Need for a Hearing Conservation Program

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QA-SCI-3A
Welcome to Suspect/Counterfeit Items
Awareness Training
Click to Continue
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Conditions for Completing this Course
In order to receive credit for this training
course, you must agree to comply with the
following conditions. All responses to this
course must be provided solely by the student.
The student may neither seek nor receive any
assistance, either written or oral, for such
responses. Seeking and/or using assistance
constitutes a violation of DOE and BNL
requirements and could result in disciplinary
action. This course is for BSA employees, onsite
contractors and suppliers use only. Do you accept
these conditions?
Accept
Reject
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Instructions
Click on the control buttons along the bottom of
each screen to navigate your way through this
course. These buttons are defined as Next
screen Previous screen
Each screen has a link that enables you to e-mail
your questions to an expert for answers, or send
comments about this training.
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Introduction to Suspect/Counterfeit Items

• At the completion of this training, you will be
  able to
• Identify Suspect/Counterfeit Items and where they
  may be discovered, including
• Contractor equipment (cranes, slings, aerial
  lifts, below the hook lifting devices, etc.)
• Supplied or purchased material
• List the Brookhaven requirements for employees,
  contractors, and suppliers concerning
  Suspect/Counterfeit Items.
• Identify potential consequences from having
  Suspect/Counterfeit parts in the workplace.
• Fulfill your role in the Suspect/Counterfeit
  Items program.
• Proceed as required once a Suspect/Counterfeit
  Item is found, including
• Required Reporting Actions and Engineering
  Evaluation

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What is a Suspect or Counterfeit Item?

• Suspect Items A suspect item is one in which
  there is an indication by visual inspection,
  testing, or other information that it may not
  conform to established Government- or
  industry-accepted specifications or national
  consensus standards.
• Counterfeit Items A counterfeit item is a
  suspect item that is a copy or substitute without
  legal right or authority to do so or one whose
  material, performance, or characteristics are
  knowingly misrepresented by the vendor, supplier,
  distributor, or manufacturer.
• The Five Suspect/Counterfeit Items Categories
  are
• Piping and piping components (including
  mechanical and metal products)
• Electrical/electronic components
• Fasteners (e.g. Grade 5 and 8 bolts)
• Hoisting and Rigging (material handling)
  components
• Documentation and Certification

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Potential Consequences of Having
Suspect/Counterfeit Items in the Workplace

• Suspect/Counterfeit Items can
• Cause an unsafe condition that puts people at
  risk of injury or death
• Cause a spill or release to the environment
• Cause extensive damage to equipment
• Cause delays that impact project schedules and
  cost
• Equipment cant be used until concern is resolved
• Reporting requirements to the Dept. of Energy
  (DOE)
• Engineering evaluation may need to be performed
• Material containing Suspect/Counterfeit Items
  must be segregated and cannot be returned to the
  supplier/subcontractor.

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The Five Categories of Suspect/ Counterfeit Items
Category 1 Piping Category 2
Electrical Category 3 Bolts/Fasteners Category
4 Hoisting and Rigging/Material
Handling Category 5 Documentation and
Certification
The following slides show examples of
Suspect/Counterfeit Items in each category.
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Counterfeit Valve WATTS Ball Valves
The ½ PSI pressure marking is incorrect for the
valve on the left (this is a 1/2 inch size valve
generally used in fluid control.) The valve on
the right is a gas ball valve with the correct
markings. Additional counterfeit information
includes extra approval markings (e.g. FM and
AGA) as illustrated on the left. WATTS gas
ball valves are only approved by UL and CSA.
Comparison between two ½ Forged CSA Ball Gas
Valves Left Counterfeit Right
Good Conflicting information ½ psi 608
WOG FM Factory Mutual marking

Counterfeit Valve
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Category 2- Electrical Example
Suspect General Electric Molded Case Circuit
Breakers Refurbished, Sold as New
Label printed with both General Electric and
GE markings - Manufacturer stopped marking
with both indicators over 20 years ago. New
breakers should now only be marked with
GE Also, look for worn labels as sign of
refurbished breakers.
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Category 3 - Fasteners Example
Ratchet Tie-down without Strap Bolt in ratchet
is a Grade 8 with no manufacturers marking.
Manufacturers mark is required. For more
information, go to Dept. of Energy
Suspect/Counterfeit Defective Items website
http//www.eh.doe.gov/paa/sci
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Fastener HeadmarkList
Known markings that indicate Suspect/Counterfeit
Fasteners

• Click here for a Fastener Headmark Card.

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Category 4 - Hoisting and Rigging Example

Shackle No manufacturer markings. China is
marked however, this is unacceptable as Dept. of
Energy standards require the manufacturers name
or trademark. (DOE-STD-1090)
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Category 5 Documentation and Certification
Example

• Counterfeit Certificate
• Certified Material Test Reports -
• Look for data/information that is
• duplicated but should be unique.
• For example
• Specification numbers are the same on multiple
  certificates
• Heat numbers are the same
• Look for data/numbers that do
• not add up correctly. For
• example
• Total of chemical alloys should be between
  99-100. This Report total is 164.

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What is Your Responsibility if a Suspect/
Counterfeit Item is Found

• If you Discover a Suspect/Counterfeit Item, You
  Must
• Stop using the equipment that contains the
  Suspect/ Counterfeit Item.
• 2. Make sure that the Suspect/Counterfeit Items
  Coordinator is notified. If you dont know who
  the Suspect/Counterfeit Items Coordinator is,
  contact

For Brookhaven Employees contact your ESH
Coordinator or Quality Representative who will
then notify the Suspect/Counterfeit Items
Coordinator.
For Contractors/Suppliers contact your
Brookhaven Point of Contact, who will then notify
the Suspect/Counterfeit Items Coordinator.
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Summary

• Your Role in Suspect/Counterfeit Items program is
  to prevent Suspect/Counterfeit Items from being
  used at BNL.
• Be aware of the potential for suspect/counterfeit
  items and the five categories where they can
  occur.
• Look for the identifiers that indicate the
  potential for a suspect or counterfeit part or
  item.
• You are required to stop using the equipment and
  notify appropriate personnel when a
  suspect/counterfeit item is found.

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Resources Available for More Information

• Click any of the tools below to help identify
  Suspect/Counterfeit Items
• Suspect Bolt Head Marking Card / Head Mark List
• Suspect Indications List
• Suspect Stainless Steel Fastener Head Mark List.

• For a complete listing of Suspect/Counterfeit
  Items, see
• Suspect/Counterfeit Items Manual
• For additional information on Brookhaven
  requirements, see
• Suspect/Counterfeit Items Subject Area

Contact your Brookhaven Point of Contact, ESH
Coordinator, or the Suspect/Counterfeit Items
Coordinator for more information.
Quiz