Status: PROCESSED

19
Person: Ghoshal, Probir ([email protected] ) Org: PMAGNT Status: PROCESSED Saved: 11/18/2019 11:24:55 PM Submitted: 11/18/2019 11:24:55 PM Operational Safety Procedure Review and Approval Form # 95104 (See ES&H Manual Chapter 3310 Appendix T1 Operational Safety Procedure (OSP) and Temporary OSP Procedure for Instructions) Type: OSP Click for OSP/TOSP Procedure Form Click for LOSP Procedure Form Click for LTT-Individual Information Click for LTT-Group Information Serial Number: ENP-19-95104-OSP Issue Date: 11/20/2019 Expiration Date: 10/20/2020 Title: HDIce Dump Solenoid – Operating Magnet to Full Field Location: (where work is being performed) Building Floor Plans 58 - Test Lab - 1127 Location Detail: (specifics about where in the selected location(s) the work is being performed) Risk Classification: (See ES&H Manual Chapter 3210 Appendix T3 Risk Code Assignment ) Without mitigation measures (3 or 4): 3 With mitigation measures in place (N, 1, or 2): 1 Reason: This document is written to mitigate hazard issues that are : Determined to have an unmitigated Risk code of 3 or 4 Owning Organization: PHALLB Document Owner(s): Ghoshal, Probir ([email protected] ) Primary Supplemental Technical Validations Mode 1: Class 1, 2, and 3 Electrical Equipment (Bill Rainey, Tim Fitzgerald) Static Magnetic Fields >5G: Fringe, High, & Quench Effect (Imani Burton, Jennifer Williams) ESH&Q Liasion (Bert Manzlak) Other Hazards: Magnet Heating (James Coleman) Document History Revision Reason for revision or update Serial number of superseded document Lessons Learned Lessons Learned relating to the hazard issues noted above have been reviewed.

Transcript of Status: PROCESSED

Page 1: Status: PROCESSED

Person: Ghoshal, Probir ([email protected]) Org: PMAGNT

Status: PROCESSED Saved: 11/18/2019 11:24:55 PM

Submitted: 11/18/2019 11:24:55 PM

Operational Safety Procedure Review and Approval Form # 95104(See ES&H Manual Chapter 3310 Appendix T1 Operational Safety Procedure (OSP) andTemporary OSP Procedure for Instructions)

Type: OSP

Click for OSP/TOSP Procedure FormClick for LOSP Procedure FormClick for LTT-Individual InformationClick for LTT-Group Information

Serial Number: ENP-19-95104-OSP

Issue Date: 11/20/2019

Expiration Date: 10/20/2020

Title: HDIce Dump Solenoid – Operating Magnet to Full Field

Location: (where work is beingperformed)

Building Floor Plans

58 - Test Lab - 1127Location Detail: (specifics about where in the selected location(s) the work is beingperformed)

Risk Classification: (See ES&H Manual Chapter 3210 Appendix T3 Risk Code Assignment)

Without mitigation measures (3 or 4): 3

With mitigation measures in place (N, 1, or 2): 1

Reason: This document is written to mitigate hazard issues that are : Determined to have an unmitigated Risk code of 3 or 4

Owning Organization: PHALLB

Document Owner(s): Ghoshal, Probir ([email protected]) Primary

Supplemental Technical Validations

Mode 1: Class 1, 2, and 3 Electrical Equipment (Bill Rainey, Tim Fitzgerald) Static Magnetic Fields >5G: Fringe, High, & Quench Effect (Imani Burton, Jennifer Williams) ESH&Q Liasion (Bert Manzlak)

Other Hazards: Magnet Heating (James Coleman)

Document History

Revision Reason for revision or update Serial number of superseded document

Lessons Learned Lessons Learned relating to the hazard issues noted above have beenreviewed.

