path forward to safety improvement nrao...path forward to safety improvement . nrao is a dynamic...
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Na#onal Radio Astronomy Observatory
Robert N. Daniels, CSP ES&S Manager, NRAO Charlo@esville, VA
Path Forward to Safety Improvement
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NRAO is a Dynamic Organization Heavy Maintenance workload
• VLBA is mature and remote • GBT is extremely large
– Many GB facilities are quite old – much maintenance is required – A long winter season means that outside maintenance is weather limited
• VLA is mature and growing at the same time (EVLA)
– New equipment installation – Heavy maintenance load on mature antennas
Project Driven Resource Demands
• ALMA – Construction of facilities and Antennas is simultaneous – We will begin data collection with first capability (Vertex 1)
• Construction vs Operations – Each makes demands on us – Our resource pool is smaller than the demand for it – Prioritization is a necessity
• Our work force continues to age & turn over – net loss of experience is good and bad
2 4/20/09
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NRAO – New Mexico
Very Long Baseline Array
Very Large Array
Science Operations Center
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Very Long Baseline Array (VLBA)
• Ten Sta#ons
• Remote loca#ons
• Fully mature assets
• ~5 year rota#on
4/20/09
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Audits Process for VLBA
• Couple Audits with scheduled (“routine”) maintenance
• Accompany NM based “Maintenance Teams” • Full Facility Audit – Environmental, Safety and
Security coverage • Spreadsheet based follow up • Experienced Auditors (Industrial/Manufacturing
Experience coupled with Certification)
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VLBA Issues • Sta#ons are quite remote and small
– no logis#cal support onsite or nearby – require drive in capability – May need AWD and no public transport – Extended travel to conduct the audit – typically 2 to 3 days of travel
required • Maintenance teams (aka “Tiger Teams”) arrive to do maximum business in
a minimum amount of #me – Compressed schedule – OUen heavy workload ‐ extended hours – Significant amounts of risk (Elevated, cri#cal liUing, etc.)
• Delays introduced by ES&S Personnel audi#ng are intrusive • Only 2 Staff at each facility to operate & support the Cycle • Very experienced employees on the maintenance team and in the facility
– Have been doing the work “this way” with great success for a career. See no need to change
– Well ingrained habits are the most difficult to change – We have a window of opportunity while new employees arrive
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Very Large Array (VLA) In service since 1980
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Inspec#ng a 25 M VLA Antenna in the Antenna Barn via LiU 230 tons and nearly 100 Ft tall
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Moving a VLA Antenna Without Using a Train!
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Audits Process for VLA
• Done on a Monthly basis by the facility Safety Officer with Ops par#cipa#on
• Heavy Risk Area Audits are scheduled when ES&S Manager can support (Antenna Barn, Petrol Storage Tanks, etc)
• Full Facility Audit – Environmental, Safety and Security are all audited – Permits include PSTB & Air – Status is Small Qty Gen – Range of Safety Risks is broad
• Audits process is conducted so as to minimize intrusions but op#mize for quality (efficient)
• Follow up is done through Site Safety Commi@ees and Management
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VLA Issues and • 79 Miles of RR Track
– Dual track on the bed – require drive in capability – no public transport (site uses a shu@le) – Very large area of coverage
• Provides support to VLBA for Maintenance, Opera#ons & ES&S – Mechanics & Technicians can be pulled away to support VLBA needs – Increased workload for those who remain – poten#al for temporary loss of cri#cal
exper#se to another facility • Significant amounts of risk (Elevated, cri#cal liUing, etc.)
– 27 Antennas (25 Meter) – Steerable (drives, gears, hi power, hi precision parts)
• Extremely broad range of work from Antenna structural & RR Maintenance to micro‐electronics , lasers and cryo lab
• Only 1 Safety Officer located at the VLA – Another at SOC (NM Tech Campus) • Very experienced employees on the maintenance team and in the facility
– Have been doing the work “this way” with great success for a career. See no need to change
– Well ingrained habits are the most difficult to change – We have a window of opportunity while new employees are arriving
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Pete V. Domenici Science Operations Center
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Audits Process for SOC
• Audits are rou#nely held on a monthly basis w/Opera#ons
• ES&S Manager may a@end in any month and can a@end on request
• Facility is a tenant of NM Tech – No Permits – Minimal Hazardous Waste Genera#on (non‐Generator) – Range of Safety Risks is limited with heavy laser & electronic exposure (laser light, solvents, heat, etc) plus typical office hazards and risks
• Follow up is done through Site Safety Commi@ees and with Management and ES&S involvement
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SOC Issues • Maintenance is handled by Owner
– We cannot control priority – During business hours the “Open Campus” academic approach to security can
be a problem – Two buildings in use are separated by some distance
• Provides support to VLBA for Maintenance, Opera#ons and ES&S – Electronics Technicians & Engineers can be pulled away to support VLBA needs – Increased workload for those who remain – poten#al for temporary loss of
cri#cal exper#se to another facility • Somewhat broad range of work from typical office work to micro‐electronics ,
laser development and cryo lab. • Only 1 Safety Officer located at SOC (NM Tech Campus) and he is part #me there
– Covers VLBA needs – Supports at VLA as well – Academic Community interface
• Very experienced employees in the facility – Have been doing the work “this way” with great success for a career...See no
need to change now – Well ingrained habits are the most difficult to change – We have a window of opportunity while new employees arrive
