ML20090K158
| ML20090K158 | |
| Person / Time | |
|---|---|
| Site: | Catawba  |
| Issue date: | 10/21/1983 |
| From: | Shropshire J DUKE POWER CO. |
| To: | |
| References | |
| A-019, A-19, NUDOCS 8405240072 | |
| Download: ML20090K158 (13) | |
Text
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UNITED STATES OF AMERICA
'V NUCLEAR REGULATORY COMMISSION
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BEFORE THE ATOMIC SAFETY AND LICENSING B'dAR 1
N O, W ' ~lJlpCu N
a In the Matter of
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DUKE POWER COMPANY, et al. )
Docket Nos.
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50-414 -
(Catawba Nuclear Station,
)
Units 1 and 2)
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TESTIMONY OF JOE C. SHROPSHIRE 1
Q.
STATE YOUR NAME AND BUSINESS ADDRESS.
2 A.
My name is Joe C. Shropshire, and my business address is Catawba 3
Nuclear Station, P.O. Box 223, Clover, South Carolina 29710 4
Q.
STATE YOUR PRESENT JOB POSITION WITH DUKE POWER 5
COMPANY AND DESCRIBE THE NATURE OF YOUR JOB.
6 A.
I am a Quality Assurance Engineer, responsible for managing and 7
directing the Quality Assurance engineering and technical support 8
group in the mechanical, welding and nondestructive examination 9
areas during construction of the Catawba Nuclear Station.
There 10 are currently eight technicians who work in my group.
It is the 11 responsibility of this group to assure that the QA program is 12 implemented and carried out in the areas of Mechanical piping, 13 equipment, and system
- testing, welding, and nondestructive 14 examination (NDE).
It is our responsibility to see that work 15 activities performed by the craft is controlled in accordance with 16_
procedures and that work is documented accordingly; to assure that 17 the work is inspected appropriately by placing inspection hold 18 points and by directing the QA review of the documentation to see 19 that the work is done and inspected Isroperly; and to work with (D
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20 inspection personnel to solve inspection and procedural questions.
8405240072 831021 PDR ADOCK 05000 G
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We also assist the records group in reviewing and solving a
2 documentational problems, and perform research on code matters 3
and nonconforming items.
4 I review and approve all construction procedures in my area of 5
responsibility, and review for approval nonconforming items that are 6
brought to me by construction person'nel, QA inspection personnel, 7
and QA support personnel.
8 I am responsible for training those who work for me and on 9
occasion those who work for others.
This includes training in QA 10 procedures, construction procedures, and safety and personnel 11 training.
12 I interface on a regular basis with auditors and inspection 13 agencies including the NRC.
14 Q.
DESCRIBE YOUR PROFESSIONAL EXPERIENCE AND 15 QUALIFICATIONS, INCLUDING YOUR PRIOR POSITIONS HELD 16 WITH DUKE POWER.
17 A.
I graduated with a
BS in Civil Engineering from Virginia 18 Polytechnic Institute in 1967 and did some graduate work in 1969.
19 I am a Registered Professional Engineer.
In my 16 years since 20 graduation, I have spent 7 years in the academics ranks as an 21 Instructor / Administrator and 9 years in industrial practice.
My 22 prior experience and qualifications are set forth in more detail in 23 my resume, which is Attachment I to my Testimony.
24 I came to Duke Power in 1978, where I was assigned to 25
. develop, coordinate, and implement a
training program for 26 certification - of QC Civil inspection personnel in the areas of 27 structural steel, concrete, soils, and coatings. In February 1979, I 28 was transferred to Catawba to assume the duties - of QA
1 Engineer-Mechanical, Welding, NDE.
At that time I also had the 2
responsibility for QA records.
On June 1, 1981, I gave up the 3
' responsibility for QA records to the newly organized QA Records 4
group.
At that time I took on the additional responsibilities for the 5
QA Hanger program.
In October, 1981 a new surveillance group 6
was created and I gave up my surveillance functions.
On 7
September 1,1982, a separate QA Hanger group was formed and I 8
passed those responsibilities to the new supervisor.
9 I have attended numerous seminars and meetings and have j
10 taken many technical and management courses over the last 16 11 years.
