1. Fermi Site Office Assessment of Fermilab Welding Quality Assurance June 20-24, 2016

2. Assessment Scope Organizations  Technical Division (TD)  Accelerator Division (AD)  Particle Physics Division (PPD)  Facilities Engineering Services Section (FESS) Projects  Muon Campus Cryo Accelerator Improvement Project  Muon Campus New Beamline Enclosure  MicroBooNE at LArTF  g-2 Cryo Welding 2

3. Assessment Members Assessment Sponsors  John Scott, Fermi Site Office  Sally Arnold, Fermi Site Office Assessment Team  John Adachi, Integrated Support Center  Lloyd Nelson, Brookhaven Site Office Laboratory Point of Contact  Jemila Adetunji, Fermilab ESH+Q 3

4. 1. Requirements Issues  No dedicated Authorized Inspector at Fermilab.  WPSs do not identify the applicable codes in the WPS.  WPSs must be certified by the responsible organization. There is no documented certification of the WPSs.  Subcontractor WPSs and PQRs are not reviewed by Fermi welding SMEs to ensure the correct welding process is utilized.  Lack of formal written approval of subcontractor WPSs.  Personnel interviewed were not aware of FESHM revisions/changes. 4

5. 2. Work Control Issues  No written guidance/policy for controlling minimum temperature/environmental conditions for welding.  Inconsistent weld identification: labeling of welds or documentation of weld locations (e.g., weld maps)  Engineer and Mechanical Technician did not have and were not aware of WPS; all welding done by certified Weld Shop welder however no WPS accompanied the work. Welder used experience to determine welding requirements although there are different WPSs for similar processes.  Segregation of weld filler metal should be controlled to ensure separation of alloy types and is in conformance with storage requirements. 5

6. 2. Work Control (continued) Strengths  Travelers are used on some projects/jobs.  PPD developed extensive notes and requirements for MicroBooNE welding requirements.  PPD MicroBooNE developed best management practices for weld inspection guidelines, assembly checklist, weld preparation for “Conspacers”, welding checklist, and descriptive In-Process Weld Inspection Guidelines. 6

7. 3. Welder and Welding Inspector Training and Qualifications Issue  No current formal welding inspection training program. Strengths  Mechanical Safety Subcommittee is developing training for Fermilab welding inspection program (to be completed shortly).  All TD welders (7 total) qualified for 6G positions.  All Fermilab welders work for the TD Weld Supervisor, who is very experienced and familiar with Laboratory welding requirements.  Fermilab has one Certified Welding Inspector (CWI) and two people in process for completing CWI. 7

8. 4. Documents and Records Issues  Several WPSs, PQRs, In-Process Welding Inspection Forms reviewed during this assessment are missing approval signatures and dates.  Multiple electronic sites used for storage of WPSs hamper document control of WPSs to latest revision. Using one consistent site aids document control.  No formal communication process to notify organizations of WPS changes. 8

9. 5. Inspection and Testing including Non-Destructive Examination Issues  No written procedure describing weld quality and completeness requirements.  Welding fit-ups are not 100% inspected; there is no written procedure for performing weld fit-up inspections.  Final inspections of finished welds rely on welder’s expertise and judgment.  New In-Process Weld Inspection Form (dated June 2015 in FESHM 5031.1TA) was not used; persons interviewed did not know new forms were issued. 9

10. 5. Inspection and Testing including NDE (continued) Issues (continued)  Contract-required field inspection of subcontractor welding was not performed. Strength  Some projects exceeded the minimum requirements for radiography (5%). 10

11. Next Steps  Using the identified Issues the assessment team, in conjunction with FSO, will develop and categorize Finding statements in accordance with SCMS.  Draft report for Site’s factual accuracy review will be provided by July 26, 2016.  Fermilab will provide any factual accuracy comments to FSO by August 16, 2016.  Assessment team, in conjunction with FSO, will consider factual accuracy comments and revise report accordingly.  Assessment team will provide final report by August 31, 2016. 11

12. Acknowledgments  All Fermilab employees interviewed for this assessment were open and cooperative.  Thanks to Jemila Adetunji and Jamie Blowers for setting up the Indico site and posting documents and records for use by assessment team.  Thanks to Jemila Adetunji for scheduling the assessment interviews.  Thanks to Sally Arnold for assessment coordination.  Thanks to Lloyd Nelson for taking time away from his duties at Brookhaven to serve on this assessment team. 12