite and thus the partial pressure of outgassed material may influence the rate of outgassing. Experimental data demonstrated, for a given temperature, the anomaly would manifest itself in a shorter time period when switches were placed in a smaller enclosure. Based on the aforementioned it is determined the anomaly is a function of temperature, time, and electrical enclosure volume. A series of experiments were thus performed to assess these three factors.
The experiments were performed using three programmable test ovens and sealed metallic enclosures. Test switches were placed in sealed metallic enclosure and heated to a fixed temperature for a defined time (thermal aging). The testing was destructive, and new switches and metallic enclosures were used for every test. Prior to use, the metallic enclosures were thermally cleaned to remove any volatile materials remaining from their manufacture. The metallic enclosure construction does not incorporate any non-metallic seals or non-metallic coatings. Switch contact operation was measured using a EXTECH 380560 milliohm meter [calibrated 6/18/2015, Due 6/18/2016] which provided discrimination from lmO to 20,0000 (open circuit); alternative methods of assessing circuit continuity were assessed but dismissed . Switch contact resistance was measured prior to and post each thermal aging test (temperature x time). All resistance measurements were performed at room temperature. The switch was considered to exhibit the anomaly when the milliohm meter registered a resistance exceeding 20,0000. The switch maker's acceptance criteria is <25m0. The industry acceptance criteria is 500m0 or less.
The relationship between the three factors was assessed by varying their levels in experiments, recording the point of anomaly onset, and plotting scatter diagrams. Using regression analysis and correlation coefficient, the relation between temperature, time, enclosure volume, and anomaly onset was progressively established.
rotor11- Page 23 of 48 Rotork Controls Limited Approved by Engineering Nuclear Engineering Report No. ER857 Issue 1 Date : 3 rd May 2016 9.2. Estimated Anomaly Onset The test data reveal two forms of switch anomaly: 1) the normally open (NO) contact failed to change state, 2) the normally closed (NC) contact failed to change state. Failure to change state means the electrical contacts become sufficiently coated with outgassed material to prevent conduction of electricity. As thermal aging progresses, at any fixed temperature, the anomaly is first observed in the NO contact and then later in the NC contact when measured at room temperature . An open contact is more susceptible to the anomaly because the two contact working surfaces are fully exposed . A closed contact partly masks each working surface and requires a higher outgas concentration to become fully coated . Given the switch contacts have identical contact geometry, it is more accurate to state the anomaly occurs first in the contact that is open and later in the contact that is closed during thermal aging. Thus no distinction should be made between NO and NC contacts.
The best fit of data was obtained by plotting temperature (T) against time (t) with a correction factor applied to time (t) that represented the difference between the actuator "switch to air volume" ratio and the metallic test enclosure "switch to air volume" ratio. Smaller than actuator enclosure test volumes were used to increase the " switch to air volume" ratio and accelerate the onset of the anomaly. The term concentration factor (Cf) was thus developed and multiplied the experiment duration time, measured in seconds (T versus t
- Cf). The electrical enclosure volume in the Rotork NA actuator is slightly different for each model size. To be conservative the smallest NA actuator enclosure volume was used to develop the best fit equation. The line displayed in Figure 19 is the estimated boundary at which the anomaly onset would be observed . Above the line both open and closed contact anomalies were observed . Below the line anomalies were not observed.
Open Contact Anomaly 200 150 y = -20.4 lln(x) + 380.88
~ R2 =0.9497
~
~ 100 Q) c..
E Q)
I-50 0
0 200000 400000 600000 800000 1000000 Time Cf (sec)
Figure 19
rotor11- Page 24 of 48 Rotork Contro ls Limited Approved by Engineering Nuclear Engineering Report No. ER857 Issue 1 Date: 3rd May 2016 The boundary was found by performing a series of experiments at fixed temperatures . The duration of each experiment was progressively reduced until only the NO contacts started to exhibit the anomaly. The activity was repeated for different temperatures to develop the graph in Figure 19.
Figure 20 displays the accumulated test data from which the following can be concluded :
- 1. At time t=O all the switches functioned correctly .
- 2. Switches function correctly from t=O (sec) to any green triangles on a constant temperature line.
- 3. Switches function correctly from temperature T=0 °C (32°F) to any green triangles on a constant time line.
- 4. Switches function correctly where constant temperature and constant time lines intersect and green triangles straddle the intersection points; two blue extension lines showing one intersection example.
- 5. Based on Rotork NCR data no utility has reported unreliable switch operation, thus at 49°C (120°F) and below the switches function correctly.
- 6. The effect of temperature is non-linear upon anomaly onset.
- 7. At 175°C (347°F) the onset of open contact and closed contact anomaly is less distinguishable.
- 8. At lower temperatures the Log anomaly onset boundary overstates the anomaly onset.
- 9. At 90°C (194°F) the anomaly was not observed . However, the test for 3,300,000 seconds at 90°C (194°F) exhibited elevated contact resistance in 50% of the open contacts. The measured resistances exceeded the supplier acceptance criteria of <25m0 but did not exceeded the industry 500m0 acceptance criteria.
rotor11- Page 25 of 48 Rotork Controls Limited Approved by Engineering Nuclear Engineering Report No. ER857 Issue 1 Date : 3 rd May 2016 250 All Test Data Open Contact Anomaly Only 200
- Open & Closed Contact Anomaly
.. No anomaly
- Log. !Anomaly Onset Boundary) 150 50 No reported switch anomalies by industry under mormal operating temperatures (48C max) 0 0 500000 1000000 1500000 2000000 2500000 3000000 3500000 4000000 4500000 Tlrne*Cf (sec)
Figure 20 9.3. Switch performance under accident profiles The figures in the following pages show a number of temperature time profiles applicable to nuclear power plants that use Rotork NA actuators that use Rotork NA actuators. Each test was performed using eight new test switches placed in a new metallic enclosure having a volume of one US gallon.
