Joint DOE/EFCOG Chemical Safety Management 2000 Workshop

Abstracts and Presentation Materials

 

Tuesday, October 24, 2000

-- TRAINING SESSION --

Overview of the New Chemical Management Program Handbook - (CSTC Project 2000-D)

James Morgan (Chemical Commodity Management Center, WSRC) -The Chemical Management Program (CMP) Handbook incorporates best practices from DOE HQ, DOE field operations and private industry, and lists components that are essential for most CMPs. The goal of the handbook is to provide a starting point for a fully integrated program, but it is not intend to be all-inclusive or proscriptive. The handbook lists issues associated with the acquisition, safe and responsible use, handling and storage, transportation and final disposition of chemicals while following the pertinent regulations applicable to all contractors. The CMP should be an integral part of contractors’ Integrated Safety Management [ISM] system(s) with the overall intent of assuring adequate integration with other applicable functional areas.

-- OPENING SESSION --

DOE Corporate Welcome, "Expectations for Chemical Safety Management at DOE"

Joe Fitzgerald, (Deputy Assistant Secretary, Office of Safety and Health, DOE-HQ/EH-5)

EFCOG Welcome, "EFCOG, ISM and Chemical Safety Management Programs at DOE"

Joseph Yanek, (WSRC/Chair, EFCOG ISM Working Group) - How do sites mitigate or eliminate chemical hazards through the application of appropriate standards; hazard identification, analysis and categorization; appropriate controls; clear delineation of roles, responsibilities, competence and priorities; confirming readiness to safely perform work with chemicals; change control; and an effective Lessons Learned program?

Completion of ISM Verifications -- How Well is Chemical Safety Being Addressed Across the Complex?

Ted Wyka, (Director, SMIT, DOE-HQ/EH-9) - On March 3, 1999, Secretary Richardson established a goal of initial implementation of Integrated Safety Management within the entire Department by September 30, 2000. The Department has largely met that goal. This briefing by the Director, Safety Management Implementation Team, will review the objectives of the ISM initiative, as well as the ISM implementation strategy and criteria used by each line manager to determine compliance with the tenets of the program. The briefing will also present a current status of implementation and summarize the "next steps" in ISM, as outlined in the Deputy Secretary memorandum of September 28, 2000, "Realizing the Benefits of ISM." The briefing additionally will review the verification protocol used by the Department to ensure consistent application of the principles of ISM and will address specific examples where chemical safety programs and precepts were examined during the course of several verifications.

Report of Portsmouth Accident Investigation

Frank Harris, UT-Battelle LLC, ORNL [presented by Barry Bervens] - On August 22, 2000, an IT Corporation subcontractor to ORNL (UT-Battelle) received significant chemical burn injuries at the Portsmouth Gaseous Diffusion Plant in Portsmouth, Ohio. A violent reaction occurred when the IT technician added crystalline sodium thiosulfate to neutralize a residual amount of concentrated sodium permanganate solution. The work was performed under an agreement between UT-Battelle and Bechtel Jacobs, Company, LLC. The DOE Oak Ridge Operations Office Type B Accident Investigation concluded that ORNL’s and Bechtel Jacobs Integrated Safety Management programs were not complete or effectively implemented with respect to this off-site work. Bechtel Jacobs implemented safety a stand-down at Portsmouth until projects demonstrated that work activities could be performed in accordance with ISM. ORNL stopped work at other sites to perform a work control assessment of all its off-site work. ORNL is developing and implementing corrective actions to address the managerial controls and safety measures identified as judgments of need by the DOE review.

 

-- REPORTS FROM THE FIELD AND A ROUND TABLE DISCUSSION --

Chemical Safety Management Programs at the DOE: How are the ISMS Principles Being Addressed?

Carol Scott, (ORNL) - Oak Ridge National Laboratory is enhancing its materials management life cycle to better manage surplus chemicals accumulated over years. ORNL is starting an initiative that will provide a centralized facility for storing and segregating surplus chemicals for reuse and recycling. Our fiscal year 2000 goal is to reduce the hazardous materials inventory by 30% and up to an addition 20% next fiscal year.

Sandra L. Johnson, (DOE RL) - Prime contractors at the Hanford Site are required to use Chemical Management Program Requirements (CMP) to implement consistent chemical management across the site. Each contractor’s CMP incorporates the principles of Integrated Safety Management and is based on the complexity and severity of each contractor’s chemical hazards.

Dave Quigley, (INEEL) - INEEL developed the Chemical Data Summary Sheet (CDSS) to correct and eliminate many identified deficiencies in their chemical management program. The CDSS provides employees with critical safety information about every chemical or chemical product they use or store.

 

Wednesday, October 25, 2000

Chemical Safety Topical Commitee Team Products for 2000

 

-- TRAINING SESSION II --

Approaches to Chemical Safety Management in the Chemical Industry

Moderator: Syl Turicchi, (AICHE-CCPS)

Robert Rosen , (BASF Corp.) Chemical handling in a facility can be managed as a life cycle comprised of ordering, receiving, and disposal of materials. Spills or other incidents will also be discussed.

