|Environment, Safety, and Health INTEGRATED HAZARD APPRAISAL of BERKELEY ENGINEERING DIVISION|
|for Work and Hazards Identification to Define the Necessary and Sufficient Standards Set and Direct Appraisal Efforts|
|Team Member||Technical Specialty|
|Chester Chang||Facilities Mgmt. - DOE Site Office|
|James Chwang||Fire Protection - DOE Oakland|
|Paul Davis||Industrial Hygiene and Team Leader|
|Connie Grondona||Health Services|
|Steve Leeds||Fire Protection (LLNL)|
|Curtis Nunnally||Engineering Division Safety Coordinator|
|Don Rondeau||Engineering Division Reviewer|
|Carl Schwab||Environmental Protection - Site Office|
|Anita Whichard||Engineering Division Safety Coordinator (substitute)|
|Maxwell Yao||Environmental Protection|
|Tony Yuen||Fire Protection|
|Collect and Review Information||6/17/96 - 6/27/96|
|Establish Team Members||6/27/96|
|Overview of Division||7/11/96|
|Initial Hazards Identification & Grouping||7/22/96|
|Field Check Spaces||7/31/96|
|Finalize Risk Survey Sheets||8/1/96 - 8/6/96|
|Summary Report Draft||8/13/96|
The Engineering Division consists of eight line departments which provide resources and activities in support of the whole Division. Department heads report directly to the Division Director (Ed Burgess) and are responsible for the scientific excellence, relevance to the DOE mission, and fiscal integrity, of their departments. This also includes adherence to all administrative and regulatory requirements. The Division Safety Coordinator (Curtis Nunnally) is charged with oversight pertaining to environment, safety, and health (ES&H) matters. The Division Safety Coordinator reports to the Deputy Division Director (Don Rondeau). An ES&H Committee meets periodically and provides guidance to the Division Director with regard to ES&H concerns. The ES&H Committee is chaired by the Division Safety Coordinator and is composed of representatives from different departments.
The Engineering Division is responsible for the following buildings: 25 complex, 29 complex, 40, 41, 44B, 46 complex, 77 complex and 81. In addition, to they occupy labs, shops, etc. in the following Buildings: 2, 10, 31, 58, 70, 70A, 71 complex and 74.
Research Program Management Responsibility for Safety
Line Management is responsible for the protection of the public, the workers, and the environment.
At the Berkeley Laboratory the following documents establish the policy and provide the implementation guidance that makes line management effectively accountable for protection of workers, the public and the environment:
Clear Roles and Responsibilities
Clear and unambiguous lines of authority and responsibility for ensuring safety are established and maintained at all organizational levels within the Department and its contractors.
Each Division making up the Berkeley Laboratory has clearly defined lines of responsibility down to the working level. Each division designates a research investigator to represent its views and concerns on the Laboratory Safety Review Committee and a full time employee to act as the ES&H Coordinator. This Coordinator acts as the interface between ES&H concerns and compliance in the workplace and the EH&S technical professionals. Organizational information is updated every 60 days and is retained in the Functional/Facility Notebooks as appropriate (see OAP).
Competence Commensurate with Responsibilities
Personnel possess the experience, knowledge, skills, and abilities that are necessary to discharge their responsibilities.
Job assignments, including hires, are reviewed by line management and by the compensation group within Human Resources to ensure that the requirements and responsibilities of a job are matched by the experience, knowledge and skills of individuals selected for assignment. A performance expectation for managers and supervisors in the Engineering Division is how well the talents, knowledge and skills of staff are matched to work assignments and responsibilities
The Laboratory's training program ensures that each staff member, including participating guests, is adequately trained to participate safely in Laboratory activities. Staff, with supervisor participation, fill out the Jobs Hazards Questionnaire (JHQ) describing the hazards associated with their job assignment and work area. Evaluation of the responses by the Training Coordinator and the cognizant supervisor determines the training regimen needed to carry out work in a manner that protects the employee, co-workers, the public and the environment.
Resources are effectively allocated to address safety, programmatic, and operational considerations. Protecting the public, the workers, and the environment is a priority whenever activities are planned and performed.