Some topics included in those courses and seminars were 12 structural steel design,
radiation
- safety, fatigue
- fracture, 13 nondestructive testing, welding, pressure vessel and piping failure i
14 analysis, ASME Code training, and management training.
15 Q.
DESCRIBE THE FUNCTIONS WITHIN THE QA ORGANIZATION AT i
16 THE CATAWBA SITE WHICH YOU ARE RESPONSIBLE FOR.
17 A.
I am responsible for implementation of the QA program in the 1
18 mechanical, welding, and NDE areas.
I am responsible for the 19 review of - documentathn and procedures; for the generation of 20 checklists that the QA Records group uses to review documentation; 21 for the implementation and review of the Q-1 program; for the 22 implementation of the NDE program,' including QA film review; and I l
23 am a resource person for QA inspection personnel.
24 Q.
HOW. DID THE QA FUNCTIONS REPORTING TO YOU DIFFER 25
- DURING 1981?
26 A.
The QA functions performed by me were the. same as previously 27 stated with the following exceptions.- In June,: 1981, a separate QA
'28' Records group was created and I gave up the responsibility for i l I
I records review and storage.
At the same time I took on the i
2.
responsibility for QA Hangers.
In October,1981 the responsibility 4
3 for surveillance in my areas of ;esponsibility was turned over to a 4
surveillance group.
5 In February 1,
1981, QC became a part of QA and the 6
interface with the inspection group was greatly. increased.
QA 7
became the support group for inspectors questions on procedures, 8
inspections, techniques, and other matters.
9 Q.
EXPLAIN THE ROLE OF THE QA ENGINEER AS A PART OF THE 10 OVERALL QA PROGRAM.
11 A.
The QA Engineer provides supervision and direction for the 12 implementation of the QA program in specific disciplines as required 13 by design specifications, and various codes and standards.
The 14 QA Engineer provides for the timely and appropriate response to 15 resolution of NCI's; provides coordination of work-related activities 16 with other organizational units, departments and outside vendors; 17 provides for the preparation and revision of QA procedures in
^
18 compliance with required regulations and codes; provides for 19 compliance with construction schedules for systems flush, hydro, 20 and turnovers; provides the technical assistance to QA inspectors 21 for work related activities; and maintains a productive and
~22 motivated start through human resource management and the i
23 -
enforcement of personnel policies.
24
-Q.
DESCRIBE THE ROLE OF THE QA ENGINEER IN THE REVIEW OF 25 NONCONFORMING ITEMS WHILE YOU HAVE BEEN QA ENGINEER.
26 A.
The _QA Engineer is responsible for the review and approval of l
27-nonconforming items.
This includes review at the initiation stage 28, for completeness, accuracy, and clarity.
At this time, the review l :
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I also determines if the NCI is valid or invalid.
I also review the 2-disposition and actions stated to assure that the disposition is 3
accurate, reflects true conditions, addresses the problem, and 4
states the ultimate disposition of the item. I also review the action 5
assignments to assure that they accomplish the tasks necessary to 6
implement the disposition of the NCI.
Throughout the review 7
process, I check to see that all statements are clear, concise, and 8
appropriate to address the problem and that compliance with QA 9
procedures, code, and design documents are met.
10 If other procedures describe the appropriate corrective action 11 for the item or the problem identified turns out to be a 12 "non-problem," then the NCI may be determined invalid and 13 processing terminated at the initial review stsge.
The reason for 14 determining an NCI invalid is discussed with the originator.
The 15 reason for voiding the NCI is stated on the NCI, in the 16
" disposition" section of the form.
The originator is given a copy 17 and the original is filed in the NCI files in the vault.
18 Q.
IS THERE ANYTHING IMPROPER OR INCONSISTENT WITH A 19 SOUND QUALITY ASSURANCE PROGRAM FOR A QA ENGINEER OR 20 OTHER SUPERVISOR TO REVIEW AN NCI WRITTEN BY AN 21 INSPECTOR AND VOID THE NCI BECAUSE IN JUDGMENT THE QA 22 ENGINEER OR SUPERVISOR, THE NCI SHOULD NOT BE WRITTEN.
