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<td><a href="https://misportal.jlab.org/ll/index.jsf?function=view&lessonId=859">Review of Vendor Manuals by Appropriate Functions Is Essential to Ensure Equipment Performs as Expected – Savannah River Remediation</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.
When equipment is selected as part of a process modification, the equipment operating manuals must be obtained from the vendor and reviewed by the design engineer, startup engineer, design authority engineer, and Operations to ensure the equipment performs as expected.
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<h2 style="white-space:nowrap">Discussion of Activities</h2>
<pre>A new Effluent Treated Water sampler at the Savannah River Site (SRS) was designed and installed per specifications. After installation, during start-up testing, it was determined that the field controller, provided by the manufacturer, would not operate in a flow proportional mode as specified in the design input document. This resulted in a redesign to replace the field controller with control logic using the Effluent Treatment Facility (ETF) Distributed Control System (DCS)
The sampler and controller selected for the ETP process was a similar sampler that is currently in use in another location. It was manufactured by Sentry. The current sampler and controller was manufactured by Bristol. Sentry bought out Bristol. The Sentry sampler was the only off-the-shelf sampler that was capable of obtaining the liquid sample from the ETP process line. It was logical that the design engineer selected the Sentry sampler and the controller to minimize installation and operational issues.
The original design input for the controller stated the following:
"The sample collection station shall be a flow proportional composite sampler; HE-241018-TRW-FT-7066 may be used as an input to the sampler for the flow proportional function."
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<h2 style="white-space:nowrap">Analysis</h2>
<pre>Based on the literature available, the design engineer believed that the controller was capable of performing in the desired manner. It became apparent during the startup testing that the controller could not operate in the manner that was acceptable for Operation.
When it was realized that the controller could not operate in the desired manner, the design input was revised in the following manner:
"The sample collection station shall be a totalized flow proportional composite sampler; HE-241018-TRW-FT-7066 will be used as an input to the flow totalizer which will provide the totalized flow proportional function to the sampler."
This input provided a more detailed description of how the sampling system must operate.
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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.
Establish Process Modification teams at the onset of the design process and have them meet on a regular basis to avoid last minute process changes.
Organization/Facility Operating Experience Program Coordinators (see SRNS Operating Experience Program Web Page) is to share the incident report with their organizations.
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<h2 style="white-space:nowrap">JLab Preventive Measures</h2>
<pre>Jefferson Lab has a process in place that allows for an adequate equipment manual review by the design authorities, relevant operations, and safety personnel to ensure equipment and design performance. </pre>
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<h2>Comments</h2>
<h5 style="white-space:nowrap">11/12/2014 1:05:16 PM by Bailey, Mary Jo</h5>
<pre>Submitted to those with the following current training:
SAF117: EH&S MANAGEMENT TRAINING
SAF101: Work Planning and Control Familiarization
SAF120kd: SAFETY OBSERVATION PROCEDURE</pre>
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<legend>Summary</legend>
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<td class="label" nowrap>Lesson ID:</td>
<td class="dataval">859</td>
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<tr class="row">
<td class="label" nowrap>Status:</td>
<td class="dataval">OK</td>
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<tr class="row">
<td class="label" nowrap>Doc ID:</td>
<td class="dataval">2014-JLAB-859</td>
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<td class="label" nowrap>Priority:</td>
<td class="dataval">Best Practice</td>
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<td class="label" nowrap>Safety Related:</td>
<td class="dataval">NO</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">11/12/2014 1:00:43 PM</td>
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<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">11/12/2014 1:05:16 PM</td>
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<td class="label">Source:</td>
<td class="dataval">
DOECRD
</td>
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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">Terry L. Allen, SRR Design Services – Mechanical, (803) 208-1339</td>
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<tr class="row">
<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">4 times</td>
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</fieldset>
<fieldset>
<legend>Attachments</legend>
<a name="attachments"></a>
<ul class="lesson_attribute_listing">
<li><a target="_blank" href="https://misportal.jlab.org/ll/downloadAttachment?attachmentId=3480">DOE - Blue - VendorManuals.pdf</a></li>
</ul>
</fieldset>
<fieldset>
<legend>Hazard Issues</legend>
<ul class="lesson_attribute_listing">
<li>Other: Work Planning and Communication,</li>
</ul>
</fieldset>
<fieldset>
<legend>Skills</legend>
<ul class="lesson_attribute_listing">
<li>SAF117: EH&S MANAGEMENT TRAINING</li>
<li>SAF101: Work Planning and Control Familiarization </li>
<li>SAF120kd: SAFETY OBSERVATION PROCEDURE</li>
</ul>
</fieldset>
<fieldset>
<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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