Brookhaven Science Associates U.S. Department of Energy 1 George A. Goode Brookhaven National...

Brookhaven Science AssociatesU.S. Department of Energy 1

George A. GoodeGeorge A. GoodeBrookhaven National LaboratoryBrookhaven National Laboratory

Environmental Summit 2006Lessons Learned from a Maturing EMS


Lessons Learnedfrom a Maturing EMS - AgendaLessons Learnedfrom a Maturing EMS - Agenda

Overview of Brookhaven National Lab Evolution of BNL’s EMS

• Key Decisions during Implementation Lessons Learned

• What worked?• What didn’t?

Keys to Success Q & A


Brookhaven National LaboratoryBrookhaven National LaboratoryBrookhaven National LaboratoryBrookhaven National LaboratoryMission: Basic and applied research in a variety of Basic and applied research in a variety of

scientific fields: Physics, Chemistry, Materials scientific fields: Physics, Chemistry, Materials Science Biology, Medicine and forefront technologyScience Biology, Medicine and forefront technology

Facts:Operated by Brookhaven Sciences Associate (BSA) for DOEOperated by Brookhaven Sciences Associate (BSA) for DOE

2600 employees; 4,000 visiting scientists annually 2600 employees; 4,000 visiting scientists annually 5,000 acre site located on eastern Long Island, NY5,000 acre site located on eastern Long Island, NY


BNL Facilities, Programs, OperationsBNL Facilities, Programs, Operations BNL MACHINESBNL MACHINES

Collider-AcceleratorsRelativistic Heavy Ion ColliderAlternating Gradient SynchrotronBooster Applications FacilityLinear Accelerator

National Synchrotron Light Source

SCIENTIFIC ACTIVITIESSCIENTIFIC ACTIVITIESCenter for Functional NanotechnologyMedical Research OperationsComputational Research CenterMaterial Science ResearchBench-top ExperimentsEnvironmental Research

FACILITY OPERATIONSFACILITY OPERATIONS• Physical Plant Operations

– Sewage Treatment Plant– Central Steam Facility– Major Petroleum Facility

• Waste Management Facility• Environmental Restoration

SUPPORT PROCESSESSUPPORT PROCESSES• Radiation Source Material Storage• Machining Operations• Photography• Fleet Operations• Bulk Chemical Distribution Operations


Historical Environmental Management Reactive ModeHistorical Environmental Management Reactive Mode Small, centralized Environmental support organization within

Safety & Health Physics Division Environmental risk overshadowed by health and safety risks Limited jurisdiction of EPA regulation at federal facilities Proliferation of regulations exceeded BNL response

capability Staff reactive to “urgent” environmental issues Scientific staff shielded from regulatory requirements External communication when and if required by law; limited

“marketing” of accomplishments


Achieving Environmental ExcellenceSystematic Approach of ISO 14001 EMSAchieving Environmental ExcellenceSystematic Approach of ISO 14001 EMS

BNL embarked on a project to implement an ISO 14001 EMS in 1999• Phased approach

BNL Registered to ISO 14001 standard in 2001• First DOE National Lab

Key Elements• Unwavering Sr. Mgmt Support• Commitment of resources

– Financial and people• “Systems Thinkers”• Integration with Mgmt Systems• Prevention based programs


Planning EMS ImplementationKey Decisions: Level of ImplementationPlanning EMS ImplementationKey Decisions: Level of Implementation

Implementation at the Laboratory Level• Benefits: Least documentation, consistency, one management review,

consolidated list of aspects, objectives/targets, transparent to line, easier to manage and audit

• Drawbacks: Less line involvement and ownership, tends to be “bottled up” in Environmental Dept, fewer focused objectives/targets, little culture change

Implementation at the Directorate Level• Benefits: Less documentation than division level, good ownership and line

management involvement, limited number of management reviews, good focused objectives/targets, promotes teamwork and achieves culture change

• Drawbacks: More documentation than Lab level, more meetings, less consistent and more difficult to audit

Implementation at the Division Level• Benefits: Most ownership and focus• Drawbacks: Most documentation, least consistent, most difficult to manage/audit


