**BROOKHAVEN NATIONAL LABORATORY**

**PROCESS ASSESSMENT FORM**

**I. General Information**

+--------------------------+----------+-----------+---------+---------+
| Process ID:              | SM       |           |         |         |
|                          | -551-ESS |           |         |         |
+--------------------------+----------+-----------+---------+---------+
| Process Name:            | Employee |           |         |         |
|                          | Service  |           |         |         |
|                          | Station  |           |         |         |
+--------------------------+----------+-----------+---------+---------+
| Process Flow Diagrams:   | SM-55    |           |         |         |
|                          | 1-ESS-01 |           |         |         |
+--------------------------+----------+-----------+---------+---------+
| Process Description:     | This     |           |         |         |
|                          | process  |           |         |         |
|                          | includes |           |         |         |
|                          | the      |           |         |         |
|                          | on-site  |           |         |         |
|                          | au       |           |         |         |
|                          | tomotive |           |         |         |
|                          | service  |           |         |         |
|                          | station  |           |         |         |
|                          | and      |           |         |         |
|                          | fueling  |           |         |         |
|                          | op       |           |         |         |
|                          | erations |           |         |         |
|                          | for BNL  |           |         |         |
|                          | employee |           |         |         |
|                          | v        |           |         |         |
|                          | ehicles. |           |         |         |
|                          | The      |           |         |         |
|                          | f        |           |         |         |
|                          | ollowing |           |         |         |
|                          | ac       |           |         |         |
|                          | tivities |           |         |         |
|                          | are      |           |         |         |
|                          | included |           |         |         |
|                          | under    |           |         |         |
|                          | the      |           |         |         |
|                          | Employee |           |         |         |
|                          | Service  |           |         |         |
|                          | Station  |           |         |         |
|                          | Ope      |           |         |         |
|                          | rations: |           |         |         |
|                          | minor    |           |         |         |
|                          | repairs, |           |         |         |
|                          | oil      |           |         |         |
|                          | changes, |           |         |         |
|                          | engine   |           |         |         |
|                          | fluid    |           |         |         |
|                          | repl     |           |         |         |
|                          | acement, |           |         |         |
|                          | tire     |           |         |         |
|                          | repl     |           |         |         |
|                          | acement, |           |         |         |
|                          | battery  |           |         |         |
|                          | repl     |           |         |         |
|                          | acement, |           |         |         |
|                          | etc. The |           |         |         |
|                          | fueling  |           |         |         |
|                          | o        |           |         |         |
|                          | peration |           |         |         |
|                          | is       |           |         |         |
|                          | a        |           |         |         |
|                          | ttendant |           |         |         |
|                          | service  |           |         |         |
|                          | on       |           |         |         |
|                          | either   |           |         |         |
|                          | regular, |           |         |         |
|                          | plus or  |           |         |         |
|                          | super    |           |         |         |
|                          | unleaded |           |         |         |
|                          | g        |           |         |         |
|                          | asoline. |           |         |         |
|                          | Section  |           |         |         |
|                          | II and   |           |         |         |
|                          | the      |           |         |         |
|                          | above    |           |         |         |
|                          | re       |           |         |         |
|                          | ferenced |           |         |         |
|                          | Process  |           |         |         |
|                          | Flow     |           |         |         |
|                          | Diagram  |           |         |         |
|                          | provide  |           |         |         |
|                          | more     |           |         |         |
|                          | details  |           |         |         |
|                          | on the   |           |         |         |
|                          | Employee |           |         |         |
|                          | Service  |           |         |         |
|                          | Station. |           |         |         |
|                          |          |           |         |         |
|                          | The      |           |         |         |
|                          | envir    |           |         |         |
|                          | onmental |           |         |         |
|                          | aspects  |           |         |         |
|                          | as       |           |         |         |
|                          | sociated |           |         |         |
|                          | with     |           |         |         |
|                          | this     |           |         |         |
|                          | process  |           |         |         |
|                          | include: |           |         |         |
|                          | r        |           |         |         |
|                          | egulated |           |         |         |
|                          | in       |           |         |         |
|                          | dustrial |           |         |         |
|                          | waste    |           |         |         |
|                          | gen      |           |         |         |
|                          | eration, |           |         |         |
|                          | h        |           |         |         |
|                          | azardous |           |         |         |
|                          | waste    |           |         |         |
|                          | gen      |           |         |         |
|                          | eration, |           |         |         |
|                          | atm      |           |         |         |
|                          | ospheric |           |         |         |
|                          | dis      |           |         |         |
|                          | charges, |           |         |         |
|                          | and      |           |         |         |
|                          | storage  |           |         |         |
|                          | and use  |           |         |         |
|                          | of       |           |         |         |
|                          | ch       |           |         |         |
|                          | emicals. |           |         |         |
|                          |          |           |         |         |
|                          | The      |           |         |         |
|                          | relevant |           |         |         |
|                          | subject  |           |         |         |
|                          | areas    |           |         |         |
|                          | include: |           |         |         |
|                          | h        |           |         |         |
|                          | azardous |           |         |         |
|                          | waste    |           |         |         |
|                          | man      |           |         |         |
|                          | agement, |           |         |         |
|                          | oil      |           |         |         |
|                          | man      |           |         |         |
|                          | agement, |           |         |         |
|                          | p        |           |         |         |
|                          | ollution |           |         |         |
|                          | pr       |           |         |         |
|                          | evention |           |         |         |
|                          | and      |           |         |         |
|                          | waste    |           |         |         |
|                          | minim    |           |         |         |
|                          | ization, |           |         |         |
|                          | spill    |           |         |         |
|                          | r        |           |         |         |
|                          | esponse, |           |         |         |
|                          | and      |           |         |         |
|                          | storage  |           |         |         |
|                          | and      |           |         |         |
|                          | transfer |           |         |         |
|                          | of       |           |         |         |
|                          | ha       |           |         |         |
|                          | zardous. |           |         |         |
+--------------------------+----------+-----------+---------+---------+
| Dept./Div.:              | Finance  |           |         |         |
|                          | &        |           |         |         |
|                          | Admini   |           |         |         |
|                          | stration |           |         |         |
|                          | Division |           |         |         |
+--------------------------+----------+-----------+---------+---------+
| Dept. Code:              | SS       |           |         |         |
+--------------------------+----------+-----------+---------+---------+
| Building(s):             | 630      |           |         |         |
+--------------------------+----------+-----------+---------+---------+
| Room(s):                 | N/A      |           |         |         |
+--------------------------+----------+-----------+---------+---------+
| Point of Contact:        | K.       | x2526     |         |         |
|                          | Mohring  |           |         |         |
+--------------------------+----------+-----------+---------+---------+
| Prepared by:             | P. D.    | Reviewed  | ##      | K.      |
|                          | Pohlot   | by:       | ### J.  | Mohring |
|                          |          |           | Swenson |         |
+--------------------------+----------+-----------+---------+---------+
| Approved by:             |          | J.        | ####    |         |
|                          |          | Swenson   | # Date: |         |
+--------------------------+----------+-----------+---------+---------+