23 A.
It is not inconsistent with the QA program for questions of 24 nonconformance to be answered at the supervisor's level. Questions 25 of nonconformance do not become NCIs until the QA review is 26 performed.
At that time it is determined whether the question is a 27 nonconformance and thus an NCI or that the question raised is not 28 a nonconformance and may be answered in another manner..
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1 Supervisors are trained in QA procedures and how they are to 2
be implemented.
Supervisor's are experienced personnel and 5
knowledgeable in the areas supervised and are responsible for 4
making decision's relating to nonconformances.
5 If the inspector was not satisfied with the decision to declare 6
the NCI invalid, he should pursue the question with higher i
7 supervision or QA support groups.
Since 1982, an inspector has 8
the option to file a technical recourse and he is encouraged to do 9
so.
This will get his concerns reviewed by others and will also 10 provide him a written response when the determination of the 11
. validity of the question is answered.
12 Inspector's are also questioned during surveillance and audits i
13 to determine if the QA program is being properly implemented.
14 They have the opportunity at that time to voice concerns about the-15 QA program.
16 Q.
WHAT OPTIONS ARE AVAILABLE TO A WELDING INSPECTOR.WHO 17 BELIEVES THAT A SUPERVISOR MADE AN INCORRECT JUDGMENT 4
18 IN INSTRUCTING HIM TO VOID AN NCI?
19 A.
The inspector has the option to raise the question with higher 20 management and QA support groups on site or QA Technical 21 Services in Charlotte.
His first option is to approach his 22 supervisor and then his supervisor's supervisor with his question 23 of nonconformance.
They are obligated to provide him a verbal 24 answer.
If. he is still dissatisfied his supervisor may take the 25 option of asking the question to QA on site or the QA Technical 26 Services in Charlotte.
Again the response is verbal.
If the 27 inspector is still dissatisfied, he can take the route of technical 28 recourse which requires him to put his question in writing, and he _
1 is given a written response. Technical recourse can be pursued to 2
the Corporate QA Manager's level and then to Company Corporate 3
Management level if desired.
The inspector is always allowed to approach the NRC with his 4
5 concerns of nonconformance, but we encourage inspectors to pursue I
6 the matter within the company first.
l 7
Q.
HAVE YOU BEEN INVOLVED IN THE PROCESS WHICH SETS THE 8
PAY CLASSIFICATION FOR INSPECTORS?
I 9
A.
No.
10 Q.
IN YOUR VIEW, HAVE THE CHANGES IN THE MANNER OF 11 QUALIFICATION AND CERTIFICATION OF WELDING INSPECTORS 12 RESULTED IN LESS QUALIFIED WELDING INSPECTORS AT 13 CATAWBA?
14 A.
No.
The requirements for certification for welding inspectors have 15 not changed.
Classroom training, on-the-job training, and prior 26 work / inspection experience are still evaluated the same as they have 4
17 always been.
Supervisors, after careful evaluation of the inspector 18 on the job, and after reviewing test scores, recommends the 1
19 certification of a candidate for welding inspector after the training 20 and testing program.
Welding inspectors are qualified to perform 21 their. duties now, just as they were in the past.
There has been 22 no notice of decrease in quality of inspection.
4 23 Q.
DESCRIBE YOUR INVOLVEMENT WITH THE TASK FORCES.
24 A.
I had no involvement with the initial task force, the Technical Task 25 Force, or the Nontechnical Task Force.
l 26 Q.
DESCRIBE YOUR INVOLVEMENT WITH LEWIS ZWISSLER OF 27 MANAGEMENT ANALYSIS COMPANY.
4 7_
'v 1
A.
My involvement with Lewis Zwissler was limited to being interviewed 2
by him.
We talked about the welding inspector's concerns, the 3
make-up and involvement of the Task Force, construction activities, 4
and the QA program.
5 Q.
WERE YOU INVOLVED IN THE IMPLEMENTATION OF 6
RECOMMENDATIONS ISSUED BY ANY,OF THE TASK FORCE?
7 A.
Yes, I was involved in implementing some of the recommendations 8
made by the Technical Task Force.
