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Revision 8 DOE M 440.1-1
3-29-96
DOE Explosives Safety Manual
FOREWORD
1.0 PURPOSE
This Manual describes the Department of Energy's (DOE's)
explosives safety requirements applicable to operations involving
the development, testing, handling, and processing of explosives
or assemblies containing explosives. It is intended to reflect
the state-of-the-art in explosives safety and to ensure that
applicable criteria and requirements for implementing this policy
are readily available and known to those responsible for
conducting DOE programs. This document shall be periodically
reviewed and updated to establish new requirements as
appropriate. Users are requested to submit suggestions for
improving this Manual through their Operations Office to the
Office of Field Support.
2.0 SUMMARY
DOE policy requires that all DOE activities be conducted in a
manner that protects the safety of the public and provides a safe
and healthful work place for employees.
DOE has also prescribed that all personnel be protected in any
explosives operation undertaken. The level of safety provided
shall be at least equivalent to that of the best industrial
practice. The risk of death or serious injury shall be limited
to the lowest practicable level.
DOE and contractors shall continually review their explosives
operations with the aim of further refining and improving safety
practices and protective features.
3.0 CONTACTS
a. For additional information or technical interpretation of
this Manual, contact the Office of Field Support (EH-53) at
(301) 903-3477.
b. For technical interpretations of DOE-prescribed worker
protection standards, consult the DOE Technical Information
Services database, or call the DOE Response Line at (800)
292-8061.
c. Consult the DOE Directives Checklist for current Guides and
Safety Manuals associated with this Manual. The Directives
Checklist is available from the Office of Organization and
Management (HR-6) at (202) 586-4716.
BY ORDER OF THE SECRETARY OF ENERGY:
ARCHER L. DURHAM
Assistant Secretary for
Human Resources and Administration DOE M 440.1-1 Revision 8
3-29-96
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3-29-96
TABLE OF CONTENTS
FOREWORD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .iii
FIGURES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xiii
TABLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xiii
ACRONYMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xv
CHAPTER I INTRODUCTION
Section Page
1.0 SCOPE, PURPOSE, AND JUSTIFICATION. . . . . . . . . . . . . . . . . .I-1
2.0 APPLICABILITY. . . . . . . . . . . . . . . . . . . . . . . . . . . .I-2
3.0 EXEMPTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . .I-2
4.0 WAIVERS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .I-3
5.0 MANUAL ADMINISTRATION AND MANAGEMENT . . . . . . . . . . . . . . . .I-3
5.1 DOE Explosives Safety Committee Organization . . . . . . . . .I-4
5.2 DOE Explosives Safety Committee Functions. . . . . . . . . . .I-4
6.0 Definitions. . . . . . . . . . . . . . . . . . . . . . . . . . . . .I-5
CHAPTER II OPERATIONAL SAFETY
Section Page
1.0 GENERAL OPERATIONS SAFETY GUIDELINES . . . . . . . . . . . . . . . II-1
1.1 Protection of Explosives . . . . . . . . . . . . . . . . . . II-1
1.2 Equipment Checks . . . . . . . . . . . . . . . . . . . . . . II-1
1.3 Inspection Frequency . . . . . . . . . . . . . . . . . . . . II-1
1.4 Laboratory Operations. . . . . . . . . . . . . . . . . . . . II-2
1.5 Toxicity Hazards . . . . . . . . . . . . . . . . . . . . . . II-2
1.6 Hazard Identification and Communication. . . . . . . . . . . II-2
1.7 Process Hazard Analysis. . . . . . . . . . . . . . . . . . . II-3
2.0 WORK ENVIRONMENT . . . . . . . . . . . . . . . . . . . . . . . . . II-5
2.1 General Requirements . . . . . . . . . . . . . . . . . . . . II-5
2.2 Emergency Exit Requirements for Explosives Operations. . . . II-5
2.2.1 Building or Structure Occupancy. . . . . . . . . . II-5
2.2.2 Hazards of Contents Classification . . . . . . . . II-6
2.2.3 Personnel Protective Restrictions and
Requirements . . . . . . . . . . . . . . . . . . . II-6
2.2.4 Requirements for Existing Facilities . . . . . . . II-7
2.2.5 Requirements for New Facilities. . . . . . . . . . II-7
2.2.6 Single Exits . . . . . . . . . . . . . . . . . . . II-8
2.2.7 Blast-Resistant Doors. . . . . . . . . . . . . . . II-8
2.2.8 Slide Escapes. . . . . . . . . . . . . . . . . . . II-9
3.0 BUILDING AND EQUIPMENT MAINTENANCE . . . . . . . . . . . . . . . .II-11
3.1 Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . .II-11
3.2 Maintenance and Repair . . . . . . . . . . . . . . . . . . .II-11
3.3 Hot Work Permits . . . . . . . . . . . . . . . . . . . . . .II-12
4.0 REMOTE OPERATIONS. . . . . . . . . . . . . . . . . . . . . . . . .II-13
4.1 Personnel Protection Criteria. . . . . . . . . . . . . . . .II-13
4.2 Access and Equipment Controls. . . . . . . . . . . . . . . .II-13 DOE M 440.1-1 Revision 8
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5.0 GENERAL EXPLOSIVES AREA CONTROLS . . . . . . . . . . . . . . . . .II-15
5.1 Smoking, Matches, Lighters, Metal Articles . . . . . . . . .II-15
5.2 Cooking and Eating . . . . . . . . . . . . . . . . . . . . .II-15
5.3 Access to Explosives Areas . . . . . . . . . . . . . . . . .II-17
6.0 ELECTRICAL STORMS AND LIGHTNING PROTECTION . . . . . . . . . . . .II-17
6.1 Assessment . . . . . . . . . . . . . . . . . . . . . . . . .II-17
6.2 Evacuation . . . . . . . . . . . . . . . . . . . . . . . . .II-17
6.3 Shutdown of Operations . . . . . . . . . . . . . . . . . . .II-17
6.4 Lightning Protection . . . . . . . . . . . . . . . . . . . .II-18
7.0 STATIC ELECTRICITY . . . . . . . . . . . . . . . . . . . . . . . .II-19
7.1 General. . . . . . . . . . . . . . . . . . . . . . . . . . .II-19
7.2 Bonding and Grounding of Equipment . . . . . . . . . . . . .II-19
7.3 Testing Equipment Grounds. . . . . . . . . . . . . . . . . .II-19
7.4 Conductive Floors, Shoes, Mats, and Wristbands . . . . . . .II-19
7.5 Conductive Floor, Work Surface, and Wristband
Specifications . . . . . . . . . . . . . . . . . . . . . . .II-20
7.6 Conductive Floor Tests . . . . . . . . . . . . . . . . . . .II-22
7.7 Humidification . . . . . . . . . . . . . . . . . . . . . . .II-23
7.8 Ground Fault Circuit Interrupter . . . . . . . . . . . . . .II-23
8.0 ELECTRICAL EQUIPMENT AND WIRING. . . . . . . . . . . . . . . . . .II-25
8.1 Location/Operation Electrical Hazard Classification. . . . .II-25
8.2 Electrical Supply System . . . . . . . . . . . . . . . . . .II-26
8.3 Building Electrical Service Entrance . . . . . . . . . . . .II-27
8.4 Permanent Wiring and Equipment . . . . . . . . . . . . . . .II-28
8.5 Flexible Cords/Wiring. . . . . . . . . . . . . . . . . . . .II-29
8.6 Electrical Equipment and Instrumentation . . . . . . . . . .II-29
8.7 Electrical Requirements for Outdoor Test Areas . . . . . . .II-30
8.8 Hand-Held, Battery-Powered Lights and Instruments. . . . . .II-31
8.9 Non-Rated Extension Lighting . . . . . . . . . . . . . . . .II-31
8.10 Laboratories . . . . . . . . . . . . . . . . . . . . . . . .II-32
8.11 Modifications. . . . . . . . . . . . . . . . . . . . . . . .II-32
9.0 VACUUM EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . .II-33
9.1 General. . . . . . . . . . . . . . . . . . . . . . . . . . .II-33
9.2 Labeling . . . . . . . . . . . . . . . . . . . . . . . . . .II-33
9.3 Disassembly. . . . . . . . . . . . . . . . . . . . . . . . .II-33
9.4 Traps and Filters. . . . . . . . . . . . . . . . . . . . . .II-33
10.0 EXPLOSIVES DUST EXHAUST VENTILATION AND COLLECTION
SYSTEMS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .II-35
10.1 General. . . . . . . . . . . . . . . . . . . . . . . . . . .II-35
10.2 Exhaust Ventilation. . . . . . . . . . . . . . . . . . . . .II-35
10.3 Dust Collection Systems. . . . . . . . . . . . . . . . . . .II-35
10.4 Dust Collection Location . . . . . . . . . . . . . . . . . .II-36
11.0 DRAINS AND SUMPS . . . . . . . . . . . . . . . . . . . . . .II-37
11.1 Collection . . . . . . . . . . . . . . . . . . . . . . . . .II-37
11.2 Effluent . . . . . . . . . . . . . . . . . . . . . . . . . .II-37
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TABLE OF CONTENTS (Continued)
12.0 PROCESSING . . . . . . . . . . . . . . . . . . . . . . . . .II-39
12.1 Heating, Drying, and Thermal Conditioning. . . . . . . . . .II-39
12.1.1 General. . . . . . . . . . . . . . . . . . . . . .II-39
12.1.2 Heating and Drying Equipment . . . . . . . . . . .II-40
12.1.3 Heating and Drying Operations. . . . . . . . . . .II-41
12.2 Pressing . . . . . . . . . . . . . . . . . . . . . . . . . .II-42
12.2.1 General. . . . . . . . . . . . . . . . . . . . . .II-42
12.2.2 Isostatic/Hydrostatic Pressing . . . . . . . . . .II-43
12.2.3 Punch and Die Pressing . . . . . . . . . . . . . .II-44
12.3 Extruding. . . . . . . . . . . . . . . . . . . . . . . . . .II-44
12.4 Machining. . . . . . . . . . . . . . . . . . . . . . . . . .II-45
12.4.1 Equipment Requirements . . . . . . . . . . . . . .II-45
12.4.2 Contact or Remote Operations . . . . . . . . . . .II-46
12.4.3 Setup and Preparation. . . . . . . . . . . . . . .II-47
12.4.4 Operations Guidelines. . . . . . . . . . . . . . .II-48
12.4.5 Specific Machining Operations. . . . . . . . . . .II-49
12.5 Dry Screening. . . . . . . . . . . . . . . . . . . . . . . .II-50
12.6 Blending . . . . . . . . . . . . . . . . . . . . . . . . . .II-51
12.7 Melting. . . . . . . . . . . . . . . . . . . . . . . . . . .II-51
12.8 Assembly and Disassembly . . . . . . . . . . . . . . . . . .II-52
12.8.1 Assembly Operations. . . . . . . . . . . . . . . .II-52
12.8.2 Loading Assemblies with Plastic or Extrudable
Explosives . . . . . . . . . . . . . . . . . . . .II-52
12.8.3 Disassembly Operations . . . . . . . . . . . . . .II-52
12.8.4 Personnel Protection for Disassembly
Operations . . . . . . . . . . . . . . . . . . . .II-53
12.9 Inspection . . . . . . . . . . . . . . . . . . . . . . . . .II-53
12.10 Synthesis. . . . . . . . . . . . . . . . . . . . . . . . . .II-54
12.10.1 Laboratory-Scale Synthesis . . . . . . . . . . . .II-54
12.10.2 Pilot- or Processing-Scale Synthesis . . . . . . .II-55
12.11 Formulation. . . . . . . . . . . . . . . . . . . . . . . . .II-56
12.11.1 General. . . . . . . . . . . . . . . . . . . . . .II-56
12.11.2 Mixing . . . . . . . . . . . . . . . . . . . . . .II-57
12.11.3 Ball or Jar Milling. . . . . . . . . . . . . . . .II-57
12.11.4 Roll Milling . . . . . . . . . . . . . . . . . . .II-57
12.12 Concurrent Contact Operations. . . . . . . . . . . . . . . .II-58
12.13 Contamination Prevention . . . . . . . . . . . . . . . . . .II-58
12.14 Hand-Cutting and Finishing Operations. . . . . . . . . . . .II-59
12.15 Use of Low-Pressure Fluids . . . . . . . . . . . . . . . . .II-59
13.0 TESTING. . . . . . . . . . . . . . . . . . . . . . . . . . .II-61
13.1 General. . . . . . . . . . . . . . . . . . . . . . . . . . .II-61
13.2 Test Planning. . . . . . . . . . . . . . . . . . . . . . . .II-61
13.2.1 Hazards Analysis . . . . . . . . . . . . . . . . .II-61
13.2.2 Firing Areas . . . . . . . . . . . . . . . . . . .II-61
13.3 Test Firing. . . . . . . . . . . . . . . . . . . . . . . . .II-62
13.3.1 General Range Standards. . . . . . . . . . . . . .II-62
13.3.2 Test Setup . . . . . . . . . . . . . . . . . . . .II-63 DOE M 440.1-1 Revision 8
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13.3.3 Pin Switches and Other Noninitiating
Circuits . . . . . . . . . . . . . . . . . . . . .II-63
13.3.4 Lightning Storms . . . . . . . . . . . . . . . . .II-64
13.3.5 Low-Energy EEDs. . . . . . . . . . . . . . . . . .II-64
13.3.6 Explosives Storage in Firing Areas . . . . . . . .II-66
13.3.7 Warning Signals. . . . . . . . . . . . . . . . . .II-67
13.3.8 Grass Fires. . . . . . . . . . . . . . . . . . . .II-67
13.3.9 Firing Leads . . . . . . . . . . . . . . . . . . .II-67
13.3.10 Unattended Test Assemblies . . . . . . . . . . . .II-67
13.3.11 Postfiring Controls. . . . . . . . . . . . . . . .II-67
13.3.12 Contamination of Firing Areas. . . . . . . . . . .II-68
13.3.13 Test Range Firing Circuit Criteria . . . . . . . .II-68
13.4 Test Firing in Tanks or Chambers . . . . . . . . . . . . . .II-69
13.5 Gun Firings. . . . . . . . . . . . . . . . . . . . . . . . .II-70
13.6 Ballistic, Environmental, Physical Property, and
Sensitivity Testing. . . . . . . . . . . . . . . . . . . . .II-71
13.6.1 Checkout of Dynamic Engineering Test
Equipment for Explosive Assemblies . . . . . . . .II-71
13.6.2 Testing Explosives and Hazardous Radioactive
Materials. . . . . . . . . . . . . . . . . . . . .II-71
13.6.3 Heating of Explosives Test Specimens . . . . . . .II-72
13.6.4 Instrumentation. . . . . . . . . . . . . . . . . .II-72
13.6.5 Explosives Limits. . . . . . . . . . . . . . . . .II-73
13.6.6 Drop Testing . . . . . . . . . . . . . . . . . . .II-73
13.7 Test Failures and Misfires . . . . . . . . . . . . . . . . .II-73
13.7.1 Explosives Misfire . . . . . . . . . . . . . . . .II-73
13.7.2 Misfire of a Remotely Fired Gun. . . . . . . . . .II-74
13.8 Electrical Instruments for Use with Explosives Systems . . .II-74
13.8.1 Classification . . . . . . . . . . . . . . . . . .II-74
13.8.2 Certification. . . . . . . . . . . . . . . . . . .II-75
13.8.3 Electrical Instruments for Use with
Initiating Electrical Circuits . . . . . . . . . .II-75
13.8.4 Electrical Instruments for Use with
Noninitiating Electrical Circuits. . . . . . . . .II-76
14.0 MATERIALS HANDLING . . . . . . . . . . . . . . . . . . . . .II-77
14.1 General. . . . . . . . . . . . . . . . . . . . . . . . . . .II-77
14.2 Manual Handling of Bare Consolidated Explosives. . . . . . .II-77
14.3 Carts or Hand Trucks . . . . . . . . . . . . . . . . . . . .II-78
14.4 Mechanical Handling Equipment. . . . . . . . . . . . . . . .II-78
15.0 MATERIALS RECEIPT. . . . . . . . . . . . . . . . . . . . . .II-81
15.1 Motor Vehicles . . . . . . . . . . . . . . . . . . . . . . .II-81
15.2 Railcars . . . . . . . . . . . . . . . . . . . . . . . . . .II-82
15.3 Damaged Shipments. . . . . . . . . . . . . . . . . . . . . .II-82
16.0 TRANSPORTATION . . . . . . . . . . . . . . . . . . . . . . .II-83
16.1 Equipment. . . . . . . . . . . . . . . . . . . . . . . . . .II-83
16.1.1 General. . . . . . . . . . . . . . . . . . . . . .II-83
16.1.2 Motor Vehicles . . . . . . . . . . . . . . . . . .II-83
16.1.3 Railcars . . . . . . . . . . . . . . . . . . . . .II-85
16.1.4 Materials Handling Equipment . . . . . . . . . . .II-85 Revision 8 DOE M 440.1-1
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16.2 General Operation Guidelines . . . . . . . . . . . . . . . .II-87
16.3 Emergency Conditions . . . . . . . . . . . . . . . . . . . .II-87
17.0 EXPLOSIVES STORAGE . . . . . . . . . . . . . . . . . . . . .II-91
17.1 Storage Magazine Facilities. . . . . . . . . . . . . . . . .II-91
17.2 Storage Magazine Operations. . . . . . . . . . . . . . . . .II-92
17.3 Storage Review Program . . . . . . . . . . . . . . . . . . .II-93
17.4 Storage Compatibility. . . . . . . . . . . . . . . . . . . .II-97
17.5 Containers (On-Site) . . . . . . . . . . . . . . . . . . . II-100
17.6 Storage in Buildings Other Than Storage Magazines. . . . . II-101
17.6.1 Packing and Shipping Buildings . . . . . . . . . II-101
17.6.2 Service Magazines. . . . . . . . . . . . . . . . II-101
17.6.3 Warehouses . . . . . . . . . . . . . . . . . . . II-102
17.6.4 Pre-positioned Storage of Security
Response Munitions . . . . . . . . . . . . . . . II-102
18.0 DECONTAMINATION AND CLEANING . . . . . . . . . . . . . . . II-105
18.1 General. . . . . . . . . . . . . . . . . . . . . . . . . . II-105
18.2 Cleaning Contaminated Equipment. . . . . . . . . . . . . . II-105
18.3 Cleaning Screw Threads . . . . . . . . . . . . . . . . . . II-105
18.4 Final Decontamination and Disposal of Equipment. . . . . . II-106
18.5 Inspection . . . . . . . . . . . . . . . . . . . . . . . . II-107
18.6 Identification and Control of Decontaminated Items . . . . II-107
18.7 Decontamination of Real Estate . . . . . . . . . . . . . . II-108
18.8 Decontamination and Cleaning References. . . . . . . . . . II-108
19.0 WASTE COLLECTION . . . . . . . . . . . . . . . . . . . . . II-109
19.1 General. . . . . . . . . . . . . . . . . . . . . . . . . . II-109
19.2 Solid Wastes . . . . . . . . . . . . . . . . . . . . . . . II-109
19.3 Vacuum Collection of Explosives Dusts. . . . . . . . . . . II-109
19.4 Explosives Slurries. . . . . . . . . . . . . . . . . . . . II-111
19.5 Metal Scrap. . . . . . . . . . . . . . . . . . . . . . . . II-111
19.6 Explosives Recovery and Reuse. . . . . . . . . . . . . . . II-111
20.0 WASTE DISPOSAL . . . . . . . . . . . . . . . . . . . . . . II-113
20.1 Preparation for Open Burning . . . . . . . . . . . . . . . II-113
20.2 Destruction by Burning or Flashing . . . . . . . . . . . . II-114
20.3 Ignition System Malfunctions . . . . . . . . . . . . . . . II-114
20.4 Postburn Operations. . . . . . . . . . . . . . . . . . . . II-114
20.5 Disposal Area. . . . . . . . . . . . . . . . . . . . . . . II-115
20.6 Destruction by Detonation. . . . . . . . . . . . . . . . . II-116
20.7 Use of Solvents. . . . . . . . . . . . . . . . . . . . . . II-116
20.8 Burial . . . . . . . . . . . . . . . . . . . . . . . . . . II-116
21.0 Laboratory Operations. . . . . . . . . . . . . . . . . . . II-119
21.1 General. . . . . . . . . . . . . . . . . . . . . . . . . . II-119
21.2 Safety Shields . . . . . . . . . . . . . . . . . . . . . . II-120
21.3 Heating Operations . . . . . . . . . . . . . . . . . . . . II-120
21.4 Laboratory Setups. . . . . . . . . . . . . . . . . . . . . II-122
21.5 Low Concentration of Explosives in Solution. . . . . . . . II-122
21.6 Explosives Sample Control. . . . . . . . . . . . . . . . . II-122 DOE M 440.1-1 Revision 8
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22.0 EMERGENCY CONTROL. . . . . . . . . . . . . . . . . . . . . II-123
22.1 Placarding and Fire Symbols. . . . . . . . . . . . . . . . II-123
22.2 Explosives Emergency Control Plans . . . . . . . . . . . . II-123
CHAPTER III EXPLOSIVES AND PERSONNEL LIMITS AND CONTROL
Section Page
1.0 EXPLOSIVES LIMITS. . . . . . . . . . . . . . . . . . . . . . . . .III-1
2.0 PERSONNEL LIMITS . . . . . . . . . . . . . . . . . . . . . . . . .III-1
3.0 LIMIT CONTROL. . . . . . . . . . . . . . . . . . . . . . . . . . .III-1
3.1 Posting and Recording. . . . . . . . . . . . . . . . . . . .III-1
3.2 Limit Review and Approvals . . . . . . . . . . . . . . . . .III-2
3.3 Personnel Controls . . . . . . . . . . . . . . . . . . . . .III-2
4.0 IHE LIMIT. . . . . . . . . . . . . . . . . . . . . . . . . . . . .III-2
CHAPTER IV PERSONAL PROTECTIVE CLOTHING AND EQUIPMENT
Section Page
1. CLOTHING AND PERSONAL EQUIPMENT. . . . . . . . . . . . . . . . . . IV-1
1.1 Clothing . . . . . . . . . . . . . . . . . . . . . . . . . . IV-1
1.2 Footwear . . . . . . . . . . . . . . . . . . . . . . . . . . IV-1
1.3 Respirators. . . . . . . . . . . . . . . . . . . . . . . . . IV-1
1.4 Eye Protection . . . . . . . . . . . . . . . . . . . . . . . IV-1
1.5 Gloves . . . . . . . . . . . . . . . . . . . . . . . . . . . IV-2
2.0 MAINTENANCE AND TESTING. . . . . . . . . . . . . . . . . . . . . . IV-2
2.1 Equipment Maintenance and Inspection . . . . . . . . . . . . IV-2
2.2 Conductivity Testing . . . . . . . . . . . . . . . . . . . . IV-2
2.3 Cleaning and Disinfecting. . . . . . . . . . . . . . . . . . IV-2
2.4 Contaminated Clothing. . . . . . . . . . . . . . . . . . . . IV-2
CHAPTER V TRAINING
Section Page
1.0 GENERAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .V-1
2.0 SUPERVISORY RESPONSIBILITY . . . . . . . . . . . . . . . . . . . . .V-1
3.0 TRAINING AND QUALIFICATION PROGRAMS. . . . . . . . . . . . . . . . .V-1 Revision 8 DOE M 440.1-1
3-29-96
TABLE OF CONTENTS (Continued)
CHAPTER VI QUANTITY-DISTANCE AND LEVEL-OF-PROTECTION
CRITERIA FOR EXPLOSIVES ACTIVITIES
Section Page
1.0 GENERAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . VI-1
2.0 APPLICABILITY OF CRITERIA. . . . . . . . . . . . . . . . . . . . . VI-1
2.1 Specific Applications. . . . . . . . . . . . . . . . . . . . VI-1
2.2 Explosives Limits. . . . . . . . . . . . . . . . . . . . . . VI-1
2.3 Areas Where Criteria Are Not Applicable. . . . . . . . . . . VI-1
3.0 QUANTITY-DISTANCE CRITERIA . . . . . . . . . . . . . . . . . . . . VI-2
3.1 Hazard Classes and Class Division. . . . . . . . . . . . . . VI-2
3.2 Establishing Quantity of Explosives and Distances. . . . . . VI-4
3.2.1 General. . . . . . . . . . . . . . . . . . . . . . VI-4
3.2.2 Use of Metric System . . . . . . . . . . . . . . . VI-4
3.3.3 Railcars and Transport Vehicles. . . . . . . . . . VI-5
3.3.4 Utilities Installations. . . . . . . . . . . . . . VI-5
3.3.5 Petroleum Storage Tanks. . . . . . . . . . . . . . VI-6
4.0 LEVEL-OF-PROTECTION CRITERIA . . . . . . . . . . . . . . . . . . . VI-6
4.1 Hazard Classes . . . . . . . . . . . . . . . . . . . . . . . VI-6
4.2 Required Level of Protection . . . . . . . . . . . . . . . . VI-7
4.2.1 Explosives Bay . . . . . . . . . . . . . . . . . . VI-7
4.2.2 Bays for Joint Explosives-Plutonium
Activities . . . . . . . . . . . . . . . . . . . . VI-9
5.0 FIRE PROTECTION. . . . . . . . . . . . . . . . . . . . . . . . . .VI-10
5.1 Vegetation Control . . . . . . . . . . . . . . . . . . . . .VI-10
5.2 Fire Protection Criteria . . . . . . . . . . . . . . . . . .VI-10
6.0 EXPLOSIVES FACILITY SITING AND DESIGN CRITERIA REFERENCES. . . . .VI-10
CHAPTER VII OPERATING PROCEDURES
Section Page
1. GENERAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .VII-1
1.1 Requirements . . . . . . . . . . . . . . . . . . . . . . . .VII-1
1.2 Types of Procedures. . . . . . . . . . . . . . . . . . . . .VII-1
2.0 GUIDELINES . . . . . . . . . . . . . . . . . . . . . . . . . . . .VII-1
2.1 Before Operation . . . . . . . . . . . . . . . . . . . . . .VII-1
2.2 Supervisory Responsibility . . . . . . . . . . . . . . . . .VII-2
2.3 Preparation. . . . . . . . . . . . . . . . . . . . . . . . .VII-2
2.4 Approval . . . . . . . . . . . . . . . . . . . . . . . . . .VII-2
2.5 Control. . . . . . . . . . . . . . . . . . . . . . . . . . .VII-2
2.6 Audits . . . . . . . . . . . . . . . . . . . . . . . . . . .VII-3
2.7 Reviews. . . . . . . . . . . . . . . . . . . . . . . . . . .VII-3
DOE M 440.1-1 Revision 8
3-29-96
TABLE OF CONTENTS (Continued)
2.8 Content of SOPs. . . . . . . . . . . . . . . . . . . . . . .VII-3
2.8.1 General Operating Procedures . . . . . . . . . . .VII-3
2.8.2 Unit Operating Procedures. . . . . . . . . . . . .VII-4
2.9 Content of Special or Experimental Procedures. . . . . . . .VII-5
CHAPTER VIII FORMULATION SCALEUP
Section Page
1.0 EXPLOSIVES DEVELOPMENT PROGRAM . . . . . . . . . . . . . . . . . VIII-1
1.1 Explosives Development Committee . . . . . . . . . . . . . VIII-1
1.2 Phase-by-Phase Approvals . . . . . . . . . . . . . . . . . VIII-1
1.3 Modified Formulations. . . . . . . . . . . . . . . . . . . VIII-1
1.4 Sensitivity Data from Another Laboratory . . . . . . . . . VIII-1
2.0 DEVELOPMENT PROCEDURES . . . . . . . . . . . . . . . . . . . . . VIII-1
2.1 General. . . . . . . . . . . . . . . . . . . . . . . . . . VIII-1
2.2 Synthesis Phase. . . . . . . . . . . . . . . . . . . . . . VIII-3
2.3 Compatibility Testing. . . . . . . . . . . . . . . . . . . VIII-3
2.4 Phase I Preliminary Explosives Testing . . . . . . . . . . VIII-4
2.5 Phase II Experimental Characterization and Development . . VIII-4
2.6 Phase III Full-Scale Testing and Production. . . . . . . . VIII-5
CHAPTER IX INSENSITIVE HIGH EXPLOSIVES QUALIFICATION
Section Page
1.0 INSENSITIVE HIGH EXPLOSIVES (IHE). . . . . . . . . . . . . . . . . IX-1
2.0 IHE SUBASSEMBLIES. . . . . . . . . . . . . . . . . . . . . . . . . IX-2
3.0 IHE WEAPONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . IX-2
4.0 REFERENCE DOCUMENTS. . . . . . . . . . . . . . . . . . . . . . . . IX-5
REFERENCES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Ref-1
INDEX. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Index-1 Revision 8 DOE M 440.1-1
3-29-96
FIGURES
II-1 Testing shoes on wearer. . . . . . . . . . . . . . . . . . . . .II-21
VI-1 Application of Hazard Classification System. . . . . . . . . . . VI-3
TABLES
II-1 Minimum safe distances between RF transmitters and
electric
blasting operations. . . . . . . . . . . . . . . . . . . . . . .II-65
II-2 Minimum safe distances between TV and FM broadcasting
transmitters and electric blasting operations. . . . . . . . . .II-65
II-3 Minimum safe distances betwen mobile RF transmitters and
electric blasting operations . . . . . . . . . . . . . . . . . .II-66
II-4 Storage compatibility groups for explosives and
explosive-containing devices . . . . . . . . . . . . . . . . . .II-95
II-5 Storage compatibility mixiing chart. . . . . . . . . . . . . . .II-98
II-6 Safety shields for explosives laboratory operations. . . . . . II-121
VI-1 Divisions of Class 1 . . . . . . . . . . . . . . . . . . . . . . VI-2
VI-2 Explosives facilities: protective design requirements by
activity type. . . . . . . . . . . . . . . . . . . . . . . . . .VI-13
VIII-1 Scaleup procedure guidelines for new explosives and
formulations . . . . . . . . . . . . . . . . . . . . . . . . . VIII-2
IX-1 DOE qualification tests for IHE. . . . . . . . . . . . . . . . . IX-3
IX-2 Approved IHEs. . . . . . . . . . . . . . . . . . . . . . . . . . IX-4
IX-3 DOE qualification tests for IHE subassemblies. . . . . . . . . . IX-4
IX-4 Approved IHE subassemblies . . . . . . . . . . . . . . . . . . . IX-4
IX-5 IHE hazard classification. . . . . . . . . . . . . . . . . . . . IX-5
DOE M 440.1-1 Revision 8
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This page intentionally left blank. Revision 8 DOE M 440.1-1
3-29-96
ACRONYMS
ACGIH American Conference of Government Industrial Hygienists
ASTM American Society for Testing and Materials
ANSI American National Standards Institute
BOE Bureau of Explosives
DBA design basis accident
DDESB Department of Defense Explosives Safety Board
DoD Department of Defense
DOE Department of Energy
DOT Department of Transportation
DSC differential scanning calorimetry
DTA differential thermal analysis
EBW exploding bridgewire
EDC Explosives Development Committee
EED electroexplosive device
EOD explosives ordnance disposal
FMECA Failure Modes, Effects, and Criticality Analysis
HAZOP Hazard and Operability Study
HE high explosive
HMX cyclotetramethylene tetranitramine
IHE insensitive high explosive
LEL lower explosive limit
LFL lower flammable limit
MCE maximum credible event
MSDS Material Safety Data Sheets
NEC National Electric Code
NEW net explosive weight
NEQ net explosive quantity
NFPA National Fire Protection Association
OSHA Occupational Safety and Health Administration
PBX plastic bonded explosive
PEL permissible exposure limit
PETN pentaerythritol tetranitrate
RDX cyclotrimethylene trinitramine
SOP standard operating procedure
SPMS Safety Performance Measurement System
SSR Safe Secure Railcar
SST Safe Secure Trailer
TATB triamino trinitrobenzene
TMAC Toxic Materials Advisory Committee
TNT trinitrotoluene
UL Underwriters Laboratory
UNO United Nations Organization CHAPTER I
INTRODUCTION
1.0 SCOPE, PURPOSE, AND JUSTIFICATION
This Manual prescribes the Department of Energy (DOE) safety
standards and procedures used to implement the DOE safety policy
contained in DOE O 440.1, WORKER PROTECTION MANAGEMENT FOR DOE
FEDERAL AND CONTRACTOR EMPLOYEES, of 9-30-95, for operations
involving explosives, pyrotechnics, and propellants, or
assemblies containing these materials. With the exception of on-
site explosives storage and transportation, this Manual does not
apply to commercial activities such as routine construction or
routine tunnel blasting.
Explosives handling and processing operations by the DOE are an
integral part of DOE weapons and weapons-related development
manufacturing and dismantlement activities. Safety in all
operations associated with weapons development is an ongoing,
prime concern and must continually be given high priority in all
program direction and management. This Manual provides uniform
guidance for all DOE facilities and installations involved in
explosives handling or processing. DOE will update the Manual
periodically to incorporate lessons learned, new technology, and
suggestions for improvements. The Assistant Secretary for
Environment, Safety and Health (EH-1) is responsible for this
task.
Maintaining explosives safety in all operations within DOE is an
ongoing process that, to be truly effective, must be given high
priority in all program direction, management, and line
activities. Due to the unique nature of DOE's highly active role
in research and development in new explosives formulations,
explosives synthesis, charge geometry, and explosives assemblies,
as well as the proximity of explosives to weapon components, it
is necessary to maintain the level of explosives safety standards
commensurate with risks.
This Manual closes the considerable safety gap created by DOE's
unique activities by establishing safety controls not found in
existing DOE or non-DOE regulations to govern the DOE explosives
safety process and ensure that explosives safety is commensurate
with the actual risk. However, Department of Defense (DoD),
Occupational Safety and Health Administration (OSHA), and other
nationally recognized standards, such as the National Fire
Protection Association (NFPA) codes, provide the basic framework
and are cited where applicable and pertinent. Since the
conception of the first DOE Explosives Safety Manual in 1978, and
the formation of the expert DOE Explosives Safety Committee, no
explosives-related fatalities have occurred in DOE and explosives
safety practices have significantly improved. Continued
maintenance of this Manual, combined with field adherence, will
maintain the high level of explosives safety evidenced within DOE
over the past two decades.
2.0 APPLICABILITY
This Manual applies to all DOE facilities engaged in developing,
manufacturing, handling, storing, transporting, processing, or
testing explosives, pyrotechnics and propellants, or assemblies
containing these materials, and safely managing such operations.
