The only official copy of this file is the one one-line on the Superconducting Magnet Division website. Before using a printed copy, verify that it is the most current version by checking the document issue date on the website.

 

Superconducting Magnet Division, BNL

Self-Assessment Program CY07

Revision A (2/26/07)

 

CONTENTS

I. DIVISION SUMMARY

II. POLICY & GOALS

III. ORGANIZATION & RESPONSIBILITIES

IV. COMPLIANCE METHODS

 

I. DIVISION SUMMARY

The Superconducting Magnet Division at Brookhaven National Laboratory designs, fabricates, and tests superconducting magnets as well as develops and tests superconducting materials needed to support these activities.  The Division is organized into 4 sections responsible for magnet design and testing, magnet production, electrical engineering support, and cryogenic support.  The Division collaborates with many other institutions world wide in a varied program of superconducting magnet development and production.  An R&D program seeks to establish concepts and technologies for future Projects.

The primary output of the Superconducting Magnet Division is:

·        Innovative magnets for use in both particle accelerators and experimental facilities.

·        Superconducting Materials suitable for use in this and other magnet programs.

The stakeholders or customers of the Superconducting Magnet Division are:

1.      Brookhaven Science Associates in its role of management of the BNL Scientific Program

2.      The DOE in support of the mission of the Office of Science

3.      Other BNL departments, in providing expertise or equipment to carry out their programs

4.      The U.S. and world wide science community

The important features of the Superconducting Magnet Division operation in providing this output include:

·        A superconductor wire and cable test facility.

·        A large cryogenic plant.

·        In-house magnet production facilities and tooling.

·        Magnet test and field measuring capabilities.

·        Magnet design and analysis capability.

The Magnet Division aims to maintain a balance between magnet production, superconductor development, and magnet R&D.  The Magnet Division collaborates with other U.S. HEP laboratories as well as other major international research organizations in programs of mutual benefit.  The BNL Magnet Division is one of only a handful of facilities in the world that possess these kinds of skills and equipment and represents a significant capital investment of behalf of the DOE over several decades.  Potential future research facilities and the utilization of new technologies define the overall goals of the R&D program.  Magnet production is generally restricted to low volume, more complex, devices.  The Division collaborates with U.S. industries where possible in the high volume production of magnets, and materials vendors for superconducting wire and cables.  The cable test facility is unique and provides a national role in supporting many diverse U.S. programs, not only those in the HEP community.

The Superconducting Magnet Division is responsible for the activities located in buildings 899, 902, 903, 904, 905, 924, 943, 944, and 948.  The operational boundaries within which to conduct safe and environmentally sound operations are contained in the corresponding Facility Use Agreement.

The Superconducting Magnet Division is committed to carrying out this mission in a safe and environmentally sound way.  The Division has an aggressive and comprehensive program of self-assessment to ensure this commitment is maintained.

 

II. POLICY & GOALS

It is the policy of the Superconducting Magnet Division to develop and implement a Self-Assessment Program.  The program shall be described in a documented Self-Assessment Plan that is updated on an annual basis and is accessible via the Magnet Division website.  The overriding goal of the Plan is to promote continuous improvement in the Division's safety and environmental performance.

Using the BNL Assessment Planning and Evaluation Criteria Framework, and a graded approach, organization objectives shall be identified and prioritized in accordance with customer requirements and expectations, including BNL Critical Outcomes.  This will ensure that performance improvements are made in areas critical to the Division and the Laboratory.

Once objectives have been identified, resources will be committed, and assessment activities scheduled based on priorities, risk, and results of previous assessments.  Information collected from assessment activities will be analyzed to identify strengths and weaknesses in performance, and opportunities for improvement; and to monitor progress of objectives.  Where weaknesses or opportunities for improvement exist, appropriate corrective, preventive, and improvement actions will be identified.  For each action identified, a responsible individual will be assigned, along with a due date for completion.  Actions shall be tracked for progress, through completion using computer databases.  Actions associated with Tier I inspections shall be tracked using the Assessment Tracking System (ATS); all others shall be tracked using the Division's Assessment and Corrective Action Tracking System (ACATS).

