Construction Safety and Lessons Learned Waste Treatment and Immobilization Plant

1. Construction Safetyand Lessons LearnedWaste Treatment and Immobilization Plant Jim Navarro, Facility Representative DOE Office of River Protection (ORP)

2. ORP Mission The ORP mission is to safely retrieve and treat Hanford’s tank waste and close the tank farms to protect the Columbia River.

3. Hanford Site 200 East and West Area Point out WTP site, 200 east tank farms and 200 west tank farms Note that there are six miles between the two. Point out WTP site, 200 east tank farms and 200 west tank farms Note that there are six miles between the two.

4. WTP Project Scope Design, build and commission processing facilities, Process facilities are, Pretreatment, Low-Activity Waste Vitrification High-Level Waste Vitrification Also, design and build, Analytical laboratory 20 support buildings and facilities Read the slide The nitrogen purging evolution was also going to be conducted by the construction subcontractor. I thought; “what’s the worst thing that can happen during the job?” Read the slide The nitrogen purging evolution was also going to be conducted by the construction subcontractor. I thought; “what’s the worst thing that can happen during the job?”

5. WTP Site Layout

6. Construction status

7. Quick Facts – (March 2008 data) About 1,000 craft workers on site, peak of 3500 183,000 CY concrete placed (71% of total) 11,300 Tons steel erected (33%) 275,000 linear feet of piping (28%) 369 tons of ductwork (18%) 170,000 feet of electrical cable (4%) Gave the FWS a copy of a Lessons Learned Safety Notice I had just gotten a couple of weeks before this job on two fatalities that had occurred in a plant in Delaware due to nitrogen asphyxiation. This is a copy of it. The FWS discussed this Safety Notice in a pre-job briefing. Read the first few sentences of this Safety Notice Gave the FWS a copy of a Lessons Learned Safety Notice I had just gotten a couple of weeks before this job on two fatalities that had occurred in a plant in Delaware due to nitrogen asphyxiation. This is a copy of it. The FWS discussed this Safety Notice in a pre-job briefing. Read the first few sentences of this Safety Notice

8. Construction Safety Bechtel works to its “WTP Worker Safety and Health Program” which, Meets the 10CFR851 Worker Safety and Health Program, requirements, Includes specific requirements such as, Worker involvement OSHA Construction Industry Stds OSHA General industry Stds (partial)

9. Construction Safety Construction site Lessons Learned include, Fall Protection 29CFR1926 subpart M Falling Object Protection 29CFR1926 subpart L .451(h)

10. Fall Protection Most OSHA cited serious construction industry violation yearly At WTP methods to prevent a 6ft or more fall include, Scaffolding & aerial lifts Personal fall arrest (safety harness and lanyard) Positioning device systems Lifelines This is not the same equipment that was used for this evolution, but it is almost identical. Pressure gage, relief valve, valving, etc. This is not the same equipment that was used for this evolution, but it is almost identical. Pressure gage, relief valve, valving, etc.

11. Fall Protection Aerial Lifts Inspected daily Attach bodybelt only to lift anchor points No use of rails to climb/sit Boom and basket load limit not exceed manufacturer limit Scaffolding Top rail 38”- 45” above work level Midrails, screens, vert members Guardrails withstand 200# Toeboards This is the outdoor enclosure that housed the nitrogen purge equipment. Note that one side of this enclosure is cut out and that it is enclosed on three sides. This was done later by the TFC’s safety organization. When I first got there, it was enclosed on all four sides and the top Note the two nitrogen lines to the right entering the sample ports in the building and the nitrogen piping running along the ground to the right from the dewar. Note that the heater is an electric one. This is the outdoor enclosure that housed the nitrogen purge equipment. Note that one side of this enclosure is cut out and that it is enclosed on three sides. This was done later by the TFC’s safety organization. When I first got there, it was enclosed on all four sides and the top Note the two nitrogen lines to the right entering the sample ports in the building and the nitrogen piping running along the ground to the right from the dewar. Note that the heater is an electric one.

12. Fall Protection Personal Fall Arrest Used in lieu of railing or safety net when =>6’ Body belt not allowed, must be safety harness Dee-rings and snap hook min 5000 lb strength Attachment point at back center or above head Needed a heat exchanger to heat up the nitrogen to greater than 40 degrees F. to protect the encasement. Heater heats the nitrogen flowing through the HX coils. Note also the chairs in the back that the workers (pipefitters) placed inside. This purging and blanketing evolution went on for 24 hours a day for several days. Needed a heat exchanger to heat up the nitrogen to greater than 40 degrees F. to protect the encasement. Heater heats the nitrogen flowing through the HX coils. Note also the chairs in the back that the workers (pipefitters) placed inside. This purging and blanketing evolution went on for 24 hours a day for several days.

