understanding and addressing environment, health,...

EHS Division

Understanding and Addressing Environment,

Health, and Safety Risks of PV Manufacturing

WREF

May 15, 2012

Organized by SEMI

Contact: Sanjay Baliga

[email protected]

For the PV industry to live up to its commitment

of responsibly producing clean solar energy,

environment, health and safety (EHS) risks need

to be better understood and managed. As a step

toward this reality, SEMI / PV Group is hosting

this Forum to identify EHS risks in PV

manufacturing and share approaches to

address these risks

Forum Overview

Speakers will share best practices on protecting

the health and safety of workers, conserving

energy use, protecting the earth's climate,

reducing and properly disposing of wastes,

reducing use of hazardous substances, and

promoting product safety.

Forum Overview

World Renewable Energy Forum

Sunny Rai, Intertek 1

Hazard Associated with PV

Manufacturing Equipment

Saranpal S. Rai “Sunny” Regional Vice President

Renewable Energy

E-mail: [email protected]

Tel: 650 463 2950

Fax: 650 463 2910

1

mailto:[email protected]

Sunny Rai, Intertek

Agenda

• Hazards associated with PV manufacturing – Manufacturing Equipment

– Facilities

• Understand Applicable Standards – Basic Safety Philosophy

– Order of precedence for controls

– Methods of Hazard assessment

– Risk ranking (SEMI S10)

– SEMI S2 Safety Guidelines


Hazards Associated with PV

Manufacturing

Hazard Assessment Methodology For PV


Sunny Rai, Intertek

Solar Panel Manufacturing Equipment

• Glass Carrying Equipment (conveyers, robots, cutters and lifters)

• Washing/drying equipment

• Glass sealing/heating equipment

• Chemical process equipment (CDV, PVD)

• Laser scribing equipment

• In-line testing equipment

• Wire and connector placing equipment

• Heating & encapsulating equipment

Sunny Rai, Intertek

Major Hazards

Mechanical hazards – Pinch hazards

– Crush hazards

– Entanglement hazards

– Cut hazards

Electrical hazards – Equipment (hazardous voltages, energies)

– Panels (final product or broken product)

Sunny Rai, Intertek

Major Hazards

Industrial Hygiene/ Chemical Hazards

– Exposure to the hazardous gases, vapors

– Explosion hazard

– IR/UV

– Magnetic field

– Laser exposure hazard

– Hot surface/area hazards

– Confine space hazard

Sunny Rai, Intertek

Major Hazards

Additional Hazards

– Exposure to the broken glass

– Trip Hazard

– Slip Hazard

– Ergonomics hazards (heavy lifting, awkward

positions in manipulation of glass/panels)

– Noise


Applicable Industry and Regulatory

Standards



Sunny Rai, Intertek

Safety Standards and Guidelines

SEMI EHS Guidelines

SEMI S2

Guidelines would cover most of the hazards • Equipment related

• Technology related

SEMI S26

Could be used to evaluate Integration Hazards

European Directives and Standards • Low Voltage Directive

• Machinery Directive

• EMC Directive & others

ANSI, NFPA, JIS, CNS Standards

Sunny Rai, Intertek

SEMI EHS Guidelines

Equipment related

• S2 – EHS for SME

• S26 – EHS for FPD

• S1 – Safety labels

• S3 – Process liquid heating systems

• S6 – Ventilation

• S12 – Decontamination

• S13 – Manuals

• S14 – Fire risk

• S16 – Disposal

• S17 – Unmanned Transport Vehicles

• S20 – Lockout Tagout

• S22 – Electrical Design

• S23 – Measurement & Conservation of Energy & Materials

Training

• S19 – Service personnel training

• S21 – Worker Protection

• S24 – Multi-Employer Work Areas

Other

• S4 – Chemical cylinder separation

• S5 – Flow limiting devices

• S7 – Evaluation of equipment

• S10 – Risk Assessment

• S18 – Silane family of gases

• S25 – Hydrogen Peroxide systems

Withdrawn

• S9 – Electrical design tests

• S11 – Mini-environments

• S15 – Gas Detection Systems

Sunny Rai, Intertek

SEMI EHS Guidelines

• Applies to equipment used to manufacture, measure,

assemble, and test semiconductor products.

• Order of precedence for resolving identified hazards:

Design to Eliminate Hazards

Incorporate Safety Devices

Provide Warning Devices

Provide Hazard Alert Labels

Develop Administrative Procedures and Training


Hazard Analysis

&

Risk Assessment



Sunny Rai, Intertek

Examples of Frequently-Used Hazard

Analysis Methods

Hazard Analysis Methods

• Hazard and Operability Studies (HazOp)

• Failure Modes, Effects and Criticality Analysis

(FMECA)

• “What If?” Analysis

Sunny Rai, Intertek

Risk Assessment

SEMI S10

• The document provides a method for

assessing the risk associated with any hazard

and for ranking different hazards according to

the risk they present.

