In 2000 the Hanford Tank Farms had one of the worst safety records in the Department of Energy Complex. By the end of FY08 the safety performance of the workforce had turned completely around, resulting in one of the best safety records in the DOE complex for operations of its kind. This paper describes the variety of programs and changes that were put in place to accomplish such a dramatic turn-around. The U.S. Department of Energy's 586-square-mile Hanford Site in Washington State was established during World War II as part of the Manhattan Project to develop nuclear materials to end the war. For the next several decades it continued to produce plutonium for the nation's defense, leaving behind vast quantities of radioactive and chemical waste. Much of this waste, 53,000,000 gallons, remains stored in 149 aging single-shell tanks and 28 newer double-shell tanks. One of the primary objectives at Hanford is to safely manage this waste until it can be prepared for disposal, but this has not always been easy. These giant underground tanks, many of which date back to the beginning of the Manhattan Project, range in size from 55,000 gallons up to 1.1 million gallons, and are buried beneath 10 feet of soil near the center of the site. Up to 67 of the older single-shell tanks have leaked as much as one million gallons into the surrounding soil. Liquids from the single-shell tanks were removed by 2003 but solids remain in the form of saltcake, sludges and a hardened heel at the bottom of some tanks. The Department of Energy's Office of River Protection was established to safely manage this waste until it could be prepared for disposal. For most of the last seven years the focus has been on safely retrieving waste from the 149 aging single-shell and moving it to the newer double-shell tanks. Removing waste from the tanks is a difficult and complex task. The tanks were made to put waste in, not take it out. Because of the toxic nature of the waste, both chemically as well as radiologically, all retrieval operations must be performed using remote-controlled equipment which has to be installed in each tank, then removed when retrieval is completed. This process involves a variety of potentially hazardous construction activities including crane and rigging, excavation, electrical and piping work. It also requires strong attention to safety to avoid injuries to personnel and contamination of the environment.

This Tank Farm Health and Safety Plan (HASP) for the conduct of all operations and work activities at the Hanford Site 200 Area Tank Farms is provided in order to minimize health and safety risks to workers and other onsite personnel. The HASP accomplishes this objective by establishing requirements, providing general guidelines, and conveying farm and facility-specific hazard communication information. The HASP, in conjunction with the job-specific information required by the HASP, is provided also as a reference for use during the planning of work activities at the tank farms. This HASP applies to Westinghouse Hanford Company (WHC), other prime contractors to the U.S. Department of Energy (DOE), and subcontractors to WHC who may be involved in tank farm work activities. This plan is intended to be both a requirements document and a useful reference to aid tank farm workers in understanding the safety and health issues that are encountered in routine and nonroutine work activities. The HASP defines the health and safety responsibilities of personnel working at the tank farms. It has been prepared in recognition of and is consistent with National Institute of Safety and Health (NIOSH), and Occupational Safety and Health Administration (OSHA)/Unlimited State Coast Guard (USCG)/U.S. Environmental Protection Agency (EPA), Occupational Safety and Health Guidance Manual for Hazardous Waste Site Activities (NIOSH 1985); WHC-CM-4-3, Industrial Safety Manual, Volume 4, {open_quotes}Health and Safety Programs for Hazardous Waste Operations;{close_quotes} 29 CFR 1910.120, Hazardous Waste Operations and Emergency Response; WHC-CM-1-1, Management Policies; and WHC-CM-1-3, Management Requirements and Procedures. When differences in governing regulations or policies exist, the more stringent requirements shall apply until the discrepancy can be resolved.