ML20214U749

Rev 0 to TVA Employee Concerns Special Program,Training & Certification of Const Welding Insps

ML20214U749
Person / Time
Site:	Sequoyah
Issue date:	11/20/1986
From:	Russell J TENNESSEE VALLEY AUTHORITY
To:
Shared Package
ML20214G966	List: ML20214G963 ML20214G989 ML20214T991 ML20214U124 ML20214U174 ML20214U216 ML20214U247 ML20214U308 ML20214U341 ML20214U367 ML20214U384 ML20214U415 ML20214U473 ML20214U502 ML20214U520 ML20214U550 ML20214U625 ML20214U639 ML20214U689 ML20214U749 ML20214U779 ML20214U814 ML20214U843 ML20214U860 ML20214U882 ML20214U924 ML20214V018 ML20214V037
References
WP-06, WP-06-R00, WP-6, WP-6-R, NUDOCS 8612090383
Download: ML20214U749 (10)

Text

c

+

TVA EMPLOYEE CONCERNS REPORT NUMBER: WP-06 SPECIAL PROGRAN REPORT TYPE: Welding Project REVISION NUMBER: 0

?-

TITLE: Training and Certification of Construction Welding Inspections

(

REASON FOR REVISION: N/A SWEC SUNNARY STATENENT: N/A 1

?

PREPARATION PREPARED BY:

Orizinal Sinned By J. E. Rose 04-07-86 SIGNATURE DATE REVIEWS PEER:

Original Simned By R. N. Bateman 0.-07-86 SIGNATURE DATE Y

E TAS: TECHNICAL REVIEW ONLY

//!/f A

SIGNATURE DATE CONCURRENCES I

E Original Signed By CEG-H:

L. E. Martin 09-03-86 l

SRP:

w$

ll-24 84 SIGNATURE DATE SIGNATURE

• DATE APPROVED BY:

lh$b N/A 2A ECSP flANAG M DATE MANAGER OF NUCLEAR POWER DATE g

CONCURRENCE (FINAL REPORT ONLY)

• SRP Secretary's signature denotes SRP concurrences are in files.

...RT wmm mm 7 1

.,s.

vg

~~

WELDING PROJECT i 1 GENERIC ENPLOYEE CONCERN EVALUATION REPORT REPORT NUMBER: WP-06-SON. R0 P

DATE 04-08-86

SUBJECT:

' TRAINING AND CERTIFICATION OF CONSTRUCTION WELDING INSPECTORS CONCERNS CONSIDERED:

IN-85-476-004 IN-85-981-001 WI-85-081-007 WI-85-041-002

. PREPARED BY Original Signed by J. E. Rose 4/7/86

, OC, WP REVIEWED BY oriainal Signed by R. Bateman 4/7/86

, OC, WP 3

y*

REVIEWED BY. Original Signed by Ri P. Lynskey 4/7/86

, QA, Wp

/

, CEG-H, WELDING REVIEWED B yy APPROVED BY A-x

, PROGRAN MANAGER i

e ge '~,4 00260

~~

, } }; ' ~

G,ENERIC EMPLOYEE CONCERN as:y.-

7

SUMMARY

SHEET

- + _.

Report Number:

WP-06-50N. R0 Report

Title:

TRAINING AND CERTIFICATION OF CONSTRUCTION WFLDING INSPECTORS I.

CONCERNS CONSIDERED:

IN-85-476-004 IN-85-981-001 WI-85-081-007 s

WI-85-041-002 II.

ISSUES INVOLVED 1.

Prior to 1981, an ina'dequate 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 2.

,_)

with ANSI N45.2.6.

4Property "ANSI code" (as page type) with input value "ANSI N45.2.6.</br></br>4" contains invalid characters or is incomplete and therefore can cause unexpected results during a query or annotation process..

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

III. STATEMENT OF CONCERN / ISSUE VALIDITY Yalidity: Y

,N I

, Substantiated: Y

,N I

1 IV.

EFFECT ON HARDWARE AND/OR PROGRAM i

None V.

