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Rev 1 to Welder Training Program for Const & Nuclear Operations, Welding Project Employee Concern Evaluation Rept
	ML20203M912
Person / Time
Site:	Sequoyah
Issue date:	09/03/1986
From:	Briggs R, Lewis J, Lynskey R; TENNESSEE VALLEY AUTHORITY
To:	;
Shared Package
ML20203M897	List: ML20203M895; ML20203M901; ML20203M904; ML20203M909; ML20203M912; ML20203M916; ML20203M924; ML20203M929; ML20203M931; ML20203M936; ML20203M941; ML20203M944;
References
	WP-07-SQN, WP-07-SQN-R01, WP-7-SQN, WP-7-SQN-R1, NUDOCS 8609050165
	Download: ML20203M912 (10)
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WELDING PROJECT GENERIC EMPLOYEE CONCERN EVALUATION REPORT REPORI NUMBER: WP-06-SON. R0 DATE 04-08-86 3UBJECT: TRAINING AND CERTIFICATION OF CONSTRUCTION WELDING INSPECTORS CONCERNS CONSIDERED: IN-85-476-004 r IN-85-981-001 i WI-85-081-007 WI-85-041-002 PREPARED BY orfeinnt signed br J. E. Rose 4/7/86 , OC, WP i i REVIEWED BY original Signed by R. Bateman 4/7/86 , OC, WP REVIEWED BY Original Signed by R. P. Lynskoy 4/7/86 , QA, WP REVIEWED B f 8 , CEG-H, WELDING

                                          ,,,,f j

U i ( APPROVED BY A e , PROGRAM MANAGER x 4 i i 4 i 00260 L e

GENERIC EMPLOYEE CONCERN

SUMMARY

SHEET Report Number: WP-06-SON R0 Report

Title:

TRAINING AND CERTIFICATION OF CONSTRUCTION WELDING INSPECTORS I. CONCERNS CONSIDERED: IN-85-476-004 IN-85-981-001 WI-85-081-007 WI-85-041-002 II. ISSUES INVOLVED

1. Prior to 1981, an inadequate Welding Inspection Training and Certification Program allowed welding inspectors to complete their training in two weeks.

2. The Training / Qualification Program for AWS welding inspectors is questionable because they only have two months On-Job-Training (0JT) which is not documented.

3. The Topical Report has been " bastardized" regarding TVA compliance-with ANSI N45.2.6.

4. Welding inspectors are not qualified. They should be welders before becoming welding inspectors.

III. STATEMENT OF CONCERN / ISSUE VALIDITY Validity: Y ,N X , Substantiated: Y ,N X _. IV. EFFECT ON HARDWARE AND/OR PROGRAM Nano V. JUSTIFICATION The Office of Construction had a Welding Inspector Training / Certification Program in effect which was implemented effectively and met code, standard, and regulatory requirements for SQN Construction. VI. RECOMMENDATION AND/OR CORRECTIVE ACTION NEEDED None VII. REINSPECTION NEEDED: Y ,N X . Page 1 of 2 00260

    ,                                                    WP-06-SQN, R0  '

VIII. ISSUE CLOSURE 1 Close based on this report. l l II. ATTACHMENT

1. Test of Employee Concerns i

i l i i l Page g og g , I l 00260 l t

GENERIC EMPLOYEE CONCERN Report Number: WP-06-SON. R0 Report

Title:

TRAINING AND CERTIFICATION OF CONSTRUCTION WELDING INSPECTORS I. SCOPE EVALUATION This engineering analysis covers the following WBN concerns deemed to have possible generic implications at SQN: IN-85-476-004 IN-85-981-001 WI-85-081-007 WI-85-041-002 II. ISSUES ADDRESSED BY CONCERNS Each concern was analyzed to determine the issues voiced by the concerned individuals. These issues are as follows:

1. Prior to 1981, an inadequate Welding Inspection Training and Certification Program allowed welding inspectors to complete their training in two weeks.

2. The Training / Qualification Program for AWS welding inspectors is questionable because the inspectors only have two months OJT which is not documented.

3. The Topical Peport has been " bastardized" regarding TVA compliance with ANSI N45.2.6.

4. Welding inspectors are not qualified. They should be welders before becoming welding inspectors.

III. CONCERN VALIDITY OR SUBSTANTIATION It appears that the issues voiced by these concerns center around the evolution of the Visual Welding Inspection Program. Additionally, the NDE Discipline Program will also be addressed. The development of the Visual Welding Inspection Program for the Division of Construction (now Office of Construction) at SQN has paralleled the evolution of the requirements for Visual Welding Inspection Programs in the nuclear industry, Qualification of personnel in construction at SQN parallels ANSI Standard N45.2.6, " Qualifications of Inspection, Examination, and Tasting Personnel for the Construction Phase of Nuclear Plants." Page 1 of 5 00260

                      -               -    -    _- . - _ _ . _ _ ~ , -.

