Department of Energy Best Practices Workshop

Hazard Analysis

Patricia Allen, Deputy ESH ManagerJim Tisaranni, ISM Director

Washington Savannah River Company

September 12-13, 2006

ISM at the Savannah River Site

2

Hazards Analysis – Applies to All Industries

5400 people evacuated 550 people injured 240 people hospitalized 9 people killed Economic downturn

January 6, 2005, Graniteville, South CarolinaChlorine gas was released from a 90 ton railroad tanker in local community. The 42 car train crashed into an engine and 3 cars on a rail siding. The switch was in the wrong position.

3

Savannah River Site

Missions Operations

Tritium Non-proliferation

Closure Environmental

remediation Waste management Natural resources &

ecosystem management

Deactivation & demolition

Research & Development National Laboratory

Hazards Industrial Chemical Criticality Environmental Operational Radiological Waste

4

Hazard Analysis Time Evolution

WorksClearance

Permit (WCP)

JobHazard

Analysis

AutomatedHazard

Analysis

AssistedHazard

Analysis

WCP

06/05-Present

Automated Hazard Analysis

Assisted Hazard Analysis

03/03-01/0605/97-03/0300/00-01/04

Job Hazard Analysis

03/0305/97 06/05 Continuous Improvement

5

Lessons Learned

Success Areas Database Simple process Walkdowns to identify hazards

Improvement Areas Need a more consistent hazards analysis process

ProceduresImplementation

Work scope must be clearly defined by knowledgeable workers

Emphasis placed on hierarchy of controls

Need to simplify documentation for workers

More training needed on overall process including tools

6

Assisted Hazard Analysis Development Philosophy

Core team established to improve process.

Team included workers, planners,

managers, and customers :Define hazard analysis improvementsCrafted solutionsPlan implementation

Customer integrated from the start Leadership concurrence throughout

process Pilot in diverse facilities

7

Implementation Rollout and Evaluation Process

Involvement Commitment Responsibility and accountability

Project/Facility Leadership Team In-brief

Leadership Planning Leaders trained and

develop implementation plan

Implementation Facility training and rollout Established expectations

Performance Coached Provided dedicated coaching during rollout Obtained feedback on process and modified

Assessments

Initial Implementation Mid Term Effectiveness Review

Metrics

8

Hazard Analysis Training

Modularized training includes varying degrees of Hazard Analysis theory, ISMS, application of tools, functional needs, and facility specific practical exercises.

Manager

Planner and Supervisor

Worker

Engineer

Train-the-Trainer

Subcontractor Technical Representative

Subcontractor

Subcontractor Lead Work Group Supervisor

Procedure Writer

Subject Matter Expert

Training Courses

9

Assessment Feedback

Initial Assessment – completedPurpose: Attain satisfactory working knowledge and acceptable

proficiencyLessons Learned:

Facilities required more tailoring (training and application) than initially anticipated Roll out duration based on facility needs

Mid-term – completedPurpose: Ensure transition stayed on courseLessons Learned:

Problems detected and corrected early in the roll out Picked up best practices and lessons learned to share

Effectiveness Review – in progressPurpose: Evaluate overall roll out successLessons Learned:

Overall roll out effectiveness is satisfactory Receiving excellent feedback on technical accuracy of hazard tree and Site

procedures Opportunities for improvement identified:

Hazard analysis for Operations procedures Feedback Hazard integration (Rad Con)

10

What’s Next – Got Data?

Developed Performance IndicatorsSME resource demandsDistribution of each hazard and associated controlsFeedback analysisDistribution of hierarchy of controlsProcess approval cycle time

If you don’t measure it - - - you can’t manage it.

Metrics capability only limited by our imagination.

MetricsHazard Control Selection by Type

SRS AHA Control Selection by Type (Jan - May 2006)

0.000

0.100

0.200

0.300

0.400

0.500

0.600

Jan-06 Feb-06 Mar-06 Apr-06 May-06

Month

Per

cen

t

Admin

Elim

Eng

PPE

12

0

200

400

600

800

1000

1200

170A

Che

mic

als

/ che

mic

al p

rodu

cts

used

(not

incl

udin

g pa

ints

or

finis

hes)

?41

0 W

orke

rs p

oten

tially

exp

osed

to n

oise

at o

r abo

ve 8

5 dB

A in

an

area

or

room

NO

T po

sted

for h

earin

g pr

otec

tion? 33

0 H

ot W

ork?

