AGENDAShutdown Safety Meeting
M. DallasClosing
M. DallasSTOP/Safety Leadership
B. ManzlakReview Hall Task List
S. SuhringAccelerator Task List
W. MerzElectrical Work
P. MuttonProcedures
B. MayAnalysis of Safety Data from May 2006 to Present
W. MerzWelcome
SHUTDOWN SAFETY MEETING
12 JULY 2007
Safety Data Analysis Since last May ‘06
ESH&Q Deputy Dawg
Bob May
Data Analysis Last Safety Shutdown
• First Aid and Injury Events• Safety Performance though 2Q FY07• Other Significant Events• STOP 2006 Data• CATS Data – Cause Codes Since 01-
Jan-07• Work Observations during the SAD• Additional General Safety Items• Final Notes
First Aid and Injury Events• Since last SAD on May 16, 2006…
• 14 First Aid Events – does not count FAE’s elevated to Reportable Injury
• 5 Lacerations (2 forearms, 2 thumbs, 1 finger)• 3 Sprains (ankle, back, knee) • 3 Abrasions (head, forearm, neck)• 2 Foreign body (eye, finger)• 1 each Insect sting to face and hand contusion
• 2 Injury Events – that have been assigned to JLab• April 19, 2007 14:30 PM - subcontractor injured the tip of his
finger (left hand) while preparing to perform corrective maintenance on the motor-drive of overhead door at Bldg. 38
• November 3, 2006 07:10 PM - guard slipped took a misstep off the edge of the sidewalk and twisted her left ankle on sidewalk while walking down the way to the F Wing of building 12.
Safety Performance Through 2Q FY2007
TRC DART
Other Significant Events• June 2, 2006 to June 16, 2006 – NL, subcontract technologist tech
experienced respiratory tract irritation. JLab staff denatured alcohol P-Card purchase from Home Depot. No MSDS. IH later determined that the denatured alcohol contained up to 60% methanol.
• June 24, 2006 – FEL outside, metal tent frame structure fell; no injuries
• July 10, 2006 5:00 PM – NL, Staff noticed wires hanging from a combination starter in the North LINAC. Further investigation revealed that the wires were connected to a breaker that was labeled spare and had a “SPARE” sticker on it and was turned off.
• July 28, 2006 Noon – NL, while removing extension cord, receptacle cover plate pulled out of the aluminum wire-way exposing live connections and causing seeing sparks
• Sept. 21, 2006 – Exterior, Test Lab - mobile equipment left unattended with the keys in it borrowed by untrained/unauthorized subcontractor.
Other Significant Events, cont’d.• Oct. 24, 2006 - 10:00 AM Test Lab, during a lift, a staff member
tipped multi-drawer roll around toolbox over backwards out of the slings, and it fell to the floor.
• Oct. 31, 2006 11:50 PM - ARC Bldg Telephone Room, smoke detector went into alarm, UPS failed
• March 2, 2007 15:40 – Test Lab, leaky scrubber o-ring dripped causing potential acid exposure to employee’s head
• April 3, 2007, 4:00 PM – Hall A, technicians receive what they believe was a low voltage shock while performing a beam cavity tuning procedure.
• April 6, 2007, Hall C - section of large diameter beam line stored without proper RadCon postings
• June 27, 2007, Bluecrab - activated Lambertson magnet coil found
L/L from Other Significant Events
• Common work planning issues
– Availability of materials
– Task planning (design of work sequence)
– Training and preparation based on hazards (procedures?)
• Common work conduct issues
– Interim status of work or equipment at the job-site
STOP 2006 Data• 177 Engineering recorded Observation Reports
– 4145 discrete observations– 165 (or 4%) representing unsafe or potentially
unsafe acts• Considerable effort given to the STOP process by
Engineering line managers and Ops Crew Chiefs• Ongoing effort by FM for STOP Observations of
subcontractors• Although most new effort was observations
conducted by Engineering, observations covered activities in most all lab organizational units.