Planning EMS ImplementationKey Decisions: IntegrationPlanning EMS ImplementationKey Decisions: Integration

Integrate EMS Elements with existing management systems• Most important and powerful strategy for success• Work with Management System owners to get buy-in

1. Aspects: Work Plan & Environmental2. Legal & Other Reqmt’s: Reqmt’s Mgmt3. Objectives/Targets: Planning4. Resources/Roles: Planning and HR5. Competence/Training: Training6. Communication: Communication/PR7. Documentation: Quality Assurance8. Control of Docs: Quality Assurance

9. Operational Control: Work Planning10. Emergency Prep: Emergency Mgmt11. Monitoring/Measuring: Quality & Assessment12. Evaluation of Compliance: Environmental13. Nonconformance: Quality Assurance14. Control of Records: Quality Assurance15. Internal Audit: Integrated Assessment16. Management Review: Integrated Assessment


Lessons LearnedLessons Learned

What worked………..what didn’t

Review of some ISO 14001 elements and what we learned….


Environmental PolicyEnvironmental Policy

KEEP IT SIMPLE!!! Policy writers were well versed

in BNL operations, ISO language and had full management commitment

Commitments translated well into an acronym (P2C4)

Policy reflected real changes (not too lofty)

Lots of Posters, Training Aids, and reminders

P2C4P2C4Pollution PreventionPollution Prevention

ComplianceComplianceCommunity InvolvementCommunity Involvement

CleanupCleanupContinual ImprovementContinual Improvement

EMS Policy evolved EMS Policy evolved to include Safety, to include Safety,

Security and HealthSecurity and Health

Issues EncounteredIssues EncounteredWhat workedWhat worked Policy awareness fades over

time• Frequent reinforcement needed• Heightened attention prior to

audits needed Integration with safety, health,

and security blurred message


Environment, Safety, Security, and Health PolicyEnvironment, Safety, Security, and Health Policy Environment: We will perform our research and operations in a manner that protects

the environment, conserves resources, prevents pollution.

Safety: We will plan and perform work safely. We expect personal commitment to safety and take responsibility for the safety of ourselves and coworkers.

Security: We will perform our work in a manner that protects people, property, information, and facilities.

Compliance: We will achieve and maintain compliance with applicable ESSH requirements.

Community: We will develop and maintain proactive and constructive relationships with our employees, neighbors, regulators, DOE, and our other stakeholders. We will openly communicate progress and performance.

Continual Improvement: We will continually improve ESSH performance. We will define, prioritize, and aggressively prevent, correct, and/or clean up existing environmental, safety, security, and health problems.


Environmental AspectsEnvironmental Aspects

Integrated into Work Planning• Experimental Safety Reviews• Routine Work Planning

Deploy Env Professionals to field Process Mapping Approach

• Key for routine processes• Identified aspects, operational

controls, and P2 Opportunities

“Products” not initially addressed• Especially “intellectual property”

Failed to consider Positive Aspects

Criteria may be too focused and may be missing obvious (everyday) aspects• Skill of the craft not fully captured

P2P2AwardAwardWinnerWinner

Issues EncounteredIssues EncounteredWhat workedWhat worked

Wire onSpools

Scrap Material,Spent Wire,

Backing Platesto MetalsRecycling

CSD-131-EDM-01 to 04

EDM(2 units)

4.0

DisposableMat

4.1

Material tobe Cut

Cut Part

BROOKHAVEN NATIONAL LABORATORYPROCESS ASSESSMENT PROGRAM

Central Shops Division - Electrical Discharge MachineProcess Flow Diagram

Chiller

3.0

RecirculatedWater

Sludge toIndustrial

Waste (withBurning Table

Sludge)