The enclosure volume and number of switches provided a concentration factor of 1.125 thus assuring margin in the testing. In all cases the switches operated after the test and met the industry acceptance criteria of 500m0 or less. A large proportion of the switches met the supplier acceptance criteria of
<25m0. Switch resistances were measured before and after test at room temperature . All test instruments were calibrated under the Rotork Appendix B quality program. The data below demonstrates the test switch temperatures either exceeded the computed actuator switch temperature or equaled the oven air temperature.
Three temperature lines are displayed in each graph:
- Tao pin t is the computed temperature time profile of the switches in an actuator switch mechanism and add-on-pack, based on the environmental air temperature time profile.
- Tair is the measured environmental (oven) air temperature for the provided profile.
- T(8 t est s witches) is the measured temperature profile of 8 test switches, within the closed metallic enclosure, exposed to the Tair temperature time profile.
rotor11- Page 26 of 48 Rotork Controls Lim ited Approved by Engineering Nuclear Engineering Report No. ER857 Issue 1 Date: 3 rd May 2016 Priori ty 1
__.,_ TiW 40 0 5000 10000 15000 lOOO'l l11ne(~c)
Figure 21 a Measured at 20C 4/15/16 Priorityl test data As provided resistance data mJH ohms Sample No-> .. 4/15-1 " 4/15 -2 4/15-3 4/15-4 4/15 -S 4/15-6 4/15-7 4/15 -8 NC NO NC NO NC NO NC NO NC NO NC NO NC NO NC NO 5.8 4.2 4.0 3.3 3.3 4.0 2.4 5.2 3.4 3.6 4.8 3.4 3.2 4.2 3.0 3.0 5.1 3.4 4.7 2.8 4.0 3.5 2.8 3.6 3.7 3.5 3.5 3.2 3.8 3.9 2.9 3.0 4.4 2.9 4.4 3.0 3.9 3.3 2.9 3.2 3.1 3.0 3.9 3.2 3.6 3.6 2.9 2.8 4.1 2.8 4.0 2.9 3.6 3.4 2.9 3.4 3.0 3.2 4.7 3.1 3.9 3.9 2.9 2.8 4.2 2.8 4.0 2.8 3.6 3.3 3.0 3.2 3.3 3.5 4.1 3.1 3.8 4.0 3.0 2.8 4.2 2.8 4.0 2.6 3.1 2.8 3.0 3.1 3.4 3.0 4.1 3.0 4.1 3.7 3.0 2.7 Std 3.9 4.5 0.7 2.7 3.1 0.5 4.3 4.2 0.3 2.5 2.8
- 0. 3 3.5 3.6 0.3 3.0 3.3 0.4 3.0 2.9 0.2 3.0 3.5 0.8 3.4 H
0.2 2.9 3.2 0.3 4.6 4.2 0.5 2.9 3.1 0.2 4.4 3.8 0.4 3.3 3.8 0.3 3.2 3.0 0.1 2.7 2.8 0.1 Measured at 60C (140f) 4/18/16 Post thermal aging using Priority l temp time profile Sample No-> ,,. 4/15-1 ' 4/15-2 ' 4/15-3 4/15-4 4/15 -5 4/15-6 4/15 -7 4/15 -8 NC NO NC NO NC NO NC NO NC NO NC NO NC NO NC NO 2.2 3.9 2.3 4.2 2.6 3.9 2.6 4.1 2.4 2.3 3.3 2.3 4.7 2.2 7.2 Measured at 20C 4/19/16 Post the rmal aging usi ng Priority l temp time profile Sample No -> ,. 4/15-1 .. 4/15-2 ,,. 4/15-3 4/15-4 4/15 -S 4/15-6 4/15 -7 4/15 -8 NC NO NC NO NC NO NC NO NC NO NC NO NC NO NC NO 2.6 iO 3.0 14.0 3.4 6.2 3.3 5.0 2.8 'DO 3.3 3.8 3.4 5.3 2.8 6.0 2.9 12.0 3.0 5.5 3.8 6.0 3.0 5.2 3.1 3.2 3.9 3.6 4.0 3.1 4.3 3.0 6.0 3.0 4.8 4.1 7.3 3.6 5.9 3.0 eo.11 3.2 3.2 3.6 4.1 3.2 3.6 2.9 3.3 3.0 5.2 4.2 7.6 4.1 4.0 3.1 ~ 3.6 3.0 3.6 4.0 3.3 4.0 3.0 3.4 2.9 3.9 4.4 7.0 4.9 3.5 3.0 so.o 3.0 2.9 3.7 4.1 3.3 3.4 3.1 3.0 2.8 3.7 4.2 10.2 4.1 3.2 3.3 ao.o 3.0 2.7 3.8 3.9 3.2 3.2 Ave Std 3.1 2.9 0.2 3.1 8.7 9.9 2.9 2.9
- 0. 1 3.1
- 5. 7 3.7 5.0
- 4. 2 0.5 6.6 7.3 1.4 4.0 O.ti 3.1 4.3 1.1 2.9 3.0 0.2 C'jS.0 53.6 19.5 3.1 3.2 0.2 2.8 3.2 0.5 3.8 3.6 0.1 4.1 4.2 0.5 3.3 3.2 0.2 3.1 3.9 1.0
~the contac1 resistance meets the industry accep tan~ wtena of 5CO mili ohms memo: the contact resistance mel!!ts the supplier accep tan ce criteria of <25 mill ohms Figure 21b
rotor11- Page 27 of 48 Rotork Controls Limited Approved by Engineering Nuclear Engineering Report No. ER857 Issue 1 Date : 3 rd May 2016 Priority2 1101..