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Comments forreviewers/approvers:

Attachments

Procedure: HDIce Dump Solenoid_OSP_11182019.pdf THA: HDIce Dump Solenoid_THA.pdf

Additional Files:

Review Signatures

Person : Subject Matter Expert : Magnet Heating Signed on 11/19/2019 9:59:42 AM by JamesColeman ([email protected])

Subject Matter Expert : Electricity->Mode 1: Class 1->2-> and 3 Electrical Equipment

Signed on 11/19/2019 7:19:47 AM by TimFitzgerald ([email protected])

Subject Matter Expert : Static Magnetic Fields >5G:Fringe-> High-> & Quench Effect

Signed on 11/19/2019 10:48:47 AM by ImaniBurton ([email protected])

Approval Signatures

Division Safety Officer : PHALLB Signed on 11/19/2019 11:56:14 AM by Ed Folts ([email protected]) ESH&Q Division Liasion :PHALLB Signed on 11/19/2019 11:39:15 AM by Bert Manzlak ([email protected])

Org Manager : PHALLB Signed on 11/20/2019 3:28:43 PM by Patrizia Rossi ([email protected])

Safety Warden : Test Lab - 1127 Signed on 11/19/2019 12:35:59 PM by Matthew Poelker([email protected])

Page 3: Status: PROCESSED

For questions or comments regarding this form contact the Technical Point-of-Contact Harry Fanning

This document is controlled as an on line file. It may be printed but the print copy is not a controlled document. It is the user’s responsibility to ensure that the

document is the same revision as the current on line file. This copy was printed on 11/18/2019.

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fa

Operational Safety Procedure Form (See ES&H Manual Chapter 3310 Appendix T1

Operational Safety Procedure (OSP) and Temporary OSP

Procedure for instructions.)

Title: HDIce Dump Solenoid – Operating Magnet to Full Field

Location:

UITF Enclosure (Cave 2) Type:

OSP

TOSP

Risk Classification

(per Task Hazard Analysis attached)

(See ESH&Q Manual Chapter 3210 Appendix T3 Risk Code Assignment.)

Highest Risk Code Before

Mitigation 3

Highest Risk Code after

Mitigation (N, 1, or 2): 1

Owning Organization: Magnet Group Date: November 18, 2019

Document Owner(s): Probir Ghoshal

DEFINE THE SCOPE OF WORK

1. Purpose of the Procedure – Describe in detail the reason for the procedure (what is being done and why).

This OSP is to be used to power the HDIce Dump Solenoid within the UITF enclosure. This magnet has

an expected maximum operational current of 350 Amps (normal expected operating current is 318.2 A).

This will be the permanent location for the magnet up on its stand on the beam line. Normal operation

will be to remotely operate the magnet (i.e. from the control room) but there may be instances when the

magnet will have to operated (for temporary testing purposes) with staff still inside the UITF enclosure.

For such instances, temporary tape barriers will be erected at the 5 Gauss line together with warning

signage and flashing beacons.

2. Scope – include all operations, people, and/or areas that the procedure will affect.

This OSP identifies and specifies mitigation measures for all aspects of significant hazards associated

with the HDIce dump solenoid.

This OSP does not cover maintenance or internal adjustment of the power supply or access to LCW and

electrical leads on top of the magnet in the UITF enclosure.

3. Description of the Facility – include building, floor plans and layout of the experiment or operation.

The UITF Enclosure (Cave 2) is located at the East side of area 1127 of the Building 58 High Bay – far

left of Figure 1 below.

Click

For

X

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Operational Safety Procedure Form

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Figure 1 – The UITF Enclosure showing the location of the HD-Ice experiment and the PSU connected to

the solenoid at the top of the picture. The solenoid can be seen on the top of its stand.

ANALYZE THE HAZARDS and IMPLEMENT CONTROLS

4. Hazards identified on written Task Hazard Analysis

The solenoid magnet is located in the UITF Enclosure. When powered at 350 A, (i.e. approx. 10% above

expected operating current), the solenoid will produce a 0.275 Tesla (2750 Gauss) field at its bore center.

