APS Beamline Safety Coordinators Meeting Tom Barkalow PSC ESH/QA Coordinator August 6, 2013.

APS Beamline Safety Coordinators Meeting

Tom BarkalowPSC ESH/QA CoordinatorAugust 6, 2013

APS Beamline Safety Coordinators Meeting 8-7-13

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Topics

Stepper Motor Driver Unit Hazardous Voltage to Ground Issue

Work Planning & Control Documents

General Discussion


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Hazardous Voltage to Ground Issue

Background

AC Powered Stepper Motor Driver Units Involved

Two Solutions

Information Needed from Beamlines

Time Frame for Solution Implementation


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Background

Electrical shock occurred on December 20, 2012

Traced to damaged wiring insulation inside ungrounded ELCO type connector

PSC Safety Notice issued January 15, 2013

Later measured hazardous voltage to ground present on AC powered driver units


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Background Cont’d

Survey taken in Late February and early March 2013 of driver units in use on beamlines– Identified over 5100 units in use of which about 460 are AC powered units of concern– 17 sectors identified as having AC powered units of concern; mostly APS operated

Several models of AC powered driver units have this issue

Compensatory measure taken of labeling problem AC driver units and their cables between the driver units and their stepper motors


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AC Powered Driver Unit Models Involved

All Kohzu AC powered models

All Oriental Motors (Vextra) AC powered models

Parker Aries ACR, RAM, & Zeta Series

Industrial Devices Next Step models

Compumotor OEMZL4 & S6 series

Bodine 120 V Stepper model (not in use)


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Sectors Involved with Number of Driver Units

Sector # Units %1 133 28.542 48 10.3

30 48 10.34 45 9.653 30 6.44

32 30 6.447 28 6.016 22 4.72

33 21 4.5120 20 4.2914 13 2.7916 8 1.7213 6 1.2912 5 1.0734 4 0.865 3 0.649 2 0.43

Total 466 100

Sector # Units1 1332 483 304 455 36 227 289 2

12 513 614 1316 820 2030 4832 3033 2134 4

Total 466


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Source of Hazardous Voltage

120 VAC distribution system has delta-wye transformers with the secondary neutral winding grounded

Driver units are pulsing the DC voltage being delivered to the stepper motors, but the pulsing is overlaid on an AC voltage level with a 60 hertz cycle

Need to eliminate the 60 hertz AC voltage


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Two Solutions

1. Replace AC powered driver unit with a DC powered driver unit

2. Install an AC-AC isolation transformer in the power feed to AC powered driver unit


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Solution 1: Replace with DC Powered Driver Unit

Removes AC input concern

Simply swap out driver unit

May require adding a DC power supply (need information from beamlines to determine power requirements for any new DC power supplies)

Beamline staff need to evaluate whether stepper motor performance would be adequate with a DC powered driver unit


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Solution 2: Install AC-AC Isolation Transformer

Removes the hazardous voltage to ground on the driver unit output

Several sizes and models of isolation transformers are available

Information is needed from beamlines to determine power requirements for the isolation transformer installations

Selection of isolation transformer make and model will be made after evaluating information provided

Current warning labels must be retained for this solution


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Information Needed from Each Involved Beamline Need to have the following information for each involved beamline (not station) in

order to determine the needed power output for isolation transformers or DC power supplies and how many are needed:– the total number of driver units with makes and model numbers – how the driver units are grouped together and each group’s location within the

beamline – the number of driver units in use simultaneously for each group – the maximum amperage setting actually used for each unit – the number of groups in use simultaneously and which groups they are– a beamline drawing or sketch showing where the groups are located and the distances

they are apart

Clay White has already collected this information from a few beamlines as a pilot exercise; these beamlines do not need to submit the already gathered information

A web link with form to submit information is nearly ready – will send link

Submit by COB August 16, 2013 (Revised to August 30, 2013 in meeting)


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Implementation Schedule & Costs

One of the two solutions must be implemented for each driver unit of concern before the start of the 2014-3 operating run (tentatively 10/1/2014)

AES will provide an engineer to coordinate the implementation and all 3 APS divisions will participate in the implementation and any needed DEEI inspections

Costs remain to be determined, but Brian Stephenson has stated APS will assist the involved CAT beamlines

Strongly recommend that AC powered driver units not be installed in the future

Anyone installing AC powered driver units will be responsible either for demonstrating the units do not exhibit the hazardous voltage to ground concern or for installing isolation transformers


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Open Discussion on Hazardous Voltage Issue

???