!COO
~
~
800
~ - T,111
! 70.tJ bO.O SO.Cl 40.U 150000 lWOOJ Figure 22 a Measured at 20C 4/19/1!Jl6 Priority2tHtdata As provided resistance data mili ohms Sam ple No -> ,.4/19-1 "4/19 -2 ..4/l!J-3 ' 4/19-4 ' 4/19 -5 '"4/19-6 ' 4/19 -7 ' 4/19 -8 NC NO NC NO NC NO NC NO NC NO NC NO NC NO NC NO
- 2. 5 2.8 3.6 3.8 3.3 3.7 4.4 3.3 2.5 3.2 3.4 5.3 2.5 2.7 4.3 4.9 3.6 2.7 3.7 3.4 3.3 3.7 4.2 3.4 3.3 2.8 3.1 4.4 2.8 2.7 3.9 5.9 3.4 2.6 3.8 3.4 3.4 3.1 4.2 3.4 4.6 2.8 3.9 4.2 2.9 2.6 3.6 7.0 3.2 2.6 4.0 3.1 3.4 3.1 3.9 3.4 4.6 2.7 3.3 3.9 2.9 2.5 3.4 7.5 3.2 2.S 3.6 3.3 3.2 2.8 3.3 3.1 4.0 2.9 3.1 3.6 3.0 2.5 3.0 3.6 3.3 2.S 3.4 2.9 3.0 2.9 4.0 3.1 4.2 2.7 2.9 3.3 3.1 2.5 3.3 3.1 3.1 2.6 3.5 2.9 2.9 2.8 4.0 2.9 3.9 2.7 3.1 3.3 2.8 2.5 3.1 3.3 Av* 3.2 2.6 3.7 3.3 3.2 3.2 4.0 3.2 3.9 2.8 3.3 4.0 2.9 2.6 3.S 5.0 Std 0.34 0.11 0.1!) 0.32 0.1!J 0.'19 O.'IS 0.1!J 0.75 0.18 0.33 0.71 0.19 0.10 0.46 1.80 Measured at 60C (140F) 4/23/1!Jl6 Post thermal aging using Priority 2 temp time profile Sam ple No -> "4/ ~l ,.4/19 -2 ,.4/19 -3 I' 4/19 . 4 ' 4/19 -5 ' 4/19-6
- 4/19 -7 ,. 4/J!j -8 NC NO NC NO NC NO NC NO NC NO NC NO NC NO NC NO 2.3 12.0 2.5 10.0 2.3 5.3 2.6 6.8 2.4 5.2 2.4 5.0 2.9 3.8 2.4 6.0 Measured at 20C 4/25/1!Jl6 Post thermal aging using Priority 2 temp time profile Sample No -> ,.4/19-1 "'4/ 19 -2 "4/19 -3 ..4/19*4 "4/19
- 5 ' 4/19 -6 "4/ 19 -7 "4/19
- 8 NC NO NC NO NC NO NC NO NC NO NC NO NC NO NC NO 3 8.3 4.7 S.6 4.1 4.4 5.6 13 2.4 5 3 5.3 3.3 4.6 3.1 7.9 3.6 7.1 3.3 3.9 3.7 5.2 12 2.8 4.8 3.2 4.9 3.6 3.5 4 7.7 3.9 6.2 3.9 3.7 3.3 3.7 6.3 5.6 3.2 6,3 3.5 4.6 3.8 4.5 3.8 5.9 3.8 4.9 6 4.2 5 2.7 6.5 4.4 3.1 3.4 4.3 3.7 4 4.6 4.5 4.1 4.9 3.6 3.3 5.5 3.7 6.5 5.1 3.2 3.4 3.8 4.2 2.9 4.1 4.5 3.5 3.9 5.5 3.5 4.2 3.5 6.8 5.9 3.5 4.2 3.5 39 3.1 2.8 5.2 5.1 Ave 4.2 "3.9 4
"'s.2 ...
6.6 3.6
"'3.7 4.7
'4.4 3
"'3.4 6.7
'6.3 4
"3.3 3.3
"'4 .4 3.5
"'3 .4 3.6
'4.2 3.9 "1.8 2.7 "3.4 4.4 4.4 5.3 "s.s Std 0.21 "1.26 *1.39 0.33 "o.79 *o.43 O.ss 0.41 "1.03 "0.12 O.so O.n 0.73 O.so "1.20 llWtaO: lbe contact resistance meets the mdustry acceptance cnter1a of 5CX) m1l1 ohms memo: the contilct resi stance meets the su pplie r ;1cce ptance a1t en;1 of <25 m1l1 ohms Figure 22b
rotor11- Page 28 of 48 Rotork Controls Limited Approved by Engineering Nuclear Engineering Report No. ER857 Issue 1 Date : 3 rd May 2016 Pr io r ity 3 100
"° 70 memo: for this test the oven profile temperatures between h(\ the start and end point were
£ elevated 3 centlarade to assure temperature maralne.