• It is the method used to evaluate risk

presented by identified hazard and provide

basis/means to prioritizing corrective actions.

Sunny Rai, Intertek

Methods of Risk Assessment

• SEMI S10 is the specific method referenced in

S2

– Based upon assessing two factors:

• Severity of injury or mishap

• Likelihood of injury or mishap

– Combining both factors into an overall risk category

from example assessment matrix

Sunny Rai, Intertek

Risk Matrix - SEMI S10-0307

RISK ASSESSMENT MATRIX

LIKELIHOOD

Frequent

A

Likely

B

Possible

C

Rare

D

Unlikely

E

Not Reasonably

Foreseeable

SEVERITY

Catastrophic

1

Severe

2

Moderate

3

Minor

4

Very High High Medium Low Very Low


Using SEMI S2 Safety Guidelines

Hazard Associated with PV


Sunny Rai, Intertek

SEMI S2

Safety-Related Interlocks • Electromechanical (preferred)

• PLC (FECS) is acceptable if approved to appropriate standard for electronic safety systems (e.g. IEC-61508)

• Software based interlock may be considered where severity of mishap is Minor per SEMI S10

• Single point failure not cause a hazard

• Restoration of interlock not allow motion or other hazards

Emergency Shutdown • EMO circuit consist of electromechanical components

• Not include features that are intended to allow its defeat/bypass

• EMO button have a yellow background

• Safety related devices and data/alarm logging computers to remain energized after EMO activation

Sunny Rai, Intertek

Example of EMO Button/Shroud Configuration

Sunny Rai, Intertek

SEMI S2

Electrical • Critical components certified by an Accredited Testing Laboratory,

Main protection disconnect should be rated 10,000 AIC min.

• Nameplate includes manufacturer, model, serial no., voltage, phase, frequency and full-load current

• Move as many tasks as practical from category Type 4 to Types 1, 2, or 3.

• Routine Type 4 tasks, excluding troubleshooting, should have specific written instructions in the maintenance manuals.

• Equipment should conform to the appropriate international, regional, national or industry product safety requirements

• Equipment grounding circuits should have a measured resistance of one-tenth (0.1) ohm or less between the main equipment grounding conductor terminal

• Leakage current 3.5 mA max. for cord-connected equipment

Sunny Rai, Intertek

SEMI S2

Energy Isolation • Lockable energy isolation capabilities for all source of hazardous

energy

• Energy isolation capabilities readily accessible and capable of being locked in the position in which the hazardous energy is isolated

Mechanical Design • Machine Stability

– Ref. IEC 1010-1 (10 degree tip test)

• ‘Breaking-up’ During Operation

• Moving Parts

– Guard & Protective Devices

• Lifting Operations & Extreme Temperatures

Sunny Rai, Intertek

SEMI S2

Seismic Protection • Design to control risk from an earthquake

• Section intent

– provide end-users with the information needed to appropriately secure equipment within their facility

– Supplier not provide attachment hardware - considerations

• Vibration, Seismic Zone, Soil condition, Building Design

Automated Material Handlers • Scope

– Wafer Handlers, Industrial Robots and Industrial Robot Systems, Unmanned Transport Vehicles

• Hazard Analysis => Safeguarding

– Size, Speed, Power, Capacity

• Industrial Robot and Industrial Robot Systems

– ANSI/RIA R15.06

– ISO 10218

– EN 775

Sunny Rai, Intertek

SEMI S2

Environmental • Resource Conservation

– Water use and reuse/recycling

– Process chemical use and reuse/recycling

– Energy

– Maintenance chemicals & Packaging materials

• Prevent/Control Unwanted Releases

– Secondary containment - at least 110%

– Alarms and gas detection/liquid sensing

– Overfill level detectors and alarms

– Equipment designed to accept signal from monitoring device and stop chemical supply

– Equipment designed to allow operators to determine levels of in-equipment containers

Sunny Rai, Intertek

SEMI S2

Exhaust Ventilation • Primary control against chemical exposures for systems not

otherwise protected (e.g., wet benches)

• Exhausted enclosures should be tested using approved

methods to ensure control of worst-case release to 25% OEL.

