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Environment, Safety and Health Steve Hoey, ESH Manager NSLS-II Project Advisory Committee Meeting March Environment, Safety and Health Steve Hoey, ESH Manager NSLS-II Project Advisory Committee Meeting March 29, 2012 1 BROOKHAVEN SCIENCE

Outline • • Baseline • Scope, Staffing Progress since February 2011 Recommendation Status Accelerator Outline • • Baseline • Scope, Staffing Progress since February 2011 Recommendation Status Accelerator Readiness Reviews Project Safety Record Risks Issues Summary 2 BROOKHAVEN SCIENCE

ESH Scope • ESH Support for: • Design & Procurement – Conventional Facilities – ESH Scope • ESH Support for: • Design & Procurement – Conventional Facilities – Accelerator Systems – Experimental Systems • Construction – Ring Building – LOB’s – BORE’s P-1 Storage Ring • Pre Ops & Operations – Experimental Facilities – Experimental Reviews – Equipment installation RF Building transmitters • Authorization Basis & Commissioning – Safety Assessment Documents – Accelerator Safety Envelopes - Instrument, Readiness Reviews, ARR’s 3 Support Building Utilities BROOKHAVEN SCIENCE

ESH Program Responsibilities • • • • 4 Safety system configuration control Self-assessment Risk ESH Program Responsibilities • • • • 4 Safety system configuration control Self-assessment Risk assessment Interlock testing • • • Experiment safety review Work planning support Emergency planning Environmental management Hazardous waste management Industrial hygiene Industrial safety Radiation safety ESH Facility & Equipment Design (radiation and laser) Tier I inspections Compliance audits Readiness Reviews Construction Safety Conduct of Operations Authorization Basis BROOKHAVEN SCIENCE

Environment, Safety and Health Organization Environment, Safety and Health Manager – S. Hoey Deputy Environment, Safety and Health Organization Environment, Safety and Health Manager – S. Hoey Deputy – A. Ackerman ESH Operations** Manager Laboratory Support*** A. Ackerman ESH Design, Construction & Commissioning Radiation Control Manager ESH Coordinator S. Hoey L. Stiegler COMMITTEES ALARA Committee Beam line Review Committee EMS/OHSAS Committee ES&H Improvement Committee Interlock Working Group Review Committee PS Directorate Safety Committee Instrument Readiness Review Committee Radiation Physics G. Wilson P. K. Job F. Flannigan S. Townsend S. Walker F. Zafonte ESH Engineer Health Physics B. Heneveld W. R. Casey Industrial Hygiene C. Weilandics Safety Officer Authorization Basis B. Chmiel N. Gmur Safety Engineer Construction* T. Mc. Donald T. Anschutz Environmental Compliance D. Bauer Readiness Review R. Travis R. Chilakala Readiness Evaluation B. Heneveld *Decrease one FTE coincides with construction downsizing ** Decrease two FTE retirement and re-org QA function *** Staffing increase to support commissioning 5 BROOKHAVEN SCIENCE

Progress - ESH Operations • Significant increase lab, assembly, and office space 725 – Progress - ESH Operations • Significant increase lab, assembly, and office space 725 – NSLS – 162, 156 ft (Exp floor = 123, 644 ft 2 2) 726 – NSLS - Mechanical Tech Support 3519 ft 2 727 – NSLS – Mech/Magnet Measurement 3519 ft 2 NSLS 729 - NSLS Source Development Lab – 8018 ft 2 902/905 – Magnet test and assembly, vacuum – 22, 690 ft 2 703 – Experimental Facilities Division, 9 new labs – 7, 360 ft 2 NSLS-II 945 – Vacuum lab – 4, 068 ft 2 832 – RF development, magnetic measurement – 7, 895 ft 2 820 – Front Ends Diagnostics – 5, 700 ft 2 740, 746 & 747 – Ring Building - 400, 000 ft 2 • Risk well understood & Controlled – lab work, mechanical Assembly, chemicals, haz waste etc. • Work processes covered by Project Safety Review and/or Enhanced Work Permits • Experienced ESH Operations Staff being utilized for installation and commissioning • Lessons learned from these operations being applied to ring building installations. 6 BROOKHAVEN SCIENCE