~
~
- Taop1nt
- - Ta1r I
40 20 10 20000 40000 60000 1()00)()
r1me(sec. 1 Figure 23a Menu*ed1120C 4/2S/'l016 Priority3tu1du1 A*p!'Ovidedreslu1nced11tamlllohm*
Sample No -> ' 4/25-1 NC
!1.0 9.4
'4/25
- 2 NC 1.S NO 12
- ..,,JS . )
NC NO
' 4/2S
- 4 NC NO
' 4/2S -S NC NO
' 4/2S
- 6 NC l .6 NO u
' 4/2S
- 7 NO
' 412s -1 NO u 4.7 u
..*1* 12 u
<1
,, 17 17 u
.. ..*... .,"u u
31 31 17 .. . u
... ...'*' u
" u
- ~
u u
"' 1'2 Menu1ed1t60C( l40f l *126'2016 Post thermil iglng using Prior ity) temp time pro Ille 5-lmpleNo -> "*12s-1 NO 5.1
- 12s -2 4/27/1016 NO u
..4/2S
- l NO 5.0 .
' 4/1S -4 NC
- 4/2S *S NC
- 4/2S *6 NO u
' 4/25 *1 Postthe1m1l1gingusingPrioritylttmptimep<ofile S...mpleNo * >
"412s.1 NC
- u.
NO
- 412s -2 u
NO s.1 "41zs .1 NO u
' 4125 .4 NC u
- O
- 4/2S -S NC 17
' 411s -6 u
NO 10
' 412s -1 NO NC NO u
u
- 4/2S *I NC NO 1U 17 u
.,u ......
u u
u
.,u l .0 J.1
- .1 u
u u ....,
u u
- .1 {
u u
7.*
u 17 31
- .", l .7 l.1
~:~
'3.t
.,, <.o "u
~~ '-u ~~
"" "0.41 Ci0914'<1 re.1Ui1n<e meet$ the 1nduUf)' le<l'l)Unu* r111em1ol '!OJ m>h ohm'
'0. 39
"" 'o.n '0.11 *2.ll me1110; tn. QOl'IU<-1 re ols11nce mee t$ the suppl ie r acu ptance uite111 o f <n mill ohm s Figure 23b
rotor11- Page 29 of 48 Rotork Controls Limited Approved by Engineering Nuclear Engineering Report No. ER857 Issue 1 Date: 3rd May 2016 Summary Three factors cause the anomaly onset namely temperature, time, and enclosure volume (concentration factor) . An equation relating the three factors to anomaly onset has been developed and is provided for information purposes only - not for prediction. The equation accuracy has not been verified against an adequate sample of design based temperature time accident profiles. The equation is not linear. Testing demonstrated anomalies were not observed at 90°C and below.
Published literature suggest that some level of outgassing always occurs.
When temperature varies with time, estimating anomaly onset is far more complicated and requires the integration of the outgassed material mass. Furthermore, it would be necessary to established if an elevated temperature for a brief period of time would then permit the outgassing of material at lower temperatures for an extended period . Given the available time, the latter could not be accomplished and verified by experimentation . Switch performance was thus evaluated by experimentation . Switches within closed metallic enclosures having an actuator representative volume were thermally aged using accident condition temperature time profiles. The test results indicate the switches, though degraded, would operate correctly after completing the thermal aging profiles displayed in Figure 21 through Figure 23.
rotor11- Page 30 of 48 Rotork Controls Limited Approved by Engineering Nuclear Engineering Report No. ER857 Issue 1 Date : 3rd May 2016
- 10. Results from independent test lab An independent test laboratory, Exova, was requested to investigate the contamination on contact rivets of micro-switches that had exhibited the anomaly after being thermally aged in-house at 125°C (257°F). Contacts were analysed by FTIR (Fourier-Transform Infra-Red) spectroscopy and by SEM-EDX (Scanning Electron Microscope/Energy Dispersive Using X-Ray) analysis.
FTIR spectroscopy is a valuable tool to study the molecular structure of organic materials.
SEM-EDX enables an elemental analysis of the contamination.
Figure 24 compares the infrared spectra of the residue collected from the NO contact of an aged switch manufactured in 2015 vs. an aged switch manufactured in 2007. Both infrared fingerprints virtually mirror each other which suggest that they appear to be the same type of contaminant. The following infrared bands were observed :
- 2915, 2850, 1415 cm -1 which are likely to relate to alkyl groups (CH2, CH3)
- 1535 cm-1 which could relate to alkyl groups (CH2, CH3) or amide (NH-C=O) groups
- 1650 cm-1 which could relate to alkene (C=C), aromatic groups ( 1 ~ 1 ), amide (NH-C=O) or amine groups (R-NH-)
- 1310 cm-1 which could relate to amine groups (R-NH -) or alcohol groups (-OH)
- 1030 cm-1 which could relate to carbonyl groups (C=O) or alcohol groups (-OH)
- 720 cm -1 which could relate to aromatic groups (V ), chlorinated compounds or methylene groups (CH2)
The infrared spectrum of the residue collected from the NO contact rivet of the 2007 switch was compared to the infrared fingerprints of the Araldite adhesive (Figure 25), the DAP case (Figure 26) and the nylon 66 operating plunger (Figure 27) as they are the only organic components and therefore the only possible direct or indirect sources of contamination. The infrared spectrum of the residue did not match any of the organic materials.
rotor11- Page 31 of48 Rotork Controls Lim ited Approved by Engineering Nuclear Engineering Report No. ER857 Issue 1 Date : 3rd May 2016
- POLYM50SO: resi due from bottom contact rivet of Sw itch J (2015! - 6 da>JS at 125"C
'POL YM5053: residue from bottom contact rivet of Switch . 2007) - 4 days at 125"C 9 7 ~"'~'~.4/r,JJll'J/I.~ ... .