All environment, safety and health activities in the Laboratory are described in technical terms with budgetary information included. Each year this information is updated, reviewed and prioritized on the basis of risk to workers, public, and the environment by a Laboratory wide committee selected to represent programmatic line management and ES & H professionals. This document is utilized by Laboratory Senior Management in strategically planning the immediate focus and long term goals of the environment, safety and health program at the Laboratory.
Hazard Controls Tailored to Work Being Performed
Administrative and engineering controls to prevent and mitigate hazards are tailored to the work and associated hazards being performed.
Chapter 6 of the Environment, Health and Safety Manual clearly defines the steps for each line manager to develop the appropriate engineering and administrative controls to mitigate hazards in the workplace. The Laboratory's Self Assessment Program, including Functional Appraisals by ES & H professionals, and the UC/DOE Contract 98 Performance Measures provide assurance that implementation of hazards control is adequate to protect the worker, the public and the environment.
Identification of Safety Standards and Requirements
Before work is performed, the associated hazards are evaluated and an agreed-upon set of safety standards and requirements are established which, if properly implemented, provide adequate assurance that the public, the workers, and the environment are protected from adverse consequences.
The Laboratory is dedicated to following the Necessary and Sufficient Closure Process (DOE 450.3) on an iterative basis at all levels of activities in the Laboratory to ensure the Safety Standards are adequate to provide protection to workers, the public and the environment. This process is completed by reevaluation of work in those situations where current work is significantly modified, new work is proposed or substantial facility modifications are being made (Chapter 6, Environment Health and Safety Manual).
The conditions and requirements to be satisfied for operations to be initiated and conducted are clearly established and agreed-upon.
Conditions and requirements for facilities determined to be of higher risk based on the Preliminary Hazards Analysis are contained in a Safety Analysis Document. Activity Hazard Documents are the basis for meeting this requirement for specific operations and activities falling into the higher risk category at the Berkeley Laboratory. Internal agreements describing the performance expectations by each party are used for operations between two functional areas where the quality of performance might adversely impact the Laboratory's ability to meet its responsibility to protect workers, the public and the environment.
The primary mission of the Engineering Division is to provide engineering and technical expertise to support Berkeley Laboratory's research and development programs. This is accomplished by:
The Engineering Division is responsible for the following buildings: 25 complex, 29 complex, 40, 41, 44B, 46 complex, 77 complex and 81. In addition, to they occupy labs, shops, etc. in the following Buildings: 2, 10, 31, 58, 70,70A, 71 complex and 74.
The types of rooms this Division occupies vary widely, ranging from offices and assembly shops to research labs, machine shops, and plating facilities.
Electronic Type Laboratories
These types of laboratories are found in buildings 7, 25A, 29, 40, 41, 70/263, 70A/2212, and 70A/4475. They typically design, assemble, and test various types of electronic equipment.
Chemical / Inerts: Generally small quantities of cleaning type solvents such as ethyl alcohol and acetone. Some cryogens and inert gases may also used, though the quantities are also small. Hazards associated with these materials are low because of the small quantities and proper storage (e.g., flammable storage cabinets) facilities that are available.
Electrical: Electrical shock is perhaps one of the greater hazards in these types of laboratories. To reduce this risk employees attend electrical safety classes, including LOTO.
Sealed Sources: A few of these laboratories have sealed radioactive sources. They are stored in locked cabinets, logs of their use are kept, and all users have dosimeters.
Building 25 (East Side)
This area contains a machine shop, plastics shop, optics lab and a vacuum coating lab.
Chemical / Inerts: Generally small quantities of cleaning type solvents such as ethyl alcohol and acetone are used in the machine shop. The vacuum coating lab has a wide variety of carcinogens, corrosives, flammable, reactive and toxic chemicals, though generally in small quantities. Some cryogens and inert gases are also used, principally in the vacuum coating lab to backfill vacuum equipment. The optics lab has hydrofluoric acid and xylene. Hazards associated with these material are low, because there are proper storage cabinets, ventilated work stations, and the employees using these chemicals are aware of the hazards and trained in proper handling procedures.
Radiation: There is one x-ray machine in the vacuum coating lab, it has a x-ray safety document.
Vacuum Equipment There are 2 large vacuum vessels in the vacuum coating lab, and one in the plastic shop. High voltage electrical power is used in the vacuum coating lab's vacuum oven.