170B

Che

mic

als

loca

ted

or s

tore

d in

clo

se p

roxi

mity

invo

lved

?

120C

Mat

eria

l is

chem

ical

(toxi

c, c

orro

sive

, rea

ctiv

e, fl

amm

able

, exp

losi

ve)

or a

sphy

xian

t, or

bio

logi

cal h

azar

d?

440

Dus

ts /

parti

cula

tes?

170D

Pot

entia

l rel

ease

of g

as /

vapo

r (In

clud

es a

sphy

xiat

ion)

?

360

Con

fined

Spa

ce E

ntry

?

660

Con

cret

e or

mas

onry

wor

k?

350D

Pre

viou

sly

pain

ted?

460

Asb

esto

s co

ntai

ning

mat

eria

ls?

350B

Sol

vent

bas

ed?

470

Lead

or l

ead-

cont

aini

ng m

ater

ials

?

350A

Spr

ay p

aint

ing?

690

Pot

entia

l ber

ylliu

m a

rea

or p

rese

nce?

420

Add

ition

al n

oise

sou

rce(

s) in

trodu

ced

in a

n ar

ea o

r roo

m a

lread

ypo

sted

for h

earin

g pr

otec

tion?

130E

Invo

lves

the

use

of P

orta

ble

heat

ing

equi

pmen

t?

710

Pot

entia

l exp

osur

e to

bio

haza

rds?

670B

Wor

k A

ctiv

ity a

t RC

RA

/ C

ER

CLA

Was

te s

ites

/ Site

Eva

luat

ion

Are

as? 67

0A W

ork

Act

ivity

at a

TS

D?

530

Dem

oliti

on /

Ren

ovat

ions

? (

See

Min

i Hel

p fo

r dem

oliti

on d

efin

ition

)

620

Inst

alla

tion,

mod

ifica

tion

or m

aint

enan

ce o

f bre

athi

ng a

ir sy

stem

s?

680

Use

of O

SH

A re

gula

ted

or A

CG

IH A

1 or

A2

Car

cino

gens

?

110I

16 U

niqu

ely

Eng

inee

red

or D

esig

ned

Con

tain

men

t?

450

Act

ivity

invo

lves

con

flict

ing

IH, I

S, E

lect

rical

Saf

ety

and

Rad

con

trols

?

310C

Act

ivity

invo

lves

cha

nges

, cle

anin

g or

repa

irs to

labo

rato

ry h

oods

and

loca

l exh

aust

?

330B

Poo

r ven

t or S

S o

r Gal

v?

350C

Lea

d ba

sed

pain

ts?

120C

Mat

eria

l is

chem

ical

(tox

ic, c

orro

sive

, rea

ctiv

e, fl

amm

able

, exp

losi

ve)

or a

sphy

xian

t?

540C

Exc

avat

ion

cont

ains

or c

ould

con

tain

a h

azar

dous

atm

osph

ere?

670C

Pot

entia

l for

exp

osur

e >=

PE

L?

740

Pot

entia

l exp

osur

e to

non

-ioni

zing

radi

atio

n (N

IR) e

mitt

ers

whi

ch h

ave

pote

ntia

l to

exce

ed th

e Th

resh

old

Lim

it V

alue

(TLV

) or M

axim

um46

0 A

sbes

tos

cont

aini

ng m

ater

ials

(or p

oten

tial a

sbes

tos

cont

aini

ngm

ater

ials

)?