Progress - Area Monitoring • • • 7 Required area monitors (2) are installed Progress - Area Monitoring • • • 7 Required area monitors (2) are installed at Linac and are ready for commissioning Area monitors for Booster and storage ring are ordered and are arriving (16 on hand at this point) Remainder of 55 are scheduled for delivery by Sept. 1, 2012 BROOKHAVEN SCIENCE

Progress - Top-off Safety • Work of task force establishing engineered safeguards which will Progress - Top-off Safety • Work of task force establishing engineered safeguards which will prevent the top-off accident continues • Preliminary safety review by external independent committee conducted 3/7 -8, 2012. Committee endorsed overall strategy and commented on the quality of the work. A number of suggestions were made which the task force will follow-up. • Final safety review planned for Fall, 2012 8 BROOKHAVEN SCIENCE

Progress - Top-off Radiological Incident Analysis • • • Radiological analysis of the topoff Progress - Top-off Radiological Incident Analysis • • • Radiological analysis of the topoff injection accidents have been completed • Full injected beam loss at front end inside SR results in <500 mrem/h (injection rate 15 n. C/s)on experimental floor; at least one interlocked PPS required to prevent this accident scenario. • Full injected beam conveyed down to FOE results in dose rate at experimental floor ~300 rem/hr (15 n. C/s); redundant interlocked PPS required to prevent this injection accident scenario. Top-off interlock strategies have been recommended to the top-off task force The results are published as a scientific paper (Nucl. Instr. and Meth. , A 648 (2011) 15 -21) 9 BROOKHAVEN SCIENCE

Progress - Construction Safety • • Contractor(s) performing better than industry average • Torcon Progress - Construction Safety • • Contractor(s) performing better than industry average • Torcon – improved performance • EWH – perfect record thus far, exceeding all goals Ring Building Construction complete only PL’s remain Many programmatic enhancements, best practices; & Lessons Learned (LL) • Increased use and detail of PHA’s (LL) • Increased communications – daily ESH planning mtgs; weekly ESH Mgmt mtgs; monthly ESH group mtgs, schedule and coordination mtgs with ESH. (LL) • On site medical provider – NYS licensed EMT’s • Drug screening, pre-employment and post-incident/cause • Construction safety assessment program – contractor and NSLS-II (LL) Modified Safety Incentive – workers receive 90%, 2 mos period (LL) – Torcon – $ 490, 608. 20 (available $ 908, 470, 52) 53. 97% (Initial program TC lost 100% due to 1 DART) – EWH - $159, 372. 92 (available $159. 372. 92) 98. 75% 10 BROOKHAVEN SCIENCE

Construction Manpower • Peak 243 11 Manpower was expected to exceed 300, however peaked Construction Manpower • Peak 243 11 Manpower was expected to exceed 300, however peaked at 243 in late FY 10: • Torcon finished ring building in Feb 2012 will go down to <50 for punch list • EWH is ramping up however overall manpower will decrease from peak in 8/10 • Decrease in manpower equates to less risk exposure BROOKHAVEN SCIENCE

Progress-Transition from Construction • • • Laboratory Beneficial Occupancy Readiness Review (BORE) process is Progress-Transition from Construction • • • Laboratory Beneficial Occupancy Readiness Review (BORE) process is being used Officially turns over sections of facility to allow machine installation Specific NSLS-II BORE Plan in place that; • Defines scope • Establishes schedule • Identifies resources Project Lessons Learned passed to Assigned Lab PSD BORE Coordinator Ring building BORE’s start Feb 2011 and finished February 2012 total of 8 phases to match construction phases LOB BORE’s to start June/July 2012 and finish in Dec 2012 12 BROOKHAVEN SCIENCE

Area Ring Building BORE Status Actual Occupancy Days to Baseline Occupy # Pre. Starts Area Ring Building BORE Status Actual Occupancy Days to Baseline Occupy # Pre. Starts P-1 2/1/11 3/14/11 42 44 RF/Comp 3/23/11 5/26/11 6/13/11 19 22 P-2 6/2/11 7/8/11 7/21/11 13 10 Injection 5/18/11 8/10/11 8/12/11 2 8 P-3 9/27/11 10/14/11 10/20/11 6 8 Cooling tower 3/23/11 10/10/11 10/20/11 10 11 P-4 11/28/11 12/15/11 12/20/11 5 4 P-5, Lobby, UT & Generators 2/19/12 2/16/12 13 5 2/29/12 13 BROOKHAVEN SCIENCE

