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valign="top">Lesson Learned "Identified Suspect/Counterfeit Bolts on Ratchet Tie Downs - URS CH2M > Oak Ridge LLC (UCOR)"</td>
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valign="top"><strong><span
style="font-size: 18px">INTERNAL MEMO</span></strong></td>
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valign="top"><span style="font-size: 14px">
<strong>April 5, 2018</strong><br>
<strong>Sent on behalf of ESH&Q</strong><br>
<strong>SUBJECT:</strong> Lesson Learned "Identified Suspect/Counterfeit Bolts on Ratchet Tie Downs - URS CH2M > Oak Ridge LLC (UCOR)"<br>
<strong>CONTACT:</strong> mbailey@jlab.org
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<td><a href="https://misportal.jlab.org/ll/index.jsf?function=view&lessonId=1050">Identified Suspect/Counterfeit Bolts on Ratchet Tie Downs - URS CH2M > Oak Ridge LLC (UCOR)</a></td>
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<h2 style="white-space:nowrap">Statement of Lessons Learned</h2>
<pre>During a company-wide surveillance, four legacy ratchet tie downs were discovered that contained suspect bolts. None of the ratchet tie-downs (straps) were in use at the time of identification. The tie downs were removed from service, tagged out and Non-Conformance Reports (NCRs) were written and issued. The bolts lacked the required head-markings as required under the Fastener Quality Act (FQA) of June 8, 1999 (Short title: 15 United States Code 5401). Because the manufacturer of the bolts could not be determined, the recognized quality system exemption allowed under the FQA could not be invoked.</pre>
<h2 style="white-space:nowrap">Discussion of Activities</h2>
<pre>Acting on a Department of Energy Operating Experience Level 3 Document on Suspect/Counterfeit Items (S/CI) and an OPEXSHARE report, UCOR conducted site-wide surveillances specifically designed to identify any suspect bolts associated with the use of ratchet straps.</pre>
<h2 style="white-space:nowrap">Analysis</h2>
<pre>UCOR analysis indicated that the non-conforming straps were legacy equipment that had been purchased prior to the current receipt inspection requirements. The receipt inspection requirements for ratchet straps were put in place in FY 2012. Current receipt inspections require checking the head markings of component bolts during the receipt of newly purchased ratchet straps. This is part of the overall check for S/CI items. It was also determined that additional sources of non-conforming ratchet straps occurs when commercial delivery vehicles inadvertently leave straps after dropping off purchases.
UCOR does not require ratchet straps to be maintained in controlled storage areas. UCOR does require transportation specialists to inspect ratchet straps prior to each use. While bolts manufactured prior to 1999 and 15 USC 5401 are still in circulation, UCOR treats them as suspect, unless it can be established that the bolt manufacturer has a recognized quality system. When identified, UCOR will determine if it is economically viable to have the ratchet straps reworked and recertified by one of its NQA-1 hoisting and rigging testing approved vendors. If it is determined that it is not economical to do so, the ratchet straps is removed from service and destroyed.
It was also determined that the critical failure point for the ratchet straps was the ratchet mechanism. Ungraded bolts (Grade 2 or less) exceed the strength required to maintain the ratchet mechanism as the failure point. The removal of these ratchet straps was, therefore, based on the bolts being S/CI and not from a safety failure basis.
UCOR conducted a similar site-wide action in FY2013 following the publication of DOEs Energy Facility Contractors Group (EFCOG) position paper, DOT Ratchet Type Tie-Down Suspect/Counterfeit Bolt Issue - EFCOG Waste Management Working Group. May 21, 2013. At that time UCOR identified ratchets on site that did not meet requirements of 15 USC 5401.Those non-conforming ratchet straps were taken out of service and destroyed.</pre>
<h2 style="white-space:nowrap">Recommended Actions</h2>
<pre>Contractors and their subcontractors are to conduct periodic surveillances of DOT ratchet tie down straps to ensure compliance with 15 USC 5401 and current requirements on graded fasteners.
Surveillances will be conducted to ensure that no non-conforming ratchets straps have been inadvertently introduced to the project. Contractors and subcontractors are to continue to reinforce S/CI identification requirements to project personnel. Transportation Specialists, Quality Control Receipt Inspectors, and Quality Engineers are to remain vigilant for all S/CI fasteners.</pre>
<h2 style="white-space:nowrap">JLab Preventive Measures</h2>
<pre>"ES&H Manual Chapter 6140 Appendix T2 Procurement of Material Handling Equipment" defines the requirements for purchasing material handling equipment and accessories such as ratchet straps. Inspect any type of strap prior to use as wear and tear, improper or unauthorized repair or modification and design flaws are the leading causes for strap failure</pre>
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<h2>Comments</h2>
<h5 style="white-space:nowrap">4/5/2018 1:14:53 PM by Bailey, Mary Jo</h5>
<pre>Submitted to those with
SAF405: MASTER RIGGING WORKSHOP
SAF502: FORKLIFT OPERATOR</pre>
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<legend>Summary</legend>
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<tr class="row">
<td class="label" nowrap>Lesson ID:</td>
<td class="dataval">1050</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">2018-JLAB-1050</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">4/5/2018 1:13:33 PM</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">4/5/2018 1:14:53 PM</td>
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<td class="label">Source:</td>
<td class="dataval">
DOECRD
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<td class="label" nowrap>Location:</td>
<td class="dataval">ORNL</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">Donald Xiques, 865-241-9516</td>
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<td class="label" nowrap>Queued Emails:</td>
<td class="dataval">197</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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<li>Material Handling Equipment</li>
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<legend>Skills</legend>
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<li>SAF405: MASTER RIGGING WORKSHOP</li>
<li>SAF502: FORKLIFT OPERATOR</li>
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