• Ventilation Design Considerations

– Exhaust interlocks required for systems using HPMs

– Audible or visible alarm

– Time delay after interlock trips is okay if system shutdown

is safe based upon risk assessment

– Visual indicators for non-HPM systems

Sunny Rai, Intertek

SEMI S2

Chemicals • Priority of Controls

– Elimination or substitution

– Engineering controls

– Administrative controls

– Personal Protective Equipment (PPE)

• Chemical Emission Limits

– Normal operating conditions • Chemical concentrations < 1 % OEL (or < limit of detection)

– Maintenance conditions • Chemical concentrations < 25 % OEL

• In worst case personnel breathing zone

– Equipment Failure • Chemical concentrations < 25 % OEL

• In worst case personnel breathing zone

– Flammable chemicals without OEL • < 25 % LEL outside of enclosure

Sunny Rai, Intertek

SEMI S2

Non-Ionizing Radiation • Radiofrequency (RF) & Microwave

– 30 kHz to 300 GHz

– <3 kHz Sub RF Fields

• Ultraviolet (UV) – 100 nm to 400 nm

• Infrared (IR) – 1 mm to 700 nm

• Visible Light – 400nm - 700nm

• Static Magnetic (0 Hz)

Ionizing Radiation • Goal is to reduce emissions to “As Low As Reasonably Achievable” ALARA

• Conformance to international regulations for use and disposal of sources and materials

• Hierarchy of control methods

– engineering

– administrative

– personal protective equipment

Sunny Rai, Intertek

Summary

• Identify hazards associated with the PV Equip

– Systems & facilities

– Use applicable standards

• Use Hazard Analysis methodology

– HazOp, What-If, FMECA

• Perform Risk Assessment of the Hazards

– SEMI S10

Sunny Rai, Intertek

Summary

• Select Risk Reduction criteria

– Order of precedence for resolving identified

hazards:

Design to Eliminate Hazards

Incorporate Safety Devices

Provide Warning Devices

Provide Hazard Alert Labels

Develop Administrative Procedures and Training

Sunny Rai, Intertek

Questions

Sunny Rai, Intertek



Thank You !

Sunny Rai

Intertek

1365 Adams Court

Menlo Park, CA 94025

Tel: 650 463 2950

Fax: 650 463 2910

E-mail: [email protected]

Safety in a PV Solar Start-up

John Shober

Renewable Energy Safety Systems Engineering and Development

http://aboundpower.com/projects

http://aboundpower.com/sites/default/files/_MG_1322_cropped and brightened_for website_0.jpg



Overview

PV Solar Safety Progression

Culture

Production Safety Considerations

Managing the Potential for an Exposure

Glass Handling

Machine Safety

Maintenance

Sustainability






Understand the Process

Design Review

Define Requirements

Develop Safety Systems

Develop Administrative

Controls

Train

Assess & Improve

http://www.abound.com/solar-modules/manufacturing

What about Safety in a PV Start-up?



Design Review

Define Requirements



Controls

Train

Assess & Improve


What about Safety in a PV Start-up? Where do you start? Compressed Timelines

Dynamic Change

Communication Can Be Challenging

New Stakeholders

Etc.



Design Review

Define Requirements



Controls

Train

Assess & Improve




Design Review

Define Requirements



Controls

Train

Assess & Improve


Prioritization Concerns: - Life Safety Critical

- Impending Equipment Damage

- Code/Standard Driven

- Stakeholder Expectation

Safety Culture

Accountability & follow-through for all!

Leadership sets the tone.

Walk the talk in all that you do. This can be challenging in a start-up.

Define expectations early!

Beliefs & Values

In Development

Production = Business

Who defines the critical elements?

Ownership & Passion

Who, Why, How

Why is culture so important?

Safety Culture





Beliefs & Values

In Development

Production = Business

Who defines the critical elements?

Ownership & Passion

Who, Why, How

Safety Culture





Production Safety Considerations

Detailed Product & Process Review

Product Inventory Control Processes

Manufacturing Safety Systems & Support

Injury/Release Prevention

Hazardous Materials

Flammable Liquids & Gases

Controls

Secondary Containment

Hazard Detection

Storage Areas

Transport Quantities & Paths

Leak Detection & Monitoring

Remote Emergency Control

Close Calls & Investigations

Process Reviews

Hazard Analysis

Engineering Reviews


Equipment Safety

Managing the Potential for an Exposure Time: traditional vs. extended shifts

Manufacturing Tasks Material Handling

Characteristics: acute effects vs. chronic


Glass Handling Tempered

vs. Annealed

All Glass is

Not Equal

Capture, Change, Improve

Material Handling

vs. Glass Recovery

Regulated Space vs. Module

Build


An Example of Glass Handling Equipment:

Glass Handling Protection:

Safety Glasses

Face Shield

Neck Protection

Chest Protection

Waist & Leg Protection

Gloves

Forearm Protectors

Shin Protectors

Safety Shoes

Metatarsal Protection

Machine Safety Issues


Operations vs. Maintenance

Process/Metrology

Exposure/Fire Lasers Contamination

Control (Chemicals, Metals, etc.)

