ML20212F529

Rev 3 to TVA Employee Concerns Special Program Welding Project Rept WP-24-SQN, Improper Welding Certification

ML20212F529
Person / Time
Site:	Sequoyah
Issue date:	02/21/1987
From:	Rose J, Schofield R, Stewart D TENNESSEE VALLEY AUTHORITY
To:
Shared Package
ML20212F190	List: ML20212F185 ML20212F275 ML20212F313 ML20212F342 ML20212F370 ML20212F389 ML20212F438 ML20212F458 ML20212F498 ML20212F529 ML20212F562 ML20212F581
References
WP-24-SQN, WP-24-SQN-R03, WP-24-SQN-R3, NUDOCS 8703050108
Download: ML20212F529 (9)

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~. TVA RNPLOYER CONCERNE REPORT NUMBER: WP-24-SQN SPECIAL PRDGRAN REPORT TYPE: Welding Project REVISION NUMBER: 3 r

f TITLE: Improper Welding Certification REASON FOR REVISION: Added Corrective Action Report - Attachment 2 i

SUMMARY

STATEMENT: N/A PREPARATION PREPARED BY:

Original Signed by R. Schofleid 01-21-87 SIGNATURE DATE i

REVIEWS i PEER:

Orir.inal Signed by J. E. Roso 01-21-87 SIGNATURE DATE AS*%I ' TECilNICAL REVIE ONLY GW .

SIGNATURE ebb DATE CONCURRENCES Original Signed By CEG-il: J. F. Lewis 01-27-87 SRP:Q WM p/+87 SIGNATURE DATE

[ SIGNATP)tt[ DATE f APPROVED BY:

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'* I*N'A7 N/A ECSP MANAG8R DATE MANAGER OF NUCLEAR POWER DATE CONCURRENCE (FINAL REPORT ONLY) l *SRP Secretary's signature denotes SRP concurrences are in flies.

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B703050108 870226 PDR ADOCK 05000327 p PDit 2

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.s . 1 WELDING PROJECT EMPLOYEE CONCERN EVALUATION REPORT REPORT NUMBER: WP-24-SQN R2 g.==.-

DATE: O/-2/-87

SUBJECT:

WELDER PERFORMANCE QUALIFICATION lR2

. CONCERN (S) CONSIDERED: JLH-85-002 i

t PREPARED BY N. b ,

[ Olb /ff 7 , OC, WP REVIEWED BY . 8dh 1 / st/

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• 2/* 8% OC, WP e-.

REVIEWED BY +f a #/TS!87 , Q A , WP

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6 REVIEWED BY fnm3 > A/ />N xt e 4 CEG-il, WELDING

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APPROVED BY PROGRAM MANAGER Revision 1 issued to include consents by the Senior Review Panoi ar.d TAS.

Revision 2 rewritten to delete welder continuity issue, provido additional information about welder qualification and to specify corrective action 0548I

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, ENPLOYEE CONCERN i

SUNNARY SNEET Report Number: WP-24-SQN, R2 Report Title WelderPehformanceQualification lR2 5

I. CONCERN CONSIDERED: JLN-85-002 j

II. ISSUES INVOLVED f 1. Welder being qualified without the appropriate number of bend tests.

! 2. A secondary issue evolving from the first concerning welder continuity was espressed by the Concerned Individual.

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III. STATEMENT OF CONCERN / ISSUE VALIDITY

Validity

Y Z ,N , Substantiated: Y X ,N -

The concern that a welder has been qualified without the appropriate l l

number of bend tests was substantiated and validated. This welder was

! quellfled by Muscle Shoals (PSS MS) for Sequoyah Nuclear Operations (R2 i

(SQN NO). The statement of concern addresses only issue No. 1. Issue l No. 2 is addressed by CAR 85-09-14 and WP-03-SQN. l f 'IV. EFFECT ON HARDWARE AND/OR PROGRAN To be determined through implementation of corrective action. lR2 i

!j V. JUSTIFICATION:

1. The concern that a welder was qualified (welder qualification was l l

' performed by Muscle Shoals) without the appropriate number of bend I

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tests was substantiated and validated. One welder has been retested and his qualification and previously made welds have been l addressed by SQ-DR-85-08-095R. Additional questions were raised lR2

' during review of the DR and conversations with TVA Welding l personnel. It is apparent that thete may have been other welders l qualified by Muscle Shoals for SQN NO with only two bond tests l whose production work,at SQN has not been addressed. l i

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Report Number: WP-24-SQN, R2 VI. RECOMMENDATION AND/OR CORRECTIVE ACTION NEEDED TVA should determine whether any other welders were improperly l qualified for SQN NO by Muscle Shoals, and what effect, if any, the IR2 improper qualifications had on work performed at SQN. l VII. REINSPECTION NEEDED: Y I ,N (Records review) lR2 VIII. ISSUE CLOSURE CLOSURE BASED ON THIS REPORT l l

1. Issue 1 - Open l lR2

2. Issue 2 - Address by CAR-85-09-014 and WP-03-SQN l IX. ATTACllMENTS Text of Employee Concern IR2 i

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<  ;- 4 ATTACHNENT 1  !

