United States Nuclear Regulatory Commission - Protecting People and the Environment

ACCESSION #: 9505090038


April 28, 1995

Thomas Murley
Office of Nuclear Reactor Regulation
11555 Rockville Pike
Rockville, MD 20852

Reference: Report No.  10CFR21-0072

Subject:  Reportable defect with General Electric HEA 63
          lockout relay

Dear Mr.  Murley:

MKW Power Systems' report 10CFR21-0072 is attached which addresses a
10CFR21 reportable defect with the General Electric type HEA63 lockout

This report is also being mailed to Florida Power & Light Turkey - Point
plant, our only customer affected by this notification.

Yours very truly,


Michael Nuding
General Manager - Quality Assurance



     Post Office Box 1928 o Rocky Mount, North Carolina 27802-1928
                          Phone: (919) 977-2720
                TWX: (510) 929-0725 o FAX: (919) 446-3830


                                        Report No.  10CFR21-0072
                                        April 28, 1995

                      10CFR21 REPORTING OF DEFECTS
                           AND NON-COMPLIANCE

COMPONENT:     General Electric HEA63 Lockout Relay
               with electric reset

SYSTEM:        Diesel Generator control system

CONCLUSION:    Defect is Reportable in Accordance with 10CFR21

PREPARED BY:                                           DATE:
               Donald D.  Galeazzi
               Engineering Manager

PREPARED BY:                                           DATE:
               Michael Nuding
               General Manager, Quality Assurance

                                             REPORT NO.  10CFR21-0072
                                             PAGE: 1 OF 2


MKW Power Systems received notification on 4/24/95 from General Electric
(see Exhibit 1) about a reported mechanical defect in the shaft length of
some HEA63 lockout relays manufactured between 1990 and 1994.  The
problem was corrected in September 1994.


General Electric HEA63 lockout relay.


Florida Power and Light - Turkey Point

MKW SO#   PART#               CUST PO#       SHIP-DATE           QTY

500148    12HEA63C240X2       B88636 90030   02-12-90              1
504216    12HEA63C240X2       C91663 90073   10-03-91              1
506834    12HEA63C240X2       C92659 90391   02-25-93              1
30122     12HEA63C240X2       C91663 90073   02-04-94              1

The defect has been identified as a short front shaft which connects the
HEA handle to a floating coupling on the rotary solenoid.  This can
result in binding of the front shaft if it should disconnect from the
rotary solenoid.


1)   Check the suspect HEA63 relays for the date codes listed below.  The
     date codes are located on the back of the relay.

                           SUSPECT DATE CODES

     YEAR  JN  FB  MR  AP  MY  JN  JL  AG  SP  OC  NV  DC
     1990: NE, OE, PE, RE, SE, TE, UE, VE, WE, XE, YE, ZE
     1991: NF, OF, PF, RF, SF, TF, UF, VF, WF, XF, YF, ZF
     1992: NG, OG, PG, RG, SG, TG, UG, VG, WG, XG, YG, ZG
     1993: NH, OH, PH, RH, SH, TH, UH, VH, WH, XH, YH, ZH
     1994: NI, OI, PI, RI, SI, TI, UI, VI, WI

2)   Perform the Inspection Procedure contained in Exhibit 1 on any
     relays identified as suspect in accordance with the above date
     codes.  Order replacement shaft #0286A5616G1 to correct any relays
     found to be defective.

                                                 REPORT NO.  10CFR21-0072
                                                 PAGE: 2 OF 2

                                EXHIBIT 1
                                (1 page)


                                                            GE Protection
                                                            & Control

                              Protection & Control
                              General Electric Company
                              205 Great Valley Parkway,
                                Malvern, PA 19355-1337

                       RELAY SERVICE ADVICE LETTER

Subject: HEA63 Lockout Relay

     Issued by: Customer Service             Number: 511.1
     Prepared by: J. Kennedy                 Date: April 10, 1995

One utility has reported an incident in which an HEA63 failed to operate.
The HEA63 is a lockout relay with-electric reset.  The failure was caused
by binding of the front shaft when it disconnected from the rotary
solenoid used for resetting the HEA. The root cause was identified as a
short front shaft.  The front shaft connects the HEA handle to a floating
coupling on the rotary solenoid.  (These parts are used only in the
electric reset model, HEA63).  Manufacturing and inspection procedures
were revised in September, 1994 to preclude a reoccurrence of this

The utility later checked a large number of other HEA63 relays and found
10 with shafts short enough to potentially misoperate.  Date codes found
on the relays with short shafts covered the period between 1990 and 1994.
These shafts are cut to length, per order, in our factory from long
lengths of shaft material.  Each one is individually measured and cut by
a machine operator.  Even though the problem is not generic, we are
informing customers through this letter because of the critical role of
the HEA in protection systems.

Users of HEA63 relays may choose to check for the condition described
above using the inspection procedure given below.  Only HEAs with
electric reset need to be checked for this condition.  This includes
special models of the electric reset relay: HEA99AA, AC, AD, AK, AN, BB,
BD, BH, BJ, BK, BL, BM, BN, and BR.
NOTE: BEA61 and HEA62 series relays are not electric reset.  Therefore
they are not affected by this service advice letter.

Inspection Procedure:
1. Check amount handle and front shaft can be rotated without rotating
the coupling.  (Use this information as reference for Step 5.)

2. Manually reset the relay.

3. Push handle firmly toward rear of relay.  This will remove all slack
along the axis of shaft.  If handle bottoms on escutcheon, remove handle.

4. Pull shaft firmly toward front of relay.  Reinstall handle, if

5. Repeat Step 1.  A Significant increase in rotation, e.g., 15 - 90
degrees indicates the shaft may have disconnected from its coupling and
has the potential to cause misoperation of the HEA.

Replacement shafts are available and can be ordered on a no-charge basis
until May 1, 1996.  Order one kit for each HEA found with a short shaft.
               For models ending in X2: order kit 0286A5616G1
               For models ending in X12: order kit 0286A5616G3
               For models ending X16: order kit 0286A5616G2
               For models ending in X24: order kit 0286A5616G4

Field labor associated with this Service Advice Letter is the
responsibility of the user.


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