Filename: EDM Drawing.doc

Vapors toRoom

VentilationSystem

4.3

Filter

1.0

Supply andMakeupWater

IonExchange

2.0

Ion ExchangeCanisterFilters

Spent Ion ExchangeCanister to

Vendor

Spent Filtersto MetalsRecycling

1.1

PlasticSpoolsto WireSupplier

4.2

ReusableMaterial to

MaterialStorage

DisposableMat (withSludge) toIndustrial

Waste

4.4

Spent Waterto Water

Eater

BackingPlate

Legend

Solid Waste

Air Emissions

Wastewater

SS = Sanitary Sewer

DIWater

2.1

Bypass forRecirculatedWater

4.64.5


Objectives, Targets and ProgramsObjectives, Targets and Programs

Integrate with Planning Processes• Demonstrates connection to

institutional priorities ESH&Q Environmental Priorities

• Helps line focus on key objectives• Allows ESH staff to get their agenda

implemented Divisions specific O&T’s

• Helps build line management ownership for continual improvement

Use of Self Assessment Plan Feedback at Management reviews

• Management involvement flowed down into objectives

Flowdown not always clear• Must make sure someone is

responsible and hold accountable Good measurable objectives

and targets (They were often based on routine work)• Needed Training


Important: Benefits of an EMS You get from your EMS what

you put in• Set easy goals…reap few benefits• Challenge yourself…let people

step up and succeed


Competence, Training and AwarenessCompetence, Training and Awareness

Training tailored to ‘need to know’• All Employees: Gen Env Training (Policy,

Emergency Response)• All Managers: EMS Overview Briefing• EMS Representatives: Overview,

Obj/Targets, Audits• Staff involved with significant aspects:

Job Specific Training• Contractors: Contractor/Vendor

Orientation (Policy, Emergency Response)

Web-based CBT

Maintaining Awareness is a constant challenge• Need constant vigilance

(Advertising)• Constant reminders by EMS

Reps and Lab director Skill of the craft may assume

that they understand E issues and may be outside of training systems.



CommunicationCommunication

Dedicated Communication Staff Lots of avenues to promote

• (Bulletin)• (Monday Memo)• (Interoffice Bulletins)

Proactive engagement of the community• Community Advisory Council• We offer information rather then wait

to be asked Policy is posted in obvious places.

Hard to communicate to all employees due to the diverse job base.



Control of DocumentsControl of Documents

Web-based documentation• Reduces doc control problems

- Out of date- Current revisions

Large number of documents, procedures, and forms• Lots of opportunities for

nonconformance No common Lab-wide system

• Difficult for auditors to understand

Lack of common understanding of what documents need to be controlled



Emergency Preparedness and ResponseEmergency Preparedness and Response

Integration with existing Emergency Response systems

Improved awareness of staff• Spill Reporting• Effluent monitoring• RCRA• SPCC

Most existing systems meet the intent but must be sure all EMS concerns are addressed• Be sure to properly address

compliance (spills) issues well. • Routine drills must be up to

date- will be included in EMS Audits



Evaluation of ComplianceEvaluation of Compliance

BNL ISO 14001 Plus• Plus = compliance and community

Dedicated procedure requires compliance assessments• Targeted Assessments based on past

performance and importance• Common format and scope

Self Assessment process includes compliance

Regulatory (external) assessment results well communicated

Reliance on other management systems can lead to vulnerabilities• Management system owners

must take responsibility for implementation effectiveness

Results of Self Assessments not rolled up effectively



Internal AuditInternal Audit

Rolled up to Lab Level• Reduces audit burden at line level

Ensure scope involves line input• Document on audit planning forms

Use industry experts and peers• Fresh set of eyes• Bring other implementation experience

Trained Internal Staff• Certified auditors

Share Internal Auditor resources with other Labs• Allows staff to see how it’s done at other

sites

Started out making all departments audit themselves• Too many and low quality

Awareness of ISO auditing standards• ISO 19011• ANSI/ISO 14010• ANSI/ISO 14011• ANSI/ISO 14012



Management ReviewManagement Review

Lab Level Mgmt Review• Reviews major trends and issues

with Sr. Mgmt Department level Mgmt Review

• Specifically reviews performance• Creates very good ownership

Good opportunity to show Value Lots of metrics Tool to document Senior

Management input and continual improvement.