96 -
- ~*-ww~~~~\ .~~:.
~* .\ ~
~ ,*
95 -
1\\
~
94 - 1650
- ~~I 10~ J 2860 1310 93 - I 2916 1635 1415 92 - 720 91 -
4000 3000 2000 1000 Wavenumbers (cm -1)
Fig ure 24: Infrared spectra of residue on NO contact rivets 9s :PoLYM5053: residue from bottom contact rivet of Switch s (2007) - 4 d;iys ;it 125"C
- POLYM3246: Araldite Gl ue (24hrs;it WC) an;ilysed i n 2011 I-
~
93 :
92:
91 :
so:
89 -
4000 3000 2000 1000 Wavenumbers (cm-1)
Figure 25: Infrared spectra of residue from NO contact rivet and Araldite adhesive
rotor11- Page 32 of 48 Rotork Controls Limited Approved by Engineering Nuclear Engineering Report No. ER857 Issue 1 Date : 3 rd May 2016 98-POLYM!i053: residue from bottom contact nvet of Switch S (2007) - 4 days at 125"C
- POLYM3210: new OAP C3Se an:ilysed in 2011 97 ~.-..J.,J, 96-96-0~
94-93-92 -
91-so:
4000 3000 2000 1000 Wavenumbers (cm-1)
Figure 26: Infrared spectra of residue from NO contact rivet and OAP case 98 *POL YM5053: residue from bottom contact rivet of Switch S (2007) - 4 days at 125"C
- POL YM5053: Latamid 66 operating plunge- of switch S (2007) - 4 days at 125"C 1440 92*
1535 1460 91
- so:
4000 3000 2000 1000 W;ivenumbers (cm-1)
Figure 27: Infrared spectra of residue from NO contact rivet and nylon 66 operating plunger
rotor11- Page 33 of 48 Rotork Controls Limited Approved by Engineering Nuclear Engineering Report No. ER857 Issue 1 Date: 3rd May 2016 SEM photographs of the NO and moving contact rivets of an unaged 2015 switch, an aged 2015 switch and an aged 2007 switch are shown in Table 3. The SEM photographs show clear contamination on both the NO and moving contact rivets of aged switches. The pattern was consistently different between the NO and moving rivets and suggests the contamination deposited on the NO contact is then transferred to the moving contact during operation. This observation is in line with the results observed from in-house tests (Figure 6 to Figure 9).
Switch NO contact rivet Unaged, manufactured in 2015 Aged, manufactured in 2015 Aged, manufactured in 2007 Table 3: SEM photographs Elemental analysis results are compiled in Table 4. Results show the presence of a significantly higher level of carbon (C) on the aged contacts relative to the unaged contacts . This suggests that the contaminant appears to be mainly organic, which is in line with FTIR results. A significantly higher level of oxygen (0) was observed on the aged contact rivets, especially the sample from 2007, which could suggest the presence of oxidative products.
rotor11- Page 34 of 48 Rotork Controls Limited Approved by Engineering Nuclear Engineering Report No. ER857 Issue 1 Date : 3 rd May 2016 Switch Contact location c 0 Mg Ag Cd Si Ca Cr Fe Ni Cu Br Unaged , NO 1 2.9 3.5 0.5 83.1 9.3 - - - - - - -
manufactured in 2015 Moving 1 2.2 1.0 0.4 94.5 1.9 - - - - - - -
1 54.1 5.4 - 28.8 11.7 - - - - - - -
NO 2 53.0 4.7 - 31.4 11.0 - - - - - - -
Aged, 31*1 7.5 2.4 - 84.2 5.9 - - - - - - -
manufactured in 2015 1 45 .2 6.5 - 42.3 6.0 - - - - - -
Moving 2 42.8 6.9 - 44.8 5.6 - - - - - - -
31*1 4.5 0.5 93.3 1.8 - - - - - -
1 19.9 13.0 - 62.0 5.1 - - - - - - -
NO 2 31.3 10.5 0.2 52.1 5.9 - - - - - - -
Aged , 31*1 2.8 2.9 0.5 89.9 3.8 - - - - - - -
manufactured in 2007 1 29.2 17.0 0.3 47.8 - 0.6 0.3 - - - - 4.9 Moving 2 32.6 12.2 0.3 47.7 - - - 1.2 4.3 0.5 - 1.3 31*1 12.l 11.1 0.3 73.2 2.9 - - - - - 0.3 -
l*l away from main contaminated area Table 4: EDX elemental analysis results indicating % of each element at spectrum location Summary
- The contaminant appears to be mainly organic. This is in agreement with literature (section 7), test results of an unglued switch (section 8.1) and UV images (Figure 10 and Figure 11) which all identify the adhesive being the root cause .
- The contaminating residue is not formed on the moving contact rivet but is transferred from the NO contact during operation.
rotor11- Page 35 of 48 Rotork Controls Limited Approved by Engineering Nuclear Engineering Report No. ER857 Issue 1 Date: 3rd May 2016
- 11. Conclusion The altered adhesive formulation outgases at elevated temperatures and deposits an insulating material layer onto the switch internal electrical contacts as it cools. The deposit of insulation material results in contact resistances exceeding the supplier acceptance criteria of 25m0 max, the industry 500m0 max acceptance criteria and in some cases causes an open circuit.
It should be noted that tests were performed at constant temperatures . The effect of varying temperature with time has not been investigated in the available time and the possibility exists that an initial high temperature for a short period could subsequently cause outgassing to continue at lower temperatures. Rotork thus recommend that the risk be assessed by testing switches under representative temperature time profiles.
