Ln-mpia-des-gen

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LINC-NIRVANA Safety: Hazard Analysis and Risk Assessment Doc. No. Short Title Issue Date Prepared Approved Released LN-MPIA-DES-GEN-006 Safety 1.0 09 May 2011 M. Kürster 09 May 2011 Name Date LN Core team 09 May 2011 Name Date M. Kürster 09 May 2011 Name Date Signature Signature Signature LN-MPIA-DES-GEN-006 – Safety – Issue 1.0 Change Record Issue Date Sect. Reason/Initiation/Documents/Remarks 0.1 20.04.2011 All New document 1.0 09.05.2011 All Comments by T. Herbst, A. Conrad, R. Hofferbert implemented LN-MPIA-DES-GEN-006 – Safety – Issue 1.0 Contents 1 Scope 1 2 Applicable documents 2 3 Terms and Abbreviations 2 4 General regulations in place 3 5 4.1 Authorized personnel 3 4.2 Signs 3 4.3 Safety notes in project manuals 4 4.4 LBTO safety guidelines 5 Hazard analysis and risk assessment 6 5.1 Adopted standard 6 5.2 Categorization of hazards 6 5.3 Hazard analysis 6 5.4 Risk assessment 8 5.5 Prevention of risks 10 5.6 Implementation of risk prevention 12 5.7 Conclusion 17 Appendix A: Memo on the operation of the ceiling crane in the integration hall 18 Appendix B: LBTO safety guidelines 19 List of Figures Fig. 1. Dust control regulations for the integration hall ............................................................................... 3 Fig. 2. Safety regulations for the portable scaffolding ................................................................................. 4 List of Tables Table 1. Risk assessment - probability Table 2. Risk assessment – severity/impact Table 3. Risk assessment – risk index Table 4. Risk assessment – acceptability category Table 5. Hazard analysis and risk assessment Table 6. Risk assessment - summary 8 8 9 9 13 17 LN-MPIA-DES-GEN-006 – Safety – Issue 1.0 LN-MPIA-DES-GEN-006 – Safety – Issue 1.0 1 1 Scope This document addresses potential safety issues for personnel presented by the LINC-NIRVANA instrument as well as potential hazards to the instrument itself, parts thereof, or to equipment in general. Before the start of the main integration phase all safety critical issues need to be identified with a clear proposal for prevention or alleviation. In the LINC-NIRVANA project the phase of manufacturing or procuring units and sub-systems of the instrument is largely nearing its end. For the upcoming AIV (assembly, integration, and verification) efforts at MPIA as well as at LBT Observatory on Mt. Graham a set of rules and procedures is needed in order to protect people and hardware as far as possible. Concerning safety procedures and hardware handling all team members need to work according to the same principles. Not only will such an approach constitute an improvement for the efficiency of the work and make the work safer, but it will also permit the project to remain focused by avoiding unforeseen events that would jeopardize the schedule or the whole project. The document is structured as follows: An overview of regulations already in place for the integration of the instrument is followed by a hazard analysis and risk assessment. To this end, the hazards are characterized by category following the ISO 14121-1:2007 standard for safety of machinery (AD1). Hazards related to the LINC-NIRVANA instrument are identified along with their potential occurrence in the different phases of the life cycle of the instrument as well as their effect on personnel or equipment. Subsequently, these hazards are then evaluated according to severity and probability of occurrence, and both criteria are combined into a risk index. Measures to alleviate these risks are then identified. Finally, the acceptability of each risk is derived from the risk index. An earlier document “Safety and Hazard Management” was presented at the LINC-NIRVANA Final Design Review (AD2). Risks identified there can in principle also be found in the present document, but while the earlier document largely associated them with the individual sub-systems of the instrument, the present document groups them into risk categories as defined by the ISO 14121-1:2007 standard. A similar, slightly modified assessment scheme was applied in the earlier document. Whenever the present