Protecting People and the EnvironmentUNITED STATES NUCLEAR REGULATORY COMMISSION
ACCESSION #: 9701090073
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Struthers-Dunn Model 255XCXP Relay
Root Cause Evaluation Principal
for
Salem Nuclear Generation Station
October 30, 1996
FPI 96-829
Struthers-Dunn Model 255XCXP Relay
Root Cause Evaluation Principal
for
Salem Nuclear Generation Station
October 30, 1996
FPI 96-829
Principal
Investigators: James Riddle
Mike Ramsey
Technical
Contact: Craig Bersak, PSE&G
Approved By:
Dr. Chong Chiu
This report was prepared for Public Service Electric and Gas Company. No
part of this document may be reproduced without the consent of FPI,
International.
Table of Contents
Executive Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Failure Analysis . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Visual Inspection . . . . . . . . . . . . . . . . . . . . . . . . 3
Electrical testing . . . . . . . . . . . . . . . . . . . . . . . . 5
Force-Balance Analysis . . . . . . . . . . . . . . . . . . . . . . 8
Analysis Conclusions . . . . . . . . . . . . . . . . . . . . . . . . .11
Root Cause Evaluation . . . . . . . . . . . . . . . . . . . . . . . . .12
Corrective Actions . . . . . . . . . . . . . . . . . . . . . . . . . .13
Attachments:
I Photodocumentation
II Correspondence - Application Information
III Product Data
Executive Summary
FPI, International received four (4) relays for failure analysis and Root
Cause Evaluation from Public Service Electric and Gas Company, Salem
Nuclear Generating Station. One of the relays was reported to have
spuriously unlatched and a second relay was reported to not have latched
on actuation. The other two relays, one a new style and the other an old
style relay, were supplied as correlation samples.
Failure analysis confirmed the failure to latch of the one relay and the
spurious unlatching, under mild mechanical shock, of the second relay. A
significant finding was construction differences between the old style
(1972 vintage) and new style relays (1995 vintage). The construction
differences make the new type relays more prone to latching problems than
the older style relay. The most significant difference is the lower
latching force on the new style relays. This problem is the direct
result of lower spring tension on the latch lever. Another significant
concern is the deviation of the electrical characteristics of the new
release coils from the design specifications which indicate that the new
relays are not direct replacements for the old relays.
The root cause of the two relay failures is design differences between
the old and new relays that make the new relays more prone to latching
problems and spurious unlatching than the old style relays.
The three corrective action recommendations are to (1) review safety
related applications for susceptibility to failure of the new style
relays and replace or rework relays which present significant compromise
of plant safety, (2) review new relay design to justify like for like
compatibility with the old style relays and (3) conduct tests and
measurements to determine adjustments to be made on new relays to assure
operability in challenging environments. FPI, International has the
expertise to assist in implementing all the corrective actions.
1
Introduction
FPI, International received four (4) relays for failure analysis and Root
Cause Evaluation from Public Service Electric and Gas Company, Salem
Nuclear Generating Station. One of the relays was reported to have
spuriously unlatched and a second relay was reported to not have latched
on actuation. The other two relays were correlation samples. The
component identification and system designation was supplied to FPI in a
memo dated September 20, 1996 which is included in Attachment II at the
end of this report. Additional background information was obtained via
FAX on October 3, 1996, also included in Attachment II.
The failed relays are new components which had been recently installed in
Bailey Meter Company Relay modules, part number 6615692A, as part of a
general relay change out due. to the aging of the original relays which
have been operating for the life of the plant. There have 5 reported
failures of the new type relays. The relays are procured as Safety
Related components after being dedicated by a third party vendor. The
manufacturer, Magnacraft Struthers-Dunn does not supply the relay as
Appendix B, Safety Related items. The Bailey Product Instructions and
relay manufacturer data sheet are in attachment III at the end of this
report.
2
Failure Analysis
Visual Inspection
The relays are Magnacraft Struthers-Dunn (S-D or MSD) model 255XCXP type
latching relays. The operate coils are 24-28 VDC. The release coils are
also 24-28 VDC.
Relay #1 is an old relay, date code 7228. It was supplied as a
correlation sample. The part markings are 255XCX111, manufactured by S-
D. The plastic case was slightly darkened with age. The switch contacts
were clean and the exterior of the coils showed no evidence of
degradation which is usually seen as darkening or cracking of the
insulation. The mechanical design of this relay is significantly
different that the three new relays.
Relay #2 is a new relay, date code 9549. It was reported to have
spuriously unlatched in service. It was later reported that the
unlatching of this relay was concurrent with the actuation an adjacent
relay in the same Bailey module. The part markings are 255XCX128. The
suffixes in the part numbers is either for a Bailey (111) part or a
Public Service (128) part. Internal inspection revealed that this relay
was essentially new. There was no evidence of aging on any of the
internal components. There was no evidence of any loose parts or gross
misalignment the coils or latching mechanism. No wear was evident on the
latching mechanism or any other moving parts.
Relay #3 is a new relay, date code 9616. It was reported to have failed
to latch upon actuation while in service in a Bailey Relay module. The
part markings are 255XCX128. Internal inspection revealed that this
relay was new. There was no evidence of aging on any of the internal
components. There was no evidence of loose parts or gross misalignment
of the coils or latching mechanism. No wear was evident on the latching
mechanism or a... other moving parts.
3
Relay #4 is a new stock relay, date code 96** (date code marking on case
smudged). It was supplied as a correlation sample. The part markings
are 255XCX128. Internal inspection revealed that this relay was new.
There was no evidence of aging on any of the internal components. There
was no evidence of any loose parts or gross misalignment of the coils or
latching mechanism. No wear was evident on the latching mechanism or any
other moving parts.
As was mentioned earlier, there are significant differences in the
mechanical construction of the old relay and the three new relays. Most
of the differences are in the reset coil and latch assembly.
1. The presence of a frame in the new relays is a major difference
compared to the old relay. On the old relay the reset coil
assembly is attached directly to the top of the operate coil
assembly. On the new relays the operate and reset assemblies
are attached to a U shaped frame. The frame provides less
torsional rigidity to the assembly, especially in the alignment
of the resent and operate coils.
2. There are numerous alignment adjustments on the both the new
and old assembles, all intended to precisely position the
plastic latch on the reset coil armature to the latch lever on
the operate coil armature. On the old style relay these
adjustments are made with the hardware on rigid clamps which
connect the reset coil assembly to the operated coil assembly.
On the new style relay these adjustments are in the frame
attachment hardware and in the case of the height adjustment
via shims between the reset coil assembly and the frame. The
alignment scheme on the new style relays is less rigid then
that on the old style relays.
3. The switch contact spring arms are significantly more bent,
preloaded, on the new relays. This results in a higher contact
force on the new relays but also a higher pull-in force of the
operate coil and stronger pull-out force on the reset coil
latch.
4
4. The reset coils are completely different on the old and new
style relays. The coil resistance of the new reset coils is in
the range of 460 Ohms and the old reset coils measures 309 Ohms
(cold). The core is also larger on the old style reset coil.