A Self-Assessment Review shall be performed on an annual basis.  The Review shall include an evaluation of assessment activities, including the identification of strengths and opportunities for improvement.  As a result of the Review, focus areas for improvement shall be identified, including appropriate corrective/preventive/improvement actions.  For each action identified, a responsible individual shall be assigned, along with a due date for completion.  Actions shall be tracked for progress, through completion.  The Review shall be documented via meeting minutes, which shall form the basis of the annual Self-Evaluation Report.

The Self Assessment Program shall be compliant with, and integrated into, Laboratory management initiatives and their corresponding SBMS Management System Descriptions and Subject Areas.  Self-Assessment activities shall be integrated with the initiatives to the extent practicable.

 

III. ORGANIZATION & RESPONSIBILITIES

The Superconducting Magnet Division, which is depicted in the Division Organization Chart, is managed by the Division Head, who reports directly to the BNL Associate Laboratory Director for Nuclear and Particle Physics.  The responsibilities of the Division Head and other Division members are as follows:

Division Head

The Division Head has the overall responsibility for the Division Self-Assessment Program.  This includes the responsibility to ensure that a Self-Assessment Plan is prepared and effectively implemented.  In accomplishing this, the Division Head is responsible to identify organizational objectives, disseminate them throughout the Division, and ensure that the necessary resources are allocated to support their accomplishment.  In addition, the Division Head shall institute an annual review of the program.  This includes the responsibility to review the results of assessment activities and to approve corrective, preventive, and improvement actions recommended by staff members.  The Division Head shall also ensure that an annual Self-Assessment summary report is generated.

Section Heads

Section Heads are responsible to ensure that staff R2A2s and Job Training Assessments (JTA) are reviewed on an annual basis, and are kept current.  In addition, Section Heads shall ensure that staff have fulfilled their training requirements, and that employees only perform work for which they have been trained and qualified.

QA Representative

The QA Representative reports directly to the Division Head, and is responsible to assist him in the development and implementation of the Self-Assessment Plan and the summary report.  In addition, the QA Representative shall perform assessments in accordance with the assessment schedule, and shall recommend appropriate corrective, preventive, and improvement actions to the Division Head.  The QA Representative is also responsible to maintain the Division Corrective Action Tracking System (ACATS).  Additional responsibilities include the generation and maintenance of Facility Use Agreements.

ES&H Coordinator

The ES&H Coordinator reports directly to the Division Head, and is responsible to assist him in the development and implementation of the Self-Assessment Plan and the summary report.  In addition, the ES&H Coordinator shall perform assessments in accordance with the assessment schedule, and shall recommend appropriate corrective, preventive, and improvement actions to the Division Head.  The ES&H Coordinator is also responsible to prepare the Division Tier I Inspection Schedule, and to maintain Tier I Inspection findings in the ATS.

Training Coordinator

The Training Coordinator shall be responsible for the management and coordination of the training program in accordance with SMD-OPM 2.1.  Additional responsibilities include the periodic review of Job Training Assessments and staff links to requirements.

Work Control Manager, Work Control Coordinator, Primary Reviewer

The Work Control Manager (WCM) shall be responsible to ensure that an effective Work Planning & Control System is in effect in accordance with SMD-OPM 2.12.  Primary Reviewers are responsible for the effective application of the system and are authorized to approve work permits.  Work Control Coordinators (WCC) are responsible to screen work (where required) and determine the level of work planning.  A listing of Magnet Division Work Planning & Control personnel is maintained on the BNL Work Control Managers and Work Control Coordinators website.

Building Manager

Building Managers shall be cognizant of all building-related activities within their designated buildings, and are responsible to maintain a working knowledge of applicable Facility Use Agreements.  In addition, Building Managers are responsible to participate in Tier I inspections.  A listing of Magnet Division Building Managers is maintained on the BNL Building Manager website.

Division Secretary

The Division Secretary shall maintain the records of self-assessment activities, including reports of individual assessments, the summary report, and the Self-Assessment Plan.  In addition, the Division Secretary shall maintain the R2A2s of Division employees.

Staff

Superconducting Magnet Division staff members are responsible to work in a safe and environmentally sound way, in accordance with responsibilities contained in their R2A2s.  In addition, staff are responsible to maintain their training current in accordance with their JTAs.  Staff members are also responsible to identify opportunities for improvement in their work and work processes.

