ML20203M916
| ML20203M916 | |
| Person / Time | |
|---|---|
| Site: | Sequoyah  |
| Issue date: | 09/03/1986 |
| From: | Bateman R, Lynskey R, Rose J TENNESSEE VALLEY AUTHORITY |
| To: | |
| Shared Package | |
| ML20203M897 | List: |
| References | |
| WP-06-SQN, WP-06-SQN-R00, WP-6-SQN, WP-6-SQN-R, NUDOCS 8609050172 | |
| Download: ML20203M916 (10) | |
Text
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WELDING PROJECT GENERIC EMPLOYEE CONCERN EVALUATION REPORT REPORT NUMBER: WP-07-SON, R1 DATE 08/12/86
SUBJECT:
WELDER TRAINING PROGRAM FOR CONSTRUCTION AND NUCLEAR OPERATIONS CONCERNS CONSIDERED: IN-85-706-001 XX-85-045-001 EX-85-008-001 lR1 Original Signed by Robert D. Brir.r.s 8/12/86 , OC, WP PREPARED BY Original Signed by James F. Lewis 8/12/86 , OC, WP REVIEWED BY Original Signed by R. P. Lynsitey 8/13/86 , QA, WP REVIEWED BY Original Signed by L. E. Martin 8/18/86 , CEG-H, WELDING REVIEWED BY APPROVED BY -. PROGRAM MANAGER x t v- ' Revision 1 to tt'is report is being issued to add an employee concern which has been evaluated and determined to involve issues previously evaluated, dispositioned, and closed by the WP. 00410 l n-
O GENERIC EMPLOYEE CONCERN
SUMMARY
SHEET Report Number: WP-07-SON. R1
SUBJECT:
WELDER TRAINING PROGRAM FOR CONSTRUCTION AND NUCLEAR OPERATIONS I. CONCERNS CONSIDERED: IN-85-706-001 XX-85-045-001 i EX-85-008-001 lR1 II. ISSUES INVOLVED
- 1. The TVA Welder Training Program is inadequate for nuclear construction.
- 2. Welder performance qualification tests do not test a welder's overall ability.
III. STATEMENT OF CONCERN / ISSUE VALIDITY Validity: Y ,N X , Substantiated: Y ,N X . IV. EFFECT ON HARDWARE AND/OR PROGRAM None V. JUSTIFICATION None VI. RECOMMENDATION AND/OR CORRECTIVE ACTION NEEDED None VII. REINSPECTION NEEDED: Y ,N X . VIII. ISSUE CLOSURE Based on this report. IX. ATTACHMENTS l
- 1. Text of Employee Concerns lR1
- 2. Excerpts From Bechtel Audit - Key Element 3.0, 4.0, and 5.0 Page 1 of 1 00410
D GENERIC EMPLOYEE CONCERN Report Number: WP-07-SON, R1 Report
Title:
WELDER TRAINING PROGRAM FOR CONSTRUCTION AND OPERATION I. SCOPE OF EVALUATION This engineering analysis covers the following WBN and BLN concerns deemed to have possible generic implications to SQN: IN-85-706-001 XX-85-045-001 EX-85-008-001 lR1 II. ISSUES ADDRESSED BY CONCERNS Each concern was analyzed to determine the issues voiced by the concerned individuals. These issues are as follows:
- 1. The TVA Welder Training Program is inadequate for nuclear construction.
- 2. Welder performance qualification tests do not test a welder's overall ability.
III. CONCERN VALIDITY OR SUBSTANTIATION SQN and other TVA construction sites have historically had extensive welder training programs. SQN had a welder training facility in operation from the beginning of construction at SQN until approximately 1981. This training program put heavy emphasis on individual instruction and training to perform specific tasks such as open butt GTAW pipe welding. Instructors were craftsmen with considerable skill and experience in all aspects of welding. There is no regulatory requirement which mandates a welder training program. These programs were developed for the purpose of development of a qualified labor pool of welders from which expert craftsmen could be drawn who would be capable of performing quality work in an efficient manner. This is a prudent business practice. These programs also increased the probability that welders would pass the welder performance qualification test prior to making production welds. The requirements for welder performance qualification testing outlined in AWS, ANSI, and ASME B&PV Codes address the issue of skill level. These codes state that the purpose and intent of individual welder performance qualification tests are to determine the welder's ability to produce sound welds. This qualification test is the requirement mandated by codes and standards to determine the minimum skill level of welders, not the content or existence of a welder training program. Page 1 of 2 00410 l
. WP-07-SQN, R1 The requirements for welder performance qualification tests are incorporated into both the OC and NO Quality Assurance Programs, and their details are well documented. They have been audited through the ASME Implementation Survey for Certificates of Authorization and by organizations such as INPO and NRC.
