february 17-18, 2010 r&d erl edward t. lessard r&d erl meeting accelerator safety order...

February 17-18, 2010

R&D ERL

Edward T. Lessard

R&D ERLMeeting Accelerator Safety Order (ASO)

Requirements

E. Lessard, Associate Chair for ESSHQ

Collider-Accelerator Department



R&D ERL

Edward T. Lessard

Meeting ASO Requirements

2

R&D Energy Recovery Linac Status

Project Organization Chart Complete

Prototype ERL Safety and Environmental Review Schedule Complete

Hazard Screening Report Complete

NEPA Review Complete

Prototype ERL Safety Assessment Document (SAD) Complete

Prototype ERL USI Complete

Prototype ERL Accelerator Safety Envelope (ASE) Complete

Proposed Schedule for Commissioning Complete

Commissioning Plan (12-09 Draft) Draft

Conduct of Operations Document (Draft) Draft

Accelerator Readiness Review (ARR) Report Open

http://www.c-ad.bnl.gov/ESSHQ/SND/ERL/ERL%20Org%20Chart.pdf

http://www.c-ad.bnl.gov/ESSHQ/SND/ERL/ERL%20Safety%20Review%20Schedule.pdf

http://www.c-ad.bnl.gov/ESSHQ/SND/ERL/Hazard%20Screening%20Report%20for%20ERL%20Prototype.pdf

http://www.c-ad.bnl.gov/ESSHQ/SND/EMS/ecoolerNEPA.pdf

http://www.c-ad.bnl.gov/ESSHQ/SND/ERL/ERL%20SAD%20June%202008.pdf

http://www.c-ad.bnl.gov/ESSHQ/SND/ERL/USI%20Changes%20to%20ERL%20SAD.pdf

http://www.c-ad.bnl.gov/ESSHQ/SND/ASE/ERL%20ASE%20December%202008%20%20Final.pdf

http://www.c-ad.bnl.gov/ESSHQ/SND/ERL/Proposed%20ERL%20Commissioning%20Schedule%20for%20Module%201%20and%20Module%202.pdf

http://www.c-ad.bnl.gov/ESSHQ/SND/ERL/Proposed%20ERL%20Commissioning%20Plan%20Draft%203.pdf

http://www.c-ad.bnl.gov/ESSHQ/SND/ERL/ERR%20C%20of%20O%20Draft.pdf


R&D ERL

Edward T. Lessard

O 420.2B CRD 1.a. (Complete)

Identify hazards and associated onsite and offsite impacts to workers, the public, and the environment from the facility for both normal operations and credible accidents.

• R&D ERL Hazard Screening Report, NEPA Review, Safety Assessment Document (SAD)– Ionizing Radiation– Oxygen Deficiency– Electrical Hazards– Fire Hazards– Industrial Hazards

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Edward T. Lessard

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Ionizing Radiation

ERL Hazards• Unshielded dose rates

– Bremsstrahlung dose rates of 4x107 rad/h in the forward direction at 1 meter and 5x105 rad/h in the transverse direction

– neutron dose equivalent rates range between 6x103 and 1x105 rem/h at 1meter

ERL Controls• Shielded enclosure• Interlocked gates


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Edward T. Lessard

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Ionizing Radiation

ERL Hazards ERL Controls• Interlocking area-

radiation monitors


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Edward T. Lessard

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Oxygen Deficiency

ERL Hazards ERL Controls• ODH alarms• ODH exhaust fans


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Edward T. Lessard

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Laser Radiation, RF and X-rays

ERL Hazard• Class IV laser system• 1 MW klystron source

ERL Controls• Access to laser area controlled

with door interlocks• Protective housing for laser and

laser shutter interlock• Laser beam transported in pipe• Coordinated key system

preventing access to klystron enclosure

• RF transported in pipe• Steel shield housing around the

klystron tube and tube base to attenuate x-rays


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Edward T. Lessard

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Electric Shock/Arc Flash

ERL Hazards• Energized conductors • Operation of

breakers and disconnects

ERL Controls• Exposed conductors and terminals

are covered or barriered for protection of personnel

• Training for workers• Use of work planning, LOTO and

Permits• Use of proper PPE and compliance

with NFPA 70E• Magnets de-energized when

routine work is done• Electrical equipment is NRTL

registered or equivalent


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Edward T. Lessard

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Fire

ERL Hazards• The maximum credible fire incident

was determined to be a fire in one magnet and damage to the two adjacent magnets

• While the klystron’s 100 kV transformers have 800 gallons of oil, it was felt that smoke detectors, interlocks to turn off power to the 100 kV transformers, fire sprinklers, low-flammability oil in the transformers, secondary containment and onsite fire responders would result in a less credible fire incident

ERL Controls• Combustible loading was

minimized in design• Periodic safety inspections• Fire detection and suppression

system• Design reviewed by BNL Fire

Protection Engineer• Design meets NFPA

requirements• On-site fire responders• Interlocks to turn off power


R&D ERL

Edward T. Lessard

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O 420.2B CRD 1.d. (Complete)

Prepare a single document addressing the hazards of the entire accelerator or prepare separate SADs for discrete modules of the facility such as injectors, targets, experiments, experimental halls, and other type modules.

