DEFENSE NUCLEAR FACILITIES SAFETY BOARD 

February 7, 1997 

Staff member Ralph Arcaro was on-site this week to review tank characterization and safety documentation 

progress and to attend a DOE-wide systems engineering conference. 

A. "As-Built" Drawing Issues: A recurring issue across the site has been the adequacy of as-built drawings for 

use by operations and maintenance personnel. Incorrect as-built drawings are frequently cited as a contributing 

cause of near-miss events on site. The following information relative to this subject was obtained this week: 

1. Following the 701-A near-miss event last June, Tank Farms reconstituted its labeling and drawing 

upgrade program into a project organization. On February 7, Mr. Gubanc reviewed the project's progress. 

The project enjoys strong DOE and contractor management support, is clearly focused and involves the 

appropriate standards and workers. Delivery of the first upgraded tank farm is expected in early Spring 

1997. 

2. In November 1996, a tank farm cognizant engineer walked down a set of 35 drawings, which he 

understood to be "as-built", for a newly installed tie-in from the 222-S laboratory. He identified 56 

discrepancies with the new drawings and 16 instances where existing tank farm drawings also needed 

revision. The Project Manager contends these drawings were not formally transmitted for approval but 

only for information. Mr. Gubanc is gathering more data. 

3. As discussed in our letter of December 20, 1996, "independent inspection" of site construction projects is 

currently performed by the same contractor who is responsible for the construction, Fluor Daniel 

Northwest (FDNW). On January 27, 1997, DOE-RL formally asked Fluor Daniel Hanford (FDH) to 

demonstrate the independence of the construction inspection function performed by FDNW. 

The subject of rigorous configuration management, especially for new projects, is gaining recognition as a 

major site-wide issue. We will continue to follow this area closely. 

B. Pu Stabilization Milestones: On February 3, we met with DOE-RL to discuss the status of 

Recommendation 94-1 Pu stabilization milestones. Similar to the situation in the TWRS program and the SNF 

program, the shortfall in the FY 1997 budget will affect the contractors ability to meet some of the key Board 

recommendation milestones. In the case of Pu stabilization, DOE-RL is currently unwilling to admit that any 

milestone will be missed, pending negotiations at the national level on Pu disposition, Pu packaging standards 

for long-term storage, and potential use of Pu in tritium production. However, in its December 1996 monthly 

progress report for Pu stabilization, DOE-RL reported that the milestone to commence solution stabilization by 

June 1997, (milestone IP-3.1-022) was at risk due to a lack of funding. 

Additionally, the Plutonium Stabilization and Packaging (PuSAP) system, originally scheduled to be complete 

by December 1998, (milestone IP-3.2-029) is delayed about one year because DOE has identified the project as 

a FY 1998 line item rather than a FY 1997 line item as planned. 

C. Canister Storage Building (CSB) Construction: On February 5, Mowat placed concrete for the deck of the 

second vault in the CSB. While this activity was originally scheduled during the week of February 17, no 

outstanding issues remained to prevent the start of work. Concrete placement for the deck of the third vault will 

not commence until Duke resolves a Design Change Notice on the position of the Hot Conditioning System 

pits. DOE-RL expects this activity will be complete during the week of February 17. 

TO: G. W. Cunningham, Technical Director 

FROM: P.F. Gubanc & D.G. Ogg, Hanford Site Representatives 

SUBJECT: Activity Report for Week Ending February 7, 1997
D. N-Basin Monolith Recovery: On February 4, Mr. Ogg observed a Bechtel (BHI) test of a new rigging 

arrangement proposed for use in recovering the #10 monolith from the floor of the N-Basin. The new 

arrangement makes use of four 12-ton capacity plate clamps that will grasp the 1⁄2" thick steel plate sides of the 

monolith. This is necessary because the regular lifting trunnions of the monolith were damaged during the drop. 

The mock-up test consisted of an outdoor crane lift of a clean monolith loaded with weights and water using the 

new rigging. The plate clamps appeared to hold the cask firmly with no indication of slippage. BHI plans to 

retrieve the #10 monolith during the week of February 10. 

cc: Board Members