assessment of a risk differs from that identified for a similar risk in the earlier document the new assessment supersedes the old one. 2 LN-MPIA-DES-GEN-006 – Safety – Issue 1.0 2 Applicable documents No. Document Number / Issue Title AD1 ISO 14121-1:2007 Safety of machinery – risk assessment AD2 LN-MPIA-FDR-GEN-006 Safety and Hazard Management, Issue 1.0 AD3 LN-MPIA-MEM-PM-007 Risk assessment for LINC-NIRVANA, Issue 0.1 AD4 IEC 61010-1:2010 Safety requirements for electrical equipment for measurement, control, and laboratory use AD5 Guidelines for observers at the LBT 3 Terms and Abbreviations AD AIV el. ESO FFTS GWS HW IEC ISO Applicable document Assembly, integration, and verification electronics European Southern Observatory Fringe and flexure tracking system Ground-layer wavefront sensor Hardware International Electrotechnical Commission International Organization for Standardization He LBT LBTO MHWS MPIA RF SW Helium Large Binocular Telescope Large Binocular Telescope Observatory Mid-high wavefront sensor Max Planck Institute for Astronomy Radio frequency Software LN-MPIA-DES-GEN-006 – Safety – Issue 1.0 3 4 General regulations in place 4.1 Authorized personnel The LINC-NIRVANA team has been repeatedly informed during team meetings and through the pertinent minutes that handling devices may only be operated by authorized personnel who have received suitable training in their correct use. Available user manuals and the safety instructions therein must be followed. These devices comprise • the ceiling crane of the integration hall (see Appendix A.1 for the corresponding memo) as well as that of the neighbouring hall for AIV activities planned there (the so-called “pathfinder” assembly) • the hydraulic instrument tipping device (the whole instrument can be inclined by 90°, a mechanical telescope simulator used for flexure characterization tests) • the motorized cryostat installation device and rail system 4.2 Signs The following instructions exist as posted signs. Fig. 1 shows regulations for dust control located at the entrance to the air lock of the integration hall in order to maintain a class 100 000 clean room standard in the main hall. This is also a precondition for the proper operation of the class 100 clean room (laminar flow unit) inside the hall where cryo-mechanical and optical components are assembled. The equivalent sign is also posted in German (not shown). Fig. 2 shows a bilingual (German/English) safety regulation concerning the proper use of a hatch in the auxiliary scaffolding in order to prevent accidents. Fig. 1. Dust control regulations for the integration hall 4 LN-MPIA-DES-GEN-006 – Safety – Issue 1.0 Fig. 2. Safety regulations for the portable scaffolding 4.3 Safety notes in project manuals All hardware manuals produced by the LINC-NIRVANA project for the individual sub-systems of the instrument have a section on safety. The applicable document template foresees a corresponding section “READ FIRST” (safety information and precautions). The hardware manuals also foresee a section on handling and cleanliness. To give an example, defined safety instructions exist for all user manuals that will become available for the various motion control electronics (an MPIA development). They will address the following points: • personnel qualifications o technical training o necessary experience o proper instructions • general safety instructions o observance of standard regulations and guidelines o country-specific installation standards, prevailing safety regulations, and accident prevention rules o explicit warnings of mains voltage, restrictions applying when opening the chassis, necessity to prevent objects or liquids from penetrating into the equipment, need for grounding1 • appropriate use, i.e. shutting down and securing equipment in cases of o visible damage o damaged connectors or cables o improper functioning • warning about misuse 1 Power supply units are built according to IEC 61010-1:2010 (AD4). LN-MPIA-DES-GEN-006 – Safety – Issue 1.0 5 4.4 LBTO safety guidelines The LBTO has issued “Guidelines for observers at the LBT” (AD4) which can be found here: http://abell.as.arizona.edu/~lbtsci/Documents/LBT_observer_guidelines.pdf . These guidelines must be adhered to by all personnel assembling, installing, and operating LINCNIRVANA at the LBT (not only by “observers,” i.e. astronomers, as the title may suggest). The following important regulations can be found there • medical alerts • road warnings • safety guidelines A signed acceptance declaration must be sent to the LBT prior to arrival. To facilitate cross-referencing, this guideline is replicated here as Appendix B to the present document (see below). Please note that Appendix B necessarily reflects the status of the guideline at the time of writing of the present document. Should it undergoes change, the new version becomes binding. 6 LN-MPIA-DES-GEN-006 – Safety – Issue 1.0 5 Hazard analysis and risk assessment 5.1 Adopted standard Since there are no formal safety standards provided by the Large Binocular Telescope Observatory (LBTO) for instruments to be installed on Mt. Graham, we adopt the ISO 14142-1:2007 standard for safety of machinery as the basis of this hazard analysis and risk assessment. This standard is also applied during CE-certification of products delivered within the European Union. Since the instrument is located in Europe during a large part of its life cycle this standard is a natural choice.2 5.2 Categorization of hazards The check list for potential hazards provided by ISO 14121-1:2007 (AD4) is represented in the first four columns of Table 5. It yields a categorization of the potential hazards into the following types or groups: (1) Mechanical hazards (2) Electrical hazards (3) Thermal hazards (4) Noise hazards (5) Vibration hazards (6) Radiation hazards (this includes also laser light) (7) Material/substance hazards (8) Ergonomic hazards (9) Hazards associated with environment in which the machine is used (10) Combination of hazards For each of these groups the check list provides examples of hazards, along with their origin and potential consequences (third and fourth column in Table 5). 5.3 Hazard analysis The fifth column of Table 5 (“Phase of machine life cycle”) indicates the phases of the machine life cycle at which hazards that exist in the LINC-NIRVANA project may occur. These hazards are listed in the sixth column. The seventh column indicates whether the hazards affect people or equipment. The following definitions apply: 2 A similar procedure for hazard categorization and risk assessment is applied by the European Southern Observatory (ESO) and documented in their internal document VLT-SPE-ESO-10000-0017. LN-MPIA-DES-GEN-006 – Safety – Issue 1.0 7 Machine life cycle (following ISO 14121-1:2007) (1) Transport (2) Assembly, installation, commissioning (3) Setting, teaching/programming and/or process changeover (4) Operation (5) Cleaning, maintenance (6) Fault finding/troubleshooting (7) Decommissioning, dismantling This machine life cycle definition does not include design and manufacture even though safety features can and must be designed into the instrument early on. Whenever this has been done it is considered in the present analysis as a preventive measure. Designs are regularly subjected to design reviews. The manufacturing processes follow established safety regulations for the mechanics and electronics workshops supervised by institute internal safety officers and the “Berufsgenossenschaft” (institution for statutory accident insurance and prevention). These regulations are not repeated here. Aggrieved person or target (P) People (E) Equipment 8 LN-MPIA-DES-GEN-006 – Safety – Issue 1.0 5.4 Risk assessment Columns 8-10 in Table 5 provide the severity, probability, and a risk index for each hazard thereby assuming “average” or “typical” cases; note, however, that under actual circumstances these values can differ substantially from case to case. The following assessment scheme is adopted: Probability (see also AD3) Table 1. Risk assessment - probability Grade Probability Approximate frequency Description 1 Rare 10% The occurrence of this hazard is unlikely in the corresponding phase or over the lifetime of the Instrument 2 Possible 20% The chance that this hazard occurs in the corresponding phase or the lifetime of the Instrument definitely requires