**II. Detailed Process Descriptions and Waste Determination**

##### The BNL Employee Service Station performs automotive repairs, NYS vehicle inspections and fueling services for BNL employees and guests. Operations include engine repair, engine fluid replacement, tire replacement and battery replacement. These activities are conducted by the Employee Service Station (ESS) in the vehicle maintenance shop in Building 630. The service shop consists of four bays (three of which are equipped with hydraulic lifts), a spare parts storeroom and an office area. Bodywork and/or painting are operations not conducted by the ESS. The activities of BNL Employee Service Station have been graphically depicted in Process Flow Diagram SM-551-ESS-01, provided in attachment 1

Vehicle repair and maintenance involves the replacement of broken or
worn engine components. The ESS removes, repairs, and installs engine
parts. Metal components that cannot be reserviced (broken or worn parts,
mufflers, etc.) are disposed of as scrap metal. Some electrical parts
may be sent off-site for reservice and reinstallation.

Engine fluids (oil, water, antifreeze, washer fluid, etc.) are replaced
as needed to insure proper operation and emission control. Used oil is
stored in a satellite 55-gallon drum. When the drum is full it is
emptied into a 450-gallon storage tank located in back of the service
area in Building 630. In agreement with a local laundry cleaning
operation (Sterebel's), the used oil is hauled off-site and used as
fuel. Used oil filters are sent to building 423 (Facility Vehicle
Maintenance Shop) for crushing and are then directed to the HWMF for
disposal. Used antifreeze is also stored in a 55-gallon drum. When full,
the drum is emptied into an outside vendor's truck and taken off-site
for disposal. Unused oil and antifreeze are contained in 1-quart and
1-gallon containers, stored in the parts room and the trailer located
adjacent to the service station.

After replacement, used tires are put in a dumpster outside before
removal by Plant Engineering's Custodial Services. Removal and recycling
of used tires is discussed in detail in PAF EP-330-CS.