4 4 WP-06-SQN. RO. I The base requirement for visual inspection is mandated through both AWS ' and ASME B&PV Code rules but the training, qualification, and certification requirements have not been addressed in detail. This remains true today. The American Society for Nondestructive Testing (ASNT) presently has a committee which is working tosard the formulation of a recommended practice for visual weld inspection in the nuclear industry. t TVA has committed to ANSI N45.2.6 with certain exceptions. These exceptions are minimal and simply substitute training and qualification elements which are generally accepted in the nuclear industry. These

'             exceptions include levels of certification and alternate training and
,             qualification requirements where industry codes and standards do not mandate such requirements. This is true of the Visual Weld Inspection i              Training, Qualification, and Certification program. IVA's commitment is described in the Topical Report (IVA-TR75-1A).

From the beginning of construction through the end of construction in 1981, the Office of Construction (OC) complied with the requirements of

 !            ANSI N45.2.6 regarding program development and documentation l

requirements. This program is outlined in SQN Construction Procedure No. P-33 " Certification of Inspectors." 4 i, ANSI N45.2.6 allows the use of SNT-TC-la for certifying nondestructive i testing personnel. In the absense of clear source document requirements regarding visual i inspection TVA interpreted ANSI N45.2.6 to apply to visual inspection

,              personnel and modeled the details of the program such as worktime

) experience on SNT-TC-1A recommendations for Liquid Penetrant and ] Magnetic Particle Testing. Certification in these disciplines required i three months of worktime experience prior to certification. Certification in these disciplines was a orerequisite for certification i in the visual inspection method. The initial classroom training, testing, and certification was done at the unit-level by a certified Level III instructor. This practice continued through the construction ! era at SQN. The requirements for training, qualification, and certification of nondestructive testing personnel are mandated in both AWS and ASME B&PV j Code rules which reference SNT-TC-1A. OC complied with the requirements of SNT-TC-1A for methods other than visual inspection

from the beginning of construction through the end of construction in 1981.

1 The Bechtel SQN Implementation Audit conducted in January 1986, directly addressed the Training, Qualification, and Certification i Program in use during construction in Key Element 6.0, " Initial l Welding Inspection Personnel Qualification"; Key Element 7.0,

                 " Maintenance of Welding Inspection Personnel Qualification"; Key l

Element 8.0, " Renewal of Welding Inspection Personnel Qualification"; l and Key Element 17.0, " Employee Concerns." j Pagn 2 of 5 j 00260

WP-06-SQN, R0 The audit report makes the following statements regarding these Key Elements:

K.EY ELEMENT 6.0 OFFICE OF CONSTRUCTION INITIAL WELDING INSPECTION PERSONNEL QUALIFICATION Qualification / certification records for nondestructive examination personnel (weld inspection) were reviewed for compliance with TVA NDE personnel qualification procedures covering a time span from January, 1971 through March, 1983. - TVA personnel qualification procedures used for the qualification / certification of NDE personnel complied with and referenced the applicable edition of SNT-TC-1A (American Society of Nondestructive Testing). Records evidencing qualifications and certifications contained sufficient detail to confirm compliance with applicable codes, standards, and specifications in effect during construction activities. KEY ELEMENT 7.0 0FFICE OF CONSTRUCTION MAINTENANCE OF WELDING INSPECTION PERSONNEL QUALIFICATION i Review of innpection personnel qualification records for completeness and recertification confirmed compliance with TVA procedures used for qualification certification of NDE personnel. Recertification of inspection personnel was accomplished as required by applicable procedures. In many instances, recertification of personnel was accomplished on a more frequent - schedule than required by TVA procedures or industry standards (SNT-TC-1A). l KEY ELEMENT 8.0 ( OFFICE OF CONSTRUCTION g,ENEWAL OF WELDING INSPECTION PERSONNEL QUALIFICATION Renewal of all welding inspection personnel qualifications selected for audit indicated compliance with referenced TVA programs and procedures. Page 3 of 5 00260

    '                                                                                                             'WP-06-SQN, R0 KEY ELEMENT 11.0 0FFICE OF CONSTRUCTION USE OF APPROPRIATELY TRAINED AND CUALIFIED PERSONNEL Records of all certified personnel audited indicated that appropriate training had been administered and qualifications were                                                                     '

in accordance with TVA programs and procedures. For personnel trained and qualified in visual examinations, actual copies of written examinations were maintained as evidence of training and qualifications. Training records of personnel not requiring certificatien were not mainteined since they were classified as Duration of Construction (DOC) documents. Classification as DOC documents was in accordance with TVA programs and procedures and referenced codes and standards. 4 KEY ELEMENT 17.0 ' \ OFFICE OF CONSTRUCTION EMPLOYEE CONCERNS 17.4 Concern No. IN-85-476-004 and WI-85-041-002 regarding welding inspectors training program. ,This concern could not be substantiated as evidenced by audit of training programs. , In summary, the Bechtel SQN Implementation Audit concludes that all training, qualification, and certification activities for both nondestructive testing and visual welding inspection personnel were accomplished through a program which was in compliance with code and standard requirements and that this program was effectively implemented during construction at SQN. i In summary, Issues 1, 2, 3, and 4 are not subsr.aatiated due to the following factors:

1. A pecgram was in place during the construction era which adequately addressed the applicable requirements for training, qualification, and certification of both visual welding'and nondestructive testing personnel.