Reactions of People
Personal Protective Equipment
Positions of People
Tools and EquipmentProcedures
Orderliness Standards
0.0
1.0
2.0
3.0
4.0
5.0
6.0
7.0
Reactions of People 1.9Personal Protective Equipment 3.2Positions of People 5.2Tools and Equipment 2.4Procedures 6.3Orderliness Standards 2.4
Percentage of UNSAFE Observations
Quick look at 2006 STOP Observations
STOP 2006 Summary
• Common to most all observations--Anyone can be observed; staff, users, subs, students-----Verbal positive feedback from observer is routine------ Positive response back to observer (less than 5 direct
negative responses) is routine---
• Net result seems to be: ---Raised safety consciousness and situational awareness------Consistent observed management safety commitment------Improved safety performance---
• New tools are being developed to enter and manage data. These will be available October 2007
Primary CATS Cause CodesLevel 0 & Tracking Only Removed
0
5
10
15
20
25
30
35
40
Pro
cedu
res:
Not
adeq
uate
Trac
king
Onl
y
Des
ign
Con
tinuo
usIm
prov
emen
t
Per
sonn
el: T
rain
ing
Pro
cedu
res:
Non
-ex
iste
nt
Per
sonn
el: I
natte
ntio
nto
det
ail
Mat
eria
ls
Man
agem
ent:
Pla
nnin
g
Man
agem
ent:
Res
ourc
e A
lloca
tion
Pro
cedu
res:
Not
Follo
wed
Inad
equa
te o
r No
Insp
ectio
n
Sup
ervi
sion
PP
E
Qua
lific
atio
n
Cause
Cou
nt
Since inception of cause codes in January 2007
CATS Data
Work Observations during the SAD• At some time (and probably several times) during the SAD
you will be approached by supervisors, line managers, coworkers, safety staff, or some combination thereof.
• They will want to observe your work from a safe perspective and then talk with you about your reasons for and your approach to working safely.
• They will also talk to you about things particular to your work like task hazard analyses or pre-job planning, any procedures in use, your PPE, any tools and equipment in use, etc.
• Please work with them. Observations usually take about 15 minutes. The observation is anonymous – only the observer name is recorded.
• If you have questions about a particular work observation or the work observations in general, just ask the observer!
Additional General Safety Items• Radioactive Material Movement: two recent events point to a need
for rigor in the control of radioactive material
• Lambertson coil at Bluecrab
• C50 - multiple activated components isolated during disassembly
• Contact RadCon, work out a process for managing radioactive components for your task, make sure every one in your workgroup follows that process!
• Critters (spiders, snakes, chiggers, mosquitoes). If you have a pest control problem, call 7400 and obtain support from FM pest control subcontractors!
• Summer students and visitors are on site! Traffic safety (parking lot etiquette) seems to suffer first. Please dialog with students and pass on the expectation to work deliberately and safely.
Final Notes• Summer is traditionally a “high injury” time
• Lots of distractions• New staff and new students, subcontracted work• Intense work schedule – 3 month SAD• Our first aid case rate says we’re not immune from injury!
• What is the antidote?
• Carefully planned activity; plans that reduces opportunities for injury by properly engineering a task or introducing controls.• Deliberate actions; follow procedure and accepted work practice; don’t work-around with out stopping, thinking, reevaluating!• Situational awareness; what’s my next possible injury and how can it be avoided? How am I impacting others working around me and vice versa?
QUESTIONS?
Proceduresa.k.a.
(Work Control Documents)
Why?Which Type?
Phil MuttonJuly 12, 2007
STOP Observations, Lessons Learned, and Other Feedback
• Common Findings (JLab and other labs)– Lack of procedures– Inadequate procedures– Incomplete procedures– Procedures not followed– Unclear lines of responsibility
Why Procedures?
Why Written Procedures?
• Consistently safe and high quality work every time.– Capture knowledge and use best practice
– Safety Precautions– Environmental Precautions– Methods– Specific Procedures
– Authority– Responsibility – Qualifications– Equipment
• Avoid ambiguity:
Which Type to Use?
• SOP – Standard Operating Procedure
• OSP – Operational Safety Procedure
• TOSP – Temporary Operational Safety Procedure
• Formal• Specified Approval
Process• ESH&Q Archiving
• Less Formal• Approved and
Controlled within Department
or• “Procedure”
Standard Operating Procedure• Standardize recurring processes• Use when hazards are common (well understood)
– ESH&Q Manual, referenced standards, and established methods provide mitigation guidance - typically to get to RC 0 or 1
Example:Electrical Safety SOP (a few pages)• Applies to all electrical work in the department. • Emphasizes Authorization, Qualifications, Classes and Modes of work,
PPE guidelines…
Procedure
• A step by step guide for a specific task.• Less formal than SOP, OSP, or TOSP• May contain only technical details• Includes other information (safety, environmental,
equipment, etc.) as appropriate
ExampleKlystron Replacement Procedure (19pp)Reset Box Power Supply Procedure (3pp)• Typically provides task and
equipment specific details that are not included in an SOP
Procedures
• Format defined by department to suit specific needs
• Managed and Approved within department
• A Safety Oriented Document for Special Situations• For Work Involving “Unusual” Hazards• Work may be repeated periodically• May require work to be performed under RC 2 conditions• Documents the people, equipment, methods, specific procedures,
hazard analysis, and safety requirements
Operational Safety Procedure
SOP and OSP (Chapter 3310)
Expiration = 3 years
Same Approvals
Temporary Operational Safety Procedure
• A Safety Oriented Document for Special Situations• Temporary work procedure for unique tasks• For Work Involving “Unusual” Hazards
• Documents the people, equipment, methods, specific procedures, hazard analysis, and safety requirements
TOSP (Chapter 3320)
Expiration = 3 months max.