Machine Shop (70A/2245,2253 Area)
Mechanical hazards from moving machinery is perhaps one of the greater hazards in this area. Guards have been installed on all machines, and shop training is given by the shop manager. There is one bridge crane, and all crane operators are certified. There is also a brazing/welding area equipped with an oxygen/acetylene torch.
Chemical Generally small quantities of cleaning type solvents such as ethyl alcohol and acetone for wipe cleaning. The brazing/welding area has corrosives, such as brite dip and nitric acid, which are used to clean metals. Hazards associated with these material are low because of the small quantities and proper storage (e.g., flammable storage cabinets) facilities that are available.
Laser Fluorescence Experiments (70A/2203)
This laboratory has two 3b lasers, a Laser safety document has been written and approved for this area. A small quantity of epoxies, cleaning solvents, and inert gases (i.e., argon, nitrogen) are used in this area.
Sealed Sources: There are a few radioactive sources in this area, they are stored in a locked cabinet, a log is kept of their use is kept, and all users have dosimeters.
Volcano Field Ionizer 70A (2263 & 2263A)
This laboratory has one 3b laser and a class 2 laser for alignment purposes. A Laser safety document has been written and approved for this area
Chemical Inerts This laboratory has an extensive inventory of different types of carcinogens, corrosives, flammable and toxic chemicals. Inert gases, such as argon, nitrogen, and helium are also used.
Gas Cylinder Storage (Building 81)
This is an "open air" building that contains inert compressed gases, such as helium and nitrogen. These gases are delivered to different locations at the Berkeley Lab. The primary hazard here involves the moving and transportation of heavy gas cylinders and tanks.
Photo Fabrication Shop (Bldg 25, Rooms 132, 140, 145, 150, 174, 174 A,B,C
Chemical Inerts This area contains some flammable liquids (primarily for wipe cleaning), large quantities of various types of corrosives, and various types of toxic material and carcinogens. To mitigate hazards employees are extensively trained and these materials are used in tanks equipped with local exhaust ventilation. An AHD describing safety systems, spill procedures, and the waste treatment unit has been written and approved for this area,.
Environmental There is a permitted wastewater treatment unit in this area for the treatment of corrosives and metals. In addition this area contains a Waste Accumulation Area (WAA) and several Satellite Accumulation Areas (SAA's).
Instrument Support Laboratory (70A, 3rd floor)
Chemical / Inerts This area uses various types of corrosives, chlorinated solvents, flammables, and carcinogens, as well as lesser amounts of reactives, toxic and highly toxic materials and hazardous gases. To mitigate these hazards there are ventilated work stations, equipment specific local exhaust systems, and a toxic gas alarm system. There is a AHD for the Ion Implanter. In addition, Building 70A is equipped with emergency standby power and a permitted acid waste neutralization system, both of which are maintained by Facilities.
Environmental There are 7 SAA's in this area, they were all found to be in compliance.
Sealed Sources: There are radioactive sources in this area, they are stored in a locked cabinet, a log is kept of their use is kept, and all users have dosimeters.
Sheetmetal and Weld Shops (77/107 & 108)
Chemical / Inerts These areas use small amounts of flammable liquids such as acetone and isopropyl alcohol, for wipe cleaning. Acetylene and oxygen are piped in from cylinders that located outside of the building. The sheet metal shop has a small amount of corrosives (i.e., hydrochloric acid) that are used for cleaning metal prior to soldering.
Both shops perform different types of welding (in the shop and field locations), consequently there is acetylene, oxygen and various types of inert gases in these areas. During the welding process various toxic fumes and gases are generated, depending the on type of welding and the metals involved. Examples of these are nickel, chromium and lead fumes (from paint), as well as nitrous oxides and ozone. Risk associated with these materials are low because both shops have fixed and portable local exhaust ventilation systems, as well as trained personnel who are familiar with respiratory protection and enrolled in a medical surveillance program.
Various types of shop equipment are also found in these areas, such as shears and brakes. Cranes are used in both of these shops, and all crane operators are certified. Work takes place both in the field and the shop, and can involve working from ladders and elevated platforms. There is a high incident rate of back injuries and strains/sprains for employees in these areas.