 

IV. COMPLIANCE METHODS

Superconducting Magnet Division Environmental and Safety goals and policies are obtained by an established and controlled system that ensures the following:

  • Designs are safe and will not adversely impact the environment;
  • Facilities are safe for personnel to work in and do not adversely impact the environment;
  • Standard Operating Procedures or Work Control Permits are established and reviewed for safety and will not adversely impact the environment;
  • Personnel are adequately knowledgeable and trained to perform work safely and will not cause an adverse impact to the environment.

To support these goals and policies, the Superconducting Magnet Division Operations Procedure Manual (OPM) establishes an ES&H Office, controls for Standard Operating Procedures (SOPs), a Training and Qualification Program, and a Work Control Program.  The ES&H Office supports the Division by performing safety inspections, performing safety analyses, reviewing documentation and procedures, and identifying safety and environmental concerns.  The majority of the work performed in the Division involves the fabrication and testing of magnets.  OPMs, Magnet Assembly Procedures (MAPs), and travelers are controlled SOPs which are reviewed for safety and environmental impact.  Operations that are not covered by SOPs and would not be considered as Skill of the Craft shall fall under the Work Control Program.

Implementation for the Division is shown in Table 1.  The elements of Table 1 will be reviewed annually to determine compliance with the Division's Environmental and Safety goals and policies.  The column labeled Planning & Evaluation Criteria provides a link, for each of the listed measures, to the associated element of the BNL Assessment Planning and Evaluation Criteria Framework, found in section 9.2 of the SBMS Management System Description: Integrated Assessment Program. The column labeled Performance Target provides a link to the associated BNL Performance Goals, Objectives, Measures, and Targets contained in Contract Appendix B, as applicable.

 

 

TABLE 1

Superconducting Magnet Division Self Assessment Program

Activity: Management Commitment

Measure

Goal

Line Ownership

Performance Target

Planning & Evaluation Criteria

EMS Management Review.

Conduct review in accordance with Environmental Assessments Subject Area.

Division Head

5.2.2.1

1.0 Leadership Commitment and Involvement

OSHMS Management Review

Conduct review in accordance with OHSAS 18001 Interim Procedure Integrated Management Review.

Division Head

5.2.2.1

Senior Management ESH&Q walk-through participation.

12 per year.

Division Head

N/A

ES&H topics discussed at Department meetings.

100% compliance.

Division Head

Activity: Design and Production Activity

Measure

Goal

Line Ownership

Performance Target

Planning & Evaluation Criteria

Design Reviews accomplished prior to prototyping, testing, or production.

Review all designs for safety and environmental impact.

Production/ Design Supervisor

N/A

4.0 Process Management

Production in accordance with approved documentation.

Approve all drawings, travelers, and OPMs.

Technical Support Supervisor

Review Facility Use Agreements.

Annual

ES&H Coordinator

Activity: ESH&Q Inspection Program

Measure

Goal

Line Ownership

Performance Target

Planning & Evaluation Criteria

Tier I Inspections.

Conduct in accordance with Tier I schedule.

ES&H Coordinator

N/A

5.0 Business and Operational Results

EMS Audits

Conduct audits in accordance with Environmental Assessments Subject Area.

QA Representative

5.2.2.1

OSH Audits

Conduct audits in accordance with OHSAS 18001 Interim Procedure 18001 Audit Checklist.

QA Representative

5.2.2.1

Lock Out/Tag Out

Compliance with ESH Std 1.5.1.

ES&H Coordinator

N/A

Interlock Safety for Protection of Personnel

Conduct assessment IAW Integrated Assessment Subject Area

ES&H Coordinator

N/A

Internal Controlled Documents

QA Representative

Activity: Waste Management and Minimization Program

Measure

Goal

Line Ownership

Performance Target

Planning & Evaluation Criteria

90-Day Area Management

Inspections conducted as required.

Building Manager

N/A

6.0 Compliance with Laws, Regulations, and Contractual Requirements

Waste Minimization Procedures

Procedures posted and implemented.

Building Manager

N/A

Activity: Training and Administration

Measure

Goal

Line Ownership

Performance Target

Planning & Evaluation Criteria

Training and Qualification

95% of staff linked to job-specific JTA.

95% of training requirements completed.

Training Coordinator

N/A

6.0 Compliance with Laws, Regulations, and Contractual Requirements

 

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