Slightly DifferentApprovals
Communication
• Provide a user sign-off sheet– Participants acknowledge having read and
understood the procedure– An agreement to work in accordance with the
procedure
• Use the document while working– Discuss it in the pre-job briefing– Post in the work area, or carry in toolkit...– Use it as a checklist
Safe, High Quality Work
• Without procedures, you may miss the boat!
• Don’t take a chance
– Write it all down, and then use the document
QUESTIONS?
Electrical Safety BriefingBill Merz
Topics• Worker Qualifications
• Circuit Breaker Operations
• NFPA 70E Assessment Findings
Safety Requirements for Workers• Qualified Electrical Workers
– Knowledge– Generalized Training
• General Electrical Safety– Hazards Identification and Policy– Modes and Class– Work Practices, PPE
• NFPA -70E Training (Arc Flash Hazards, Boundaries)
• CPR-AED• Lock Tag and Try
– Equipment Specific Training• For the task being performed
– Authorization• Supervisor
• “Unqualified” Workers– Basic Recognition and Avoidance of Hazards
• Working in the vicinity of electrical hazards• Familiarity with electrical safe work
practices– Potential for Injury
• Due to electrical shock– Training and Knowledge
• Commensurate with task
Safety Requirements for Workers
Circuit Breaker Operationa clarification of rules
• These rules apply if all covers are closed• The two pertinent hazard categories
– Category 0• Applies to all Accelerator 480/208/120 VAC
Circuit breakers, safety switches, Motor Control Centers
• De facto default category• Exceptions to the above rule:
– >25 kAmp fault current, 30 msec fault clearing times
– Labels indicate a higher category– Breakers on unit substations (outdoor
hardware)– Category -1
• Allows the reduction to a lower level if:– Available fault Current is <10 kAmps
• Category 0– Use this category PPE on all 480 VAC service
circuit breakers or switches (except as noted on previous slide)
• Safety glasses• Long pants – Non-melting or natural fiber
clothing– cotton, wool, silk, rayon, or blends,
4.5.oz/yd2
• Long sleeve shirt – Non-melting or natural fiber clothing
– cotton, wool, silk, rayon, or blends, 4.5.oz/yd2
• Undergarments – non melting…..• Note: Gloves not required by NFPA 70E
Circuit Breaker OperationRequired PPE
Breakers and Switches 32• Examples of 480VAC
Switches
• Category -1– Use this on all 208/120 VAC inside the fence
• Safety glasses• Long pants – Non-melting or natural fiber
clothing– cotton, wool, silk, rayon, or blends ,
4.5.oz/yd2
• Short sleeve shirt, T-shirt – Non-melting or natural fiber clothing
– cotton, wool, silk, rayon, or blends, 4.5.oz/yd2
• Undergarments – non melting…..• Note: Gloves not required by NFPA 70E
– Only exception I can verify for whole lab site is in VARC, but there may be others outside the fence or in the end stations
Circuit Breaker OperationRequired PPE
Breakers and Switches• Examples of 208/120 VAC
DoE NFPA 70 E Assessment Results• Electrical Gloves
– Gloves must be tested• They should have a date stamp on them• They must be re-tested or discarded after 6 months from last test,
whether used or not.• They must be retested after each use (air test)• Must be retested electrically after each use if leather outer gloves
not used• Recommendation – use leather outer gloves whenever using
electrical gloves
• FR Clothing– FR rated clothing is required for Hazard Category 1 and
Up• In accordance with NFPA 70E – 130.7(C)(12)(c) “Underlayers”.
Meltable fibers such as acetate, nylon, polyester, polypropyleneand spandex shall not be permitted in fabric underlayers (underwear) next to skin
• Any employee performing work requiring FR clothing MUST wear the appropriate natural fiber underneath
DoE NFPA 70 E Assessment Results• Meters
– Verify that electrical test meters are rated for the application.
• Newer meters are categorized as CAT 1, 2, 3, or 4.• Typically a category 3 or 4 is appropriate to verify
zero energy for lock, tag, and try (LTT) applications.• The category is usually listed on the front of the
meter near the connections for the test leads but may be posted somewhere else on the meter.