Hard to maintain focus when things are going well• Competing with the issue of the day

Multi-level management reviews sometimes considered redundant

Slow to get effective input from management• Significant improvement as

Managers realized the value



Keys to SuccessGetting the most from your EMSKeys to SuccessGetting the most from your EMS

Summary of Lessons Learned that ensure the value of the EMS is realized


Senior Management Commitment and Visible Involvement• Formal Project Management Plan with Project Charter signed by Sr. Exec• Visible support, attendance at key meetings, accountability for Sr. Staff

Tap expertise when designing EMS• Project manager was ISO 14001 expert• Used top consultant to get Sr. Management on board• Tap Systems Thinkers for implementation team

Set Meaningful Objectives and Targets• Think Big and Long-Term• Hold competitions to engage the imagination and competitive spirit of employees• Allow line to set objectives that are meaningful to them• Remember: What gets measured gets managed




Use Web-based systems• Procedure and documentation delivery

Patience…maturation of system takes time• Anticipate “Requisite floundering” stage • Expect resistance to organizational change

Self-Examine, Self-Identify & Self-Correct• Test programs & provide feedback• Minimize external audit costs by minimizing findings - be prepared• Set & prioritize your own improvement agenda

Base your EMS on a Strong Pollution Prevention Program• Clearest examples of value to management


Achieving Environmental ExcellenceBNL Pollution Prevention ProgramAchieving Environmental ExcellenceBNL Pollution Prevention Program

Scope is multimedia• Emissions, effluents, wastes (air, water, land)

Priority focus on:• Radioactive, Hazardous, Mixed waste

Multi-program:• Classical P2: Source Reduction, Reuse• Recycling Program• Resource Conservation: Water, Energy• “Buy Recycled” procurement policy


Return on Investment Program

Funded P2 ProposalsReturn on Investment Program

Funded P2 ProposalsRank Project Name

Directorate, Dept/Div and POC Cost Savings

Payback (Years)

1 Radioactive Waste Sorting TableHigh Energy Nuclear Physics, CAD (J. Scott) $2,500 $5,000 0.5

2 Reducing Dose From BLIP Air Emissions

Life Sciences, Medical (L. Mausner)

$13,400 $13,450 1

3 Kinetic Phosphorescence AnalyzerEENS, Environmental Sciences Dept. (J. Gillow) $20,000 $22,556 0.9

4 Scintillation Vial CrusherLife Sciences, Medical (A. Gifford) $3,795 $2,168 1.75

5 Microplate Scintillation Counter

Life Sciences, Biology (J. Shanklin)

$35,000 $27,690 1

6 RTF Photoprocessor

Life Sciences, Medical (L. Wielopowski)

$13,860 $16,489 0.8

7 Oil-free Vacuum Pumps and new Catalyst

EENS, Environmental Sciences Dept. (L. Nunnermacker) $6,000 $3,516 1.7

8 Bulk Motor Oil

F&A, Staff Services (H. Hauptman)

$4,000 $2,200 1.8

TOTAL INVESTED $96,055TOTAL SAVINGS $88,069

AVERAGE PAYBACK PERIOD 1.2


Results:

BNL Photographic Waste Generation Reduced by 85%

High Tech SolutionConversion to digital

Low Tech SolutionsSegregate fixer from developerSilver recovery

Brookhaven National LaboratoryPhotographic Waste Generation from ISD

Technology change to digital processing reduced waste by 80%

0

5000

10000

15000

20000

25000

30000

CY1993 CY1994 CY1995 CY1996 CY1997 CY1998 CY1999 CY2000 CY2001

Calendar Years

Poun

ds


Results:

Metal Cleaning Waste Generation Completely eliminated TCA

waste from degreasing operations

High Tech SolutionsReplaced acid/solvent cleaning

system with ultrasonic systems using biodegradable detergents

Low Tech SolutionsAutomobile service part washing

provided by Safety Kleen (non-hazardous)

Changed to petroleum (kerosene) cleaning in non critical operations

Use non-chlorinated solvents

Brookhaven National LaboratoryNSLS Beam-Tube Cleaning Hazardous Waste

Technology change to Ultrasonic Detergent Cleaning (1998) eliminated waste

0

500

1000

1500

2000

2500

3000

3500

CY1993 CY1994 CY1995 CY1996 CY1997 CY1998 CY1999 CY2000 CY2001

Calendar Years

Po

un

ds


Life SciencesLife SciencesFY02 Funded P2 Proposal: Silver Waste ReductionFY02 Funded P2 Proposal: Silver Waste ReductionLife SciencesLife SciencesFY02 Funded P2 Proposal: Silver Waste ReductionFY02 Funded P2 Proposal: Silver Waste Reduction

Cost: $1670 Annual Savings: $30k +Benefits:

Reduce hazardous waste Decrease safety hazards Reduce materials cost

Status: Completed!