The higher resistance on the new coils is disturbing because it
is not in accordance with the data sheet specification. The
electrical performance differences will be discussed below in
the Electrical Testing section of the report.
5. A most significant difference between the old and new style
relays, as related to the failure mode, is the reset coil
armature spring. The armature return spring on the old relay
is significantly stretched in the latched and released states.
This delivers significant force to the latch. The return
spring on the new relays is almost fully relaxed in the
released position and slightly stretched in the latched
position. This condition provides reduced holding force to the
latch. The details of this condition will be discussed on the
Force Balance section of this report.
Electrical testing
Initial electrical testing confirmed the failure to latch of the #3
relay. The #3 relay would not remain latched when the operate coil was
actuated and power was removed. After the cover was removed the relay
began to latch successfully. It was noted during removal of the cover
that it was a tight fit and reinstallation of the cover confirmed that
the tight fit was interfering with the relay frame, causing it to bend.
Testing after the cover was reinstalled revealed that the relay would not
latch. The presence of the cover is interfering with the alignment of
the latch mechanism. It was noted during subsequent testing, after the
cover was removed that the relay could be made to release with a minor
flexing (twisting) of the frame.
5
Initial electrical testing of relay #2 revealed that the relay would
latch at normal voltage/current compared to #4 but could be made to
unlatch under mild mechanical shock (pencil tap on side of case).
Initial electrical testing of #1 and #4 revealed that they both set and
rest normally. Relay #4 could be made to release with moderate
mechanical shock (screw driver handle tap to side of case) and #1 could
be made to release under strong mechanical shock (banging relay on table
top).
Static electrical testing was performed with a DMM in the resistance mode
(Fluke 8060A) for coil resistance measurements and a millivolt meter and
a constant current source (10.00 mA) for the switch contact resistance
measurements. The switch contact resistances in the N/O and N/C states
on all the relays were good, in the range of 0.001 Ohms. The coil
resistance measurements on the relays revealed that there was a
significant difference on the reset coils on the old and new style
relays:
Sample Operate coil Reset coil
#1 240 Ohms 309 Ohms
#2 250 Ohms 460 Ohms
#3 240 Ohms 470 Ohms
#4 250 Ohms 460 Ohms
The Struthers-Dunn specification sheet shows a nominal resistance for the
operate coil of 250 Ohms and a nominal resistance for the reset coil of
300 Ohms. The higher resistance (more windings) of the new coils results
in a lower current (cold) necessary to actuate the reset coil as
indicated by the following data:
Sample Volts Release mA
#1 24 VDC 78.2 mA
#2 24 VDC 52.0 mA
#3 24 VDC 51.0 mA
#4 24 VDC 52.5 mA
6
Again, The Struthers-Dunn data sheet specifies a nominal release current
of 80 milli-Amps for these relays. The new relays are not in compliance
with the published specifications.
Another result of the different release coil assembly is a lower reset
voltage on the new relays due to the lower overcoming force necessary on
the reset armature spring. The pick-up and drop-out voltages are
recorded as follows:
#1 Pick-up = 16.8 VDC
Release = 15.5 VDC
Pick-up = 15.3 VDC
#2 Pick-up = 12.9 VDC
Release = 11.9 VDC
Pick-up = 13.3 VDC
#3 Pick-up = 14.0 VDC
Release = 10.0 VDC
Pick-up = 13.5 VDC
#4 Pick-up = 15.9 VDC
Release = 12.2 VDC
Pick-up = 12.9 VDC
Note that the release voltage is somewhat lower on the new relays which
is a result of the lower return spring overcoming force as discussed in
the Force Balance section of the report.
7
Force Balance Analysis
A force-balance analysis was performed on the latching mechanism of the
old relay compared to the new relays. Samples #1, #2 and #4 were used
for the testing. Sample #3 was left intact for possible future testing
as a worst case condition.
Diagram omitted.
The above diagrams are the force balance schematics. The left schematic
is in the latched position and the right schematic is in the unlatched
position.
Relays #1 (Old Style) and #2 (New Style) were used to take direct
measurements of the spring and latch geometries. The spring on the #1
relay was noted to be extended in both the latched and unlatched
positions. The spring on the #2 relay appeared to n--be extended in the
latched position.
The spring dimensions were taken from established reference points across
the collapsed and extended spring coils. The spring extension was
measured on the release armature springs, in place, in the latched and
unlatched state. The springs were then removed from the relays and the K
factor was measured. The armatures were measured to obtained the lever
ratio from the spring center of force to the lip of the latch. The
following data was obtained:
8
PARAMETER OLD #1 NEW # 2
Spring Constant 66 gram/mm 78.6 gram/mm
Extended Length Latched 10.4 mm 6.3 mm
Extended Length Unlatched 10.65 mm 6.7 mm
Collapsed Length (Removed) 8.5 mm 6.25 mm
Spring Force Latched 125.4 gram 3.93 gram
Spring Force Unlatched 142.0 gram 35.0 gram
Lever Ratio 2.64 : 1 3.2 : 1
Latched Clamping Force 47.5 gram 1.23 gram
The latching force is significantly lower at the latch on the new relays
than on the old relays. Combined with the higher switch contact spring
tension on the new relays, which work to pull the relay open, the new
relays are more susceptible, by design, to a failure to latch (based on
minor misalignments) and spurious unlatching under minor mechanical
shock.
A calculation was made to determine what adjustments would be necessary
to increase the latching force on the new relays to that on the old
relay. It was determined that bending the spring attachment tab
approximately 1.88 mm open was sufficient to increase to latching force
at the latch on the new relays to the 50 gram range measured on the old
relays. This may be the most efficient fix for the weak latching
problem.
However, simply bending the tabs on the reset relay armature may affect
relay timing and release coil pick-up voltage. A simple experiment was
performed on #2 to test the effect of bending the armature tab to open
the spring. Note that this relay had been disassembled and the spring
manipulated (loop opened) prior to the experiment. The relay was
reassembled to approximate the original condition. The spring extension
measured 6.5 mm in the latched condition. The release voltage (worst
case, cold) measured 11.62 volts at 24 mA. The tab on the release coil
frame was bent open 1.9 mm. It was noticed that the opening of the tab
caused the spring coils to open slightly but most of the stretch was
taken up by opening of the coil attachment loop. The spring extension
measured 6.9 mm in the latched position at the same
9
datum as the original measurement. The extension resulted in a
calculated increase of the latching force from 2.45 gm to 12.3 gm at the
latch. The pickup voltage measured 11.69 VDC at 24.8 mA after the bend.
The conclusions from this experiment are that bending the tab out to
extend the spring does not significantly affect the pickup voltage
characteristics of the relay. one observation made during this
experiment is that, as a rule of thumb, one must be able to see light
between the spring coils in order to assure some spring extension in the
latched condition. Light could not be detected in the original 6.5 mm
extension but could be seen in the 6.9 mm extension. This parameter
could be quantified as a spacing measurement between coil loops. The
result of the bend is a 5X increase in latching force between the two
adjustments with no significant change in the electrical performance.
