ML20053C763
| ML20053C763 | |
| Person / Time | |
|---|---|
| Issue date: | 05/03/1982 |
| From: | Barnes I, Oller R NRC OFFICE OF INSPECTION & ENFORCEMENT (IE REGION IV) |
| To: | |
| Shared Package | |
| ML20053C758 | List: |
| References | |
| REF-QA-99900359 NUDOCS 8206020543 | |
| Download: ML20053C763 (14) | |
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e, ORGANIZATION:
EXIDE CORPORATION I
RICHMOND, KENTUCKY REPORT INSPECTION INSPECTION NO.:
99900359/82-01 OATE{S) 3/16-19/82 ON-SITE HOURS: 27 CORRESPONDENCE ADDRESS:
Exide Corporation ATTN:
Mr. Charles Reichart Contracts Administrator 101 Gibraltor Rd.
Horsham, PA 19044 ORGANIZATIONAL CONTACT:
Mr. Earl Price, Plant QA Manager TELEPHONE NUMBER:
(606) 624-1000 PRINCIPAL PRODUCT: Lead Acid Batteries NUCLEAR INDUSTRY ACTIVITY: The Richmond, Kentucky, plant nuclear output, based on sales is 8%.
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ASSIGNED INSPECTOR:
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p R. E. Oller, Reactive & Components Program Date Section (R& CPS)
OTHER INSPECTOR (S):
APPROVED BY:
b Y 2 2, I. Barnes, Chief, R& CPS Date INSPECTION BASES AND SCOPE:
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BASES:
2.
SCOPE:
Status of previous inspection findings; manufacturing process control; change control, and nonconformances and corrective action.
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PLANT SITE APPLICABILITY:
Perry Nuclear Station, Units 1 and 2, Dockets 50-440 and 50-441
___.,.e.-rn nRIGINAL s 8206020543 820514 gt @
PDR GA999 EMVEXIDE Gortified W W ~
99900359 PDR
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ORGANIZATION:
EXIDE CORPORATION RICHMOND, KENTUCKY REPORT I INSPECIlON NO.:
99900359/82-01 RESULTS:
PAGE 2 of 6 A.
VIOLATIONS:
None B.
NONCONFORMANCES:
None C.
UNRESOLVED ITEMS:
None D.
STATUS OF PREVIOUS INSPECTION FINDINGS:
1.
(Closed) Deviation A (79-01):
Failure to include the purchase order number in the identification of 60 type 2 GN-15 batteries, as required by paragraph 8.3.7 of the QA Manual, Revision 8.
The inspector verified that in accordance with the vendor's response letter, dated June 19, 1979, review by Exide had t
established that the stationary battery post design could not accommodate the appiication of the P.O. number.
To resolve this problem, Exide has revised paragraph 8.3.7 of the QAM to delete this requirement.
The current practice is to identify the batteries by stamping the posts with codes traceable to test data reports which identify the type, catalog designation, location, shipping date and P.O. number.
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2.
(Closed) Deviation B (79-01):
Failure to provide MRB hold areas for segregation of nonconforming manufactured parts, subassemblies, and assemblies, as required by paragraph 15.9 of the QA Manual, Revision 8.
The inspector verified by observations in tt.e shop, that in accordance with the vendor's response letter, dated June 19, 1979, four MRB hold areas are now identified in the shop with signs and boundary paint marks.
Items placed in these areas are red tagged and monitored on a daily basis by the assigned QC area controller.
ORGANIZATION:
EXIDE CORPORATION RICHMOND, KENTUCKY REPORT IN5PtLi10N NO.:
99900359/82-01 RESULTS:
PAGE 3 of 6 3.
(Closed) Deviation C (79-01):
Failure to define and document the effective date of corrective action for Corrective Action Requests Nos. R-006 and R-013, as required by paragraph 16.4.2 of the QA Manual, Revision 8.
The inspector verified that in accordance with the vendor's response letter, dated June 19, 1979, the two above CARS and current CARS had the corrective actions defined, signed, and dated by the plant QC Manager.
Discussion, however, established that the requirements of paragraph 16.4.2 of the QAM were not clear, and the Exide QA Engineer indicated this paragraph will be revised to more clearly define this requirement.
4.
(Closed) Deviation 0 (79-01):
Failure to perform and document yearly audits in the areas of M/P cell assembly, stationary cell assembly, and plate finishing prior to March 30, 1979, and of the areas of casting / pasting / filling after August 25, 1977, as required by paragraph 18.3.1 of the QA Manual, Revision 8.
The inspector verified that in accordance with the vendor's response letters dated June 19 and Novemoer 1, 1979, the entire Richmond plant QA program was audited on June 20, 1978, by the Chief Engineer, and on April 13, 1979, by the Manager, Design Engineering, and more recently by a management audit team.
The inspector also determined that while procedure QCP-57.0, which controlled the audits by QA management, listed nine l
production activities which would be audited on an annual basis, the assigned checklist used by the auditors, did not specifically address the nine areas.
The checklist, instead, addressed the entire QA program, and it could not be specifically related to the nine production activities.
The Exide QA Engineer indicated he would revise the checklist to clarify this condition.
5.
(Closed) Deviation E (79-01):
Failure to maintain the required melt time of 15 seconds and a mating time of 20 seconds for stationary cells, as required by paragraph 3.8.7.a of the Temporary Manufacturing Requirement No.14.1(R), dated May 16, 1978, and failure to air test the stationary cells at both 1.5 and 2.0 psi as required by Special Manufacturing Instruction j
No. 6, dated July 26, 1978.