Equipment & Process Maintenance

Production & Facility

Equipment

Process Control & Safety Systems


Safety Sustainability

Industry Importance

Less Hazardous Substitutions

In the Beginning: An economy of

scale

Expanding Need for New Processes

Best Practices & Industry Standards


References

Electric Power Research Institute, (2003). Potential Health & Environmental Impact Associated with the Manufacture and Use of Photovoltaic Cells. California Energy Commission.

Fthenakis, V., (2003). Overview of Potential Hazards. Practical Handbook of Photovoltaics: Fundamentals & Applications, Chapter VII-2.

Fthenakis, V., (2003). Environmental Health and Safety (EHS) Issues in III-V Solar Cell Manufacturing. Brookhaven National Laboratory, National PV EHS Assistance Center.

Fthenakis V., Morris S., Moskowitz P., Morgan D., (1999). Toxicity of Cadmium Telluride, Copper Indium Diselenide, & Copper Gallium Diselenide. Progress in Photovoltaics, 7, 589-497.

Komp, R., (2002). Practical Photovoltaics Electricity from Solar Cells. 1-62.

Occupational Health and Safety Administration, (2010). Cadmium 1910.1027. Occupational Health and Safety Standards, http://www.osha.gov/pls/oshaweb/owadisp.show_document?p_table= STANDARDS &p_id=10035 U.S. Department of Energy, (2010).

U.S. Department of Energy, (2010). Photovoltaic Basics. http://ww1.eere.energy.gov/ solar/pvbasics.html.

Yassin, A., Yebesi, F., Tingle, R., (2005). Occupational Exposure to Crystalline Dust in the United States 1998-2003. Environmental Perspectives, 113(3), 255-260.

Questions?


NREL is a national laboratory of the U.S. Department of Energy, Office of Energy Efficiency and Renewable Energy, operated by the Alliance for Sustainable Energy, LLC.

EH&S Risks in Crystalline Silicon PV Module Manufacturing

John Wohlgemuth

May 15, 2012

World Renewable Energy Forum

2

Outline

• Look back at crystalline Si PV manufacturing from when I joined Solarex in 1976

• We have come a long way since then

• What should our major concerns be

o Now

o In the future

3

I remember when

• There were cyanide plating solution footprints through the lobby one morning

• The fire department arrived because of the plume of smoke exhausted from the CP etching of wafers.

• Operators cut their fingers frequently on spinning wafers

• One of our competitors was on the list of the 10 worst air polluters in CA due to their exhaust of organics into the air

4

I remember when (Continued)

• Operators were sent to the hospital for exposure to HF

• Digging through the factory floor and half way across the parking lot before we could find any sign of the drain pipe.

• Molten Si dissolving the bottom of the casting station and the concrete floor.

• Evacuation of the lab due to a phosphine leak.

5

Dramatic improvements

• Changes in materials o Eliminated gaseous dopants o Eliminated plating solutions o Eliminated photolithography and lift-off o Switched from acid etch to NaOH o Many module manufacturers eliminated lead based solder

• Changes in Equipment o Automation reduced/removed direct personnel exposure to

toxic chemicals. o Eliminating manual handling of cells reduces cuts. o Casting stations and wire saws are specifically designed for

PV and supplied by equipment manufacturers with safety systems built in.

6

Dramatic improvements (Continued)

• Changes in management philosophy

o Having the company name on a list of major polluters became totally unacceptable for a renewable energy company.

o Worker safety received much higher priority

o PPE/Safety Training/Safety Culture

7

But there are still dangers in PV manufacturing

• Casting: A large pot of molten Si

o Failure of the coolant could result in meltdown

o Rupture of containment could result in exposure of molten Si to water, which would likely result in an explosion.

• Deposition of Silicon Nitride AR Coating

o Uses Silane which is toxic and extremely flammable

o Uses ammonia which is caustic and an irritant

8

Results of transfer of manufacturing to Asia

• Have gone back to manual processing in many factories so operators can once again be exposed to toxic chemicals and cut hazards.

• China in particular does not have the EH&S laws or culture so it is likely that we can expect more accidents and pollution.

• Have heard of accidents including a casting station explosion that resulted in at least 1 death.

• Almost all Chinese module manufacturers are using lead based solder as it is easier to process and less expensive.

9

What is in store for the future

• The Bad o Pressure of lower pricing is likely to result in some

manufacturers taking short cuts with safety. o When your company is fighting to survive EH&S may not be a

top priority

• The Good o Continued pricing pressure may ultimately lead to automation

even in Asia (already happened in some Chinese factories) o Oversupply and pricing pressure likely to result in a reduction

in number of manufacturers. o Emphasis on Quality with strong EH&S component

• The How o Large US module purchasers should require a strong EH&S

component to manufacturing QA plan as part of “Bankability” and due diligence

understanding and addressing environment, health,...

Documents