With the exception of explosives storage and transportation, this
Manual does not apply to commercial activities such as routine
construction or routine tunnel blasting.
The design of all new explosives facilities shall conform to the
requirements established in this Manual and implemented in
DOE O 430.1, LIFE CYCLE ASSET MANAGEMENT, of 8-24-95, or
DOE O 420.1, FACILITY SAFETY, of 9-30-95, whichever is
applicable. It is not intended that existing physical facilities
be changed arbitrarily to comply with these provisions, except as
required by law. Existing facilities that do not comply with
these standards may continue to be used for the balance of their
functional lives, as long as the current operation presents no
significantly greater risk than that assumed when the facility
was originally designed, and it can be demonstrated clearly that
a modification to bring the facility into compliance is not
feasible. However, in the case of a major renovation, the
facility must be brought into compliance with current standards.
The requirements are presented as either mandatory or advisory.
Mandatory requirements, denoted by the words "shall," "must," or
"will," must be followed unless an exemption is granted by DOE.
Advisory requirements denoted by the words "should" or "may," may
be deviated from with a written waiver granted by facility
management.
3.0 EXEMPTIONS
An exemption is a written release from a mandatory standard of
this Manual that has been granted, as applicable, by the DOE
Assistant Secretary for Environment, Safety and Health (EH-1) or
by the Operations Office Manager.
The DOE Operations Office Manager is permitted to grant
exemptions from the mandatory requirements of this Manual
provided compliance is not feasible and the facility operator has
demonstrated that the conditions, practices, means, methods, or
processes to be used will not decrease the level of safety.
Requests for exemptions shall be submitted to the DOE Operations
Office Manager for action. Each such request shall contain the
following information:
description of the condition;
safety requirement necessitating deviation;
reason why compliance cannot be achieved;
steps taken to provide protection;
statement of whether equivalent safety is provided and, if
not, assessment of the residual risk;
any proposed corrective action and schedule; and
duration of the exemption.
The DOE Director, Office of Field Support (EH-53), shall be
notified and sent copies of all exemptions granted.
The DOE Operations Office Manager shall submit to the DOE Office
of Defense Programs all requests for exemptions from a mandatory
requirement for which equivalent protection of operating
personnel, the public, and property cannot be achieved. After
review of the request for exemption, the DOE Director, Office of
Defense Programs, shall recommend to EH-1 whether to grant
approval of the exemption. EH-1 is responsible for final
determination to grant or disapprove the exemption, and for
notification to the DOE Operations Office Manager. The DOE
Operations Office Manager may grant a temporary exemption for the
period of time an exemption request is being processed at DOE
Headquarters.
4.0 WAIVERS
If an activity, operation, or process is determined not to be in
compliance with the Manual's guidance, but the activity,
operation, or process is determined to be safe and necessary,
facility management may grant written approval for an alternate
solution. Waivers will be granted for the minimum time
necessary; those of an ongoing nature shall be updated every
3 years. Facility management shall maintain a central file of
active waivers and provide a copy of each waiver to the local DOE
contracting officer. Each waiver shall contain, as a minimum,
the following information:
description of the condition;
safety guidance requiring alternate solution;
reason why compliance is not achieved;
steps taken to provide alternate protection;
any proposed corrective actions and schedule; and
waiver duration or expiration date.
5.0 MANUAL ADMINISTRATION AND MANAGEMENT
This Manual shall be kept current. The Office of Environment,
Safety and Health shall ensure that a current version of this
Manual is maintained on the DOE Safety Performance Measurement
System (SPMS).
The DOE Explosives Safety Committee, through the Office of Field
Support (EH-53), shall administer and manage this Manual.
5.1 DOE Explosives Safety Committee Organization
The DOE Explosives Safety Committee is composed of a member from
each of the following:
DOE Office of Field Support (EH-53);
DOE Office of Military Application and Stockpile Support;
DOE Operations Office, Albuquerque;
DOE Operations Office, Oakland;
DOE Operations Office, Nevada;
DOE Kirtland Area Office;
DOE Operations Office, Idaho;
Los Alamos National Laboratory;
Lawrence Livermore National Laboratory;
Pantex Plant, Mason & Hanger-Silas Mason Co., Inc.;
Mound, EG&G Applied Technologies, Inc.;
Kansas City Plant, Allied Signal, Inc.;
Idaho National Engineering Laboratory, LITCO;
DOE Operations Office, Nevada, Bechtel Nevada Corporation;
and
Sandia National Laboratories.
The committee shall be chaired by the DOE Office of Field Support
(EH-53) Representative and will report directly to the DOE
Director, Office of Field Support.
5.2 DOE Explosives Safety Committee Functions
The DOE Explosives Safety Committee shall perform the following
functions.
Review, evaluate, and act under authority delegated from the
DOE Director, Office of Field Support, on proposed changes
or revisions to this Manual.
Evaluate and respond to requests for interpretations of the
Manual.
Meet periodically, as appropriate, to review and evaluate
Manual adequacy and existing exemptions and to initiate
Manual changes as needed.
Recommendations to correct and improve this Manual are encouraged
and should be sent to the chairperson of the DOE Explosives
Safety Committee through the Office of Field Support (EH-53).
6.0 DEFINITIONS
For purposes of this Manual, the following terms are defined.
APPROVED. Complying with the provision(s) of this Manual and
with instructions and details issued by the authority having
jurisdiction or with those of other approving agencies specified
herein.
ARM. A general term that implies the energizing of electronic
and electrical circuitry, which in turn controls power sources or
other components used to initiate explosives. The arming
operation completes all steps preparatory to electrical
initiation of explosives except the actual fire signal.
BARRICADE. An intervening approved barrier, natural or
artificial, of such type, size, and construction as to limit in a
prescribed manner the effect of an explosion on nearby buildings
or personnel.
BAY. A location (room, cubicle, cell, work area, etc.)
containing a single type of explosives activity, which affords
the required protection specified for appropriate hazard
classification of the activity involved.
BLENDING. The mixing of solid materials (usually dry) by gravity
flow, usually induced by vessel rotation.
BOOSTER (or boostering). Explosives used in an explosive train
to amplify the shock output of the initiating device and cause
detonation of the main explosive charge.
CASUAL. A person other than an operator who intermittently
visits an explosives operation for the purpose of supervision,
inspection, maintenance, etc.
COMBUSTIBLE MATERIAL. Any material that, when ignited, will
sustain burning.
COMPATIBILITY. The chemical property of materials to coexist
without adverse reaction for an acceptable period of time.
Compatibility in storage exists when storing materials together
does not increase the probability of an accident or, for a given
quantity, the magnitude of the effects of such an accident.
Storage compatibility groups are assigned to provide for
segregated storage.
CONCURRENT OPERATIONS. Operations performed simultaneously and
in close enough proximity that an incident with one operation
could adversely influence the other.
CONTACT OPERATIONS. An operation in which an operator and an
explosive item are both present with no operational shield.
CONTROL POINT. The location used for personnel control and
operation coordination in an explosives operating or test area.
CORING. A machining operation that removes material in the form
of a cylinder by cutting at the circumference to create a hole or
recover the material from the center of the cut.
CRITICAL TEMPERATURE. Temperature above which the self-heating
of an explosive causes a runaway reaction. It is dependent on
mass, geometry, and thermal boundary conditions.
DANGER ZONE. That area around a test site where personnel could
be in physical jeopardy due to overpressure, fragments, or
firebrands released during an explosive test.
DEFLAGRATION. A rapid chemical reaction in which the output of
heat is sufficient to enable the reaction to proceed and be
accelerated without input of heat from another source.
Deflagration is a surface phenomenon with the reaction products
flowing away from the unreacted material along the surface at
subsonic velocity. The effect of a true deflagration under
confinement is an explosion. Confinement of the reaction
increases pressure, rate of reaction, and temperature and may
cause transition into a detonation.
DETONATION. A violent chemical reaction within a chemical
compound or mechanical mixture involving heat and pressure. A
detonation is a reaction that proceeds through the reacted
material toward the unreacted material at a supersonic velocity.
The result of the chemical reaction is exertion of extremely high
pressure on the surrounding medium, forming a propagating shock
wave that is originally of supersonic velocity. When the
material is located on or near the surface of the ground, a
detonation is normally characterized by a crater.
DIFFERENTIAL SCANNING CALORIMETRY (DSC). A technique in which
the difference in energy inputs into a substance and a reference
material is measured as a function of temperature or time while
the substance and the reference material are subjected to a
controlled temperature program, or are held isothermally. The
record is the DSC curve. The energy input is substituted for DT
and is plotted in the same manner as a normal DTA curve.
DIFFERENTIAL THERMAL ANALYSIS. A technique in which the
temperature difference between a substance and a reference
material is measured as a function of temperature while the
substance and the reference material are subjected to a
controlled temperature program. The record is the DTA curve.
DRYING. The removal of volatiles from ingredients or mixtures.
DSC. See DIFFERENTIAL SCANNING CALORIMETRY.
DTA. See DIFFERENTIAL THERMAL ANALYSIS.
EBW. See EXPLODING BRIDGEWIRE.
EED. See ELECTROEXPLOSIVE DEVICE.
ELECTRICAL BONDING. Electrical connection between two conductive
objects intended to prevent development of an electrical
potential between them.
ELECTROEXPLOSIVE DEVICE (EED). A device containing some reaction
mixture (explosive or pyrotechnic) that is electrically
initiated. The output of the initiation is heat, shock, or
mechanical action. See also LOW-ENERGY EED.
EXPERIMENTAL OPERATING PROCEDURE. A procedure prepared for
conducting a specific experiment a limited number of times under
close technical supervision.
EXPLODING BRIDGEWIRE (EBW). An EED that is initiated by the
discharge of a high current through the device bridgewire,
causing the wire to explode and produce a shockwave. An EBW as
defined herein is a device containing no primary explosive.
EXPLOSIVE. Any chemical compound or mechanical mixture that,
when subjected to heat, impact, friction, shock, or other
suitable initiation stimulus, undergoes a very rapid chemical
change with the evolution of large volumes of highly heated gases
that exert pressures in the surrounding medium. The term applies
to materials that either detonate or deflagrate. DOE explosives
may be dyed various colors, except pink, which is reserved for
mock explosives.
EXPLOSIVE DECONTAMINATION. The removal of hazardous explosive
material.
EXTRUDING. Forcing a plastic-type material, under pressure, into
a confined space or through a confined opening to produce a
desired configuration.
FACILITY. A group of buildings or equipment used for explosive
operations at one geographic location, generally owned by DOE.
FACILITY MANAGEMENT. Management staff of the facility operator
(the contractor).
FACILITY OPERATOR. The organization responsible for conducting
operations at a DOE facility.
FIREBRAND. A projected burning or hot fragment whose thermal
energy is transferred to a receptor.
FIRING PAD. The prepared site where explosive items are fired
for test data acquisition.
FIRING SITE. Controlled access area where test firing of
explosives is conducted.
FLAMMABLE LIQUID. Any liquid having a flash point below 60øC and
a vapor pressure not exceeding 280 kPa (41 psia) at 37.8øC. This
is the definition as applied in this Manual; it includes some
materials defined as combustible liquids by the Department of
Transportation (DOT).
FLASH POINT. The temperature at which a liquid or volatile solid
gives off a vapor sufficient to form an ignitable mixture with
air near the surface of the material or within the test vessel.
FORMULATION. The operation of combining ingredients to produce a
mixture of a final desired composition possessing specific
physical and explosive properties.
An explosives composition.
HEATING LIMITS. The conditions established for safely heating an
explosive system (maximum temperature, heating time, heating
rate, etc.). These limits are based on the estimated critical
temperature of the explosive system with a suitable margin of
safety.
HIGH-ENERGY INITIATOR. Exploding bridgewire systems, slapper
detonators, and EEDs with similar energy requirements for
initiation.
HIGH PRESSURE. Gas pressure greater than 3,000 psig (21 MPa
gauge); liquid pressure greater than 5,000 psig (35 Mpa gauge).
HOLE (as applied to machine explosives). Any cavity that is more
than one-half diameter deep, being cut by any tool with the
direction of feed along the axis of rotation.
HOT WORK (thermal). Any operation requiring the use of a flame-
producing device, an electrically heated tool producing a
temperature higher than 109øC, or a mechanical tool that can
produce sparks or heat explosives or explosives contamination to
provide an initiation stimulus.
HYDROSTATIC PRESSING. The operation of compacting a material
that is confined in a press by a diaphragm by hydraulically
applying pressure to the diaphragm.
IHE. See INSENSITIVE HIGH EXPLOSIVES.
IHE SUBASSEMBLIES. IHE hemispheres or spheres with booster
charges, with or without detonators, that pass the DOE
qualification tests listed in Table IX-3.
IHE WEAPONS. Weapons listed in DOE-DNA TP 20-7, Nuclear Safety
Criteria (for Warhead Storage), as being exempt from storage and
transportation limits are classified as IHE weapons when stored
or transported alone or in combination with each other. This
classification is valid only if the spacing between individual
units is that provided by storage/shipping containers or, if not
in containers, by the spacing specified in TP 20-7.
INERT MATERIALS. Material that shows no exothermic decomposition
when tested by DSC or DTA. Moreover, the inert material shall
not show any incompatibility with energetic material with which
it may be combined when tested by recognized compatibility tests.
Inert material shall neither alter the onset of exotherm of the
DSC or DTA trace of the energetic material nor increase the rate
of decomposition or gas evolution of the energetic material.
IN-PROCESS STORAGE MAGAZINE (facility, vault, rest house, etc.).
See SERVICE MAGAZINE.
INHABITED BUILDING. A building or structure other than operating
buildings, magazines, and auxiliary buildings occupied in whole
or in part as a habitation for people or where people are
accustomed to assemble, both within and outside DOE facilities.
Land outside DOE facilities shall be considered as sites for
inhabited buildings.
INHABITED-BUILDING DISTANCE. The minimum distance permitted
between explosives locations and inhabited buildings,
administrative areas, site boundaries, main power stations, and
other facilities of vital or strategic nature.
INITIATION STIMULUS. Energy input to an explosive in a form
potentially capable of initiating a rapid decomposition reaction.
Typical initiation stimuli are heat, friction, impact, electrical
discharge, and shock.
INITIATION, WITH ITS OWN MEANS. Explosives or ammunition having
their normal initiating device (e.g., detonators, squibs)
assembled to them so that this device is considered to present a
significant risk of activation during storage.
INITIATION, WITHOUT ITS OWN MEANS. Explosives or ammunition that
(1) are not stored with an initiating device assembled to them;
or (2) have the initiating device assembled to them, but
(a) safety features preclude initiation of the explosives filler
of the end item in the event of accidental functioning of the
initiating device, or (b) the initiating device does not contain
any primary explosives and has a high threshold of initiation
(e.g., EBW or slapper detonators). The power source for the
initiator(s) should not be present within the assembly or system.
If the initiator(s) power source is present, two or more
management-certified safety devices connected in series shall be
present to interrupt any flow of energy from the power source to
the initiator(s).
INSENSITIVE HIGH EXPLOSIVES (IHE). Explosive substances that,
although mass detonating, are so insensitive that there is
negligible probability of accidental initiation or transition
from burning to detonation. The materials passing the DOE
qualification tests in Table IX-1 are classified as IHE, and are
listed in Table IX-2.
INTERMEDIATE PRESSURE. Gas pressure from 150 to 3,000 psig
(1 to 21 MPa gauge); liquid pressure from 1,500 to 5,000 psig
(10 to 35 MPa gauge).
INTRALINE DISTANCE. The distance to be maintained between any
two operating buildings or sites within an operating line, at
least one of which contains, or is designed to contain,
explosives.
INTRINSICALLY SAFE. An apparatus or system whose circuits are
incapable of producing any spark or thermal effect capable of
causing ignition of a mixture of flammable or combustible
material under test conditions described in ANSI/UL 913.
ISOSTATIC PRESSING. The operation of compacting a material in a
sealed flexible container. The container is submerged in a
pressure vessel, and the vessel is pressurized with liquid.
LABORATORY OPERATIONS. Experimental study, testing, and analysis
of small quantities of energetic materials. Manufacturing
processes with small quantities of materials are not included.
LEL. See LOWER EXPLOSIVE LIMIT.
LFL. See LOWER FLAMMABLE LIMIT.
LOW-ENERGY EED. All EEDs except exploding bridgewire (EBW)
detonators and slapper detonators.
LOW PRESSURE. Gas less than 150 psig (1 MPa gauge); liquid less
than 1,500 psig (10 MPa gauge).
LOWER EXPLOSIVE LIMIT (LEL). The concentration of vapor or dust
in air below which an explosion cannot occur.
LOWER FLAMMABLE LIMIT (LFL). The concentration of a vapor or
dust in air below which a burning reaction cannot be sustained.
MACHINING. A forming operation accomplished by removing material
with a mechanically operated cutting tool.
MACHINING OVERTEST. A test to evaluate the susceptibility of an
explosive material to initiation during machining.
MAGAZINE. See SERVICE MAGAZINE or STORAGE MAGAZINE.
MAGAZINE DISTANCE. The minimum distance permitted between any
two storage magazines. The distance required is determined by
the type(s) of magazine and also the type and quantity of
explosives stored therein.
MAXIMUM CREDIBLE EVENT (MCE). The MCE from a hypothesized
accidental explosion or fire is the worst single event that is
likely to occur from a given quantity and disposition of
explosives/explosives devices. The event must be realistic with
a reasonable probability of occurrence considering the explosive
propagation, burning rate characteristics, and physical
protection given to the items involved.
MELTING. Operations involving change in the physical state of
explosives from solid to liquid.
MILLING. (1) Operations that either reduce solid material
particle size by attrition or apply high-shear mixing to
incorporate solid materials into plastic binders; (2) a surface
machining operation performed on a mill.
MIXING. A mechanical operation that combines dissimilar
materials.
MOCK EXPLOSIVE. Substances bearing similar physical properties
(texture, density, cohesion, etc.) to an explosive material.
They are nondetonable; however, some are exothermic materials and
will burn. Mock explosives are used to represent explosives for
purposes such as dry run testing of equipment. DOE mock
explosives are normally pink in color.
NEW. Net explosive weight expressed in pounds.
NEW (OR EXPERIMENTAL) EXPLOSIVE. Explosive, explosive mixture,
or explosive and binder mixture that has not been characterized
by the Explosives Development Committee.
NON-DOE FACILITY PERSONNEL. Personnel of a contractor who does
not have a continuing contract with DOE at the facility
concerned.
OPERATIONAL SHIELD. A barricade constructed to protect
personnel, material, or equipment from the effects of a possible
fire or explosion occurring at a particular operation.
PERSONNEL BARRIER. A device designed to limit or prevent
personnel access to a building or an area during hazardous
operations.
PRESSING. The operation of increasing the density of explosive
material by the application of pressure.
PROPELLANT. Explosive composition used for propelling
projectiles and rockets and to generate gases for powering
auxiliary devices.
PUBLIC-TRAFFIC-ROUTE DISTANCE. The distance from an explosives
facility to any public street, road, highway, or passenger
railroad (including roads on DOE-controlled land open to public
travel).
PUNCH AND DIE PRESSING. The operation of compacting a material
confined by a die by forcing a punch or punches into the die and
against the material.
PYROTECHNIC MATERIAL. Physical mixtures of finely divided fuels
and oxidizer powders; may include various organic binders and
color intensifiers. The material is intended to produce an
effect by heat, light, sound, gas or smoke, or a combination of
these as the result of nondetonative, self-sustaining exothermic
chemical reactions.
REMOTE OPERATION. An operation performed in a manner that will
protect personnel in the event of an accidental explosion. This
can be accomplished by distance, shielding, barricades, or a
combination thereof.
RISK. A measure of the combination of the probability and
consequences of the hazards of an operation, expressed in
qualitative or quantitative terms.
SAFETY ANALYSIS. A document prepared to systematically identify
the hazards of a DOE operation; describe and analyze the adequacy
of measures taken to eliminate, control, or mitigate identified
hazards; and analyze and evaluate potential accidents and their
associated risks.
SCREENING. An operation using screens to separate particles of
differing sizes.
SERVICE MAGAZINE, REST HOUSE, ETC. An auxiliary building or
suitably designated room (vault) used for the intermediate
storage of explosives materials not exceeding the minimum amount
necessary for safe and efficient operation.
SHUNT. An electrical interconnection of various portions of EED
circuitry to prevent the development of an electrical charge
differential between the parts.
SLAPPER DETONATOR. An EED initiated by a rapid discharge of a
high current through a metal foil. The expansion of the metal
vapor causes a plastic or metal covering to be propelled across
an air gap and detonate a high-density explosive pellet.
SMALL ARMS AMMUNITION. (1) Ammunition designed to be fired from
a pistol, revolver, rifle, or shotgun held by the hand or to the
shoulder; (2) ammunition of less than 20-mm caliber with
incendiary, solid, inert, or empty projectiles (with or without
tracers) designed to be fired from machine guns or cannons;
(3) blank cartridges.
SOP. See STANDARD (STANDING) OPERATING PROCEDURE.
SPECIAL OPERATING PROCEDURE. A procedure prepared for the
performance of a specific task on a one-time basis, or for
situations not encountered in normal operation.
STANDARD (STANDING) OPERATING PROCEDURE (SOP). A procedure
prepared for the operation of a facility or performance of a task
on a routine basis.
STORAGE MAGAZINE. A structure designed or specifically
designated for the long-term storage of explosives or ammunition.
SUBSTANTIAL DIVIDING WALL. An interior wall designed to prevent
the propagation of an accidental detonation on one side of a wall
to explosives on the other side.
SYNTHESIS. The chemical operation(s) required to produce a
desired chemical compound.
TARGET. The area, structure, or material into which a projectile
is fired.
TNT EQUIVALENT. A measure of the blast effects from explosion of
a given quantity of material expressed in terms of the weight of
TNT that would produce the same blast effects when detonated.
TRANSIENT. Any person within inhabited-building distance but not
inside an explosives bay or other occupied areas (offices, break
areas, shops, etc.).
UNITED NATIONS ORGANIZATION (UNO) CLASS 1 EXPLOSIVES.
(a) Explosive substances (a substance that is not itself an
explosive but that can form an explosive atmosphere of gas,
vapor, or dust is not included in Class 1), except those that are
too dangerous to transport or those where the predominant hazard
is appropriate to another class; (b) explosive articles, except
devices containing explosive substances in such quantity or of
such a character that their inadvertent or accidental ignition or
initiation during transport shall not cause any effect external
to the device either by projection, fire, smoke, heat, or loud
noise; and (c) substances and articles not mentioned under (a)
and (b) that are manufactured with a view of producing a
practical, explosive or pyrotechnic effect. CHAPTER II
OPERATIONAL SAFETY
1.0 GENERAL OPERATIONS SAFETY GUIDELINES
1.1 Protection of Explosives
Explosives are energetic materials that can react violently.
Explosives should be protected from abnormal stimuli or
environments, including:
friction forces;
excessive pressures;
excessive temperatures;
impact, shock, pinching;
deformation;
electrical sparks, abrasive or welding sparks, open flame;
contamination; and
contact with incompatible materials.
1.2 Equipment Checks
Before being used in the explosives process, and at established
intervals, processing and test equipment shall be checked for:
proper design;
proper function;
specified clearances between parts in relative motion;
abnormal metal-to-metal rubbing of moving parts potentially
contacting explosive materials;
cracks, voids, or screw threads where explosives may
accumulate; and
contamination incompatible with the materials to be
introduced.
This checkout may require the use of mock explosives in process
or test conditions. Explosive materials must not be pinched or
confined between equipment lids or covers and their mating
surfaces. These surfaces shall be cleaned before cover
placement. This includes pressing operations.
1.3 Inspection Frequency
When this Manual calls for an inspection, but the inspection
interval is not specified, such inspection interval shall be
established by local facility management. Inspection intervals shall be modified when
experience dictates a need.
1.4 Laboratory Operations
The special safety guidelines applicable to general laboratory
operations involving explosive materials are contained in
Section 21 of this chapter.
1.5 Toxicity Hazards
Explosives materials, explosives components (additives or
adhesives), and materials such as organic solvents used in
explosives processing can be toxic when inhaled, ingested, or
absorbed through the skin. Skin contact with explosives
materials, or with solvents and adhesives used in conjunction
with explosives operations, can result in a skin rash. This is
the most frequently reported effect from working with these
materials. The following general precautions should be used to
prevent overexposure to these materials during explosives
processing and handling.
a. Know the health hazard and controls before beginning
operations.
b. Evaluate the operation during startup to ensure that
occupational exposure limits are not exceeded; routine
operations should be monitored periodically.
c. Handle in a well ventilated area; local exhaust ventilation
is preferred.
d. Avoid skin contact; wear appropriate protective clothing.
e. Practice good personal cleanliness; wash before eating,
smoking, or using toilet facilities. End of shift showers
may be required for some operators.
1.6 Hazard Identification and Communication
Before beginning explosives operations, managers shall ensure the
following:
a. Identify and maintain a current list of explosives and other
hazardous materials used in conjunction with their
operations.
b. Determine the hazardous properties and toxicity of these
materials through the use of the manufacturer's Material
Safety Data Sheets (MSDS) or other information sources and
through consultation with the facility Industrial Hygiene
staff. For explosives without published toxicological data,
guidance can be obtained through the DOE Toxic Materials
Advisory Committee (TMAC). Health hazard information must
be communicated to employees who work with or generate
hazardous materials.
c. Educate and train employees in the hazards of and
precautions required for handling explosives and materials
used in conjunction with explosives operations. This
training should be part of the employee training and
qualification program specified in Chapter V.
1.7 Process Hazard Analysis
a. Before beginning any explosives synthesis, formulation,
manufacturing, testing, or disposal operation, a process
hazard analysis shall be performed, as required by
29 CFR 1910.119. A single process hazard analysis may be
performed for similar processes performed in a single
facility, provided that the "worst-case" process is the
basis for the hazard analysis. Selection criteria for the
worst-case process are:
sensitivity of materials;
quantity of materials;
number of personnel potentially affected; and
impact on other operations/activities.
b. The process hazard analysis shall be performed as a team
effort. The team shall consist of a minimum of three
personnel and should not include more than seven personnel.
The team shall include at least one engineer and one
operator, and should have the following makeup.
Team Leader, who is familiar with the analysis
methodology used;
Technical Member(s), who is/are familiar with the
process being analyzed; and
Scribe, who writes notes of meetings and interviews and
drafts reports.
c. The analysis methodology used may be selected by either the
facility manager or the team leader, but should be one of
the following:
Preliminary Hazard Analysis;
Checklist (usually for similar batch operations);
What-if Analysis;
Hazard and Operability Study (HAZOP);
Failure Modes, Effects, and Criticality Analysis
(FMECA);
Fault Tree Analysis; and
Event Tree Analysis.
d. The process hazard analysis shall be formally documented.
e. Employees and employee representatives shall be consulted on
the process hazard analysis. The result of the process
hazard analysis shall be provided to employees involved in
or affected by the operation.
f. The process hazard analysis shall be updated and revalidated
at least every 5 years by a team meeting the above criteria.
g. The facility manager shall be responsible for establishing a
system to address promptly the team's findings and
recommendations. Corrective actions, schedules for
corrective actions, and completion of corrective actions
shall be formally documented, and such documentation filed
with the process hazard analysis.
h. Files containing process hazard analyses, updates, and
corrective action statuses shall be maintained for the life
of the process.
2.0 WORK ENVIRONMENT
2.1 General Requirements
a. Adequate work space shall be provided to perform operations
safely and efficiently.
b. Work shall be organized to eliminate clutter in the area
while operations are being performed.
c. Walkways should be kept clear.
d. In work environments where solid, bare explosive pieces are
handled, the floor should be cushioned, and all hard objects
that may be struck by explosives in a handling incident
should be cushioned where it is practical.
e. An accounting procedure should be established for hand tools
that may be inadvertently dropped into an explosives
processing operation, thus creating a hazard.
f. Personnel shall be assigned in such a manner that each
worker's presence is frequently monitored and assistance can
be provided or aid summoned in the event of an emergency.
g. Safety analysis of explosives facilities shall be performed.
The safety analysis shall be performed during the design of
new explosives facilities or the redesign of existing
facilities. Facility management shall maintain readily
available analyses documentation.
h. Noisy environments caused by explosives testing operations
or process and handling equipment shall be evaluated. Areas
with noise above the allowable occupational exposure limits
must be posted and appropriate control measures instituted
(e.g., engineering controls, protective equipment, and a
hearing conservation program).
2.2 Emergency Exit Requirements for Explosives Operations
Exit requirements for any building or structure containing
explosives shall comply with the Life Safety Code, NFPA 101,
except as otherwise permitted in this section.
2.2.1 Building or Structure Occupancy
In determining occupancies:
a. explosives operating buildings shall be classified as
industrial occupancies (NFPA 101, Chapter 28);
b. explosives storage or staging buildings or structures shall
be classified as storage occupancies (NFPA 101, Chapter 29).
2.2.2 Hazards of Contents Classification
The hazard of contents classification of any explosives occupancy
shall be determined using the requirements given in NFPA 101 and
the following guidelines.
a. High-hazard explosives contents are those that, because of
form, character, or volume, are likely to burn with extreme
rapidity or from which poisonous fumes or explosions can be
expected in the event of fire. The expectation of poisonous
fumes or explosions is a relative matter to be determined on
a case-by-case basis. Operating buildings containing
propellant, pyrotechnic, or explosive powders shall be
classified as high-hazard occupancies unless a reduced
hazard classification can be justified.
b. Reduced-hazard explosives contents are those that burn with
moderate or less rapidity and will not produce poisonous
vapors. This criterion shall be documented by a hazard
analysis.
2.2.3 Personnel Protective Restrictions and Requirements
DOE occupancies containing high explosives dictate personnel
protection from blast overpressures and fragments (and spread of
plutonium in some occupancies) from an accidental detonation.
This accidental detonation of explosives is usually the result of
stimuli other than a fire.
Noncompliance with some NFPA 101 provisions (such as those
covering exit doors, exit travel distance, number and location of
exits, and common path of travel to exits) is authorized where
required to provide protection from blast overpressure and
fragments. When NFPA 101 requirements are not met the following
additional personnel protective restrictions or requirements
should be imposed.
a. The building and means of egress should be protected by
supervised automatic sprinkler systems connected to sound
evacuation alarms. This requirement is not applicable to
explosives storage magazines, firing chambers, or rooms used
as firing chambers, within explosives operating buildings.
b. Explosives operating buildings and their means of egress
should have automatic, early warning fire detection systems
connected to sound evacuation alarms where such early
warning might reasonably aid in prevention or mitigation of
personnel injury. This requirement is not applicable to
explosives storage magazines, firing chambers, or rooms used
as firing chambers within explosives operating buildings.
c. Personnel limits within the explosives work area (bay, cell,
etc.) shall be established and controlled. These should not
exceed 20 for reduced hazard occupancies or 6 for high-
hazard occupancies. The need for personnel in numbers
greater than these limits shall be documented in a hazards
analysis based on the criteria of paragraph 2.2.5 of this
chapter.
2.2.4 Requirements for Existing Facilities
Existing facilities may deviate from current NFPA 101
requirements in the following situations.
a. Current code requirements were not in effect when the
building was constructed. The building, however, is still
required to meet the code of record.
b. Deviations were made to meet the level-of-protection and
design criteria in Chapter VI, Section 6, of this Manual.
c. Building construction predates both current and level-of-
protection criteria, but a hazards analysis has shown the
risk of operations to be at an acceptable level.
d. The risk from deviation has been analyzed and accepted by
current hazards analysis.
Those facilities requiring hazards analysis to determine whether
a deviation from the Life Safety Code is acceptable shall follow
the considerations and criteria described in paragraph 2.2.5 of
this chapter.
2.2.5 Requirements for New Facilities
New facilities shall comply with the requirements of NFPA 101,
except when deviation is necessary to provide personnel
protection from blast overpressure and fragments per Chapter VI
of this Manual.
2.2.5.1 If deviations from NFPA 101 requirements are made, the
Fire Hazards Analysis required by Chapter VI of this
Manual shall document the following aspects related to
each explosives operation, bay, and/or workroom where a
deviation exists.
a. Clear pathway to exit in explosives bay or
workroom.
b. Potential for sustained fire in work environments
from the presence of combustible and flammable
materials and the presence of ignition sources.
c. Total time required to exit the bay or workroom.
2.2.5.2 The criteria considered acceptable for the components
of the analysis in paragraph 2.2.5.1 of this chapter
are, respectively:
a. No obstruction shall limit the width of the
pathway to less than 36 in.
b. Combustible and flammable material quantities
shall be minimized, justified, documented, and
reviewed by site fire protection personnel and
approved by line management. Ignition sources
shall be identified and eliminated where possible.
c. The total time for 6 people to exit the workroom
or bay is 30 seconds or less, including the
opening of doors where necessary. The total time
for 20 people to exit the workroom or bay is 90
seconds or less. Noncompliance with this
criterion shall be evaluated and justified during
the conceptual design review.
2.2.6 Single Exits
Where at least two exits are required by NFPA 101 and provisions
for personnel protection from a blast will not permit at least
two exits from a room or structure, a single exit is acceptable,
provided the requirements of paragraph 2.2.3 of this chapter and
the following are met.
a. The path of exit travel shall be arranged so it is not
through or toward a hazardous operation.
b. The room containing a high-hazard explosives occupancy shall
not exceed 500 ft2, and the occupant load of the room shall
be restricted to two operators and two transients.
c. The room containing an ordinary-hazard explosives occupancy
shall not exceed 1,000 ft2.
Explosives storage magazines may have only single exits for the
purpose of maintaining integrity of design. The conditions of
this section do not apply to these magazines.
2.2.7 Blast-Resistant Doors
Blast-resistant doors required for the purpose of personnel
protection from the effects of an accidental detonation may be
located in the means of egress, provided the requirements of
paragraphs 2.2.3 through 2.2.5 of this chapter and the following
are met.
a. Where power-operated doors are required to accomplish
unlatching and opening, they shall have reliable power
supplies and shall be capable of being opened manually (to
permit exit travel) or closed where necessary to safeguard
the exits.
b. The time required to fully open or close a door shall be as
short as reasonably possible.
c. A revolving door is acceptable if a secondary means of
escape (with swinging doors) is provided at the same
location. The revolving door must also be prevented from
rotating at too rapid a rate to permit orderly exit of
personnel.
d. The following exceptions to NFPA 101 may be allowed when
justified and documented.
Swinging doors may exceed 48 in. wide.
It is acceptable to omit the NFPA-required swinging
doors adjacent to a revolving blast door.
Revolving blast doors need to collapse into book-fold
position.