consideration 3 Likely 50% There is a high chance, however it is not inevitable, that the hazard occurs in the corresponding phase or the lifetime of the Instrument 4 Highly Likely 75% The occurrence of the hazard is almost inevitable in the corresponding phase or the lifetime of the Instrument Severity / impact (see also AD3) Table 2. Risk assessment – severity/impact Grade Severity Impact on people Impact on equipment 1 Insignificant Minor injury that can be healed, small effect on working capacity Minor impact on functionality requiring remedial action 2 Moderate Injury that requires medical treatment and leads to nonproductive time Performance or functionality is compromised requiring review and possible changes to science specification or operation mode 3 Major problem Permanent occupational disability, albeit with a minor impact on the quality of life Failure to meet one or more major requirements, leading to severely restricted science capabilities 5 Catastrophic Death or permanent occupational disability with a high impact on the quality of life Failure is so severe that the instrument can effectively not be used Problem Note: the highest severity is graded at level 5 to highlight the significant impact of these hazards LN-MPIA-DES-GEN-006 – Safety – Issue 1.0 9 Risk index The risk index is calculated as the product of severity and probability. Risk indices <3, 3-8, and >8 indicate low, medium, and high risk, respectively, as shown in the following chart. Table 3. Risk assessment – risk index Risk Index Probability highly likely 4 4 8 12 20 likely 3 3 6 9 15 possible 2 2 4 6 10 rare 1 1 2 3 5 Severity / 1 2 3 5 Impact insignificant moderate major catastrophic Acceptability In order to decide under which circumstances the risk associated with a given hazard is acceptable or not the following chart is applied. Table 4. Risk assessment – acceptability category Level Risk index Acceptability category High >8 Unacceptable risk under any circumstances Medium 3-8 Acceptable, but requiring review and approval by team and observatory Low <3 Acceptable 10 LN-MPIA-DES-GEN-006 – Safety – Issue 1.0 5.5 Prevention of risks The last column of Table 5 indicates the preventive measures in place. They comprise: Personnel qualification and procedures: • Clear procedures, e.g. for handling • Checklists and plans • Labels, signs, and memos • Regular preventive inspections/maintenance • Only trained and authorized personnel operates critical equipment • Instructions/training of personnel • Staying clear of moving hardware • Inspection for and removal of loose objects • Ventilation as needed • Suitable breaks and rest periods • Avoid rushes • Stop work during extreme conditions • Close telescope building (“dome”), if needed • Ensure sufficient water supply to prevent dehydration • Use lip balm, if needed • Rapid medical treatment (to limit damage), see LBTO safety guidelines (AD5 and Appendix B) • Emergency procedures, including shutdown • Do not work alone • Stay in radio contact Standards: • International low voltage directives • Documentation Design choices: • Proper material selection by design • Risk avoidance by design • Use of nonhazardous devices (e.g. class 1 and class 1M lasers only) LN-MPIA-DES-GEN-006 – Safety – Issue 1.0 Technical safety equipment: • Safety protection devices, such as chains • Emergency stop buttons distributed throughout the instrument • Software and hardware collision control systems • Software and hardware interlocks • Safety valves • Dew point control • Circuit breakers • Line fuses • Housing and covers • Labels for high voltage • Clean room conditions Safety equipment for personnel: • Safety shoes • Helmets • Hearing protection, if needed • Proper clothing such as parkas, caps, gloves 11 12 LN-MPIA-DES-GEN-006 – Safety – Issue 1.0 5.6 Implementation of risk prevention In order to proactively prevent or minimize risks the following measures are already installed or foreseen: Training of personnel Before team members begin to work with the related tools and machineries they routinely receive instructions by the appointed MPIA safety officers for (a) radiation protection (b) lasers (c) cryogenics and vaccum technology - Uwe Graser or Ulrich Grözinger - Peter Bizenberger or Ralf-Rainer Rohloff - Werner Laun The MPIA has offered training courses on safety, fire fighting, etc., and will continue to do so. Supervision of safety standards is routinely provided by trained institute internal safety officers and, upon request, also by the “Berufsgenossenschaft” (institution for statutory accident insurance and prevention). Communication of identified risks and procedures to be followed Risks identified in the LINC-NIRVANA project as well as the established procedures to follow in order to avoid or alleviate them are communicated via a dedicated wiki page https://svn.mpia.de/trac/gulli/ln/wiki/safety within the team-internal groupware (LINC-NIRVANA Trac: https://svn.mpia.de/trac/gulli/ln ). These procedures are established by the LINC-NIRVANA project manager upon consultation with the LINCNIRVANA team.  Team members are repeatedly notified by e-mail and at team meetings that the procedures are binding, and that they are expected to know them. Relevant safety documents and memos can be downloaded from the dedicated wiki page. While the page is still evolving all team members are encouraged to contribute to these procedures in order to optimize them and make sure they cover a spectrum of cases as broad as possible, but without unnecessary overregulation. Institute internal safety officers are asked to review these regulations. Any change to the procedures and regulations is not only reflected by the corresponding modification of the wiki page, but also communicated to the LINC-NIRVANA team by e-mail and at team meetings. LN-MPIA-DES-GEN-006 – Safety – Issue 1.0 13 Table 5. Hazard analysis and risk assessment # 1 Type or group Mechanical hazards Examples of hazards (according to ISO 14121:2007) Origina Potential consequencesb − Acceleration, deceleration (kinetic energy) − Angular parts − Approach of a moving element to a fixed part − Cutting parts − Elastic elements − Falling objects − Gravity (stored energy) − Height from the ground − High pressure − Machinery mobility − Moving elements − Rotating elements − Rough, slippery surface − Sharp edges − Stability - Being run over - Being thrown - Crushing - Cutting or severing - Drawing-in or trapping - Entanglement - Friction or abrasion - Impact - Injection - Shearing - Slipping, tripping and falling - Stabbing or puncture - Suffocation Phase of machine life cycle Description of the potential hazard Affect -ed Sever -ity Probability Risk Prevention index (averge/typical value) Handling errors: 2-3, 5-7 - Cryostat can fall during erroneous installation process P,E 5 1 5 - Only trained and authorized personnel; clear procedure to be 2-3, 5-7 - Disregard of center-of-gravity of loads during crane P,E 3 2 6 - Only trained and authorized personnel, memo, do not work 2-3, 5-7 - Falling from bench (height about 4m) P 5 1 5 - Safety protection chains; training of personnel; signs 2-3, 5-7 - Falling from scaffolding or telescope P 5 1 5 - Training of personnel; signs; do not work alone 2-3, 5-7 - Dropping of components and assemblies P,E 3 2 6 - Handling procedures, safety shoes, helmets 2-3, 5-7 - Loads falling from crane P,E 3 2 6 - Only trained and authorized personnel, memo, handling 2-7 - Accessing or working on the moving telescope area P,E 5 1 6 - Clear disable procedure for telescope, do not work alone or defined and implemented; do not work alone operation or erroneous fixation of loads alone do not work alone procedures, safety shoes, helmets stay in radio contact − Vacuum Fatigue of material: 1-7 - Material failure of fixations and mounts E 3 1 3 - Preventive inspections/maintenance; proper material selection by design Collision/contact with 1-3, 5-7 - Crane hook or load P,E 2 2 4 - Helmets; only trained & authorized personnel operates crane 2-7 - Rotating GWS bearings P 3 1 3 - Switch off control rack or cabinet; nearest emergency stop 2-3, 5-7 - Rotating K-mirrors P,E 3 1 3 - Switch off control rack or cabinet; nearest emergency stop 2-3, 5-7 - Mechanical cryostat installation device P,E 3 1 3 - Switch off device; emergency stop button; signs 2-3 - Tipping instrument moved by the telescope simulator P 2 