ML23082A112

10 CFR Part 21 Report – Inconsistent Crimping of Motor Leads to Ring Terminal Connectors and Failure to Comply. Trillium Valves USA Part 21 Evaluation I211003

ML23082A112
Person / Time
Site:	Summer, Vogtle
Issue date:	03/17/2023
From:	Fisher A TRILLIUM Valves USA
To:	Document Control Desk, Office of Nuclear Reactor Regulation
Shared Package
ML23087A159	List: ML23082A112 ML23087A129
References
Download: ML23082A112 (1)

Text

M arch 17, 2023

U.S. Nuclear Regulatory Commission ATTN: Document Control Desk Washington, D.C. 20555-0001

Subject:

10 CFR Part 21 Report - Inconsistent crimping of motor leads to ring terminal connectors and Failure to Comply. Trillium Valves USA Part 21 Evaluation I211003

Trillium Valves USA is providing this written notification in accordance with the requirements of 10 CFR 21.21(d)(3)(ii). This notification pertains to the inconsistent crimping of motor lead ring tongue terminal connectors attached to quick disconnect connectors for SMB actuators and failure to comply.

The failure to comply concerns failure to provide initial notification within 2 days and written notification within 30 days.

Sincerely,

Allen Fisher Director of Engineering Trillium Valves USA 29 Old Right Road Ipswich, MA 01938-1119 Phone +1 (978) 825-8451 Mobile+1 (252) 940-9508 Email allen.fisher@trilliumflow.com

Attachments:

1. Evaluation of ring tongue terminal connectors (8 pages)

2. List of affected orders (3 pages)

3. Reportable condition per 21.21(d)(4) (2 pages)

TRILLIUM Valves USA' O: +1 978 744 5690 29 Old Right Road Page 1 of 1 F: +1 978 741 3626 Ipswich, MA 01938-1119 USA E: valvesusa@trilliumflow.com

ATTACHMENT 1

Limitorque

LIMDOC-2022-004 July 1, 2022

Subject:

Inspection of terminal samples returned from Trillium Valve Photo # 1 provided by Trillium Valve shows five ring tongue terminal connectors removed from the actuator identified as serial #L983445. Two of these terminals were returned to Limitorque from Trillium Valve. The returned samples, designated as RS1 and RS2 are shown in photos # 2 & 3. The terminals were forwarded to the engineering special test lab for evaluation. For comparison purposes, Flowserve QA also provided the lab with three samples of terminal connectors that were installed and crimped by the Lynchburg production wiring department. These are shown in photo #4.

Comments from Lab Inspection:

Terminal RS1, identified as the terminal with the longest wire protruding, showed no continuity initially but when the end of the wire was manipulated continuity was intermittent. The wire appears to have been partially pulled out of the connector evident by the crimp impression in the wire insulation below the terminal and, also evident by the wire conductor not extending to the end of the barrel on the terminal side. Also, the wire did not appear to be firmly held when the wire was manipulated for the continuity test. The wire conductor was approximately 0.045 short of reaching the end of the terminal barrel.

Terminal RS2, identified as the terminal with the short wire protruding, initially checked good continuity however manipulation of the wire caused continuity to drop on at least one occasion. The wire appears to be still firmly held by the crimp however there is very little wire protruding from the terminal to make this evaluation. The wire conductor was approximately flush with the end of the terminal barrel.

The terminals provided by QA for comparison have an obviously different impression from the crimp tool than the samples returned from the customer. Also, the wire extends well beyond the end of the crimp barrel on these samples. Numbering on these terminals is different than those received from the Customer. (Regarding this comment, the terminals received from the customer are T & B part # RB863 which has a hole for a #8 screw typically used on the control and power Marathon terminal strip. The samples provided by QA are a T & B part # RB873 which has hole for a #10 screw typically used on the geared limit switch and torque switch terminals. Otherwise, the terminals are identical.)

Flowserve, Lynchburg VA Operations Page 1 of 8 Limitorque Engineering Department Limitorque

Discussion:

The crimping tool used by Limitorque (reference photo # 6) has jaws that crimps the connector in two places simultaneously. The primary crimp compresses the serrated barrel (reference Figure 1 and Photo #7) onto the wire conductor. The secondary crimp compresses the funnel entry barrel onto the outer wire insulation.

The three comparison samples shown in photo #5 are uniform in appearance. In contrast, the terminal connectors shown in photos #1, 2, 3, & 4 show inconsistencies in the location of the crimp and the extent of deformation of the barrel and insulator.

