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<td><a href="https://misportal.jlab.org/ll/index.jsf?function=view&lessonId=890">AY-102 Annulus Sampler: Designing Equipment for Unique Purposes under Time Constraints - Washington River Protection Solutions</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 designing equipment for a unique purpose under time constraints, essential functions need to be prioritized and communicated, along with any environmental, or operational constraints that may be encountered. Minimum requirements, to achieve acceptable results, need to be documented and provided to the design authority.
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<h2 style="white-space:nowrap">Discussion of Activities</h2>
<pre>As part of a tank-leak investigation, a remote underground sampler (RUS) was to be designed, fabricated and deployed into the tank’s annulus space to obtain material samples.
A subcontractor was tasked with designing, fabricating, and testing the RUS so it would be able to obtain and dispense, into a jar, multiple 120 milliliter samples from the tank’s annulus floor and refractory air-slot. The characteristics of the sample material were not provided, nor were any unusual environmental conditions. The RUS was fabricated from “off the shelf” material. It was successfully tested by obtaining and dispensing material using a mock-up of the tank’s annulus and two types of material: sand and soft mud.
During actual deployment of the RUS the following major issues were encountered:
• Difficulty fitting the RUS into the tank The riser diameter was less than 12" and the crawler is 10" in width.
• Failure of several RUS’ components and functions due to the high radiation and heat from the extended period of time the sampler was in the tank
• Delays in the field due to supporting equipment issues including cables, cameras, scaffolding, resources, and competing priorities of field personnel.
The complications that occurred during the sampling event ultimately resulted in insufficient sample material for the full range of desired testing and analysis.
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<h2 style="white-space:nowrap">Analysis</h2>
<pre>Functions and requirements of the RUS were not document at the start of the planning phase, thus the RUS was not designed nor built to withstand the conditions in which it was expected to perform.
Adjustments had to be made in the field due to loss of functionality and ultimately an inadequate amount of sample material was obtain.
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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.
Completed a functions and requirements document and a failure mode analysis during the initial planning of a design, re-evaluating the primary functions and failure modes as the scope and design evolved. Decisions and design changes were documented throughout the process.
Revised the design drawings incorporating lessons learned, and developed a functions and requirements document in anticipation of future needs.
Identified specific approval criteria required for testing prior to deployment.
Integrated organizations, including identification of roles, responsibilities, authorities, and accountabilities in the initial planning stages to limit design evolution and mis-communication during the design and implementation process.
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<h2 style="white-space:nowrap">JLab Preventive Measures</h2>
<pre>Jefferson Lab has a robust Work Planning Control and Authorization Process which is used throughout work planning to ensure hazards are identified and requirements are met. Jefferson Lab’s Work Planning Control and Authorization Work Process is introduced to employees on their first day of work and process steps are incorporated within all phases of work.</pre>
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<h2>Comments</h2>
<h5 style="white-space:nowrap">6/1/2015 3:57:58 PM by Bailey, Mary Jo</h5>
<pre>Submitted to those with ES&H Management Training</pre>
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<legend>Summary</legend>
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<td class="label" nowrap>Lesson ID:</td>
<td class="dataval">890</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-890</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">6/1/2015 3:55:48 PM</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">6/1/2015 3:57:58 PM</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">Terry Sams, (509)376-4653</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">1 times</td>
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<legend>Attachments</legend>
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<ul class="lesson_attribute_listing">
<li><a target="_blank" href="https://misportal.jlab.org/ll/downloadAttachment?attachmentId=3840">DOE - Blue - Remote Take Investigation.pdf</a></li>
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<legend>Hazard Issues</legend>
<ul class="lesson_attribute_listing">
<li>Other: Work Planning and Communication,</li>
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<legend>Skills</legend>
<ul class="lesson_attribute_listing">
<li>SAF117: EH&S MANAGEMENT TRAINING</li>
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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>
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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>.