Pantex Plant Chemical Management Program

DOE-HDBK-1139/2-2002

Pantex Plant Chemical Management Program

1.0 Introduction and Scope

BWXT Pantex LLC, as the prime contractor, manages the Pantex site for the DOE. BWXT Pantex is

committed to performing work safely using ISMS principles and has established programs for the safe

and effective management of work with hazardous chemicals.

2.0 Chemical Life-cycle Program

2.1 Hazard Identification and Analysis

Pantex does not have any chemical processes that exceed the OSHA PSM Standard thresholds, except for

explosives in Manufacturing Processes. Almost all of Pantex's chemical processes are also explosive

manufacturing processes and are therefore managed per the PSM Standard. In addition, many non-

explosive chemical processes are also managed per the PSM Standard as best business practice."

At Pantex, the preliminary hazards analysis takes the form of a questionnaire (PX-1245), which is used to

collect information about facility inventories of highly hazardous chemicals, explosives, and nuclear

material. This information serves as an objective basis for facility hazard classification. The information

also allows ranking of facilities based on the quantity and form of nuclear material; the consequences

associated with an explosive event, as well as the type of explosives operation; and the consequences of a

release of highly hazardous materials.

Pantex uses its Facility Hazard Classification as the basis for determining if a facility is "nuclear" (which

requires the development of Authorization Basis Documents) or if a facility requires control under the

plant's PSM program because it is classified as an Explosive Manufacturing Operation or has threshold

inventories of Highly Hazardous Chemicals. The Preliminary Hazard Analysis serves as the safety basis

for facilities that are not classified as nuclear or covered by PSM.

The techniques used to complete PHAs include "What-if" analyses, Explosive Safety Checklist

Analyses, General Industry Checklist analyses and FMEA analyses. The information from Preliminary

Hazards Analyses, previous Final Safety Analysis Report analyses, Fire Hazards Analyses, and other

analyses are used to support PHAs.

A multifunctional team that includes a PHA Leader, Facility Manager, Operations Manager, Process

Engineer, Process Operator/Engineering Technician, and Explosives Safety Expert completes the PHA

(per the requirements of 29 CFR 1910.119). The PHA leader is trained and certified in the analysis

techniques that are used. The Facility Manager provides expertise in the management, maintenance, and

design of the facility. The Operations Manager and Operator provide expertise in the operation and

ergonomics associated with the processes In addition to the designated team members, several subject

matter experts, such as Industrial Hygiene personnel, Waste Operations personnel, Fire Protection

personnel and Electrical Classification personnel usually are consulted during the performance of a PHA.