Evaluate these results with caution, the effect on switching time has not
been determined.
Analysis Conclusions
Testing and failure analysis first confirmed the failure to latch on #3.
This relay recovered the ability to latch when the cover was removed and
failed when the cover was replaced. The latch could be made to release
under mild twisting stress to the frame during testing with the cover
removed. Relay #2 was made to unlatch under much lower mechanical shock
stress than the old design #1 relay.
The old style and new style relays have significant design differences
especially in the latching mechanism. These differences contribute to
the propensity for the failure to latch mechanism and the spurious
release failure mechanism. The major differences are listed as follows:
A. The presence of the surrounding frame in the new relays is a
much less torsionally rigid system for maintaining the latching
mechanism critical dimensionality than the old style direct
bracket arrangement between the operate and reset coil
assemblies.
10
B. The lack of rigidity in the frame means that the latching
adjustment tolerances must be maintained to a very precise
degree to insure proper operation. The new style relays are
prone to spuriously release under much lower mechanical shock
than the old style relays. Stress from pressure from the cover
caused relay #3 to fail due to distortion of the frame.
C. The lower latching force on the new relays is the primary cause
of the lowered ability of the new relays to latch and remain
latched. The most direct corrective action is to increase the
spring force on the new relay reset latch armature.
D. The electrical characteristics of the new release coils are
significantly different than the old coil and are not in
compliance with the manufacturers published data. As a result
of this difference (and the reset mechanism differences), the
new relays are not "like for like" replacements for the old
relays.
Root Cause Evaluation
The root cause of the two relay failures is design differences between
the old and new relays that make the new relays more prone to latching
problems and spurious unlatching than the old style relays. Another
significant concern is the deviation of the electrical characteristics of
the new release coils from the design specifications which indicate that
the new relays are not direct replacements for the old relays.
11
Corrective Actions
Three corrective actions are recommended. FPI, International has the
expertise to assist in implementing all the corrective actions.
First, a review should be performed of all the plant applications of the
new relays for their adequacy in the operating and design environment.
Determine if the reliability of the new style relay is adequate for the
Safety Related applications at the Salem Nuclear Generating Station.
This corrective action is necessary to justify the installation of the
new relays in safety critical applications. If adequate justification
cannot be made, the relays will have to be changed out.
Secondly, review the adequacy of the new relay design. This corrective
action involves a review of the results of this analysis with the
manufacturer and supplier in order to determine the reasons for the
design changes and the manufactures basis for assuming that the relays
are interchangeable. This is especially critical in the lowering of the
holding force on the reset coil latch and incidentally important on the
release coil electrical parameter changes (which if justified would
require a specification sheet change). We suspect that the coil changes
are the result of maintaining switching time specifications but we do not
have access to that design information.
Thirdly, conduct necessary tests, adjustments and experiments to justify
the use of the new relays in challenging environments. One experiment
performed at FPI on the new relays determined that simply adjusting the
spring tension on the release armature spring as little as 1 mm will
increase the latching force to the range of the old style relays. This
adjustment could potentially correct the problem. Similar mechanical
adjustments or repairs may increase the reliability of the relays to
acceptable levels. It is possible that augmented testing, dimensional
verification or design change justification may be adequate to assure the
reliability of the replacement relays.
12
It is a also incumbent on PSE&G to inform other users of this model relay
of the problems encountered with the spurious unlatching. A short report
on the INPO Nuclear Network of the problems encountered at Salem would be
a responsible action. There may be Part 21 issues associated with the
dedication of the relays for Safety Related applications. This issue
should be evaluated by the supplier.
13
Attachment I
Photodocumentation
Figure 1: "Photograph of the old style relay #1, case removed.
Note the bracket attachment of the reset coil assembly." omitted.
Figure 2: "photograph of relay #1, side view, showing the frame
arrangement for the coil assemblies." omitted.
Figure 3: "Close up of the reset assembly on relay #1, unlatched."
omitted.
Figure 4: "Close up of the reset assembly on relay #1, latched."
omitted.
Figure 5: "Close up of relay #1 reset coil spring assembly." omitted.
Figure 6: "Magnified view of Figure 5 showing the spring extension
on the #1 relay, latched position." omitted.
Figure 7: "Photograph of relay #2, case removed. The relay is in the
latched position." omitted.
Figure 8: "Close up of Figure 7 showing the reset coil assembly in
the latched position. Note the coil extension." omitted.
Figure 9: "Photograph of relay #3 with the cover removed, unlatched
position." omitted.
Figure 10: "Close up of the reset coil assembly in Figure 9." omitted.
Figure 11: "Photograph of relay #4, cover removed, in the unlatched
position." omitted.
Figure 12: "Close up of the reset coil assembly on relay #4,
latched position. Note the spring extension." omitted.
Attachment II
Correspondence
Application information
MEMO
To: Dr. Chong Chiu
From: Craig D. Bersak (609) 339-7463, FAX (609)339-2210
PSE&G Nuclear Business Unit, PO Box 236, Hancocks
Bridge, NJ 08038
Subject: Proposal for Relay Failure Analysis
Date: September 20, 1996
The following is being provided in anticipation of approval of
a Purchase Order by PSE&G, it is not authorization to begin
work.
Enclosed are four relays for your evaluation.
Relay #1 was is an old relay that has NOT had a failure
associated with it.
Relay #2 spuriously tripped from a latched condition to its
reset condition.
Relay #3 failed to maintain itself latched following an operate
demand.
Relay #4 is a new relay that has not been installed in a Salem
system. The case was opened and the wire from pin 5 to the
RESET coil repositioned due to its having been crimped.
Relay #2 (83 relay for 22RH29) functions as the AUTO-MANUAL
relay for the RHR Heat Exchanger Bypass valve. Its failure
occurred when it swapped to MANUAL (reset condition) as RHR
loop flow was being reduced to its low flow setpoint. The low
flow signal energizes a 219 style 115 Vac relay co-located with
this relay in its Bailey Can. [The 83 relay is in the K1
position in the can, two 219 style relays are in the K2 and K3
position actuated on High and Low flow signals respectively.]
Relay #3 (18SS relay for 22 BAT Pp) is the Slow Speed Start
relay for a Boric Acid Transfer Pump. It failed to maintain
the latched condition when the demand condition was removed.
[The 83 relay is in the K1 position in the can, two 219 style
115 Vac relays are in the K2 and K3 position, actuated on High
and Low flow signals respectively.]
Additionally, I am including the following documentation:
Circuit diagrams for relays #2 and 3.
Manufacturer's Specifications for 255 and 219 style relays
Bailey Relay Module Technical Manual
If I can be of any assistance please call me at (609) 339-7463.
MEMO
To: Mr. James Riddle FAX (714)361-5479
From: Craig D. Bersak (609) 339-7463, FAX (609)339-2210
PSE&G Nuclear Business Unit, PO Box 236, Hancocks. Bridge, NJ
08038
Subject: Response to Questions from 10/2/96
Date: October 3, 1996
Here are answers to your questions from yesterday.