Where fire-rated doors are required, blast doors are
considered to have the required fire rating.
An airlock provided with two or more doors with the
intended purpose of preventing continuous and
unobstructed passage by allowing the release of only
one door at a time, shall be permitted in a means of
egress where there are provisions for continuous and
unobstructed travel during an emergency egress
condition.
e. A reliability analysis must be conducted to demonstrate that
the reliability of the doors and associated hardware is
equivalent to the requirements of ANSI A156.
2.2.8 Slide Escapes
Slide escapes should be provided for elevated explosives
operating locations from which rapid exit may be vital and cannot
be obtained by other means. Slide escapes should be located on
opposite sides of the explosives operation to reduce the
likelihood of personnel being trapped by fire between them and a
single slide. Exits to slide escapes must open onto platforms
that are not less than 3 ft square, and the platforms must be
equipped with guardrails. The slides shall begin at the outside
edge of the platform, not at the edge of the buildings. Slide
escape landings shall be located at selected places leading
directly to escape routes that are free from tripping hazards,
low guy lines, drains, ditches, or other obstructions. Manually
or automatically controlled devices (trips) that sound an alarm
in the operating building shall be installed at or near the
entrances to slide escapes. These devices may also actuate
deluge valves and water curtains in the building or room
affected.
Recommended slide escape specifications:
angle, 40 to 50 degrees horizontal;
slide depth, 24 in.;
radius at bottom of slide, 12 in.; and
height at lower end of slide, not over 24 in. above the
landing.
If necessary, the end of the slide must have a horizontal run
sufficient to prevent an employee injury because of exit speed
without the use of landing cushions, which are unsatisfactory in
cold weather. One foot of horizontal run is required for a
15-ft-long slide. One additional foot of horizontal run will be
provided for each additional 5 ft of slide length. The juncture
of the two sections must be well rounded. The metal sheets
constructing the slide must overlap in the direction of travel.
3.0 BUILDING AND EQUIPMENT MAINTENANCE
3.1 Cleaning
a. Structures containing explosives shall be kept clean and
orderly.
b. Explosives and explosives dust shall not be allowed to
accumulate on structural members, radiators, heating coils,
utility lines, equipment, or electrical fixtures.
c. To maintain safe conditions, there shall be a regular
cleaning program for building interiors to prevent
explosives dust and waste accumulation. This program should
not be conducted in any bay where a hazardous operation is
being conducted.
d. In buildings containing explosives, hot water or water-steam
mix should be used wherever practical for cleaning floors.
Sweeping compounds that are nonabrasive and compatible with
the explosives involved may be used when the use of water-
steam mix or hot water is not practical. Such compounds may
be combustible but must not be volatile (closed-cup flash
point must not be lower than 110øC). Sweeping compounds
containing wax shall not be used on conductive flooring.
Where nitrated organic explosives (which may form sensitive
explosive compounds with some alkalies) are involved, the
use of cleaning agents containing those alkalies is
prohibited.
e. Before beginning explosives decontamination activities that
involve the use of large amounts of organic solvents
(generally over 1 L), provisions must be made for
(a) adequate ventilation or respiratory protection, (b) fire
protection, and (c) adequate protective clothing.
3.2 Maintenance and Repair
a. Records shall be maintained for inspection, repair, and
servicing of process and handling equipment and fire
protection systems.
b. Maintenance operations involving major repairs, changes, or
the use of hazardous equipment should not be performed
within bays (rooms) while explosives are present. Before
these operations, explosives should be removed and the area
prepared. An approval procedure shall be established to
ensure that the area has been inspected and is safe for
these operations.
c. Maintenance or construction operations performed by non-DOE
facility personnel shall be at least intraline distance from
any explosives operation and should be at least intraline
distance from any building containing explosives.
(Intraline distance separation may be satisfied by providing
equivalent protection.) Transportation of explosives is
permitted on roadways at less than intraline distance.
d. New equipment or equipment subjected to major repair or
modification shall be test-operated, and handling equipment
shall be tested before being returned to operations. The
DOE HOISTING AND RIGGING HANDBOOK (1090-95) may be used as a
guide.
e. Maintenance work shall be performed by authorized personnel
only.
f. Before resuming operations following maintenance, the area
shall be cleaned and approved by the operations supervisor.
3.3 Hot Work Permits
Where explosives are involved, a written permit shall be required
for the temporary use of portable, heat-producing equipment that
generates temperatures higher than 109øC. Explosives
decontamination of the immediately affected work areas and
explosives removal shall be required before hot work operations.
The permit should state the location, time, duration, purpose of
use, details of safety, and fire-fighting equipment required.
The permit shall be kept at the named location for availability
to and checkout by supervisory personnel.
a. Authorization of permits shall be by signature of personnel
designated by the local facility management. Designated
personnel should be qualified by experience in explosives
work, fire prevention, and general safety precautions,
particularly with regard to the purging of equipment,
presence of flammable mixtures, and the avoidance of
electrical and mechanical hazards that could be incident to
repair work.
b. Designated personnel should represent supervision of the
location where the work is being performed, supervision of
personnel performing the hot work, and a third group
independent of the first two (usually the local safety and
fire protection group).
c. Someone should remain at the site of a cutting or welding
job for approximately 30 minutes after the job has been
completed to extinguish or report any fires that develop.
Designated supervisors should inspect the job site before
job initiation, during the job, and after job completion. 4.0 REMOTE OPERATIONS
4.1 Personnel Protection Criteria
Explosives operations judged to present a high enough level of
risk to be performed remotely shall be conducted in facilities
where the construction of the operating bay or the control room
is capable of affording sufficient protection to personnel to
prevent serious injuries. Criteria for the prevention of serious
injuries are specified in Chapter VI, paragraph 4.2.1.d.
Prevention of serious injury from a remote operation applies to
transient personnel as well as to personnel involved in the
operation.
4.2 Access and Equipment Controls
Control procedures and equipment shall be used to prevent
personnel from entering the hazardous bay or area in which a
remote operation is occurring or to prevent the operation from
proceeding when personnel enter, as follows.
a. Roads shall be blocked at a minimum of the public-traffic-
route distance from buildings where hazardous (remote)
operations are being performed. Public traffic route
separation may be satisfied by providing equivalent
protection.
b. Corridors leading to bays in which hazardous (remote)
operations are being performed shall be adequately marked to
warn of the danger. Barriers shall also be set up.
c. Visual methods such as closed circuit television should be
used to monitor remote operations and to enable viewing the
operating area conditions before entering. Remote audio
monitoring and video recording should also be considered.
d. Interlocking of remote operating equipment to access doors
should be required for each remote operation.
e. Buildings or bays in which remote operations are performed
shall be conspicuously identified by lights or similar
warning devices to indicate when operations are under way.
This page intentionally left blank. 5.0 GENERAL EXPLOSIVES AREA CONTROLS
5.1 Smoking, Matches, Lighters, Metal Articles
a. There shall be no smoking in explosives storage, processing,
or test areas, except in designated locations.
b. No matches, lighters, other fire-, flame-, or spark-
producing devices shall be taken into an explosives control
area except with written authorization. If authorized to be
carried, matches shall be contained in a metal carrying
device too large to fit in pockets. Kitchen ("strike
anywhere") matches shall not be used.
c. In explosives processing areas, metal articles (keys,
jewelry, knives, coins, etc.) should not be carried by
operating personnel where such items could constitute a
hazard if dropped into the process operation.
5.2 Cooking and Eating
a. There shall be no consumption of food or beverages in an
explosives building, except in designated areas.
b. There shall be no personal dishes or utensils in an
explosives building, except in designated eating areas.
c. Coffee pots, hot plates, ovens (including microwave), and
portable electric heaters shall not be permitted in rooms
where:
explosives may be present;
combustible vapors or dust may be present;
smoking or drinking is prohibited because there are
toxic materials present; and
electrical classification of appliances is not
compatible with the area.
5.3 Access to Explosives Areas
Access control procedures shall be established for entry to all
explosives areas.
This page intentionally left blank. 6.0 ELECTRICAL STORMS AND LIGHTNING PROTECTION
6.1 Assessment
Whenever an electrical storm approaches, personnel shall exit any
location wherein a hazard exists due to explosives being
initiated by lightning. The existence of such a hazard shall be
determined based on the assessment of the specific operation and
facility or area lightning protection. Locations where
evacuation may be necessary are listed below.
All outdoor operations and operations in buildings that do
not afford lightning protection, and locations within
inhabited-building distance of the hazard. (When an
electrical storm is imminent, explosives operations should
not be initiated.)
Explosives-carrying vehicles and railroad cars and locations
within magazine distance of the hazard.
Locations (with or without lightning protection) where
operations involving electrostatic-sensitive bulk explosives
or electroexplosive devices (EEDs) are being performed.
6.2 Evacuation
Evacuated personnel shall proceed to a suitable protective
shelter. A suitable shelter is one that will protect personnel
from overpressures greater than 16 kPa (2.3 psi), structural
collapse, and missiles in the event of explosion of any adjacent
facility containing explosives.
6.3 Shutdown of Operations
The following guidelines should be used for shutdown of an
operation during an electrical storm.
a. Process equipment containing explosives should be stopped as
soon as safety permits.
b. When buildings or bays containing explosives are evacuated
during periods of electrical storms, operations that cannot
be shut down immediately should be manned by the minimum
number of personnel required for safe shutdown. When the
operation has been brought to a safe condition so that
personnel can exit, remaining personnel should evacuate.
c. Automatic emergency power equipment should be provided if
electrical power is critical to an explosives operation
during a power shutdown or interruption.
6.4 Lightning Protection
It is DOE policy to install lightning protection on all
facilities used for storage, processing, and handling of
explosives materials where operations cannot be shut down during
electrical storms and personnel evacuated. Specific operations
shall be assessed for the risk of initiation of process materials
by lightning. Assessment shall consider the need for protection
factors outlined in NFPA 780, "Lightning Protection Code,"
Appendix L ("Protection of Structures Housing Explosives"). When
risk is high, as in operations with highly sensitive
electrostatic materials or components, operations shall be
conducted in lightning-protected facilities only. Approved
lightning protection systems must conform with the requirements
of NFPA 780, Appendix L. Examples of acceptable lightning
protection systems can be found in DoD 6055.9-STD, DoD Ammunition
and Explosives Safety Standards, Chapter 7.
a. Visual inspection of lightning protection systems should be
conducted every 7 months and shall be conducted at least
annually. A report shall be filed following each
inspection. Any evidence of corrosion, broken wires or
connections, or any other problem that would negate the
system's usefulness will be noted and repaired.
b. Electrical testing for lightning protection systems should
be conducted every 14 months and shall be conducted at least
every 47 months to afford testing during all seasons and
immediately following any repairs or modifications. The
testing shall be conducted only with instruments designed
specifically for earth-ground system testing. The
instruments must be able to measure 10 ohms plus or minus
10% for ground resistance testing, and 1 ohm plus or minus
10% for bonding testing. Electrical resistance readings
shall be recorded.
c. Inspection records shall contain the most recent electrical
test report and any subsequent visual inspection reports for
each building.
See paragraph 8.3 of this chapter for additional requirements.
7.0 STATIC ELECTRICITY
7.1 General
Positive steps must be taken to control or eliminate static
electricity in areas where materials that are ignitable by static
spark discharge are processed or handled. This includes spark-
sensitive explosives, propellants, and pyrotechnics as well as
solvent vapors and flammable gases.
7.2 Bonding and Grounding of Equipment
Bonding straps should be used to bridge locations where
electrical continuity may be broken by the presence of oil on
bearings, paint, or rust at any contact point. Permanent
equipment in contact with conductive floors or table tops is not
considered to be adequately grounded. Static grounds shall not
be made to gas, steam, or air lines, dry pipe sprinkler systems,
or air terminals of lightning protection systems. Static grounds
can be made to water pipes, ground cones, buried copper plates,
driven ground rods, or to down conductors of lightning protection
systems. If a structure is equipped with a lightning protection
system, all grounds must be interconnected. Wires used as static
ground conductors should be at least No. 10 AWG or equivalent.
7.3 Testing Equipment Grounds
Grounding systems shall be tested for electrical resistance and
continuity when installation has been completed and, in the case
of active equipment, at intervals to be locally determined. The
ground system shall be visually inspected for continuity (before
reactivation of the system) if the equipment has been inactive
for more than 1 month. All exposed explosives or hazardous
materials shall be removed before testing. When testing for
resistance-to-ground, equipment should be considered as a unit,
except in the case of a belt-driven machine. In measuring the
total resistance-to-ground for belt-driven machinery (to ensure
compliance with the paragraph below), resistance of the belting
is to be excluded. The maximum resistance-to-ground permitted
for different types of equipment is as follows:
Hazardous locations (operations where a static spark
discharge may be dangerous). All conductive parts of
equipment shall be bonded so that resistance to ground
does not exceed 25 ohms, unless resistance is not to
exceed 10 ohms because of the lightning protection
installation. For existing equipment, the rate of
static generation should be considered before changes
in grounding systems are made. The resistance of
conductive rubber hose should not exceed 250,000 ohms.
7.4 Conductive Floors, Shoes, Mats, and Wristbands
a. Conductive floors and shoes should be used for grounding
personnel in operations involving explosives, propellants,
pyrotechnics, etc., that are sensitive to initiation by the
electrostatic spark discharge from a person. These include
lead azide, lead styphnate, mercury fulminate, CP, some
propellants, some pyrotechnics, etc. Many flammable liquids
and air mixtures can be ignited by static discharge from a
person. When personnel come into the proximity of (possible
contact with) static-sensitive explosives or vapors,
conductive floors shall be installed except where the
hazards of dust-air or flammable vapor-air mixtures are
eliminated by adequate housekeeping, dust collection,
ventilation, or solvent recovery methods. Conductive floors
may also be required where operations are performed
involving electroexplosive devices (EEDs) that contain a
static-sensitive explosive.
b. Conductive floors are not required throughout an entire
building or room if the hazard is localized. In such cases,
conductive mats or runners may be used where required.
These mats or runners will be subject to all the
specifications and test requirements that apply to
conductive floors. Conductive wristbands may be substituted
for conductive mats and footwear at fixed, grounded work
stations or outdoor locations.
7.5 Conductive Floor, Work Surface, and Wristband Specifications
Conductive floors must be made of nonsparking material such as
conductive rubber or conductive flooring composition and shall
meet the following requirements.
a. The flooring and its grounding system must provide for
electrical resistance not to exceed 1,000,000 ohms (measured
as specified in paragraph 7.6 of this chapter).
b. The surface of the installed floor must be free from cracks
and reasonably smooth. The material must not slough off,
wrinkle, or buckle under operating conditions. Conductive
tiles are not recommended for use in areas where
contamination can be caused by explosive dust. The large
number of joints and the tendency of tiles to loosen provide
areas where explosive dust can become lodged that are not
easy to clean with normal cleanup procedures.
c. Where conductive floors and shoes are required, resistance
between the ground and the wearer shall not exceed
1,000,000 ohms (i.e., total resistance of conductive shoes
on a person, plus the resistance of floor to ground). (See
Figure II-1 for testing method.) Where conductive floors
and shoes are required, table tops on which exposed
explosives or dusts are encountered should be covered with a
properly grounded conductive material that meets the same
requirements as those for flooring.
d. Conductive floors must be compatible with the explosive
materials to be processed.
e. Conductive wristbands shall not exceed a resistance between
the wearer and ground of 1,200,000 ohms. This resistance
shall be measured with a suitably calibrated ohmmeter.
Wristbands shall be of a design that maintains electrical
contact with the wearer when used.
f. Table-top work surface mats that are not part of a total
conductive system (paragraph 7.5c) shall have a resistance
not to exceed 1,200,000 ohms. This resistance shall be
measured by a method similar to that outlined in paragraph
7.6 and records shall be maintained.
7.6 Conductive Floor Tests
a. Initial tests shall be made of all conductive floors, and
subsequent tests shall be made at least semiannually. Test
results shall be permanently recorded and a copy filed in a
central location. Instruments used in making tests shall be
used only when the room is free from exposed explosives and
flammable gas mixtures.
b. Maximum floor resistance shall be measured with a suitably
calibrated ohmmeter that operates on a normal open circuit
output voltage of 500 volts dc and a short circuit current
of 2.5 milliamperes with an effective internal resistance of
approximately 200,000 ohms. Minimum floor resistance will
be measured with an ohmmeter suitably calibrated for the
task.
c. Each electrode shall weigh 2.3 kg and shall have a dry,
flat, circular contact area 6.5 cm in diameter, which shall
comprise a surface of aluminum or tinfoil 1.3 to 2.5 mm
thick, backed by a layer of rubber 0.6 to 0.65 cm thick and
measuring between 40 and 60 durometer hardness as determined
with a Shore Type A durometer (ASTM D-2240-68).
d. The floor shall be clean and dry. "Electrode jelly" such as
brushless shaving soap or saline solution shall not be used.
e. The resistance of the floor shall be more than 5,000 ohms in
areas with 110-volt service and 10,000 ohms in areas with
220-volt service, and less than 1,000,000 ohms in all areas,
as measured between a permanent ground connection and an
electrode placed at any point on the floor and also as
measured between two electrodes placed 3 ft apart at any
points on the floor. Measurements shall be made at five or
more locations in each room. If the resistance changes
appreciably with time during a measurement, the value
observed after the voltage has been applied for about
5 seconds shall be considered the measured value.
7.7 Humidification
Humidification for preventing static electricity accumulations
and subsequent discharges is usually effective if the relative
humidity is above 60%. However, certain materials such as
metallic powders and some pyrotechnic mixtures cannot be exposed
to air with 60% relative humidity due to the possibility of
spontaneous ignition. Where this technique is used to prevent
static electricity accumulations, a daily preoperational check of
the humidity levels will be accomplished before work starts.
7.8 Ground Fault Circuit Interrupter
Ground Fault Circuit Interrupter protection should be provided in
static grounded areas where personnel may come in contact with
AC-powered electrical equipment.
This page intentionally left blank. 8.0 ELECTRICAL EQUIPMENT AND WIRING
8.1 Location/Operation Electrical Hazard Classification
The National Electric Code (NEC) does not specifically address
explosives; however, Article 500, "Hazardous (Classified)
Locations," does establish requirements for the design and
installation of electrical equipment and wiring in locations
containing combustible dusts and flammable liquids, vapors, or
gases that, in general, are comparably hazardous. Although
explosives do not normally fit these classifications, the
atmosphere surrounding explosives is treated as Group D or
Group G to restrict ignition sources, such as sparks from
electrical faults, and to control surface temperatures of
electrical equipment because explosives dusts or vapors may
collect on electrical appliances in the vicinity. Therefore, the
NEC definitions of Class I and Class II hazardous locations are
as modified and their applications are implemented as follows for
DOE explosives facilities.
a. Class I, Division 1 electrical hazardous location is one in
which (a) ignitable concentrations of flammable gases or
vapors can exist under normal operating conditions; or
(b) ignitable concentrations of such gases or vapors may
exist frequently because of repair or maintenance operations
or because of leakage; or (c) breakdown or faulty operation
of equipment or process might release ignitable
concentrations of flammable gases or vapors, and might also
cause simultaneous failure of electrical equipment.
Equipment and wiring approved for Class I locations may not
be acceptable in Class II locations. Operations involving
solvents and explosives usually require dual-rated
(Class I/Class II) systems. See paragraph 8.1d of this
chapter.
b. Class II, Division 1 electrical hazardous locations are
areas containing explosives dusts or explosives that may,
through handling or processing, produce dust capable of
being dispersed in the atmosphere. Explosives operations
requiring this classification include, but are not limited
to, screening, grinding, blending, pressing, and dry
machining explosives plus weighing of explosives powders.
All explosives operations not specified elsewhere are also
included in this classification.
c. Class II, Division 2 electrical hazardous locations are
areas that contain exposed explosives but where no dust
hazard exists. Explosives operations requiring this
classification include, but are not limited to, storage,
inspection, assembly, and wet machining of explosives, plus
heating of fully encased explosives. Class II, Division 1
or dual-rated equipment and wiring can be substituted for
all explosives operations in this classification.
d. Dual-Rated (Class I, Division 1/Class II, Division 1)
electrical hazardous locations are areas where explosives
are processed and sublimation may occur or where flammable
gases or vapors may be present in sufficient quantities to
produce explosive or ignitable mixtures. Explosives
operations requiring this classification include, but are
not limited to, synthesis, mixing, wet blending, and casting
explosives, and heating/drying of uncased explosives.
e. General Purpose (Non-hazardous rated) electrical locations
are areas where no special hazards exist that might be
influenced by the electrical wiring. Areas and explosives
operations allowed in this classification include, but are
not limited to, offices, control rooms, halls, rest rooms,
and mechanical equipment rooms in explosives facilities plus
shipping and receiving operations with explosives packaged
in DOT/DoD-approved shipping containers and handling and
assembly of fully encased explosives. General Purpose Areas
may be established in Hazardous Locations if facility
management can determine, based on analysis of the processes
involved, that the following can be satisfied. Separation
between the Class I or Class II operation and the General
Purpose Area is established and maintained such that:
Migration of explosives into the General Purpose Area
from the classified area will not occur under normal
operating conditions;
Ignition energy that may be developed in the General
Purpose Area will not be transferred to the classified
area, even under electrical fault conditions.
8.2 Electrical Supply System
Mutual hazards may exist where explosives facilities are located
near electrical supply lines and stepping equipment. To protect
against these hazards, the NEC (NFPA 70) and the following
requirements apply to all new construction or major
modifications, and should be considered for existing facilities.
Quantity distance requirements are based on air blast
overpressure only, and fragment distances are not considered.
a. Electric transmission lines (those carrying 69 KV or more)
and the tower or poles supporting them shall be located no
closer to explosives facilities than:
inhabited-building distance if the line in question is
part of a grid/system serving a large, off-site area;
public-traffic-route distance if loss of the line will
not create serious social or economic hardships to off-
site areas.
b. Electric distribution lines (those carrying less than 69 KV)
and the tower or poles supporting them shall be located no
closer to explosives facilities than public-traffic-route
distance.
c. Aboveground, DOE-controlled electric service lines required
to be in close proximity to an explosives facility shall be
no closer to that facility than the length of the lines
between the poles or towers supporting the lines, unless an
effective means is provided to ensure that broken, energized
lines cannot come into contact with the facility or its
appurtenances. Acceptable controls include, but are not
limited to, geographic terrain features, instantaneous
circuit interrupters, cable trays and linking lines
together. Equivalent underground service lines shall be
located as specified in Chapter VI, paragraph 3.2.4 and
Table VI-1.
d. Electric lines serving explosives facilities shall be
installed underground from a point not less than 50 ft away
from such facilities.
e. Unmanned privately owned or contractor-owned electrical
substations (not to include building transformers and
associated switch gear) shall be no closer to explosives
facilities than public-traffic-route distances.
f. Certain types of auxiliary power facilities, transformer
stations, etc., present fire hazards to explosives
facilities. Transformers and associated electrical
switching apparatus serving one explosives facility or
complex that do not present a fire hazard to the facility
(i.e., dry-type, "less flammable" oil-insulated, etc.) shall
be located as specified by NFPA 70 and Factory Mutual Data
Sheet 5-4/14-18. Normal oil-insulated transformers shall be
located at least 50 ft from an explosives facility or as
specified in DoD 6055.9-STD.
8.3 Building Electrical Service Entrance
Each electrical service entrance for explosives facilities should
be provided with the following protection.
a. Arrestors
An intermediate, valve-type lightning arrestor shall be
provided on the primary side of the transformer located
in, on, or near the facility. See Section 6 of this
chapter for additional lightning protection guidance.
Surge arrestors and surge capacitors shall be provided
on the supply side of the main service disconnect.
b. Grounding
The lightning arrestor, surge arrestor, surge capacitors, service
entrance ground, and building ground shall be interconnected.
This interconnection shall be made outside the building.
8.4 Permanent Wiring and Equipment
The NEC and this section are minimum requirements for DOE
facilities containing explosives. (For laboratories, see
paragraph 8.10 of this chapter).
a. Permanent facility wiring includes installed electrical
wiring, communications wiring, security systems wiring, and
fire protection systems alarm and response wiring.
Permanent equipment includes the installed electrical
fixtures and equipment associated with this wiring.
Permanent equipment also includes equipment such as (but is
not limited to) HVAC, hoods, vacuum pumps, hydraulic pumps,
etc.
b. New Facilities and Renovations
(1) All permanent equipment and wiring of a room shall
conform to the NEC electrical hazard class (see
paragraph 8.1 of this chapter) required for the
operations for which the room is designed.
(2) To maintain maximum, long-term flexibility of use of
facilities, facility management is encouraged to
consider installing dual-rated (i.e., Class I,
Division 1 and Class II, Division 1) permanent wiring
and equipment in explosives operating rooms. As a
minimum, installation shall allow for easy conversion
to dual-rated wiring and equipment.
(3) Explosives storage facilities shall meet Class II,
Division 1 requirements.
(4) Rated electrical fixtures shall not be painted.
c. Existing Facilities
(1) Permanent wiring and equipment shall meet the
requirements in effect at the time the facility was
built. The wiring and equipment shall be brought into
conformance with paragraph 8.4.b of this chapter if
remodeling or renovation affect the wiring or
equipment.
(2) As a minimum, the permanent wiring and equipment shall
meet the requirements of paragraph 8.1 of this chapter
for the explosives operations performed.
(3) Where equipment cannot meet the above requirements, the
equipment should be located outside the hazardous
environment. Otherwise, the equipment shall be
controlled as specified for electrical equipment and
instrumentation in paragraph 8.6 of this chapter.
8.5 Flexible Cords/Wiring
Wiring from the permanent premises wiring to process equipment or
process instrumentation should be rated for the actual explosives
operation being performed, per paragraph 8.1 of this chapter. As
a minimum, flexible cords shall be type SO hard service cord or
rubber-covered heater cord type HSJ. Splices are not allowed.
In addition all flexible cords, receptacles, and attachment plugs
must be equipped with three prongs so that the third prong (green
wire) acts as ground. The cord shall be supported so that there
is no tension on the terminal connections. Seals shall be
provided where the cord enters explosion-proof enclosures. For
NEC Class I or Class II dual-rated operations, the cord shall
also be equipped with explosion-proof attachment plugs. Flexible
cords shall not be used where fixed installed electrical wiring
is required by equipment design.
8.6 Electrical Equipment and Instrumentation
a. Non-permanent electrical equipment and instrumentation shall
comply with the following.
(1) Process instrumentation and process equipment should be
rated for the actual environment based on the
explosives operation being performed as defined in
paragraph 8.1 of this chapter.
(2) If the properties of an explosive are such that NEC
Class II, Group G equipment provides inadequate surface
temperature limits, special protection shall be
provided, or the equipment shall be excluded from the
hazardous location.
(3) When NEC Class I or II, as applicable, equipment or
instrumentation is not available, the substitute
equipment should be purged or pressurized in accordance
with NFPA 496, or be determined intrinsically safe
(without regard to voltage) in accordance with NEC
Article 504/ANSI 913/NFPA 493 by facility management,
or in NEC Class II locations sealed to prevent
explosives contamination. When the equipment is purged
or sealed, the surface temperature shall not exceed
120øC.
(4) If the required NEC-rated equipment or instrumentation
is not available or cannot be purged or sealed or is
not listed by Underwriters Laboratory (UL) or Factory
Mutual Corporation as intrinsically safe, facility
management shall evaluate the equipment or
instrumentation as to the probability of its initiation
of the explosives by the following events.
Malfunction of electrical equipment or process
instrumentation.
Breach of containment resulting in exposed
explosives or spillage of explosives.
Ignition sources arising from physical damage to
the wiring method used (e.g., crushing by forklift
or other material handling equipment, frayed
cords, etc.).
Exposed electrical conductors or connectors that
could make contact with leg wires or cables of
explosive devices during routine handling.
Exposed electrical conductors or connectors on
which explosives dust or vapors could collect.
Collection of explosives dust on or in the
equipment.
Sensitivity to heat and spark, and thermal
stability of explosives involved.
This equipment shall not have a surface temperature
exceeding the lowest onset of the exotherm of the
explosive, as determined by the differential thermal
analysis (DTA) test or the differential scanning
calorimetry (DSC) test in paragraph 12.1.1c of this
chapter and Chapter VIII, paragraph 2.2d. Approved
instrumentation and equipment shall be administratively
controlled and marked accordingly.
(5) If the equipment is purged, the air flow shall be
monitored per NFPA 496 and interlocked to the
equipment.
(6) A waiver is not required when the equipment or
instrumentation meets the requirements of either
paragraphs 8.6a(3) or (4) of this chapter. If the
equipment or instrumentation cannot meet these criteria
or has not been evaluated by facility management, it
shall meet the appropriate electrical hazard class
requirements.
b. Watertight equipment (that would pass a NEMA 4 hose test)
should be provided in those locations where water-explosives
mixtures may come in contact with the electrical equipment
and wiring.
8.7 Electrical Requirements for Outdoor Test Areas
Requirements for outdoor test areas shall be contained in the
specific test procedures.
8.8 Hand-held, Battery-Powered Lights and Instruments
a. Flashlights and hand lanterns, powered by low-voltage dry
cell batteries and "miners' cap lamps" approved as
"Permissible" by the U.S. Bureau of Mines and by UL for NEC
Class I hazardous locations, are authorized for use in both
Class I and Class II locations. Devices that provide "cold
light" through chemical action are acceptable for use in any
location.
b. Hand-held instruments, watches, calculators, hearing aids,
cameras, self-contained flashes, and communication devices
powered by low-voltage dry cell batteries are authorized for
use in the vicinity of NEC Class II, Division 2 rated
hazardous operations and during setup of NEC Class I or
Class II, Division 1 hazardous operations. They shall be
evaluated as to their intrinsic safety and approved by
facility management prior to use during NEC Class I or
Class II, Division 1 hazardous operations.
c. Hand-held, battery-operated equipment shall not come in
direct or indirect contact with bare explosives. Batteries
shall not be removed or replaced in a NEC hazard rated area
(paragraph 8.1 of this chapter).
8.9 Non-Rated Extension Lighting
When it is necessary to use extension lights within 10 ft of
exposed explosives, where no airborne dust exists, the following
requirements shall apply.
Lights shall be mounted on heavy tripod stands.
The lights shall be fitted with exterior globes to prevent
the falling of hot sparks or particles that might ignite the
explosives.
The lights shall be fitted with adequate guards to protect
the globes from physical damage.
The wire providing power to the lights shall be positioned
so as to prevent vehicles and personnel damaging the cord.
The flexible cord shall comply with paragraph 8.5 of this
chapter.
The light stand shall be secured to prevent tipping.
Neither the light nor the power cord shall be allowed to
come in direct or indirect contact with the explosives.
Lights shall be positioned outside the fall-down distance to
the explosives.
8.10 Laboratories
a. Permanent wiring and equipment for existing laboratory areas
are not required to meet the requirements of paragraph 8.4
of this chapter, except as noted in paragraph 8.4c(1).
b. Process equipment used for synthesis, heating, drying,
mechanical mixing, and blending shall be dual rated.
Weighing equipment shall be Class II, Division 1 or
mechanical. These operations shall be isolated from non-
rated wiring, electrical equipment, and instrumentation in a
manner that prevents dust or vapors reaching an ignition
source.
c. When laboratory equipment cannot meet the requirements of
paragraph 8.10b of this chapter, see paragraphs 8.6a(3) or
(4) of this chapter.
8.11 Modifications
Operating buildings and magazines are constructed to perform a
specific function that dictates the requirements for electrical
installation. Procedures shall be established by each DOE
facility to control the use and modification of electrical
equipment in explosives areas and ensure that uniform standards
are adhered to throughout the facility.
9.0 VACUUM EQUIPMENT
9.1 General
Precautions shall be taken to prevent explosives from entering
any vacuum system not specifically designed for the collection of
explosives.
9.2 Labeling
All vacuum lines used for explosives operations should be labeled
to warn maintenance personnel that explosive residues may be
present in these lines. One suggested label is:
DANGER, MAY CONTAIN EXPLOSIVES
9.3 Disassembly
Vacuum lines should not be disassembled unless they are flanged
or connected by elastomeric tubing. Remote means shall be used
to disassemble threaded connections that are potentially
contaminated with explosives. The design or installation of any
new vacuum lines shall not employ any demountable, internal
screwed or threaded fittings or connections unless welded or
fixed permanently in place.
9.4 Traps or Filters
Vacuum pumps used to evacuate processes for explosives operations
shall be equipped with primary and secondary intake line traps or
filters to prevent contamination of the pump with explosives.
This page intentionally left blank. 10.0 EXPLOSIVES DUST EXHAUST VENTILATION AND COLLECTION SYSTEMS
10.1 General
Exhaust ventilation should be used to control explosives dust (or
other hazardous materials used in or resulting from explosives
operations) that may create a hazard to operating personnel or
contaminate the operating area. When exhaust ventilation is used
to remove explosives dust, an approved dust collection system is
required to prevent the release of the dust outside the building.
10.2 Exhaust Ventilation
Exhaust ventilation and collection systems for control of
explosives dust and materials associated with explosives
production shall be designed to meet minimum requirements
established in the ACGIH Ventilation Manual (most current
edition) and this Manual. The exhaust ventilation system should
have sufficient capture and adequate makeup air to reduce
exposure to explosives dusts, or materials used in conjunction
with explosives, to as low as reasonably achievable. This is
particularly important when toxicity information and occupational
exposure limits are not available for the explosives in use.
10.3 Dust Collection Systems
a. A "wet collector" that moistens the dust close to the point
of origin and keeps it wet until the dust is removed for
disposal is preferred. A "dry-type collector" is permitted
when authorized by an SOP.
b. Dust collectors shall be designed to prevent explosives dust
from reaching any mechanical power source of the collection
system.
c. All conductive portions of the collection system shall be
grounded and bonded.
d. There shall be no screw threads, recesses, or cracks that
may be exposed to explosives contamination in a dust
collection system.
e. Dust collection lines should be equipped with flanged
connectors and inspection ports.
f. Pipes or ducts through which explosives are conveyed shall
have long radius bends with a centerline radius at least
four times the diameter of ducts or pipes.
g. Dust collectors shall be emptied and cleaned on a regular
basis, as warranted by system use, and must be inspected
periodically.
10.4 Dust Collection Location
a. Wherever practical, dry-type explosives dust collection
chambers should be located outside operating buildings, in
the open, or in buildings exclusively set aside for the
purpose.
b. Stationary and portable wet-type collectors may be placed in
the explosives operating bays or cubicles, provided the
quantity of explosives in the collectors does not
exceed 2 kg.