– This does not mean you need to get rid of your present meter if not a CAT 3 or 4
• You may be able use it on applications that do not require this rating
• This rating is not the same as a voltage rating
Meters – from Fluke web sitehttp://us.fluke.com/usen/support/appnotes/
Summary
If it doesn’t seem right, even if you are trained,and your supervisor asked,
don’t do it…talk about it first!
QUESTIONS?
ACCELERATOR SAD
STEVE SUHRING
ANOTHER ALL HANDS MEETING…
Accelerator Down Information• Scheduled Accelerator Down
– Friday, July 13th to Saturday, October 13th
• Regular Day:– 0800 MCC Meeting
• Overall Work planning and coordination• Broad representation• All are invited
– Toolbox Meeting• Work groups talk through their plans
– Work professionally– Housekeeping
• End of the day cleanup and work assessment
• Communication Changes– ATLIS Map (new!)– Calendar (soon to be “on line”)
• Points of Contact– Emergency: 9-911– Crew Chief: 630-7050– Work Questions?
• Supervisor• Steve Suhring: 584-7670• Jack Ludwig: 584-7416• Ron Lauzé: 584-7186
Accelerator Down Information (cont.)
A
B
C
! General
Stone Work ۞ Alignment
Keep Out V VacuumElectrical
Material HandlingATLis Work Map
7/13/07
Radiation
Keep Out
V LL Gun
Hi Pot ion packs
Alignment Equip.
۞ Alignment
! 1330 2L09 U-tubes
• Major Tasks (ATLis Driven)– PGun removal– Installation of new Load Locked Gun– Installation of a new 500keV Mott beamline– Cryomodule gyrations: SRF, EES, Cryo, Vacuum– ESR PM– CHL to 4K– Rolling power outages– PSS certification
Accelerator Down Information (cont.)
QUESTIONS?
End Station Work Procedures Bert Manzlak
Summer 2007Scheduled Accelerator DownEnvironment Health & Safety
Working in the Experimental Halls
Prior to Working in the Experimental Halls
• Plan work in advance with the appropriate Hall Work Coordinator
• Where appropriate, supervisors shall conduct a Task Hazard Analysis – outlined in the JLab EH&S Manual Chapter
3210 - Hazard Identification and Characterization
• Supervisors must verify that they and the people they supervise have the required and up-to-date training.
Prior to Working in the Experimental Halls (cont.)
• Review information on Hall specific EH&S Bulletin Board, which is located at the entrance to the hall on the lower level/labyrinth.
• Review specific work control documents and assess and gather necessary personal protective equipment.— Radiation Work Permits, Temporary Operational Safety Procedures, Standard Operational Procedures, etc.— PPE Example: Hall B — hard hat required and no open-toed shoes
• Communicate daily with the Hall specific Work Coordinator/Area Safety Warden
Physics Division Experimental Hall Work Coordinators and Area Safety Wardens
55127555
Walter KellnerAndrew Kenyon*
Hall C
78577115
Doug TillesGeorge Jacobs*
Hall B
78577242
Ed FoltsJack Segal*
Hall A
Ext./Pager
Minimum JLab EH&S Training for Working in the Experimental Halls
• SAF 100 EH&S Orientation• SAF 801 Radiation Worker I, Hall A/Hall C• SAF 103 O.D.H.• Hall Specific EH&S Awareness
Training Contacts
B. Vulcan, [email protected]/Hall CSAF 112*
A. Deur, [email protected]/, D.TillisHall BSAF 111*
J. LeRose, [email protected]/, E. FoltsHall ASAF 110*
*Required for unescorted access
If You Have Environmental, Health, and or Safety Questions, Issues/Concerns in the Experimental Halls
• Contact your Supervisor• Contact Area Safety Warden or Alternate• Contact Physics Division
7740Dennis [email protected]
7608Charles [email protected]
7556Bert [email protected]
Major Activities Scheduled• Hall A
– E05-110 Experiment Installation– Polarized Target Work– Cryogenic System Work– Electrical Power Supply Work
• Hall B– FROST Experiment Installation
• Hall C– E04-108 (GEPIII) Experiment Installation– Cryo Target Work– G0 Experiment Disassembly and Removal– Focal Plane Polarimeter (FPP) Installation– SANE Preparations
Additional Information• Complete work schedules (MS project) are
posted in each Hall
• Cross divisional work activities are now entered in ATLis
QUESTIONS?
STOP/Safety LeadershipClosing Comments
Mike Dallas