FUNDED FY03: Elimination of mixed wasteFUNDED FY03: Elimination of mixed wasteKinetic Phosphorescence Analyzer (KPA) systemKinetic Phosphorescence Analyzer (KPA) systemFUNDED FY03: Elimination of mixed wasteFUNDED FY03: Elimination of mixed wasteKinetic Phosphorescence Analyzer (KPA) systemKinetic Phosphorescence Analyzer (KPA) system

Current Wet-Chemistry Method: Generates 75.6 L (2.7 cft) of mixed

waste annually. 2 ml:

natU sol’n

(1-100 g)

2 ml: trans-1,2-diaminocyclohexane-N,N,N’,N’-tetraacetic acid (CyDTA),

sulphosalicylic acid, sodium fluoride, triethanolamine

2 ml: 2-(5-bromo-2-pyridylazo)-5(diethylamino)phenol [Bromo-PADAP]

in ethanol

10 ml: 200 proof ethanol

Total volume=25 ml per analysis 3024 analyses annually

40% ethanol=mixed waste

Proposed KPA Method: Will generate 7.6 L (2 gal.) of liquid rad. waste annually and

NO mixed waste.

2 ml: natU sol’n(0.001-1 g)

2 ml: non-hazardous complexing solution

Total volume=2.5 ml per analysis3024 analyses annually

Liquid radioactive waste

Cost: $20,000 Annual Savings: $22,560k +Benefits:

Eliminates 75 lit Mixed Waste Reduces rad handling 90% Reduce materials cost

Status: Completed!

Environmental Sci Dept• Total elimination of

mixed waste (Uranium)• Lower detection limit• Increased productivity

from autosampler


BNL Performance Track Goals: (3 year commitment) Land conservation/restoration

Goal: Restore 10 acres/year of previously disturbed land by replanting with native vegetation

Results: Restored or recovered 26 acres Mercury use reductions

Goal: Reduce mercury inventory by 80% pounds by end of 2006Results: Reduced “non-essential” mercury inventory by 38%, including over 450

thermometers Ozone-depleting-substances (ODS) reductions

Goal: Reduce ODS in refrigeration and fire suppression systems by 30 tons by end of 2006

Results: Reduced ODS by 32.5 tons Radioactive air emissions reduction

Goal:Reduce emissions from the BLIP by 30%Results: Reduced emission by 32%, and made process more efficient

Performance Track Member, Since 2005Performance Track Member, Since 2005


Today at BNLToday at BNL

All BNL facilities, experiments & operations certified to ISO 14001 Unprecedented knowledge of environmental aspects & comprehensive

system to control/minimize impact EPA Performance Track member Improving compliance status Pollution prevention projects saving millions Survey shows managers believe environmental stewardship important Openly communicating on issues & progress; highlighting science Regaining reputation & receiving independent recognition

• Recent Awards: L.I. Pine Barrens Society Env Stewardship award, EPA Environmental Quality award, White House ‘Closing the Circle’ award, DOE Office of Science ‘Best in Class’ Pollution Prevention award and Stony Brook Univ WRMI Env. Stewardship award


Resources Resources

Web ResourcesP2 Web Page, http://www.bnl.gov/esd/pollutionpreve

EMS Web Page, http://www.bnl.gov/esh/ems/

People ResourcesGeorge Goode: [email protected], 631-344-4549John Selva (EMS): [email protected], 631-344-8611Bob Lee (Performance Track): [email protected], 631-344-3148

Brookhaven Science Associates U.S. Department of Energy 1 George A. Goode Brookhaven National...

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