11.0 DRAINS AND SUMPS
11.1 Collection
a. All drain lines handling explosive wastes shall be provided
with sumps or basins of adequate design and capacity for the
removal of explosives by settling. The drains shall be of
adequate capacity, free of pockets, and have sufficient
slope (at least 1/4 in./ft) to prevent the settling out of
explosives in the line until it reaches the sump or settling
basin.
b. Drain gutters within buildings may be constructed with a
slope of 1/8 in./ft. However, a satisfactory program of
cleaning must be developed to ensure that all hazardous
material is removed from drain gutters.
c. Sumps must be designed so that suspended and settleable
solid explosive material cannot be carried in the wash
waters beyond the sumps. The design shall allow sufficient
settling time on the basis of the settling rate of the
material and the usual flow rate. The sump shall be
constructed so that the overflow will not disturb any
floating solids. The design must also permit easy removal
of collected explosives and retention of those explosives
that float on water (until they can be skimmed off). If
settling basins are used to supplement sumps, they will be
cleaned periodically and a log will be maintained.
d. Explosives collection trays for sumps will be constructed of
nonferrous metal. Hoisting equipment used for lifting the
trays will be designed to prevent the trays from binding on
the sides of the sump. Bolted sump tanks or other types of
construction that permit the explosives to settle in obscure
or hidden spaces are prohibited.
e. Drains between the source of explosives and the sump shall
be troughs with rounded bottoms and removable ventilated
covers to facilitate inspection for accumulation of
explosives. This requirement applies to all new
construction and major modifications and should be
considered for existing facilities. Short sections of
closed pipe or trough are permitted if they can be visually
inspected for blockage or explosives buildup. Explosives or
explosives-contaminated waste liquids shall not be run into
closed drains and sewers.
f. Drains shall be inspected periodically and necessary steps
taken to prevent the buildup of explosive deposits in them.
11.2 Effluent
a. Drains containing explosives waste materials must not be
connected in a manner that allows such wastes to empty into
the normal sewage systems carrying inert or sanitary wastes.
b. Care must be taken to avoid the possibility of deposition of
explosives from sump effluent due to drying, temperature
changes, or interaction with other industrial
contaminations. When explosives that are appreciably
soluble in water are handled, sweeping and other dry
collecting measures shall be used to keep them out of the
drainage system.
c. The combination of sumps, settling ponds, etc. must remove
explosives so that outflows meet environmental standards.
12.0 PROCESSING
12.1 Heating, Drying, and Thermal Conditioning
12.1.1 General
a. Heating explosives is potentially dangerous for several
reasons.
Elevated temperature can increase the sensitivity of an
explosive to other stimuli such as impact, shock,
friction, and static electricity.
At or above the critical temperature of the system (see
definition in Chapter I, Section 6), a runaway chemical
reaction may occur that can produce an explosion or
fire.
Elevated temperature of an explosive in a sealed
container can cause gas generation and pressure rupture
of the containment at temperatures below the critical
temperature.
Chemically incompatible or reactive materials, which
may be present as accidental contaminants, as
components of the formulation, or in external contact
with the explosive, can intensify the preceding dangers
or cause them to occur at lower temperatures.
Nonuniform heating can cause excessively hot regions in
the explosives. Causes may include inadequate
agitation of fluid explosives, nonuniform heaters, and
nonuniform heat conduction.
b. The critical temperature is a system property that depends
on a combination of the chemical decomposition reactions of
the explosive, its mass and shape, the heat transfer and
other thermal characteristics of the system, and the
confinement or pressure of decomposition products,
especially gases. The determination or estimation of the
critical temperature can be accomplished by several
different methods of thermal analysis, but the process is
typically quite complex. For operational safety, a
conservative estimate (i.e., lower limit) of the critical
temperature for a heating operation shall be made
(uncertainties of 10 to 25øC are common). Analogy of one
explosive or system to another similar system with a
reliable thermal analysis may be used to determine safe
heating temperatures and heating times (heating limits).
c. The DTA, DSC, or other comparable techniques can be used to
measure the temperature of the onset of an exothermic
reaction in an explosive. The result of this test can be
used to rank the thermal stability of explosives and as part
of a thermal analysis. Because of the complexity of
chemical decomposition, however, the DTA/DSC exotherm has no
systematic relationship to the critical temperature and is
unreliable for estimating safe heating limits. The exotherm
temperature is always considerably above the critical
temperature and usually increases with the heating rate of
the test. Where the DTA/DSC exotherm is specified as a
standard for control of temperature, the test heating rate
shall not exceed 10øC per minute. The DTA/DSC shall not be
used alone (except as specified in paragraph 8.6a(4) of this
chapter) for establishing heating limits.
d. Each facility shall conduct or obtain a thermal analysis of
any explosives system before the explosive is heated in a
contact operation or in association with hazardous
radioactive materials as described in paragraph 13.6.2 of
this chapter. A heating limit for the explosives system
shall be established from this analysis and should be
approved by the Explosives Development Committee. All
factors in paragraphs a and b, above, shall be considered.
Any significant change in the geometry or an increase in
mass should be considered a new explosives system. For a
contact operation, the maximum temperature should be set at
least 10øC below the critical temperature. For heating
explosives in association with hazardous radioactive
materials, the maximum temperature should be set at least
20øC below the critical temperature. Heating to a
temperature greater than the above specifications may be
approved by facility management if a documented analysis of
the explosive's thermal characteristics indicates that an
acceptable time or temperature safety factor is still
present for a specific operation. These operations shall be
conducted remotely.
e. Heating controls for each operation shall be established and
specified in written operating procedures. The specified
condition should be set at the lowest temperatures and
heating times to do the job efficiently and should not
exceed the heating limit for the explosives system. When
establishing heating controls, consider the heating limit
and the accuracy of the estimated critical temperature, the
accuracy of the temperature control equipment, and the
likelihood of incompatible chemical contamination along with
other operational parameters.
12.1.2 Heating and Drying Equipment
a. Heat should be supplied by steam, hot water, friction air,
or electrically heated transfer fluid. Temperatures shall be
limited by redundant, automatic heat controls.
b. In systems heated by steam only, the requirements for
redundant, automatic heat controls shall be satisfied if the
steam pressure is controlled by a pressure-reducing valve,
pressure relief valve, and thermostatic valve on the system.
c. In systems heated by electricity, a manual reset secondary
overtemperature system consisting of a controller, fail-safe
sensor, and an interrupting device shall be provided to
interrupt the heat supply source in the event of primary
system failure. The secondary interrupter shall be separate
from the primary interrupter. The upper limit of the
primary controller is determined by the desired operating
temperature limit. The secondary (override) controller is
set at a higher temperature but should not exceed the
maximum temperature determined by the heating limit
specified for the explosives system as determined in 12.1.1d
of this chapter.
d. Visual and/or audible alarms should be provided to alert
operating personnel to abnormal temperature conditions. The
heating of explosives should be monitored at all times.
e. The air or gas used to condition exposed explosives shall
not be recirculated if directly heated by electrical
resistance elements.
f. Drying or heating ovens should be vented to a safe location
outdoors. Water wash or filtration of the exhaust may be
required. If exhaust fans are used, they shall be
interlocked with the heat source.
12.1.3 Heating and Drying Operations
a. Heating and drying shall be performed under the mildest set
of conditions that will accomplish the task safely and
efficiently. A thermal analysis shall be made and a written
procedure prepared consistent with paragraph 12.1.1 of this
chapter. The procedure shall include controls on the mass
and geometry (thickness of the layer, etc.) of the material
that may be heated.
b. Except as described in 12.1.3c, below, drying shall be
achieved by circulating a warm, dry gas either air or
inert over or through the material.
c. Small samples may be dried by placing them in desiccators or
by subjecting them to vacuum. Vacuum drying of larger items
should be preceded by drying at atmospheric pressure to
remove quantities of moisture or solvent before vacuum is
applied to remove the final traces of moisture or solvent.
Explosives having a vapor pressure exceeding 1 10 4 mm Hg
at the drying temperature shall not be subjected to vacuum
drying. A cold trap shall be used for vacuum drying where
the vapor pressure of the explosive is unknown.
d. Formation of a vapor-air mixture within explosive
concentration limits shall be avoided. This can be
accomplished by providing sufficient airflow to maintain a
vapor concentration well below the lower flammability limit
or by using an inert atmosphere. For inert atmosphere,
positive purge shall be used to preclude oxygen leakage into
the unit. If vapor concentrations approaching a flammable
level are anticipated, they shall be monitored. Airflow
shall be controlled to prevent dusting.
e. When heating explosives whose vapor pressure may cause
undesired condensation of explosives on parts of the
equipment, heating shall be conducted in a manner that
controls condensation of the explosive materials. This
control should be accomplished by heating the exhaust system
or by circulating the air at a rate that will keep the
explosives concentration below the level at which
condensation could occur.
f. The proper operation of heater controls shall be verified on
a regular schedule established by site management.
12.2 Pressing
Explosives pressing operations are those in which explosives are
subjected to high pressures to achieve a physical change.
Pressing of explosives formulations is done routinely to
consolidate explosive materials into configurations required for
test assemblies or weapon systems. Two types of pressing
operations commonly performed are isostatic/hydrostatic and punch
and die. The following safety guidelines apply to these types of
pressing operations.
12.2.1 General
a. Explosives pressing operations shall be conducted as remote
operations.
b. The correct functioning of press interlock systems shall be
verified at regular intervals.
c. Pressing mandrels, punches, and dies used in explosives
operations shall be examined regularly during periods of use
for evidence of structural failure. Examination shall be
performed by suitable nondestructive test methods. Intervals
between inspections shall be established by site management
for each tooling design before committing the tooling to
use. The inspection interval and updating should be
dictated by experience with similar tooling designs and
configurations. All new or modified mandrels, punches, and
dies shall be inspected before their first use. At least
one pressing cycle should be completed with mock explosives
before proceeding to explosives.
d. Pressure controllers and indicators shall be calibrated
periodically to ensure accurate control and monitoring of
pressing operations.
e. Press parts that contact explosive materials shall be
thoroughly cleaned of residual explosives before they are
used with a different explosive formulation.
f. Temperature control for heated presses and dies shall comply
with the requirements of paragraphs 12.1.2a and b of this
chapter.
g. All pressing assemblies shall be designed or procedural
controls established so that the extrusion of explosives
between two mating metal surfaces will be minimized or
eliminated during the pressing operation.
h. Operations with explosive powders should be performed in a
manner that reduces the liberation of explosive dust in
order to reduce operator exposure and general room
contamination. For operations involving large amounts of
powders, local exhaust ventilation with a dust collection
system should be provided. Respiratory protection to
prevent inhalation of explosives dust may be required when
adequate ventilation is not available.
12.2.2 Isostatic/Hydrostatic Pressing
a. Before an elastomeric container or mandrel constructed of a
new material is introduced into a pressing operation (where
it will contact explosives), the material shall be evaluated
for compatibility with the explosives.
b. All pressing vessels shall be examined for evidence of
cracking or other signs of incipient structural failure at
regular use intervals by suitable nondestructive test
methods. Examination intervals shall be established by
local management.
c. Before large-scale pressings of new explosives or explosives
formulations are made, these materials shall be evaluated
for thermal stability (see scaleup procedures,
Chapter VIII). "New explosives or explosives formulations"
refer to those that are "new" to large-scale pressing.
Stability test results shall be used to assist in
establishing safe pressing conditions for the specific
pressing size.
d. For isostatic pressing, procedural controls shall be
established to ensure that:
an acceptable vacuum on the mandrel assembly can be
obtained to prevent adiabatic heating during pressing;
and
air is bled out of the press before pressurization.
e. Consideration should be given to the use of fire-resistant
hydraulic fluids. The compatibility of any new fluids must
be checked with the explosives used.
12.2.3 Punch and Die Pressing
a. All pressing punches and dies shall be visually inspected
for damage, deformation, and cleanliness before installation
on a press. Any questionable condition(s) shall be resolved
before the pressing proceeds to ensure that the operation's
safety is not compromised.
b. All punches, dies, and press attachment fixtures shall be
designed to minimize the possibility of the punch being
misaligned with the die (resulting in gouging of a die
surface during pressing). Press setup procedures shall
provide for operator verification of proper alignment before
pressing.
c. Punches and dies should be maintained in matched sets and
shall be controlled by the responsible user or a gauging
section capable of performing the necessary measurements. A
group other than the user should check critical punch and
die dimensions before initial use and at suitable intervals
thereafter. Suitable check intervals for each punch and die
design should be determined as in 12.2.1c of this chapter.
12.3 Extruding
Extrusion operations involve the flow of plastic explosives
material under pressure into a cavity in a component of an
assembly. The following general safety guidelines are given for
this type of extrusion operation.
a. Extrusion operations shall be conducted remotely. Contact
extrusion may be performed only when nonexplosive or mock
materials are to be extruded or when hand-extruding small
quantities with no metal-to-metal contact. Precautions
shall be taken to prevent personnel from being injured by
the rupture of pressurized equipment.
b. The explosive shall be protected against extrusion beyond
the tooling cavity. Precautions shall be taken to prevent
foreign material from entering the explosive.
c. New designs and significant design changes in equipment,
tooling, or components shall be tested by mock explosives
extrusion before actual explosives extrusion.
d. Pressure controllers and indicators shall be periodically
calibrated to ensure that proper sealing and extrusion
pressures are being maintained.
e. Extrusion press parts shall be thoroughly cleaned of
residual explosives remaining from the previous operation
before the press is loaded with a different explosive
formulation.
f. Hand-loading of extrudable explosives is covered in
paragraph 12.8.2 of this chapter.
12.4 Machining
Explosives machining is a class of forming operations that
involves mechanical cutting of the explosive material, often in
conjunction with harder inert materials. Thermal initiation of
the explosive substance due to heat buildup from friction at the
cutting surface can occur. Precautions must be taken to limit
this buildup and to facilitate the dissipation of thermal energy.
12.4.1 Equipment Requirements
a. Interlocks shall be provided for wet machining operations to
ensure coolant flow before machine operation. The coolant
flow shall be monitored and the equipment automatically and
safely shut down if loss-of-coolant flow is detected. The
interlocks shall be protected from tampering and
unauthorized disabling by physical means or supervisory
control.
b. The vacuum on vacuum chuck holding fixtures shall be
monitored and interlocked with the equipment for automatic
shutdown of machining in the event of vacuum loss.
c. Tool path controls (stops, limits, design patterns, etc.)
shall be provided to prevent the unplanned travel path of a
tool or work piece. Equipment speed and feed rates shall be
controlled and limited by positive means or secondary
verification.
d. Pressure-relief devices should be installed on pneumatically
or hydraulically powered equipment when necessary to ensure
safe operation.
e. Metal chip waste from machining operations should be kept
separate from explosives waste. When this is not possible,
mixed explosives and metal waste should be completely
segregated from unmixed waste and held for separate
disposal.
f. Dull or damaged tools shall not be used. A cutting tool
inspection and control program shall be established for
explosives machining operations.
g. Consideration will be given to using additional safety
control devices (i.e., design patterns, safety templates,
chip thickness sensors, tool pressure sensors, etc.),
depending on the type of machining operations, size of
explosives pieces, types of explosives, etc.
h. The "machining overtest" shall be considered a testing
operation (see paragraph 12.4.4e of this chapter) and shall
be exempt from equipment requirements.
12.4.2 Contact or Remote Operations
a. The following explosives may be contact machined if a
compatible, nontoxic, noncombustible coolant is used.
Explosives not listed below shall be machined remotely.
Amatol
Baratol
Boracitol
Explosive D
Octol with no more than 75% HMX
Pentolite (no more than 50% PETN)
RDX/TNT compositions with no more than 75% RDX. These
compositions include: Composition B, Composition B-3,
75/25 cyclotol.
TATB and TATB compositions with an inert plastic binder
TNT
b. Explosives assemblies composed of any combination of
explosives listed in the above paragraph and the following
nonexplosive materials may be contact machined if a
compatible, nontoxic, noncombustible coolant is used. If an
assembly contains an explosive not listed in the above
paragraph or a nonexplosive material not listed below, the
assembly shall be machined remotely:
foamed plastics,
solid plastics,
adhesives,
amorphous graphite,
calcium sulphate casting powder, or
explosives mockup.
c. On any explosive, with certain exceptions for IHE and for
those explosives being machined by fluid jet (see
paragraph 12.4.2e of this chapter), the following operations
shall be performed remotely:
drilling of holes smaller than 5 cm in diameter, except
for IHE, where drilling of holes smaller than 5 mm
shall be done remotely;
coring operations (except contact operations on those
explosives listed in 12.4.2a of this chapter, when the
requirements of paragraph 12.4.5b of this chapter are
met and a coolant is used);
machining of any metal/explosives interface;
machining IHE subassemblies with Hazard
Class/Division 1.1 boosters installed;
dry machining, except that IHE booster pellets may be
contact machined provided a dust collection system (see
Section 10 of this chapter) is used; and
machining of explosives in Phase II or earlier stage of
scaleup (see Chapter VIII).
d. Machining of primary explosives shall be avoided.
Alternative methods, such as forming or pressing to final
dimensions, should be used to achieve the desired shape.
e. The machining of IHE, PBX 9404, and LX-10 may be performed
contact by high-pressure fluid jet. The fluid-jet system
pressure shall not exceed 20,000 psig. The velocity of the
fluid jet shall not exceed 520 meters per second
(theoretical). The jet nozzle orifice diameter shall not
exceed 0.010 in. The system machining fluid shall be water
and shall not contain any abrasives. See paragraph 12.15 of
this chapter for use of low-pressure fluids.
f. Concurrent contact machining operations should not be
permitted in the same bay. However, concurrent IHE contact
machining is permitted when other explosives are not
present.
g. Provisions shall be made for visual monitoring of remote
machining operations. Consideration should be given to
video recording and audio monitoring.
12.4.3 Setup and Preparation
The following precautions are provided for preparation and setup
before beginning the machining operation.
a. Before setting up the explosive work piece, the equipment
shall be checked for proper function and the absence of
interference between stationary and moving parts. For the
more complex machining operations, an inert mockup should be
used for testing equipment function before the first run.
b. The explosive component to be machined should be inspected
for cracks, voids, and high-density foreign objects. The
explosive component for contact machining shall be
inspected. Radiography can be used for this purpose. The
component shall also be checked for proper size.
c. Caution shall be exercised during setup and adjustment to
avoid pinching, dropping, crushing, or otherwise applying
abnormal forces to explosives present. Special care must be
given to mounting and centering a part on a vacuum chuck.
Special attention must be given to the proper functioning of
the vacuum system and its surface holding area.
d. Limits on machine speed, depth of cut, and feed rate shall
be set before the machine is activated.
e. Interlocks shall be functional before the machine is used to
machine explosives. They should be tested once per shift.
12.4.4 Operations Guidelines
a. The minimum tool speed necessary for safe and efficient
operation should be maintained. The following maximums
shall apply:
(1) the relative velocity between the explosives surface
and the cutting tool shall not exceed 65 m per minute;
(2) work pieces or cutting tools shall not be rotated at
speeds exceeding 525 rpm; and
(3) the feed rate of the cutting tool or work piece shall
not exceed 1 mm per revolution.
b. The work piece, fixture, cutting tools, equipment, floor,
troughs, drains, etc., should be cleaned frequently to
prevent accumulation of explosive wastes.
(1) Approved measures should be taken to prevent rust and
minimize deterioration of precision surfaces.
(2) All tools, equipment, fixtures, and parts should be
cleaned before being removed from the work area for
storage.
c. For contact machining operations, coolant shall be used to
aid in removal of heat and cutting waste. Coolant should be
used for remote operations when practical.
(1) Coolant should be used on explosives/inert assemblies.
When the explosives portion is included in the cut,
coolant shall be used for contact machining. Coolant
is not required if the explosives portion of the
assembly is contained (no bare explosives) and is not
included in the cut, or the machining is conducted
remotely.
(2) Spray mist coolant may be used during machining of the
explosive-containing assemblies if the explosives
portion is not included in the cut.
d. All visible explosives shall be removed from the machine
before maintenance or repairs are performed. No safeguards
or interlocks of any kind shall be removed or made
ineffective, except by authorized personnel.
e. Before submitting an explosive for contact machining
approval, a machining overtest program shall be conducted to
identify the machinability and associated hazards. These HE
qualification tests should be performed in facilities set
aside for these purposes.
(1) Machining overtests shall be conducted remotely.
(2) Operations performed during sample preparation may
include gauging and assembly, but shall not include any
contact cutting, scraping, or other material-removing
operations on the explosives specimens.
12.4.5 Specific Machining Operations
a. Drilling
(1) Drilling operations should be set up to maximize the
ease of achieving and maintaining proper alignment and
to facilitate removal of explosives chips, fines, and
powder.
(2) Length of fluting on the drill bit shall exceed the
depth of the hole to be drilled by a minimum of 1.3 cm
or one hole diameter, whichever is greater.
(3) The depth of a hole shall not be extended more than
1.5 times the hole diameter (up to a maximum of 2 cm)
during a single insertion of the drill into the
material. After each insertion, it may be advisable to
withdraw the drill completely and remove loose
explosives from the cavity and drill bit before
reinserting.
(4) Coolant flow (when used) shall be directed to the
explosives/cutting edge interface. Drill bits that
have coolant channels to the tip of the drill should be
used. Pulsating high-pressure types of coolant
supplies are recommended for drills of 6-mm diameter or
less.
b. Coring
(1) Coolant flow (when used) shall be directed at the
explosives/cutting edge interface.
(2) The coring will be accomplished in increments if the
hole is not positioned to provide continuous breakout.
When done in increments, no more than 1.5 times the
diameter of the hole shall be cored at one time.
Before the maximum distance has been cored, the tool
shall be totally retracted from the hole and cleaned.
The hole shall be flushed with coolant.
c. Sawing
(1) The feed rate of the saw blade or work piece shall not
exceed 7.5 cm per minute.
(2) For band saws, coolant flow should be directed onto the
saw blade at the cutting interface, guide rollers, and
the drive wheel/saw blade interface. For circular
saws, the coolant flow should be directed at the
explosives/cutting edge interface.
12.5 Dry Screening
Screening of dry explosives is often required for size
classification or to remove extraneous objects. Use of magnetic
separators is often advisable for removal of ferrous materials
that may have passed through the screens. The following
guidelines shall be observed for screening operations and
equipment.
a. Screening operations using mechanical screens shall be
performed by remote operations. Equipment shall be designed
and operations performed to avoid subjecting explosive
materials to pinching, friction, or impact.
b. Screening small samples may be performed as a contact
operation where approved by facility management.
c. Equipment shall be electrically bonded and grounded.
Resistance-to-ground shall be 10 ohms or less and shall be
inspected on a regular basis. Equipment used to transfer
electrostatic-sensitive explosives to or from screens shall
be conductive and electrically bonded to the screen during
transfer.
d. Operations and equipment shall be set up to minimize and
control dust generation.
e. The operating area and equipment therein shall be cleaned
frequently to avoid accumulation of explosives dust.
f. Precautions shall be taken to prevent metal-to-metal rubbing
during vibration of the screens. Particular attention shall
be paid to frequent inspection of vibrating equipment for
development of cracks subject to contamination by
explosives.
12.6 Blending
a. Dry blending of explosives shall be performed remotely.
However, dry, hand blending of small samples may be
performed as a contact operation when approved by facility
management.
b. Equipment should be designed and operations performed to
minimize generation and dispersion of explosives dust.
c. Equipment shall be electrically bonded to provide a
continuous path-to-ground. Resistance-to-ground shall be
10 ohms or less and shall be inspected on a regular basis.
Equipment used to transfer electrostatic-sensitive
explosives to or from blenders shall be conductive and
electrically bonded to the blender during transfer.
12.7 Melting
a. The heat for melting explosives shall be supplied by
saturated steam, hot water, or other temperature-controlled
medium. The steam pressure shall be controlled in
accordance with paragraph 12.1.2b of this chapter.
b. Temperatures used for contact melting of TNT-based
explosives [except those containing PETN (e.g., pentolite)]
and keeping them molten shall not exceed 121øC. The
temperature limit for TNT explosives containing PETN shall
be 109øC.
c. Feeding of the melt kettle and the melting operation shall
be controlled or regulated to prevent the formation of large
chunks of explosives.
d. Alarms shall be provided on the melt temperature and on melt
kettle agitation when the operation will be left unattended.
Alarms shall sound if the temperature exceeds the
specifications of paragraph 12.7b, above, or if agitation
ceases.
e. Wherever possible, valves, piping, and threaded bolts and
fasteners should be eliminated from melted explosives
handling systems.
f. Provisions should be made for emergency emptying of melt
kettles in the event of temperature control problems or
power failures.
g. Melt kettle construction materials shall be corrosion
resistant. Construction shall not contain blind holes,
threads, or cracks in areas exposed to melted explosives.
Welds shall be inspected and found free of cracks and
porosity.
12.8 Assembly and Disassembly
During assembly and disassembly operations, hand tools and
electrical and pneumatic tools that may subject the explosives to
abnormal frictional forces, pinching, or excessive pressure, or
cause significant deformation, shall not be used. They may,
however, be used on nonexplosive components.
12.8.1 Assembly Operations
During assembly operations, the operator should be alert for
mismatching parts and misalignment of components. Hard surfaces
contacting explosives shall be precisely machined to mate with
the explosives or lined with cushioning material, or other
methods shall be used to keep sharp corners or projections from
being forced into explosives.
12.8.2 Loading Assemblies with Plastic or Extrudable
Explosives
a. The workability and plasticity of plastic and extrudable
explosives improves with an increase in temperature.
Plastic explosive Compositions C-3 and C-4 may be softened
by warming to between 21øC and 38øC before working.
Extrudable explosives LX 13 and Extex should be kept as cool
as practical to prevent premature curing.
b. Contamination of these explosives with abrasive or foreign
substances shall be avoided.
c. The assembly shall be loaded with small increments of the
explosive and may be tamped with suitable non-metallic tools
to eliminate air voids.
12.8.3 Disassembly Operations
a. Before beginning disassembly, the condition of the device
shall be assessed to determine if it can be safely handled.
b. The disassembly operation shall be planned before actual
disassembly. Possible problem areas caused by method of
construction or physical condition shall be considered. A
safety procedure for all disassembly should be written and
reviewed.
c. Pressurized units shall be thoroughly depressurized before
beginning disassembly, if disassembly would normally cause
release of the pressure or if there is a credible hazard of
the pressure causing components to fly apart.
d. If approved for use, compressed air shall be applied
cautiously during disassembly operations to avoid causing
components to fly apart. This may require remote operation.
Use hydraulic pressure if possible.
12.8.4 Personnel Protection for Disassembly Operations
a. The operator and all other personnel shall be provided
complete protection from disassembly operations involving
conditions that are known or expected to require the use of
abnormal force. This requires either remote operation or
the use of an operational shield. The shielding shall be
designed to protect personnel at any other operation or
location from blast and missiles arising from a possible
explosion.
b. When disassembly is required to be performed with the
operator protected by an operational shield, disassembly
shall be defined as complete separation (threads or other
connections) of component parts. For example, parts shall
not be loosened while the operator is properly protected and
then separated without the same protection.
12.9 Inspection
This section deals with the following types of explosives
inspection operations: (1) inspection of incoming explosives raw
materials and pressed explosives billets for foreign bodies or
cracks that could cause operating or safety problems in
processing operations; and (2) measurement of physical parameters
of explosives pieces and assemblies.
a. To enhance the safety of process operations, positive steps
shall be taken to ensure that explosives used are properly
identified and that foreign material is kept from entering
the operation via the explosives raw materials or via
materials in process (i.e., pressed explosives billets).
Some of the means by which this can be accomplished include:
screening,
visual inspection,
magnetic separation,
radiographic inspection, and
chemical analysis.
b. In the design and operation of explosives inspection
equipment, the following principles shall be followed.
(1) Pinch points shall be eliminated or steps taken to
preclude explosives contamination of pinch points.
(2) Threaded fasteners or threads of measuring equipment
shall be protected from explosives contamination. Care
shall be taken to prevent any parts of the measuring or
handling equipment from becoming loose and getting into
the explosives.
(3) Where inspection fixtures are used, they shall be
designed to hold the explosives piece or assembly
securely to prevent toppling, rolling, or dropping
during measurement operations. This is especially
critical if the explosives assembly is in motion
(i.e., spinning, vibrating, etc.) during measurement.
12.10 Synthesis
Synthesis and other chemical processing of new explosives
compounds are ongoing activities at DOE weapons facilities.
Synthesis operations are conducted both on laboratory and pilot
scales, and new operations and materials will be approved by the
Explosives Development Committee (EDC) (see Chapter VIII). In
the laboratory, the new material will initially be prepared on a
small scale and characterized as to sensitivity, physical, and
explosive properties. Also, the laboratory will develop
processing techniques for the material. If the explosive is of
continuing interest as a result of the laboratory studies, it may
be advanced to the Pilot Plant where processing techniques will
be refined and scaled up. The Pilot Plant will produce
sufficient material for larger-scale physical, explosive, and
sensitivity characterizations.
12.10.1 Laboratory-Scale Synthesis
a. Before initiation of work, the professional staff member who
is directing or conducting the synthesis work shall analyze
each experiment involving explosives or potential explosives
for type and magnitude of hazards. This staff member shall
be responsible for planning the proper selection of
conditions, quantity of explosives, and safety devices to be
employed.
b. Experiments should be designed to minimize the amounts of
explosives involved and to use the mildest conditions that
will yield the desired information.
c. New explosives materials shall be afforded extra protection
against impact, pinching, friction, pressure, sparks,
contamination, and deterioration. If it is necessary to
subject explosives to any of these conditions, the operation
shall be conducted remotely or adequate personnel shielding
shall be provided.
12.10.2 Pilot- or Processing-Scale Synthesis
a. When operations are conducted using flammable or toxic
liquids or gases, local ventilation shall be provided to
preclude the formation of hazardous vapor concentrations in
the work area.
b. Alarms should be provided for coolant flow to the reactor,
for reaction vessel agitation, and for reactor temperature.
These alarms should be energized whenever coolant supply or
agitation is critical to prevent a runaway reaction. Also,
if agitation is critical, the reactor should be equipped
with at least two sources of power to maintain agitation in
the event of failure. For example, a reactor might employ
an air or inert gas bubble tube as a backup for a mechanical
agitator.
c. The reaction vessel should be equipped with an emergency
system. Upon activation, it will automatically cool the
vessel or open or close a vessel dump valve as required by
the process.
d. The building exhaust ventilation system shall be operating
during all synthesis operations involving flammable liquids.
e. An alarm or monitor should be provided for the critical
exhaust ventilation system to warn operating personnel if
air flow rates drop below a predetermined level.
f. Emergency plans shall be established for the synthesis area,
specifying action to be taken in the event an alarm sounds.
g. Before operating, all equipment shall be set up and checked
for proper function. Any new equipment, or equipment that
is not used frequently, shall be tested in a "dry run"
before being used with any hazardous material.
h. All explosives synthesis process equipment shall be
inspected and maintained on a routine basis. Equipment
found to have any defects that could affect safe operations
shall be tagged to prevent its use until repairs are
completed.
i. Before any process operation is started, the transfer lines
to be used should be properly labeled and their function
specified in the operating procedure.
j. Transfer hoses and portable equipment not involved in the
process shall be removed from the work area and stored in
their proper places.
k. All control valves shall be correctly identified according
to function.
l. Safety equipment and clothing shall be worn as defined in
the individual operating procedures.
m. Agitator blades on reactors and mixers shall be inspected
for proper clearance at regular intervals. This is to
ensure that there are no pinch points or metal-to-metal
contact. The inspection schedule shall be set up and
approved by local facility management.
n. Explosives warning signs shall be conspicuously displayed on
any processing vessel in which explosive materials are to be
left overnight.
o. Any vessel that can be sealed and that can operate above
atmospheric pressure shall be equipped with overpressure
protection.
p. All closed vessels should be purged with inert gas before
introducing flammable liquids.
q. Inert gas pressure should be used for transferring flammable
liquids when gravity flow or pumping are not practical.
12.11 Formulation
Formulation operations considered in this section are those
involving the combining of compounds or mixtures when one or more
of the ingredients being combined is an explosive. This
combining of ingredients is commonly accomplished at DOE
explosives-handling facilities to obtain some desired physical
property, combination of properties, or reaction parameter(s).
12.11.1 General
a. Explosives may be loaded as a contact operation (operator
attended) into mixers, mills, and deaerators. However, the
starting, operating, and stopping of such equipment with
explosives present shall be accomplished remotely.
Exception: mixing-type operations involving a low energy
transfer may be allowed as a contact operation. Examples:
slurry coating and melt agitation.
b. Equipment used for explosives formulation shall be checked
for proper operation before adding explosives. In
particular, equipment shall be examined for proper
clearances and for metal-to-metal rubbing of moving parts
potentially contacting explosives. Bearings should be
sealed to preclude contamination with explosives.
c. Fast-action deluge systems shall be considered for equipment
(e.g., mixers, mills, and deaerators) used for easily
ignitable explosives formulations.
d. Hot or cold water or steam can be applied to mixers and
mills, but heating fluid temperatures shall not exceed known
safe operating temperatures for the particular explosive(s)
involved. In the case of roll milling, allowance shall also
be made for viscous shear heating of the explosives during
working. Heated systems shall comply with the requirements
of paragraphs 12.1.2a and b of this chapter.
12.11.2 Mixing
a. Mixer seals and gaskets shall be checked on a regular
schedule and cleaned or replaced as required.
b. Checks should be made to ensure that maximum particle sizes
of ingredients or hard agglomerates of proposed mixes are
less than the blade-to-blade or blade-to-bowl clearances.
c. Initial cleaning with solvents used for dissolving or
suspending the explosives residues shall be done remotely
(other than melt-mix or slurry coating vessels).
d. Explosive powders and plastic-bonded explosives formulations
may be mixed wet in a contact operation. This can be
accomplished if the wet mixture cannot be initiated with
energy sources available and if the viscosity is kept low
and the possibility of isolated portions of the mix becoming
dry is precluded.
12.11.3 Ball or Jar Milling
a. Balls that are porous or contain cavities shall not be
permitted in mills for grinding explosives.
b. Grinding media contaminated with explosives slurry shall be
protected from excessive impact during emptying of the mill.
c. After grinding, a careful inspection shall be made to ensure
that the explosive is free of grinding media. Dispose of
any explosives contaminated with broken media.
d. After separation of the explosive, the grinding media shall
be thoroughly cleaned and inspected before reuse or
disposal.