Are the capacitors electrolytic?
Electrolytic capacitors are used in some Bailey control circuits. I
looked over the Boric Acid Transfer Pump and 22RH29 control circuits
and neither of these circuits use capacitors. You may be confusing
the contacts off of the control room's pushbutton stations for
capacitors. A pushbutton's contact appears as: (Equation omitted.)
The capacitors shown in the Bailey manual, page 3, as pan of the
Suppression Circuit Board, are not in the models of the modules used
at Salem (6615692A1, A2, A3).
Where electrolytic capacitors are used they are being inspected
/tested and replaced when necessary.
What is the voltage at the relay cabinets?
The 28 VDC system voltage is nominally maintained between 28 to 30.3
VDC. Per a verbal discussion with a technician, they typically see
29+ VDC when they check at the back of a relay cabinet.
What is the significance of the suffixes -111, -128 on the relay IDs?
I have not been able to identify the specific special construction
features identified by these suffixes. The S-D catalog states "when
a special type of construction is not covered by a 'common' feature
or when it combines several of them, a "special number is assigned
at the factory. This number will always be '100' or greater, and
applies only to the relay to which it was assigned." I've tried
repeatedly to contact Mr. Thomas Mahaffey, Production Engineering
Manager at Magnecraft/Struthers-Dunn (803) 395-8512, for the details
without his returning my calls. When I get in contact with him I
will inform you of the results.
Should you need any other information please contact me.
FAX
To: W. James Riddle FAX# 714-361-5479
From: Craig D. Bersak (609) 339-7463, FAX (609)339-2210
PSE&G Nuclear Business Unit, PO Box 236, Hancocks Bridge,
NJ 08038
Subject: Relay suffix numbers
Date: October 3, 1996
Spoke to Tom Mahaffey of MSD, the suffix numbers mean that the relays
were marked with a Bailey Part number (Suffix 111) or Public Service part
number (Suffix 129).
Otherwise they are the standard 255XCXP relays,
Attachment III
Product Data
SECTION
Bailey
E92-52
PRODUCT INSTRUCTIONS
RELAY MODULE
PT. NO. 6615692A [ ]
Figure omitted.
BAILEY METER COMPANY o WICKLIFFE, OHIO 44092
FORM 1E92-52-670
LITHO IN U.S.A.
E92-52
Page 2 Bailey
MODULE DESCRIPTION
The Relay Module for Bailey 660 Systems is a three-unit wide (3-3/8
inches) module designed for plug-in mounting in a standard Bailey
electronic systems cabinet (see Figure 1). The unit is frequently used
with the Type RZ Multiple Switch and Light Station for contact interlock
and signal light operation.
Figure 1 - "Relay Module" omitted.
The module can contain three plug-in, multiple-contact relays and is
used primarily for interlocking or circuit protection. As options,
diodes can be added for selective relay operation or a warning flasher
can be installed.
Three general purpose relays can be installed in one module. If a
flasher is used, height interference permits a maximum of two latch type
relays and one general purpose relay to be installed in one module.
Relay variations are listed in Table 1. The complete assembly of the
module is shown in Figure 4.
All electrical connections are made thru one or two rectangular 32-
pin connectors mounted on the rear of the module.
Table 1 omitted.
[copyright] BAILEY METER COMPANY 1970
E92-52
Relay Module Page 3
CIRCUIT DESCRIPTION
Suppression Circuit Board
Six sets of resistors (R1 thru R6) and capacitors (C1 thru C6 can be
provided on an optional suppression circuit board (PC1). The circuit
provides protection to the coil initiating contacts to prevent burning or
erosion due to coil inductance. Incoming transients are also suppressed
with the addition of this circuit. See Figure 2.
Figure 2 - "Schematic Wiring Diagram" omitted.
Three sets of resistors and capacitors are permanently connected to
relay operating coils. Remaining sets must be connected to the release
coils when using a latch type relay and must be connected at
installation.
Blocking Diode Circuit
Blocking diodes (CR1 thru CR6) are optional and are located on
rectangular connector pins at rear of module. Diodes provide selective
relay operation on bidirectional operating voltages. See wiring
schematic shown in Figure 2.
Flasher
One optional flasher can be provided in the module. Circuit wiring
for flasher must be provided external to module. Input voltage of
flasher is 18 to 32v DC with a power consumption of 1 watt. Contact
rating is 0.5a (resistive load) with a flashing rate of 1/2 second on,
1/2 second off. Flash rate is not adjustable.
Control Relay
Internal wiring diagrams for various types of relays are shown in
Figure 3.
Figure 2 "Schematic Wiring Diagram" omitted.
E92-52
Page 4 Bailey
FIGURE 3 - "Relay Internal Wiring Diagrams" omitted.
SERVICING
Check operation of Relay Module by substituting a known trouble-free
module for the one in service. If trouble is definitely traced to the
module, check for broken wires, damaged connectors or shorted leads. If
trouble continues after repair, consult a Bailey service representative
or return unit to factory for repair.
Flasher Replacement
(Refer to Figure 4.)
1. Remove fastener studs and pull Relay Module from systems
cabinet.
2. If module has plug-in relay installed in KX3 position, remove
relay.
3. Disconnect wires to flasher (12).
4. Disassemble flasher by removing hex nuts (20) and washers (21).
5. Install new flasher and rewire in accordance with Figure 5.
6. Replace relay in KX3 position if removed in step 2.
7. Install Relay Module in systems cabinet. Replace fastener studs
and tighten.
REPLACEMENT PARTS
A Parts Drawing covering the Relay Module is shown in Figure 4.
This drawing will normally apply to the units furnished. However, there
may be individual differences in specific assemblies due to:
a. Design changes made since the printing of this Instruction
Section.
b. Special design of equipment furnished to mae it suitable for
special application.
Therefore, when ordering parts, assure receipt of correct
replacements by specifying on the order:
1. Complete nomenclature, code label number and part number of
equipment for which parts are desired.
2. Parts Drawing number on which each part is illustrated. (The
Parts Drawing Number is given in the title for the Figure.)
E92-52
Relay Module Page 5
FIGURE 4 - "Parts Drawing E92-58, Relay Module, Part No. 6615692A"
omitted.
E92-52
Page 6 Bailey
FIGURE 5 "Relay Module Wiring Diagram" omitted.
Instructions for Understanding
Bailey Relay Cabinet
Arrangement and Wire Tabulations
The Bailey Relay Cabinets an sectioned in 11 rows, which contain the
following equipment and designations:
Row 1 1634-pin Amphenol Series 93 Cable Connectors. Cables that
route to the Control Console plug in here. The cable
connector position number is identified by numbers 2 thru
16. The pins on each connector art identified by letter
designation A thru NN.
Rows 2 thru 9 Bailey Relay Modules. The relay modules consist of three
relay sockets, identified as KX1, KX2, and KX3 (front to
rear of module), a flasher relay in some but not all
modules), and two male 32-pin Amphenol Blue Ribbon style
connectors (mounted to the rear of the module). Female
32-pin connectors am mounted on the back of the relay
cabinet, while the rear doors of the cabinet provide
access to this wiring. The pins of the connectors am
identified by numbers 1 to 32, and there are 15 of these
connectors mounted per row on the cabinet's back panel.