TEST OF EMPLOYEE CONCERN  :

Report Number: JLil-85-002 ,

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Plant: SQN l l

f This concocn was not documented per SQA166 but has been included in the employee concern log. .

Welders tested at Muscle Shoals for SQN NO may not have received the appropriate number of qualification tests.

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. p c ENPLOYEE CONCERN Report Number: WP-24-SQN, R2 F

j Report

Title:

Walder Performance Qualification lR2 0

fI. SCOPE OF EVALUATION

JLH-85-002. i I 'The subject concern was previously investigated by the SQN onsite lR2

' Employee Concern Impact Evaluation Program.. Our findings and conclusions I (in section III) are based on the review of the previous investigator's notes, review of SQN-DR-85-08-095R and discussions w'th -ognizant TVA lR2 Welding personnel. I II.' ISSUE (S) ADDRESSED BY CONCERN b A. Welders tested at Muscle Shoals for SQN NO may not have received the appropriate number of bend tests when taking performance qualification test.

B. The concerned individual also feels the current welder continuity l program at SQN does not ensure the proficiency of Nodification lR2 Welders. This portion of the concern is addressed by CAR-85-09-14 l and WP-03-SQN and will not be addressed in this report.

l III. CONCERN VALIDITY OR SUBSTANTIATION One welder in question was originally quallflod for the Sequoyah Nuclear l a Plant at TVA's Muscle Shoals facility B.ased on the qualification records l at Muscle Shoals, it is questionable if the welder was properly l gualified. Two bend specimens per qualification test were l l

satisfactorily bent and recorded on the Wclders Qualification Record. l The ASME Code, Section IK 1974 Edition, Article III, " Welding l

[ Performance Qualification," requires the type and number of test l j e specimens required for mechanical testing shall be in accordance with l QW-302.3 for guided bend tests. Paragraph QW-302.3 was not printed in lR2

. this edition (1974) of Section IX. Table QW-452 specified one face bend l

! and one root bend or two side bends could be substituted for the l required face and root bend tests for thicknesses over 3/8-inch but less l than 3/4-inch. Based on the omission, paragraph QW-302.2 could lead one 3

l i to interpret the qualification requirement to require a two bond test. l l The Errata to the 1974 Edition of Section IX published in the l Summer 1974 Addenda to Section IX added paragraph QW-302.3 which l requires that four specimens (for 50 and 60 positions) pass the test. l 2563T Page 1 of 3 t

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R: port _ Number: WP-24-SQN, R2 I

• To provide absolute clarity to the number of bend test specimens l required for the SG and 6G positions, the Summer Addenda to 1978 Edition l of Section II added a foot note to table QW-453 which stated, "a total lR2 of four specimens is required to qualify for positions SG and 6G as l prescribed in QW-302.3." Due to the omission of paragraph QW-302.3, it l appears that the: welder's qualification was granted based on the two I bend specimen per performance qualification test.

l ConversationswikhMuscleShoalspersonnel(PSS-MS)indicatethatfour l bend coupons were bent per welder qualification test in the 50 or 60 122 position but only two bend specimens were recorded on the Welders i Qualification Records (see reply to meno dated August 14, 1985 for David l H. Tullis to John Foz). .

i The basic criterion established for welder qualification is to determine I the welder's ability to deposit sound weld metal. The welder in lR2 guestion was issued 12 performance qualification from Muscle Shoals. l All 12 test were taken and successfully passed within approximately a )

three week period (08/12-09/01/77).

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The welder's continuity was maintained at SQN through at least l August 14, 1985. On this date (August 14, 1985) the welder successfully lR2 2

• completed four performance qualification tests which represents Welds alltothe made prior l welding processes he had previously used at SQN. i i

the requalification test were addressed on SQ-DR-85-08-095R and accepted, l

Based on the fact that the welder satisfactorily performed 12 l performance qualification tests at Muscle Shoals, satisfactorily lR2 performed additional qualification testing at SQN and continued to l l

produce satisfactory fleid welds over an eight year period, the intent l of ASME Section II for welder gus11fication (to determine the welder's ]

j ability to deposit sound weld metal) was satisfied.