12.11.4 Roll Milling
a. Positive stops should be installed on roll mills to prevent
rolls from rubbing each other.
b. Before a milling operation is started on a roll mill, the
contact of the scraper blade with the roll should be
adjusted to the minimum pressure necessary to perform the
operation.
c. Roll gaps should be set as wide as possible while still
allowing adequate working of the material. Minimum gap
setting shall be 0.1 mm.
d. Roll rpm should be held at the minimum required to process
the material adequately.
e. All roll mills that may be contact operated (e.g., with
nonexplosive materials) shall be equipped with emergency
stop devices (breaker bar, chain) within easy reach of the
operator.
12.12 Concurrent Contact Operations
Arranging explosives operations so that each operation is
performed in a separate location to preclude any adverse
operation interaction is preferred. Since such an arrangement is
frequently impractical, concurrent operations may be permitted if
the following conditions exist.
a. Potential equipment-operator interactions between the two
operations have been analyzed and the risk is not
appreciably greater than that for both operations considered
separately.
b. Explosive materials in either operation are not exposed to
stress conditions such as elevated temperature (melting or
heat conditioning), elevated pressures (pressing or
extruding), or deformation/shear (machining or cutting).
c. Mixing of materials in the concurrent operations will not
create compatibility problems.
d. Each operator is aware at all times of concurrent operations
in his or her area.
12.13 Contamination Prevention
a. When two or more incompatible explosives or materials are
handled on a line or within a building or room, precautions
shall be taken to avoid mutual contamination. This includes
vacuum systems and explosives scrap collection. Inadvertent
mixing of incompatible explosives materials can be hazardous
not only to manufacturing facilities and personnel but also
to the user if such materials are loaded into explosives
devices.
b. When two or more explosives are used in a line or within a
building and mixing is not intended, the materials shall be
segregated in separate locations. The containers shall be
clearly marked with the weight and contents identification.
Care shall be exercised to properly segregate material in
service magazines as well as in operating buildings.
c. When a different explosive is to be used in process
equipment, the equipment shall be thoroughly cleaned, and
excess explosive from the previous job should be removed
from the bay. This eliminates the hazards caused by mixing
materials.
d. In any explosives operation, all permanent service lines
shall be labeled as to contents. All valves and switches on
service lines whose operation can result in a hazardous
situation shall be labeled as to function.
12.14 Hand-Cutting and Finishing Operations
Hand-cutting and finishing may include cutting, trimming, coring,
and lapping (surface polishing) explosive materials. Hand
operations shall be performed using the mildest energy input that
will accomplish the task safely and efficiently. The safety of
hand-cutting and finishing operations shall be reviewed by the
facility's EDC, approved and incorporated into an operating
procedure prior to performing the operation.
12.15 Use of Low-Pressure Fluids
Low-pressure fluids (liquid pressure less than 1,500 psig) may be
handled as in a contact operation to aid in explosives
dissolution, rinsing, system flushing and similar operations
under the following conditions:
a. The fluid system shall have a pressure relief device
installed to prevent the system from being over pressurized.
b. Low-pressure fluid operations may be used with those
explosives that have impact sensitivity properties less
sensitive than PETN. Such operations may be used on other
explosives only after analysis of the energies involved.
c. Solvents must be compatible with the explosive material.
Controls for their use must be specified in operating
procedures.
d. See paragraph 12.4.2e of this chapter for use of pressures
above 1,500 psig.
This page intentionally left blank. 13.0 TESTING
13.1 General
This section covers the following types of testing operations.
a. Explosives test shots, gun firings (both small arms and
large caliber), and environmental, physical-property, and
sensitivity testing of explosives specimens.
b. Explosives-related experiments or tests for which the
explosive material is used to provide desired results such
as a seismic yield, overpressure effects, pulse energy, or
other special applications.
13.2 Test Planning
13.2.1 Hazards Analysis
a. Every proposed testing program shall be examined for all
foreseeable hazards involved in the test. This shall be
done with a knowledge of the construction and operation of
all standard and nonstandard equipment to be used, as well
as the type of explosives involved.
b. Those tests that are unique in their application or pose
obvious hazards shall adhere to the requirements contained
in Chapter VII, Section 2.1.
c. In the case of large-scale tests that have the potential for
propelling missiles off Government land, a formal risk
analysis of worst-case conditions for each different test
type shall be performed. Such analysis shall address both
the probability of a hazard occurring and the potential
severity of the hazard with respect to injury and property
damage.
13.2.2 Firing Areas
a. A secured firing area (danger zone) shall be established for
each test to ensure that personnel are not exposed to
hazardous blast overpressure, firebrands, fragments, or
projectiles from an explosives shot or gun firing.
b. Firing areas shall be selected for their suitability to
conform to the requirements of DoD 6055.9-STD, DoD
Ammunition and Explosives Safety Standards.
c. Firing areas shall be selected so as to not adversely affect
the environment or have a potential to cause secondary
fires.
13.3 Test Firing
13.3.1 General Range Standards
Procedures shall be established at each DOE explosives test site
to ensure that no site personnel or transients are exposed to
firebrands, fragments, or excessive blast overpressure from a
test shot. In establishing these procedures, the following
guidelines shall be considered.
a. Personnel access to each test site shall be controlled
during actual testing operations. If unattended roadblocks,
gates, or doors are used to prevent personnel from entering
the danger zone during a test, they should be interlocked or
locked with specially controlled keys.
b. All firing site personnel and visitors shall be accounted
for and in a safe place before test firing.
c. A visual inspection of the danger zone shall be performed
immediately before each test shot or series of shots as
applicable, to ensure that no transients are present.
d. The danger zone shall be free of service personnel (such as
telephone repairmen, surveyors, road maintenance
crews, etc.) during test operations. The control point
shall notify service personnel of the specific requirements
under which they may safely work when testing is not in
progress. In addition, the control point shall notify
firing site personnel of the presence and location of
service personnel in their areas.
e. Clearance for a test or test series shall be coordinated
with all test sites and other potentially affected areas. A
warning shall be provided to every affected area immediately
before each firing.
f. Detonation of very large explosive shots, numerous smaller
shots, or gun firings may result in hearing damage and may
exceed the DOE allowable limits for impulse noise. Perform
a noise evaluation of these activities to ensure that
adequate hearing protection is provided to those involved.
g. During test operations, all personnel assigned to the test
area shall be continuously alert for movement of personnel,
vehicles, and aircraft.
h. Test firings often create hazardous conditions for aircraft
operating in the airspace near the danger zone. If this
airspace is periodically subject to air traffic, precautions
shall be taken to ensure that the airspace will be clear of
traffic at the time of firing.
i. Each firing site shall establish personnel limits based on
the number of people actually needed to conduct an operation
and the number of transients that should be present. These
personnel limits shall be enforced by the responsible person
at the firing site.
j. Testing of explosives can result in personnel exposure to
toxic decomposition products such as carbon monoxide,
hydrogen chloride, hydrogen fluoride, hydrogen cyanide, and
nitrogen oxides. It is good practice to allow the
detonation cloud to disperse before leaving protective
bunkers. Fragment-danger-zone distances are normally
adequate to allow cloud dispersal and protect outside
personnel from excessive exposure.
k. If the nature of a proposed test is such that hazardous
conditions of abnormally long duration may exist following
the test, the procedure shall require a suitable waiting
period before personnel leave their shelter or safe haven
area.
13.3.2 Test Setup
In setting up a test, all work should be done that can be done
before receipt of the explosives. Such work includes the
following items.
a. All firing site safety devices shall be checked at regular
intervals. Such safety devices include warning lights, door
and gate firing circuit interlocks, emergency firing circuit
cutoff switches, grounding, etc. (including those that are
remote from the firing bunker).
b. All firing pad and shot stand setup work that requires power
tools or other potential spark-producing devices should be
completed. The firing pad shall be cleared of all
unnecessary gear. Special precautions and procedures will
be developed and implemented if power tools or other
spark-producing devices are needed after the explosive has
been received at the firing pad.
c. If a special structure is required, as much work as possible
should be accomplished on the structure, including assembly
of all materials.
d. When possible, all diagnostic equipment shall be set up,
checked, and dry runs performed.
13.3.3 Pin Switches and Other Noninitiating Circuits
Whenever pin switches and other noninitiating circuits are to be
checked (such as for charging current or leakage) and are in
contact with or close proximity to explosives, the check should
be performed remotely. Other noninitiating electrical circuits
include strain gauges, pressure transducers, thermocouples, etc.,
that may be affixed to or close to the explosives within an
assembly. If a continuity-only (resistance) check is desired,
this may be accomplished as a contact operation with an
electrical instrument approved for use with the particular
explosive device. When low-firing-current actuators are
involved, it may be advisable to conduct these tests remotely
(see paragraph 13.8 of this chapter).
13.3.4 Lightning Storms
All operations in open, test-firing areas shall be discontinued
during lightning storms when explosives are present. Completion
of a test after receipt of a lightning alert may be allowed only
if test preparation has progressed to the extent that
discontinuance of testing would represent a greater personnel
exposure than completion of testing.
13.3.5 Low-Energy Electroexplosive Devices
When using hot-wire or low-energy electroexplosive devices (EEDs)
for a test firing, apply the following requirements.
a. Procedures shall be established to ensure that RF, FM, and
television transmitters that have sufficient output energy
to initiate an EED at the test site are either restricted to
a safe distance from the site or not operated. Tables II-1,
II-2, and II-3 specify minimum safe distances for the
various types of transmitters at several output power
levels.
b. Blasting caps and other low-firing-current igniters or
detonators shall be kept separate from explosives at all
times, except during actual test charge assembly and setup.
c. The entire wiring system of the explosive charge and of any
low-firing-current initiators shall be kept insulated at all
times from every possible source of extraneous current
except for weapon components that have an exposed electrical
ground by design. Connections that are made using weapon
wiring connectors and/or cables are acceptable without
further modification. Shunts shall be left on all
low-energy initiators or lead wires until actual connections
are to be made. Connections shall be taped or otherwise
insulated.
d. Test units containing low-firing-current actuators or
detonators shall be clearly marked. No contact operations
involving electrical testing shall be permitted on this type
of unit unless an electrical meter for the specific
application is used.
13.3.6 Explosives Storage in Firing Areas
a. Explosives or ammunition storage at a firing area shall be
located such that ignition or detonation is improbable in
case of a fire or unplanned detonation in the area.
b. Those tests that require explosives or ammunition to be
stored at the firing site beyond a day's event shall conform
to the requirements of Section 17 of this chapter.
13.3.7 Warning Signals
Each DOE explosives testing facility shall use standard audible
signals to warn personnel of any impending firing in a test area.
Signals shall be established by each facility and approved by
facility management.
13.3.8 Grass Fires
Evaluation shall be made before a test shot outside firing pads
to determine the necessity to control any grass fires that may be
initiated by the test.
13.3.9 Firing Leads
All detonator lead wires shall be electrically insulated. Firing
leads or cables of low-energy detonators for explosive assemblies
shall be kept properly shorted during setup on the firing point.
13.3.10 Unattended Test Assemblies
If necessary, a test assembly may be left unattended on the
firing pad during off-shift hours under the following minimum
conditions.
a. If explosives are present, appropriate safety warning signs
shall be displayed at all entrances to the firing pad.
b. Protective services and fire department personnel shall be
notified of the explosives location. This location must be
in a controlled-access or secured area.
c. If low-energy detonators are present on the assembly, their
leads or cables shall be shorted.
13.3.11 Postfiring Controls
a. If the firing appears to be normal, a suitable waiting
period shall be observed before test personnel leave the
protective shelter. The waiting period shall be sufficient
to ensure adequate dissipation of smoke and dust and shall
be specified by the facility or test procedure. In some
cases, it may be helpful to develop and analyze the
diagnostic film for misfires.
b. During the waiting period, all power to the firing units
shall be turned off or disconnected. Whenever possible,
detonator cables should be disconnected from the firing
units, shunted, and grounded, and the firing unit capacitor
grounded.
c. After the waiting period, one qualified operator or
technician shall inspect the firing pad in person or by
remote television to determine the results of the shot
before other personnel leave the shelter.
d. If the inspecting operator is certain safe conditions exist,
the lead operator shall signal "all clear."
e. After any test misfire, suspected misfire, or partial
detonation, the firing area shall be inspected for unreacted
explosives after the minimum waiting period (see
Section 13.7 of this chapter).
f. Recovered explosives from a test shot shall be considered as
potentially contaminated and/or partially reacted material
and stored in Group L storage facilities (see Section 17.4
of this chapter) or stored separately pending disposition.
13.3.12 Contamination of Firing Areas
Most test firing areas are subject to explosives contamination
due to incomplete detonations or to detonation failures when the
explosives are subjected to varying forms of energy input. Most,
but not all, of this contamination will be cleaned up in the
postshot inspection of the test sites. The following steps shall
be taken to reduce the hazards from residual explosives
contamination.
a. The contamination zone for each firing area shall be
established and permanently annotated on facility site
plans.
b. Personnel access to explosives-contaminated areas shall be
controlled.
c. Service personnel shall not work in the area without the
permission of testing-area management and only when
supervised by a person approved by management.
13.3.13 Test Range Firing Circuit Criteria
The following criteria are guidelines for the design of
electrical circuits that are used to arm and initiate squibs,
igniters, detonators, and similar electroexplosive devices (EEDs)
during test firing activities.
a. The fire control circuit shall include both an ARM switch
and a FIRE switch. In the case of low-firing-current
initiators, the safe mode of the arming circuit should not
only interrupt the firing circuit, but also short-circuit
and ground the EED terminals. Manual shorting and grounding
is permitted.
b. Every electrical ARM and FIRE circuit on a test range shall
include an interlock device consisting of a safety plug or a
key-operated switch to prevent inadvertent energization.
c. The safety plug design and configuration shall be unique for
its application and use to prevent unauthorized or
accidental activation of a firing circuit. Key-operated
switches for ARM and FIRE circuits shall be designed to lock
in the safe (off) position when the control key is removed.
Duplicate keys or safety plugs shall not be permitted in any
one test area.
d. During shot-preparation operations, the key or safety plug
for a firing site shall be in the control of the lead
operator at all times.
e. All FIRE control circuits in test operation areas shall be
properly documented for operational control purposes.
Documentation shall include complete wiring diagrams,
electrical schematics, and cable function lists. All
changes or modifications to FIRE control circuits shall be
reviewed for safety and approved by other appropriate
departments before being incorporated into the circuits.
f. Each FIRE control circuit shall be adequately isolated from
all other circuits. A shielded, twisted pair of wires with
an outer insulating jacket or coaxial cable should be
employed for each circuit.
g. All programmers (sequential timers) used in firing circuits
shall be "fail-safe." That is, failure of a component or
circuit must not energize the firing circuit.
h. Test current from the electrical instruments used to perform
resistance checks shall not exceed 10% of the no-fire rating
of the EED in the circuit.
i. Firing circuits shall be clearly marked or otherwise
identified in a distinctive manner, and shall be installed
so as to prevent their inadvertent energization by other
circuits.
13.4 Test Firing in Tanks or Chambers
Small quantities of explosives may be detonated in cubicles or in
pressure vessels. The following requirements apply to such
vessels.
a. The firing vessel and flanges shall be capable of
withstanding and confining the effects of the explosion and
properly safeguarding personnel.
b. The firing circuit should be interlocked with the vessel
access door latch in such a manner that the door must be
closed and latched before the explosive can be fired.
c. Inspections of the vessel by qualified engineering personnel
shall be made periodically to ensure that structural
integrity is maintained after repeated detonations.
d. Test firing is often conducted inside large containment
vessels that allow personnel entry but provide a confined
working space and limited egress. The requirements for
ventilating and evaluating the atmosphere of the tank or
chamber before personnel entry must be included in the SOP.
13.5 Gun Firings
a. No work, adjustment, or observation shall be permitted on
any gun while a live round is in the firing chamber. The
only exception is to check azimuth and elevation.
b. Precautions shall be taken to protect against errors in
assembly or preparation of equipment and ammunition that may
create hazards to personnel or equipment. In particular,
the following areas shall be checked.
Adequate filling of hydraulic recoil mechanisms.
Safe function of the firing mechanism. (Firing
mechanisms shall be tested before use, particularly in
the case of electric firing mechanisms, to ensure that
mere insertion of the round or closing of the breech
will not result in firing.)
Absence of obstructions in the bore.
c. With the exception of manually fired small arms, test
weapons should be equipped for remote control of the safety
and for remote cocking. The safety shall not be advanced to
the fire position and the weapon shall not be cocked until
all personnel are in a safe location.
d. Guns used to fire projectiles at explosives targets shall
meet the following criteria.
(1) The gun shall be rigidly mounted in such a way that the
impact area is defined and controlled.
(2) The target shall have an adequate backstop.
(3) Provision should be made for remotely moving the gun,
remotely removing the propelling charge, or removing
the explosives from the line of fire in the event of a
gun misfire.
(4) Provisions shall be made for the collection and removal
of undetonated explosives from the chamber or area.
e. When hydrogen gas is used in the firing of a light gas gun,
the operation shall be remote while hydrogen is present in
the gun pressure tanks or in the gun barrel and catch tank
after firing. The hydrogen shall be purged from the entire
system with inert gas and the atmosphere checked before
personnel are allowed to reenter the gun bay.
13.6 Ballistic, Environmental, Physical Property, and Sensitivity
Testing
13.6.1 Checkout of Dynamic Engineering Test Equipment for
Explosive
Assemblies
a. To minimize the possibility of an incident during dynamic
testing of explosive assemblies, load-bearing members of the
test equipment or the explosive assembly should be
proof-tested and examined if:
(1) the test equipment is new or has undergone a design
modification;
(2) existing test equipment is to be used under unusually
severe test conditions (i.e., conditions of velocity,
vibration, pressure, load, etc.); or
(3) a new or modified explosive assembly that affects the
loading characteristics of the equipment is to be
tested.
b. Proof-testing of the explosive assembly or test equipment
should be conducted before running tests involving actual
systems with explosives.
c. As a minimum, proof-testing should consist of the following
sequence of checkouts.
(1) Check out load-bearing members (i.e., lifting devices,
hold-down mechanisms, fixtures, vehicle cases) to at
least 125% of rated load using simulated loads (see
Section 14.4 of this chapter).
(2) "Dry run" tests of actual systems with mock materials
in place of explosives and hazardous radioactive
materials.
d. In the event of a part failure in either of the two checkout
tests given above, no tests involving explosives or
radioactive material shall be run until additional checkout
tests have demonstrated that the failure cause has been
eliminated.
13.6.2 Testing of Explosives and Hazardous Radioactive
Materials
Explosives and hazardous radioactive materials (i.e., plutonium,
enriched uranium, etc. depleted uranium and natural thorium are
not considered hazardous radioactive materials for this purpose)
shall not be included in the same test or operation if the test
or operation is not contained and involves:
a. Application of high-energy stimuli (i.e., high shock,
impact, or friction levels) to the explosive.
b. Heating the explosive to within 10øC of the heating limit
determined for the explosive system without hazardous
radioactive materials consistent with paragraph 12.1.1d of
this chapter.
c. Intimate contact of incompatible material with the explosive
as determined by compatibility testing.
d. Unacceptably high risk of accidental application of stimuli
listed in (a), (b), or (c) above.
13.6.3 Heating of Explosives Test Specimens
a. Heating of an explosive shall be preceded by a thermal
analysis and preparation of a written procedure consistent
with paragraph 12.1.1 of this chapter. See paragraph 12.1.2
of this chapter for requirements on heating equipment.
b. Contact operations on explosives specimens undergoing
thermal conditioning may be permitted if (1) the specimen
will not be subjected to excessive friction, impact, or
spark stimuli during normal operations or during a credible
accident scenario and (2) the explosive involved has
satisfied appropriate scaleup sensitivity and stability
criteria (see Chapter VIII) and has sufficient handling
history to reveal any special characteristics affecting its
safe use.
c. If an explosives test specimen in a contact operation is
discovered to have exceeded the established heating limit
for the explosive system, the test shall be terminated and
the specimen cooled to ambient temperature. A procedure
should be prepared and approved for the required corrective
action (i.e., disassembly or disposal).
13.6.4 Instrumentation
a. Instrumentation directly applied to explosives in a test
specimen shall be physically disconnected, isolated, or
grounded before personnel may enter the test cell. Only
those instrumentation channels that contain devices that
limit the current below the level capable of initiating the
explosive are exempt.
b. Environmental control transducer leads, not attached to the
test specimen and permanently installed in an approved
control system, do not need to be grounded or disconnected.
13.6.5 Explosives Limits
Explosives specimens shall not be permitted to accumulate in a
test cell beyond the number required to sustain the test. For
short-term testing (less than 1 day), specimens present shall not
exceed a 4-hour supply.
13.6.6 Drop Testing
After an explosives drop test, personnel shall wait a minimum of
5 minutes before leaving the control bunker to inspect the test
pad. If smoke or flame is observed at the drop test area, entry
shall not be permitted until at least 30 minutes after all visual
signs have disappeared.
13.7 Test Failures and Misfires
13.7.1 Explosives Misfire
a. If no audible detonation is heard after once pulsing the
firing circuit, the firing circuitry and detonator(s) may be
checked for continuity. This checking shall be accomplished
from within the control bunker or from a protected location.
If the firing circuits and detonator(s) appear operative,
one or more attempts to fire may be made.
b. If the shot still does not fire, the following precautions
shall be taken:
(1) Disconnect and deenergize all electrical power sources
connected to the shot.
(2) Ensure that all personnel in the danger zone are aware
that a misfire has occurred and that they must remain
under cover until notified otherwise.
(3) Before any personnel are permitted to leave the cover
of the bunker, a preestablished waiting period shall be
observed. It is advisable in most situations to
establish this waiting period at 30 minutes minimum.
(4) A carefully prepared review of the situation, in
consultation with another knowledgeable person, should
be initiated.
(5) Before other personnel are permitted to leave cover of
the bunker and after an agreement has been reached, one
qualified person should carefully approach and examine
the setup to verify that it is safe.
13.7.2 Misfire of a Remotely Fired Gun
a. When a misfire occurs, several more attempts to fire the gun
may be made. If these subsequent attempts are also
unsuccessful, the following precautions should be taken.
(1) Disconnect all electrical circuitry to the gun to
ensure that the firing system cannot be energized.
(2) If the gun is light-gas driven, ensure that it is in a
safe condition by venting all pressure in the gun
breech before approaching the gun. To reduce the risk
of a gas explosion in the case where the driving gas is
flammable, the gun breech shall be purged with inert
gas after venting.
(3) An appropriate waiting period shall be observed before
approach to the gun is permitted. In no case shall the
waiting period be less than 10 minutes.
(4) If there is any indication that powder is burning when
the gun is approached, personnel shall return to a safe
area and observe an additional waiting period of at
least 20 minutes.
(5) The gun shall not be approached within the known recoil
distance behind the breech or from the front. Approach
to and work on the gun shall be from the sides.
(6) If the gun is a separate loading type (i.e., propellant
charge is loaded separate from projectiles), the
propellant igniter shall be disconnected from the
firing mechanism and removed from the gun before any
other gun operations.
(7) If possible, the powder chamber of the gun shall be
checked for the presence of pressure and vented to the
atmosphere before opening the chamber.
b. If an unforeseen failure situation arises (e.g., the
explosive projectile is stuck in the bore), an emergency
procedure shall be prepared and followed to resolve the
situation.
13.8 Electrical Instruments for Use with Explosives Systems
(except those covered by DOE O 5610.11, NUCLEAR EXPLOSIVE
SAFETY)
13.8.1 Classification
Test instruments shall be assigned to categories on the basis of
electrical characteristics that affect their safe use with
explosives systems. Specifically, the instrument categories
shall be established so that each category can be safely applied
to one or more of the following classes of explosives systems:
(a) low-energy or hot-wire initiators (blasting caps, actuators,
squibs, etc.); (b) high-energy initiators (exploding bridgewires,
slappers, etc.); and (c) noninitiating electrical circuits.
Test instruments that do not meet the safety criteria may only be
used on an explosive system if the activity is considered a
remote operation and adequate personnel shielding or separation
distance is provided.
13.8.2 Certification
a. Each DOE facility engaged in the use of electrical test
instruments on explosives systems shall establish a formal
system for the purpose of reviewing and certifying these
instruments. Procedures for marking instruments to show
their approved use and restrictions on their use should also
be established.
b. Every individual test instrument designated for use on
explosives systems shall be certified and prominently
labeled with its approved use and with a warning if there is
a restriction on its use.
c. Inspection and calibration of certified instruments shall be
required at prescribed intervals or whenever the instrument
is opened for servicing or repair. Access to internal
circuitry of certified instruments shall be controlled to
prevent unauthorized repairs, maintenance, or alteration.
d. Records of all instrument types certified shall be
maintained by each DOE facility using electrical instruments
to test explosives systems. These records should include
type, manufacturer, model, electrical specifications, wiring
diagrams, and failure mode analyses. The Explosives Safety
Committee chairperson shall be notified in writing by DOE
facilities when they approve new electrical instruments for
use with initiating systems. The chairperson shall
disseminate this information to all committee members.
13.8.3 Electrical Instruments for Use with Initiating
Electrical Circuits
Instruments in this category are used with electrical initiation
circuits connected to electroexplosive devices (EEDs).
Instruments may be further categorized for use with either
low-energy initiators or high-energy initiators. All test
instruments used for this purpose shall be current-limited.
Before being used on initiating circuits, every individual
instrument wiring diagram and internal circuitry design shall be
analyzed, examined, and certified for the following.
a. The output current through a resistance, equivalent to that
of the minimum resistance initiator of the class, should not
exceed 1% and shall not exceed 10% of the no-fire rating for
the most sensitive initiator of the class. The
current-limiting features of the test instrument shall be
internal to the instrument and shall not depend on test
circuit load characteristics.
b. The internal circuitry shall ensure isolation features that
require, as a minimum, two independent failure modes before
the specified output current can be exceeded.
c. A comprehensive (point-to-point, if possible) wiring check
should be made to ensure that the wiring corresponds to the
diagram and that all components are functioning properly and
within specifications.
13.8.4 Electrical Instruments for Use with Noninitiating
Electrical
Circuits
Instruments in this category are used with electrical circuits
connected to strain gauges, pin switches, pressure transducers,
thermocouples, electrical components, etc., that are affixed to
or within an assembly with explosives. These instruments shall
meet the following requirements.
a. Each specific use of the instrument shall be analyzed to
ensure that there is no credible scenario whereby the normal
test energy from the instrument can ignite explosives
charges or initiators in the test. Guidance on operational
requirements is contained in paragraphs 13.3.3 and 13.6.4 of
this chapter.
b. When an instrument is used to make measurements on sensors
directly applied to explosives (e.g., bonded strain gauges
or pin switches), the instrument shall be certified and have
met the requirements of paragraph 13.8.3.
c. Instruments used with noninitiating electrical circuits
shall be prominently marked with the restrictions on use.
Many of these instruments do not meet the requirements for
use with initiating systems and must be marked to prevent
their use on this type of circuit.
14.0 MATERIALS HANDLING
14.1 General
a. The distance that explosive materials can fall, if
accidentally dropped during handling, shall be maintained at
a minimum.
b. Hard surfaces and edges of equipment that could be struck by
accidentally dropped, consolidated explosives should be
padded with cushioning mats or coverings whenever possible
and needed. (Protective padding includes both sheet
material on work surfaces and on equipment and approved
floor coverings.)
c. Explosives handling shall be permitted only where handling
areas are free of obstructions and where the walkway
surfaces provide positive footing with no slipping or
tripping hazards (e.g., explosives shall not be handled on
walkways coated with snow or ice).
d. Explosives and materials that are not compatible shall not
be handled together.
e. Detonators, actuators, EEDs, and other items that would
normally be shipped as Hazard Class/Division 1.4 explosives,
should be kept in nonpropagating trays or containers unless
handled individually.
f. Dry explosive materials that generate dust shall be
transported in closed containers.
g. Containers of explosives or explosive assemblies shall be
labeled for contents identification during handling,
storage, and transportation.
h. Any explosives items that cannot be identified and labeled
shall be submitted for disposal.
i. Only those components or devices that contain no explosives
may be labeled/marked "Inert" or "Dummy."
14.2 Manual Handling of Bare Consolidated Explosives
a. Manual handling shall be minimized as follows:
(1) One person may lift or carry up to 25 kg of explosive
(if it can be securely gripped).
(2) Two people may lift or carry 50 kg of explosive (if
manual lifting and handling tooling is provided).
(3) Any explosive item over 50 kg in weight or that cannot
be securely gripped should not be manually handled.
b. Explosives should not be carried up or down stairs except
when in protective containers.
c. Operations shall be arranged to minimize the handling
distance in all manual explosives handling situations.
14.3 Carts or Hand Trucks
a. Explosives that cannot be manually handled shall be handled
only on suitable carts or hand trucks. Carts used for bare
explosives handling shall be provided with a padded surface
to support the explosives. These carts shall be equipped
with either a lip, sides of sufficient height, or tiedown
straps to prevent the explosives from sliding or rolling off
the cart. The cart-explosive load combination shall have a
center of gravity low enough to prevent tipping in the event
of a sudden stop caused by a wheel contacting an
obstruction.
b. Explosives handling carts or hand trucks should be provided
with brakes. Carts containing explosives shall be
positively secured (e.g., setting wheel brakes or chocking)
when the cart is stationary.
14.4 Mechanical Handling Equipment
a. All items of mechanical handling equipment (i.e., cranes,
hoists, slings, etc.) used to lift and move explosives or
assemblies containing explosives shall be initially
proof-tested, periodically inspected, and maintained in
first-class working condition. The DOE Hoisting and Rigging
Handbook (1090-95) may be used as a guide for testing,
inspection, and maintenance.
b. Equipment for vacuum lifting of consolidated explosives must
comply with the following requirements.
(1) The lifting equipment shall be designed so that jerks
or other irregular motions in the hoisting apparatus or
bumping of other equipment will not dislodge explosives
from the vacuum head.
(2) Equipment shall be designed to monitor the available
vacuum and to control loss of vacuum in the event of a
power failure or vacuum-source failure.
(3) Any handling where a loss of vacuum would allow the
explosive to drop an excessive distance shall
incorporate some safety device (collar, net, strap) to
prevent dropping. "Excessive distance" shall be
defined as a distance greater than the minimum drop
height that would cause drop-skid initiation for the
explosive being handled. "Initiation" in the drop-skid
test is used here to refer to any indication of sample
decomposition. An alternative method of protection can
be the use of a cushioning surface under and over all
items that may be struck by the falling explosives.
This page intentionally left blank. 15.0 MATERIALS RECEIPT
The following guidelines shall apply to the inspection, receipt,
and unloading of explosives materials.
15.1 Motor Vehicles
a. Incoming motor vehicles loaded with explosives shall be
carefully inspected by a competent person using an approved
checklist at a designated inspection station.
(1) When an inspection reveals that an incoming tractor is
in an unsatisfactory condition, the tractor should be
disconnected from the trailer at the inspection station
and moved to a position where it will not endanger any
other explosives.
(2) When inspection reveals that a trailer or its load is
in an unsatisfactory condition, the trailer shall be
moved to a location that is at least inhabited-building
distance for the particular material involved from
inert and administration areas, hazardous locations,
and the facility boundary. At this location,
correction of unsatisfactory conditions shall be
accomplished before moving the vehicle to its
destination within the facility. When moving from the
inspection station to the isolated locations, the route
should be as far away as possible from built-up areas
and areas where personnel concentrations are high.
(3) Vehicles that cannot be immediately dispatched to
points where they are to be unloaded may be moved to a
holding yard that shall be sited in accordance with
Chapter VI, paragraph 3.2.3.
(4) Incoming or outgoing explosives-loaded trailers that
cannot be exchanged directly between the carrier and
DOE facilities may be moved to an interchange yard.
Quantity-distance provisions do not apply if the
trailers are moved expeditiously.
b. Vehicles shall not be backed up to a dock where explosives
are resting and could be damaged if the dock were struck.
c. The building doors at the receiving facility should be
closed while the motor vehicle is in motion or the engine is
running.
d. Once the vehicle is in position, the engine shall be shut
off, the brakes set, and the wheels chocked.
e. After unloading, the vehicle shall be inspected for loose
explosives materials, and any spilled material shall be
cleaned up after the inspection. If a spill involves liquid
explosives or explosives in solution, the spill shall be
reported immediately to the building supervisor and
appropriate cleanup procedures shall be used.
15.2 Railcars
Railcars containing explosives and ammunition entering a DOE
facility must be inspected. This inspection comprises the
examination of the outside and underside of each car for damage
such as defective brakes, couplings, wheel flanges, etc.; for
unauthorized and suspicious articles; and for correctness of the
individual car numbers and seal numbers against bills of lading.
a. Cars of ammunition or explosives showing a defect that could
affect the facility or contents of the car should be removed
to the suspect car spur for additional inspection
(Chapter VI, paragraph 3.2.3b).
b. Cars that satisfactorily pass the inspection outlined above
may be considered reasonably safe, but care must be
exercised in breaking car seals and opening car doors
because of possible damage or shifting lading, leaking
containers, etc. Interior inspection should be accomplished
after the cars have been spotted at the unloading point.
15.3 Damaged Shipments
a. Explosives shipments shall be inspected for damage before
storage.
b. Contents of a damaged or broken container shall be removed
to another container. Any spilled materials shall be
cleaned up before continuing with loading or unloading.
c. Any shipment received in damaged condition as a result of
inadequate or improper blocking and bracing or as a result
of not being loaded in accordance with appropriate DOT
requirements shall not be reshipped until the damage is
corrected.
16.0 TRANSPORTATION
16.1 Equipment
16.1.1 General
a. Explosives shipped on common carriers shall be packaged and
shipped in accordance with DOT regulations.
b. Explosives-containing items transported by weapons couriers
in a Safe Secure Trailer (SST) or Safe Secure Railcar (SSR)
are exempt from the equipment requirements given below.
c. Security and authorized emergency vehicles carrying approved
quantities of explosives in support of approved contingency
plans are not considered "in transportation," as defined by
49 CFR Part 171.8.
16.1.2 Motor Vehicles
a. Motor vehicle shipments on public highways are governed by
DOT regulations. All motor vehicle shipments from a DOE
installation shall comply in full with the applicable
portions of DOT regulations, and with state and municipal
regulations, except as provided for in these regulations.