In tests performed by Rotork the anomaly was not observed at temperatures 90°C (194°F) and below.
The maximum service temperature for A range and NA5/5E actuators is 70°C (158°F) thus they can be excluded from the scope of this Part 21.
Nuclear power plants that use Rotork NA actuators provided temperature profiles which also were tested . Anomalies were not observed using these profiles.
Rotork are recommending the replacement of the switches in the affected orders which are identified in the Part 21 notification letter.
rotor11- Page 36 of 48 Rotork Controls Limited Approved by Engineering Nuclear Engineering Report No. ER857 Issue 1 Date : 3rd May 2016
- 12. References
- 1) Czarnecki, N. (2012) Nema White Paper. Cadmium in Electrical Contacts [online] . Rosslyn, VA . Available from :
https ://www.google.co.uk/url?sa=t&rct=j&g=&esrc=s&source=web&cd=l&ved=OahUKEwjK SdCdt7PMAhWjBsAKHbPtBbcQFggtMAA&url=https%3A%2F%2Fwww.nema.org%2FProducts
%2FDocuments%2Fnema%2Bwhitepaper%2Bon%2Bcadmium%2Bin%2Belectrical%2Bcontac ts.pdf&usg=AFQjCNFevJ949rWGVG650efdbr4ejjT6kw&sig2=s1UgMfEIFnKDWWhowkA41g
[Accessed 29 April 2016)
- 2) Buffing, M . (2009) Outgassing of glue in the Outer Tracker of LHCb; measurements with a quadrupole mass spectrometer [online] . BSc, Vrije Universiteit Amsterdam . Available from :
http ://www.nikhef.nl/pub/experiments/bfys/lhcb/Theses/bachelor/2009 MaartenBuffing.p df [Accessed 29 Apri l 2016)
- 3) Tuning, N., et al. (2011) Ageing in the LHCb outertracker: Aromatic hydrocarbons and wire cleaning. Nuclear Instruments and Methods in Physics Research A . 656, pp. 45-50
rotor11- Page 37 of 48 Rotork Controls Limited Approved by Engineering Nuclear Engineering Report No. ER857 Issue 1 Date: 3'd May 2016 C""1'10 N I ~
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rotor11- Page 39 of 48 Rotork Controls Limited Approved by Engineering Nuclear Engineering Report No. ER857 Issue 1 Date: 3'* May 2016 SPECIFICA TIQ N MAX. ACTUATING FORCE 2.8 N MIN . RELEASE FORCE 11 N MAX FREE POSITION 197mm ITTDTll CONN ECTIO N DIAGRAM OPERA TING POSITION 18 1f l6 7mm NOTE OPERATING BUTT OH MAY 127mm BE DEPR:ESSfD R.USH WTTH CASE SEALING IP40 D
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rotor11- Page 40 of 48 Roto rk Controls Limited Approved by Engineering Nuclear Engineering Report No. ER857 Issue 1 Date: 3 May 2016 Appendix B- Pre and post-aging resistance results, Test 1 and 3 All results in Ohms.
Test 1-125' C (257'Fl aging of V12 switches manufactured in 2015 Results before ageing Into oven Out of oven Total aging Results after ageing 011eration 1 011eration 2 011eration 3 011eration 4 011eration 5 011eration 6 Date Code !:ill. WQ !:ill. WQ !:ill. WQ !:ill. WQ !:ill. WQ !:ill. WQ F 3715K 0.003 0.003 0.004 0.005 0.004 0.005 0.004 0.003 0.005 G 3715K 0.004 0.005 0.004 0.003 0.005 0.003 14:00 08:00 0.005 0.005 0.005 138 hrs H 3715K 0.004 0.005 0.004 0.004 0.004 0.004 Tue Mon 0.006 0.006 0.010 0.006 0.007 (5.75 days) 3715K 0.004 0.004 0.006 0.003 0.005 0.004 26/01/16 01/02/16 0.004 0.005 0.005 3715K 0.004 0.004 0.004 0.004 0.004 0.003 0.005 0.006 0.008 Test 3 -125'C (257'Fl aging of V12 switches manufactured in 2007 Results before ageing Into oven Out of oven Total aging Results after ageing 011eration 1 011eration 2 011eration 3 011eration 4 011eration S 011eration 6 Date Code !:ill. WQ !:ill. WQ !:ill. WQ !:ill. WQ !:ill. WQ !:ill. WQ p 2807K 0.004 0.008 0.008 0.007 0.008 0.007 0.004 0.279 0.004 184 0.004 0.124 15:45 14:00 Q 2807K 0.005 0.008 0.006 0.007 0.006 0.007 94.25 hrs 0.004 0.009 0.005 Mon Fri s 2807K 0.014 0.014 0.012 0.007 0.009 0.012 01/02/16 05/02/16
{3.93 days) 0.004 0.004 0.004 T 2807K 0.005 0.009 0.006 0.007 0.006 0.007 0.004 0.642 0.004 0.030 0.007 0.049
- indicates open circuit
- indicates that the resistance value was fluctuating between several ohms, to hundreds of ohms, to open circuit
rotor11- Page 41of48 Rot ork Co ntro ls Limited Appro ved by Engineering Nuclear Enginee ring Report No. ER85 7 Issue 1 Date : 3'd May 2016 A1rnendix C - Resistance results (!Ost-curing and subseguent agi ng, Test 5 All resu lts in Ohms.