1 2 - Tipping only by authorized personnel; stay clear of bench 2-3 - Overheating of hydraulic system of tipping device E 1 1 1 - New cooling system in preparation; before installed limit the 2-6 - Objects falling from bench when instrument is tipped P,E 3 1 3 - Inspect for & remove loose objects from bench; stay clear 2 - Switch off control rack or cabinet; nearest emergency stop button; signs; do not work alone or stay in radio contact button; signs do not work alone or stay in radio contact 2-3, 5-6 - Moving star enlargers of the wavefront sensors MHWS P,E 2 1 duration of use and GWS (eople: hazard for hands; equipment: collision button; SW and HW collision control systems and regular of parts) maintenance thereof 2-3, 5-6 - Moving motorized optical adjustments P,E 1 1 1 - Switch off control rack or cabinet; nearest emergency stop 2-3, 4-7 - Moving fold mirror of the calibration units P 1 1 1 - Switch off control rack or cabinet; nearest emergency stop 2-3, 5-7 - Moving fibre plates of the calibration units P 1 1 1 - Switch off control rack or cabinet; nearest emergency stop 2-3, 5-7 - Moving parts in the cold channel during warm tests P 1 3 3 - Switch off control rack or cabinet; nearest emergency stop 2-3, 5-7 - Support structure, cabinets, etc. in crowded areas P,E 1 3 3 - Helmets and safety shoes; signs button button button (cold mechanisms and wheels, FFTS drive and shields) button 14 # LN-MPIA-DES-GEN-006 – Safety – Issue 1.0 Type or group Examples of hazards (according to ISO 14121:2007) Origina Phase of machine life cycle Description of the potential hazard Affect -ed 2-3, 5-7 - Collapsing assemblies due to break of materials P 2 3 6 - Review of designs and delivered product; preventive 2-3, 5-7 - Interior of turbo-molecular pump (hands) P 1 1 1 - prevented by design, all moving parts are encapsulated P 3 1 3 Potential consequencesb Mechanical hazards (cont’d) Sever -ity Probability Risk (averge/typical value) inspections and maintenance; safety shoes Hazards associated with cryogenics and vacuum: 2-7 - Suffocation due to evaporating coolant/He leaks - Ventilation (open door) when in cooling machine room; (in cooling machine room at MPIA) 2 Electrical hazards Prevention index − Arc − Electromagnetic phenomena − Electrostatic phenomena − Live parts − Not enough distance to live parts under high voltage − Overload − Parts which have become live under fault conditions − Short-circuit − Thermal radiation − Burn − Chemical effects − Effects on medical implants − Electrocution − Falling, being thrown − Fire − Projection of molten particles − Shock designed-in safety valves minimize leaks - Avoided by design 2-7 - Implosions P,E 5 1 5 2-7 - Overpressure during warm-up, explosions P,E 5 1 5 P,E 3 1 3 - Electronics built according to international low voltage P 5 1 5 - Mechanical housing covers live parts, identification of high - Procedures; safety valves close above 40 bar; inbuilt redundancy in safety valve system Overheating and electrical shock: 2-6 - Overheating due to electrical short or interruption in power cables 2-3, 5-7 - Electrical shock caused by high voltage for directives, circuit breaker and line fuses, regular inspections piezo elements voltage by labels, technical documentation, regular inspection of insulation 2-6 - Spikes in electrical systems P,E 5 1 5 - Electronics built according to international low voltage 2-6 - Short circuits due to glycol/water leaks E 5 1 5 - Safety protection valves, avoided by design - Damage of electronics due to glycol/water leaks E 5 1 5 - Safety protection valves, avoided by design E 5 1 5 - UPS is provided by the observatory P 3 1 3 - Designed-in safety valves minimize leaks; directives, circuit breaker and line fuses, regular inspections Loss of power: 2-6 - Concerns all critical components that require uninterrupted poser supply (UPS) 3 Thermal hazards − Explosion − Flame − Objects or materials with a high or low temperature − Radiation from heat sources − Burn − Dehydration − Discomfort − Frostbite − Injuries by the radiation of heat sources Frostbite due to 2-3, 5-7 instructions/training; rapid medical treatment, see LBTO safety guidelines (AD5 and Appendix B) Overheating: − Scald 4 Noise hazards - Cavitation phenomena - Exhausting system - Gas leaking at high speed - Manufacturing process (stamping, cutting, etc.) - Moving parts - Scraping surfaces - Unbalanced rotating parts - Whistling pneumatics - Worn parts - Discomfort Loss of awareness Loss of balance Permanent hearing loss Stress Tinnitus Tiredness Any other (e.g. mechanical, electrical) as a consequence of an interference with speech communication or with acoustic signals - Contact with coolant (He) and cold parts - Loss of electronics cooling E 2 2 4 - Software and hardware interlocks Hearing disorders due to 2-3 - Noise from hydraulic instrument tipping device P 1 1 1 - Hearing protection; signs 2-3, 5-7 - Leaking coolant (He) P 3 1 3 - Designed-in safety valves minimize leaks; rapid medical Treatment, see LBTO safety guidelines (AD5 and 2-7 Appendix B) - Noise from stirling cooler P 1 1 1 - Hearing protection, signs LN-MPIA-DES-GEN-006 – Safety – Issue 1.0 # 5 Type or group Vibration Hazards Examples of hazards (according to ISO 14121:2007) Origina Potential consequencesb - Cavitation phenomena - Misalignment of moving parts - Mobile equipment - Scraping surfaces - Unbalanced rotating parts - Vibrating equipment - Worn parts - - Ionising radiation source - Low frequency electromagnetic radiation - Optical radiation (infrared, visible and ultraviolet), including laser - Radio frequency electromagnetic radiation - Aerosol - Biological and microbiological (viral or bacterial) agent - Combustible - Dust - Explosive - Fibre - Flammable - Fluid - Fume - Gas - Mist - Oxidizer - Burn - Damage to eyes and skin - Effects on reproductive capability - Genetic mutation - Headache, insomnia, etc. Discomfort Low-back morbidity Neurological disorder Osteo-articular disorder Trauma of the spine Vascular disorder 15 Phase of machine life cycle Description of the potential hazard Affect -ed Sever -ity Probability Risk Prevention index (averge/typical value) Self-made vibrations due to 2-3, 6 - Work with shakers/vibration causing test equipment 2-6 External vibrations - Vibrations from the building (MPIA) or telescope P,E 1 1 1 - Only trained and authorized personnel E 2 2 4 - Designed-in damping through carbon fibre substructure and structure (LBTO) transmitted into instrument instrument bench; installed vibration monitoring system at the telescope; regular vibration mitigation efforts 6 7 Radiation hazards Material/ substance hazards - Breathing difficulties, suffocation - Cancer - Corrosion - Effects on reproductive capability - Explosion - Fire - Infection - Mutation - Poisoning - Sensitization Damage of vision due to 2-3, 6 - Optical and infrared lasers (RF compliant) P 1 1 1 - Only nonhazardous class 1 and class 1M lasers are in use; Instruction/training and warning signs, if needed Breathing difficulties and suffocation due to 2-3 - He in cooling machine room due to leaks P 3 1 3 - Ventilation (open door) when in cooling machine room; designed-in safety valves minimize leaks; warning signs; instruction/training Damage by dust and chemicals: 2-6 - Contamination of optical surfaces E 3 2 6 - Handling procedures; clean room conditions; suitable covers; 2-6 - Wind borne dust E 3 2 6 - Close telescope dome and instrument cover trained personnel Falling debris: 2,6 - Oil spill from ceiling crane E 3 2 6 - Regular maintenance of cranes; procedure: use defined park 2-7 - Ice falling from telescope dome P,E 5 1 5 - Established procedure: defrosting mechanism, inspection position outside instrument area before opening dome Condensation: 2-7 8 Ergonomic hazards - Access - Design or location of indicators and visual displays units - Design, location or identification of control devices - Effort - Flicker, dazzling, shadow, stroboscopic effect - Local lighting - Mental overload/underload - Posture - Repetitive activity - Visibility - Discomfort Fatigue Musculoskeletal disorder Stress Any other (e.g. mechanical, electrical) as a consequence of human error - Oxidation and shorts in electronics E 3 2 6 - Dew point controlled cooling systems Physical stress and disorder due to 2-3, 5-7 - Work in uncomfortable postures P 1 2 2 - Foresee suitable breaks 2-3, 5-7 - Work on