The Bechtel SQN Implementation Audit performed in January 1986, directly addressed this issue in Key Element 3.0, " Initial Welder or Welding Operator Qualifications," Key Element 4.0, " Maintenance of Welder or Welding Operator Qualifications," and Key Element 5.0, L " Renewal of Welder and Welding Operator Qualifications." For both OC l and NO, the audit indicates that the programs met upper-tier commitments and were effectively implemented. The SQN Reinspection Program also provides objective evidence of welder skill. No substantial welding problems were discovered which were attributable to welder skill. In summary, the issues considered in these concerns are not substantiated due to the following factors:
- 1. There is no requirement relative to welder training programs.
I
- 2. The base requirement for welder skill is the Welder Performance Qualification Test Program.
- 3. The Welder Performance Qualification Test Program is outlined in both the OC and NO QA programs.
- 4. The Bechtel SQN Implementation Audit has established that these
' programs have been and are being effectively implemented by OC and NO. [ 5. No indications of a generic welder skill problem was discovered by I the SQN Reinspection Program. Based on the foregoing analysis, the issues considered in these concerns are closed. l l i l l Page 2 of 2 00410
. Attachment 1 Page 1 of 1 07/25/86 (EMPLOYEE CONCERNS)'
03:44:38 CAT ISSUE PLANT PRIORITY ORG QTC EGG
~
INSP SD RD GD IO ------CONCERN-----.
~~ ~~~ "~~~ ~ '~ ~~ ~ ~~ ~' ~
"EE 5F5' ~~E i 555 ~ E5 552 i 5E 5 IN-85-706-001 KEYWORDS: QUALIFICATION CRAFTSKAN SPECIFIC PROB: WCPTT WELDERS WHO WENT THROUGH TVA'S WELDER TRAINING PROGRAM HAVE INSUFFICIENT l
TRAINING AND EXPERIENCE TO HANDLE ALL VARIABLES INVOLVED TO PERFORM ADEQUATE ! WELDS FOR A NUCLEAR INSTALLATION. THIS INADEQUACY HAS CREATED A LOG OF RE'40RI. CI KAS NO MORE DETAILS. IR: STAT: RC: WP-07-SQN TECHNICAL COMMENTARY: CAT ISSUE PLANT PRIORITY ORG QTC EGG INSP SD RD GD IO ------CONCERN------ MP B 1 EGG A5 512 N NS A XX-85-045-001 KEYWORDS: QUALIFICATION CRAFTSKAN SPECIFIC PROB: WCPQV BELLEFONTE-TVA POLICY ALLOWS FOR PERSONEL TO BE SENT TO THE TEST SHOP AND IN A SHORT-TIME BE CERTIFIED AS AN ELECTRICAL WELDER. THESE WELDERS DO PASS A STRICT TEST DOES NOT TEST THEIR ABILITY WHEN DEALING WITH ALL THE VARIABLES AN EXPERIENCED WELDER CAN HANDLE. INSUFFICIENT WELDER TRAINING (It'SP RPT# I-85-352-BLN) IR: I-85-352-BLN STAT: RC: WP-07-SQN TECHNICAL COMMENTARY: CAT ISSUE PLANT PRIORITY ORG QTC EGG INSP SD RD GD IO ------CONCERN------ l- l WE W 1 EGG 511 Y SR EX-85-008-001 I
- l KEYWORDS
- QUALIFICATION CRAFTSMAN SUBJOURNEYMEN PROB: WCPTT l
! l l SUBJOURNEYMEN USED TO DO WORK THAT THEY'RE NOT QUALIFIED TO DO: THEY NEEDN'T
- l l HAVE ANY SPECIFIC TRAINING, BUT DO WORK (EG PIPE FIT-UPS AND WELD ON 1/4" l R1 l LINES) NORMALLY DONE BY A' CLOSER TECHNICAL SIIPERVISION THAN TVA PROVIDES. WHEN l CRAFT COMPLAIN THEY ARE "CHEUED OUT" BEYOND ALL REASON /.BLE LIMITS. NO l MORE DETAILS KNOWN.
( l l IR: IN-85-130-001 V STAT: RC: WP-07 --SQN ! l l TECHNICAL COMMENTARY: I l l IN PROCESS UNION POLITICS l l 1 l f
Attachment 2 Page 1 of 4 fr KEY ELDEIT NO. 1.0 , ( OFFICE OF CCMSTRUCTICM PREPARATICU FOR AUDIT OF WELDI!G ACTIVIT!IS - identified applicable documents specific manuals, and and specifica
' procedures which described and implemented the TVA welding activities .
~ '
The audit team developed an audit checklist to address a'll elements for significance and integration into the checklist. identified cerns in th The from audit teamTVA applicable identified and selected a cross section of welded systems specifications.
-Welds.were randomly selected from drawings applicable to each individual system for programmatic audit .
KEY ELDEIT 2.0 OFFICE OF CCNSTRUC'ICN ADEOUACY OF DESIGN OUTPUT CCCU:'.E'ITS a For items selected for audit, drawings, welding procedures and supporting j records were procedures. reviewed and showed compliance with the TVA program and
'k OBSERVATICN .