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The Robert C. Byrd Green Bank Telescope
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The Robert C. Byrd Green Bank Telescope 555 feet 5 1/8 inches
305 U
485 feet
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Audits Process for GBT
• Audits are rou#nely held on an annual basis w/Opera#ons • Check List Driven • Typically involve several days and are led by Safety Officer
• ES&S Manager a@ends • Facility is completely self contained
– Cafeteria, Dormitory, Apartments and individual homes – Recrea#onal facili#es for Employees, visi#ng Scien#sts & Guests – Sewer Permit (WW Treatment by Lagoon) no excursions since Jan 2007 – Small Quan#ty Hazardous Waste Genera#on – Range of Safety Risks is very broad – requires broad audits background
• Heavy machining • Wide range of chemical and cryo hazards • Cri#cal liUing, elevated work is extreme • Wide variety of Antenna facili#es to manage
• Follow up is done through Site Safety Commi@ees and with Management and ES&S involvement
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GBT Issues • Maintenance is handled by Site Operator (we do it)
– GB Management must determine priority in light of the mission and “other” variables – There is public access (48,000 visitors in 2008) to the facility and leU unwatched, security could
grow to be a problem – Site is quite remote – many services are not available locally
• Provides support to the rest of NRAO and ALMA – Fabricates parts and machinery – Support projects with technology and people
• Very broad range of work from typical office work to micro‐electronics and cryo lab in addi#on to the heavy work done in support of the GBT
– Elevated safety (~4 year pain#ng cycle) – Extremely heavy machinery to drive (~17,000,000 lbs of moving weight) – Loca#on presents unique difficulty in that the winter weather is harsh – GBT is very sensi#ve to electrical noise and much effort is expended to control it (NRQZ/WVRQZ)
• Only 1 Safety Officer located at GBT – Covers a por#on of Charlo@esville/NTC needs – Supports the Jansky Lab for ES&S needs – Supports Academic Community interface
• Very experienced employees in the facility – Have been doing the work “this way” with great success for a career...See no need to change now. – Well ingrained habits are the most difficult to change – We have a window of opportunity while new employees arrive
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Atacama Large Millimeter/submillimeter Array (ALMA)
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NRAO ES&S Contributions to ALMA
• System safety reviews and Safety Manual Support
• Hazard Identification and Risk Mitigation for various systems • Front and Back End • General Laser Safety • US & other Manufacturing Centers Safety • Resolution of specific safety problems • Coordination of US/EU/CH Safety Standards
• Security Assessments & Support for the ALMA project operations in VA & NM
• Safety consultation for the ALMA Project (Project Safety Officer, IPT’s and Project Management Team) includes International standards rationalization
• Safety Support to NTC Front End Integration Center (Audits, OSHA Concerns, Safety Consultation)
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ALMA Issues
• Remote Location – Extended travel time ~ 4 days
• Harsh Climate – High Altitude, low humidity – What works for radio astronomy doesn’t always work as well for people!
• Cultural Diversity – Language differences – Customs and concerns – Differences in food requirements
• Many different interests in JAO – Different Observatories partnered – Different Companies with some different interests
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A General Dynamics 12 M Antenna Taking a ride on the ALMA Transporter
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ALMA • JAO is building a small city at 3000 Meters & a
neighboring Antenna “city” at 5000. – Lighting, Services, Roads and Infrastructure of all
sorts – Many cultures, many companies and organizations – NRAO is a Partner providing resources and
technology
• NRAO ES&S group continues to provide support to the ALMA Team as requested.
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So….The problem Observatory wide is….
• Mul#ple Major Projects (ALMA & EVLA) coupled with . . .
• Aging Infrastructure . . .1956 at Greenbank, WV and 1980 at the VLA near Magdalena, NM
• The Working popula#on is “losing service “ (experience) faster than it is gaining it due to rou#ne turnover and some early re#rement coupled with project driven growth
• Training processes have become nearly “appren#ceships” and are mostly OJT – they are technically rigorous but not well documented around safety
• EHS Resources are stretched to the limit by travel distance, breadth of knowledge requirements coupled with increasing complexity of inves#ga#on requirements
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2.07
3.17
1.50
2.08 2.09
1.32
2.64
0.90
1.49 1.61
0.00
0.50
1.00
1.50
2.00
2.50
3.00
3.50
2004 2005 2006 2007 2008
OSHA Freq
OSHA DART
Linear(OSHA DART)
OSHA Freq & Dart NRAO Wide
One Picture is worth a thousand words
We may have reached a plateau in terms of injury performance
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The Program and Objectives:
• 2009 – Develop, document and deliver Hazard Identification
and Risk Mitigation (JSA process) training to all primary groups (Mechanics, Technicians plus some Professionals)
– Status: Training is now being reviewed by Observatory Safety Officers We expect to begin delivery in June, 2009 at the VLA and follow with GBT in August/September Time Frame
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• 2009 (Cont’d) – Transfer Inspections process to a common format. – Status: VLA Inspections on a per building/per month
basis. VLA Safety Training system to be revised in 2009 to include routine refresh with documentation confirmed by training records audits (annually).
– Move GBT to a monthly Safety Inspection Process vice the current Annual Site Wide Inspection
– Status: Will conduct the Comprehensive Inspection this Spring and determine a timeline with GBT Management for the changes to begin after Hazard Identification/ Risk Mitigation training is complete
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