Stan Grossel, (Process Safety & Design, Inc.) Factors to prevent or minimize accidents during the storage and handling of hazardous liquids are discussed. Topics include the types of hazardous liquids, relevant standards, and practices for safe handling and storage.

 

Identification and Management of Shock-sensitive/Time-Sensitive Reactive

Dave Quigley, (INEEL)- This presentation will discuss hazards associated with time sensitive chemicals and how these chemicals can be safely managed.

David Blair, (Environmental and Technical Specialists, Inc.) - Knowledge of the chemistry of time sensitive and shock sensitive chemicals allows them to be managed safely and without injury to personnel and the environment.

 

-- CSTC PROJECT 2000-B --

Chemical User Safety and Health Requirements – A DOE Network of Chemical SafetyRequirements

Information - Dave Quigley, (INEEL)

Results of the Chemical Storage Requirements Pilot - The Chemical Storage Requirements Pilot conducted in 1999 distributed a consolidated listing of requirements for safe chemical storage, along with a survey, to chemical users across the DOE complex. The results indicate that the effort to consolidate requirements is useful and should continue.

DOE Chemical-Related Requirements and Safety Analysis Expectations - The project on DOE Chemical-Related Requirements and Safety Analysis Expectations addressed DOE facility authorization bases and safety analyses for non-nuclear facilities that use chemicals. DOE’s expectations in a facility authorization basis document and the existing DOE mandated chemical safety requirements are discussed.

 

 

-- CSTC PROJECT 2000-E --

Approaches to Chemical Safety Analysis at DOE -- Reports and a Round Table Discussion

Current Chemical Safety Analysis Practices at the DOE Complex - Ingle Paik, (EFCOG/WSMS) - Representatives of ten major DOE sites provided examples of procedures and analyses, including chemical hazard category, chemical facility categorization criteria, chemical screening criteria, functional classification methodology , risk binning, and others. A draft report will be posted on the DOE-EH Chemical Safety Program and EFCOG/Chemical Safety Subgroup's websites.

Chemical Safety Analysis at INEEL - Robert Nitschke,( INEEL) - The presentation entails a brief description of the hazard classification and safety analysis process for other-than-nuclear facilities at INEEL with specific emphasis on chemical hazards.

Experimental Safety Review in a Basic Research Facility - Sue Morss, (ANL) -

Industrial Hygiene Coordinating Committee Perspectives on Non-Nuclear Safety Analysis - Jay Larson, (DOE/SC-83, IHCC Chair) - An ongoing debate in the DOE as to the need for a chemical safety directive is based on the perceived regulatory gap between the OSHA Process Safety Management regulation and standards that address smaller quantities of chemicals. The Department's policy requiring the implementation of Integrated Safety Management (ISM) programs, requires the identification and control all hazards, regardless of the applicability of specific regulations or standards. The key to managing DOE's chemical risks is effective integration into the overarching framework of ISM, not the development another stovepipe approach to hazard control.

Chemical Safety Analysis at ORNL/Y-12 Sarah Hartson, (DOE/NNSA/Y-12/DP) - At Y-12, it is DOE’s expectation that all hazardous activities and operations are properly identified, analyzed and controlled and that at the facility level an authorization basis (AB) is developed that will not only document the hazards and controls but also provide for all worker, public and environmental commitments. The AB will define the safety management programs that must be implemented and complied with in order to ensure that work is done in a safe, formal and integrated manner. In order to ensure continued safe operations within this AB, a formal change control process must be developed so that all modifications and changes will be analyzed for impact against the current AB and potential incorporation. Additionally, an authorization agreement delineating the scope of activities within the facility, current and future safety and health commitments as well as vulnerabilities must be defined and signed by both the M&O contractor and DOE. This will establish formal acknowledgment and agreement on the work being done within the facility and mechanisms in place to ensure that the work is accomplished in a safe manner.

This presentation is Y-12's implementation of this expectation. The first part of the presentation is what we (Y-12) believe should be the Complex-wide objective and expectation for non-nuclear safety analysis which entails the development of an authorization basis. Following this is a high-level guide which delineates an approach to building the authorization basis for a non-nuclear hazardous facility, specifically a chemically hazardous facility. The final part of this presentation will highlight the M&O command media which is used to for the development and maintenance of the authorization basis.

David Sheffey, (LMES, Oak Ridge) -

Chemical Safety Analysis at LANL - Lisa Garner, (MST-OPS Engineering, LANL) - The process to prepare non-nuclear authorization basis documents for the new Beryllium Technology Facility (BTF) at Los Alamos National Laboratory was a challenge because guidelines were not readily available. A "What If" Chemical Safety Analysis Conducted at LANL identified hazards and established controls for worker safety for each operation.

 

Thursday, October 26, 2000

The Path Forward to Chemical Hazards Management Program Excellence: CSTC Issues for 2001

-- BREAKOUT SESSIONS --

 

Plenary Session: Project-2001 New Teams Report-Out

- Titles and member lists

- Draft project descriptions and goals

Recognition of Progress of CSTC Project 2000 Teams

C. Rick Jones, Director, Office of Worker Protection Policy and Programs, EH-52