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Chemical Inventory Reduction Processes and Metrics at Sandia National Laboratories/CA (SNL/CA)

Sandia Report SAND2006-6335P Unlimited Release Printed October 2006. Chemical Inventory Reduction Processes and Metrics at Sandia National Laboratories/CA (SNL/CA). Mark Brynildson Susie Orth SNL/CA Environmental Management Department Hazardous Materials Management Program.

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Chemical Inventory Reduction Processes and Metrics at Sandia National Laboratories/CA (SNL/CA)

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  1. Sandia ReportSAND2006-6335PUnlimited ReleasePrinted October 2006 Chemical Inventory Reduction Processes and Metrics at Sandia National Laboratories/CA (SNL/CA) Mark Brynildson Susie Orth SNL/CA Environmental Management Department Hazardous Materials Management Program Sandia is a multiprogram laboratory operated by Sandia Corporation, a Lockheed Martin Company,for the United States Department of Energy’s National Nuclear Security Administration under contract DE-AC04-94AL85000.

  2. SNL/CA Hazardous Material Reduction Drivers • 2006 SNL/CA EMS Goal - 5% reduction by container • 2006 reduce NFPA Health 3 and 4 materials in the 5 EPHA target areas with the objective of eliminating at least 2 out of the proposed 5 areas. • New DOE Requirements • DOE O 151.1C Emergency Management - Hazards Survey focus on NFPA Health 3 & 4 Materials (11/2005) • DOE requirement on the Management of Unneeded Materials and Chemicals (UMC) (12/2005) • Existing Sandia Requirements • ES&H Manual • Section 4P - Housekeeping • Chapter 5 - Fire Protection • Section 6D/6E - Haz Comm/Lab Standard - Chemical Hygiene Plan • Section 6U - Chemical Barcoding and Inventory • Fire Protection • International Fire Code Implementation

  3. Inventory Reduction Campaign Emphasis • Hazardous Materials (> 10 years old) • 23% of the SNL/CA site inventory is > 10 years old • 24% of the NFPA Health 3 & 4 inventory is > 10 years old • Hazardous Materials (> 5 years old) • 45% of the SNL/CA site inventory is > 5 years old • 47% of the NFPA Health 3 & 4 inventory is > 5 years old

  4. Chemical Information System (CIS) • Integrated Chemical Inventory and Material Safety Data Sheet (MSDS) Container Tracking System • Current Inventory and Historical Data Storage • ~120,000 Tracked Chemical Containers at SNL/NM • ~35,000 Tracked Chemical Containers at SNL/CA • ~ 25,000 Unique Chemicals/Chemical Products • 1500 Chemical Storage Locations (building/room) • Dynamic Inventory - Daily Inputs (new entries and disposals) • MSDS library of over 85,000 via the SNL Internet • Available for Routine or Emergencies On-site and Off-site 24 x 7 • Dynamic Library - Daily Inputs (new entries and updates) • Basis for federal/state reporting (i.e. Emergency Planning Community Right-To-Know Act)

  5. Key CIS Business Rules/Functions • Conservative Inventory Tracking Rule • All Chemical Containers are Considered Full While in the Inventory • Inventory Data is Linked an MSDS • CAS used in MSDSs forIingredients • CAS Unique Identifier for Chemical Structure • Identifies Basic Physical State but not Form • Off-line CIS Data Available Quarterly to EOC • Used when CIS is Unavailable (i.e., network/power outage)

  6. Quality Assurance • Annual Chemical Inventory Reconciliation • Reconcile differences between physical inventory and database information • Wall-to-wall walk down is conducted (May – August) • Process ensures that CIS database is in line with physical inventory • Results forwarded to lab owners and ES&H professionals for review

  7. Inventory Reduction Data Challenges • Baseline Recalculation • Organization Ownership Changes • New Locations/Organizations • Inventory is “Lost” and “Found” each year during the Summer Reconciliation • Data Presentation • Container Count vs. Received Container Contents Weight • Very Small or Very Large Containers Allow for Gaming Reduction Results

  8. Inventory Reduction Line Challenges • Academic/Organizational Freedom • Ownership/Responsibility • Product Chemical Safety • Peroxidizable, autopolymerizable • i.e., Picric Acid • Inventory is “Lost” and “Found” Each Year During the Summer Reconciliation • Product Quality • Manufacturer Expiration Dates • General Shelf Life • Product Disposal Costs • Line labor • Waste Management Chargeback

  9. Inventory Reduction - Conclusions • Hazardous Material Safety • Chemical Exposure to Personnel Reduced • General Container Integrity Improved • Risk to Environment • Spill Potential Reduced • Fugitive Emissions Reduced • Hazardous Material Storage • Storage Space Volume Better Utilitized • Housekeeping Improved • Orphaned Hazardous Material • Legacy Cleanup Cost Reduced • Stealth Inventory Management Cost Reduced

  10. Unresolved Challenges • Procurement Controls • Inventory Accuracy Requirements & Expectations • Inventory Reduction Frequency • Inventory Ownership & Orphaned Inventory • Inventory Age Profile Metrics • Inventory Shelf Life Guidelines • Graded Risk-Based Approach • Material Safety Data Set • Location Based Material Permit Limits • Excess Material Redeployment - Chemical Exchange

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