Any motor vehicle that may be loaded with explosives (Hazard
Class/Division 1.1, 1.2, and 1.3) and is designated for
movement over public highways must be inspected and approved
by a qualified inspector for compliance with an approved
checklist. After loading, the lading must be inspected and
approved. Driver selection, training, etc., for intraplant
shipping and for operation of government-owned trucks on
public highways shall be in accordance with pertinent
requirements of 49 CFR, Parts 390-397.
b. Before motor vehicles loaded with explosive materials leave
a DOE facility, drivers shall be informed as to the nature
of their cargo and methods of fighting fires involving the
vehicle or its cargo.
c. Cargo-type trucks and truck-tractor drawn semitrailers are
the preferred types of equipment for transporting
explosives. Flat-bed semitrailers or trailers may also be
used to transport large items in special containers for such
movement. For transfer movement within facilities, open-
body vehicles (other than flat-bed types) must have sides
and tailgates or rear doors that are strong and securely
fastened so that explosives are safely retained. Vehicles
(including flat-bed types) partly or completely loaded shall
have the lading blocked, braced, chocked, tied down, or
otherwise secured to prevent shifting during transit.
d. All DOE explosives-carrying vehicles for on-site
transportation should be equipped as follows.
Explosives placards plainly visible from all directions
(except for vehicles transporting Hazard
Class/Division 1.4 items).
Tiedown bolts, rings, and straps with which to securely
fasten the explosives items and which are adequate for
the load.
On trucks, a cargo area with no sharp projections.
(Nonsparking lining is desirable when hauling
explosives in transfer containers that are not DOT
approved.)
Chock blocks.
A quick-disconnect switch on the battery if explosives
are left on the vehicle overnight.
Rear-view mirrors on both sides of the vehicle.
Two fire extinguishers with a minimum rating
of 2A:10BC, one of which should be mounted outside the
vehicle. Vehicles for transportation of Hazard
Class/Division 1.4 explosives need just one
extinguisher.
e. Precautions must be taken to avoid ignition of explosives
material by the exhausts of motor vehicles. When a motor
vehicle approaches within 25 ft of the doors of a structure
through which a shipment is to be moved, the doors must be
kept closed until the motor has been turned off unless the
exhaust system is equipped with a spark arrestor or no
exposed explosives are present. Exposed explosives exclude
finished items and explosives packaged for shipment in DOT
or DOT-equivalent containers. No explosives shall be loaded
into or unloaded from motor vehicles while their motors are
running except when required to provide power to vehicle
accessories used in loading or unloading and the vehicle
exhaust is equipped with a spark arrestor.
(1) Security patrol and response vehicles are authorized to
transport the minimum quantity of munitions needed to
support approved contingency plans and to execute their
security duties. Whenever possible, support munitions
required for defense against hostile forces should be
pre-positioned in readily accessible magazines.
Security vehicles armed with a combination of up to
25 lb net explosives weight of Hazard
Class/Division 1.1 and 1.2 munitions shall be exempt
from explosives quantity-distance requirements when
executing approved contingency plans or security
duties. Vehicles so armed will not be used for
administrative purposes and will be separated from
inhabited facilities and property lines by a minimum of
125 ft when temporarily out of security service, and
shall be downloaded into properly sited magazines or
approved facilities when parked for periods in excess
of 4 hours. Operation of vehicles loaded with
explosives will be restricted to on-site locations and
transported explosives must be secured within the
vehicle. Smoking in explosives-loaded vehicles is
prohibited. These vehicles shall be downloaded into
properly sited magazines or approved facilities prior
to repair or maintenance, except under emergency
response conditions.
(2) Security force personnel shall be allowed to transport
on their person Hazard Class/Division 1.1 and 1.2
munitions issued to them for personal use in the
execution of approved contingency plans and security
duties without regard to explosives quantity-distance
requirements. Appropriate safety precautions for the
handling of ammunition shall be observed and the
munitions shall be placed in an approved location if
temporarily removed from the uniform/load-bearing
equipment worn to carry such items.
16.1.3 Railcars
a. A railcar must not be loaded with any Hazard
Class/Division 1.1 and 1.2 explosives unless it has been
thoroughly inspected by a qualified employee of the carrier
who certifies that the railcar's condition conforms to DOT
regulations. After a certified car has been furnished by
the carrier, the shipper or an authorized employee of the
shipper must, before starting to load any such car, inspect
the interior thereof and, after loading, certify its proper
condition. A certificate will be completed and signed where
applicable. Shipments of Hazard Class/Division 1.3
explosives may be loaded in a closed car or container car in
good condition (i.e., sparks cannot enter the car and the
roof does not have unprotected decayed wood that constitutes
a fire hazard). Wooden-floored cars must be equipped with
spark shields. Such cars do not require a car certificate,
but they must have a placard in accordance with DOT
regulations.
b. The railcar certificate, printed on strong tag board
measuring 7 by 7 in. or 6 by 8 in., must be executed in
triplicate. The original copy must be filed by the carrier
in a separate file at the forwarding station, and the other
two must be attached to the car, one to each outer side on a
fixed placard board or as otherwise provided.
16.1.4 Materials Handling Equipment
a. Gasoline-powered materials-handling equipment
(forklifts, etc.) may be used only in areas where all
explosives are properly packaged and only if equipped in the
following manner.
Backfire deflectors shall be securely attached on the
throat of the carburetor and shall be the oil-bath or
screen type (certain types of air cleaners will serve
the purpose).
A tight-fitting cap, properly vented, shall be in place
on the gasoline fill pipe at all times (except during
refueling).
A flame arrestor shall be installed in the fill pipe.
If necessary, a deflector plate shall be installed to
prevent any gasoline tank overflow from reaching the
motor or the exhaust pipe.
On gravity feed systems or on pump systems where
siphoning might occur, a shutoff valve shall be
installed at the fuel tank or in the feed line to
permit shutting off the flow of gasoline in the event
of an emergency or a break in the fuel line or
carburetor.
Provisions shall be made to prevent vibrational rupture
of the fuel lines.
b. Diesel-powered equipment may be used if all the precautions
for gasoline-powered equipment (as specified above) are
followed.
c. Battery-powered equipment for handling explosive material
shall comply with the criteria listed below.
(1) Battery-powered equipment and its use in hazardous
locations shall comply with OSHA standards. All
equipment shall be appropriately labeled for ready
identification.
(2) Types E, EE, ES, and EX-rated, battery-powered
equipment are satisfactory for handling all classes of
properly packaged ammunition and explosives. Types EE
and ES battery-powered equipment may be used for
handling packaged explosives or explosive components in
corridors or ramps connecting hazardous operations,
provided the ramps and corridors are not Class I or II,
Division 1, hazardous locations (NEC). Type EE
equipment is authorized for use in Class II,
Division 2, Group G hazardous locations, and Type ES
equipment may be authorized on approval of facility
management (see NFPA 505, Powered Industrial Trucks).
(3) Type EX equipment is the only equipment approved for
use in specifically named Class I, Division 1, Group D
or Class II, Division 1, Group G hazardous locations.
At this time, EX equipment does not carry a dual rating
and shall only be used in hazardous areas for which it
is specifically rated.
16.2 General Operation Guidelines
a. Explosives-containing items transported by weapons couriers
in SSTs or SSRs are exempt from the operation guidelines
given below.
b. Drivers shall be given special training that emphasizes
caution, road courtesy, and defensive driving.
c. The operator of an explosives-carrying vehicle shall have
proper training in the general safety precautions for
explosives handling.
d. Congested areas should be avoided.
e. Road vehicles shall stop at all railroad crossings.
f. No personnel shall ride in the cargo area. There shall not
be any loose items (e.g., handling gear) in the cargo
compartment.
g. No smoking is allowed in or within 25 ft of any vehicle
containing explosives. Matches, lighters, or other fire-,
flame-, or spark-producing devices shall not be in the
vehicle or carried by personnel in the vehicle.
h. The vehicle shall be subjected to regular maintenance
checks.
i. Before shipment, explosives materials being transported by
commercial carrier shall be classified by testing or analogy
in accordance with DOT regulations.
j. Other than when opened for inspection, containers of
explosives shall not be opened or repaired on any
transportation vehicle.
k. Except for emergency situations, fueling or maintenance of
vehicles containing explosives is forbidden.
l. Each facility shall have a special set of traffic rules
governing the operation of explosives-carrying vehicles and
the operation of other on-site vehicles in the vicinity of
explosives-carrying vehicles.
m. Industrial trucks shall not be used in locations where high
concentrations of dusts or sublimation of explosives may
result in contaminated surfaces (e.g., screening buildings,
pouring bays, melt-pour units, drilling bays, consolidating
bays, and explosive washout facilities).
16.3 Emergency Conditions
a. Explosives should not be transported when hazardous
conditions (such as storms, icy roads, or poor visibility)
prevail. An emergency plan shall be prepared to provide
instruction and guidelines in the event any of these
conditions arises while an explosives-carrying vehicle is in
transit. The plan should address the following issues:
parking the vehicle;
safeguarding the vehicle from other traffic;
notifying appropriate authorities of the emergency
situation; and
leaving the vehicle unattended.
b. A plan shall be prepared to provide for an
explosives-carrying vehicle that has a mechanical breakdown.
The plan shall address the following issues:
removing the vehicle from the road as far as practical;
posting emergency reflectors, signals, etc. (carrying
flares on the vehicle is not permitted);
reporting the problem;
maintaining surveillance of the vehicle; and
if necessary, removing the vehicle load to facilitate
repair of the vehicle.
c. If an explosives-carrying vehicle is involved in an
accident, the following steps should be taken.
(1) Inspect the load for evidence of fire.
(2) If there is a fire, but the explosives material is not
presently nor imminently involved, attempt to prevent
the fire from spreading to the load. The fire may be
fought using the vehicle's fire extinguishers. If
explosives items are removed from the vehicle, ensure
their security.
(3) If there is a fire that presently or imminently
involves the explosives load, evacuate all personnel to
a preestablished safe distance. Block or divert other
traffic from the vicinity of the accident. Evacuate
any potentially affected area residents.
(4) Unless the explosive cargo is imminently involved in
fire, direct the operator to stay with the vehicle
until proper disposition of the cargo is accomplished.
(5) Immediately notify the fire department or fire brigade
of the accident and inform them of the general type and
approximate quantity of explosives involved.
(6) Inform proper authorities of the accident.
This page intentionally left blank. 17.0 EXPLOSIVES STORAGE
17.1 Storage Magazine Facilities
a. Placard(s) shall be posted on or near each door of the
magazine, specifying explosive and personnel limits and
general safety precautions that should be observed during
work in the magazine.
b. Vegetation around storage magazines should be controlled to
minimize potential damage to the magazine (see Chapter VI,
paragraph 5.1).
c. At least two fire extinguishers, minimum rating 2A:10BC and
winterized where necessary, should be provided and
maintained for immediate use by personnel working around a
magazine. These extinguishers may be permanently located in
the area or available on an explosives transportation
vehicle. The extinguishers are for the purpose of fighting
small external fires or magazine fires where explosives are
not involved.
d. Suitably rated telephone or other forms of emergency
communication equipment should be provided in magazine
storage areas. All communications equipment located
outdoors should be protected from the weather.
e. Temperature Control
(1) In general, storage magazines should not be provided
with heat. An exception shall be made in the case
where heating may be necessary to prevent damage caused
by sudden changes in temperature or where dimensional
changes of components are undesirable.
(2) Magazines requiring heat should be heated with steam,
hot water, or electrically heated hot water. Some
magazines with tight temperature controls may require
both heating and air conditioning. Electrical systems
with forced air through ducts may be allowed if the
systems are located exterior to any explosive hazard.
(3) Heating coils shall be arranged so that explosives
material cannot come in contact with the coils. They
shall be equipped with covers designed to prevent the
storage of materials on top of the coils.
(4) In all magazines where heat is supplied, maximum and
minimum temperature monitors should be provided.
17.2 Storage Magazine Operations
a. Explosives items shall be properly packaged and stored in
either DOT-approved manufacturers' container/packages or in
specified on-site containers (see paragraph 17.5 of this
chapter).
b. Explosives may be stored on magazine shelves, where
provided. The bottom of the container should not be more
than 2 m off the floor, except as permitted by paragraph
17.2c of this chapter.
c. Explosives and explosives containers in storage shall be
safely and securely positioned. If explosives containers
must be stacked, they shall be placed in stable arrays.
d. Permissible loading of all shelving should be determined for
all magazines containing explosives. If there is a
possibility of overloading, the loading conditions shall be
posted.
e. Materials shall not be left suspended by booms, cranes, or
hoists in any explosives storage facility.
f. Explosives in storage should be segregated by lot
designation. Stacks of explosives should be arranged so
that air freely circulates to all parts of the stack.
Pallets or appropriate dunnage shall be used to ensure that
containers are not stacked directly on the magazine floor.
g. Aisles shall be wide enough to accommodate inspection,
inventory, sampling, and materials handling operations on
the stored explosives containers.
h. A crew shall not be permitted to work in a position that
requires passing the work aisle or the position of a second
crew to reach the exit. Unobstructed aisles shall be
maintained to permit rapid exit of personnel.
i. Each crew working in a magazine must have its own exit route
that does not interfere with exit routes for other crews.
j. Magazines shall be locked at all times except when
permissible operations are in progress or when a magazine is
opened for ventilation. Personnel shall be present while
the magazine is open for ventilation. All exit doors shall
be unlocked and open when personnel are working in the
magazine.
k. An inventory of each magazine shall be taken at least
annually to determine the total weight of explosives present
(to ensure this weight conforms to allowable
quantity-distance constraints) and to remove and destroy
materials that are not properly identified or labeled.
l. The liquid level in storage containers for wet explosives
shall be checked and replenished if necessary at least once
a year, and a log of the checks shall be maintained.
m. Empty containers, tools, conveyors, lift trucks, skids, and
other similar equipment should not be stored in a magazine
containing explosives.
n. Combustible materials such as excess dunnage, packing
material, and boxes shall not be stored in a magazine
containing explosives. Flammable liquids shall not be
stored or used in explosives magazines unless the liquid is
an explosive, is needed as an explosives-wetting agent, or
is an integral part of an explosives device.
o. Operations in and around magazines shall be prohibited when
an electrical storm is in progress and minimized when it is
evident that such a storm is approaching.
Explosives-handling operations shall not be performed when
magazine entranceways are ice-covered or, for any other
reason, do not provide adequate footing.
p. Unless excepted, no operation in which hazardous materials
are involved shall be permitted in any magazine. The
following exceptions are recognized.
(1) Those operations incident to storage or removal from
storage.
(2) Inspection and surveillance sampling of compatibility
Group D and bulk propellants of Group C materials (see
paragraph 17.4c and Table II-4 in this chapter),
provided that each storage container sampled is in good
condition (i.e., the container is not leaking, no
evidence exists of seal failure or explosives
contamination at the closure, and the closure is
mechanically sound and free of excessive
corrosion, etc.). Only one container of explosives
shall be opened at one time in a magazine.
(3) Liquid addition to adjust the liquid composition level
in which a Group D explosive is stored. [Water and
alcohol mixtures may be used as the liquid. If only
water is added to the explosive, the water should be
distilled or deionized. Bacteria present in untreated
water may produce gas during storage.]
17.3 Storage Review Program
Each facility shall have a program to review the explosive
materials stored at that facility. In recognition of the fact
that explosives may degrade during prolonged storage and the
hazards of handling or using degraded explosives may increase
significantly, the following procedure is provided as an example.
a. A storage review date should be assigned to every bulk
explosive placed in storage. The storage review date should
be shown on or adjacent to the identification tag or sticker
attached to every container or package of explosive in
storage or should be listed in the inventory records.
b. Storage review intervals should be based, whenever possible,
on stability data. A safe storage interval should be
considered as that time period, at maximum anticipated
storage temperature, during which an explosive material can
be conservatively expected to show an acceptable level of
decomposition.
c. A storage review committee should be designated or created
by facility management to establish and approve storage
review intervals for all explosives stored at the DOE
facility. Also, the committee should prescribe for each
explosive appropriate tests to permit an evaluation of the
safety of handling and processing the material once it has
exceeded its storage review interval. These tests may be
referred to as "stability tests," although sensitivity, or
other types of testing, may be included in the material
evaluation program. In some cases, the review committee may
simply require periodic stability testing of the material
rather than establish a storage review interval
(i.e., nitrocellulose, single- and double-base
propellants, etc.).
d. To store a new explosive, to increase (or decrease) the
review interval for a previously approved material, or to
use different stability test data for an explosive, the
following procedure should be observed.
(1) A responsible person should communicate the request to
the storage-review committee.
(2) If the request concerns storage of a new explosive, the
individual should recommend a storage-review interval
and stability-evaluation testing.
(3) Supporting data should be supplied with the recommended
review interval and with the proposed stability tests
for the explosive.
(4) The storage review committee should review the request
and supporting data and then prescribe a storage review
interval and/or stability tests.
e. A new explosive should be assigned an interim storage review
and stability test interval before Phase II scaleup (see
Chapter VIII).
Table II-4. Storage compatibility groups for explosives and
explosive-containing devices.
Group A. Initiating explosives.
CP (5-Cyanotetrazolpentaamine Cobalt III
Perchlorate)
HMX (Cyclotetramethylene
tetranitramine) (dry)
Lead azide
Lead styphnate
Mercury fulminate
Nitrocellulose (dry)
PETN (Pentaerythritol tetranitrate)
(dry)
RDX (Cyclotrimethylene trinitramine)
(dry)
TATNB (Triazidotrinitrobenzene)
Tetracene
Group B. Detonators and similar initiating devices.
Blasting caps
Detonators excluding EBWs and slappers
Explosive bolts
Fragmenting actuators
Igniters
MDF (mild detonating fuse) detonator
assemblies
Pressure cartridges
Primers
Squibs
Group C. Bulk propellant, propellant charges, and devices containing propellants with or
without their own means of initiation.
Smokeless powder
Pistol and rifle powder
Rocket-motor solid propellants
Group D. High explosives (HE) and devices containing explosives without their own means
of initiation or articles containing a primary explosive substance and two or more
effective protective features.
Ammonium picrate
Baratol
Black Powder
Boracitol
Compositions A, B, and C (all types)
Cyclotols (not to exceed a maximum of 85%
RDX)
DATB (diaminotrinitrobenzene)
Detasheet
Detonating cord (primacord or mild
detonating fuse)
bis-Dinitropropyl adipate
bis-Dinitropropyl glutarate
bis-Dinitropropyl maleate
Dinitropropane
Dinitropropanol
Dinitropropyl acrylate monomer (DNPA)
Dinitropropyl acrylate polymer (PDNPA)
EBW and slapper detonators
Elastomeric plastic bonded explosives
Explosive D
HMX (Cyclotetramethylene tetranitramine)
(wet)
HMX/wax (formulated with at least 1%
wax)
HNS (Hexanitrostilbene)
Linear-shaped charge
Methyl dinitorpentanoate
Nitrocellulose (wet)
Nitroguanidine
Octol
Pentolite
PETN (Pentaerythritol tetranitrate)
(wet)
PETN/extrudable binder
Plastic Bonded Explosives, PBX (a
Group D
explosive formulated with a
desensitizing
plastic binder)
Potassium picrate
RDX
(Cyclotrimethylene trinitramine) (wet)
TATB (Triamino trinitrobenzene)
TATB/DATB mixtures
Tetryl
TNT (Trinitrotoluene)
Group E. Explosives devices without their own means of initiation and with propelling
charge.
Artillery ammunition
Rockets (e.g., 66 mm LAW)
Group F. Explosives devices with their own means of initiation and with or without
propelling charge.
Group G. Pyrotechnic material and devices that produce an incendiary, illumination,
lachrymatory, smoke, or sound effect.
Smoke pots
Flares
Incendiary ammunition
Table II-4 (Continued).
Group L. Explosives or ammunition not included in other compatibility groups that
present a special risk requiring isolation of each type.
Damaged or suspect explosives devices or containers
Explosives that have undergone severe testing
Experimental explosives, explosives of temporary interest, newly synthesized
compounds, new mixtures, and
some salvaged explosives
Group S. Explosives, explosives devices, or ammunition presenting no significant hazard
Propellant cartridge actuated devices (that yield a nonfragmenting, nonflame-producing
controlled reaction). Examples include the following:
Cable cutters
Cartridge actuated valves
Linear actuators (e.g., dimple, piston,
bellows motors)
Safety fuze
Small arms ammunition
Thermal batteries
Materials and systems that need not be stored or labeled as explosives unless they are
near other explosives that could initiate them.
When near explosives, these materials become Group D, unless otherwise indicated.
FEFO/SOL (35 wt% or less FEFO in ethyl acetate)
FEFO/solution
Group D explosives in inert solvents (explosive concentration not exceeding 25 wt%)
Nitrates; treat as Group C when with other explosives
Perchlorates; treat as Group C when with other explosives
Small arms ammunition classified for shipment by DOT as ORM-D (Other Regulated
Material Class D)
rather than Hazard Class/Division 1.4 explosives. Normally consists of ammunition not
exceeding
50 caliber for handguns and rifles and 8 gauge for shotguns.
f. The following general guidelines are offered to assist the
storage-review committee in establishing review intervals in
cases where there is insufficient stability information to
predict storage life.
(1) If there is no available information on a new material
relative to storage stability, a review interval of
90 days or less should be assigned.
(2) A new formulation should be assigned a storage review
interval not exceeding that of its least stable
component.
(3) If the compound or formulation is new to DOE, but DoD
agencies have extensive experience with it, the DoD
information should be used conservatively.
(4) If a manufacturer has an assigned shelf life for a
formulation or ingredient, a review interval that
exceeds the recommended shelf life should not be
assigned unless additional DOE tests indicate such
storage is warranted.
g. A storage review interval of up to 20 years should be
permissible for an explosive if a conservative evaluation of
stability data indicates that such an interval is justified.
17.4 Storage Compatibility
a. Explosives shall not be stored with materials or items that
increase the risk of initiation or decomposition of the
explosives. Examples are mixed storage of explosives with
flammable or combustible materials, acids, or corrosives.
b. Different types of explosives may be stored in the same
magazine if they are compatible. Explosives shall be
assigned to a storage compatibility group when they can be
stored together without significantly increasing either the
probability of an accident or, for a given quantity of
explosive, the magnitude of the effects of such an accident.
c. Each type of explosive shall be assigned to an appropriate
storage compatibility group (A through G, L, and S) for the
purpose of storage at DOE facilities. The nine groups are
defined in the following paragraphs. These definitions and
Table II-5, the storage compatibility mixing chart, are in
accordance with the principles and tables in DoD 6055.9 STD,
DoD Ammunition and Explosives Safety Standards. Table II-4
presents some examples of commonly used materials that are
assigned to each storage compatibility group. This list
does not enumerate all materials that may be included in
each group.
(1) Group A--Initiating explosives. Bulk initiating
explosives that have the necessary sensitivity to
friction, heat, or shock to make them suitable for use
as initiating elements in an explosives train.
Examples are lead azide, lead styphnate, mercury
fulminate, and tetracene.
(2) Group B--Detonators and similar initiating devices not
containing two or more independent safety features.
Items containing initiating explosives that are
designed to initiate or continue the functioning of an
explosives train. Examples are detonators (all types,
excluding EBWs and slappers), blasting caps, small arms
primers, and fuzes.
(3) Group C--Bulk propellants, propellant charges, and
devices containing propellants with or without their
own means of initiation.* Items that will deflagrate,
explode, or detonate upon initiation. Examples are
single-, double-, triple-base, and composite
propellants, rocket motors (solid propellant), and
ammunition with inert projectiles.
(4) Group D--High explosives (HE) and devices containing
explosives without their own means of initiation and
without a propelling charge, or articles containing a
primary explosives substance and containing two or more
effective protective features. This group shall
include explosives and ammunition that can be expected
to explode or detonate when any given item or component
thereof is initiated.
(5) Group E--Explosives devices without their own means of
initiation and with propelling charge (other than one
containing a flammable or hypergolic liquid). Examples
are artillery ammunition and rockets.
(6) Group F--Explosives devices with their own means of
initiation and with or without propelling charge.*
(7) Group G--Pyrotechnic materials and devices containing
pyrotechnic materials. Examples are devices that when
functioning, result in an incendiary, illumination,
lachrymatory, smoke, or sound effect.
(8) Group L--Explosives or ammunition not included in other
compatibility groups that present a special risk
requiring isolation of each type. This group shall
include explosives or ammunition having characteristics
that do not permit storage with other similar or
dissimilar materials. Examples are damaged or suspect
explosives devices or containers, explosives that have
undergone severe testing, fuel/air explosive devices,
and water-activated devices. Also included are
experimental explosives, explosives of temporary
interest, newly synthesized compounds, new mixtures and
salvaged explosives until they have been established to
be compatible with the original materials. Types
presenting similar hazards may be stored together.
(9) Group S--Explosives, explosive devices, or ammunition
presenting no significant hazard. Explosives or
ammunition so designed or packed that, when in storage,
all hazardous explosive effects are confined and
self-contained within the item or package. An incident
may destroy all items in a single pack, but must not be
communicated to other packs.
d. Newly synthesized compounds and mixtures shall be stored in
Group L storage facilities. After more complete evaluation,
those compounds or mixtures of continuing interest shall be
assigned by the Explosives Development Committee (see
Chapter VIII, Section 1.1) to the appropriate compatibility
group, and stored according to the following considerations.
(1) The material's sensitivity to initiating stimuli
(i.e., friction, impact, spark, shock, and thermal) is
similar to that of other explosives in the group.
(2) The material's reactions and the effects of these
reactions, in the event of application of initiating
stimuli, are similar to other members of the group.
(3) The material is chemically compatible with other
members of the group. Sensitivity and compatibility
testing is described in Chapter VIII.
e. Mixing of storage compatibility groups may be permitted as
indicated in Table II-5. Items from storage compatibility
groups B, C, D, E, F, G, and S may be combined in storage if
the net quantity of explosives in the items (or in bulk)
does not exceed 1,000 lb and if the items are in approved
containers. Each article of storage compatibility groups B
and F shall be segregated in storage from those of other
compatibility groups by means that will prevent propagation
of those articles. In addition, samples of explosives up to
2 kg total, may be stored in the same cubicle without regard
to the above compatibility groupings if the cubicle walls
are designed to prevent propagation and the cubicle is
designated for one of the following groups of explosives:
high explosives;
propellants;
detonators, actuators, and similar devices; or
primary and static-sensitive explosives.
17.5 Containers (On-Site)
a. Explosives containers shall be designed and constructed so
they will not leak and will protect their contents from
excessive movement, external stimuli, contamination, or
spillage during handling, transportation (including
transportation to disposal sites), and storage. Container
closures shall prevent spilling or leakage of contents if
the container is overturned. Screw-type container closures
should not be used.
b. Explosives containers should be constructed of, or lined
with, nonabsorbent materials that are compatible with the
explosive contents. Use of glass containers is discouraged,
except for small samples. Glass containers shall be used
only when the explosive reacts with other materials or when
a high degree of purity is required.
c. Metal containers for materials that are potential dust
producers shall be constructed without seams or rivet heads.
Seams and rivet heads can provide locations for dust
accumulation.
d. Containers for cast or pressed explosives pieces that are
larger than 0.3 m at their greatest dimension or weigh more
than 5 kg loaded should be provided with handles or some
other type of handhold. If the loaded container weighs more
than 50 kg, provisions should be made to allow handling by
mechanical handling equipment.
e. All explosives containers shall be labeled.
f. Whenever possible, explosive pellets and items containing
small quantities of explosives (e.g., detonators) shall be
packaged in containers constructed so the functioning of one
item will not propagate to the remaining items in the
container. When a nonpropagating array is not possible, the
pellets or detonators shall be stored inside a closed
container and shall be labeled to indicate the total weight
of the explosive contents.
g. Container closures shall be the type that will not apply
excessive pinching or rubbing forces to explosives during
closing and opening. The closures and surfaces of container
openings shall be kept thoroughly clean of explosives
contamination to minimize any hazard during closing and
opening.
h. Explosives and ammunition in damaged containers shall not be
stored in a magazine with other explosives and ammunition.
Damaged containers shall be repaired, or the contents
transferred to new or undamaged containers, or the container
plus contents moved to a Group L storage magazine.
i. Open containers and containers with covers not securely
fastened shall not be stored in magazines. Containers that
have been opened shall be properly reclosed before being
returned to storage.
17.6 Storage In Buildings Other Than Storage Magazines
17.6.1 Packing and Shipping Buildings
In buildings specifically designated for packing and shipping,
explosives may be stored subject to the following rules.
a. Incoming shipments shall not be allowed to accumulate and
shall be distributed as soon after receipt as practical.
b. Items for outgoing shipments should not be accumulated
before receipt of orders covering each specific shipment.
c. Separate rooms shall be provided for the temporary storage
of explosives awaiting shipment and for their preparation
for shipment (i.e., assembling, crating, marking, etc.).
The rooms shall be divided by walls or separated from each
other so an explosion in the preparation area will not
propagate to the temporary storage area.
d. The combined total amount of explosives permitted in
shipping/receiving buildings, platforms, and transportation
vehicles shall be based on quantity-distance constraints.
If there is an adequate barricade (sufficient to prevent
sympathetic detonation) between transportation vehicles and
the adjoining building or platform, the quantities on each
side of the barricade may be considered individually to
determine quantity-distance requirements.
e. If required by operational necessity, explosives and
pyrotechnics that are part of the work in process within the
building may be stored during nonoperational hours in
operating buildings provided: (1) explosives limits are not
exceeded, (2) containers of bulk explosives or pyrotechnics
are properly secured and covered, and (3) processing
equipment, such as hoppers and pipelines, is empty.
17.6.2 Service Magazines
The guidelines presented above in paragraphs 17.1 through 17.5 of
this chapter for storage magazines shall also apply to service
magazines, except as modified below.
a. An explosives item should be stored for no longer than
necessary in a service magazine (with a maximum of
180 days).
b. The inventory of each service magazine should be reviewed
every 3 months. Any material that has been in the service
magazine for a period approaching 180 days and is not
expected to be used immediately should be disposed of or
removed to an appropriate storage magazine.
c. When practical, explosives stored in service magazines shall
be in containers. Unpackaged explosives-containing devices
and unsealed bulk explosives containers may be present in a
service magazine. However, these items and unsealed
containers shall be stored in a manner that renders them
stable and unlikely to be dropped or spilled.
d. Minimum/maximum temperature monitors are not normally
required for service magazines.
17.6.3 Warehouses
a. Hazard Class 1.4 materials (see Chapter VI, Section 3.1)
packaged as Hazard Class/Division 1.4, storage compatibility
group S, may be stored in warehouses if they are placed in
segregated and specifically designated areas.
b. Articles in Hazard Class/Division 1.4 and storage
compatibility group S are considered inert for storage
purposes and are not subject to quantity-distance
requirements as long as they are stored with inert items or
other Hazard Class/Division 1.4S items only. This applies
only if Hazard Class/Division 1.4 and storage compatibility
group S articles remain in their original packaging
containers or are proven to be self-contained. When stored
with items in a storage compatibility group other than S,
normal quantity-distance requirements must be observed.
17.6.4 Pre-positioned Storage of Security Response Munitions
a. When required for defense against hostile forces, and in
support of response and contingency plans, limited
quantities of authorized response force munitions may be
pre-positioned at locations other than bulk-storage magazine
areas. Compliance with quantity-distance and compatibility
criteria is not required during the heightened security
condition. Munitions will be kept in their original
shipping containers unless operational necessity dictates
otherwise.
b. Personnel charged with the responsibility of overseeing
storage of munitions at guard stations and contingency
deployment sites shall be trained in explosives storage and
transportation, as required in Chapter V of this Manual.
c. In the event Hazard Class/Division 1.2 is stored inside or
at less than inhabited-building distance from inhabited
buildings, fragment barriers will be provided. Any of the
following is a minimally acceptable fragment barrier:
0.25 in. of mild steel plate; one layer of sand bags; 12 in.
of loose sand or dirt, or other equivalent protection.
This page intentionally left blank. 18.0 DECONTAMINATION AND CLEANING
18.1 General
a. Operating procedures shall be prepared to specifically cover
decontamination procedures. These procedures should cover
methods, inspection, marking, control, dismantling,
maintenance, final disposition, etc.
b. Hot water or steam may be used to clean up explosives or
remove explosives contamination from equipment. Solvents
that have been tested for and are compatible with explosives
can be used if necessary. Controls for their use must be
specified in operating procedures. Only clean cloth rags,
paper wipes, and approved non-metallic brushes or scrapers
should be used in conjunction with hot water, steam, and
solvents, to clean or remove explosives material from
equipment, work surfaces, and floors.
c. The disposal of waste generated during decontamination shall
be coordinated with site environmental/waste management
personnel.
18.2 Cleaning Contaminated Equipment
a. Items to be cleaned should be positioned so that water and
residue will drain directly into an approved collection
system. See Sections 19 and 20 of this chapter for guidance
concerning waste collection and waste disposal.
b. Personal protective equipment as required shall be used by
personnel decontaminating facilities and equipment.
Emergency shower and eyewash shall be provided where needed.
c. Exhaust ventilation may be required to remove toxic
explosives fumes or vapors and/or steam from the
decontamination area.
18.3 Cleaning Screw Threads
a. To avoid the necessity of cleaning explosives from threads,
explosives processing techniques shall be designed to avoid
the deposition of explosives on threaded fasteners. When it
is necessary to use screw threads, some type of covering or
protection (i.e., RTV cement) over the exposed threads
should be provided.
b. Threads should be cleaned by judicious use of approved non-
metal "picks," solvent, or hot water, or steam. Soaking in
solvents and the application of a penetrating oil may be
useful.
c. After decontamination of threads of screws, bolts,
pipe, etc., it may still be advisable to provide operator
protection to facilitate their disassembly.
18.4 Final Decontamination and Disposal of Equipment
a. If the item to be decontaminated has only smooth, flat
surfaces (i.e., no cracks, seams, voids, or other places
where explosive residue may be inaccessible), hot water,
steam, or solvents may be employed to effect total
decontamination. Any explosives contamination of concern
will be visible to the unaided eye and will have dimensions
(length, width, and depth).
b. If the item to be decontaminated has tight places where
explosives may remain lodged following normal cleaning
procedures, the item shall be subjected to final
decontamination techniques. To facilitate cleanup, some
items may have to be partially disassembled during the
decontamination operation.
(1) Final decontamination by thermal techniques shall be
done by subjecting the item to sustained heating at a
temperature at least 60øC higher than required for
decomposition of the most thermally stable explosive
substance present. The item shall be kept at that
temperature for a sufficient period of time to ensure
that all parts have reached the temperature and all
explosives material is decomposed. This is usually
done by placing the item(s) to be decontaminated in a
high-temperature sustained fire (see TB 700-4,
Decontamination of Facilities and Equipment) . This
operation shall be conducted remotely or with operator
protection.
