LLNL Legacy Chemical Reduction Efforts 2014 EFCOG Chemical Safety - - PowerPoint PPT Presentation

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LLNL Legacy Chemical Reduction Efforts 2014 EFCOG Chemical Safety - - PowerPoint PPT Presentation

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LLNL Legacy Chemical Reduction Efforts 2014 EFCOG Chemical Safety & Lifecycle Management Spring Meeting March 18-20, 2014 Greg Lee LLNL-PRES-651438 This work was performed under the auspices of the U.S. Department of Energy by Lawrence

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LLNL-PRES-651438

This work was performed under the auspices of the U.S. Department

  • f Energy by Lawrence Livermore National Laboratory under Contract

DE-AC52-07NA27344. Lawrence Livermore National Security, LLC

LLNL Legacy Chemical Reduction Efforts

2014 EFCOG Chemical Safety & Lifecycle Management Spring Meeting Greg Lee

March 18-20, 2014

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Lawrence Livermore National Laboratory

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  • 2010 Baseline
  • ~ 92,000 bar coded containers
  • ~ 36,600 containers considered legacy (39.7%)
  • ~ 17,300 containers 17+ years old (18.8%)
  • Challenges:
  • Motivate chemical custodians and organizations to

reduce their chemical inventory

  • Make it easy; reduce time and effort to identify and

remove targeted chemicals

Legacy Chemicals at LLNL

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  • FY2011
  • Targeted High Hazard Legacy Chemicals

— Peroxidizable — Alkali metals — Corrosive & flammable gases

  • Methodology

— The LLNL chemical management system, ChemTrack, was used to

generate the list of high hazard legacy chemicals

— Each Directorate looked at the chemicals on the list, determined if there

was a programmatic need to keep the chemicals, and approached container owners to dispose of them

  • Results

— Disposed of 44 legacy peroxidizables — Disposed of 21 legacy alkali metals — Disposed of 8 legacy corrosive gases — Disposed of 77 legacy flammable gases

Past Chemical Legacy Reduction Efforts Were Narrowly Scoped (i.e., hazard and/or location)

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  • FY2012
  • Each LLNL organization (i.e., principal directorate) committed to

reach one of the following goals:

— 10% reduction in total inventory — 10% reduction in total gas cylinder inventory — 5% reduction in legacy inventory — 5% reduction in legacy gas cylinder inventory

  • Methodology

— Used inventory baseline of 10/1/10 to reflect beginning of previous

inventory cycle

  • Results

— Attrition lead to only a modest reduction of approximately 2,500 legacy

chemicals

— How could we streamline the process to engage chemical custodians and

line management in reducing unneeded chemicals?

Achieving ISO 14001 Registration Resulted in Broader Objectives and Targets for Chemical Reduction

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  • FY2013
  • Same goals as FY2012

— 10% reduction in total inventory — 10% reduction in total gas cylinder inventory — 5% reduction in legacy inventory — 5% reduction in legacy gas cylinder inventory

  • New Inventory Tablets
  • Pilot Study

— Methodology — Results

  • Pilot Study Expansion

FY13 Efforts Expanded with Improved Tools to Achieve Our Goals

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  • Aged Inventory Equipment Hardware/Software
  • Windows CE4
  • C# code
  • Discontinued Symbol PDA hardware
  • Hardware/software/OS past life-cycle

Why a new ChemTrack Mobile?

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  • Scan barcodes
  • Data processing using local database
  • Substantial database size (~ 1M rows in multiple

tables)

  • Used at all buildings (including Limited Areas)

and LLNL’s Site 300 where WIFI/OpenLabNet may not be available

  • Data upload/download using RESTful web

service

Requirements for ChemTrack Inventory Tablets

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  • Development
  • 2 developers - 4

months designing and coding software

  • 2 developers and 2

inventory technicians - 1 month testing tablets, software and Bluetooth scanner

IT Development for Chemical Inventory Tablets

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  • Hardware
  • Windows 7 touch screen tablet

— WIFI and microphone disabled — Uses wired network to upload/download data

  • Bluetooth bar code scanner
  • Software
  • Tablet code written entirely in HTML5/Javascript
  • Local data storage holds over 1 million rows
  • Communicates with back-end server via web service

calls (Back end server code is written in Java language)

Final Tablet Specs

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  • A subset of the ChemTrack inventory is downloaded to

the tablet, so it works as a portable ChemTrack lookup database

  • As inventory personnel scan bar codes, inventory

information such as location, timestamp, custodian, etc. is captured and stored on the tablet in real time

  • The tablet alerts the inventory tech when a pre-identified

legacy item is scanned so it can be pulled

  • The tablet is also capable of identifying “orphaned”

containers, missing containers (unaccounted for in last inventory cycle), and unregistered containers

  • The captured data is uploaded to the ChemTrack

database located at the institutional Data Center

What is Stored on the Tablets?

