Title: An Approach to Chemical Life-Cycle Management Sharing
1An Approach to Chemical Life-Cycle
ManagementSharing Lessons Learned
Anthony M. (Tony) Umek
Vice President, Environment, Safety, Health
Quality Savannah River Nuclear Solutions,
LLC March 10, 2009
Joint EFCOG/DOE Chemical Safety and Lifecycle
Management Workshop
Washington, DC
2EFCOG ESH Working Group
How the EFCOG ESH Working Group can help
- Integrates Chemical Safety and Lifecycle
Management with other key ESH elements (e.g.
Industrial Hygiene) - Leverages DOE contractors experience expertise
- Leverages Chemical Safety Boards experience
expertise - Info link www.EFCOG.org
3SRS Chemical Safety and Lifecycle Management
Lessons Learned a DOE site perspective
- The Savannah River Site has a history of
excellent occupational safety performance - At SRS we are expanding the concept of Zero
Accidents to Zero Incidents, to encompass all
aspects of health, safety, security and the
environment - The potential for chemical exposures is receiving
an elevated level of visibility resulting from
10CFR851 - Managing the chemical life cycle is key to
achieving Zero Incidents
4Implementing ISMS into Chemical Safety Life
Cycle Management
The DOE Savannah River Site approach
- OBJECTIVE Manage chemicals to minimize the
potential for exposures (applying ISMS) - SRS approach (work in progress)
- Establish vision and strategic tactical
approach to achieve objective in place - Define and implement effective leading indicators
in work - Measure progress in work
5SRS Chemical Safety and Lifecycle Management
Program
Vision
- At SRS, CSLM is the effective strategic
tactical application of Integrated Safety
Management principles to safely manage the life
cycle of chemical use (planning, acquisition,
storage, transportation, use, and disposition) in
a manner that protects workers and the general
public, maximizes efficiency, and is protective
of the environment
6SRS Chemical Safety and Lifecycle Management
Strategic Approach
- Savannah River Site chemical safety strategic
approach - Reduce footprint of toxic chemicals
- Recycle/reuse
- Increase competition (expanded vendor base)
- Reduce inventory (Just-in-Time deliveries)
- Measure results
- Historically, chemical tracking relies on lagging
indicators (e.g., consumption, accidents/incidents
) - An approach using leading indicators improves
upstream management of chemicals
7Tactical Approach Chemical Management at SRS
CMC Chemical Mgt. Center Integrated, Site-wide
chemical management
Department Line Organization Chemical
Coordinators
Site Employees
Immediate access to MSDS and other Chemical
Information HazCom Training
Matrix to CMC for Procedures Training
Chemical Safety Lifecycle Management
Committee SPC for each Vice President Line
Organization Subject Matter Experts
8ISMS is Tactically Integrated into Chemical
Lifecycle Management
- Defining the scope of work clearly evaluating
needs changes - Using best practices to augment minimum
requirements (federal, DOE, contract, state) - Identifying all hazards
- Implementing effective hazards prevention/control,
including hazardous materials (e.g. piping,
hoses)
- Minimizing unnecessary transportation and
inventories/storage - Minimizing potential waste streams
- Involving trained, qualified workers and SMEs
- Engaging suppliers and subcontractors fully
- Effective use of lessons learned and
metrics/indicators
9Chemical Tracking Examples of Leading Indicators
- Toxic footprint reduction (92.5 percent
reduction) - 1995 400,000,000 pounds
- 2006 70,000,000 pounds
- Savings from reuse and recycling 17.9 million
- Acquisition and waste cost avoidance (FY03-FY06)
10Chemical Tracking Examples of Leading Indicators
- Just-in-Time contract chemicals
- 1995 Less than 100
- 2008 1,070
- Stores inventory reduction of 90 percent
- Risk reduction associated with storage and
handling - Restricted warehousing minimizes hazardous
inventory - Cross dock to delivery and end user minimizes
redundant handling
11Consequences of Ineffective Chemical Management
- DOE Complex events lower consequence
- Hanford Tank Farm (Type A investigation)
- Tank vapors
- Chemical exposures (e.g., Cr6 Maganese)
- Commercial events higher consequence
- Pesticide Waste Tank explosion in Institute, WV
(2008) 2 fatalities - Packaging Corporation of America (PCA) corrugated
cardboard mill in Tomahawk, Wisconsin (2008) 3
fatalities - Ongoing CSB current investigations
- Silver Eagle refinery in Woods Cross, Utah
January 2009 serious injuries - Chemical hazards are real and require management
attention - Reinforces the need for ISMS, for the life cycle
12Future Challenges
- Maintaining an effective program during changes
in missions and funding challenges - Preventing higher consequence events from
occurring - Integrating EO 13423 with energy policy evolution
- Implementation of potential changes to HAZCOM as
OSHA moves toward the UN program Globally
Harmonized System of Classification and Labeling
of Chemicals (GHS) - Developing a set of Leading Indicators upon which
Management can make effective decisions
13Where Can You Get More Information?
