An overview of safety assessment, regulation, and control of hazardous material use at NREL

Abstract

This paper summarizes the methodology we use to ensur_'_¢safe-use-of ...... ..... hazardous materials at the National Renewable Energy Laboratory (NREL). First. we analyze the processes and the materials used in those processes to identify the hazards presented. Then we study federal, state, and local regulations and apply the relevant requirements ).o our operations.When necessary, we generate internal safety documents to consolidate this information. We design research operations and support systems to conform to these requirements. Befo,,_ we construct the systems, we perform a semiquandtative risk analysis on likely accident scenarios. Ali scenarios presenting an unacceptable risk require system or procedural modifications to reduce the risk. FoLlowing these modifications, we repeat the risk analysis to ensure that the respective accident scenarios present an acce0table risk. Once ali risks are acceptable, we conduct an operational readiness review (ORR). A managementappointed panel performs the ORR ensuring compliance with all relevant requirements. After sac_ completion of tlm ORR, operafioas can begin. INTRODUCTIONNREL conducts research on virtually the entire spectrum of renewable energy technologies. A port/on of NREL's internal research activities is in advanced material technologies for photovoltaic (PV) applications. The fabrication ofPV devices often involves the use of materials, chemicals, and processes with intrinsic hazards.These hazards include the use of toxic, corrosive, flammable, and pyrophoric gases, liquids, and/or solids; known as hazardous production materials (HPMs) under the Uniform Fire Code (UFC -Section 51.102) I. The NREL systems using these chemicals are not production-scale operations. The quantifies of chemicals in use are small. However, they have one or more hazard makings of 3 or 4 and are used directly in research processes. Therefore, they meet the clef'tuitionof an HPM.We present in this paper a methodolo_' for ensuring the safe use of HPMs in our facilities. In the past, the elements of this methodology were applied informally. Recendy, with the assistance of Environment, Safety, and Health (ES&H) experts from Brookhaven National Laboratory (BNL), we have formalized the process. Figure 1 is a flow chart that illustrates the individual steps of this methodology. IDENTIFICATION OF HAZARDSThe fin'st step in this process is the identification of hazards. There are basically two areas that we investigate to identify hazards. First we look at the materials involved in PV device fabrication. By analyzing the material safety data sheets and