(2) Final decontamination may also be accomplished by
immersing the item in a chemical cleaning agent. The
period of immersion shall be of sufficient duration to
ensure that all explosive material is chemically
decomposed. The chemical cleaning agent shall be one
that is approved for use by the Department of Army
TM9-1300-214, Military Standards. Chemical cleaning
agents for decontamination or destruction of explosives
should not be used for more than about 1 oz. (or about
28 g) of explosives. Reference U.S. Department of the
Army TM9-1300-214 for decontaminating chemicals for
explosives and for color tests for identification of
energetic materials.
(3) Before subjecting the item to final decontamination by
thermal or chemical techniques, as much explosive as
possible shall be removed by the approved means (hot
water, steam, and approved solvents in conjunction with
cloth or paper wipes and non-metallic brushes or
scrapers).
18.5 Inspection
After decontamination procedures are complete and before transfer
to a nonexplosive area, the item shall be inspected. The degree
of decontamination shall be determined and documented, and the
item shall be labeled to indicate its decontaminated state.
Inspection should be accomplished by representatives of at least
two departments, such as the operating department and the safety
department.
18.6 Identification and Control of Decontaminated Items
a. Decontaminated items shall be marked to indicate the degree
of decontamination and stored separately from
non-contaminated items until final disposition is made.
b. Degrees of decontamination shall be designated and items
shall be tagged and/or marked with this designation.
c. Guidelines for establishing a system for designating degrees
of decontamination are provided below.
(1) X A single X indicates the facilities or equipment
have been partially decontaminated. Further
decontamination processes are required before
facilities or equipment are moved or any maintenance,
repair, etc. is performed. This degree would generally
be applied to facilities or equipment that have been
subjected to routine decontamination performed by an
operator on a piece of equipment, room, bay, or
building at the close of the workday.
(2) XXX Three Xs indicate the equipment or facilities
have been examined and decontaminated by approved
procedures and no contamination can be detected by
appropriate instrumentation, test solutions, or by
visual inspection on easily accessible surfaces or in
concealed housings, etc. and are considered safe for
the intended use. Items decontaminated to this degree
cannot be furnished to qualified, DOE, DoD, or industry
users or be subjected directly to open flame (cutting,
welding, high-temperature heading devices), or
operations that generate extreme heat, such as drilling
and machining, unless the following two conditions are
met:
(a) It is determined that decontamination to the XXXXX
level will destroy the usefulness of the item;
and,
(b) Decontamination to a degree less than XXXXX in
combination with administrative and technical
safeguards will eliminate risk of injury. As a
minimum, an approved SOP (setting forth the
specific operational limitations, precautions to
be observed, and monitoring necessary to ensure
safety) will be available and decontamination will
be performed under the direction of the
inspector(s) who will certify decontamination.
(3) XXXXX Five Xs indicate the equipment or facilities
have been completely decontaminated, are free of
hazard, and may be released for general use or to the
general public.
(4) O A (Zero) indicates the item, although located in a
contaminated area, was never directly exposed to
contamination.
d. Reference U.S. Department of the Army TB700-4,
"Decontamination of Facilities and Equipment" for
decontamination methods and marking.
18.7 Decontamination of Real Estate
For decontamination of real estate reference DoD 6055.9-STD.
18.8 Decontamination and Cleaning References
In addition to this Manual, the following are reference sources
for decontamination and cleaning.
DoD 6055.9-STD, Department of Defense Ammunition and
Explosives Safety Standard, Assistant Secretary of Defense
(Force Management and Personnel), Chairman Department of
Defense Explosives Safety Board, 2461 Eisenhower Avenue,
Alexandria, VA 22331.
Department of the Army Technical Bulletin TB 700-4,
Decontamination of Facilities and Equipment, Army AG
Publications Center, St. Louis, MO.
Department of the Army Technical Manual TM9-1300-214,
Military Explosives, Army AG Publications Center, St. Louis,
MO.
19.0 WASTE COLLECTION
19.1 General
a. Provision shall be made for removal of explosives waste from
any area in which explosives waste is generated. Removal of
explosives waste may be accomplished by collecting
dust/fines in a wet or dry vacuum system, collecting
dust/fines or chips in a slurry of water or nonflammable
solvent, or by collecting solid waste in receptacles (see
also Chapter II, Sections 9, 10, and 11).
b. Explosives waste shall be collected and maintained
separately from conventional waste.
c. Mixing of incompatible explosives shall be avoided.
Receptacles shall be clearly labeled to indicate the type of
waste permissible.
19.2 Solid Wastes
a. Each explosives area in which solid explosives wastes are
generated (that are not removed by vacuum or liquid systems)
shall be equipped with a seamless or lined receptacle in
which explosives wastes can be collected. The receptacle
should never be more than half full.
b. Explosives waste shall be removed from the collection point
on a regular basis, frequently enough to keep the aggregate
explosives levels within the explosive weight limits.
c. Rubbish not contaminated by explosives or containing
noncombustible materials shall not be placed in an
explosives waste receptacle.
d. Rubbish contaminated by explosives shall be placed in
separate waste containers and also segregated as
combustibles and noncombustibles.
e. Before being transported, explosives waste shall be packaged
to prevent spillage, leakage, or exposure to initiation
stimuli. Incompatible materials shall not be packaged
together. All packages of explosives waste shall be clearly
labeled to indicate the nature and approximate quantity of
contents.
19.3 Vacuum Collection of Explosives Dusts
a. Explosives dusts should be collected by a vacuum system,
preferably the wet type. When using a wet vacuum system,
the dust should be maintained in a wet form using a wetting
agent that is kept close to the point of origin; the dust
should also be kept wet in the collection system until
removed for disposal. Water-soluble explosives such as
Explosive D should be collected dry.
b. Storage compatibility group A explosives may be collected by
a vacuum system, provided they are maintained in a wet form
using a wetting agent that is kept close to the point of
intake. Use of a vacuum system for collecting these more
sensitive materials should be confined to operations
involving small quantities of explosives.
c. Dry-type dust collection chambers, except portable units,
should be located in the open and outside operating
buildings; they may be inside if adequate shielding is
provided. The quantity of explosives collected shall not
exceed the capacity of the shielding to protect operating
personnel. This limit shall be determined by the degree of
barricading and the appropriate intraline distance.
d. If dry dust collection outside the building is not
practical, a separate room or shielded area within the
building shall be designated for this purpose. This room or
shielded area shall not contain other operations, nor shall
it be used as a communicating corridor or passageway between
other operating locations within the building when
explosives are being collected.
e. Stationary and portable wet-type collectors may be placed in
the explosives operating bays or cubicles if the quantity of
explosives in the collectors does not exceed 2 kg. If
placed in separate cubicles, the explosive weight limits may
be increased by an amount determined by the extent of the
cubicle walls' capabilities to serve as operational shields.
f. Collection systems and chambers shall be designed to prevent
explosives from being pinched between metal parts. See
Sections 9 and 10 of this chapter for additional design
information.
g. Two collection chambers shall be installed in series ahead
of the pump or exhauster to prevent explosives dust from
entering the vacuum producer in dry vacuum collection
systems. In addition, nonsparking fans and dust-tight
motors shall be used.
h. Dry-type portable vacuum collectors shall not be located in
a bay or cubicle where explosives are present or in enclosed
ramps, but may be positioned outside the building or in a
separate cubicle. The building or cubicle walls shall
provide adequate shielding for at least 2 kg of explosives
and the explosives limits shall be defined by shielding and
quantity-distance constraints.
i. Explosives dust shall be removed periodically from the
collection chamber to eliminate unnecessary and hazardous
explosives concentrations. The entire system should be
cleaned periodically, dismantling the parts if necessary. A
cleaning schedule for the collection chamber and the entire
system shall be established using the operating hours as a
basis.
j. The entire explosives-dust collecting system shall be
electrically bonded and grounded with resistance-to-ground
not exceeding 10 ohms. The grounds shall be tested
periodically.
19.4 Explosives Slurries
a. Machine tools shall be fitted with wet boxes to catch and
direct water and explosives fines to an explosives waste
gutter system.
b. Wastewater that might contain explosives materials shall be
kept from contaminating potable water or conventional
wastewater systems.
c. Settling tanks shall be regularly inspected to monitor the
accumulation of waste. Records shall be kept of waste
removals.
d. If pumping is involved in removing the settled explosives
from a slurry settling tank, the operation shall be arranged
to preclude exposure of the explosive material to any
pinching in the operation.
e. Explosives materials in the settling basins shall be kept
wet until removed and the materials shall be maintained wet
until spread out for disposal. Explosives materials
containing powdered metals shall be kept sufficiently wet to
prevent a dangerous temperature rise resulting from a
reaction of the metal with water. The possibility of
hydrogen generation in this situation must be anticipated.
19.5 Metal Scrap
a. Metal scrap shall be inspected to detect
explosives-contaminated items and shall be certified by
qualified responsible personnel to be free from explosives
before disposition.
b. If the scrap is found to be contaminated with explosives, it
shall be decontaminated in accordance with final
decontamination procedures (see Section 18.4 of this
chapter).
19.6 Explosives Recovery and Reuse
a. Salvaged explosives materials shall be thoroughly inspected
by operating supervisors and reused, screened, reprocessed,
or destroyed as the situation warrants.
b. Salvaged explosives materials shall be classified as storage
compatibility group L until they have been established to be
compatible with the original material. This page intentionally left blank. 20.0 WASTE DISPOSAL
20.1 Preparation for Open Burning
a. Preparations for burning explosives waste on a pad or in a
pit, or for placing explosives waste, shall not begin until
24 hours after the previous burn at the same burning point.
The only exception is if the burning area has been
thoroughly soaked with water and inspected by qualified
personnel to ensure the safety of personnel during
subsequent burning operations. In any case, the burning
point shall be inspected for residual embers or hot spots
before loading with explosives.
b. Before beginning preparations, firing controls shall be
disconnected from the power source and the circuit shunted
and grounded.
c. Incompatible explosives materials shall not be in the same
pit or on the same pad at the same time.
d. Containers of explosives materials shall not be opened less
than 3 m from each other.
e. Empty explosives waste containers that are to be reused
shall be situated an adequate distance from the burning
point to prevent charring or damage during the destruction
operation.
f. A layer of excelsior or similar material should be placed on
the bottom of the pit or pad for placement of the explosives
waste.
g. Explosives in powdered, granular, or slurry form should be
placed in a layer not more than 8 cm thick. Water-wet
initiating explosives (storage compatibility Group A) shall
not be allowed to become completely dry.
h. Wood and heating oil may be used as an aid to ensure
complete combustion of the explosives waste material.
i. The ignition train should be set up to burn upwind.
j. The firing circuit shall require a key for completion. Only
one copy of the firing key shall exist, and it shall be in
the lead operator's possession.
k. Radio transmitters in the control shelter and vehicles at
the burning site shall be turned off during setup and firing
to protect against radio frequency currents.
l. Precautions shall be taken to ensure that the firing system
will not be unintentionally activated by extraneous
electrical currents from any source.
m. Priming of the burn shall be accomplished after all other
preparation work is complete and with a minimum number of
personnel present.
n. Ignition shall be accomplished remotely.
20.2 Destruction by Burning or Flashing
a. Explosives waste may be destroyed by burning (remotely) if
it can be done with little chance of detonation.
Explosives-contaminated waste may be burned remotely in a
wire cage.
b. An open furnace or burning area for explosives should be
used for destruction of wet-machining cuttings and
classified parts. The furnace or burning area may also be
used for flashing casings after washout of an explosive
charge.
c. Explosives should not be burned in closed containers or
casings, nor in large pieces likely to detonate. Special
attention should be given to the placement and orientation
of large items and those in closed containers or casings.
Approved incinerators may be used to destroy small devices
such as detonators, actuators, etc.
d. Concurrent burning operations shall not be conducted within
45 m of each other.
e. When several pads are burned, the downwind pad shall be
ignited first, followed by the others in succession to the
upwind pad.
20.3 Ignition System Malfunctions
a. If the ignition system fails to fire, check the circuit's
continuity and refire if no open circuits are detected.
b. If the squibs did fire but failed to ignite the ignition
train, survey the area by remote means, and wait at least
30 minutes. If it then appears safe to emerge from the
control shelter, disconnect, shunt, and ground the firing
circuit and inspect the squibs, firing system, or ignition
train.
20.4 Postburn Operations
a. No entry shall be allowed into the pit area until at least
8 hours have elapsed following an open burn.
b. The squib firing lines shall be disconnected, shunted, and
grounded before the burn area is entered.
c. Unburned or partially burned explosives materials remaining
in the pit shall not be raked or otherwise disturbed. The
burning operation shall be repeated to destroy any remaining
explosives waste.
d. At least 24 hours shall elapse before ashes are collected
and the pit prepared for another burn.
20.5 Disposal Area
a. Explosives waste destruction operations shall be separated
from magazines, inhabited buildings, public traffic routes,
and occupied operating buildings to ensure that personnel
and facilities are not exposed to hazardous blast
overpressure, firebrands, fragments, or projectiles from
burning or detonation of explosives.
(1) Destruction by open burning or flashing shall not be
performed within 730 m, unless carried out in pits or
with other aids for limiting the range of fragments and
debris in event of an accidental detonation. The pit
shall not be located at less than 204 m for weights of
45 kg or less and 381 m for weights exceeding 45 kg.
Sites should be located in relation to the direction of
the prevailing winds so that sparks will not be blown
toward explosives locations.
(2) The size of the danger zone for destruction by open
detonation shall be determined by the formula
D(m) = 131Q1/3 [D(ft) = 328W1/3]. The minimum separation
distance shall be:
Non-fragmenting explosive materials 381 m
Fragmenting explosive materials 762 m
Bombs/projectiles with 5 in. caliber
or greater 1,220 m
If known, the maximum fragment (debris) throw distances
with an applicable safety factor may be used to replace
the 762 m and 1,220 m minimum separation distances but
not below 381 m.
(3) Self-contained destruction facilities fully analyzed
for the intended net explosives weight (NEW) are exempt
from the above requirements.
b. The maximum quantity of explosives that may be destroyed at
one time shall be determined by starting with a small
quantity, gradually increasing until an optimum amount,
consistent with safe and efficient operation, is achieved.
c. Explosives waste and ordinary rubbish shall not be destroyed
in the same destruction area at the same time.
d. When destruction operations are being carried out, the area
within 60 m of the destruction point shall be kept clear of
dry grass, leaves, and other extraneous combustible
material. This clearance may be reduced to firebrand
distance if aids for limiting the range of fragments and
debris are provided for all the destruction points used
within the disposal area.
e. Explosives waste awaiting destruction shall be stored at
least intraline distance from the explosives being
destroyed.
f. Provisions for emergency fire fighting shall be readily
available at the waste disposal area.
20.6 Destruction by Detonation
a. Cased explosives should be removed from the case and burned
or the cased item destroyed by detonation. Detonators,
primary explosives, and other explosives that might detonate
if burned should also be destroyed by detonation.
b. The detonation should be initiated by a high-energy
detonator (e.g., an EBW).
20.7 Use of Solvents
a. Small quantities of explosives and explosive detonators may
be prepared for destruction by solvent immersion.
b. The items to be destroyed shall be soaked in a suitable,
compatible solvent until all the explosives material is
dissolved. Saturated solvent solutions shall not be reused.
c. The solvent-explosives mixture shall be destroyed by
burning.
20.8 Burial
a. Burial is the least desirable method for disposing of
explosives-contaminated equipment and should be used only if
other methods are impractical, unsafe, or impossible. Waste
material that is technically contaminated with explosives
and cannot be disposed of by burning or other means may be
buried if there is no conflict with prevailing environmental
regulations.
b. Visible explosives material shall be removed before burial.
c. Burial sites shall be appropriately marked and protected
from unauthorized personnel. The location of the burial
sites shall be noted on facility drawings.
d. Records shall be kept of the burial sites that identify the
types and quantities of materials buried.
This page intentionally left blank. 21.0 LABORATORY OPERATIONS
21.1 General
a. The safety guidelines presented in this section are
applicable to general laboratory operations involving
explosive materials. Laboratory operations shall be
conducted in a manner that maintains employee exposures to
hazardous chemicals at or below the permissible exposure
limits (PELs) and complies with the facility chemical
hygiene plan.
b. Laboratory work involving explosives materials shall be
performed only in accordance with the provisions of written
operating procedures (see Chapter VII). Laboratory
operations shall comply with the requirements of NFPA 45,
"Fire Protection for Laboratories Using Chemicals,"
including the requirements for electrical equipment and
wiring.
c. The quantity of explosives present in the laboratory shall
be the minimum required for the experiment and in all cases
shall be at or below assigned limits. Explosives not being
worked on shall be stored in closed containers.
d. No explosives other than those in process shall be left in
the laboratory during nonworking hours. They must be
secured in an approved storage container or in a service
magazine (see paragraph 17.6.1e of this chapter).
e. Smoking and open flames shall be prohibited in laboratories
where explosives or flammable solvent vapors are or may be
present.
f. Disposal of explosives through laboratory drains shall be
forbidden unless the drain plumbing has no traps and is
designed to handle explosives (i.e., is provided with a sump
or other device for the collection of solids). Even if a
drain is designed to handle explosives, deliberate disposal
of explosives in these drains should be avoided. These
drains should be used only for the purpose of cleaning up
explosives spills. Special care should be exercised to
prevent entrance of compounds into drains that may react
with iron or rust to form sensitive salts (e.g., picrates
and picric acid).
g. Solvents or other substances that are flammable shall be
protected against electrical sparks, heat, and open flames.
h. Suitable guards shall be provided for all glass or fragile
equipment that must withstand reduced or elevated pressure. 21.2 Safety Shields
a. If a laboratory operation involves an explosion hazard,
personnel should be protected by safety shields or the
operation should be performed by remote control. Table II-6
lists shields that have been tested and found acceptable for
the indicated quantities of explosive. Shields listed in
this table were not tested for metal-fragment penetration
(unless specifically indicated) and thus may not offer
effective protection when the explosive is closely confined
in a heavy-walled metal container. ("Heavy-walled" is
defined here as wall thickness to diameter ratio greater
than 0.01.)
b. If an experiment presents a metal-fragment hazard (as
opposed to a glass-fragment hazard), and the experiment
cannot be conducted remotely, the proposed shield should be
tested and approved under conditions simulating an explosion
in the experimental setup but with at least 125% of the
anticipated explosive content.
c. The shield shall be anchored to the hood frame or bench top
when it is being used for protection against more than 5 g
of TNT equivalent.
d. Other shields may be used after successfully passing a test
of 125% of the rated explosive charge and being approved.
e. For confined areas, a blast vent having less strength than
the shield should be provided.
f. When explosives operations require personnel to reach around
a shield to manipulate equipment, exposure shall be
minimized.
21.3 Heating Operations
a. During synthesis, formulation, or experimental work, heat
may be applied to initiate or maintain reaction, to increase
solubility, etc., if the principles below are followed.
(1) Heat shall be applied indirectly using steam, a water
bath, oil bath, or an approved laboratory electrical
heating device such as a mantle.
(2) Utmost caution shall be exercised to ensure that
reactive material does not come in direct contact with
the heating elements.
(3) If an experiment must be conducted behind a shield, any
heating device shall be mounted so that temperature can
be controlled from the operator side of the shield.
The heating device should be mounted so it can be
quickly separated from the reaction vessel without
operator exposure. Consideration should be given
during design of the experiment to providing emergency
cooling for the reaction vessel or its contents.
(4) Heating of explosives with devices without proper
controls shall be monitored at all times, and if the
operator must leave for any reason, the heating device
should be turned off. Heating systems that will be
operated unattended shall have dual controls, an
override shutoff, or some other protection against
failure of the primary heating control. Systems
capable of total containment of the effects of an
explosion may be exempted from this requirement.
b. Periodic checks should be made to ensure that an experiment
is proceeding satisfactorily and that the apparatus is not
boiling dry, malfunctioning, or the like. In the case of
remotely controlled operations, provisions shall be made for
such observation, using such equipment as mirrors,
television monitors, etc.
21.4 Laboratory Setups
Good workmanship and laboratory practice shall be exercised in
making and operating laboratory setups. In particular,
cognizance must be taken of the following points.
a. Equipment and apparatus shall be clean, in good condition,
and in good working order.
b. All glassware and apparatus shall be inspected for cracks,
defects, etc., before use. Defective or damaged equipment
shall be removed from service.
c. Setups shall be geometrically and structurally stable.
d. Work areas should be as neat and uncluttered as
circumstances will permit.
21.5 Low Concentration of Explosives in Solution
a. After explosives are in dilute solution (less than 33%
explosives by weight), the primary hazard shall be
considered as that associated with the solvent and not with
the explosive.
b. Until the explosive is in solution, or if for any reason the
explosive recrystallizes or precipitates out of solution,
the safety guidelines for pure explosives shall apply.
21.6 Explosives Sample Control
a. Samples shall be delivered to the laboratory only at
specific designated locations.
b. Each sample shall be properly identified and labeled.
c. Upon completion of the required tests or analyses, the
sample should be removed from the laboratory.
d. All samples of new experimental explosive material submitted
to a laboratory for analysis should be accompanied by an
information sheet giving available safety information.
22.0 EMERGENCY CONTROL
22.1 Placarding and Fire Symbols
Buildings and areas shall be placarded to warn of potential
hazards from explosives and to provide information crucial to
dealing with emergency situations. This includes the use of
appropriate fire symbols as specified in DoD 6055.9-STD or the
NFPA 704 Standard, provided placarding is applied consistently
throughout the entire facility.
22.2 Explosives Emergency Control Plans
a. Each installation shall have a written plan, prepared
specifically for that installation (it may be necessary to
break it down for each operating area), for the control of
emergencies involving explosives. The explosives emergency
control plan may be part of the overall emergency control
plan for the facility. All facility personnel shall be
trained in the content of the plan applicable to their area.
The plan shall be available to all personnel for ready
reference.
b. Emergency situations that should be covered, as applicable
to the facility, are as follows:
(1) fires and explosions;
(2) floods;
(3) extreme weather conditions;
(4) conditions resulting in environmental disturbances;
(5) civil disturbance;
(6) threats and bomb scares;
(7) enemy attack; and
(8) any other emergencies that require rapid mobilization
of personnel and equipment to minimize death and injury
to personnel or to prevent the spread of damage and
destruction.
c. Subjects that should be addressed by the plan include:
(1) reporting an emergency;
(2) decision to activate the emergency plan;
(3) authority and responsibility for administering and
executing the plan;
(4) mobilizing personnel to combat the emergency or
disaster;
(5) roles of operating personnel in combatting the
emergency;
(6) procedures for combatting the emergency or disaster;
(7) accounting for and evacuation of personnel; and
(8) plant and document security. CHAPTER III
EXPLOSIVES AND PERSONNEL LIMITS AND CONTROL
1.0 EXPLOSIVES LIMITS
The quantity of explosives at an operating location shall be the
minimum necessary to carry out the operation in a safe and
efficient manner. When practical, this quantity shall be
subdivided and adequately separated to prevent propagation of
detonation. Supplies exceeding this minimum quantity shall be
removed from the operating area.
In no case shall the quantity of explosives permitted in an
operating building exceed the maximum permitted by the quantity-
distance criteria. Quantity-distance criteria and guidelines for
application of these criteria are presented in Chapter VI of this
Manual.
2.0 PERSONNEL LIMITS
The number of personnel at an operating location shall be the
minimum consistent with safe and efficient operation. In
establishing personnel limits, the following principles shall be
followed.
a. Jobs not necessary to the performance of a hazardous
explosives operation should not be performed in the same
location as the hazardous operation. Personnel not needed
for the hazardous operations will not be allowed in
hazardous locations.
b. Personnel limits shall allow for necessary casuals.
c. Sufficient personnel shall be available to perform a
hazardous operation safely and, in the event of accident, to
obtain help and aid the injured.
d. No person shall work alone performing explosives activities
that have a high risk of serious injury. Prompt and easy
communications with other employees shall be provided.
Facility management shall specify which explosives
activities may be performed alone.
3.0 LIMIT CONTROL
3.1 Posting and Recording
All rooms, bays, and buildings containing explosives shall have
posted in a conspicuous place a standardized placard stating the
maximum amount of explosives and the maximum number of workers
and casuals permitted in the control unit at any one time.
Maximum explosives and personnel limits for all buildings and
bays for each explosives area shall be recorded and maintained on
file.
3.2 Limit Review and Approvals
Management personnel with authority and jurisdiction over an
operating bay or building shall periodically review explosives
and personnel limits for each location and recommend changes as
required. If the use of a location changes, personnel and
explosives weight limits shall be reviewed at the time of use
change and limits reestablished as required.
Changes in explosives and personnel limits shall be reviewed and
approved in the same manner as operating procedures (see
Chapter VII).
A procedure shall be established for the approval of temporary
changes in explosives and personnel limits for an operating
location.
3.3 Personnel Controls
A system shall be established to control the presence of
personnel within explosive operating areas.
4.0 IHE LIMITS
When no other explosives are present, IHE weight limitations
shall be based on separation distances for Hazard Class 1.3
explosives (see Chapter VI, Section 3.1) or equivalent protection
provided by facility design features. The quantity of IHE at an
operating location shall be the minimum necessary to carry out
the operation in a safe and efficient manner. This quantity
should not exceed an 8-hour supply.
IHE limits for pressing should be the same as those established
for other explosives pressing operations.
CHAPTER IV
PERSONAL PROTECTIVE CLOTHING AND EQUIPMENT
1.0 CLOTHING AND PERSONAL EQUIPMENT
1.1 Clothing
Each operation shall be analyzed to determine when personnel
working with explosives and toxic materials must wear approved
coveralls or laboratory coats to prevent contact with the
materials and to prevent contaminating personal apparel. Flame-
retardant coveralls may be desired for certain explosives
operations when the possibility of a flash fire exists. These
coveralls shall not have cuffs and should not have metallic
fasteners. Written procedures shall include protective clothing
and equipment requirements.
Cotton (or other antistatic material) outer and undergarments,
including socks, should be worn where generation of static
electricity would create a hazard.
1.2 Footwear
Personnel working in a building or area where electrostatic-
sensitive explosive powders or materials are handled shall wear
conductive, nonsparking footwear. Exception: personnel working
on electrical or electronic equipment shall not wear conductive
footwear unless protected by insulated mats, ground fault circuit
interrupters (GFCI), etc. Personnel working in other areas where
explosives contamination may be present shall wear nonsparking
footwear or bootie shoe coverings.
1.3 Respirators
Appropriate, approved respiratory protection shall be used when
exhaust ventilation is not available, or does not adequately
control airborne particulates, gases, or vapors liberated during
explosives operations. The employee must have current approval
to wear respiratory protection (medical exam, respirator fitting,
and training).
1.4 Eye Protection
Suitable eye protection devices must be worn by all personnel
when working or visiting in eye hazard areas, particularly when
electroexplosive devices (EEDs) are handled. The type of
explosives operation shall be evaluated for eye hazard risks.
Contact lenses shall not be considered as an appropriate eye
protection.
1.5 Gloves
Skin contact with some explosives, and with some materials used
in conjunction with explosives, can result in dermatitis or
absorption across the skin barrier. Each type of operation that
uses these materials must be evaluated for potential skin contact
hazard and the need for the proper type of glove.
2.0 MAINTENANCE AND TESTING
2.1 Equipment Maintenance and Inspection
Personal protective equipment shall be properly maintained; the
operator's life may depend on the proper functioning of the
equipment. An appropriate inspection schedule shall be
established.
2.2 Conductivity Testing
When conductive footwear is required, the conductivity shall be
tested initially and regularly thereafter to ensure continued
conductivity from person to ground.
2.3 Cleaning and Disinfecting
Provision shall be made for the laundering and disinfecting of
protective garments and devices. Attention to cleaning and
disinfecting is especially important for equipment worn about the
face. Because laundering affects the flame-retardant properties
of fabric, flame-retardant coveralls should be tested to
establish the maximum number of laundering cycles permitted.
2.4 Contaminated Clothing
If clothing becomes contaminated, as much contaminant as possible
should be removed by wiping or dusting; compressed air shall not
be used for this purpose. If obvious contamination remains,
clothing shall be changed.
CHAPTER V
TRAINING
1.0 GENERAL
Personnel shall be properly trained before they are assigned to
any explosives operation or operate any explosives-carrying
vehicle. The training for explosives work, which serves to
assist in conducting work safely and developing safety awareness,
shall ensure that personnel:
develop and maintain a safe attitude towards work with
explosives;
define and understand the potential hazards involved;
learn correct skills for safe performance of the task;
are prepared for unexpected hazardous conditions; and
read and understand the appropriate operating procedures.
2.0 SUPERVISORY RESPONSIBILITY
The supervisor shall be responsible for the following:
determining the training required for the worker (or
researcher);
verifying that the worker is adequately trained to perform
the task safely and efficiently;
ensuring that the worker can perform required emergency
duties;
providing on-the-job training for the worker; and
continually updating worker training.
3.0 TRAINING AND QUALIFICATION PROGRAMS
Each organization shall have a training and qualification
program. The following is an example.
a. After successfully completing training for an assignment,
the worker should be qualified for that task for a specific
period of time. Maintenance of qualification should be
governed by the following items:
(1) At the end of the initial qualification period,
qualification may be extended for subsequent specific
time periods if:
the worker has successfully performed the task
during the preceding 6 months and has read and
understands the current operating procedures; or
the worker receives refresher training and is
again determined to be qualified by his/her
supervisor.
(2) Retraining in the specific area of weakness should be
required of workers who do not demonstrate job
proficiency or who subsequently violate safe practices.
(3) If an operating procedure is modified substantially,
all personnel using that procedure should be retrained
in the use of the new procedure.
(4) A person should not be permitted to continue working
with explosives if the supervisor, with counsel from
medical personnel, determines that the person is unable
to perform the task safely. Possible reasons include:
physical injury or illness;
disease; and
mental or emotional disturbances.
(5) Records should be maintained for each worker,
including:
description and dates of training received;
description and dates of refresher training;
a signed "statement of understanding" for
operating procedures;
attendance at safety meetings and participation on
safety committees; and
qualification review by supervisor.
(6) The supervisor may temporarily authorize an employee
who has not completed the required training to perform
the task if the following conditions are satisfied.
The supervisor determines that the employee has a
working knowledge adequate to perform the task
safely.
The work is directly supervised by a qualified
person.
b. Employee hazardous materials information and training
programs are required for personnel working with explosives
and hazardous materials used in conjunction with explosives
operation. Training should include:
information on the physical and health hazards;
the purpose and proper use of engineering controls,
work practice controls, and protective equipment;
labeling systems and Material Safety Data Sheet terms;
and
detection methods for the presence or release of a
hazardous material in the work area. CHAPTER VI
QUANTITY-DISTANCE AND LEVEL-OF-PROTECTION CRITERIA
FOR EXPLOSIVES ACTIVITIES
1.0 GENERAL
This chapter establishes quantity-distance and level-of-
protection criteria for all DOE operations involving explosives.
The purpose of these criteria is to provide specific levels of
protection from the effects of potential fires and explosions for
personnel and property within and outside of DOE installations.
The cardinal principle to be observed at any location or in any
operation involving explosives, ammunition, severe fire hazards,
or toxic materials is to limit, in a manner consistent with safe
and efficient operation, the exposure to a minimum number of
personnel, for a minimum time, and to a minimum amount of the
hazardous material.
2.0 APPLICABILITY OF CRITERIA
2.1 Specific Applications
The criteria presented in this chapter shall be applied to the
following activities:
a. establishing maximum explosives limits for explosives
facilities and operations;
b. planning explosives activities to be performed in existing
facilities; and
c. designing and siting new explosives facilities and
operations andsiting other facilities and operations in the
explosives area.
2.2 Explosives Limits
When defining working explosives limits, those limits shall never
exceed the minimum required for efficient, safe operation (see
Chapter III).
2.3 Areas Where Criteria Are Not Applicable
The quantity-distance and level-of-protection criteria in
Section 4 of this chapter are not applicable to portable
buildings used at specified nuclear test shot locations. 3.0 QUANTITY-DISTANCE CRITERIA
Quantity-distance criteria must account for the types and
severity of hazards presented by each explosive material, the
construction and orientation of facilities to which the criteria
are applied, and the degree of protection desired for facilities
and personnel adjacent to the explosives operations. The hazard
classification system recommended by the United Nations
Organization (UNO) defines types and severities of hazards for
explosives. The guidelines presented below specify minimum
degrees of protection for various categories of facilities.
These guidelines also describe how the quantity-distance tables
are to be applied to facilities of various construction and
orientation with respect to adjacent facilities.
3.1 Hazard Classes and Class Division
Explosives shall be classified on the basis of their reactions to
specific initiating influences. The hazard classification system
recommended by the UNO shall be used for DOE explosives
classification. The UNO system consists of nine classes for
dangerous goods, with explosives included in Class 1. The
explosives hazard class is further subdivided into "divisions"
that are based on the character and predominance of the
associated hazards and on the potential for causing personnel
casualties or property damage. Table VI-1 lists the six
divisions of Class 1.
Table VI-1. Divisions of Class 1.
Hazard Class and
division designators
Hazards
1.1
1.2
1.3
1.4
1.5
1.6
Mass explosion
Non mass explosion, fragment producing
Mass fire, minor blast, or fragment
Moderate fire, no blast or fragment
Explosive substance, very insensitive
(with a
mass explosion hazard)
Explosive article, extremely
insensitive
When required to properly describe the hazard, a numerical figure
in parenthesis shall be placed to the left of the division
designators 1.1 through 1.3 [e.g., (18) 1.1, (08) 1.2, and
(06) 1.3]. This number indicates the minimum separation distance
(in hundreds of feet) for specified levels of protection from
explosive items for inhabited buildings, public traffic routes,
and personnel in the open. A minimum distance number shall be
used for all items in Class 1, Division 2, as shown in the
applicable tables. Figure VI-1 illustrates the use of the UNO
hazards classification system. Also, this figure lists the
storage compatibility group opposite each hazard class. The
listed compatibility group is typical for the expected
compatibility to hazard class relationships. Note, however, that
the two classification systems apply to different concerns.
Compatibility groupings define which explosives may be
safely stored together without increasing the risk of
initiation.
Hazard classifications indicate the initiation effects of
the various explosives.
Classification tests (described by TB 700-2, Explosives Hazard
Classification Procedures) and/or additional tests (as desired),
including United Nations ST/SG/AC.10/1 and ST/SG/AC/10/11, shall
be used in the assignment of energetic materials to the
appropriate compatibility group and hazard division. These tests
may be supplemented by other tests to characterize material
hazards more fully if material properties or anticipated material
environment are expected to significantly influence the
explosives classification.
