[DNFSB LETTERHEAD]
August 7, 2003
The Honorable Jessie Hill Roberson
Assistant Secretary for Environmental
Management
U.S. Department of Energy
1000 Independence Avenue, SW
Washington, DC 20585-0113
Dear Ms. Roberson:
The staff of the Defense Nuclear Facilities
Safety Board (Board) conducted a review of the implementation of the Board’s
Recommendation 2000-2, Configuration Management, Vital Safety Systems, at the Hanford Site during June 3–4,2003.
The Board’s staff noted significant improvements in the implementation
of this recommendation since its last review, which was conducted in October
2002.
Specifically, the staff observed improvement
in the qualification and training programs for federal subject matter experts
on vital safety systems, which previously had lacked the rigor required for
these individuals to provide effective oversight of the contractors. The systems engineer program for CH2M Hill
Hanford Group is well under way.
However, the systems engineer program at Fluor Hanford has not improved
as much as expected. Additional effort
is required to make Fluor Hanford’s systems engineer program a meaningful
endeavor. A report on the review
conducted at Hanford by the Board’s staff is enclosed for your information and
use as appropriate.
Sincerely,
John T. Conway
Chairman
c:
Mr. Roy Schepens
Mr. Keith A. Klein
Mr. Mark B. Whitaker, Jr.
Enclosure
DEFENSE
NUCLEAR FACILITIES SAFETY BOARD
Staff Issue Report
July 8, 2003
MEMORANDUM FOR: J.
K. Fortenberry, Technical Director
COPIES: Board
Members
FROM: D.
Burnfield
SUBJECT: Status
of Recommendation 2000-2, Configuration Management, Vital Safety Systems,
at the Hanford Site
This report presents observations resulting
from a review of the progress made toward implementing the Defense Nuclear
Facilities Safety Board’s (Board) Recommendation 2000-2, Configuration
Management, Vital Safety Systems, at the Hanford Site. This review addressed the Department of
Energy’s (DOE) subject matter expert/systems engineer program, the contractors’
systems engineer programs, and the status of institutionalizing Phase II
assessment criteria. The review was
conducted June 3–4,2003, by
members of the Board’s staff D. Burnfield, D. Ogg, J. DeLoach, M. Sautman, and
D. Grover.
Background. The
Implementation Plan for Recommendation 2000-2 includes commitments to improve
the competence of DOE and contractor engineering personnel, as well as to
perform summary (Phase I) and detailed (Phase II) assessments of the material
condition and operability of vital safety systems and the programs that support
them (e.g., maintenance and engineering).
DOE’s Richland Operations Office (DOE-RL), the Office of River
Protection (ORP), and their respective contractors have been working to
implement and improve programs designed to meet the requirements of the
Recommendation 2000-2 Implementation Plan.
Discussion. The
staff’s observations from this review are summarized below.
DOE’s Subject Matter Expert Programs―ORP has taken the lead in developing the
Safety System Oversight (SSO) personnel qualification program for use by all
DOE personnel (the SSOs are termed subject matter experts in the Recommendation
2000-2 Implementation Plan). The SSO
qualification requirements and process are intended to mirror the rigor of the
qualifications used in DOE’s Facility Representative Program. However, progress on implementing the SSO
program at ORP continues to lag behind that in the majority of the complex.
DOE-RL has also embarked on a rigorous
qualification program for its federal SSOs.
DOE-RL representatives described a number of
recent assessments of vital safety systems, conducted in part by the SSOs, that
have yielded noteworthy findings. The
corrective actions generated as a result of these assessments are expected to
result in significant improvements in safety and system reliability. The Board’s staff suggested that DOE-RI
develop one of its assessments of the fire protection system for the Central
Waste Complex into a lesson learned for the DOE complex.
Contractor Systems Engineer Programs―CH2M Hill Hanford Group is well under way in
the qualification of its systems engineers.
All of these systems engineers are spending time in the field; they also
regularly track system health reports, which have focused attention on system
reliability and operability. One area
for improvement is the need for systems engineers to track the status of system
component calibration. Calibration
deficiencies have been noted by the Board in the past year for facilities
operated by the CH2M Hill Hanford Group.
Field activity by Fluor Hanford systems
engineers is just beginning to mature.
Fluor Hanford has assigned 41 systems engineers (plus backups) for its
88 vital safety systems.
System notebooks have been developed for
each of these systems, and it was reported to the staff that this effort has
increased system knowledge and ownership.
Systems engineers are required to walk down their systems
quarterly. A review of a small number
of recently qualified systems engineers revealed that many had qualified within
a very short period of time (i.e., less than a month), casting doubt on the
rigor of Fluor Hanford’s program.
Representatives of Fluor Hanford’s engineering management admitted that
the knowledge level of its systems engineers had not been significantly
improved by the qualification process, except for one factor: the system engineers now had a better
understanding of the authorization bases for their respective systems. The Board’s staff encouraged Fluor Hanford
to revisit the rigor applied in the qualification program to ensure that all
systems engineers have the desired breadth and depth of technical knowledge.
Managers also noted to the staff that during
the completion of the system notebooks, systems engineers gained a better
appreciation and understanding of the associated support systems whose failure
could significantly affect the operability of the vital safety system. In general, the Fluor Hanford program is not
fully mature, and additional effort will be required to meet the intent of the DOE
Implementation Plan. Based on
information gathered during the review, the Board’s staff believes that Fluor
Hanford would benefit from a meaningful continuing education program in
technical subjects, including the pursuit of advanced technical degrees and
professional certifications for engineers.