ML20149H967

Notice of Nonconformance from Insp on 970304-07,0428 & 0502. Nonconformance Noted:Facility Did Not Document & Disposition Four Test Failures of SCE Batteries IAW 10CFR50,App B Quality Assurance Program in July 1996

ML20149H967
Person / Time
Issue date:	07/22/1997
From:	NRC (Affiliation Not Assigned)
To:
Shared Package
ML20149H948	List: ML20149H945 ML20149H959 ML20149H967 ML20149H980
References
REF-QA-99900358, REF-QA-99900359 99900359-97-01, 99900359-97-1, NUDOCS 9707250271
Download: ML20149H967 (2)

Text

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J NOTICE OF NONCONFORMANCE Yuasa-Exide, Inc. (YEI) Docket Nos.:

Reading, Pennsylvania / Richmond, Kentucky- 99900358/99900359 I l Report No.: 97-01 '

i j

Based on the results of an NRC inspection conducted at YEI facilities in

• Reading, Pennsylvania, and Richmond, Kentucky, on March 4-7, 1997, and on April 28-May 2,1997, respectively, it appears that certain of your activities were not conducted in accordance with NRC requirements as follows:

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< A.

j Criterion XV, " Control of Nonconforming Material," of Appendix B,

" Quality Assurance Requirements for Nuclear Power Generation Facilities," to Part 50 of Title 10 of _the Code of Federal Regulations (10 CFR Part 50, Appendix B), requires in part that nonconforming items shall be reviewed and accepted, rejected, repair < f or reworked in accordance with documented procedures. <

I Section 15, " Nonconforming Material, Parts, or Components," of the YEI i Quality Assurance (QA) Manual required that QA personnel prepare material review reports in cases of nonconforming material and

disposition the nonconformances.

l-i Contrary to the above, YEI did not document and disposition four test failures of the SCE batteries in accordance with its 10 CFR Part 50,

[ Appendix B quality assurance program in July 1996.

! Nonconformance 99900359/97-01-02.

4 B.

Criterion III, " Design Control," of 10 CFR Part 50, Appendix B, requires i' a review for suitability of application for safety-related structures, systems, and components.

Contrary to these requirements, the measures established by YEI-Richmond, Kentucky, for review for z H tability of application (commercial grade dedication procedue<s prescribed in QAP 70.0 and i individual technical evaluations) of purchased parts and materials to be used'in the manufacture of Class IE station batteries for nuclear power

plants were not adequate as follows

Not all critical characteristics for certain items were identified, e.g., 0-ring material and cure date, i

a Not all verification methods or acceptance criteria were appropriate or correct, or consistent with design documents

(drawings or bills of materials), or purchase specifications (which themselves were not always consistent with design documents), or expressed in technically correct terms.

d

' Not all engineering design drawing changes were incorporated into purchase specifications, technical evaluation or acceptance i proce:s attachments to QAP-70, or into incoming inspection report forms.

Nonconformance 99900358,359/97-01-03 i

t Enclosure 2 9707250271 970722 i

< PDR GA999 ENVYUASA 1-99900358 PDR

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! l C.-

Criterion VII, " Control of Purchased Material, Equipment, and Services,"

- of 10 CFR Part 50,- Appendix B, requires that measures be established to verify, .by_ review of suppliers and supplier documentation, and examination of products upon delivery, that the purchased material, equipment, or services, meet the procurement specifications.

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! Contrary to these requirements, the measures established by YEI-Richmond, Kentucky, for verification that purchased parts and materials to be used in the manufacture of Class IE station batteries for nuclear power follows:plants met the procurement specifications were not adequate as 4 For those critical characteristics that were identified, not all were adequately verified, e.g., material specified for intercell connector fasteners was not adequately verified and the wrong material was specified on incoming inspection report forms for

• i i

post-seal caps.

e Commercial grade supplier surveys used to support verification of one or more critical characteristics for various items were broad-

' based programmatic reviews (not performance based)_and without adequate specificity to verify that the supplier controls the critical characteristic of interest. Certificates of conformance

^

were accepted from distributors whose ability to provide valid certificates was not verified.

! Nonconformance 99900359/97-01-04 Please provide a written statement or explanation to the U.S. Nuclear Regulatory Commission, ATTN: Document Control Desk, Washington, D.C. 20555 with a copy to the Chief, Special Inspection Branch, Division of Inspection and Support Programs, Office of Nuclear Reactor Regulation, within 30 days of the date of the letter transmitting this Notice of Nonconformance. This reply

- should be clearly marked as a." Reply to a Notice.of Nonconformance"_ and should include for each nonconformance: (1) the reason for the nonconformance, or if contested, the basis for disputing the nonconformance, (2) the corrective steps that have been taken and the results achieved, 3) the corrective steps

• that will be taken to avoid further noncompliances, an(d-(4) the date when your corrective actions will be completed. Where good cause is shown,

! consideration will be given to extending the response time.

e i Dated at Rockville, Maryland this 2;U4' day of July,1997 4

Enclosure 2 i

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