Wetcell batteries are picked up and taken off-site for recycling or
disposal by an outside vendor (NAPA).

A System One^tm^ parts cleaner is located in the service shop. Greasy
engine parts and tools are placed on a tray in the cleaner, which is
filled with a petroleum solvent. Over time, the solvent fluid becomes
contaminated with oil and dirt is condensed and recycled by the parts
cleaner. The subsequent dirty oil and sludge is removed and mixed with
waste oil. Various shop cleaning items in aerosol cans are used with
reusable cloth towels. Empty aerosol cans are recycled through the Town
of Brookhaven as low grade metal and the used towels are cleaned by an
outside vendor (Cintas) and reused.

The refueling operation is manual attendant service on either regular,
plus or super unleaded gasoline. The pumps are equipped with VOC
recirculation nozzles. The tanks are three (3) 8,000-gallon underground
tanks, equipped with double walled construction, leak detection and a
computerized system status reporting function.

**[Regulatory Determination of Process Outputs]{.underline}**

1.  **Employee Service Station Operations**

The ESS performs all repair and maintenance operations for BNL employee
and guest vehicles. The Service Shop contains a variety of electric
power tools and equipment. All waste streams generated by the Service
Shop for Vehicle Maintenance Operations are listed below.

+--------+---------------+-----------------+-------------+------------+
| Waste  | Waste         | Dete            | Waste       | Corrective |
| ID     | Description   | rmination/Basis | Handling    | Action     |
|        |               |                 |             | Required   |
+========+===============+=================+=============+============+
|        | ##            | Non-hazardous   | Waste is    | ### None   |
|        |  Broken Parts | waste as        | discarded   |            |
|        |               | determined by   | as scrap    |            |
|        |               | process         | metal       |            |
|        |               | knowledge       |             |            |
+--------+---------------+-----------------+-------------+------------+
|        | ##            | Non-hazardous   | Waste is    | ### None   |
|        |  Broken Tools | waste as        | discarded   |            |
|        |               | determined by   | as scrap    |            |
|        |               | process         | metal       |            |
|        |               | knowledge       |             |            |
+--------+---------------+-----------------+-------------+------------+
| 1.3    | Used Oil      | Non-hazardous   | Waste is    | None       |
|        |               | waste as        | hauled and  |            |
|        |               | determined by   | used        |            |
|        |               | process         | off-site by |            |
|        |               | knowledge       | outside     |            |
|        |               |                 | source      |            |
+--------+---------------+-----------------+-------------+------------+
|        | ## Use        | Non-hazardous   | Waste is    | ### None   |
|        | d Oil Filters | waste as        | sent to the |            |
|        |               | determined by   | HWMF for    |            |
|        |               | process         | disposal    |            |
|        |               | knowledge       |             |            |
+--------+---------------+-----------------+-------------+------------+
| 1.5    | Used          | Non-hazardous   | Hauled      | None       |
|        | Antifreeze    | waste as        | off-site    |            |
|        |               | determined by   | for         |            |
|        |               | process         | recycling   |            |
|        |               | knowledge       |             |            |
+--------+---------------+-----------------+-------------+------------+
|        | ## Used Tires | Non-hazardous   | Waste is    | ### None   |
|        |               | waste as        | hauled      |            |
|        |               | determined by   | off-site by |            |
|        |               | process         | outside     |            |
|        |               | knowledge       | contractor  |            |
+--------+---------------+-----------------+-------------+------------+
|        | ## Used Wetc  | Hazardous waste | Waste is    | ### None   |
|        | ell Batteries | as determined   | hauled      |            |
|        |               | by process      | off-site by |            |
|        |               | knowledge       | outside     |            |
|        |               |                 | contractor  |            |
|        |               |                 | for         |            |
|        |               |                 | recycling   |            |
|        |               |                 | under the   |            |
|        |               |                 | Universal   |            |
|        |               |                 | Waste Rule  |            |
+--------+---------------+-----------------+-------------+------------+
|        | Used Parts    | Non-hazardous   | Recycled    | None       |
|        | Cleaner       | waste as        | within the  |            |
|        | Petroleum     | determined by   | system      |            |
|        | Solvent       | process         | One^tm^     |            |
|        |               | knowledge       | parts       |            |
|        |               |                 | cleaner     |            |
+--------+---------------+-----------------+-------------+------------+
|        | ## Empty      | Non-hazardous   | Waste is    | ### None   |
|        |  Aerosol Cans | waste as        | collected   |            |
|        |               | determined by   | and is sent |            |
|        |               | process         | to the TOB  |            |
|        |               | knowledge       | for         |            |
|        |               |                 | recycling   |            |
+--------+---------------+-----------------+-------------+------------+
|        | ## Non-empty  | Hazardous waste | Waste is    | ### None   |
|        |  Aerosol Cans | as determined   | sent to the |            |
|        |               | by Regulatory   | HWMF for    |            |
|        |               | guidelines      | disposal    |            |
+--------+---------------+-----------------+-------------+------------+
|        | ## Oily Rags  | Non-hazardous   | Waste is    | ### None   |
|        |               | waste as        | sent to the |            |
|        |               | determined by   | HWMF for    |            |
|        |               | process         | disposal    |            |
|        |               | knowledge       |             |            |
+--------+---------------+-----------------+-------------+------------+
|        | #             | Non-hazardous   | Towels are  | ### None   |
|        | # Used Towels | waste as        | cleaned and |            |
|        |               | determined by   | reused      |            |
|        |               | process         |             |            |
|        |               | knowledge       |             |            |
+--------+---------------+-----------------+-------------+------------+
|        | ## Us         | Non-hazardous   | Waste is    | ### None   |
|        | ed Speedy Dry | waste as        | sent to the |            |
|        |               | determined by   | HWMF for    |            |
|        |               | process         | disposal    |            |
|        |               | knowledge       |             |            |
+--------+---------------+-----------------+-------------+------------+
|        | Deminimus     | Controlled      | Released to | None       |
|        | releases of   | substance -     | ambient air |            |
|        | CFC's/HCFC's  | used with       |             |            |
|        | from auto     | proper controls |             |            |
|        | refrigerant   |                 |             |            |
|        | recov         |                 |             |            |
|        | ery/recycling |                 |             |            |
|        | devices       |                 |             |            |
+--------+---------------+-----------------+-------------+------------+
|        | ## Vapor      | Non-hazardous   | Released to | ### Non    |
|        | s from parts  | waste as        | ambient air | e -- tank  |
|        | cleaning tank | determined by   |             | lid is kep |
|        |               | process         |             | t closed w |
|        |               | knowledge       |             | hen not in |
|        |               |                 |             |  operation |
+--------+---------------+-----------------+-------------+------------+