JUSTIFICATION The Office of Construction had a Welding Inspector Training /

i Certification Program in effect which was implemented effectively and met code, standard, and regulatory requirements for SQN Construction, j

VI.

RECOMMENDATION AND/OR CORRECTIVE ACTION NEEDED None l

l VII.

REINSPECTION NEEDED: Y

,N I

3 i

' '3 i

~#

Page 1 of 2 I

00260

---

..,.----n.----

-,,n

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

.r-WP-06-SQN, R0 5

VIII.

ISSUE CLOSURE Close based on this report.

IX.

ATTACHMENT I.

Text of Employee Concerns i

,i l

Page 2 of 2 l

00260

s

~

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

Title:

TRAINING AND CERTIFICATION OF d

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 1

concerned individuals. These issues are as follows:

Prior to 1981, an inadequate Welding Inspection Training and 1.

Certification Program allowed welding inspectors to complete their training in two weeks.

The Training / Qualification Program for AWS welding inspectors is 2.

questionable because the inspectors only have two months OJT which is not documented.

l 3.

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

4Property "ANSI code" (as page type) with input value "ANSI N45.2.6.</br></br>4" contains invalid characters or is incomplete and therefore can cause unexpected results during a query or annotation process..

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 I

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 s

industry. Qualification of personnel in construction at SQN parallels ANSI Standard N45.2.6, " Qualifications of Inspection Examination, and l

Testing Personnel for the Construction Phase of Nuclear Plants."

O Page 1 or 5 00260

---T

-P q-7 7rwrecws

• w r v r rw c

-ww--7m9 e w gie we>

w mwqy y e, g. r w w--

=y--?va

r WP-06-SQN, R0

)

.Y The base requiremont 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 toward the formulation of a recommended practice for visual weld inspection in the nuclear industry.

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 Training, Qualification, and Certification program. TVA's commitment is described in the Topical Report (TVA-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 requirements. This program is outlined in SQN Construction Procedure No. P-33 " Certification of Inspectors."

ANSI N45.2.6 allows the use of SNT-TC-la for certifying nondestructive testing personnel.

I a

In the absense of clear source document requirements regarding visual 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 three months of worktime experience prior to certification.

Certification in these disciplines was a prerequisite for certification 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 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.

I I

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

" Maintenance of Welding Inspection Personnel Qualification"; Key Element 8.0, " Renewal of Welding Inspection Personnel Qualification";

~')

and Key Element 17.0, " Employee Concerns."

Page 2 of 5 l

00260

... - ~

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

_ KEY ELEMENT 6.0 0FFICE OF CONSTRUCTION INITIAL WELDING INSPECTION PERSONNEL QUALIFICATION Qualification / certification records for nondestructive examination personnel (weld inspection) were reviewad for compliance with TVA NDE personnel qualification procedureJ 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 OFFICE OF CONSTRUCTION MAINTENANCE OF WELDING INSPECTION PERSONNEL QUALIFICATION Review of inspection personnel qualification records for completeness and recertification confirmed compliance with TVA procedures used for qualification certification of NDE personnel.

I 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).

KEY ELEMENT 8.0 OFFICE OF CONSTRUCTION RENEWAL OF WELDING INSPECTION PERSONNEL QUALIFICATION Renewal of all welding inspection personnel qualifications selected for audit Indicated compliance with referenced TVA programs and procedures.

l i

Page 3 of 5 l

00260

WP-06-SQN, R0

~

XEY ELEMENT 11.0 i

0FFICE OF CONSTRUCTION i

USE OF APPROPRIATELY TRAINED AND QUALIFIED 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 certification were not maintained 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 i

standards, 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.

l In smamary, the Bechtel SQN Implementation Audit concludes that all j

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 I

standard requirements and that this program was effectively implemented during construction at SQN.

In summary, Issues 1, 2, 3, and 4 are not substantiated due to the 1

following factors:

I 1.