I l The above justification, however, applies only to the one welder l identified in SQ-DR-85-08-095R (reply meno dated 8-14-85/8-20-85). An I 1

attachment to the referenced DR, states in part ". . . we strongly lR2 recommend that you re-examine all Welder Performance Qualification test l records given in 1977 by pSS MS personnel for other siellar l documentation problems. . ." The copy of SQ-DR-85-08-095R provided to I l the Weld Task Group (WTG) shows no evidence of such a re-examination

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g a g- ,' R: port Number WP-24-SQN, R2

• Conversation with cognizant TVA Welding personnel indicates that a l review was performed at SQN for NO welders which included only welders l who were active at the time of the review, and some inactive NO welders l who had not yet been dropped from the qualification continuity list. A [R2 written record of this review could not be produced. It therefore I appears that there may have been welders other than the one addressed l above who were improperly qualified by PSS.MS and subsequently performed l l

welding operations at SQN for NO.

Conversation with cognizant TVA Welding personnel indicates that welder l

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quellfication by PSS MS for SQN NO welders continues to be a common practice. TVA Welding personnel believe, however, that welder lR2 performance qualification at Muscle Shoals with only two bend tests l '

documented was limited to a time frame of approximately three years. l from January 1975 through December 1977. l l

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IV. CORRECTIVE ACTION TVA should determine the exact time frame during which PSS MS provided I welder qualification services to SQN No without evidence of having lR2 l

performed the Code required number of bend. tests.

l TVA should determine whether or not any PSS MS guallfled welders other l than the one addressed by SQ-DR-85-08-095R received their qualifications [R2 during the above determined time frame, and subsequently performed l welding operations for SQN NO. l TVA should evaluate for acceptability any welding performed at SQN by l welders identified as having been improperly qualified by PSS MS. lR2 It should be noted that TVA Welding personnel believe that the above [

actions have, in part, been accomplished. In that whatever action was l taken was apparently not formally documented, it cannot be established l to what degree the problem originally extended, or to what degree it was IR2 evaluated and rer:1 red. Therefore, when the above corrective actions I are undertaken, t! ay should be formally documented. Any deficiencies l l

Identified should be documented in accordance with the estabilshed TVA deficiency reporting and tracking program. l 2563T i

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o . WP-24-SQN Attachment 2 Page 1 of 1 CORRECTIVE ACTION PLAN CATD No. WP-24-SON-01

1. PROBLEN DESCRIPTION: TVA should determine the exact timeframe durina which PSS NS provided welder quellfication services to SON.

No without evidence of havina performed the Code required number of bend tests. TVA should determine whether or not any PSS MS qualified welders other than the one addressed by S0-DR-85-08-095R received their quellfications during the above determined timeframe.

and su!)sequently performed welding operations for SON NO. TVA should evaluate for acceptability any welding performed at SON by welders identified as havina been improperly quellfled by PSS MS.

It should be noted that TVA Welding personnel believe that the above actions have. In part, been accomplished. In that whatever action was taken was apparently not formally documented, it cannot be established to what degree the problem origin?lly estended, or to what degree it was evaluated and resolved. Therefore, when the above corrective actions are undertaken, they should be formally documented in accordance W!th the established TVA deficiency reportina'and tracking program.

2. CORRECTIVE ACTION: JA) A list obtained from SON Nuclear Operations regarding welders who were tested by the Power Service Shop. Muscle Shoals was reviewed for records showing evidence that the ASME Section IX code-required number of bend specimens was not met. This review established a timeframe from August 11, 1976, throuAh September 1. 1977. Where three welders were certified in the 60 pipe position with two bend specimens instead of the code-required four bond specimens. (B) Welderes Byron L. Standifer (stamp number SNP-1) social security number 410-22-5490 Gary W. Hurley (stamp number SNP-2) social settrity number 415-78-4865._ and William T.

Basham (stamp number Shr-3) social security number 253-70-1926 were gualified withlp this ,1)meframe. William T. Basham's certifications have been identified e J resolved under S0-DR-85-08-095R. The other two welders were not idone.lfled in this DR. (C) Discrepancy report S0-DR-87-041R has been inutisted to address this. condition and will_

address the acceptability of any welding performed at SQN by

fr. Standifer and Mr. Hurley.

3. ACTION TO PREVENT RECURRENCE: Procedures have been revised to j

require four (4) bend test for welders quellfication.

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