ML20151Z045

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Rev 0 to Welding Project Employee Concern Evaluation Rept WP-07-BFN, Welder Training & Experience at Browns Ferry Nuclear Plant
ML20151Z045
Person / Time
Site: Browns Ferry  Tennessee Valley Authority icon.png
Issue date: 04/06/1987
From: Lewis J, Rose J, Shevlin E
TENNESSEE VALLEY AUTHORITY
To:
Shared Package
ML20151Z000 List:
References
WP-07-BFN, WP-07-BFN-R00, WP-7-BFN, WP-7-BFN-R, NUDOCS 8808290146
Download: ML20151Z045 (9)
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WELDING PROJECT I

C EMPLOYEE CONCERN EVALUATION REPORT WELDER TRAINING AND EXPERIENCE AT BROWNS FERRY NUCLEAR PLANT PREPARED BY A 1 [ 84-67 WP/ECTG

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PROGRAM MANAGER Report Number WP-07-BFN Revision 0 Date 4 8'/

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WP-07-BFN Revision 0 EMPLOYEE CONCERN i

SUMMARY

SMEET '

WELDER TRAINING AND EXPERIENCE' AT BROWNS FERRY NUCLEAR PLANT l

t I. SCOPE OF EVALUATION l

This report addresses three employee concerns dealing with the training and experience of welders employed in safety related applications at i Browns Ferry Nuclear Plant (BFN). These concerns were grouped into two issues to aid in the evaluation effort.

A. Qualification and experience of subjourneymen.

B. Adequacy of TVA welder training program.

Text of the three concerns is provided in the technical report (WP-07-BFN) under Attachment 1. ,

II. ANALYSIS OF ISSUES ADDRESSED BY CONCERNS A. The issue relating to the qualification and experience of subjourneymen was raised by one concern which states that subjourneymen are used to perform tasks for which they are not qualified, that they are not required to have specific training, that they do work normally done by a journeyman, and that they are not provided adequate technical supervision.

The primary purpose of the subjourneyman position is to free the journeyman from trade related tasks which do not effectively utilize his skills. The TVA practice of allowing the subjourneyman to progress beyond menial tasks as he gair.s experience is corraensurate with similar practices throughout the power construction industry. This practice is not in violation of any of r the applicable codes, standards, or commitments.

A detailed discussion of this issue is presented in the technical '

report (WP-07-BFN), Paragraph III A.

B. Two of the concerns relate to the adequacy of the training and experience of welders trained by TVA.

The TVA welder training program was offered at DFN approximately during the years 1974 through 1976. The length of training was dependent on the progress of the individual trainee.

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WP-07-BFN Re:ision 0 When sufficient competence was demonstrated, the trainee was tested under the rules of the governing codes AWS D1.1 and/or ASME Section IX in the same manner as a journeyman welder.

Complete details of this issue are discussed in WP-07-BFN, Paragraph III B.

III. COLLECTIVE SIGNIFICANCE No ade.cse effect on hardware or the TVA welding program at Browns Ferry Nuclear Plant was identified. TVA utilization of subjourneymen -

is in accordance with the trade labor agreement and commensurate with management practices throughout the construction industry. The welders trained at BFN vere tested and qualified in accordance with the Structural Walding Code and/or the ASME Boiler and Pressure Vessel Code.

IV. ROOT CAUSE(S)

The reason for the concerns relating to welder training and qualification at Browns Ferry Nuclear Plant is the TVA decision to evaluate concerns initiated at Watts Bar for generic applicability to other nuclear facilities.

- V. CORRECTIVE ACTION l(, No corrective action is required.

VI. REINSPECTION REQUIRED No.

VII. ISSUE CLOSURE Closed.

VIII. ATTACHMENTS

1. Evaluation Report WP-07-BFN, Revision 0.

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WP-07-BFN- l Revision 0 l WELDING PROJECT EMPLOYEE CONCERN EVALUATION REPORT l WELDER TRAINING AND EXPERIENCE AT BROWNS FERRY NUCLEAR PLANT I. SCOPE OF EVALUATION This report addresses three employee concerns. Text of the concerns is provided under attachment 1.

The subject concerns were originated at Watts Bar Nuclear Plant (WBN)-

and evaluated for genaric application to Browns Ferry Nuclear Plant (BFN). The expurgated text of the concerr,s was compared with the requirements of the American Welding Society Structural Welding Code and the ASME Boiler and Pressure Vessel Code. The findings presented

  • herein are based upon this comparison, redew of the site implementing procedure, and discussion with cognizant 1VA personnel.

II. ISSUES ADDRESSED BY CONCERNS A. Subjourneymen perform work for which they are not qualified and require closer technical supervision than TVA provides.

B. The TVA welder training program does not provide the welder with sufficient training and experience for nuclear installations.