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Work Planning & Control

Background

Argonne Requirements & Online System

APS Documentation Requirements

Beamline Application

Implementation Timeframe


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Work Planning & Control Background

Two significant events involving a hazardous chemical or gas occurred in 2009

DOE later levied a fine against Argonne for violating 10CFR851 Work Safety and Health Program requirements

Inconsistent hazard analyses and hazard controls implementation a root cause

Argonne committed to implementing a site-wide hazard identification and control process to be used in work planning and control

A site-wide process was developed, implemented, and then substantially revised last year based on feedback received

All work must have hazards and hazard controls identified, documented, and implemented (Remember ISM 5 Core Functions)


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WPC = Standard Method for Documenting the ISM

5 Core Functions


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Argonne WP&C Requirements

The Argonne site-wide process is described in LMS-PROC-200

LMS-PROC-200 requires local implementing procedures

Activities excluded from the local implementing procedures include:– Administrative and computer-type office conducted in an office area that does not

require permits or special training– Work performed by an Argonne subcontractor on the Argonne site

Hazards analysis & identification of controls must be performed and documented by an accepted method

ESAF is an accepted method for all APS experiments

Otherwise must use online web application https://webapps.inside.anl.gov/wpc/


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APS Local WP&C Implementation

The APS local implementing procedure was issued on February 25, 2013 with an effective date of May 1, 2013

Procedure excludes:– Service work provided by Argonne Operations personnel (e.g., FMS & ESQ staff)– Administrative/office work performed in office areas– Work performed by Argonne subcontractors

Procedure addresses 3 areas:– Non-Experimental APS Facility WP&C– Non-Experimental Beamline WP&C– Experimental WP&C (already covered by the ESAF process)


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Non-Experimental Beamline WP&C

Address activities not covered under an ESAF

A hazard analysis and identification of controls has been performed and documented to cover common beamline activities such as:– Vacuum work – Alignment & mechanical adjustments– Electronic interfacing on equipment such as slits, mirrors, monochromators, beam

position monitors, cryo-cooled options, and the associated motion control, vacuum, mechanical, and electrical systems

– Dry labs– Wet labs

This document is applicable to all beamlines

A significant benefit of this document is it relieves beamlines from having to use the Argonne web based process for the core activities covered – otherwise each beamline would need to prepare and issue a document like it


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What Do Beamlines Need to Do for WP&C?

Compare the common hazard analysis and controls identification document with their beamline operations

Identify and document all activities or specialty systems that are not included in the common document and that have not been covered by an ESAF

XSD operated beamlines will provide a copy of their lists to Paul Rossi, XSD ESH Coordinator

Non-Argonne CAT operated beamlines will provide a copy of their lists to Bruce Glagola, AES User Safety Officer

These lists will be provided by COB December 20, 2013


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What Do Beamlines Do Then?

APS staff will evaluate the lists received to determine if additional common beamline activities exist that can be covered by a new common hazard analysis and controls identification document

Beamline staff will be notified of which beamlines and associated activities will be included by a new document

All notifications will be completed by COB February 28, 2014

APS staff will proceed to perform and document the additional common hazard analysis and controls identification

For activities or specialty systems which are unique, the applicable beamlines will need to produce separate hazard analysis and controls identification documents


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Additional Implementation Details

Non-APS Argonne operated beamlines will notify Bruce Glagola if they will perform hazard analysis and controls identification in accordance with their home organizations local WP&C implementation procedure and schedule

All new Non-Experimental Beamline WP&C hazard analysis and control identification documents need to be issued by October 1, 2014

Beamline staff need to add the commitment to WP&C to their ESH Plan before their next 3 Year Sector Safety Review

It is highly recommended that non-Argonne beamline operating organizations have at least one staff member trained in use of the Argonne web-based WPC system

APS staff will be available to advise beamline staff on the WPC process


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Open Discussion on Work Planning & Control

???


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Recap on What Is Needed from Beamline Staff

Provide information on driver unit power loads by COB August 16, 2013 (Revised to August 30, 2013 in meeting)

Provide information on beamline activities and specialty systems not covered by Common hazard analysis & controls identification document or an ESAF by December 20, 2013


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Other Issues or Discussion?

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