Post-curing of each switch in a fan assisted oven Results before post-curing Into oven Out of oven Total aging Results after post-curing Oi;ieration 1 Oi;ieration 2 Oi;ieration 3 Oi;ieration 4 Oi;ieration 5 Oi;ieration 6 Date Code !:ill. ~ fil ~ fil w_g_ !:ill. ~ !:ill. ~ !:ill. ~
1 4315K 0.004 0.007 0.005 0.006 0.007 0.006 11:55 Fri 12/02/16 1.02 days 0.003 0.023 0.004 0.018 0.002 0.077 2 4315K 0.007 0.010 0.006 0.008 0.006 0.006 11:50 Mon 15/02/16 4.01 days 0.007 0.040 0.007 0.012 0.008 0.014 11:30 3 4315K 0.005 0.005 0.004 0.005 0.005 0.005 15:00 Tue 16/02/16 5.15 da ys 0.004 0.086 0.005 0.047 0.005 0.068 Thur 4 4315K 0.002 0.009 0.004 0.006 0.004 0.006 11:30 Wed 17/02/16 6 days 0.005 0.066 0.005 0.006 0.006 0.008 11/02/16 5 4315K 0.004 0.007 0.005 0.008 0.005 0.006 11:30 Thu 18/ 02/16 7 da ys 0.006 0.077 0.006 0.176 0.006 0.088 6 4315K 0.004 0.005 0.004 0.005 0.004 0.005 11:30 Fri 19/02/16 8 days 0.005 0.150 0.007 0.159 0.006 0.096 Further aging of i;iost-cured switches in metal containers Results before ageing Into oven Out of oven Total aging Resu Its after ageing Oi;ieration 1 Oi;ieration 2 Oi;ieration 3 Oi;ieration 4 Oi;ieration 5 Oi;ieration 6 Date Code !:ill. ~ fil ~ fil w_g_ !:ill. ~ !:ill. ~ !:ill. ~
1 4315K 0.010 0.024 0.011 2 4315K 0.006 4.800 0.016 0.319 0.018 0.243 Above post-c ured switches were taken and 14:30 3 4315K 90.5 hrs 0.007 0.010 0.048 each swit ch was pl aced in its own Fri 09:00 Tue 23/02/16 4 4315K (3. 77 days) 0.004 49.700 0.008 3.450 0.006 1.200 enclosure. 19/02/16 5 4315K 0.004 0.059 0. 005 0.250 0.005 0.164 6 4315K 0.009 0.028 0.040
- indicates open circ uit
- indicates that the resistance value was fluctuating between several ohms, to hundreds of ohms, to open circuit
rotor11- Page 42 of 48 Roto rk Controls Limited App roved by Engineering Nuclear Enginee ring Report No. ER857 Issue 1 Date: 3'* May 2016 Appendix D - Resistance results of KS switches, Test 6 All results in Ohm s.
Results before ageing Into oven Out of oven Total aging Results after ageing Operation 1 Operation 2 Operation 3 Operation 4 Operation 5 Operation 6 Operation 7
~ !'li..Q !'YS,. !'li..Q !'YS,. !'li..Q !'YS,. !'li..Q ~ !'li..Q ~ !'li..Q ~ !'li..Q 16 0.011 0.077 0.024 0.018 0.012 0.080 15:30 Tue 15:30 M on 0.005 0.507 0.018 0.492 0.011 0.369 0.008 0.236 6 da ys 16/02/ 16 22/ 02/ 16 17 0.007 0.054 0.020 0.038 0.017 0.020 0.036 1.423 0.054 3.230 0.022 0.720 0.016 2.170
rotor11- Page 43 of 48 Rotork Contro ls Li mited Approved by Engineering Nuclear Engineering Report No. ER857 Issue 1 Date : 3'd May 2016 Append ix E - Resistance results of switch aged w ithout adhesive, Test 7 All results in Ohms.
Results before ageing Into oven Out of oven Total aging Results after ageing Operation 1 Operation 2 Operation 3 Operation 4 Operation 5 Operation 6 Operation 7 WS,,!@WS,,!@WS,,!@ WS,,!@WS,,!@WS,,!@WS,,!@
13:55 Mon 13:55 Wed 18 0.006 0.004 0.005 0.004 0.007 0.005 29/02/ 16 02/03/16 2 days 0.004 0.020 0.004 0.012 0.004 0.018 0.004 0.005 Further aging of above switch to complete total 7 days aging Results before ageing Into oven Out of oven Total aging Results after ageing Operation 1 Operation 2 Operation 3 Operation 4 Operation 5 Operation 6 Operation 7 WS,,!@WS,,!@WS,,!@ WS,,!@WS,,!@WS,,!@WS,,!@
14:55 Wed 13:55 Mon 18 Above switch w as aged f urther 4.96 days 0.012 0.004 0.006 0.138 0.014 0.227 0.068 0.077 02/03/16 07 /03/16 Further aging of above switch to complete total 10 days aging Results before ageing Into oven Out of oven Total aging Results after ageing Operation 1 Operation 2 Operation 3 Operation 4 Operation 5 Operation 6 Operation 7 ws,_ !@ ws,_ !@ ws,_ !@ ws,_ !@ ws,_ !@ ws,_ !@ ws,_ !@
08:30 Fri 08:00 Mon 18 Above switch was aged fu rt her 3.98 days 0.007 0.117 0.082 0.006 0.174 0.015 0.006 0.017 01/04/16 04/04/16 Total aging time for switch 18 =2 + 4.96 + 3.98 =10.94 days
rotor11- Page 44 of 48 Rot ork Co ntrol s Li mited Approved by Engi neering Nuclear Enginee ring Report No. ERSS 7 Issue 1 Date : 3'* May 2016 Appendix F - Resistance results of switch aged with Duralco 4525, Test 8 All results in Ohms.