13. Fall Protection Positioning Device Systems Used to allow use of hands Free fall no more than 2 ft. Anchorage 2xLoad or 3000 lbs Snaphooks to be locking type Inspected prior to each use for wear/damage/deterioration NOT allowed at WTP when at/above 6’without lanyards connected to anchor Note the oxygen monitor on top of the heater. I saw that the oxygen monitor was turned off, and the worker inside was completely closed in in the enclosure on all four sides and the top, with nitrogen actively flowing through the purge equipment. A nitrogen leak inside would have been hazardous, even deadly. I told the pipefitter inside to turn on the oxygen monitor, that I was concerned about his safety. Then I went back over to the construction trailer to look at the JSA. Note the oxygen monitor on top of the heater. I saw that the oxygen monitor was turned off, and the worker inside was completely closed in in the enclosure on all four sides and the top, with nitrogen actively flowing through the purge equipment. A nitrogen leak inside would have been hazardous, even deadly. I told the pipefitter inside to turn on the oxygen monitor, that I was concerned about his safety. Then I went back over to the construction trailer to look at the JSA.

14. Fall Protection Lifelines Min. strength of 5400 lbs Protected against cut or abrasion Anchorage point independent of other anchorages I know you can’t see this, but this is what I found. This is the pertinent part of the JSA relating to the nitrogen hazard of this job. But first, let’s talk about what a Job Safety Analysis is, or Job Hazard Analysis, or Worksite Hazard Analysis, or whatever you call it at your site. You likely have a similar document at your site, perhaps with a different name. I know you can’t see this, but this is what I found. This is the pertinent part of the JSA relating to the nitrogen hazard of this job. But first, let’s talk about what a Job Safety Analysis is, or Job Hazard Analysis, or Worksite Hazard Analysis, or whatever you call it at your site. You likely have a similar document at your site, perhaps with a different name.

15. Fall Protection Lessons Learned Craft’s positioning device hook came free – employee fell 6’ till lanyard attached to back hook arrested fall Although trained on proper use, complacency set-in after repetitive task of tying rebar Re-enforcement of training in proper use fall protection Read the slideRead the slide

16. Fall Protection Lessons Learned Worker using retractable lanyard connected to beam clamp Incorrect size (too large) Beam Clamp fell from beam flange Beam clamps removed to clearly label with correct flange size to use with training on proper use

17. Fall Protection Lessons Learned Worker utilized wire rope guardrail as lifeline to connect lanyard Wire guard-rope was not inspected for correct load/deflection capacity to use for tie off Worker slipped on plastic and fell from edge, lanyard supported weight Workers trained to only tie-off to safety approved lifelines to tie-off

18. Falling Objects In 2004 nine ORPS reportable and five non-reportable falling object, near-miss events at WTP Persistent falling object events generated Recurring Event Occurrence in 2004 Dropped objects from height included, Rebar, tools, and construction materials Nitrogen hazard was considered to be abated by use of a three-sided enclosure. Nitrogen hazard was considered to be abated by use of a three-sided enclosure.

19. Falling Objects Fallen Pipe Pipe leaning on scaffold railing fell to ground Toe board, railing and netting installed, Pipe was bumped, fell 40’ through opening - landing on top of a shed.

20. Falling Objects 100 Lb embed fell 40’ from wall while removing form embed struck scissors lift floor, one carpenter inside lift Lowering of the concrete pour level was not communicated to all craft Embed above pour level remained attached to form, screws attaching embed to form were removed prior to removing form Read the slide The TFC also removed one side of the purge enclosure as shown in the earlier slide Read the slide The TFC also removed one side of the purge enclosure as shown in the earlier slide

21. Falling Objects Collapsed rebar curtain Splice made of 2 #5 vert bars holding ~20 #11 horiz bars As top horiz bars were tied, the tie wire on the vert #5 splice bars was cut Weight of bottom #11 bars on remaining wire-ties caused lower curtain portion to collapse No injuries

22. Falling Objects Causal analysis of events indicated, More positive controls needed to eliminate tools & material falling potential Workers leaving tools and materials loose at elevation Not always placing yellow or red tape around area nor communicating overhead hazard to others Corrective Actions included, Debris netting to avoid tools & matl falling containers used to control small tools/matl if elevated Lanyards/ropes on tools to avoid dropping Barricades, signs & tags to warn and inform of overhead work Matl not stacked above handrail & stored by shift-end if feasible

23. Fall Protection at Home Guardrail or fall protection system Restrained to prevent tipping Level, sound, rigid, footing Stable platform Poles, legs, plumbed and braced