2. The Bechtel-SQN Implementation Audit established that this program adequately addressed the code and standard requirements of the construction era and confirmed that the pecgram was effectively implemented for that era, t

Page 4 of 5 00260 t

a.

               '                                                                         WP-06-SQN, R0 The part of Issue 4 which states "they (welding inspectors) should be welders prior to becoming welding inspectors" should be dismissed. This is not an essen,tial element of any training, qualification, and ce-tification program.        It is simply a statement of personal opinion.

Based upon the foregoing analysis, these issues addressed in the Employee Concerns are closed. l 4 l Page 5 of 5 00260 l

G3/EM/SS

                                         '                                                      Attactment 1 CEMPLCYEE     CONCERMS)                       PA3E 1 of 1 11: 18.:49 LOC ~

STATUS RES? -CTC- PPP CFR INSP TC ------CCNCER.'l------- PROELEM

      -~--        ------       ----         -----   ---   ---   ----    --

ID EGSG NR IN-SS-475-CCM .WCPCI_ K-4UORDS: QUALIFICATICN INSFECTOR NONSPECIFIC OPI X: U Y: C 2: N APPROX. 1990. TVA IMPLEMENTED A UELDING INSPECTORS TRAINING ?RCORAM ANC ?EEPLk ' WITH A GROCERY CLERK BACKGROUND WERE INSPECTING WELDS WITHIN TUO UEEKS. TECHNICAL COMMENTARY: ISSUE CONSIDERED: QUALIFICATION OF WELDING INSPECTORS. LCC STATUS RESP -QTC- PPP CFR INS? TC ------CONCERN------- PROSLEM ID BO SR IN-SS-SS1-001 UCPTT XEYWORDS: QUALIFICATION INSPECTOR NONSPECIFIC X: W Y: C 2: N UELCING INSPECTORS WERE INADEQUATELY TRAINED PRIOR TO 1581. 1.E., PERSCNUEL WITH NO EXPERIENCE INUOLUING WELDING WERE SENT TO A TWO UEEK TRAINING CLASS AND THEN

  -FUNCTIONED AS A WELDING INSPECTOR. CI HAS NO MORE INFORMATION.

TECHNICAL COMMENTARY: ISSUE CONSIDERED: QUALIFICATION OF UELDING INSPECTORS. LOC STATUS RESP -QTC- PPP CFR INS? TC ------CONCERN------- PROELEM ID NR UI-SS-OSI-007 WC?QI rWCROS: QUALIFICATION INSPEGTOR NONSPECIFIC OPI X: W Y: C 2: N CI EXPRESSED THAT WELDING INSPECTORS ARE NOT CUALIFIED FOR THE JOB. CI STATED THAT AN INSPECTOR NEEDED TO BE A WELDER SO THE INSPECTOR WOULD KNOW WHAT TO LOOK FOR IN A GOOD WELD. Cf DECLINED TO PROVIDE ANY ADDITIONAL INFORMATION. CONSTRUCTION DEPARTMENT CONCERN. NO FOLLOW UP REQUIRED. TECHMICAL COMMENTARY: 1 ISSUE CONSIDERED: QUALIFICATION OF WELDING INSPECTORS. LOC STATUS RESP -GTC- PPP CFR INSF TC ------CONCERN------- PROBLEM ID i SO SR WI-85-041-002 WCPTT t XEYWORDS: QUALIFICATION INSPECTOR PROGRAM X: W Y: C 2: N QUALEFICATION/ TRAINING OF INSPECTORS FOR STRUCTURAL CAWS) WELD VISUAL EXAMINATION IS QUESTIONASLE: LEVEL II CERTIFICATION IS GRANTED WITH ONLY TED MONTHS OF OJT, WHICH IS NOT DOCUMENTED: THE TOPICAL REPORT HAS "EASTARDIZED" ANSZ N45.2.6 REGARDING QUALIFICATION OF INSPECTION / EXAMINATION PERSONNEL. CI i HAS NO FURTHER INFORMATION, TECHNICAL COMMENTARY: E CONSIDERED: TRAINING PROGRAM FOR WELDING INSPECTORS.

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