Row 10 16 34-pin Amphenol Series 93 Cable Connectors. Cables
that route to the Aux. Control System Terminal cabinets
(located in the Relay Room, directly below the, Control
Room) plug in here. The cable connector position number
is identified by numbers 1 thru 16. The pins on each
connector are identified by letter designation A thru NN.
Row 11 Service Section of the Cabinet. A 40-point terming strip
(which is identified as Position 1) and 10 circuit
breakers (identified as Positions 2 thru 11).
Table omitted.
Figures 1 and 2 "Typical Bailey Relay Cabinet Arrangement" omitted.
Examine the designation in Fig. 1. The cabinet series and cabinet number
is shown in the title block of the arrangement drawing, and identifies
the particular cabinet where the components are located (in this case,
RC25-6). The bottom three characters, as shown, call out the row, wiring
position, and pin number. The row designation should be self explanatory
(they are clearly represented on the arrangement drawings). There are
three wiring positions in each module, where relay sockets X-1 and X-2
(designated as KX1 and KX2 in PSBP #301699) are in the first wiring
position. Relay socket X-3 (KX3 on the PSBP) and the flasher are in the
second wiring position. The third wiring position (which is used for
jumpering on the rear panel of the Bailey Relay cabinet) never has any
equipment located in it.
The rear or the Relay Module has two male Blue Ribbon Connectors mounted
on the rear section, while the rear of the Bailey Relay Cabinet has three
female Blue Ribbon Connectors mounted. There are three wiring positions
in each module, and are numbered from the top to bottom, left to right.
Since there are 5 module slots per row, that yields 15 wiring positions.
Note that there is never any equipment shown in any wiring position
divisible by three (3, 6, 9, 12, & 15). For example, the location of the
74/OP relay for the Rod Control Reactor Bypass Breaker "A" is 6-6-13, or
cabinet 6, row 6, and wiring position 13.
The wiring in the cabinet is color-coded in the following manner:
118 VAC Line,- Black
118 VAC Neutral- White
118 VAC Ground - Green
28 VDC Positive - Brown
28 VDC Negative - Orange
125 VDC Positive - Blue
125 VDC Negative - Yellow
Computer Inputs and - Green
Alarms
Indication - Red
NOTES:
1. Only 2 wires per Blue Ribbon Connector pin may be terminated
(Rows 2 thru 9), and the maximum wire size is #18 AWG.
2. Only 1 wire per Amphenol Series 93 Connector pin (Rows 1 and
10), and the maximum wire size allowable is #22 AWG.
3. All soldering is to be performed by qualified personnel in
accordance with the latest soldering procedure.
Figure "MODULE PART NUMBERs" omitted.
Figure "BAILEY RELAY CABINET (Rear View) omitted.
Figures "idec GT3A SERIES; GT3A-1/GT3A-2/GT3A-3 (Multi-Mode), Four
Selectable Operation Modes In One Timer (On Delay, Interval, Cycle and
Cycle On" omitted.
Figure "GT3A-1, -2, and -3 ALL MULTI-RIVERS (MULTI-MODE TYPE)" omitted.
Figure "Timing Diagrams" omitted.
Figures and Tables "300 VOLT GENERAL PURPOSE PLUG-IN RELAYS" omitted.
Series 219 General Purpose Industrial Plug-In Relays feature a 12
pin and a 14 pin size, from 2 Form C to 4 Form C or 6 Form A/Form B
combinations. A locking clip on the plug is provided as standard. The
coil is encapsulated for protection. Gold diffused silver cadmium oxide
contacts are standard. The screw terminal socket has all terminals on a
single level, which facilitates the wiring process. Nuclear qualified
versions are available. Contact the factory for details.
PUBLIC SERVICE ELECTRIC AND GAS COMPANY
NUCLEAR DEPARTMENT
SPECIFICATION NO. S-C-RCP-CDS-0343
REACTOR CONTROL AND PROTECTION SYSTEM CONTROL RELAYS
DETAILED SPECIFICATION
REFERENCE NO: N/A
IMPORTANT TO SAFETY:
YES NO
Routing form omitted.
Specification No. S-C-RCP-EDS-0343
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TABLE OF CONTENTS
1.0 SCOPE 1
2.0 DEFINITIONS 1
3.0 CODES, STANDARDS AND REGULATORY REQUIREMENTS 3
4.0 SUPPLEMENTAL DATA 4
5.0 DOCUMENT SUBMITTALS 4
6.0 DESIGN REQUIREMENTS 6
7.0 PERFORMANCE REQUIREMENTS 6
8.0 MATERIAL REQUIREMENTS 6
9.0 FABRICATION AND ASSEMBLY REQUIREMENTS 7
10.0 INSTALLATION REQUIREMENTS 7
11.0 INSPECTIONS AND TESTS 7
12.0 QUALIFICATION 7
13.0 CLEANING 9
14.0 MARKING AND IDENTIFICATION 9
15.0 PACKAGING, HANDLING AND STORAGE 10
16.0 DEFECTS AND NONCOMPLIANCES 10
17.0 RECORDS 10
18.0 OTHER REQUIREMENTS 10
19.0 RIGHT OF ACCESS 10
20.0 GA PROGRAM REQUIREMENTS 11
21.0 RELAY SPECIFIC REQUIREMENTS 12
21.1 219 Series 300 V General Purpose Plug-In Relay
Specification Requirements 13
21.2 B255 Series 300 V Latching Plug-in Relay
Requirements 16
21.3 219 & B255 Series Mating Socket Physical
Dimensions 19
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Specification No. S-C-RCP-EDS-0343
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1.0 SCOPE
This specification defines the construction, functional,
performance, quality assurance and shipping requirements for
Struthers-Dunn 219 and B255 Series general purpose and latching
plug-in relays respectively. These relays are used in various
applications in the Reactor Control and Protection System and
various other control systems at Salem Nuclear Generating Station
Units 1 and 2. An equivalent replacement relay is acceptable. If it
meets all the requirements of this specification and has the same
form, fit and function as the Struthers-Dunn 219 and B255 Series
relays.
It is not the Intent herein to specify all details of design and
construction. It shall be the responsibility of the Vendor to
ensure that the equipment has been designed and fabricated in
accordance with engineering codes, standards, and federal and state
regulations in accordance with section 3.0 and 4.0 of this
specification.
No deviation from this specification or applicable federal, state,
and local codes and standards shall be accepted until approved by
PSE&G. Deviations are considered departures from any requirements
of this specification.
Nonconformances from federal, state, and local codes and standards
must be submitted to the cognizant jurisdictional agency for
authorization, prior to submittal to PSE&G. After obtaining
approval, Vendor shall promptly document and notify PSE&G of all
deviations and nonconformances from the purchase order/contract.