9 Q.
DESCRIBE YOUR ROLE IN IMPLEMENTING THE RECOMMENDATIONS 10 OF THE TECHNICAL TASK FORCE.
11 A.
I was given the responsibility to investigate certain concerns 12 identified in my area and to develop a solution that would satisfy 13 the concern.
Once a solution was developed, we implemented any 14 necessary changes, and trained the, inspectors with respect to the 15 changes.
I was responsible for resolving concerns in the following 16 areas:
17
- 1) Confirm filler material is correct on Steam Generator Shield 18 Wall Plate (Recommendation No. QAP-1);
19
- 2) Investigate to insure the adequacy of M-4I inspections with 20 respect to drawings used and timing used for inspections 21 (Recommendation No. QAP-2);
22
- 3) Provide training on requirements for use of Forms M-4I and 23 Q-1A for documenting construction versus nonconstruction damage l
24 (Recommendation No. QAP-6);
25 4)
Train inspectors in material identification marking 26 requirements for Class E piping (Recomm'endation No. MC-3);
27
- 5) Revise RPML to accept "SA" or "A" when appropriate, and 28 train inspectors accordingly (Recommendation No. MC-5); l
1 6)
Research M-4A on weld ICA67-11 to insure proper 2
documentation of material traceability (Recommendation MC-9); and 3
- 7) Investigate to confirm or deny the practice of welding 4
socket welds without the appropriate gap (Recommendation WP-1).
5 Meetings were held with individual inspectors and with 6
inspector crews to implement these recommendations.
7 Q.
HOW WOULD -YOU DESCRIBE THE PRIMARY CONCERN OF THE 8
WELDING INSPECTORS?
9 A.
The primary concern of the inspectors, as I see it, was a lack of 10 communication between the inspector and those with whom it was i
11 necessary to interface in order f6r him to do his job.
One cause 12 for this lack of communication may have been partially due to a 13 perception held by the welding inspector that there was no way at 14 times for him to get needed information to perform his duties.
i 15 Inspector $ resorted to NCI's to document questions.
16 Q.
THE CONCERNS EXPRESSED BY THE WELDING INSPECTOR WERE 17 INITIALLY CHARACTERIZED AS CONCERNS AFFECTING THE 18 QUALITY OF WORK OR THE SAFETY OF THE CATAWBA PLANT.
19 IN YOUR VIEW, DID THE CONCERNS EXPRESSED BY THE WELDING 4
20 INSPECTORS AFFECT THE QUALITY OR THE SAFETY OF THE 21,
CATAWBA PLANT?
22 A.
No.
In my view, the concerns raised questions the inspectors 23 reflected communications problems which did not affect the quality 24 of the construction of the plant.
The Technical Task Force 25 thoroughly _ investigated each of the concerns and confirmed that the 26 concerns did not identify any technical inadequacies.
' 27 Q.
IN YOUR VIEW, DID THIS EXPRESSION OF CONCERNS BY THE 28 WELDING INSPECTOR INDICATE THAT THERE WAS A BREAKDOWN. -
1 IN THE QA PROGRAM AT CATAWBA OR THAT THE QA PROGRAM 2
WAS NO LONGER' WORKING AT CATAWBA?
3 A.
No.
The QA Program has functioned properly to identify and 4
resolve deficiencies that may have occurred during construction.
5 Q.
HAS PRESSURE FROM THE CONSTRUCTION DEPARTMENT OR 6
ANYWHERE ELSE EVER INFLUENCED YOUR PROFESSIONAL 7
JUDGMENT IN MAKING DETERMINATIONS CONCERNING WHETHER n
8 CONSTRUCTION DEFICIENCIES IDENTIFIED BY INSPECTORS 9
SHOULD BE APPROVED OR REJECTED?
10 A.
No.
We all work under pressure to meet our schedules and 11 commitments, but this pressure has never interfered with my 12 professional judgement while performing my responsibilities.
13 14 15 16 I hereby certify that I have read and understand this document, and 17 believe it to be my true, accurate and complete testimony.
18 b
L 21 Joe /C. Shr6pshi/e i
22 23 24 Sworn to and subscribed before me 25 this c# /
day of September,1983.