Results before ageing Into oven Out of oven Total aging Results after ageing O~eration 1 O~eration 2 O~eration 3 O~eration 4 O~eration 5 O~eration 6 O~eration 7
!:ill:. !UQ WS:. !UQ !:ill:. !UQ WS:. !UQ !:ill:. !UQ !:ill:. !UQ !:ill:. !UQ 08:30 Fri 08:30 Mon 21 0.004 0.004 0.005 0.004 0.007 0.004 10 days 0.027 0.178 0.250 0.186 01/04/16 11/04/16
- indicates o pe n ci rcuit
- indicates that the resistance value w as fluctuating between several ohm s, to hundreds of ohms, t o open circuit
rotor11- Page 45 of 48 Rotork Controls Limited Appro ved by Engineering Nu clear Engi neeri ng Re port No. ER857 Issue 1 Date : 3*d M ay 2016 Appendix G - Resistance results of switches aged w ith AY105-1/HY991, Test 9 Al l results in Ohms.
Thermal aging of switches assembled with AY105-l[HY991 Results before ageing Into oven Out of oven Total aging Results after ageing Operation 1 Operation 2 Operation 3 Operation 4 Operation 5 Operation 6 Operation 7
~ !:il.Q ~ !:il.Q ~ !:il.Q ~ !:il.Q ~ !:il.Q ~ !:il.Q ~ !:il.Q 13:10 Thu 19 0.004 0.004 0.005 0 .004 0.006 0.004 2 days 0.003 0.005 0.003 0.004 0.003 0.004 0.003 0.004 13:10Tue 08/03/16 08/ 03/16 13:10 Mon 20 0.003 0.003 0.004 0.003 0.004 0.003 6 days 0.004 0.013 0.004 0.011 0.004 0.010 0.004 0.007 14/03/16 Further thermal aging of above switches Results before ageing Into oven Out of oven Total aging Results after ageing Operation 1 Operation 2 Operation 3 Operation 4 Operation 5 Operation 6 Operation 7
~ !:il.Q ~ !:il.Q ~ !:il.Q ~ !:il.Q ~ !:il.Q ~ !:il.Q ~ !:il.Q 15:30 Tue 19 12days 5hrs 0.004 0.008 0.014 0.017 Abo ve switches were aged f urther in thei r 10:30 Thu 29/03/16 enclosures. 17/03/16 14:00 Mon 4da ys 3hrs 20 0.004 0 .181 0.096 0.010*
21/ 03/16 30mins Total aging t ime for sw itch 19 = 14 days, 5 hrs Total aging ti me fo r sw itch 20 =10 days, 3 hrs, 30 mins
- in dicat es o pen circ uit
- denotes a value that was inconsistent, i. e. the ohm value moved around the va lue recorded, it did not sett le.
rotor11- Page 46 of 48 Roto rk Contro ls Li mited Approved by Engineering Nuclear Engineering Report No. ER857 Issue 1 Date: 3'd May 2016 Thermal aging of switch assembled with reduced quantity of AY105-1/HY991 Results befo re ageing Into oven Out of oven Total aging Results after ageing Operation 1 Operation 2 Operation 3 Operation 4 Operation 5 Operation 6 Operation 7
!'fil !':![Q !'fil !':![Q !'fil !':![Q !'fil !':![Q !'fil !':![Q !'fil !':![Q !'fil !':![Q 13:00 Thu 08:00 Mon lOdays 50 0.006 0.004 0.018 0.004 0.012 0.004 0.030 0.078 0.035 0.008 0.005 0.007 0.170 0.005 14/04/16 25/04/16 19hrs
rotor11- Page 47 of 48 Rotork Controls Limited Approved by Engineering Nuclear Enginee ring Report No. ER857 Issue 1 Date: 3'd May 2016 Appendix H - Resistance results of switch aged w ith Raychem 51264, Test 10 All results in Oh ms.
Results before ageing Into oven Out of oven Total aging Results after ageing Operation 1 Operation 2 Operation 3 Operation 4 Operation 5 Operation 6 Operation 7 rill r:ilQ rill r:ilQ rill r:ilQ rill r:ilQ rill r:ilQ rill r:ilQ rill r:ilQ 13:00 Thu 08:00 Mon lOdays 49 0 .004 0 .003 0 .004 0.003 0.004 0.004 14/04/16 25/04/16 0.010 0 .024 0.007 0 .021 0 .008 0 .023 0.012 0 .009 19hrs
rotor11- Page 48 of 48 Rotor k Cont ro ls Li mited Approved by Enginee ring Nuclear Engineering Report No . ER85 7 Issue 1 Date : 3'd May 2016 Appendix I - Resistance results of switch aged with X60, Test 11 All results in Ohms.
Results before ageing Into oven Out of oven Total aging Results after ageing Operation 1 Operation 2 Operation 3 Operation 4 Operation 5 Operation 6 Operation 7 MK rllQ MK rllQ MK rllQ MK rllQ MK rllQ MK rllQ MK rllQ 14:20 Mo n 14:20 Thu 53 0.006 0.002 0.005 0.002 0.006 0.003 18/ 04/ 16 10 da ys 0.008 0.040 0.016 0.042 28/04/16
- indicates open circ uit
- indicates t hat the resistance value was fluctuating between several ohms, t o hund reds of ohms, to open circ uit