scaffoldings and at height (4m) P 5 1 5 - Foresee suitable breaks; safety protection chains; do not work 4-6 - Work at nighttime and in shifts P 2 3 6 - Foresee suitable breaks and rest periods; do not work alone 4-6 - Lack of sleep P 2 3 6 - Foresee suitable breaks; stop work when too tired 4-6 - Apnea P 5 1 5 - Foresee suitable breaks; stop work when too tired; get alone rapid medical treatment, see LBTO safety guidelines (AD5 and Appendix B) 16 # 9 LN-MPIA-DES-GEN-006 – Safety – Issue 1.0 Type or group Hazards associated with environment in which the machine is used Examples of hazards (according to ISO 14121:2007) Origina Potential consequencesb - Dust and fog - Electromagnetic disturbance - Lightning - Moisture - Pollution - Snow - Temperature - Water - Wind - Lack of oxygen - Burn Slight disease Slipping, falling Suffocation Any other as a consequence of the effect caused by the sources of the hazards on the machine or parts of the machine Phase of machine life cycle Description of the potential hazard Affect -ed Sever -ity Probability Risk Prevention index (averge/typical value) Lack of oxygen, fatigue due to 2-7 - Work at high altitude (Mt. Graham, 3221m) P 2 3 6 - Work according to predefined procedures, checklists and 2-3 - He in cooling machine room due to leaks P 3 1 3 - Ventilation (open door) when in cooling machine room; plans; foresee suitable breaks; no rushes designed-in safety valves minimize leaks Discomfort and disorders due to extreme temperatures, humidity, and wind: P 3 2 6 - Proper clothing, parkas, caps, gloves (if possible); stop at too - Work at dry conditions, dehydration P 5 1 5 - Ensure sufficient water supply; use lip balm, if needed - Work at high wind speed, lose control of walking, P 3 2 6 - Stop work, close telescope building, shutdown, use proper - Work at outside temperature conditions (risk of hypothermia) extreme conditions hypothermia clothing, do not work alone Fire: - Fire in building P,E 5 1 5 - Follow established fire emergency procedures - Forest fire P 5 1 5 - Secure building and equipment, shutdown, if possible leave - Smoke damage P,E 5 1 5 - Follow established fire emergency procedures, secure the mountain building and equipment, if possible go to a smoke free area Biological contamination: - Moths in the instrument E 3 2 6 - Watch contamination, close instrument cover if needed, regular cleaning of instrument parts 10 Combination of hazards - E.g. repetitive activity + effort + high environmental temperature - E.g. dehydration, loss of awareness, heat stroke Extreme situations: 2-7 - Dehydration, loss of awareness, hypothermia P 5 1 5 - Stop work if needed; foresee suitable breaks; use proper clothing; ensure sufficient water supply; train personnel; get rapid medical treatment, see LBTO safety guidelines (AD5 and Appendix B) 2-7 - Fatigue leading to disregard of safety procedures and lack of care when moving around the building a One origin of hazards can have several potential consequences. b For each type or group of hazard, some potential consequences can be related with several origins of hazards. P 5 1 5 - Stop work if needed; foresee suitable breaks; safety training for personnel LN-MPIA-DES-GEN-006 – Safety – Issue 1.0 17 5.7 Conclusion Of the total number of 62 hazards studied (see Table 1), the following risk indices were attained: Table 6. Risk assessment - summary Level Risk index Acceptability category Number High >8 Unacceptable risk under any circumstances 0 Medium 3-8 Acceptable, but requiring review and approval by team and observatory 50 Low <3 Acceptable 12 The largest index received by any risk is 6. It can therefore be concluded that there are no unacceptable safety issues related to the LINC-NIRVANA instrument and its development, but that about 80% of the identified hazards need to be reviewed in order to verify that the proper measures are in place to prevent the associated risk. 18 LN-MPIA-DES-GEN-006 – Safety – Issue 1.0 Appendix A: Memo on the operation of the ceiling crane in the integration hall LN-MPIA-DES-GEN-006 – Safety – Issue 1.0 Appendix B: LBTO safety guidelines 19 20 LN-MPIA-DES-GEN-006 – Safety – Issue 1.0 LN-MPIA-DES-GEN-006 – Safety – Issue 1.0 21