==

Conclusion:==

Limitorques inspection has determined that the root cause of the intermittent continuity at the wire conductor to terminal connection is likely attributable to a workmanship error resulting in inconsistent crimping of the lead wire to the terminal. On sample RS2, the conductor was not fully inserted into the terminal barrel prior to crimping. On samples RS1 & RS2, the crimping tool was not positioned properly on the terminal barrel prior to the crimp. The other terminals shown in photos 1 & 2 exhibit similar inconsistencies.

Prepared By: __ _________________________

Kyle Ramsey, Principal Engineer, Flowserve Limitorque

Reviewed By:

Nathan Sochor, Special Test Lab Supervisor, Flowserve, Lynchburg VA

Flowserve, Lynchburg VA Operations Page 2 of 8 Limitorque Engineering Department Limitorque

Photo # 1: Five Terminals Removed from Actuator

Photo # 2: Five Terminals Removed from Actuator

Flowserve, Lynchburg VA Operations Page 3 of 8 Limitorque Engineering Department Limitorque

Photo # 3: Samples Returned for Evaluation

RS1: Secondary crimp partially on the wire insulation rather than the terminal insulator

RS2: Primary crimp not positioned correctly over the barrel of the terminal housing the conductor

Flowserve, Lynchburg VA Operations Page 4 of 8 Limitorque Engineering Department Limitorque

Photo # 4: Samples Returned for Evaluation

RS2 RS1

Flowserve, Lynchburg VA Operations Page 5 of 8 Limitorque Engineering Department Limitorque

Photo # 5: Samples Provided for Comparison

Photo # 5 comment: There are two visible compression marks from the crimping tool. One crimp mark is directly over the barrel housing the conductor while the second crimp mark is over the barrel that clamps on the insulation of the wire.

Flowserve, Lynchburg VA Operations Page 6 of 8 Limitorque Engineering Department Limitorque

Photo # 6: Crimping Tool

Flowserve, Lynchburg VA Operations Page 7 of 8 Limitorque Engineering Department Limitorque

Figure 1: Details of Terminal

Photo # 7: Uncrimped Terminal with Blue Insulator Removed

Flowserve, Lynchburg VA Operations Page 8 of 8 Limitorque Engineering Department ATTACHMENT 2 List of affected orders

SCAR No IR-2022-7477 WEC PO 4500292480 Sanmen - 1

WEC Item Data Sheet Qty per unit Valve Serial Number Location Limitorque Serial Number

68 APP-PV11-Z0D-120 1 1-54536-J Aux L868152 69 APP-PV11-Z0D-121 1 1-54536-K Aux L868156 70 APP-PV11-Z0D-122 1 1-54536-L Aux L868159 70 APP-PV11-Z0D-122 1 2-54536-L Aux L868158 101 APP-PV11-Z0D-123 1 1-54536-W Cont L871810 102 APP-PV11-Z0D-124 1 1-54536-Z Cont L871811 77 APP-PV11-Z0D-145 1 1-54536-S Aux L879937 77 APP-PV11-Z0D-145 1 2-54536-S Aux L879938 124 APP-PV11-Z0D-245 1 3-54536-S Aux L879936 124 APP-PV11-Z0D-245 1 4-54536-S Aux L879935 76 APP-PV11-Z0D-140 1 1-54536-R Aux L879944 76 APP-PV11-Z0D-140 1 2-54536-R Aux L879943 105 APP-PV11-Z0D-119 1 1-54536-V Aux L890503 105 APP-PV11-Z0D-119 1 2-54536-V Aux L890504 118 APP-PV11-Z0D-141 1 1-00088-20 Aux L918547 118 APP-PV11-Z0D-141 1 2-00088-20 Aux L918546

WEC PO 4500292480 Haiyang - 1

WEC Item Data Sheet Qty per unit Valve Serial Number Location Limitorque Serial Number 87 APP-PV11-Z0D-120 1 1-54537-J Aux L868153 88 APP-PV11-Z0D-121 1 1-54537-K Aux L868154 89 APP-PV11-Z0D-122 1 1-54537-L Aux L868161 89 APP-PV11-Z0D-122 1 2-54537-L Aux L868162 103 APP-PV11-Z0D-123 1 1-54537-W Cont L871809 104 APP-PV11-Z0D-124 1 1-54537-Z Cont L871812 96 APP-PV11-Z0D-145 1 1-54537-S Aux L879940 96 APP-PV11-Z0D-145 1 2-54537-S Aux L879942 126 APP-PV11-Z0D-245 1 3-54537-S Aux L879939 126 APP-PV11-Z0D-245 1 4-54537-S Aux L879941 95 APP-PV11-Z0D-140 1 1-54537-R Aux L879946 95 APP-PV11-Z0D-140 1 2-54537-R Aux L879945 106 APP-PV11-Z0D-119 1 1-54537-V Aux L911178 106 APP-PV11-Z0D-119 1 2-54537-V Aux L911179 119 APP-PV11-Z0D-141 1 1-00088-21 Aux L918548 119 APP-PV11-Z0D-141 1 2-00088-21 Aux L918549