The 5 Gauss line will be located at a distance of 1.68 m from the center of the solenoid as measured along

the bore (Z-axis) and at 1.3 m from the center of the bore measured in either the X or Y-axes. The hazards

related to solenoid operation include the following:

1. Electrical hazard

2. Magnetic field

3. Magnet Heating

5. Authority and Responsibility:

5.1 Who has authority to implement/terminate

Matt Poelker and Probir Ghoshal

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Operational Safety Procedure Form

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5.2 Who is responsible for key tasks

Probir Ghoshal

5.3 Who analyzes the special or unusual hazards including elevated work, chemicals, gases, fire or sparks (See ES&H

Manual Chapter 3210 Appendix T1 Work Planning, Control, and Authorization Procedure)

Jim Coleman (magnet power supply and coil heating) and Jennifer Williams (magnetic fields) 5.4 What are the Training Requirements (See http://www.jlab.org/div_dept/train/poc.pdf)

SAF603 Electrical Hazard Awareness

SAF104 Lock, Tag and Try

This OSP

6. Personal and Environmental Hazard Controls Including:

6.1 Shielding

N/A

6.2 Barriers (magnetic, hearing, elevated or crane work, etc.)

Temporary rope or tape barriers, flashing beacons and signage for magnetic fields

6.3 Interlocks

To be able to turn on the magnet power supply, these interlocks must be green:

1. Magnet LCW Flow (>2.00 GPM)

2. Magnet temperature (<60°C)

3. Power Supply LCW Flow (>1.25 GPM) – nominal flow is 2.2 GPM

4. Power Supply Voltage (<79 V)

6.4 Monitoring systems

All magnet-related instrumentation is monitored by a PLC and can be viewed via an EPICS GUI. 6.5 Ventilation

N/A 6.6 Other (Electrical, ODH, Trip, Ladder) (Attach related Temporary Work Permits or Safety Reviews as appropriate.)

N/A

7. List of Safety Equipment:

7.1 List of Safety Equipment:

The magnet power supply has its own ground. The copper-braid shield on the power supply to

magnet leads is grounded to this same point. The cradle (that the magnet sits on) and the solenoid

mandrel is also grounded to this same point. 7.2 Special Tools:

N/A

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Operational Safety Procedure Form

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8. Associated Administrative Controls

N/A

DEVELOP THE PROCEDURE

9. Operating Guidelines

The HDIce Dump Solenoid produces a magnetic field of about 0.25 Tesla at its normal expected

operating current of 318.2 A and operational voltage of about 47 V (as measured at the solenoid

terminals). The power associated with this operating condition is approximately 15 kW. The magnet is

wound using square copper conductor with a central water-cooling hole and consists of four 2-layer coils

connected in series and weighs approximately 400 pounds. Figure 2 indicates the final location of the

magnet on its stand on the beam line.

Figure 2 - HDIce Dump Solenoid positioned on its stand within the UITF enclosure

Hazards

The hazards related to solenoid operation include the following:

1. Electrical hazard

2. Magnetic field

3. Magnet Heating

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Operational Safety Procedure Form

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Mitigation

Electrical Hazard

The solenoid magnet power supply (shown in Figure 3) in located within the UITF Enclosure in close

proximity to the solenoid and operates with an input voltage of 480 VAC. The wall feed and associated

breaker is located outside of the UITF Enclosure, to the right of the entrance gate (Figure 8). The power

supply output over voltage trip level is set to 79 V. Maintenance and servicing of the power supply can

only be conducted by “Qualified Electrical Workers". The supply is cooled with LCW. The LCW flow is

interlocked to the power supply.

During normal operation, connections at the power supply are made inside the cabinet which has

interlocked doors. Insulated and copper braid-shielded cables carrying current to the magnet exit from the

top of the power supply cabinet and are routed to the solenoid terminals via uni-struts supported off the

wall. The electrically "live" portions of the leads at the water inlet/outlet and current in/out are insulated

with a double-layer of half-lapped Kapton tape and a half-lapped layer of self-vulcanizing electrical tape -

all electrical (power) connections are enclosed within a Lexan box. The conductor used to wind the

solenoid is insulated with Dacron glass insulation. The rest of the magnet is insulated with Nomex paper

and fiberglass tape. At the end of construction the magnet went through a vacuum impregnation. The

completed magnet has been high potted at 1150 V and has a resistance to ground of 370 MΩ.

There is one Emergency Stop button located on the power supply front panel.