- Learn more about chemical safety
- Review DOE handbook
- Access EFCOG web sites
- Access DOE HSS and lessons learned
- Review Chemical Safety and Hazard Investigation
Board (www.csb.gov) - Benchmark successful companies
- Get involved at your site and company levels
- Walk your spaces for a first hand view
- Determine what your company/industry is doing
relative to chemical safety (baseline) - Establish roles and responsibilities and an
organization and SME - Contact the EFCOG Chemical Safety and Life-Cycle
Management Subgroup Chair Jim Morgan
(james.morgan_at_srs.gov)
14Environmental Safety and Health Working Group
DOE HQ ESH Working Group Sponsors Pat
Worthington, DOE-HQ, HS-10 Frank Russo, DOE-HQ,
NA-1
DOE Subgroup Points of Contact DOE/HSS DOE/Line Ch
emical Safety and Lifecycle management Bill
McArthur, DOE-HQ, HS-11 TBD Electrical
Safety Brad Davey, DOE-HQ, HS-12 Cliff Ashley,
RL Mike Hicks, ID Environmental Steve Woodbury,
DOE-HQ, HS-21 TBD Industrial Hygiene/Industrial
Safety Bill McArthur, DOE-HQ, HS-11 Don Harvey,
DOE-HQ, NA-1 Occupational Medicine Bonnie
Richter, DOE-HQ, HS-13 Don Harvey, DOE-HQ,
NA-1 Radiation Protection Pete OConnell, DOE-HQ,
HS-11 J.E. Parsons, DOE-RL
ESH Working Group Organization Chart Effective
date 1-22-09 Rev.5
15Attachment to Briefing by Tony Umekto the Joint
DOE/EFCOG Chemical Safety Management
WorkshopMarch 10, 2009
Current CSB Investigations
16Chemical Safety Board Current InvestigationsMarch
2009
- Silver Eagle Refinery, Woods Cross vapor fire,
UtahTerminalOn the evening of January 12, 2009,
a petroleum storage tank, known as Tank 105, was
ignited by an as yet undetermined ignition
source, causing a massive flash fire. The storage
tank continued to burn for a number of hours,
until the flames were extinguished by the South
Davis Metro Fire Agency and local refinery fire
brigades early the following morning. - Two refinery operators and two contractors, who
were standing in a shed 230-238 feet from the
tank, were engulfed by the flame front and
suffered serious burns. All four were
hospitalized and are now recovering.
17Chemical Safety Board Current InvestigationsMarch
2009
- Allied Terminal Fertilizer Tank Collapse,
Chesapeake, VANovember 12, 2008 A
two-million-gallon liquid fertilizer storage tank
collapsed at the Allied Terminal distribution
facility in Chesapeake, VA. The incident
critically injured two contract workers, who were
hospitalized. Two members of the public who tried
to aid the injured men required treatment likely
related to exposure to ammonia vapor from the
released fertilizer. The fertilizer over topped a
containment dike and flooded sections of a nearby
residential neighborhood. At least 200,000
gallons of spilled fertilizer could not be
accounted for, and some reached the nearby
Elizabeth River, which flows into the Chesapeake
Bay. - Bayer CropScience Pesticide Waste Tank Explosion,
Institute, WVAugust 28, 2008 Two workers were
fatally injured when a waste tank containing the
pesticide methomyl violently exploded, damaging a
process unit at the Bayer CropScience chemical
plant in Institute, West Virginia. - Packaging Corporation Storage Tank Explosion,
Tomahawk, WIJuly 29, 2008 Three workers died
and a fourth was injured when an explosion
occurred inside an 80-foot-tall storage tank at
the Packaging Corporation of America (PCA)
corrugated cardboard mill in Tomahawk, Wisconsin.
The workers were on a catwalk above the tank and
performing hot work (welding) at the time of the
explosion. The storage tank held a mixture of
recycled paper pulp and water. The CSB is
performing microbiological and chemical testing
to determine what caused flammable gas to be
present inside the tank.
18Chemical Safety Board Current InvestigationsMarch
2009
- Goodyear Heat Exchanger Rupture, Houston, TXJune
11, 2008 One worker was killed and
approximately seven others were injured, during a
maintenance operation on a heat exchanger.
Ammonia overpressured inside the exchanger,
causing it to rupture. - Imperial Sugar Company Explosion and Fire, Port
Wentworth, GAFebruary 7, 2008 A huge explosion
and fire occurred at the Imperial Sugar refinery
northwest of Savannah, Georgia, causing 14 deaths
and injuring 38 others, including 14 with serious
and life-threatening burns. The explosion was
fueled by massive accumulations of combustible
sugar dust throughout the packaging building. - BP America Refinery Accident, Texas City,
TXJanuary 14, 2008 A worker was fatally
injured when the top of a large steel filter
housing suddenly blew off in the refinery's
ultracracker unit. This unit is across a roadway
from the ISOM unit, where a 2005 accident killed
15 workers and injured 180 others.
19Chemical Safety Board Current InvestigationsMarch
2009
- T2 Laboratories Inc. Explosion and Fire,
Jacksonville, FLDecember 19, 2007 Four people
were killed and 13 others were transported to the
hospital when an explosion occured at T2
Laboratories Inc. during the production of a
gasoline additive called methylcyclopentadienyl
manganese tricarbonyl. - Xcel Energy Company Fire, Georgetown, COOctober
2, 2007 Five people were killed and three
others injured when a fire erupted 1,000 feet
underground in a tunnel at Xcel Energy Company's
hydroelectric power plant in Georgetown,
Colorado, located approximately 45 miles west of
Denver. The fatally injured workers were trapped
deep underground during an operation to coat the
inside of the tunnel with epoxy using highly
flammable solvents. The tunnel is several
thousand feet long and connects two reservoirs
with electricity-generating turbines.