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<td><a href="https://misportal.jlab.org/ll/index.jsf?function=view&lessonId=806">Mismatched Closure Cap Creates an Unsafe Container Configuration - Lawrence Livermore National Security, LLC (LLNL)</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.
Performance, safety, and certification of a replacement part requires something beyond "it fit" as an acceptance standard.
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<h2 style="white-space:nowrap">Discussion of Activities</h2>
<pre>Closing a 5-gallon poly carboy with a cap from another manufacturer resulted in an inadequate seal and small spill of mixed waste. </pre>
<h2 style="white-space:nowrap">Analysis</h2>
<pre>U.S. Department of Transportation (DOT)-certified cap/carboys are used at LLNL for storing and transporting radioactive and hazardous wastes. If a cap is not documented for a carboy, it voids the DOT certification.
Each carboy arrives with a certified cap. Two common reasons the original cap cannot be used are:
• It was modified to accommodate tubes, thus making it unusable for transport, or
• It cannot be located.
A replacement cap, when needed, typically comes from another carboy.
There are at least three different 5-gallon poly carboys being used, having three different closure cap designs. The three caps look similar and appear to be interchangeable. All three caps are 70 mm in diameter (~3 inches), however, two have 6-threads per inch (TPI) and one has 8-TPI. Using a replacement cap with the same TPI is acceptable only if it is documented in the DOT certification.
Each carboy has a Packaging and Transportation Safety (PATS) Quality Assurance (QA) label on one side (Figure 1 in the attachment below). The label provides the reference to the purchase order. The purchase order provides verification of the cap to use.</pre>
<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.
1. When a cap is removed tape it to the outside of its carboy.
2. Prior to closing the carboy, inspect the cap and ensure the proper TPI.
3. If there is any question about whether the cap/carboy combination is correct, contact your program’s Radioactive and Hazardous Waste Management (RHWM).
Note: LLNL is in the process of migrating to the use of a single carboy/cap model to avoid issues of incompatibility over the long term.
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<h2>Comments</h2>
<h5 style="white-space:nowrap">3/31/2014 9:06:47 AM by Bailey, Mary Jo</h5>
<pre>Submitted to those with the following training:
•SAF129: R&D Chem Room Safety
•SAF305: DOT HAZARDOUS MATERIALS SHIPPING
•SAF830: RAM SHIPPING/RECEIVING
•SAF137: Chem Room Safety
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<legend>Summary</legend>
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<tr class="row">
<td class="label" nowrap>Lesson ID:</td>
<td class="dataval">806</td>
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<tr class="row">
<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">2014-JLAB-806</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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<tr class="row">
<td class="label" nowrap>Issued:</td>
<td class="dataval">3/31/2014 9:02:45 AM</td>
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<tr class="row">
<td class="label" nowrap>Approved By:</td>
<td class="dataval">Bailey, Mary Jo</td>
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<tr class="row">
<td class="label" nowrap>Approved On:</td>
<td class="dataval">3/31/2014 9:06:47 AM</td>
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<td class="label">Source:</td>
<td class="dataval">
DOECRD
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<tr class="row">
<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">Michael Hayes, hayes4@llnl.gov, 925-422-4388</td>
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<td class="label" nowrap>Queued Emails:</td>
<td class="dataval">0</td>
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<tr class="row">
<td class="label" nowrap>Sent Emails:</td>
<td class="dataval">0</td>
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<tr class="row">
<td class="label" nowrap>Viewings:</td>
<td class="dataval">3 times</td>
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<legend>Attachments</legend>
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<legend>Hazard Issues</legend>
<ul class="lesson_attribute_listing">
<li>Chemicals</li>
<li>Hazardous Material</li>
<li>Transport or Shipping - On or Off Site</li>
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<legend>Skills</legend>
<ul class="lesson_attribute_listing">
<li>SAF129: R&D Chem Room Safety</li>
<li>SAF305: DOT HAZARDOUS MATERIALS SHIPPING</li>
<li>SAF830: RAM SHIPPING/RECEIVING</li>
<li>SAF137: Chem Room Safety</li>
</ul>
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<legend>Distribution/Notification</legend>
<ul class="lesson_attribute_listing">
<li>*Division Safety Officers (DSOs)</li>
<li>*Safety Wardens</li>
<li>*DOE Notification</li>
<li>*ESH&Q Liaisons</li>
</ul>
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