• R&D ERL SAD


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Edward T. Lessard

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A documented Accelerator Safety Envelope (ASE) must define the set of physical and administrative bounding conditions for safe operations, based on the safety analysis documented in the SAD.

• ASE Approved by DOE February 3, 2009

• Bounding conditions– BNL Safety Envelope Limits– Corresponding Safety Envelope

Parameters Prototype ERL Beam Limits Control of Beam Loss Access Controls Fire Protection

– Engineered Safety Systems Requiring Calibration, Testing, Maintenance, and Inspection

– Operations Envelope / Administrative Controls


R&D ERL

Edward T. Lessard

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O 420.2B CRD 3. (Complete)

Activities that involve unreviewed safety issues (USI) must not be performed if significant safety consequences could result from either an accident or a malfunction of equipment that is important to safety and for which a safety analysis has not been performed.

Activities involving an identified USI must not commence before DOE has provided written approval.

• C-AD practices used to identify USIs– Design review– Experimental safety review– Accelerator systems safety

review• Identified USI Process

– 1.10.1 Procedure for Documenting Unreviewed Safety Issues

– 1.10.1.a CA USI Form


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Edward T. Lessard

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O 420.2B CRD 4. (ARR Open)

Accelerator Readiness Reviews (ARRs) must be performed before approval for commissioning and routine operation and as directed by the cognizant DOE field manager.

• ARR process defined in SBMS Accelerator Safety Subject Area

• Draft Commissioning Plan for ARR of R&D ERL– Module 1: G5 Test

Module 3-15-11– Module 2: Full System

Testing 10-24-11


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Edward T. Lessard

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O 420.2B CRD 5.a. (Partially Complete)

Training and qualification requirements must be established for each individual at an accelerator facility whose activities could affect safety and health conditions or whose safety and health could be affected by facility activities.

Training and qualification must be documented and kept current.

• C-AD OPM 1.12 Training and Qualification Plan

• Applies to all C-AD employees, visitors and users

• Responsibilities, qualification requirements, training requirements and records system defined

• C-AD Training Manager coordinates program


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Edward T. Lessard

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O 420.2B CRD 6.c. (Partially Complete)

At a minimum, the contractor must prepare procedures for—

(1) operation startup,

(2) normal operation,

(3) emergency conditions,

(4) conduct of maintenance,

(5) approval and conduct of experiments, (6) review and approval of facility modifications, (7) management of safety-related changes, and

(8) control of facility access.

• New or modified C-AD OPMs under development:– ERL Operational Safety Limits (2) – Configuration Management (5, 6, 7) – Lock-Out Tag-Out (2) – Local Emergency Procedure (3) – Emergency Call-Down Lists (3) – Cryogenic Systems Operation (2) – Injecting, Accelerating, Circulating

and Dumping Electron Beam (1, 2) – Laser Operations (1, 2) – Access Control System Operation

and Testing Procedures (2) – Shutdown Procedure (2, 3)

• C-AD OPM 2.28 Work Planning is in use (4)


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Edward T. Lessard

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Summary

Authorization Status1. ERL Commissioning Plan needs to

be finalized

2. Accelerator Readiness Review needs to be conducted

3. ERL needs DOE authorization to commission g-5 and ring

4. Conduct of Operations Agreement needs to be finalized

5. Procedures and training need to be completed

6. ERL needs DOE authorization to routinely operate

• Questions?


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Edward T. Lessard

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Informational Slides

• Remaining contractor requirements identified in DOE Accelerator Safety Order, 420.2B

• Additional slides showing all additional completed requirements


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Edward T. Lessard

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O 420.2B CRD 1.b. (Complete)

Provide sufficient descriptive information and analytical results pertaining to specific hazards and risks identified during the safety analysis process to provide an understanding of risks presented by the proposed operations.