Further engineering, manufacturing or fabrication after detection of
any deviation or nonconformance prior to PSE&G approval shall be at
the Vendor's risk. No departures from this specification shall be
binding on any party until an addendum or revision to the
specification has been issued.
2.0 DEFINITIONS
2.1 Abbreviations/Definitions
ANSI - American National Standards Institute
Approved - this word, when applied by the Owner to the Vendor's
drawings or documents, means that the drawings or
documents are satisfactory from the stand-point of
interfacing with all Owner-furnished components of
the installation and/or that the Owner has not
observed any statement or feature that appears to
deviate from the Specification's requirements.
Except for the interfacing
Specification No. S-C-RCP-EDS-0343
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Page 2
with all Owner furnished components, the Vendor shall
retain the entire responsibility for complete
conformance with all of the specification's
requirements.
Class 1E - the safety classification of the electrical equipment
and systems that are essential to emergency reactor
shutdown, containment and reactor host removal or are
otherwise essential in preventing significant release
of radioactive material to the environment.
Design - the time during which satisfactory performance can be
Life expected for a specific set of service conditions.
NEMA - National Electrical Manufactures Association
IEEE - Institute of Electrical and Electronic Engineers
OBE - Operational Basis Earthquake
Owner - Public Service Electric and Gas, Newark, New Jersey
PSE&G - Public Service Electric And Gas
PSIA - pounds per square inch absolute
Seismic - indicates that the equipment has been classified and
Qualified certified to meet its performance requirements during
and following one SSE preceded by five OBE's. All
seismically qualified equipment shall satisfy
Category 1 seismic requirements.
Service - the Interval from installation to removal, during
Life which the equipment may be subject to service
conditions and service demands.
SQURTS- Seismic Qualification Report & Testing
Standardization
SSE - Safe Shutdown Earthquake
Vendor- a company either submitting a proposal or selected to
fulfill the requirements of this specification.
Specification No. S-C-RCP-EDS-0343
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3.0 CODES, STANDARDS AND REGULATORY REQUIREMENTS
3.1 General
3.1.1 Various codes and addenda, standards, or other documents that
are mentioned by short form name elsewhere in this
specification are fully identified below. To the extent that
these documents apply, as stated herein, the version of the
document listed below shall be used. A later version of some
of the dated documents may become mandatory under regulations
that have jurisdiction. If this occurs, the mandated version
of the document shall be used.
3.1.2 If there is, or seems to be, a conflict between this
specification and a reference document, the matter shall be
referred to the Owner who will provide written clarification.
3.2 Various applicable documents follow:
ANSI N45.2.2 - 1972 Packing, Shipping, Receiving, Storage, and
Handling of Items for Nuclear Power Plants
ANSI N45.2.11 - 1974 Quality Assurance Requirements for the
Design of Nuclear Power Plants
IEEE 344 - 1975/87 Recommended Practices for Seismic
Qualification of Class 1E Equipment for
Nuclear Power Generating Stations
SQTS-01-GSQTP General Seismic Qualification Technical
Rev 4 Procedure
SQTS-01-CR-1-SFP General Purpose Control Relays Seismic and
Rev. 5 Functional Procedure
UL 508 - 17th edition Standards for Safety Industrial Control
Equipment
Regulatory Guide 1.38 Quality Assurance Requirements for
October 1976 Packaging, Shipping, Receiving, storage,
and Handling of Items for Water-Cooled
Nuclear Plants (endorses ANSI N45.2.2 1972)
Specification No. S-C-RCP-EDS-0343
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Regulatory Guide 1.64 Quality Assurance Requirements for the
October 1973 Design of Nuclear Power Plants (endorses
ANSI N45.2.11-1974)
Regulatory Guide 1.100 Seismic Qualification of Electrical
Equipment for Nuclear Power Plants
(endorses IEEE 344-1975)
Title 10 Code of Federal Regulations
Part 21 Reporting of Defects and Noncompliance
Part 50 Domestic Licensing of Production and Utilization
Facilities
Appendix A General Design Criteria for Nuclear Power Plants
Appendix B Quality Assurance Requirements for Nuclear Plants and
Fuel Reprocessing Plants
4.0 SUPPLEMENTAL DATA
4.1 The Public Service Electric and Gas Company's Salem Generating
Stations have committed to meeting the requirements of the
Regulatory Guides of Section 3.2. Compliance with the Regulatory
Guides shall be accomplished by satisfying the requirements of the
associated ANSI, IEEE or ISA standards.
4.2 PSE&G - Standard Specification 0-01, "Quality Requirements for
Suppliers."
5.0 DOCUMENT SUBMITTALS
5.1 Equipment Qualification Reports
5.1.1 The Vendor shall supply the Owner, for review and approval,
four (4) copies of the Qualification report demonstrating
compliance with the testing requirements of Section 12.0. Upon
approval by the Owner, this requirement may be waived.
5.1.2 The qualification report shall document the results of the
relay type testing performed and any analyses associated with
such testing.
5.1.3 Qualification reports shall Include recorded date on all
qualification tested samples.
Specification No. S-C-RCP-EDS-0343
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5.1.4 The qualification report shall document, evaluate and
disposition any malfunctions, anomalies or performance
deviations which occurred during testing.
5.1.5 All test results shall be reviewed, approved and signed by
qualified personnel.
5.1.8 The Vendor shall confirm in writing and shall submit a report,
including calculations and/or test data, for approval by the
Owner which supports his statement that the equipment furnished
under the specification meets the requirements for the Safe
Shutdown Earthquake, Operating Basis Earthquake, and any other
effects listed herein. The Vendor shall, as part of his
report, provide natural frequency data determined by either
analysis or test. The analysis or lost shall confirm that the
resulting deflections shall not cause damage to the equipment
which may be detrimental to its capability to function as
specified. The Vendor shall include a schedule of submittals,
approvals, interface resolutions, and certificates to be
submitted to, or received from, the Owner, as discussed herein.
When seismic qualification is based on testing, a fully
detailed test plan must be submitted to the Owner for approval
prior to the initiation of testing, unless equipment has been
pre-qualified. Any deviations from the approved test procedure
must be approved by the Owner. Resolution of Engineering
comments on module qualifications may require additional
testing which will be negotiated.
5.1.7 All qualification reports shall be of high quality and
legibility.
5.1.8 Manuals and reports shall be bound so that copies of each page
may be easily made and revised pages may be easily added.
5.1.9 Each qualification report submittal shall have a unique control
number for reference and control purposes.
5.1.10 Vendor provided qualification documentation should be
identified with the PSE&G name and purchase order number.
5.1.11 A controlled copy of the qualification report shall be supplied
with a purchased equipment whenever new qualification testing
has been performed.
5.1.12 One controlled copy of each qualification report shall be
retained at the Vendor's file for future reference.
Specification No. S-C-RCP-EDS-0343
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6.0 DESIGN REQUIREMENTS
6.1 The relay physical dimensions and coil & contact configuration
shall be as shown by Attachments for the applicable relay type.
6.2 Relays shall plug into the socket assembly shown by Attachment
for the applicable relay type.
