Spallation Neutron Source
Safety Program Overview
Samuel McKenzie
ESH Coordinator
Accelerator Systems Division
April 13, 2005
Oak Ridge National Lab
ORNL/SNS
Spallation Neutron Source
SNS Site – 2004
•
•
•
•
The SNS will begin operation in 2006.
At 1.4 MW it will be ~8x ISIS, the world’s leading pulsed spallation source.
SNS will be the world’s leading facility for neutron scattering.
It will be a short drive from HFIR, a reactor source.
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SNS will be World-Class!
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SNS Accelerator Complex
Front-End:
LINAC:
Accumulator Ring:
Produce a 1msec long,
chopped, lowenergy Hbeam
Accelerate
the beam to 1
GeV
Compress 1 msec long
pulse to 700 nsec
Chopper
system makes
gaps
mini-pulse
Deliver
beam to
Target
Current
Current
945 ns
H- stripped
to protons
1 ms macropulse
1ms
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SNS High Level Baseline Parameters
Proton beam energy on target
1.0
GeV
Proton beam current on target
1.4
mA
Power on target
1.4
MW
Pulse repetition rate
60
Hz
Beam macropulse duty factor
6.0
%
H- peak linac current
38
mA
Ring fill time
1.0
ms
Ring beam extraction gap
250
ns
Protons per pulse on target
1.5x1014
Proton pulse width on target
695
ns
Linac length
335
m
Total Beamline Length
903
m
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Facility Parameters
Area size of construction site
86 acres
Access and service roads
5 miles
Quantity of excavation at completion
Concrete
1.5 MCY
88,000 CY
Structural Steel
4,870 T
Electrical power (connected load)
78 MVA
Electrical power (operational demand)
49 MVA
Cooling water (heat load rejection)
37.4 MW
Cooling Tower water peak flow rate
21,000 gpm
Size of buildings and structures
616,000 sq ft
Site occupancy, including users, up to
500 persons
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Target Systems
• Converts up to 2 MW of 1 Gev Protons at 60 Hz into useful short
neutron pulses.
• Major Subsystems
– Mercury target.
– 3 Supercritical hydrogen moderators with associated cryogenic
systems and one ambient water moderator.
– Beryllium reflector system.
– Core vessel for target, moderator, reflectors.
– 10 m diameter iron shielding with shutters for neutron beams.
– Utility systems including heavy and light water.
– Remote Handling systems.
– Instrumentation and controls.
– Linac, Ring Injection and Ring Extraction beam dumps.
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Target Building and Instrument Layout
1B - Disordered Mat’ls
Diffractometer –
DOE Funded (SING) –
Commission 2010
2 - Backscattering
Spectrometer –
SNS Funded –
Commission 2006
PROTONS
3 - High Pressure
Diffractometer –
DOE Funded (SING) –
Commission 2007
4A - Magnetism
Reflectometer –
SNS Funded –
Commission 2006
18 - Wide Angle
Chopper
Spectrometer –
IDT DOE Funded –
Commission 2007
15 – Spin
Echo
17 - High Resolution
Chopper
Spectrometer –
DOE Funded (SING) –
Commission 2008
14B - Hybrid
Spectrometer –
DOE Funded (SING) –
Commission 2011
13 - Fundamental
Physics Beamline –
IDT Funding TBD –
Commission TBD
4B - Liquids
Reflectometer –
SNS Funded –
Commission 2006
5 - Cold Neutron
Chopper
Spectrometer –
IDT DOE Funded –
Commission 2007
12 - Single Crystal
Diffractometer –
DOE Funded (SING) –
Commission 2009
? – Chemical
Spectrometer
6 - SANS –
SNS Funded –
Commission 2007
11A - Powder
Diffractometer –
SNS Funded –
Commission 2007
9 - Engineering
Diffractometer –
IDT CFI Funded –
Commission 2008
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Target Region Within Core Vessel
Target Module with
jumpers
Outer
Reflector
Plug
Target
Inflatable
seal
Core Vessel
water cooled
shielding
Core Vessel
Multi-channel
flange
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History of SNS
• In 1998 DOE Broke Ground on the SNS with Critical Decision 4
(end of Project) in 2006
• In 2000 the University of Tennessee and Battelle Teamed to win
the Contract to Manage Oak Ridge National Lab.
• Later that Year a “New” SNS Project Director was Hired and
given Equal Status with the ORNL Lab Director.
• A Stream-Lined Safety Program was Envisioned with Little if
any ties to ORNL.
• In 2002 a “New” Project Director was Hired and placed SNS
Back Under the Direction of ORNL.
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Standards Based Management System (SBMS)
• A Proven System That Both PNNL and BNL Utilizes. Additionally INL
will soon begin their Implementation Process.