Figure 3: Magnet power supply within the UITF Enclosure. There is an Emergency Stop (E-Stop) button

on the front panel.

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Operational Safety Procedure Form

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Magnetic Field

The solenoid magnet is located within the UITF Enclosure. When powered at 350 A, (i.e. 10% above

expected operating current), the solenoid will produce a 0.275 Tesla (2750 Gauss) field at its bore center.

The 5 Gauss line will be located at a distance of 1.68 m from the center of the solenoid as measured along

the bore (Z-axis) and at 1.3 m from the center of the bore measured in either the X or Y axes. The 5 Gauss

line is used as the limit to restrict access to personnel with surgical implants or bioelectric devices. The 5

Gauss line is indicated via the use of temporary rope or tape barriers. A flashing red beacon will indicate

when the magnet is ON.

Figure 4 – Stray field map of the HDIce Dump Solenoid at 350 A (0.275 T central field).

Note that the stray field will have the same extent in the X-axis as it does in the Y-axis.

Field contour values are in Tesla (1 Tesla = 10000 Gauss). Distance values are in mm.

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Operational Safety Procedure Form

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Strong magnetic fields can attract loose ferromagnetic objects, possibly injuring body parts or striking

fragile components. Prior to energizing the magnet, a sweep of the cordoned-off 5 Gauss area

will be performed for any loose magnetic objects. All personnel entering the 5 Gauss area will be also

trained to remove ferromagnetic objects from themselves including wallets and watches.

A Gate Interlock will prevent access to the magnet when it is energized. However, there will be a Gate

Interlock Bypass Key to be able to enter the UITF Enclosure with the magnet ON. When the gate

interlock is bypassed, a flashing red beacon installed at the 5 Gauss line will warn personnel with surgical

implants and bioelectric devices from entering the 5 Gauss boundary.

Magnet Heating

At 318.2 A, the total power dissipated in the magnet is about 15 kW. Low Conductivity Water (LCW) is

used to cool the magnet with a flow rate of about 4 GPM. The parameters that are monitored and

interlocked are summarized in the table below.

Table I – Monitored Parameters and Interlock Thresholds

The temperature of the magnet is interlocked to the power supply using 4 Klixon 70°C Thermal Switches

mounted on each of the 4 return conductors. These switches are normally closed and open when the

temperature exceeds 70°C (158 F) and automatically reset when the temperature drops below 44.4°C (112

F). With the magnet at 318.2 A, the hottest temperature expected is about 50°C with a 4 GPM LCW flow

rate.

A FSD (Fast Shut Down) signal from the PLC/Power Supply has been provided to allow the beam to be

shut down if the solenoid power supply shuts down.

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Operational Safety Procedure Form

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Figure 5 - HDIce Dump Solenoid water manifold with supply and return headers and terminal blocks

mounted on a DIN rail for instrumentation

All interlocks must be green to be able to turn the supply ON.

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Operational Safety Procedure Form

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Figure 6 – EPICS interlock screen for the solenoid

Figure 7 shows the power supply control screen.

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Operational Safety Procedure Form

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Figure 7 – HDIce Dump Solenoid power supply control screen.

PPE Requirement to Turn Power Supply Breaker ON/OFF

As the solenoid power supply is turned ON and OFF via a circuit breaker which is located outside the

UITF enclosure – see figure below – no PPE is required to operate this breaker. However, to apply LOTO

to the ON/OFF switch on the power supply’s front panel and to work inside the power supply, the PPE

required is: safety glasses and a long-sleeved shirt. Also use the Voltage Verification Unit (VVU) on the

power supply front panel.

Figure 8 – Location of main breaker and cable-disconnect outside the UITF Enclosure for the solenoid magnet

power supply

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Operational Safety Procedure Form

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Responsible Personnel

The individuals responsible for the operation of the solenoid will be trained and listed here.