Occupied Areas/Construction Areas 14 BROOKHAVEN SCIENCE Occupied Areas/Construction Areas 14 BROOKHAVEN SCIENCE

Progress - Authorization Basis • • Phased Commissioning strategy agreed to; Safety Assessment Documents Progress - Authorization Basis • • Phased Commissioning strategy agreed to; Safety Assessment Documents (SAD) and Accelerator Safety Envelopes (ASE) are modular: • Preliminary SAD (for CD-3) – approved by DOE 2008 – Linac Commissioning SAD/ASE - complete – Booster Commissioning SAD/ASE – complete pending approval – Storage Ring Commissioning SAD/ASE – in process - Includes project beam lines • – Accelerator Routine Operations SAD/ASE Initial planning ongoing to conduct injection from Booster into P-2 prior to SR being complete will require shielding and fault study analysis and may require mods to Booster SAD/ASE and/or a USI and ARR phasing strategy 15 BROOKHAVEN SCIENCE

Recommendations from 2/11 PAC “Establish the charter for the initial task of the ARR Recommendations from 2/11 PAC “Establish the charter for the initial task of the ARR Team to cover not just the Linac, but also the complete facility, to the extent that available information allows” Complete • Team selected for all ARR’s through routine operations • Team includes internal and external ESH and Accelerator operations experts 16 BROOKHAVEN SCIENCE

Progress – ARR Process • ARR Phasing approach adopted* • • Linac - Complete Progress – ARR Process • ARR Phasing approach adopted* • • Linac - Complete Booster SR Final Ops • • Web page established to give team early access to documentation. • Coordination meeting with team in Sept at ASO mtg • Follow up conference calls preceded ARR • ARR preceded by an internal Instrument Readiness Review established to verify readiness; IRR will also be used for beam line commissioning • 17 ARR Coordinator assigned (LL) from BORE’s *May need to additional phase to support Pentant 2 injection BROOKHAVEN SCIENCE

Progress - Linac Commissioning • • • Linac Authorization Basis Documentation (SAD & ASE) Progress - Linac Commissioning • • • Linac Authorization Basis Documentation (SAD & ASE) complete and approved by BHSO Commissioning Plan - complete Injection Building occupancy 8/12/11 Equipment Installation - complete Necessary SOP’s - complete Training/qualification - complete Instrument Readiness Review compete ARR – complete – no new prestarts identified All ARR pre-starts- complete Dec 7, 2011 Linac Commissioning start week of 3/26 Sequence for Booster and SR underway 18 Jan 11, 2012 BROOKHAVEN SCIENCE

Project Injury Summary (since 2/11) • • Operations: • Cut chin Construction: • Fractured Project Injury Summary (since 2/11) • • Operations: • Cut chin Construction: • Fractured foot • Dislocated knee (Job Shopper) 19 BROOKHAVEN SCIENCE

NSLS-II Construction Injury • On Sep 22, 2011, a painter with Keller Painting [a NSLS-II Construction Injury • On Sep 22, 2011, a painter with Keller Painting [a subcontractor to Torcon] was injured • The painter and his partner were moving a box containing a cover to an electrical cabinet (approximately 100 pounds) so that they could complete painting steel columns • They had successfully moved one box and were in the process of moving a second box when the box slipped out of the hands of the painter and landed on the instep of his foot • He was taken to the on-site EMT and then to a local hospital for further evaluation • An X-Ray revealed that one of the metatarsal bones in his foot was broken • The painter was wearing appropriate ANSI approved. The box slipped from the Causes: safety shoes painters hand, apparently as a result of paint residue on his cotton gloves Corrective Actions: All trades should ensure that when manually moving pieces of material, their gloves are clean and adequate for the task Two boxes containing electrical panel covers 20 BROOKHAVEN SCIENCE