Machine and Assembly Shops (Building 77, Rooms 123-158 [excluding 156] Building 77A)
There is a large amount of machinery, and mechanical hazards are perhaps one of the greater hazards in this area. There is an active machine guarding program in the Engineering Division. Most of the rooms in Building 77 have bridge cranes, all crane operators are certified.
Chemical / Inerts This area contains small amounts of flammable liquids that are used primarily for wipe cleaning, as well as acetylene and inert gases. There are large amounts of lubricants, such as oils and grease. One room (141) has a small amount of sodium hydroxide.
Paint Shop (Building 77/165, 165A&B)
Chemical / Inerts This area contains flammable liquids, such as paints and solvents, that are stored flammable liquid lockers. The powder coating process, which does not involve the use of solvents or thinners, is used for most of the work in this shop. Room 165B contains a large, walk-in oven which is part of the powder coating process. There is a large, ventilated paint spray booth for spray painting as well as a sandblast room (165A) that is used for cleaning metal surfaces. Both the paint booth area and the sandblast room) area are equipped with supplied air respirators and a breathing air system.
Environmental In addition to a SAA there are two BAAQMD permitted sources, the paint spray booth and the sandblast room.
Ultra-High Vacuum Cleaning Facility (77/156)
Chemical / Inerts This area contains large quantities of various types of corrosives, and smaller amounts of toxic material and carcinogens, such as nickel sulfate and fluoboric acid. There are no flammable gases, and flammable liquid use is minimal, with small amounts being used occasionally for wipe cleaning. This shop has a permitted vapor degreaser which contains 1,1,1-trichloroethane. To mitigate hazards, employees are extensively trained and these materials are used in tanks equipped with local exhaust ventilation. In addition, there is a toxic gas sensor for hydrogen chloride, an emergency standby power system, and the vapor degreaser has refrigeration coils to cool the vapors. An AHD describing safety systems, spill procedures, and the waste treatment unit has been written and approved for this area
Compressed gases consist of small amount of dry nitrogen and house air, which are generally used to clean parts. Rotating equipment consists of a buffer and the limited use of small power tools, such as a grinder and electric drill.
Environmental There is a Waste Accumulation Area (WAA), a Satellite Accumulation Area (SAA), and a permitted wastewater treatment (for corrosives and metals) unit in this area.
Glass and Ceramic Shops (77/244, 244 A, B, C, D, E)
Chemical / Inerts The glass shop occasionally uses corrosives, such as nitric and hydrofluoric acids and potassium hydroxide. A variety of inert gases are also used in the this shop.
Flammables This area contains large quantities of flammable gases, primarily hydrogen. To mitigate this hazard, there is a flammable gas detection system and the hydrogen cylinders are stored in a secured, well-ventilated area outside of the building. Flammable liquids that are used in this area are stored in a flammable liquid storage cabinet.
Various types of ovens and rotating equipment are used in these areas, such as glass blowing lathes, stationary belt sanders, and rotating polishing tables. Each glassblowing lathe is equipped with a local exhaust ventilation system.
Environmental Virtually all of the above "functional" groups contain one or more SAA's, all of which were found to be in 100% compliance during this review. Before a new or modified research or construction project is implemented the Division checks to ensure that all NEPA/CEQA requirements are met.
Ergonomic hazards associated with the use of computers are the most common hazard in office areas of this division. Employees are encouraged to have their workstations evaluated and the proper chairs and keyboards accessories purchased.
UNCERTAINTIES ABOUT THE WORK
Because the primary mission of the Engineering Division is to support the research of other divisions, the type of specific work product is often changing. For example, in the Building 77 complex the STAR TPC project is nearing completion, while B-factory project components are starting to be assembled and tested. This creates challenges in areas such as employee training and hazards control.
RESOURCE AVAILABILITY AND CONSTRAINTS
No significant changes in Engineering Division resources devoted to ES&H activities are planned.
Representatives of Engineering (Curtis Nunnally and Don Rondeau) offered the following evaluation of the EH&S Division past and future resources and support:
There are no stakeholder concerns unique to Engineering Division, which has managed, controlled, and permitted (as required) air, water, hazardous, and solid waste streams.