III. ANALYSIS OF ISSUES ADDRESSED BY CONCERNS A. One of the concerns states that subjourneymen are used to perform tasks for which they are not qualified, that they are not required to have specific training, that they do work normelly done by a journeyman, and that they are not provided adequate technical supervision.

  • Subjour.7eymen have been utilized in limited numbers at Browns Ferry Nuclear Plant for approximately one year. The primary function of a subjourneyman is to perform the lesser skill tasks associated with the trade, such as material handling.

It is possible for a subjourneyman to progress to actively assisting the craf tsmen in skilled areas. This depends on the same factors associated with the development of any other members of the work force. Thus, an employee with aptitude and motivation will, when glen the opportunity, progress from the mental tasks to those requiring some degree of skill. To not only allow, but to actively promote such -kill development is nothing more than sound management practicc 11830 Page 1 of 3 , ,

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.- . 1 WP-07-BFN Revision 0 Discussion with cognizant TVA technical and administrative '

personnel revealed that a subjourneyman may progress beyond the j totally unskilled tasks in a given trade. Relative to subjourneymon, the General Agreement between TVA and the trade jl

$4 unions provides that "TVA shall assign the work to those eLployees ;I who in its judgement are qualified to safely and efficiently l' perform the work." The level of technical supervision required for i any given task depends on the worker. The Foreman is principally l, responsible for assignment of tasks within the demonstrated

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capability of each worker. He then ensures that the appropriate j technical guidance is provided, on an individual and task basis, to -

each subjourneyman. The journeyman normally provides the direct I supervision and instruction. '

One example givnn in the text of the concern is that subjourneymen I perform welds on 1/4 inch lines. It is possible within the TVA system for a subjourneyman to become a qualified welder by satisfactory performance testing under the rules of AWS Dl.1 and/or  ;

ASME Section IX. Subjourneymen have performed welds on 1/4 inch  !

and other lines ony af ter becoming properly qualified. '

The primary purpose of the subjourneyman position is to free the journeyman from trade related tasks which do not effectively utilize his skills. The TVA practice of allowing the subjournoyman j(g- to progress beyond menial tasks as he gains experience is commensurate with similar practices throughout the power construction industry. This practice is not in violation of any of the applicable codes, standards or commitments.

B. Two of the concerns relate to the adequacy of the training and experience of welders trained by TVA.

The TVA wolder training program, a voluntary of f-duty course, was offered at BFN approximately during the years 1974 through 1976.

The training was typically 250 to as high as 500 hours0.00579 days <br />0.139 hours <br />8.267196e-4 weeks <br />1.9025e-4 months <br /> of  ;

instruction and supervised hands on training. The length of '

training was dependent on the progross of the individual traineo.

When sufficient competence was demonstrated, the trainee was tested

, under the rules of governing code in the same manner as a

! journeyman welder. The acceptance standards are specified by the codes ( AWS D1.1 and/or ASME Section II) .

There is no code or regulatory requirement which quantifies the l experience required of a wolder. Rather, the governing codes l specify performance qualification testing as a means of assuring l that a wolder is capable of depositing sound weld metal.

It is recognized that certain weldments require a higher degroo of welder skill than others. A wide range of performance qualification tests have boon designed using different base and l filler materials, various geometries, thicknessos, welding positions and welding processes.

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' WP-07-BFN Revision 0 i

C. Additionally, in making work assignments, the Foreman considers the individual skill (or experience) of the welder relative to the  !

l difficulty in making the joint. Review of Corrective Action 3 Reports, Deficiency /De/lation/ Nonconformance Reports, USNRC l Inspection Reports, Quality Assurance Audit Reports, and TVA ,

welding related memoranda issued from 1972 through 1985 failed to  ;

provide any indication of a problem with the competency of TVA trained welders.

IV. COLLECTIVE SIGNIFICANCE The subjourneymen employed at Browns Ferry are utilized in accordance with the applicable labor agreement and with good management practices.

The TVA welders trained at Browns Ferry were tested and qualified in i accordance with the Structural Welding Code, AWS D1.1, and The ASME i Boiler and Pressure Vessel Code,Section IX.

This evaluation disclosed no adverse effect on hardware or the TVA welding program at Browns Ferry Nuclear Plant.

V. ROOT CAUSE(S)

( The concerns addressed by this evaluation originated at Watts Bar Nuclear Plant. The reason for the employee concerns at Browns Ferry is the TVA decision to apply the concerns to other nuclear sites for evaluation for generic applicability.

VI. CORRECTIVE ACTION No correctise action required.

VII. ATTACllMENTS

1. Text of concerns.

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1, , WP-07 -11FN Revision 0 WELDING PROJECT EMPLOYEE CONCERN EVALUATIOh' i r.r a1 ATTACHMENT 1 TEXT OF EMPLOYEE CONCEQ 3 Evaluation Report WP-07-BFN addresses three employd :: r.:;- .: . The text of the concerns is shown on the following pages.