Andy Sandorfi [email protected] 5457

Xiangdong Wei [email protected] 5266

Charles Hanretty [email protected] 5023

Kevin Banks [email protected] 7418

Probir Ghoshal [email protected] 6702

David Kashy [email protected] 7275

Nicholas Sandoval [email protected] 6645

Ruben Fair [email protected] 6113

10. Notification of Affected Personnel (who, how, and when include building manager, safety warden, and area coordinator)

11. List the Steps Required to Execute the Procedure: from start to finish.

Reference should be made to Document No. B000000400-P010 – Hall B HDIce Dump Solenoid Power

Up and Power Down Procedure for full details on how to operate the magnet. A summary of the key

steps is provided here and reference should be made to Figures 6 and 7 within this OSP. (Note: SME =

Subject Matter Expert)

Instruction Action

CHECKS AND INITIAL SETTINGS ON THE MPS CONTROL SCREEN BEFORE ENERGIZING MAGNET 1 Set the Current Setpoint to 0 (zero) A. [This is

to avoid any unintentional current ramps before all checks have been completed].

Type ‘0’ (i.e. zero) in the field and hit the Enter key on the keyboard.

If the control screen does not allow you to do this, call the SME

2 Check that all the indicator LEDs are green. If any are RED, click the ‘Faults’ Reset button

If the faults cannot be cleared, call the SME

3 Check that all interlock indicator LEDs are green

If any are RED, click the Interlocks Reset button

If the interlocks cannot be cleared, call the SME

4 Turn ON the Magnet Power Supply Click the ‘Contactor’ ON button to turn the power supply on

ENERGIZING (POWERING UP) THE MAGNET 5 Type in the required magnet current in the Current Setpoint field hit Enter on the keyboard to start the ramp

up. The magnet current will increase to the required set point at a rate of 5 A/s.

6 If there are any trips, one of more of the Interlock LED indicators will turn RED and the magnet will run down to zero current at a rate of 10 A/s. If this happens call the SME.

Instruction Action DE-ENERGIZING (POWERING DOWN) THE MAGNET 1 Type in the required magnet current in the Current Setpoint field and hit Enter on the keyboard to start the

ramp down. The magnet current will decrease to the required set point at a rate of 5 A/s.

2 If there are any trips, one of more of the Interlock LED indicators will turn RED and the magnet will run down to zero current at a rate of 10 A/s. If this happens call the SME.

Page 14: Status: PROCESSED

Operational Safety Procedure Form

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Reversing Polarity

Reversing polarity can be achieved by swapping the POSITIVE and NEGATIVE lead connections at the

power supply end, and not at the solenoid end as the connections there are all insulated.

Once all the interlock checks have been completed, the magnet can be energized as usual via the power

supply EPICS control screen.

12. Back Out Procedure(s) i.e. steps necessary to restore the equipment/area to a safe level.

Set the magnet current to zero and turn off the power supply.

13. Special environmental control requirements:

13.1 List materials, chemicals, gasses that could impact the environment (ensure these are considered when choosing

Subject Mater Experts) and explore EMP-04 Project/Activity/Experiment Environmental Review below

None

13.2 Environmental impacts (See EMP-04 Project/Activity/Experiment Environmental Review)

None

13.3 Abatement steps (secondary containment or special packaging requirements)

None

14. Unusual/Emergency Procedures (e.g., loss of power, spills, fire, etc.)

N/A

15. Instrument Calibration Requirements (e.g., safety system/device recertification, RF probe calibration)

N/A

16. Inspection Schedules

17. References/Associated/Relevant Documentation

18. List of Records Generated (Include Location / Review and Approved procedure)

Distribution: Copies to Affected Area, Authors, Division Safety Officer

Expiration: Forward to ESH&Q Document Control

Form Revision Summary Revision 1.4 – 06/20/16 – Repositioned “Scope of Work” to clarify processes

Qualifying Periodic Review – 02/19/14 – No substantive changes required

Revision 1.3 – 11/27/13 – Added “Owning Organization” to more accurately reflect laboratory operations.

Page 15: Status: PROCESSED

Operational Safety Procedure Form

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Revision 1.2 – 09/15/12 – Update form to conform to electronic review.

Revision 1.1 – 04/03/12 – Risk Code 0 switched to N to be consistent with 3210 T3 Risk Code Assignment.