One cbservation was noted during the audit of the welding output documents . organi=ational group.The TVA detailed welding procedures (CWP) did not show t By showing the name.of;the key unit that is welding documents could have been readily resolved. responsible fo KEY ELEMENT 3.0 OFFICE OF CONSTRUCTICN ! INITIAL WELDER OR WELDING OPERATOR OUALIFICATIC::S l Based on audit of welder qualification records and supporting documentatio n, -- TVA welders were qualified in accordance with TVA programs and procedures . l 0031X Pace 3 of 11 i i l - t ' ~
Attachm:nt 2 *
' Page 2 of 4 KEI ELEME'!T 4.0 .
( OFFICE OF CCNSTRUCTIC!I MAI:ITEIANCE OF WELDER OR WELDI::G OPERATCR CUALIFICA _. . Based on audit of welder maintenance records, TVA welders demonstraced welding and within procedures. certification expiration dates as required by TVA programs KEl ELEME!IT 5.0 OFFICE OF CCNSTRUCTICI REID7AL OF WELDER OR WELDI !G OPERATOR CUALIFICAT!CNS Based on audit of welder qualification records'and maintenance records , TVA welders were requalified in accordance with TVA programs and procedures . In many cases TVA welders were given the original qualification tesc for renewal which exceeded ASME IX and AWS Dl.1 requirements for renewal. KEY ELD'ENT 6.0 OFFICE OF CC:ISTRUCTIC:I INITIAL WELDING INSPECTIO:I PERSC:l?IEL OUALIFICATICN Qualification /Cartification records for nondestructive examination personnel (weld incpection) were reviewed for compliance with TVA NDE personnel qualification March, 1983. procedures covering a time span from January, 1971 through 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. 0031X Pace 4 of 11 L
r 3 , . Attachmsnt 2
- Page 3 of 4 KEY ELC!r!T NO. 1.0 j
r - b NUCLEAR OPERATIONS _PREPARATICN FOR AUDIT OF WELDI::G ACTIVITIES - Prior to the start of the audit, the audit team developed an audit plan and identified applicable documents, specific manuals, specifications and
. procedure which described and implemented the TVA welding activities.
The audit team developed an audit checklist to address all element:
^
identified in the TVA work plan in addition to analysis of employee concerns for significance and integration into the checklist. The audit team identified and selected a cross section of welded. systems based on availability, eg: only systems which had been modified,. repaired or replaced fell under Nuclear Operations program for audit. Welds were ~ randomly selected from drawings applicable to each individual system for programmatic audit.
~
KET ELEMDIT 2.0 NUCLEAR OPERATIONS ADEOUAC7 OF DESIGN OUTPUT DOCUMENTS For items selected for audit, drawings, welding procedures and supporting records were reviewed and shoued compliance with the TVA program and - procedures.
' OBSERVATION One observation was noted during the audit of the welding output documents.
The TVA detailed welding procedures (DNP) did not show the name of~the key l organizational group. By showing ~ the name of the key unit that is i responsible for the welding control documents, any questions concerning the l welding documents could have been readily resolved. KET ELEMEIT NO. 3.0 l j ' NUCLEAR OPERATIONS i INITIAL WELDER OR NELDING OPERATOR OUALIFICATICNS s Based on audit of welder qualification records and supporting documentation, . . . TVA welders are qualified in accordance with TVA programs and procedures. 0031X . i b i l Page 3 of 11
~
g* . Attachm nt 2 Page 4 of 4 . J KL"I ELETEIT NO. 4.0 ( ._ NUCLEAR OPERATIO?IS MAINTE!A! ICE OF WELDER OR WELDING OFERATOR OUALIFICATICU Based on audit of welder maintenance records, TVA welders demonstrated welding and within certification expiration dates as required by TVA programs procedures. KE'l ELE 4DIT NO. 5.0 NUCLEAR OPERATIO?IS RDIEMAL OF WELDER OR WELDING, OPERATOR OUALIFICATIONS Based on audit of welder qualification records and maintenance records, TVA welders are requalified in accordance with TVA programs and procedures. KE'I ELE 4DIT 6.0 NUCLEAR OPERATICNS INITIAL WELDING INSPECTION PERSONNEL OUALIFICATICUS All inspector qualification records (NDE. co include visual examination) audited indicated compliance with TVA programs and procedures and the <- referenced codes and standards. OBSERVATION TVA Form 6780 (as referenced in procedure 0202.14) usedtodocumentNDb qualification and certification does not clearly identify the recertification status of the individual. Additionally, certification authority is referenced as being in compliance with TVA program requirements when individuals are actually certified in accordance with the specific requirements of Procedure 0202.14 (formerly N75C01), Qualification Certification Program for NDE Personnel. Program clarity and definition could be improved by adding either the j certification expiration date or recertification status as an entry on Form 6780. Specific reference to Procedure 0202.14 on certification forms (6780) would provide for direct reference and compliance with TVA NDE personnel qualification, employed. certification requirements and practices for each NDE method + 0031X i . i/ . l\ i l . Page 4 of 11 i L -- O}}