• Creates “One Stop Shopping” for Work Control and the Standards
that the Work Shall and/or Should Follow
• Clearly Defines ALL the Necessary Steps Needed to Perform a
Certain Task.
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Safety Overview
• Since 2000, SNS (Non-Construction) has had 15 Recordable
Injuries and Illnesses (RIIs) Cases and 1 Day with Restrictions
Case (2002).
• Additionally, ASD has 3 situations where there were violations
of Internal Posting and/or Procedures (i.e. Lock Out Tag Out,
Internal Parameters, etc.).
The injury rate at SNS remains exemplary (1.2 per 200,000 hours),
and we must continue to strive for a continued safe work
environment. In the coming months, we (SNS) will assume
responsibility for the craft labor contract from Knight-Jacobs. This
means we will be directly responsible for their attitude of, and
commitment to, safety.
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Safety Chain
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Electrical Systems
• By far our most dangerous activity is working on de-energized
electrical systems, circuits and panels.
• ASD has systems in every facet of its operation that utilizes
high currents, voltages and/or capacitances!
• A rigorous Lock Out Tag Out (LOTO) program is a must.
• Our LOTO program serves us well and each group has a Safety
Officer responsible for compliance with both NEC and SNS
rules.
• Additionally, we have offered over 10 Electrical Safety Classes
that deal with the various aspects of our electrical equipment.
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Research Safety Summaries
• Research Safety Summaries (RSSs) are prepared at the Group
and Lab Level.
– Identify hazards a particular group is exposed to in their
work.
– Assist the Group Leader in determining the appropriate
training and controls that need to be in place prior to
performing work.
– Defines the complete list of SBMS requirements for that
Group.
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Job Hazard Analysis
• Job Hazard Analysis (JHA) - lynchpin of our Safety Program
– process CLEARLY understood by all ASD employees and is
the basis of Integrated Safety Management (ISM).
 Work is defined in well understood steps.
 Associated hazards determined at each step.
 Action(s) established to mitigate hazards (i.e., safety
glasses, erect a scaffolding, etc.).
 Perform work within JHA guidelines.
– JHAs are routinely reevaluated for completeness and
enhancement.
– Worker driven program with constant feedback on how we
can continue to make the work safer.
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ASD Example 1
Hoisting and Rigging
•
On Nov 5, 2001 An Employee at
our old Receiving Facility was in
the process of Lifting a Dipole
Magnet when One of the Eye Bolts
Failed.
•
As a Result of this Event we (ASD)
instituted a Formal Process of
Developing a Lift Plan for all our
Lifts. A detailed JHA is Prepared
and the Documentation is reviewed
by one of a Select Group of
Mechanical Engineers
•
The Lab’s Program is Modeled
after ours and Our External
Accelerator Review Committee has
made several statements
complimenting us on the rigor and
completeness of our Hoisting and
Rigging Program
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ASD Example 2
Lock Out Tag Out
•
On Nov 22, 2002 An Employee was
inspecting a Lock and Tag applied
to a Circuit Breaker in the Klystron
Building when the tag came off in
the employee’s hand. The incident
was not properly reported.
•
As a Result of this Event we (ASD)
immediately provided a LOTO
Practical Factors Training Program
for all Affected Employee. As a
result of finding additional
deficiencies we provided LOTO
Verification Training.
•
ASD has always employed the
OSHA Required Equipment
Specific LOTO Process. The lab’s
program now employs this process
as well.
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Where There’s Smoke…..There’s not ALWAYS
A Fire!
• On Sept 9, 2004 An Evacuation
of the Linac Tunnel, Klystron
Gallery and Front End Building
Occurred while we where
Commissioning our Warm
Accelerator (~150 MeV). This
evacuation was due to Our
Early Detection Smoke Alarm
System.
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Smoke Event Cont’
• This evacuation occurred due to
a Cryogenic Gas System heater
being in close Proximity to
Canvas Bags containing Steel
Shot that is used for shielding
Purposes. The 2 kW Heater is
normally used during the Initial
Cryomodule fill process. For
our 4 Kelvin cool down the
system remained in place ~1
month. Due to Thermocouple
Placement and other factors the
system did not respond properly
and cause the pipe to Overheat.
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Smoke Event cont’
• This Overheating never caused
an open flame fire but did burn
several Canvas Bags that Held
the Steel Shot.
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Conclusion
• SNS has done a wonderful job of developing a concise system
embracing SBMS and ISM to build a world class accelerator facility!
• We have to continue to learn from our own mistakes and from others.
• We have to be open and honest about our mistakes as well as our
successes.
• We must Continue to understand what we want to do before we
perform the Work (ISM).
• We have to recognize that the hazards within our divisions continue to
increase as we go into operation with more and more very powerful
equipment
• We have to be aware, that we share issues. Perform work in offices,
storage buildings etc that carry their own risk, which usually is not as
obvious as the technical ones.
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