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Welcome to

Suspect/Counterfeit Items Awareness

Training

QA-SCI-3A

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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.

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Instructions

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

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:1. Piping and piping components (including mechanical and metal

products)2. Electrical/electronic components 3. Fasteners (e.g. Grade 5 and 8 bolts)4. Hoisting and Rigging (material handling) components5. Documentation and Certification

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 can’t 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.

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.

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.Counterfeit Valve

Comparison between two ½” Forged CSA Ball Gas Valves

Left – Counterfeit

Right – Good

Conflicting information ½ psi – 608 WOG

FM – Factory Mutual marking

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.

Suspect General Electric Molded Case Circuit Breakers – Refurbished, Sold as New

Category 2- Electrical Example

Category 3 - Fasteners Example

Ratchet Tie-down without Strap

Bolt in ratchet is a Grade 8 with no manufacturer’s marking.

Manufacturer’s mark is required.

For more information, go to Dept. of Energy Suspect/Counterfeit Defective Items website: http://www.eh.doe.gov/paa/sci

Fastener Headmark

List

Known markings that indicate

Suspect/Counterfeit Fasteners

Click here for a Fastener Headmark Card.

Category 4 - Hoisting and Rigging Example

Shackle

No manufacturer markings. “China” is marked; however, this is unacceptable as Dept. of Energy standards require the manufacturer’s name or trademark.

(DOE-STD-1090)

Category 5 –Documentation and Certification ExampleCounterfeit Certificate

Certified Material Test Reports - Look for data/information that isduplicated but should be unique. For example: 1. Specification numbers are the same

on multiple certificates2. Heat numbers are the same

Look for data/numbers that do not add up correctly. For example:3. Total of chemical alloys should be

between 99-100%. This Report total is 164%.

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

If you Discover a Suspect/Counterfeit Item, You Must:

1. Stop using the equipment that contains the Suspect/ Counterfeit Item.

2. Make sure that the Suspect/Counterfeit Items Coordinator is notified. If you don’t know who the Suspect/Counterfeit Items Coordinator is, contact:

For Brookhaven Employees: contact your ES&H 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.

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.

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