Injury NSLS-II Job Shopper Injury • On January 13, 2012, a job shopper (sub-contractor Injury NSLS-II Job Shopper Injury • On January 13, 2012, a job shopper (sub-contractor to the project) working on technical equipment installation was injured. • The job shopper was descending a flight of “ratchet wall” stairs in Pentant 3 at the end of his work shift (approximately 3: 00 pm). • • • When he was about at the 8 th or 9 th step from the bottom, he lost his footing and started to fall. • Job Shopper was wearing area based PPE (hard hat, safety glasses and safety shoes), the safety shoes were in good condition. • Analysis/Causes: Stairs were in medication and transported to His co-workers transported him to the OMC, where he was given paingood condition, dry well lit and constructed of slip resistant materials, handrails are on both sides. mather hospital. Stairs are fully compliant with OSHA stds. The job shopper was not Subsequent time lost classifies this as a DART and he will require corrective surgery. physical condition. carrying any materials/equipment and he was in good He was leaving for the day on a Friday for the weekend. A likely contributor is that the worker may have been distracted and or descending the stairs in a hurry in order to leave for the day. • He had been holding the handrail, and tried to catch himself before reaching the bottom. When he landed at the bottom of the stairway his left knee locked up and hyperextended, causing his knee to dislocate. Corrective Actions: Workers were reminded of keeping their head in the game at all times and paying attention to their surroundings, even while doing routine tasks (i. e. descending stairs) 21 Hoey/ Stiegler; 1/13/12 BROOKHAVEN SCIENCE

Project Safety Record (March 12) Hours Worked Recordable Cases Recordable Rate DART Cases* Dart Project Safety Record (March 12) Hours Worked Recordable Cases Recordable Rate DART Cases* Dart Rate NSLS-II Staff pre-FY 09 341, 100 0 0 NSLS-II Staff FY 09 320, 396 1 0. 62 0 0 NSLS-II Staff FY 10 432, 272 0 0 NSLS-II Staff FY 11 508, 320 0 0 NSLS-II Staff FY 12 201, 314 1 . 99 0 0 1, 803, 403 2 0. 22 (Target: 0. 65) 0 0 (Target: 0. 25) Contractors FY 09 60, 208 2 6. 64 1 3. 32 Contractors FY 10 331, 424 3 1. 81 1 0. 60 Contractors FY 11 * 460, 460 2 . 87 Contractors FY 12 * 198, 704 1 1. 0 0 0. 0 Contractors Cumulative 1, 050, 795 8 1. 52 (Target: 1. 8 / 4. 7) 4 . 76(Target: 0. 6 / 2. 5) Total Project Cumulative 2, 854, 198 10 0. 70 (Target: 0. 65) 4 0. 28 (Target: 0. 25) NSLS-II Staff Cumulative *Includes Shopppers Estimated Future Hrs Early Finish 6/14 CD-4 6/15 Staff 3, 140, 760 3, 704, 760 Contractor 1, 275, 795 Total 4, 416, 555 4, 977, 555 22 BROOKHAVEN SCIENCE

Risk Analysis & Management Category Description Risk Rankin g Management ESH Minor or major Risk Analysis & Management Category Description Risk Rankin g Management ESH Minor or major injury or Construction mishap, conventional construction, R&D Ops through technical equipment installation, Prime contractor coordination Medium ESH Construction Plan (HASP); Contractor Prequalification; Safety Incentive; Dedicated CSE’s, contractor qualification; work planning & control; communications ESH Low Formal Design Reviews; (Reduce SME input; Extensive use of d from Lessons Learned Medium) Design Major change driven by ESH design Oversight or changing regulation (ring bldg and tech equipment) ESH Site Prepexcavation Legacy contamination identified during excavation, protected species impacting construction Retired Authorizatio Possibility of DOE Order 23 Retired Extensive site evaluation; Monitoring of protected species BROOKHAVEN SCIENCE Active participation in ASO

Issues • Coordination of construction contractors (Torcon & EWH) with installation activities • End Issues • Coordination of construction contractors (Torcon & EWH) with installation activities • End of construction mind set risks • Increase in number of beam lines (and BL procurements and reviews) • Commissioning/install activities (documentation, ARR’s, job shoppers, etc. ) • Need to analyze shielding & fault conditions and get buy in on booster injection into pentant 2, may require AB 24 BROOKHAVEN SCIENCE

Summary • ESH Program is well defined and documented • ESH Staff is well Summary • ESH Program is well defined and documented • ESH Staff is well qualified and in place • Performance metrics are trending positively • Early deficiencies in construction safety program implementation have been addressed and processes are in place to move forward safely with minimum risk • On track with authorization basis process including BORE, SAD’s and ASE’s for Booster & SR • Program is continually improving & incorporating Lessons Learned 25 BROOKHAVEN SCIENCE