26 hswr>e.
6 2 0 Y W W h.)
29 Notary Public 30 31 Commission Expires 7-/2-88.
RESUME NAME:
Joe C. Shropshire PRESENT POSITION:
QA Engineer Catawba Project PERSONAL DATA: Age - 39 Marries - Two children Address - 1204 Dumbarton Road Gastonia, NC 28054 EDUCATION:
Graduate of Drewry Mason High School, Ridgeway, VA 1962 Bachelor of Science in Civil Engineering from Virginia Polytechnic Institue,1967 1
Graduate study in Civil Engineering at Virginia Polytechnic Institute in l
1969-1970 Various technical courses and seminars.
Various Duke Power Company management training courses.
i EXPERIENCE:
Virginia Department of Highways, Richmond, VA.
1967-68 Highway Engineer Trainee. During my training I worked as a
bridge design
- engineer, materials
- engineer, hydraulics engineer, 'nd construction field engineer.
i Was given responsible charge for several projects.
l Project. experience included structural design, drainage studies, materials evaluation, and tunned construction.
Bluefield State College, Bluer'ield, WV 1968-69 Instructor.
I was an Instructor of Civil Engineering Technology and was responsible for the quality and content of courses taught.
Some courses taught were Structural Steel and Reinforced Concrete Design, Statics, l
Strength of Materials, Surveying.
Virginia Polytechnic Institute, Blacksburg, VA.
1969-70 Coordinator of Men's Residence Halls.
I was responsible j
for the overall student management for two student dorms.
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RESUME Joe C. Shropshire-p Page 2 O
Wake Technical Institute, Raleigh, NC 1970-71 Instructor.
I was an Instructor of Civil Engineering Technology and was responsible for course development, content and quality.
Courses taught included Materials, Statics,
Strength of Materials, Reinforced Concrete Design.
Bluefield State College, Bluefield, WV 1971-73 Administrative Assistant (Part time instructor in Technology).
I was responsible for developing and writing grant proposals and coordinating federal funding, directed institutional research and served on the Board of Regents Committee for Institutional Research, numerous special projects.
Was partially responsible for developing Mine Supervisory Training Program.
Virginia Department of Highways, Richmond, VA 1973-74 Highway Materials Engineer "A".
I was assistant Head of Soils Lab and was responsible for soils testing and evaluation of test results; responsible for materials studies; responsible for development and evaluation of test procedures.
Advised other department engineers on foundation location and design, slope design, subsidence problems, materials resources.
Spartanburg Technical College, Spartanburg, SC 1974-77 Department Head - Civil Engineering Technology.
Responsible for the course content and quality of the Civil Engineering Technology program.
Taught all courses in curriculum.
Was responsible for department budget and maintenance and purchase of equipment.
Pittsburgh Testing Laboratory, Atlanta Office, Atlanta, GA 1977-78 District Manager and Engineer.
The responsibility for managing the Atlanta Office and_ overseeing the engineering and testing activities was mine.
The office offered general, and some specialized, engineering and testing services to architects, engineers, contractors, and manufacturers.
Testing, QA services, materials research and engineering analysis were supervised by me.
Duke Power Company,. Charlotte, NC 1978-79 Assistant QA Engineer.
Assigned to QA-Engineering and Services.
I was responsible for developing, coordinating, and training. QC-Civil inspectors in structural steel, concrete, soils, and coatings.
1979-80 Associated QA Engineer. ' Assigned to the QA-Construction Division at the Catawba Nuclear Project as QA Engineer Mechanical, Welding, NDE. I im responsible for providing the supervision and direction for the implementation O
of - the QA program 'in the areas of mechanical piping,
RESUME O
Joe C. Shropshire Page 3 equipment and systems testing, and welding and NDE.
1980-Present QA Engineer. Assignment same as 1979-1980 except that during 1981-1982 I was also responsible for the implementation of the QA program for support / restraints.
PROFESSIONAL:
Registered Professional Engineer in West Virginia
(#6476)
Member of American Society of Civil Engineers (ASCE)
Member of National Society of Professional Engineers (NSPE)
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