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m' v' M7r ORGANIZATION:
EXIDE CORPORATION RICHMOND, KENTUCKY REPORT ANbFtLi1VN NO.:
99900359/82-01 RESULTS:
PAGE 4 of 6 The inspector verified that in accordance with the vendor's response letters dated June 19 and November 1, 1979, the TMI No. 14.1(R),
dated May 16, 1978, was in error and it was revised on May 9, 1979, to correct the melt and mating time to minimum values of 15 and 20 seconds, respectively.
With regard to the air test, the SMI No. 6 was cancelled and superseded by the revised TMI which specified the air test shall be performed only at 1.5 psi for 15 seconds minimum.
This TMI was subsequently superseded by Manufacturing Requirement No. 102, Section 20.6, issued August 24, 1981.
These activities are currently being monitored on a weekly basis by the QC area controllers and recorded on checklists.
6.
(Closed) Deviation F (79-01):
Failure to indicate specific hold points in documents controlling manufacturing, inspection, and test activities, to accomodate customer imposition of mandatory inspection hold points, as required by paragraph 10.12 of the QA Manual, Revi-sion 8.
The inspector verified that in accordance with the vendor's response letters dated June 19 and November 1, 1979, the procedure controlling establishment of hold points is No. QCP 60.0 and a " Customer Contract-Quality Assurance Checklist." This QCP and checklist were revised on November 1, 1979, to reflect organizational changes.
They were subsequently superseded by procedure QAP-60.0 en September 22, 1981.
Review by the inspector of QAP-60.0 and a current Customer Contract QA/C Checklist for Exide Order No. 77706/77709 for Perry Nuclear Station established that this checklist provided for Customer Witness and Hold Points.
7.
(0 pen) Unresolved Item E.3.b.1 (79-01):
Paragraph 7.11 of the QA Manual, Revision 8, and paragraph 4.2 of the QC Procedure No. 30.1, dated June 13, 1977, require that the checker at receiving initial each invoice upon receipt of purchased material.
In practice, the checker initials the Bill of Lading and initiates a Receiving Report.
The inspector verified that the statements in the QA manual and QA procedure were in error since the invoices do not go to the receiving checker, but do go directly to the accounting department.
The Exide QA Engineer indicated that the QA manual and QC procedure will be revised to reflect the actual practice.
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ORGANIZATION:
EXIDE CORPORATION RICHMOND, KENTUCKY REPORI IN5PEGl1UN NO.:
99900359/82-01 RESULTS:
PAGE 5 of 6 8.
(Closed) Unresolved Item E.3.b.2 (79-01):
Due to the area identifi-cation on the audit checklist being different from the audit area identification in the QC procedure, the inspector was unable to determine that areas were audited as required.
The inspector found during the current inspection that this item is a duplicate of deviation 0 and is closed.
E.
OTHER FINDINGS OR COMMENTS:
1.
Manufacturing Process Control:
The inspector reviewed seven sections of the Exide QA manual which were applicable to the GN (nuclear) type stationary battery parts manufacture, assembly, tests, inspections, QC monitoring, and shipping.
Observations were made of battery grids and small parts casting, grid pasting and finishing, chemical sampling, battery assembly, final inspection, and the calibration status of production measuring tools and process control indicating and recording instruments.
Review, also, included the following QC monitoring records, procedures, and specifications maintained in various manufacturing areas by the four QC Area Controllers:
10 QC procedures; 7 manufacturing require-ments procedures; 3 quality characteristic lists specifications; 1 process specification; 8 weekly castings QC checklists; 10 plate pasting QC checklists; 10 weekly stationary inspection and process verification QC checklists; 4 weekly stationary product inspection reports; 10 weekly battery finishing and shipping QC checklists; 10 weekly small parts process QC checklists; and 6 (twice weekly) charging process QC checklists.
Within this area, no nonconformances to NRC or QA program requirements were identified, and no unresolved items were identified.
2.
Change Control:
The inspector reviewed the QA Manual Section 3,
" Design Documentation and Change Control," and Section 6, " Quality Documents, Preparation and Issuance Of," which were applicable to changes in engineering generated manufacturing documents, and QA and QC documents.
A review was also made of:
an administrative document control procedure QAP-55.0; two records of Engineering Change Notices requesting changes to manufacturing requirement procedures; one record of an Engineering Specification Notice; one Design Notice covering a change in a design drawing; and one record of a Purchase Specification Notice.
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ORGANIZATION:
EXIDE CORPORATION RICHMOND, KENTUCKY REPORT INSPECTION NO.:
99900359/82-01 RESULTS:
PAGE 6 of 6 Review and discussion also established that only the QC procedures and their changes, were totally generated and approved at the Richmond plant level.
While changes to engineering, manufacturing, and QA documents may be requested at plant level using ECRs, the final approvals and changes are controlled at the Yardley and Horsham, Pennsylvania, engineering, quality assurance, and corporate levels.
Within this area, no nonconformances to NRC and QA program require-ments were identified and no unresolved items were identified.
3.
Nonconformances and Corrective Action:
The inspector reviewed two sections of the Exide QA manual which were applicable to control and disposition of deficiencies found in materials at receiving inspection, parts during manufacture and assembly, and batteries during final inspection prior to shipping.
This control of noncon-forming items involved those items which could not be dispositioned during normal processing under the red tag system.
To verify that nonconforming items were reviewed and accepted, rejected, repaired, or reworked, and that conditions adverse to quality, including the cause were corrected, a review was made of:
2 administrative QA procedures; 10 Material Review Reports common to the GN (nuclear) type batteries; 4 Vendor Defective Material Reports; and 2 Corrective Action Requests.
Observations were made of four hold areas in the shop, designated for items on hold for the Material Review Board disposition.
Within this area, no nonconformances to NRC and QA program require-ments were identified, and no unresolved items were identified.
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