A program 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 program was effectively implemented for that era.

i

.h ss Paga 4 of 5 00260

,,y,,.,,._-,----

.n.----.,,_._n_w__,,,,---,a-,

_,,._,-,,-n.s-.

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 essential element of any training, qualification, and certification program.

It is simply a statement of personal opinion.

Based upon the foregoing analysis, these issues addressed in the Employee Concerns are closed.

,b

. ;j 1

l 3

Page 5 of 5 00260

.Y' 1

~

- ~

03/2.N/88 (Ef1PLOYEE CGNCERNS)

PASE 1 of 1 4F 11i18:49.

LOC

. STATUS RESP

-DTC-PPP CFR 'INSP TC ------CONCER.'l-------

PROELEi1 ID

.If1-8S' 975-CG4 -

.VCPOL

.)

.EGGG NR

~~

. SWORDS:

QUALIFICATION INSPECTOR NONSPECIFIC OPI X: W Y: C Z: N C.PPROX. ISBO,1 TVA IMPLEt1EtiTED A WELDING INSPECTORS TRAINING PRCGRAli AND PE6PLE '

~

WITH A GROCERY CLERK-BACKGROUND WERE INSPECTING WELDS WITHIN TWO UEEKS.

' TECHNICAL COMf1ENTARY:

ISSUE CONSIDERED: -QUALIFICATION OF WELDING INSPECTORS.

LOC STATUS. RESP

-QTC-PPP CFR INSP TC ------CONCERN-------

PROSLEM ID BO SR IN-85-SB1-001 WCPTT

KEYWORDS:

QUALIFICATIOf1 INSPECTOR NONSPECIFIC X: W Y:

C.

2: N WELDING INSPECTORS WERE. INADEQUATELY TRAINED PRIOR TO iSE1.

1.E.,

PERSDNUEL WITH NO EXPERIENCE INVOLVING WELDING WERE SENT TO A TWO WEEK TRAINING CLASS AND THEN FUNCTIONED' AS A WELDING -INSPECTOR. CI HAS NO MORE INFORt1ATION.

' TECHNICAL COMt1ENTARY:

ISSUE CONSIDERED: QUALIFICATION OF WELDING INSPECTORS.

-LOC STATUS RESP

-QTC-PPP CFR INSP TC ------CONCERN-------

PROBLEM ID NR WI-ES-OSI-OO7 WCPQI WORDS:

QUALIFICATION ~ INSPECTOR NONSPECIFIC OPI X: W Y: C 2: N CI EXPRESSED THAT WELDING INSPECTORS ARE'NOT DUALIFIED 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.

'CI DECLINED TO PROVIDE ANY ADDITIONAL INFORt1ATION.

CONSTRUCTION DEPARTMENT

. CONCERN.

NO FOLLOW UP REQUIRED.

TECHNICAL COr1r1ENTARY:

ISSUE CONSIDERED: QUALIFICATION OF WELDING INSPECTORS.

LOC STATUS RESP

-QTC-PPP CFR INSP TC ------CONCERN-------

PROBLEM ID l

BO SR WI-BS-Oil-002 WCPTT KEYWORDS:

QUALIFICATION INSPECTOR PROGRAt1 X: W Y: C 2: N QUALIFICATION /TRAININC OF INSPECTORS FOR STRUCTURAL CAWS) WELD VISUAL, EXAMINATION IS QUESTIOllABLE: LEVEL II CERTIFICATION IS GRANTED WITH ONLY TWO

. MONTHS OF DJT, WHICH IS NOT DOCut1ENTED: THE TOPICAL REPORT HAS "SASTARDIZED"

!. ANSI N45.2.8 REGARDING OUALIFICATION OF INSPECTION / EXAMINATION PERSONNEL. CI HAS NO FURTHER If1 FORT 1ATION, t

TECHNICAL COf1t1ENTARY:

s.hECONSIDERED: TRAINING PROGRAti FOR WELDING INSPECTORS.

ti l

fj.

e O

-m.------y_,

.. ~,

-