WEC PO 4500309727 Vogtle - 3

WEC Item Data Sheet Qty per unit Valve Serial Number Location Limitorque Serial Number

21 APP-PV11-Z0D-140 1 1-55022-R Aux L911115 21 APP-PV11-Z0D-140 1 2-55022-R Aux L911116 11 APP-PV11-Z0D-120 1 1-55022-J Aux L911614 12 APP-PV11-Z0D-121 1 1-55022-K Aux L911615 13 APP-PV11-Z0D-122 1 1-55022-L Aux L911617 13 APP-PV11-Z0D-122 1 2-55022-L Aux L911618 51 APP-PV11-Z0D-245 1 2-55022-Z Aux L911621 51 APP-PV11-Z0D-245 1 1-55022-Z Aux L911624 44 APP-PV11-Z0D-119 1 1-55022-X Aux L911629 44 APP-PV11-Z0D-119 1 2-55022-X Aux L911630

Page 1 of 3 List of affected orders SCAR No IR-2022-7477

22 APP-PV11-Z0D-145 1 1-55022-S Aux L912774 22 APP-PV11-Z0D-145 1 2-55022-S Aux L912776 46 APP-PV11-Z0D-123 1 1-55022-V Cont L912777 48 APP-PV11-Z0D-124 1 1-55022-W Cont L912782 58 APP-PV11-Z0D-141 1 1-00188-320 Aux L983444 58 APP-PV11-Z0D-141 1 2-00188-320 Aux L983445

WEC PO 4500309727 Vogtle - 4

WEC Item Data Sheet Qty per unit Valve Serial Number Location Limitorque Serial Number

62 APP-PV11-Z0D-141 1 2-00188-360 Aux L1003458 62 APP-PV11-Z0D-141 1 1-00188-360 Aux L1003459 42 APP-PV11-Z0D-140 1 3-55022R Aux L911111 42 APP-PV11-Z0D-140 1 4-55022R Aux L911112 43 APP-PV11-Z0D-145 1 3-55022S Aux L911622 53 APP-PV11-Z0D-245 1 4-55022Z Aux L911623 43 APP-PV11-Z0D-145 1 4-55022S Aux L911625 53 APP-PV11-Z0D-245 1 3-55022Z Aux L911627 33 APP-PV11-Z0D-121 1 2-55022K Aux L912764 32 APP-PV11-Z0D-120 1 2-55022J Aux L912766 34 APP-PV11-Z0D-122 1 3-55022L Aux L912768 47 APP-PV11-Z0D-123 1 2-55022V Cont L912778 49 APP-PV11-Z0D-124 1 2-55022W Cont L912781 45 APP-PV11-Z0D-119 1 3-55022X Aux L912787 45 APP-PV11-Z0D-119 1 4-55022X Aux L912788 34 APP-PV11-Z0D-122 1 4-55022L Aux L979720

WEC PO 4500309289 Summer - 2

WEC Item Data Sheet Qty per unit Valve Serial Number Location Limitorque Serial Number 21 APP-PV11-Z0D-140 1 1-55023R Aux L911113 21 APP-PV11-Z0D-140 1 2-55023R Aux L911114 11 APP-PV11-Z0D-120 1 1-55023J Aux L911613 12 APP-PV11-Z0D-121 1 1-55023K Aux L911616 13 APP-PV11-Z0D-122 1 2-55023L Aux L911619 22 APP-PV11-Z0D-145 1 2-55023S Aux L911626 44 APP-PV11-Z0D-119 1 1-55023X Aux L911631 44 APP-PV11-Z0D-119 1 2-55023X Aux L911632 13 APP-PV11-Z0D-122 1 1-55023L Aux L912767 51 APP-PV11-Z0D-245 1 2-55023Z Aux L912769 51 APP-PV11-Z0D-245 1 1-55023Z Aux L912770 22 APP-PV11-Z0D-145 1 1-55023S Aux L912772 46 APP-PV11-Z0D-123 1 1-55023V Cont L912780 48 APP-PV11-Z0D-124 1 1-55023W Cont L912784 58 APP-PV11-Z0D-141 1 1-00211-570 Aux L983442 58 APP-PV11-Z0D-141 1 2-00211-570 Aux L983443

