Acquisition - hdbk11392002vol20032

DOE-HDBK-1139/2-2002

PHAs are performed using the software program Leader 4.0, from EQE International, Inc., in Knoxville,

Tennessee. These analyses typically yield action items that have the potential to significantly affect

safety and recommendations that address minor safety concerns or increased efficiencies. Per the plant

procedure, action items must be acted upon; and recommendations must, at minimum, be evaluated by the

Facility Manager.

The PHA is the definitive analysis for non-nuclear chemical facilities at the Pantex Plant and is used to

supercede all of the previous analyses. PHAs are also used to write the Safety Basis Document for non-

nuclear chemical facilities. This document identifies all of the systems important to safety and the

administrative controls required to mitigate or prevent the consequences of interest as defined in the plant

procedure.

Pantex has also prepared Specific Hazards Analyses in support of the Safety Basis for Nuclear Facilities.

An example of this is the analysis of a chlorine release from the water treatment plant. This analysis

focused on the effect of a chlorine spill on the operations within Nuclear Facilities.

2.2 Acquisition

Requestors of new chemicals are required to submit a Pantex Form PX-761, Chemical Request Form.

The requestor provides the name of the chemical, its proposed use, estimated frequency and quantity of

use, where it is planned to be stored and used, and any engineering controls and/or PPE that are planned

to be used in conjunction with the new chemical. After the requestor's portion of the form is completed,

the requestor forwards it to the Chemical Control Committee for review. Following final approval, the

PX-761 is entered into a database that is accessible by all of the procurement personnel on the site. They

routinely check this database to ensure that the item has been approved prior to placing the order.

An item that does not require any excessive reviewer comment or special handling can be processed

completely through the system in 2 to 3 work days. An emergency request can be completely processed

in a matter of hours if all of the necessary reviewers (or their alternates) are available. It is reasonably

rare for any request to take more than 5 work days to be processed. Although this sounds like a long

involved process, the simultaneous review by multiple committee members and the electronic routing of

the form on the Plant unclassified network actually moves the process along rapidly.

2.3 Inventory and Tracking

The Hazard Communication (HazCom) Group maintains approximately 14,000 MSDSs in the Master

MSDS Library. As each MSDS is received, the HazCom Group processes it, examining it for

completeness and correctness. If the HazCom Group finds any errors in the data, they contact the supplier

of the MSDS to alert them to the error. Sources used for comparison of data include National Consensus

Standards, OHSA Standards and Publications and a third-party MSDS Service (MDL-OHS MSDS on

CD-ROM).

Each MSDS has a unique number assigned to it, known as a P-Number. The P-Number is a six-digit

identifier (five digits and one decimal place) that can be used to track a specific MSDS by the type of

chemical that it represents and the manufacturer or supplier of that product. When there are numerous

manufacturers or suppliers of the same product, the decimal place differentiates them. An example would

be isopropyl alcohol. The first five digits for all isopropyl alcohols are 00518. However, since it is a

fairly common chemical, it is purchased from a number of different sources. The P-Number for isopropyl

alcohol from Allied Chemical Company is 00518.1; the P-Number for isopropyl alcohol from Ashland

Chemical is 00518.3. When there are more than nine manufacturers or suppliers, two decimal digits are

used to continue this logic.