Chemicals / Haz Atmosphere is 40% of IH Involvement

Metrics IH Mandatory Hazard Analysis Reviews by Question

Chart reflects the selection frequency of Hazard Tree Questions

Chemical Hazards Identified

13

Future Vision (Continuous Improvement)

Intranet

Server

RemoteDataInput

FacilityWorkstations

Mobile Phones

PDAs

TelephoneNetwork

Improve hazard tree

Strengthen procedures

Personal DigitalAssistants (PDAs)

Web based

14

Use of Electronic Media for Hazard Analysis

Example of Visual SurveyData Systems (VSDS) currently in use at the Savannah River Site

Benefits:

Easy access to prior surveys

Provides immediate trending capabilities

Relational – integrates with other database systems

15

Benefits of Process

Consistent approach to hazards analysis

Improved worker hazard analysis knowledge

Improved work planning and execution performance

An exportable process –

Utilize the computer software

Implementation Process

Training developed and availableAssessment ToolsMetricsProcedure

16

Approach to Hazard Management

Integrated Safety Management Systems(ISMS)

Define Scope of Work Analyze Hazards Develop and Implement

Controls Perform Work Feedback and Improvement

ISMS

Develop and implement

hazard controls

Analyze the hazards

Define the work scope

Provide feedback & continuous

improvement

Perform work within

controls

17

Define Scope of Work

Total scope Technical work scope

Work activity

Task breakdown

Hazard identification Walk downs and Work Scope

Definition Checklist Work environment Work activity Work method Waste streams Facility and system impacts

Worker involvement

Develop and implement

hazard controls

Analyze the hazards

Define the work scope

Provide feedback & continuous

improvement

Perform work within

controls

ISMS

18

Analyze Hazards

Apply hierarchy of controls Eliminate the hazards Engineering controls Administrative controls Personal Protective

Equipment Worker involvement

Develop and implement

hazard controls

Analyze the hazards

Define the work scope

Provide feedback & continuous

improvement

Perform work within

controls

ISMS

19

Develop/Implement Controls

Develop and implement

hazard controls

Analyze the hazards

Define the work scope

Provide feedback & continuous

improvement

Perform work within

controls

ISMS

Hazards Output

Documents

Proc

edur

es

Regulations

Orders

Less

ons

Lear

ned

HazardTree

20

Replace and Test Elevated Light

As an Example

Work ScopeDefinition Checklist

13

Light

Replace and test elevated light.

SL-46 GS N/A 123-F NSA

Tested satisfactorily.

Replace elevated light..Test elevated light.

OutdoorHeat Stress

Work Environment Checklist

Work ScopeDefinition Checklist

1414

Can any of the hazards be eliminated?

Elevated Work

Determine worker involvement required to

complete the work activity

E&I

23

AHA Hazard ID Navigation

140 Portable Ladder?

Hierarchy of Controls:Consider accessing the worksite without exposing the worker to an elevated height. Consider using

engineering controls such as extended tools, Chain Operators, etc. to provide access. Consider using powered platform or scaffolding if it would provide

safer access to area.

Hazard ID/Hierarchy of Controls

24

Perform visual inspection and test operation of platform dailySelect platform which is inspected and testedAssign trained equipment operator(s) for platformOperator know maximum load capacity and weight distribution restrictions of platform

Mandatory Controls:

Controls Selection

25

Safe Work PermitManagement ControlsManagement ControlsSafe Work Permit

Disposition By

Controls Disposition

Safe Work Permit

Scope of Work

Lead WorkGroup Supervisor

Work Authorization

WorkerSign-On

18

27

Safe Work Permit

Hazards

Controls

Tasks

28

Management Control Report Example

29

Technical Work Document Control Report Example

30

Perform Work

Use of Safe Work Permit Bounds the work scope Provides work authorization Lead work group supervisor

Hazard AnalysisConcurrenceImplementation

Worker acknowledgementTaskHazardsControls

Technical work documents Permits Scope, hazard change or gut feel

Workers call Timeout or Stop-Work

ISMS

Develop and implement

hazard controls

Analyze the hazards

Define the work scope

Provide feedback & continuous

improvement

Perform work within

controls

31

Work history

Worker experience

Lessons learned

Timeout feedback

Post work reviews

Feedback and Improvement

Continuous Improvement Process from Problem Identification Through Post Job Review

32

Employee Involvement

Summary

Identify and

Implement Controls

Define the Scope

PerformWork

Feedbackand

Improvement

Analyze the Hazards

33

Questions

Patricia Allen patricia.allen@srs.gov(803) 952-8359

Jim Tisarannijim.tisaranni@srs.gov(803) 952-9382