6.3 Relays shall have a design life of not less then 40 years while
in service under the mild environment defined in Section 6.4.
The relay application (normally energized vs. normally de-
energized) shall not affect the 40 year design life. The
following exceptions shall apply;
- maximum of 10 million mechanical operations
- 100,000 at rated load
- 500,000 at half rated load
6.4 Environmental Design Requirements
6.4.1 Relays shall be designed to operate in various instrument and
relay racks with the following service condition environment
Minimum Maximum
Temperature (degrees F) 40 140
Pressure (PSIA) 14.69 15.20
Relative Humidity (%) 20 90
Radiation (Total Integrated
Dose in RADS-gamma for 40 yrs.) <.10**4
7.0 PERFORMANCE REQUIREMENTS
7.1 The relays shall have performance characteristics which meet or
exceed the specific performance requirements for each relay
type in accordance with the Attachments to this specification.
For specific performance requirements for each relay type see
the applicable Attachment.
8.0 MATERIAL REQUIREMENTS
8.1 Relays shall be constructed of high quality materials.
Specification No. S-C-RCP-EDS-0343
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9.0 FABRICATION AND ASSEMBLY REQUIREMENTS
9.1 Relays shell be designed and constructed in accordance with the
applicable Attachments. Equivalent replacement relays shall
have the same physical dimensions, mounting, and coil and
contact configuration as previously qualified relays to achieve
the form, fit and function of the original relay.
9.2 Relay design, material and workmanship shall result in a high
quality product.
10.0 INSTALLATION REQUIREMENTS
10.1 Relays shall be designed for mounting In a socket in accordance
with the applicable Attachment. Mounting may be in the
vertical or horizontal plane in various equipment racks.
11.0 INSPECTIONS AND TESTS
11.1 The Owner's authorized representatives shall reserve the right
to inspect design, materials and workmanship and to report
thereon, at any time during the program of design, fabrication
or testing.
12.0 QUALIFICATION
12.1 Electrical and Environmental Qualification Requirements
12.1.1 Relays shall be qualified for operation in the environment
specified in Section 0.4. Relay parts shall not be subject to
degradation for the specified life of the component.
12.1.2 Relays shall have UL 508 certification. The Vendor shall
document the applicable parts of the UL 508 certification.
12.1.3 Design changes, part substitutions and other modifications to
previously qualified designs require either additional
qualification testing or analysis to prove now designs are
qualified or to confirm changes have no impact on previous
qualification testing respectively. The Vendor shall notify
and inform the Owner of design changes or modifications to
previously approved designs.
Specification No. S-C-RCP-EDS-0343
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12.2 Seismic Qualification Requirements
12.2.1 Seismic Qualification adequacy of the equipment shall be
established by the results of seismic tests performed in
accordance with IEEE Standard 344-1975/1987 as applicable and
the combination of SQTS-01-GSQTP titled, "General Seismic
Qualification Technical Procedure" and SQTS-01 CR-1-SFP titled,
"General Purpose Control Relays Seismic and Functional
Procedure."
12.2.2 The Vendor shall qualify the equipment for the specified
seismic requirement either by performing a similarity analysis
to a previously qualified equipment whose seismic qualification
level is adequate to envelope the required seismic response
spectra for the new equipment, or by performing the required
simulated seismic qualification tests. Qualification testing
or analysis should address relay mounting in the vertical or
horizontal plane.
12.2.3 The equipment should be seismic tested to its fragility level
or test response spectra (TRS) shall envelope the site specific
required response spectra (RRS) when attached.
12.2.4 The minimum acceptance criteria or each seismically tested
module shall include the following:
- No loss of function or ability to perform designed
functions before, during and after testing.
- No structural or electrical failure which could compromise
equipment integrity,
- No adverse operation or misoperation before, during and
after testing. Maximum allowable contact bounce (change
of state) shall be 2 milliseconds during seismic testing.
Test equipment shall be capable detecting contact bounce
of 2 milliseconds or shorter duration.
12.3 Prototype Testing
12.3.1 Qualification programs may be based on prototype testing of
equipment. A representative sample of each module type must be
tested. Engineering justification of the program must be
provided to assure qualification of all equipment supplied.
Specification No. S-C-RCP-EDS-0343
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Vendors may qualify equipment based on prior testing provided
the test report is available to the Owner and the Vendor
submits a report showing that this prior test meets seismic
testing requirements herein. Changes to standard qualification
documentation will be negotiated if review and approval
requires modification.
A final analysis and/or test report shall be compiled by the
Vendor and submitted to the Owner for approval. It is required
that the qualification document be complete and address fully
the equipment being supplied in accordance with this
specification.
12.4 Certification of Compliance
12.4.1 The seismic testing data report shall be stamped and signed by
a Registered Professional Engineer. The Vendor shall submit a
Certificate of Compliance (COC) documenting compliance to the
design and qualification requirements of the specification.
The certificate should reference the applicable purchase order,
this specification and the applicable qualification report.
The certificate shall be signed by the appropriate Quality
Assurance representative.
12.4.2 The assemblies used for seismic testing or qualification shall
not be used as a deliverable to the Owner. These test
specimens are previously fatigued and are not suitable for
operation.
12.4.3 The equipment shall perform its intended function when exposed
to the service conditions environment specified in Section 6.4.
A Certificate of Conformance shall be supplied. This should
state that the equipment will perform its intended function
within the applicable accuracies when subjected to the
environmental conditions identified herein.
13.0 CLEANING
13.1 Before testing and prior to shipping, relays shall be
thoroughly cleaned to remove dust, debris and other foreign
materials. Cleaning agents used shall not damage finished
surfaces or adversely affect material properties and function
of equipment.
14.0 MARKING AND IDENTIFICATION
14.1 Each relay shall have a nameplate which identifies the model
number, part number, serial number, coil voltage rating and
manufacturing date.
Specification No. S-C-RCP-EDS-0343
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15.0 PACKAGING, HANDLING AND STORAGE
15.1 The packaging, handling, storage and preparation of relays for
shipment shall be in accordance with ANSI N45.2.2 level B
requirements. Relays shall be thoroughly protected against the
elements and damage during transit and storage.
15.2 Equipment contents, part numbers and the Owner's purchase order
number shall be clearly marked on shipped packages.
15.3 Vendor shall provide to the Owner instructions for applicable
storing and handling instructions.
16.0 DEFECTS AND NONCOMPLIANCES
16.1 The equipment covered by this Specification is safety related
and is subject to the requirements of 10CFR Part 21 for the
reporting of defects and noncompliances.
17.0 RECORDS
17.1 See Section 5.0 of this specification for all required
documentation.
17.2 Qualification documentation and other correspondence related to
the relays procured by this specification shall be retained by
the Vendor for a minimum period of at least the equipment
design life. These records should be forwarded to PSE&G for
retention if they will not be retained by the Vendor.
17.3 All records shall be reproducible end capable of being
microfilmed.
18.0 OTHER REQUIREMENTS
18.1 The terms and conditions of any warranty for the relays shall
be clearly defined by the Vendor.