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Inventory Tablet – Main Menu

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Inventory Tablet – Certification of Scan Head

Certified Count:

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Inventory Tablet – Scanning Bar Codes

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Inventory Tablet – Scanning Bar Codes (continued)

DOE, JOHN

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Inventory Tablet – Data Correction

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Inventory Tablet – Data Correction, Search Application

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Inventory Tablet – Data Correction, Search Application Results

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Inventory Tablet – Data Correction

(continued)

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Inventory Tablet – Data Correction

(continued)

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Inventory Tablet – Data Correction

(continued)

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Inventory Tablet – Data Correction

(continued)

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Inventory Tablet – Data Correction

(continued)

DOE DOE, JOHN

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Inventory Tablet – Data Correction

(continued)

JOHN DOE

123456

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Inventory Tablet – Orphaned Containers

DOE, JOHN

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Inventory Tablet – Targeted Containers

DOE, JOHN

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  • Chemicals are bar coded and tracked

electronically using ChemTrack

  • An annual wall-to-wall chemical inventory scan

is conducted every year

  • Was it possible to use the functionality of the

new inventory tablets for targeted legacy chemical reduction?

  • A pilot reduction effort was developed for Building 151,

a former nuclear chemistry facility with lots of legacy items

Using the Annual Chemical Inventory Process for Legacy Reduction

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Legacy Chemicals in B151

B151 has ~ 75 laboratories Total number of chemicals: ~ 10,000 Number of legacy chemicals (>10 years old): 4,173

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  • ChemTrack generated a list of legacy chemicals (>10 years
  • ld) for B151
  • Chemical Science Division Deputy Department Leader

(DDL) sorted the list according to locations and owners

  • Total number of legacy chemicals: 4,173
  • Total number of owners: ~ 70 (top 5 owned ~ 57%)
  • DDL decided to focus on the top 5 owners, identifying 2,398 potential

chemicals for disposal

  • DDL worked with owners to identify chemicals for disposal
  • Reinforce that the process would just involve highlighting chemicals to

be disposed on a spreadsheet

  • Initially, 696 legacy chemicals identified for disposal

Methodology for Identifying Targeted Chemicals

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  • ChemTrack and waste management personnel reviewed the

list of targeted chemicals, ensuring a coordinated effort to safely handle and dispose of the identified materials

  • The list of targeted chemicals was also reviewed to evaluate
  • pportunities for repurposing
  • The list of targeted chemicals was loaded onto the tablets
  • A kickoff meeting was held with key players to ensure that

everyone was on the same page before starting field work

  • Safety considerations
  • Controlling access
  • Upfront coordination with waste management techs for timely

disposition

Methodology for Identifying Targeted Chemicals (continued)

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  • Coordinated Effort
  • Chemical Science Division provided access/escort to the

laboratories

  • Waste techs provided secondary containers and guidance
  • n segregation
  • ChemTrack inventory techs scanned and sorted chemicals
  • The area ES&H Technician performed swipes to verify

containers were free of radiological contamination

  • Waste techs picked up and processed chemicals before

removal from the ChemTrack Inventory database

  • The field work minimally impacted the chemical custodians

Field Work

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  • A total of 811 chemicals disposed
  • Repurposing was minimal due to the nature of

the effort and the age of the selected chemicals

  • Fifty percent of the disposed chemicals were

19+ years old

Legacy Pilot Program Results

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  • Need to label the temporary staging areas to

maintain control of the chemicals being stored (and prevent inadvertent additions)

  • In the future, personnel will do a more thorough

review of the targeted chemicals list (one secondary explosive was found during the pilot and the chemical custodian was unaware of its explosive properties)

Lessons Learned

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  • FY2013
  • Pilot Program subsequently expanded to 6 additional

buildings

— 3,466 legacy chemicals disposed — 94 legacy chemicals repurposed

  • Total Legacy Reduction for FY2013 (including

attrition)

  • 6,577 bar coded containers

Expansion of Pilot Program

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  • FY2014
  • Continue to expand Pilot Program to additional

facilities

  • LLNL Experimental Test Site (Site 300) Methodology

FY2014 Chemical Legacy Reduction Efforts

# of Bar Coded Containers Targeted for Reduction Percent Reduction Bar Coded Containers (as

  • f 12/30/13)

5745 Bar Coded Containers 5-10 years old 939 213 22.7 % Bar Coded Containers > 10 years old 1840 1324 72.0 %

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  • What has your site undertaken recently to reduce

(legacy) hazardous material inventories?

  • What has worked well? or not?
  • How do you prioritize and resource legacy reduction

efforts at your site?

  • Progress in reducing legacy inventories in the past

has not always been sustained…what strategies (e.g., policies, processes, and/or tools) can we employ to continuously improve?

  • What chemical safety issues and lessons learned

have you encountered in your legacy reduction efforts that you can share with the rest of the group?

Discussion Topics

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Shoot for slow but steady progress as the inventory continues to age

35.5 36 36.5 37 37.5 38 38.5 39 39.5 40 40.5 1/1/2010 1/1/2011 1/1/2012 1/1/2013 1/1/2014

Percentage Legacy

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