Revision 1.0 – 12/01/11 – Added reasoning for OSP to aid in appropriate review determination.

Revision 0.0 – 10/05/09 – Updated to reflect current laboratory operations

ISSUING AUTHORITY FORM TECHNICAL POINT-OF-CONTACT APPROVAL DATE REVIEW DATE REV.

ESH&Q Division Harry Fanning 06/20/16 06/20/19 1.4

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Task Hazard Analysis (THA) Worksheet (See ES&H Manual Chapter 3210 Appendix T1

Work Planning, Control, and Authorization Procedure)

Author: Ruben Fair Date: November 11, 2019 Task #: If applicable

Complete all information. Use as many sheets as necessary

Task Title: HDIce Dump Solenoid Task Location: UITF Enclosure (Cave 2)

Division: ENP Department: Magnet Group Frequency of use: Daily

Lead Worker: Probir Ghoshal

Mitigation already in place: Standard Protecting Measures Work Control Documents

See OSP, “HDIce Dump Solenoid”

Sequence

of Task

Steps Task Steps/Potential Hazards Consequence

Level

Probability

Level

Risk

Code

(before

mitigation)

Proposed Mitigation (Required for Risk Code >2)

Safety Procedures/

Practices/Controls/Training

Risk

Code (after

mitigation

1 Electrical Hazard M M 3

All electrical leads covered.

Temporary rope or tape

barriers, flashing beacons and

signage for magnetic fields

Read and Adhere to this OSP Training:

SAF603 Electrical Hazard Awareness

SAF104 Lock, Tag and Try

1

2 Magnetic Field Hazard L H 3

Interlocked door Postings:

Signs, Strobe lights, flashing

red beacons 5 Gauss barrier

markings

Read and Adhere to

This OSP

ESH Manual Chapter 6420

1

3 Magnet Heating L M 2 LCW cooling, Thermal switch

Interlocks Read and Adhere to this OSP 1

Highest Risk Code before Mitigation: 3 Highest Risk Code after Mitigation: 1

Click

For Word Doc

Page 17: Status: PROCESSED

Task Hazard Analysis (THA) Worksheet (See ES&H Manual Chapter 3210 Appendix T1

Work Planning, Control, and Authorization Procedure)

For questions or comments regarding this form contact the Technical Point-of-Contact Harry Fanning

This document is controlled as an on line file. It may be printed but the print copy is not a controlled document. It is the user’s responsibility to ensure that the document is the same revision as the

current on line file. This copy was printed on 11/11/2019.

Page

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When completed, if the analysis indicates that the Risk Code before mitigation for any steps is “medium” or higher (RC≥3), then a formal Work Control Document (WCD) is developed for

the task. Attach this completed Task Hazard Analysis Worksheet. Have the package reviewed and approved prior to beginning work. (See ES&H Manual Chapter 3310 Operational

Safety Procedure Program.)

Page 18: Status: PROCESSED

Task Hazard Analysis (THA) Worksheet (See ES&H Manual Chapter 3210 Appendix T1

Work Planning, Control, and Authorization Procedure)

For questions or comments regarding this form contact the Technical Point-of-Contact Harry Fanning

This document is controlled as an on line file. It may be printed but the print copy is not a controlled document. It is the user’s responsibility to ensure that the document is the same revision as the

current on line file. This copy was printed on 11/11/2019.

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Form Revision Summary Periodic Review – 08/29/18 – No changes per TPOC

Periodic Review – 08/13/15 – No changes per TPOC

Revision 0.1 – 06/19/12 - Triennial Review. Update to format.

Revision 0.0 – 10/05/09 – Written to document current laboratory operational procedure.

ISSUING AUTHORITY TECHNICAL POINT-OF-CONTACT APPROVAL DATE REVIEW DATE REV.

ESH&Q Division Harry Fanning 08/29/18 08/29/21 0.1

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By signing this page, you testify that you have read, understand, and agree to abide by the procedurespecified in the above referenced work control document:

Serial Number: ENP-19-95104-OSPTitle: HDIce Dump Solenoid – Operating Magnet to Full Field

Name Signature Date