• SAD 4.10.3. Risk Assessment to Workers, the Public and the Environment– SAD 4.10.3.1.Radiation Risks– SAD 4.10.3.2.Environmental Risks

from Radiation– SAD 4.10.3.3.Fire Risks– SAD 4.10.3.4.Electrical Risks

• SAD Appendix 6, Qualitative Risk Assessments


R&D ERL

Edward T. Lessard

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O 420.2B CRD 1.c. (Complete)

Provide appropriate documentation and detailed descriptions of engineered controls (e.g., interlocks and physical barriers) and administrative measures (e.g., training) taken to eliminate, control, or mitigate risks of operation.

• 3.2. ERL Characteristics Related To Safety

• SAD 3.5. Design Features That Exclude or Minimize Exposure to Hazards to As Low As Reasonably Achievable (ALARA) During Operation, Maintenance and Facility Modification

• SAD 4.8. Selection of Control Measures that Reduce Risks to Acceptable Levels

• SAD Table 4.9.a. List of Credited Controls


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Edward T. Lessard

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O 420.2B CRD 1.e. (Complete)

Include or reference a description of facility function, location, and management organization in addition to details of major facility components and their operation.

• SAD 3.Site, Facility and Operations Description– 3.1. Environment Within Which

the ERL is Constructed– 3.3. Management Methods

Used In Operating the ERL– 3.4. Design Criteria and As-

Built Characteristics, Supporting Systems and Components with Safety-Related Functions

– 3.6. BNL, C-AD and R&D ERL Organizational Structure


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Edward T. Lessard

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Any activity violating the ASE must be terminated immediately and the activity must not be restarted before the DOE has been notified.

• C-AD OPM 2.5 Series of ASE procedures for operators– Separate procedure for

each C-AD Accelerator Facility

• Defines operator responsibilities and notification steps for unpermitted operating conditions– ASE Authorized Alternatives

are listed in ASE procedure• C-AD OPM 1.1 and BNL SBMS

Accelerator Safety Subject Area define restart authorizations and includes DOE approval


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Edward T. Lessard

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O 420.2B CRD 1.f. (Complete)

Maintain the SAD current and consistent with the administrative control measures and physical configuration of the facility and major safety equipment.

• C-AD OPM 13.4.2.d List of C-AD Records – SADs are defined as

Controlled Documents• BNL SBMS Document

Control Subject Area– 5 year review period

• Identified USI process is used to maintain the SAD current during the interim


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Edward T. Lessard

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Only appropriately trained and qualified personnel, or trainees under the direct supervision of trained and qualified personnel, are permitted to perform tasks that may affect safety and health.

• Draft Conduct of Operations Agreement for R&D ERL includes C-AD OPM C of O Procedures:– 2.2 Operating Practices– 2.3 Activities in Control

Rooms – 2.4 Operator Trainees– 2.12 Communications

Practices– 2.28 Work Planning and

Control for Operations


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Edward T. Lessard

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All personnel assigned to or using the accelerator facility (including emergency response personnel) must be trained in the safety and health practices and emergency plans consistent with their involvement and the hazards present.

• C-AD OPM 14.31.2 Occupational Safety and Health Training Summary for C-AD Operations and Maintenance Activities

• C-AD Access Training• Job Training Assessments


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Edward T. Lessard

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Written procedures for conducting activities safely must be maintained; must be clear, current, and consistent with management systems and the configuration of the facility and equipment; and must be approved by the facility contractor’s senior line management who are actively involved in the day-to-day operation of the facility.

• C-AD OPM 1.4.3 Procedure for Implementing New or Revised Permanent Procedures, or Canceling Permanent Procedures

• C-AD procedures require Department Chair approval


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Edward T. Lessard

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Procedures must include descriptions of the tasks to be performed; safety and health precautions and controls; and requirements for initial conditions to be verified, operating conditions to be maintained, and data to be recorded, as applicable.

• 1.4.1 Format of C-A Policies, Programs and Operating Procedures – Format meets O

420.2B CRD 6.b. requirements


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Edward T. Lessard

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An internal safety review system must be established and maintained to periodically assess and document the condition of the facility, equipment, and engineered safety systems.

• C-AD safety review programs include:– Inspections of facilities– Outdoor storage area

inspections– Inspection of satellite-waste

stations– Tank inspections– 90-day waste area

inspections– Testing of engineered safety

systems


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Appropriateness and implementation of procedures, administrative controls, and personnel training and qualifications must be periodically reviewed and documented by the internal safety review system.

• C-AD safety review programs include:– Critiques of off-normal

events– QA assessment of

procedure implementation– QA assessment of training

and qualifications of staff– Manager work observations– Supervisor work

observations– Documenting and tracking

corrective actions


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Edward T. Lessard

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O 420.2B CRD 8. (Complete)

The contractor must approve and implement a written statement of the shielding policy for ionizing and nonionizing radiation.

• Shielding Policy for the R&D ERL is the approved C-AD Shielding Policy