[DNFSB LETTERHEAD]
April 4, 2003
The Honorable Linton Brooks
Acting Administrator
of the National Nuclear Security
Administration
U.S. Department of Energy
1000 Independence Avenue, SW
Washington, DC 20585-0701
Dear Ambassador Brooks:
During the past 16 months, the Defense
Nuclear Facilities Safety Board (Board) has held a number of reviews at the
Pantex Plant to evaluate conduct of operations and the site’s training
programs. The Board is pleased to see
that procedural adherence and conduct of operations for operational personnel
are improving and that a program to improve operating procedures is ongoing.
However, a review by the Board’s staff has
revealed problems at Pantex with the processes used to develop training, to
evaluate personnel knowledge, to assess training program elements, and to
conduct continuing training. These
training deficiencies, detailed in the enclosed report, may affect the ability
to improve and maintain satisfactory conduct of operations at the Pantex Plant.
Therefore, pursuant to 42 U.S.C. § 2286b(d), the Board requests a report
within the next 60 days regarding the measures that are being taken to address
these training deficiencies.
Sincerely,
John T. Conway
Chairman
c:
The Honorable Everet H. Beckner
Mr. Daniel E. Glenn
Mr. Mark B. Whitaker, Jr.
Enclosure
DEFENSE
NUCLEAR FACILITIES SAFETY BOARD
March 24,
2003
MEMORANDUM FOR: J.
K. Fortenberry, Technical Director
COPIES: Board
Members
FROM: J.
Deplitch
SUBJECT: Conduct
of Operations and Training Programs at the Pantex Plant
This report documents a review by the staff
of the Defense Nuclear Facilities Safety Board (Board) of conduct of operations
and the training programs at the Pantex Plant.
Members of the Board’s staff J. Deplitch and A. Matteucci, together with
outside experts L. McGrew and R. West, reviewed numerous related Pantex Plant
standards and records and performed on-site reviews.
Background. In
October 2001, the Board sent a letter to the Department of Energy (DOE) noting
issues associated with inadequate procedural compliance at the Pantex
Plant. These issues are of particular
concern given the significant reliance on administrative controls to implement
many of the Technical Safety Requirements at the site.
During the past few months, the Board’s
staff has been reviewing the set of actions being taken to improve procedural
adherence, conduct of operations, and related training. The staff reviewed Pantex Plant standards
for conduct of operations and the training program, and reviewed records of
training for the W62 and W87 weapon programs and for the maintenance
program. The staff discussed with
representatives of BWXT Pantex and the Pantex Site Office (PXSO) the status of
actions designed to improve procedural adherence and the coordination of
material movements at the site, the Pantex training program, and W62 and W87
training. The staff also observed W62
training and W87 and W79 weapons operations.
Conduct of Operations. Recent observations have indicated that BWXT has improved procedural adherence and conduct of operations for operational personnel. During this review, the Board’s staff noted improvements in the control of combustibles and in formality of operations for the W87 and W79. Actions were still ongoing to improve operating procedures; therefore, the quality of these revised procedures will need to be evaluated in the future. Reports of occurrences and noncompliance conditions indicated that operational problems remain. Actions to improve conduct of operations appeared to be achieving positive results; however, improvements in the training program may be needed to sustain this trend.
Training Program.
BWXT has a set of standards and procedures setting forth the elements of
its training program. The Board’s staff
found that these instructions and the supporting records did not ensure
accomplishment of significant elements of the training program as required, nor
did they comply with DOE Order 5480.20A, Personnel Selection, Qualification,
and Training Requirements for DOE Nuclear Facilities:
Summary. These training deficiencies may
affect the ability to improve and maintain satisfactory conduct of operations
at the Pantex Plant. The Board’s staff should review the plan of corrective
actions and the improvements to the training program.