Physical Changes (Hardware Changes)

DOESTD107393

Physical Changes (Hardware Changes). Uncontrolled physical changes can be a major

contributor to the loss of facility configuration. They are changes made to SSCs that after the

characteristics or function of the facility. A fundamental objective of the change control

element is to ensure that each physical change is formally processed to evaluate consistency

with the design requirements and to identify possible impacts on the facility documents.

Physical changes that are associated with design changes are easily recognized and, thus,

tend to be well controlled. For example, changes processed formally as projects under DOE

4700.1 are obvious changes and receive more rigorous review and implementation than some

other changes. Other sources of physical changes (such as maintenance or operations

activities) can be less obvious and can receive inadequate attention. Temporary physical

changes, such as hoses and temporary pumps, that have been allowed to remain in place for

extended durations can be major contributors to configuration problems.

Document Changes. Document changes are usually necessary to implement changes in the

physical configuration. Each physical change may involve a number of facility document

changes to maintain configuration control. For example, the following document changes may

be needed: drawing revisions, procedure revisions, setpoint list revisions, equipment list

revisions, and training lesson plan revisions.

A subset of document changes is document-only changes. These changes do not affect the

facility physical configuration, but do after the intent, content, or accuracy of facility documents.

Document-only changes are often made to correct errors or discrepancies or to enhance

existing documentation. Possible document-only changes are drawing corrections, corrected

equipment lists, procedure changes, or training lesson plan changes. Each document-only

change needs to be carefully evaluated to ensure that it is consistent with the design

requirements and the facility physical configuration. A common problem affecting facility

configuration is updating facility documents to reflect the as-built configuration without

performing the appropriate technical review.

Inadequately evaluated document changes can result in facility equipment being operated

outside of the design requirements. For this reason, changes to documents that are controlled

within the CM program need to be included in the change control program and be evaluated to

determine possible impact on facility operation and consistency with the design requirements.

Because document changes with subtle or no physical changes often may not receive a

technical review, special attention should be given to deviations from normal valve line-ups,

special tests, setpoint changes, or other changes that can be a departure from the design

requirements or previously evaluated conditions.

Sources of Changes. The basic change types can be initiated from a variety of sources. Changes can

be initiated by numerous organizations such as operations, maintenance, procurement, design

engineering, and technical support/systems engineering. The following discussion of major change

sources demonstrates some of the ways the facility configuration is changed.

Operations changes are those adjustments of normal practices and operational limits made to enhance

system availability or to accommodate special operating conditions. Operations can be the source of

design changes, such as a change to a control system to provide better flexibility or more margin. Such a

design change would also result in a change to the physical configuration and the facility documentation.

Operations can also be the source of physical changes that do not involve a design change, such as an

allowed alternate mode of operation or a setpoint change within the established design envelope.

Operations also initiates document changes such as operating procedure changes.

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