EX-85-008-001 IN-85-706-001 IN-86-158-006 l((

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REFEREllCE .  ;

CPS 132J-ECPS132C TEtitlESSEE .EY AUTHORITY FREQUEllCY REQUEST OFFICE OF nuCLEAK P0 LIER PAL - - 'I OtiP - ISSS - Ritti EMPLOYEE C0tlCERii PROGRAM SYSTEM (ECPS) RUti sIME - 11:56 Rutl DATE - 03/16,,

CATEGORY: HE t!ON QA/QC HELDItt0 EMPLOYEE CONCERil INFORt1ATION BY CATEGORY / SUBCATEGORY HP - 07 HELDER TRAINING PROGRAM FOR C0flST -

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H 1 REPORT APPL SUB R PLT 2 SAF RELATED HISTORICAL C0flCERN REF. SECTI.

C0tlCER!l flUMBER CAT CAT D LLC . BF El SQ IIB REPORT CAT -

t ORIGIN -

CutlCERil DESCRIPTION SUBCAT - t4 EX 003-00101 NE 50107 N HBil 1Y Y Y Y EX-85-010-002 QTC T50051 -

2 SR SR SR SR SUBJOUR!IEYME!I USED TO DO HORK THAT T HEY'RE fl0T QUALIFIED TO DO: THEY NE EDff'T HAVE AtlY SPECIFIC TRAIllIllG, BU T DO !!ORK (EG PIPE FIT-UPS AllD HELDS

, Ott 1/4" LIllES) NORMALLY D0tlE BY A J

. OUR!!EYMAtt HITH 5 YEARS MIllIffUM EXPER IEllCE. SUBJOURNEYMEft REQUIRE CLOSER TECHilICAL SUPERVISI0tl thall TVA PROV IDES. IIHEta CRAFTS COMPLAIll, THEY AR E "CHEHED OUT" BEY 0 TID ALL REAS0tlABLE LIf1I TS. 110 f! ORE DETAILS Kil0!!!I. (SQ

!! ISSUES ADDRESSED Ill RPT HP-07-SQtt RI)

IN 706-00101 HE 50107 N HB!t 1Y Y Y Y QTC T50064 2 SR SR SR SR HELDERS HHO HEllT THROUGH TVA'S HELDE R TRAlfilflG PROGRAM HAVE IllSUFFICIElli TRAIIIIllG AtlD EXPERIEllCE TO HAIIDLE A LL VARIABLES IllVOLVED TO PERFORM ADE QUATE HELDS FOR A NUCLEAR It!STALLATI 0 71 . THIS IllADEQUACY HAS CREATED A L

. OT OF REll0RK. CI HAS !!D MORE DETAIL S. (SQti ISSUES ADDRESSED III RPT HP-0 7-SQti RI) 2 C0!!CERtis FOR CATEGORY HE HP - 07 9

C0flCERfiS ARE GROUPED BY LAST 2 DIGITS OF SUBCATEGORY NUMBER.

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tEFEREllCE - tCPS132J-ECPS132C FREQUE!!CY TEllllESSEE VALLEY AUTHORITY PAGE

- REQUEST OFFICE OF IIUCLEAR P011ER 1

JtlP - ISSS - RII;1 EMPLOYEE CartCERf1 PROGRt.M SYSTEM (ECPS)

RUll TIME - 11:56:4 EMPLOYEE C0!!CERfl IllFORt1ATI0tl BY CATEGORY /SUBCATEGDRY Ruta DATE - 03/16/3 iTEGORY: ilE !!0!I QA/QC IlELDIIIG IIP - 14 ADI1IIIISTRATIVE POLICY S

H 1 REPORT APPL SUB R PLT 2 SAC RELATED HISTORICAL C0tlCERil REF. SECTIO C0t!CERf1 fluitBER CAT CAT D LOC BF BL SQ HB CAT - IIE REPORT ORIGIII CarlCER!! DESCRIPTIO!I SUBCAT - 14

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ill 153-00601 IIE 50914 11 WBf1 1Y Y Y Y QTC T50180 2 SR SR SR SR UllTIL 1973 TVA DID 110T LET THEIR APP REllTICESHIP PEOPLE IIELD. DURI!1G THA '

T YEAR, EVEft HITH Til0 OR THREE !!0tlTH S EXPERIEllCE, 'll APPREllTICE COULD TA KE THE TEST, PASS, AtlD BE ABLE TO HE LD Ill THE FIELD. THE SYSTEst HAS IIOR KED THAT HAY EVEll SIllCE 1973. CortST DEPT. Cat!CER!i. C/I HAS NO FURTHER IllFORMATI0tl. (SQft ISSUES ADDRESSED Ill RPT HP-14-SQil RI) 1 C0!!CER!as FOR C%TEGORY HE HP - 14 CollCERr10 ARE GROUPED BY LAST 2 DIGITS OF SUBCATEGuRY flUMSF.R.

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