2.  **Vehicle Fueling Operations**

The Service Station provides fueling services. The facility is **not** a
self-serve operation. An attendant operates the pumps and pumps the
requested amount of fuel into the vehicle. The pumps are equipped with
VOC recirculation nozzles and automatic shut off handles, however
minimal amounts of VOCs escape during the refueling operation. The pumps
are equipped with inline filters, which get changed every 6-months. The
spent filters are crushed and sent to the HWMF for disposal.

+--------+---------------+-----------------+-------------+------------+
| Waste  | Waste         | Dete            | Waste       | Corrective |
| ID     | Description   | rmination/Basis | Handling    | Action     |
|        |               |                 |             | Required   |
+========+===============+=================+=============+============+
|        | ## Ga         | Hazardous waste | Release is  | ### None   |
|        | soline vapors | as determined   | minimized   |            |
|        |               | by process      | by current  |            |
|        |               | knowledge       | applied     |            |
|        |               |                 | technology  |            |
+--------+---------------+-----------------+-------------+------------+
|        | ## Inline     | Non-hazardous   | Waste is    | ### None   |
|        |  Fuel Filters | waste as        | discarded   |            |
|        |               | determined by   | as          |            |
|        |               | process         | Industrial  |            |
|        |               | knowledge       | Waste       |            |
+--------+---------------+-----------------+-------------+------------+

###### III. Waste Minimization, Opportunity for Pollution Prevention

None

**IV. Assessment Prevention and Control**

[]{.mark}

1.  **Vehicle and Equipment Maintenance**

The three hydraulic lifts operate with their own hydraulic reservoirs.
The hydraulic fluid they contain is probably DT light. The service
station should look into the economic feasibility of using a
vegetable-based hydraulic fluid. This would include looking into the
manufactures specifications and warranties for use of alternative
hydraulic fluids.

Some hydraulic equipment has been switched over to the vegetable based
hydraulic fluid and its integration is being evaluated.

During calendar year 2001 there was a hydraulic leak detected in Bay #3
lift. This was the only remaining hydraulic lift whose ancillary piping
and cylinder were under ground. The replacement system was installed
above ground. Pending evaluation of the switchover to canola based
hydraulic oil at the Motor pool shop, SS will evaluate a comparable
switchover for the Employee Service Station.

**ATTACHMENT 1**

**PROCESS FLOW DIAGRAM**