WEC PO 4500309289 Summer - 3

WEC Item Data Sheet Qty per unit Valve Serial Number Location Limitorque Serial Number

62 APP-PV11-Z0D-141 1 1-00211-610 Aux L1003460 62 APP-PV11-Z0D-141 1 2-00211-610 Aux L1003461 42 APP-PV11-Z0D-140 1 3-55023R Aux L911117

Page 2 of 3 List of affected orders SCAR No IR-2022-7477

42 APP-PV11-Z0D-140 1 4-55023R Aux L911118 34 APP-PV11-Z0D-122 1 3-55023L Aux L911620 53 APP-PV11-Z0D-245 1 4-55023Z Aux L911628 32 APP-PV11-Z0D-120 1 2-55023J Aux L912763 33 APP-PV11-Z0D-121 1 2-55023K Aux L912765 43 APP-PV11-Z0D-145 1 4-55023S Aux L912771 53 APP-PV11-Z0D-245 1 3-55023Z Aux L912773 43 APP-PV11-Z0D-145 1 3-55023S Aux L912775 47 APP-PV11-Z0D-123 1 2-55023V Cont L912779 49 APP-PV11-Z0D-124 1 2-55023W Cont L912783 45 APP-PV11-Z0D-119 1 4-55023X Aux L912785 45 APP-PV11-Z0D-119 1 3-55023X Aux L912786 34 APP-PV11-Z0D-122 1 4-55023L Aux L979719

Page 3 of 3 M arch 17, 2023

Part 21 Evaluation I211003

ATTACHMENT 3: Reportable Condition per 21.21(d)(4)

1. Name and address of the individual or individuals informing the Commission.

Allen Fisher Director of Engineering Trillium Valves USA 29 Old Right Road Ipswich, MA 01938-1119

2. Identification of the facility, the activity, or the basic component supplied for such facility or such activity within the United States which fails to comply or contains a defect.

Butterfly Valves with SMB motor actuators supplied to Westinghouse Electric Company from 2010 to 2016.

3. Identification of the firm constructing the facility or supplying the basic component which fails to comply or contains a defect.

Trillium Valves USA 29 Old Right Road Ipswich, MA 01938-1119

4. 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.

Inconsistent crimping of motor leads caused lack of continuity and intermittent function, or non-function of the actuator motor preventing the butterfly valve to close on demand.

See Attachment 1.

5. The date on which the information of such defect or failure to comply was obtained.

July 1, 2022, See Attachment 1.

6. In the case of a basic component which contains a defect or fails to comply, the number and location of these components in use at, supplied for, being supplied for, or may be supplied for, manufactured, or being manufactured for one or more facilities or activities subject to the regulations in this part.

The butterfly valves with motor actuators were supplied to Westinghouse Electric Company under orders identified in Attachment 2. Westinghouse was notified of the affected orders via their SCAR No IR-2022-7477 on March 6, 2023.

TRILLIUM Valves USA ' O: +1 978 744 5690 29 Old Right Road Page 1 of 2 F: +1 978 741 3626 Ipswich, MA 01938-1119 USA E: valvesusa@trilliumflow.com

M arch 17, 2023

Part 21 Evaluation I211003

7. The corrective action which has been, is being, or will be taken; the name of the individual or organization responsible for the action; and the length of time that has been or will be taken to complete the action.

(1) Trillium Valve USAs Approved Suppliers List has been updated to add restriction for any repairs or service of safety related equipment must be completed at the suppliers facility. No service or repair of safety related equipment at Trillium site.

This action was completed on March 2, 2023.

(2) The failure to comply with initial notification and written notification has been initiated under Trillium Valves USA Corrective Action Program. Corrective actions will include additional training on the implementation and reporting requirements under 10CFR21.

This action will be completed by March 31, 2023.

8. Any advice related to the defect or failure to comply about the facility, activity, or basic component that has been, is being, or will be given to purchasers or licensees.

Trillium Valves USA recommends the inspection of these actuators listed in Attachment 2 for the lack of continuity at the motor leads which may be impacted by inconsistent crimping of the lead wire to the ring tongue terminal.

9. In the case of an early site permit, the entities to whom an early site permit was transferred.

Not applicable.

TRILLIUM Valves USA ' O: +1 978 744 5690 29 Old Right Road Page 2 of 2 F: +1 978 741 3626 Ipswich, MA 01938-1119 USA E: valvesusa@trilliumflow.com