19.0 RIGHT OF ACCESS
19.1 The Owner shall have access to all vendor and sub-tier
facilities and records which are directly related to the relays
procured by this specification.
Specification No. S-C-RCP-EDS-0343
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19.2 The Owner shall notify the Vendor seven (7) calendar days in
advance of such inspections.
20.0 QA PROGRAM REQUIREMENTS
20.1 Suppliers of equipment to this specification are required to
have a quality assurance programs which comply with the
requirements of 10CFR50, "Quality Assurance Criteria for
Nuclear Power Plants and Fuel Processing Plants," Appendix 5
and ANSI N45.2.11-1974 and demonstrate implementation through
audit and/or inspection by the Owner.
20.2 The Vendor shall comply with PSE&G standard specification 0.01,
Quality Assurance Requirements for Suppliers.
20.3 The Vendor's Quality Assurance Program shall be documented and
shall, be approved by the Owner prior to the award of the
contract.
20.4 Inspection and witnessing of in-process testing shall to be
made available at the Owner's discretion and dependent upon
proper notification by the Vendor prior to the performance of
in-process testing. The Vendor shall notify the Owner's
Quality Assurance Department by facsimile at (609) 339-7707 at
least 72 hours prior to all vendor hold points.
20.5 Prior to shipment, the Owner has the option of performing a
detailed inspection of the assembled relays. This inspection
shall not lesson the responsibility of the Vendor for the
completeness and correctness of the modules.
20.6 Parts or materials indicating irremediable or injurious
defects, improper fabrication, excessive repairs, and/or not in
accordance with this specification, the QA program, or approved
drawings shall be subject to rejection. They shall also be
subject to repair or replacement by the Vendor if such
conditions are discovered after delivery at the Owner's
facility.
Specification No. S-C-RCP-EDS-0343
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21.0 RELAY SPECIFIC REQUIREMENTS
Note: A site specific required response spectra (RRS) will be
attached when required. Reference Section 12.2.3.
21.1 219 Series 300 V General Purpose Plug-In Relay Specification
Requirements
219 Series Relay Physical Dimensions and Contact Arrangement
21.2 B255 Series 300 V Latching Plug-In Relay Requirements
B255 Series Relay Physical Dimensions and Contact Arrangement
21.3 219 & B255 Series Mating Socket Physical Dimensions
Specification No. S-C-RCP-EDS-0343
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SECTION 21.1
219 Series 300 V General Purpose Plug-in Relay Specification Requirements
Reference: Struthers-Dunn Commercial/Industrial Relays Catalog
Type 219BBXP: Double-pole, double-throw plus 2 normally-open sets of
contacts
Type 219ABAP: Double-pole, double-throw plus 1 normally-open and 1
normally-closed set of contacts
General Data:
Insulation: 1/4" surface, 1/8" air
Dielectric: 1500 VAC minimum
Operate Time: 25 ms maximum
Release Time: 20 ms maximum
Coil Data:
120 VAC Relay, 50-60 Hz, 5 VA:
Voltage: 102 - 132 VAC
Current: 75 mA open, 40 mA closed (typical)
Impedance: 2700 ohms (typical)
Resistance; 540 ohms +/- 10%
24/28 VDC Relays, 2.3 W at 25 degrees C:
Voltage: 19.2 - 30.8 VDC
Current: 77 mA hot, 915 mA cold (typical)
Resistance: 250 ohms +/- 10%
115/125 VDC Relays, 2.5 W at 25 degrees C:
Voltage: 90 - 140 VDC
Current: 16 mA hot, 20 mA cold (typical)
Resistance: 6200 ohms +/- 10%
Specification No. S-C-RCP-EDS-0343
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SECTION 21.1
219 Series 300 V General Purpose Plug-in Relay Specification Requirements
Contact Data:
Composition: Gold diffused silver cadmium oxide contacts unless
specified otherwise
120 VAC: 30 A make, 10 A carry, 10 A resistive break, 3 A inductive
break
24/28 VDC: 30 A make, 10 A carry, 10 A resistive break, 3 A Inductive
break
115/126 VDC: 30 A make, 10 A carry, 0.5 A resistive break, 0.1 A
inductive break
Optional Features:
- Indicator Lamp
- Coil suppression
Specification No. S-C-RCP-EDS-0343
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SECTION 21.1
Figure "219 Series Relay Physical Dimensions and Contact Arrangement"
omitted.
Specification No. 6-C-RCP-EDS-0343
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Page 16
SECTION 21.2
B255 Series 300 V Latching Plug-In Relay Requirements
Reference: Struthers-Dunn Commercial/Industrial Relays Catalog
Type B255XCXP: Three-pole, double-throw
General Data:
Insulation: 1/4" surface, 1/8" air
Dielectric: 1500 VAC minimum
Operate Time: 25 ms maximum, mechanically latches until reset coil is
energized, even if power is interrupted
Release Time: 20 ms maximum, when reset coil is energized
Coil Data:
120 VAC Relay, 50-60 Hz, 5 VA;
Voltage: 102 - 132 VAC
Reset Coil (3 VA):
Current @ 60 Hz: 22.6 mA (typical)
Resistance: 1700 +/- 10% ohms
Operate Coil (5 VA):
Current @ 60 Hz: 75 mA open, 40 mA closed (typical)
Resistance: 540 +/- 10% ohms
24/28 VDC Relays, 2.3 W at 25 degrees C:
Voltage: 19.2 - 30.8 VDC
Reset Coil (1, 7 W):
Current: 70 mA (typical)
Resistance: 340 +/- 10% ohms
Specification No. S-C-RCP-EDS-0343
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SECTION 21.2
B255 Series 300 V Latching Plug-In Relay Requirements
Operate Coil (2.3 W):
Current: 96 mA (typical)
Resistance: 250 + /- 10% ohms
115/125 VDC Relays, 2.5 W at 25 degrees C:
Voltage: 90 - 140 VDC
Reset Coil (, 7 W):
Current: 13.8 mA (typical)
Resistance: 9000 +/- 10% ohms
Operate Coil (2.5 W):
Current: 20 mA cold, 16 mA hot (typical)
Resistance: 6200 +/- 10% ohms
Contact Data:
Composition: Gold diffused silver cadmium oxide contacts unless
specified otherwise
120 VAC: 30 A make, 10 A carry, 10 A resistive break, 3 A inductive
break
24/28 VDC: 30 A make, 10 A carry, 10 A resistive break, 3 A inductive
break
115/125 VDC: 30 A make, 10 A carry, 0.5 A resistive break, 0.1 A
inductive break
Optional Features:
- Indicator Lamp
- Coil suppression
Specification No. S-C-RCP-EDS-0343
Revision 0
Page 18
SECTION 21.2
Figure "B255 Series Relay Physical Dimensions and Contact Arrangement:
omitted.
Specification No. S-C-RCP-EDS-034-3
Revision 0
Page 19
SECTION 21.3
Figure "219 & B255 Series Mating Socket Physical Dimensions" omitted.
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