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<td><a href="https://misportal.jlab.org/ll/index.jsf?function=view&lessonId=881">Weld Record Deficiencies Results in Re-work - Savannah River Site Salt Waste Processing Facility</a></td>
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<h2 style="white-space:nowrap">Statement of Lessons Learned</h2>
<pre>For a copy of the original report, see “Attachments” on Lessons Learned page.
During an audit of of over 70,000 required radiographic weld images, it was found that many were missing. The extent of condition ultimately identified the need to re-perform radiography of approximately 1400 welds. The reason for the missing information included lack of training on new and evolving CRT software, worker turnover, lack of adequate optical disc storage, and inadequate review by subcontractor of final documentation records prior to submittal.
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<h2 style="white-space:nowrap">Discussion of Activities</h2>
<pre>The Salt Waste Processing Facility (SWPF) is being constructed to support the processing of legacy radioactive liquid waste. The facility includes over 23 miles of pipe and approximately 70,000 welds. Many of these welds require documented volumetric examinations, and all welds within the process cells require radiographic examination.
Radiography activities at the SWPF were performed by a subcontractor with oversight from the prime contractor. A sreview of the radiographic records identified deficiencies including missing original radiographic images and issues with computed radiography (CRT) implementation. The extent of condition ultimately identified the need to re-perform radiography of approximately 1400 welds.
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<h2 style="white-space:nowrap">Analysis</h2>
<pre>In relation to missing CRT images, a variety of human errors occurred when saving the images to the optical disc. A number of likely situations could have resulted in the missing information including new and evolving CRT software, worker turnover, and inadequest optical disc storage. While considerable software training was provided, specific steps for saving images were not included in the written instructions.
In relation to CRT implementation, a variety of human errors occurred in relation to code compliant radiographic techniques, image quality, and report inconsistencies. Compliant procedures were in place and all involved individuals were trained, qualified, and certified (as appropriate). Despite these provisions, final reviews by certified individuals did not identify the issues as it seems they were focused on training, qualification, and certification and not the actual performance and documentation.
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<h2 style="white-space:nowrap">Recommended Actions</h2>
<pre>Below are the consequences of the above event. They are provided for information and discussion purposes only.
Conduct oversight of subcontractor activities with sufficient depth and breadth to ensure accurate documentation that the work is performed in accordance with requirements. Conduct timely reviews when processes change to avoid/minimize rework if issues are identified.
Ensure procedures/instructions include appropriate steps for activities that affect or are important in demonstrating quality.
Anticipate properly trained and qualified individuals will make errors and ensure sufficient checks and balances are in place to identify and minimize the consequence of errors.
Subcontractor corrective actions included re-training and upgraded software to better control records. </pre>
<h2 style="white-space:nowrap">JLab Preventive Measures</h2>
<pre>Jefferson Lab has a robust Hot Work Program, which includes welding documentation and training requirements for all welding performed by lab employees or subcontractors. See the ES&H Manual, Welding and Brazing Program Supplement, and QACI Welding Documentation. The Pressure System Program Supplement provides design review and documentation requirements.
Jefferson Lab’s Subcontracting Officer’s Technical Representative (SOTR) program provides oversight for the review and accuracy of records and documentation provided by subcontractors.
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<h2>Comments</h2>
<h5 style="white-space:nowrap">3/23/2015 9:31:16 AM by Bailey, Mary Jo</h5>
<pre>Submitted to those with current SOTR Training and Welding training</pre>
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<legend>Summary</legend>
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<td class="label" nowrap>Lesson ID:</td>
<td class="dataval">881</td>
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<td class="label" nowrap>Status:</td>
<td class="dataval">OK</td>
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<td class="label" nowrap>Doc ID:</td>
<td class="dataval">2015-JLAB-881</td>
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<td class="label" nowrap>Priority:</td>
<td class="dataval">Info</td>
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<td class="label" nowrap>Safety Related:</td>
<td class="dataval">YES</td>
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<td class="label" nowrap>Originator:</td>
<td class="dataval">Bailey, Mary Jo</td>
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<td class="label" nowrap>Issued:</td>
<td class="dataval">3/23/2015 9:23:53 AM</td>
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<td class="label" nowrap>Approved By:</td>
<td class="dataval">Bailey, Mary Jo</td>
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<td class="label" nowrap>Approved On:</td>
<td class="dataval">3/23/2015 9:31:16 AM</td>
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<td class="label">Source:</td>
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DOECRD
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<td class="label" nowrap>Location:</td>
<td class="dataval">OTHER</td>
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<td class="label" nowrap>Cost Savings:</td>
<td class="dataval"></td>
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<td class="label" nowrap>Contact:</td>
<td class="dataval">Dave Tuttel (803-643-1682)</td>
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<td class="label" nowrap>Queued Emails:</td>
<td class="dataval">0</td>
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<td class="label" nowrap>Sent Emails:</td>
<td class="dataval">0</td>
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<td class="label" nowrap>Viewings:</td>
<td class="dataval">2 times</td>
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<legend>Attachments</legend>
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<legend>Hazard Issues</legend>
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<li>Welding, Cutting, Brazing, and Grinding (i.e. Hot Work)</li>
<li>Other: SOTR</li>
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<legend>Skills</legend>
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<li>SAF150: WELDING SAFETY</li>
<li>GEN020: SOTR QUALIFICATION </li>
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<legend>Distribution/Notification</legend>
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<li>*Division Safety Officers (DSOs)</li>
<li>*Safety Wardens</li>
<li>*DOE Notification</li>
<li>*ESH&Q Liaisons</li>
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Do you have a lesson learned you would like to contribute? Contact the <a href="mailto:cjohnson@jlab.org,sjsmith@jlab.org,mbailey@jlab.org">Lesson Learned Coordinator</a>.