Though DOT hazard classifications require the use of the Bureau
of Explosives' (BOE) Impact Apparatus to determine impact
sensitivity, other impact apparatus may be used, providing:
a. test results for at least two reference explosives are
compared to results for the reference explosives on the BOE
Impact Apparatus; and
b. a minimum of ten trials each is run for the reference
explosives and the explosives being classified.
3.2 Establishing Quantity of Explosives and Distances
3.2.1 General
The principles and tables presented in DoD 6055.9-STD, DoD
Ammunition and Explosives Safety Standards, shall be used to
determine the following.
a. The total quantities of explosives in adjacent magazines,
operating buildings, or other explosives facilities that
must be applied to quantity-distance tables.
b. When the levels of protection required by Section 4 of this
chapter for different types of facilities differ from the
requirements of DoD 6055.9-STD, Section 4 shall take
precedence.
c. The minimum separation distances required for facilities are
based on the desired level of protection and total
quantities of explosives.
d. The total quantity of explosives is determined by defining
and examining the maximum credible event (MCE). If an
explosives event occurs, the maximum credible explosives
event is the largest credible amount of explosives that
could be involved in the event (not necessarily the total
quantity of explosives present).
3.2.2 Use of Metric System
Throughout DoD 6055.9-STD, the net explosive weight (NEW) is used
to calculate distance by means of a formula of the type D = KW1/3,
when D is the distance in feet, K is a factor depending on the
risk assumed or permitted, and W is the NEW in pounds. When
metric units are used, the symbol Q denotes net explosive
quantity (NEQ) expressed in kilograms. In the formula D = KQ1/3,
the distance D is expressed in meters. Thus, the respective
units of K are ft/lb1/3 and m/kg1/3 in the two systems. The value
of K in English units is approximately 2.5 times its value in
metric units [e.g., if D(m) = 6Q1/3, then D(ft) = 15W1/3].
3.2.3 Railcars and Transport Vehicles
Explosives-loaded railcars, motor vehicles, or any other
transport vehicles in holding yards are considered as aboveground
magazines for quantity-distance purposes. These railcars, motor
vehicles, or other transport vehicles shall be kept in groups,
and each group shall be limited to a maximum of 250,000 lb of
high explosives.
a. When a railcar receiving yard or point is provided for the
interchange of cars containing explosives between the common
carrier and the facility rail system, quantity-distance
provisions do not apply, provided that the cars are moved
expeditiously to a suitable location.
b. When inspection of a railcar of explosives indicates that it
may be in a hazardous condition, the railcar should be moved
at once to a suspect car spur track or an isolated section
of track. This spur or section of track should be
accessible directly from the inspection point. The distance
between the spur or track and facility boundaries,
classification yards, inhabited buildings, administration
areas, operating buildings, magazines, inert storage
locations, and public traffic routes should be the
inhabited-building distance, which is based on the maximum
quantity of explosives that the facility can receive in one
railcar. Only one car is permitted at this location at any
time.
c. Incoming explosives-laden motor vehicles shall be inspected
at a station located remotely from hazardous and populated
areas.
3.2.4 Utilities Installations
a. Permanent DOE-controlled underground utilities installations
(excluding building service lines) should be separated from
explosives locations containing Class 1.1 materials (see
Table VI-1.). Privately owned or operated utilities
installations (aboveground and underground) shall be
separated from explosives locations by at least public-
traffic-route distances. If these installations include
structures, they should be separated from explosives
facilities by inhabited-building distance.
b. Certain types of auxiliary power facilities, transformer
stations, etc., present fire hazards to explosives
facilities. Transformers and associated electrical
switching apparatus serving one explosives facility or
complex that do not present a fire hazard to the facility
(i.e., dry-type, "less flammable" oil-insulated, etc.) shall
be located as specified by NFPA 70 and FM Data
Sheet 5-4/14-18. Normal oil-insulated transformers shall be
located at least 50 ft from an explosives facility or as
specified in DoD 6055.9-STD.
3.2.5 Petroleum Storage Tanks
Aboveground tanks containing 500 gal or less of petroleum that
serve equipment (such as oil heaters or diesel generators)
located in or near explosives buildings shall be located a
minimum of 50 ft from explosives locations and comply with
NFPA 30. Tanks located near intentional detonation areas should
be barricaded. Similar underground tanks complying with NFPA 30
do not require separation from explosives facilities. In both
cases, the tanks shall be equipped with an antisiphoning device,
unless the tank is installed such that siphoning is impossible.
4.0 LEVEL-OF-PROTECTION CRITERIA
4.1 Hazard Classes
The level of protection required for any specific explosives
activity shall be based on the hazard class (accident potential)
for the explosives activity involved. These four hazard classes
are defined for explosives activities as follows.
a. Class I. Class I consists of those explosives activities
that involve a high accident potential; any personnel
exposure is unacceptable for Class I activities, and they
thus require remote operations. In general, Class I would
include activities where energies that may interface with
the explosives are approaching the upper safety limits, or
the loss of control of the interfacing energy is likely to
exceed the safety limits for the explosives involved. This
category includes those research and development activities
where the safety implications have not been fully
characterized. Examples of Class I activities are
screening, blending, pressing, extrusion, drilling of holes,
dry machining, machining explosives and metal in
combination, new explosives development and processes, and
explosives disposal.
b. Class II. Class II consists of those explosives activities
that involve a moderate accident potential because of the
explosives type, the condition of the explosives, or the
nature of the operations involved. This category consists
of activities where the accident potential is greater than
for Class III, but the exposure of personnel performing
contact operations is acceptable. Class II includes
activities where the energies that do or may interface with
the explosives are normally well within the safety
boundaries for the explosives involved, but where the loss
of control of these energies might approach the safety
limits of the explosives. Examples of Class II activities
are weighing, some wet machining, assembly and disassembly,
and environmental testing.
c. Class III. Class III consists of those explosives
activities that represent a low accident potential.
Class III includes explosives activities during storage and
operations incidental to storage or removal from storage.
d. Class IV. Class IV consists of those explosives activities
with IHE or IHE subassemblies. Although mass detonating,
this explosive type is so insensitive that a negligible
probability exists for accidental initiation or transition
from burning to detonation. IHE explosions will be limited
to pressure ruptures of containers heated in a fire.
Although the fire hazards of IHE or IHE subassemblies are
not as great as those of other explosives, they are
classified as Hazard Class/Division 1.3 (mass fire) to be
consistent with DoD 6055.9 STD. Most processing and storage
activities with IHE and IHE subassemblies are Class IV.
However, the following examples of explosives activities
with IHE and IHE subassemblies will remain Class I:
pressing;
some machining (see Chapter II, paragraph 12.4.2c);
dry blending;
dry milling; and
dry screening.
4.2 Required Level of Protection
Each bay (i.e., storage, handling, or processing building)
housing an explosives activity shall have levels of protection
that are based on the hazard class determined for the activity.
The levels of protection may be accomplished by equipment design,
structural design, operation separation, or provision of
operational shields. The levels of protection required for each
hazard class are as follows and shall be required for all new
facilities or redesign of any existing facilities where changes
in activities will result in a change to a more hazardous class.
4.2.1 Explosives Bay
a. Class IV. Bays for Class IV (negligible probability of
accidental initiation) activities shall provide protection
from fire hazards effects. This protection may be achieved
by Hazard Class/Division 1.3 aboveground-magazine distance
separation or by a design that contains the effects of an
accident. Because accidental detonation is not considered
credible, Class IV bays shall be sited and designed as
acceptors rather than donors for the effects of blast
overpressure, structural collapse, and missiles (hazardous
fragments).
b. Class III. Bays for Class III (low accident potential)
activities shall provide protection from explosion
propagation from bay to bay within buildings and between
buildings that are located at intraline or magazine
distance. If intermediate storage of explosives is within
an operating building containing Class II or Class I
operations, the intermediate storage or staging bay will
require Class II level of protection. Minimum separation
distances may be reduced when explosives bays are designed
to adequately contain the effects of an accident (blast
pressures and missiles).
c. Class II. Bays for Class II (moderate accident potential)
activities shall, in addition to complying with the
requirements for Class III bays, include design to prevent
fatalities and severe injury to personnel in all occupied
areas other than the bay of occurrence. (For the purpose of
this Class II Category, access ramps and plant roads are not
considered occupied areas.) Prevention of fatalities and
severe injuries is satisfied where personnel in occupied
areas other than the bay of occurrence will not be exposed
to the following.
Overpressures greater than 100 kPa (15 psi) maximal
effective pressure.
Structural collapse resulting from overpressure or
debris impact structural collapse is the failure of a
structural component as a direct result of loss of
structural integrity of the facility being subjected to
various loadings (judged in accordance with the ability
of the structure to remain intact so that explosion
propagation, fatalities, or severe injuries will not
occur).
Missiles (hazardous fragments) generated in acceptor-
occupied areas hazardous fragments that can cause
fatalities and severe injuries are defined as those
having greater than 58 ft-lb impact energy. These
values are taken from Chapter 3, Section III of
TM5-1300. The threshold pressure for eardrum rupture
is 34 kPa; one-half of the threshold pressure for lung
damage is 100 kPa.
d. Class I. Bays for Class I (high accident potential)
activities shall, in addition to complying with the
requirements for Class II bays, provide protection to
prevent serious injuries to all personnel, including
personnel performing the activity, personnel in other
occupied areas, and all transient personnel. This
protection may be achieved by controlling blast and debris
through suppression, containment, or establishment of an
exclusion area with positive access control. Prevention of
serious injuries is satisfied where personnel will not be
exposed to:
overpressures greater than 34 kPa (5 psi) maximal
effective pressure, and should not exceed 16 kPa
(2.3 psi) peak positive incident pressure;
structural collapse of the building from overpressure
or debris impact structural collapse is the failure of
a structural component as a direct result of loss of
structural integrity of the facility being subjected to
various loadings (judged in accordance with the ability
of the structure to remain intact so that explosion
propagation and serious injury to personnel will not
occur);
missiles (hazardous fragments) hazardous fragments that
can cause serious injuries are defined as those having
greater than 11 ft-lb impact energy; and
thermal fluxes greater than 0.3 cal/cm2/sec.
4.2.2 Bays for Joint Explosives-Plutonium Activities
Bays for joint explosives-plutonium activities shall comply with
the requirements of paragraph 4.2.1 of this chapter for the class
of explosives activity involved and DOE DNA TP 20-7. In
addition, because of the potential for plutonium contamination,
they shall comply with the following.
a. Bays for Uncased Explosives Plutonium Activities. Where it
is necessary to store, handle, or process uncased explosives
components in the same bay with plutonium, the enclosing
structure and its associated ventilation, electrical, fire
protection, and utility system shall be designed to ensure
that, in the event all the explosives present should
detonate, radiation exposures shall comply with DOE O 420.1
from the standpoint of hypothesized accidental releases.
The quantity of plutonium allowed in such a bay will be
governed by the safety analysis report. Activities may be
performed in Class IV bays if only IHE, IHE subassemblies,
or IHE weapons are present; however, the quantity of
plutonium allowed will be governed by criticality
considerations.
b. Bays for Cased Explosives Plutonium Activities. Where it is
necessary to handle or process cased high-explosive
components that contain plutonium, the enclosing structure
shall be designed as a Class II explosives bay. Storage
shall conform to Class III requirements. The limit of
plutonium shall be 25 kg per bay. The plutonium limits for
magazines are specified in DOE-DNA TP 20-7. Activities may
be performed in Class IV bays if only IHE, IHE
subassemblies, or IHE weapons are present; however, the
quantity of plutonium allowed will be governed by
criticality considerations.
5.0 FIRE PROTECTION
5.1 Vegetation Control
Vegetation around storage magazines and explosives-operating
facilities should be controlled to minimize potential damage to
the magazine or facility from grass, brush, or forest fires, or
from erosion. A firebreak at least 15 m wide and free from
combustible material should be maintained around each aboveground
magazine or facility processing or containing explosives. If the
aboveground magazine or explosive facility exterior is fire
resistant, the firebreak need not be devoid of vegetation, but
the growth must be controlled by mowing to prevent rapid
transmission of fire to the magazine or facility. The
maintenance of firebreaks around earth-covered magazines and the
cutting of grass covering these structures are not normally
required, except around ventilators to prevent transmission of a
fire into a structure.
5.2 Fire Protection Criteria
These fire protection criteria shall be required for all new
facilities or for redesign of any existing facilities where
changes in activities will result in a change to a more hazardous
class.
a. Automatic fire suppression systems shall be installed in all
buildings containing high explosives and plutonium, with the
exception of storage magazines.
b. For buildings containing explosives, but no plutonium, the
need for fire suppression systems shall be determined by the
facility management, on the basis of maximum fire loss
criteria and program mission interruptions and delays as
outlined in DOE O 420.1, FACILITY SAFETY; DOE O 430.1, LIFE-
CYCLE ASSET MANAGEMENT; and DOE O 440.1, WORKER PROTECTION
MANAGEMENT FOR DOE FEDERAL AND CONTRACTOR EMPLOYEES.
c. Where fire suppression is required, each explosives bay
shall have an individual feed with its controls protected
outside the bay and located so as to remain operable in the
event of a detonation in any bay.
d. Transmitted fire alarms shall distinguish between explosives
and nonexplosives areas through the use of annunciator
panels at safe locations; small non-high explosives areas
are exempt from having separately transmitted alarms.
6.0 EXPLOSIVES FACILITY SITING AND DESIGN CRITERIA REFERENCES
Explosives facilities shall comply fully with TM5-1300,
Structures to Resist the Effects of Accidental Explosions, and
DOE/TIC-11268, A MANUAL FOR THE PREDICTION OF BLAST AND FRAGMENT
LOADING OF STRUCTURES.
Blast-resistant design for personnel and facility protection
shall be based on the TNT equivalency of the maximum quantity of
explosives and propellants. In accordance with TM5-1300, the TNT
equivalency shall be increased by 20% for design purposes.
For an unproven facility design, either a validated model or
full-scale test is required to ensure structural adequacy unless
a high degree of confidence can be provided by calculations or
other means. The contract administrator (Head of Field
Organization) with competent engineering review shall concur in
any determination regarding test requirements.
The design of all new facilities, or those with major
modifications, shall conform to the DOE explosives safety
requirements. For a tabular summary of the types of protective
design established by these criteria, see Table VI-2. Protective
construction design features are specified in TM5-1300 and
DOE/TIC-11268.
Studies necessary to provide the technical basis for location,
engineering, design, and operation [under normal and potential
design basis accident (DBA) conditions] of the buildings shall
follow the stricter of this Manual and DoD 6055.9-STD, DoD
Ammunition and Explosives Safety Standards, for establishing
explosives quantity-distance separation.
DoD 6055.9 requires that the minimum distance for protection from
hazardous fragments to facility boundaries, critical facility,
and inhabited structures shall be 1,250 ft for explosives
quantities of 101 to 20,000 lb and 670 ft for 100 lb or less of
Hazard Class/Division 1.1 explosives, unless it can be shown that
there will be no hazardous fragments or debris at lesser
distances. The methods of calculation presented in the
Department of Defense Explosives Safety Board (DDESB) Technical
Paper No. 13 may be used to establish a smaller fragment
exclusion zone. It is not intended that these minimum fragment
distances be applied to operating facilities or dedicated support
functions within an operating line. For these exposures, the DOE
criteria presented in this Manual, for Class I, II, III, or IV
activities with appropriate quantity-distance separations are the
required protection levels.
In addition to this Manual, the following are resource documents
for the siting and design of explosives facilities:
DOE O 420.1, FACILITY SAFETY, 10-13-95, U.S. Department of
Energy, Washington, D.C. 20545.
DOE O 430.1, LIFE-CYCLE ASSET MANAGEMENT, 8-24-95, Office of
Project and Facilities Management, U.S. Department of
Energy, Washington, D.C. 20545.
10 CFR 830, Nuclear Safety Management.
TM5-1300, NAVFAC P-397, AFM 88-22, Structures to Resist the
Effects of Accidental Explosions, Departments of the Army,
the Navy, and the Air Force, Chairman, Department of Defense
Explosives Safety Board, 2461 Eisenhower Avenue,
Alexandria, VA 22331.
DOE/TlC-11268, A MANUAL FOR THE PREDICTION OF BLAST AND
FRAGMENT LOADING OF STRUCTURES, U.S. Department of Energy,
Albuquerque Operations, Amarillo Area Office, Facilities and
Maintenance Branch, P.O. Box 30030, Amarillo, TX 79120.
DoD 6055.9-STD, DoD Ammunition and Explosives Safety
Standards, Assistant Secretary of Defense (Manpower,
Installations, and Logistics), Chairman, Department of
Defense Explosives Safety Board, 2461 Eisenhower Avenue,
Alexandria, VA 22331.
DDESB, Technical Paper No. 13, "Prediction of Building
Debris for Quantity Distance Siting," April 1991, Chairman,
Department of Defense Explosives Safety Board,
2461 Eisenhower Avenue, Alexandria, VA 22331
AMC-R-385-100, AMC Safety Manual, Headquarters, United
States Army Materiel Command, 5001 Eisenhower Avenue,
Alexandria, VA 22333.
TR-828, Blast Environment from Fully and Partially Vented
Explosions in Cubicles, W. A. Keenan and J. E. Tancreto,
Civil Engineering Laboratory, Naval Construction Battalion
Center, Port Hueneme, CA 93043.
AD 411445, Industrial Engineering Study to Establish Safety
Design Criteria for Use in Engineering of Explosives
Facilities and Operations, Process Engineering Branch, APMED
Picatinny Arsenal, Dover, NJ; Defense Technical Information
Center, Defense Logistics Agency, Cameron Station,
Alexandria, VA 22314.
AFWL-TR-74-102, The Air Force Manual for Design and Analysis
of Hardened Structures, Air Force Weapons Laboratory, Air
Force Systems Command, Kirtland Air Force Base, NM 87117;
AD B004152, Defense Technical Information Center, Defense
Logistics Agency, Cameron Station, Alexandria, VA 22314.
HNDM-1110-01-2, Suppressive Shields, Structural Design and
Analysis Handbook, U.S. Army Corps of Engineers, Huntsville
Division, HNDED-CS, P.O. Box 1600, Huntsville, AL 35807. CHAPTER VII
OPERATING PROCEDURES
1.0 GENERAL
1.1 Requirements
This section establishes requirements for preparing and
controlling all procedures used for operations involving
explosives at DOE installations. These requirements for
procedures minimize the chances of an incident resulting from
operations using outdated, inapplicable, or incomplete
procedures, or from operations performed in violation of
established practices.
This section also specifies that procedures must be generated for
all explosives operations because the step-by-step reasoning
process that is used in developing the procedure will identify
many safety-related problem areas that might be overlooked
otherwise. In addition, the approval system for new or revised
procedures provides other viewpoints and knowledge that may not
be available to the originator and may need to be incorporated
into the procedure.
1.2 Types of Procedures
Two general types of operating procedures are described in this
chapter: (1) standard operating procedures (SOPs) and
(2) nonstandard procedures, which include experimental and
special procedures. SOPs are formalized documents prepared for
performance of a task on a routine basis. Experimental and
special procedures are documents prepared for performance of a
task on a limited basis. For the purpose of this Manual, special
procedures are those written to correct a problem encountered in
an explosives operation.
2.0 GUIDELINES
The following general guidelines should be used in creating
operating procedures.
2.1 Before Operation
a. Before starting any operation involving explosives a hazard
or risk analysis shall be undertaken to identify any
abnormal problems that will require special training,
equipment, or procedures to safeguard personnel conducting
the operation.
b. A thorough review shall be conducted to determine whether
the operation will require a safety analysis report
according to the current version of DOE O 5481.1B, SAFETY
ANALYSIS AND REVIEW SYSTEM, which will establish if the
operation is safe to field.
c. General operating procedures shall be written and approved
for each activity to ensure consistency and safety of
operations.
2.2 Supervisory Responsibility
Supervisory personnel shall be responsible for enforcement of the
provisions of all procedures that are used in their jurisdiction.
2.3 Preparation
a. Procedures shall be prepared by responsible personnel with
knowledge of the operations involved.
b. All material in the procedure and operational steps called
out shall be checked for compliance with the guidance in
this Manual and other DOE directives that may be applicable
per DOE O 440.1.
c. The specific types of equipment and building or area in
which the operation is to be conducted should be designated
in the procedure, when applicable.
d. If similar operations in the same area involve differences
in equipment or process, supplemental procedures or sections
shall be written.
2.4 Approval
a. All new or revised operating procedures shall be reviewed
and approved prior to use. Levels of approval required
should be based on the inherent risk in the operation and be
established by each operating contractor. Review and
approval requirements shall include, as a minimum, line and
safety organizations.
b. Work control processes shall be in place prior to any
operational activities.
2.5 Control
a. Distribution of procedures shall be controlled to ensure
that each operating area has the most current revision.
Superseded or inactive procedures shall be removed from
operating areas. No operation shall be performed with a
superseded, inactive, or unapproved procedure.
b. Files of active procedures should be maintained.
2.6 Audits
a. An audit system should be established that will evaluate
routinely the adequacy, availability, and currency of
procedures. Also, audits should include an evaluation of
operator knowledge and compliance with procedures.
b. Groups conducting the audits should include personnel from
other than the operating department or division using the
procedure.
2.7 Reviews
a. All active procedures should be reviewed a minimum of once a
year by the appropriate departments.
b. If the procedure is no longer completely applicable to the
operation or if new safety considerations
(i.e., compatibility, toxicity, ignition sources, etc.) have
been identified, the procedure shall be revised.
c. If a procedure is not expected to be used during the coming
year, it may be placed in an inactive procedure file.
d. Before an inactive procedure can be reactivated, it shall be
reviewed and approved. Minimum approval shall be the same
as that required for a new or revised procedure (see
Section 2.4).
2.8 Content of SOPs
The following presentation is intended to specify procedures
content, not format or organization. Each operating contractor
can develop its own system for preparing safety procedures.
2.8.1 General Operating Procedures
a. Introduction. The introduction to the procedure should
include the following:
a statement of the scope of the procedure, defining
what facilities and equipment are covered;
the name of the department and/or individual
responsible for the operation; and
if the procedure serves as the basis for an exemption
or waiver from the requirements of this Manual, a
statement to this effect and a specific reference to
the standard involved.
b. Safety and Health. The safety section of the procedure
should present the following information or reference a
safety manual that specifies the requirements.
General safety rules to be observed and techniques to
be applied that will ensure safety of operations,
prevent injury or illness to personnel, and prevent
damage to equipment. In particular, this section of
the SOP should describe the personnel control features
of the facility that protect personnel from exposure to
hazardous operations, toxic materials, or tests.
Personnel number and explosive weight limits.
Additional or specific emergency controls not addressed
by the facility emergency plan.
c. Operations. The operations section should consist of
general directions for operation of all major items of
explosives-handling equipment. Particular emphasis should
be placed on safety interlocks and controls, and the proper
use of these systems.
If operation of a particular item of equipment or of an area
requires that no other operation be performed simultaneously
in this same work area, this requirement shall be clearly
stated in the procedure.
2.8.2 Unit Operating Procedures
a. Introduction. The procedure introduction should include the
following:
a statement of the nature of the operation and its
objectives;
the name of the department responsible for the
operation and the procedure;
a description of the range of work authorized by the
procedure; and
if the procedure serves as the basis for an exemption
or waiver from the standards of this Manual, a
statement to this effect and a specific reference to
the standard involved.
b. Materials and Equipment. The materials and equipment
section should present the following information:
all significant tools, supplies, chemicals, and
equipment necessary to perform the operation should be
listed in the SOP or in a separate required document; specifications for approved chemicals, supplies,
tooling, and equipment should be referenced where
applicable; and
an explanation of any specific hazard involved in the
handling of chemicals or explosives for the operation,
or a reference to a document that describes the hazards
should be included.
c. Safety. The safety section should present the following
information or reference a safety manual that specifies the
requirements:
safety rules that are specific to the operation;
protective equipment that must be used during the
operation; and
emergency controls applicable to the operation that are
not considered in the general operating procedures.
d. Operations. The operations section should consist of
sequential directions written or pictured in clear, concise
steps that describe how to perform a particular operation.
If a particular operation requires that no other operation
be performed simultaneously in the same work area, this
requirement shall be clearly stated in the procedure.
2.9 Content of Special or Experimental Procedures
In addition to the applicable requirements listed in paragraph
2.8 of this chapter, the following shall also be addressed.
a. Field operations that, due to their remoteness, will have to
factor in procedures to ensure that both fire and medical
emergency services will be responsive within a reasonable
time or be staged at the event site.
b. Personnel involved with the operation shall be briefed or
trained on any unique aspects of the operation and emergency
procedures.
When a special or experimental operation will be conducted a
number of times, an SOP should be written and approved. CHAPTER VIII
FORMULATION SCALEUP
1.0 EXPLOSIVES DEVELOPMENT PROGRAM
1.1 Explosives Development Committee
A committee shall be established at each DOE facility engaged in
explosives development to be the approving authority for each
phase of an explosives development program. This committee will
be referred to in this Manual as the Explosives Development
Committee (EDC), but it may have a different name at each DOE
facility. Individuals chosen to serve on the EDC should have
considerable experience in explosives handling, processing,
chemistry, sensitivity, and safety.
1.2 Phase-by-Phase Approvals
The EDC shall review and approve data generated in each phase of
a development project that involves a new explosive or new
explosive formulation before the next phase begins.
1.3 Modified Formulations
Compositional modifications to previously evaluated explosive
formulations shall be approved by the EDC. However, the EDC may
approve minor modifications to the explosives formulation for a
given phase of development without requiring all of the
developmental steps and tests.
1.4 Sensitivity Data from Another Laboratory
If comparable sensitivity data for the subject material are
available from another laboratory, the EDC may waive some
developmental phase tests.
2.0 DEVELOPMENT PROCEDURES
2.1 General
All DOE explosives handling facilities shall establish an
administrative procedure that defines the basic steps for
developing and evaluating new explosives and explosive
formulations. The procedure shall require that each development
effort proceed in phases from small to large quantities. The
quantities of materials that may be handled in each phase shall
be limited. The EDC shall be responsible for establishing
criteria for acceptable explosive behavior in each test of each
phase of the explosives development Table VIII-1. Scaleup procedure guidelines for new explosives and
formulations.
Quantity of new
materiala
Recommended dataa
Data desired
Additional
recommendations
Synthesis
Specified by the
lab performing
the synthesis
Impact, friction,
spark, thermal
stability
Before using the new
ingredient in a
formulation
_____
Formulation
Compatibility
testing:
2 g
Thermal
compatibility of
new ingredient with
other ingredients
of formulation
Before proceeding to
Phase I
Materials should be
processed remotely
Phase I:
10 g
Impact, friction,
thermal stability
Before nonremote
processing and
handling in Phase I
or scaleup to
Phase II
Materials should be
processed remotely
before passing
sensitivity and
stability tests
Phase II:
500 gb
Compatibility,c
impact, friction,
spark, thermal
stability, thermal
characterization
before elevated
temperature
pressing
d
e
Phase III:
Specified by EDC
Compatibility,
high-speed
machining, drop
skid
Before Phase III
machining or handling
of billets 7 kg or
greater
Composition of
formulation shall be
fixed
a Quantities and recommended data apply to both new formulations and explosive ingredients.
b The EDC may allow more than 500 g in Phase II when larger quantities are needed for some
tests.
c Compatibility of explosives and formulations with materials contacting the explosives in
test and
production assemblies.
d Before proceeding to Phase III if:
(1) The formulation to be scaled up to Phase III differs from that tested in Phase I,
or
(2) The explosive or formulation prepared for Phase II development is produced by
techniques different from those used in Phase I.
Before proceeding to Phase II, if the composition of a formulation is modified so that the
composition is
no longer within the limits specified by the EDC.
e Materials investigated in this phase should be produced by techniques similar to those that
will be used
to produce larger batches in a subsequent phase. procedure. The development procedure should consist of three
phases plus a synthesis phase and compatibility testing, when
required. Guidelines for establishing this procedure are
proposed in the following paragraphs. Table VIII-1 summarizes
these guidelines.
2.2 Synthesis Phase
Before mixing a new explosive with other materials, the
sensitivity and stability of the explosive should be determined
and should comply with the criteria set by the EDC. Recommended
tests include the following:
a. drop-weight impact;
b. friction;
c. spark;
d. thermal stability (these tests should include two or more of
the following):
differential thermal analysis or differential scanning
calorimetry;
thermal gravimetric analysis;
gas evolution rate at elevated temperature (chemical
reactivity test, vacuum stability, etc.); and
time-to-explosion analysis.
2.3 Compatibility Testing
a. If a proposed formulation contains new ingredients
(explosive or nonexplosive), the new ingredients should be
tested for compatibility with the other ingredients before
preparing batches for Phase I testing. Compatibility tests
should include any of the stability tests listed under
paragraph 2.2d of this chapter.
b. No more than 2 g of the new formulation should by prepared,
handled, or stored before compatibility testing.
c. Formulations for compatibility testing should be processed
remotely, whenever possible.
2.4 Phase I Preliminary Explosives Testing
a. The total quantity of material that may be processed,
handled, or stored at any one time in Phase I should not
exceed 10 g. Whenever possible, this material should be
processed remotely.
b. The new explosive or formulation should be subjected to
sensitivity and stability tests. As a minimum, drop-weight
impact, friction, spark sensitivity, and thermal stability
tests should be run. Thermal stability testing need not be
performed here if one or more of the compatibility tests
listed under paragraph 2.2d of this chapter have already
been conducted on the new formulation.
c. If the new explosive or formulation is acceptable in the
above tests, it may be scaled up to Phase II. The EDC may
impose handling or processing restrictions or precautions on
the material if its performance in any of the above tests is
questionable.
d. After Phase I testing of a formulation is complete, the EDC
should define, on the basis of the test results, what
variations in composition are permissible during Phase II
development without retesting.
2.5 Phase II Experimental Characterization and Development
a. The total quantity of materials that may be processed or
handled at any one time in Phase II should not exceed 500 g.
No limit exists on the quantity that may be stored, other
than the storage facility limits for Group L explosives.
b. Materials investigated in Phase II should be produced by
techniques similar to those that will be used to produce
larger batches in a subsequent scaleup phase.
c. A thermal characterization test and evaluation should be run
before pressing the new material at elevated temperature.
d. The Phase I sensitivity and stability tests should be rerun
in Phase II if the following conditions apply.
The formulation to be scaled up to Phase III differs
from that tested in Phase I. In this case, testing
should be completed before Phase III scaleup.
The explosive or formulation prepared for Phase II
development is produced by techniques different than
those used in Phase I. Testing should be completed
before Phase III scaleup. During Phase II, the composition of a formulation is
modified to an extent that the composition is no longer
within the limits specified by the EDC (see
paragraph 2.4d of this chapter). Testing should be
completed before proceeding with Phase II.
The compatibility of explosives and formulations with
materials that contact the explosives in test and
production devices shall be evaluated before any such
device is assembled. If compatibility testing is
required, one or more of the tests listed under
paragraph 2.2d of this chapter should be recommended.
2.6 Phase III Full-Scale Testing and Production
a. The maximum quantity of materials that may be processed or
handled in Phase III should be defined in the EDC's grant of
authorization to proceed with Phase III. No limit is
imposed for the storage facilities except the limits imposed
by the quantity-distance tables.
b. All additional testing necessary to define storage
compatibility grouping should be completed before committing
bulk quantities of the material to storage (see Chapter II,
Section 17.4).
c. During Phase III development, the composition of all
formulations should be fixed.
d. Any new explosive material that is to be contact machined
shall be subjected to a machining overtest. Reaction
threshold should be determined if possible.
e. If billets of 7 kg or greater are to be produced in
Phase III, drop-skid testing should be performed and EDC
criteria for this test should be met.
f. Paragraph 2.5e of this chapter should also apply to
Phase III development.
CHAPTER IX
INSENSITIVE HIGH EXPLOSIVES QUALIFICATION
1.0 INSENSITIVE HIGH EXPLOSIVES (IHE)
Some explosive substances, although mass detonating, are so
insensitive that there is negligible probability of accidental
initiation or transition from burning to detonation. Any
explosive that is a candidate for classification as an IHE shall
be subjected to the DOE qualification tests listed in Table IX-1.
Test procedures, where not specified, are contained in
MHSMP-84-22, IHE Material Qualification Tests, Description and
Criteria. Test data for each explosive requested for this
classification will be submitted by the DOE laboratory or
contractor through the appropriate Operations Office to DOE
Headquarters Office of Field Support (EH-53). The DOE Explosives
Safety Committee will independently analyze the data and
recommend action on including the explosive in Table IX-2 as an
approved IHE.
New candidate explosives formulations will not be classified by
analogy as IHE until reviewed by the DOE Explosives Safety
Committee. The general guidelines for requesting and obtaining
an IHE approval by analogy are listed below.
All requests, including rationale, must be submitted in
writing to the DOE Explosives Safety Committee for their
analysis and recommended action.
Approved IHE(s) with complete test data must be used for
baseline comparison purposes.
More specific guidelines will depend on circumstances surrounding
the specific analogy request.
In many instances a partial analogy can be drawn, necessitating
only partial testing. This will depend on the type and extent of
change in the candidate IHE relative to the baseline IHE and the
potential effects of these changes on specific initiation
mechanisms (shock, thermal, mechanical, impact,
electrostatic, etc.). A candidate IHE can be placed in one of
the following categories to define the tests required for
approval.
Case I (partial testing required). The candidate IHE
formulation involves substitution of the inert binder
component of the approved baseline IHE with a new inert
binder component. Sufficient testing is required to verify
that no chemical incompatibilities have been introduced that
would destabilize the base IHE. In this case, test data
normally generated by the requesting facility during their
explosive development scaleup phasing process may be
submitted for approval consideration in lieu of the
qualification tests of Table IX-1. During this development
phase, each facility EDC may dictate restrictions consistent
with an IHE internal to their facility only. Final approval
as an IHE must be obtained through the DOE Explosives Safety
Committee. Tests 1, 2, 3, and 7 of Table IX-1 or equivalent
are required as a minimum.
Case II (all IHE tests of Table IX-1 required; analogy
inappropriate). The candidate IHE involves the addition of
an untested (IHE tests) energetic component to the approved
baseline IHE.
Or:
The candidate IHE involves the same energetic and inert
components as the approved baseline IHE, the only change being a
volume-% increase in the energetic component content.
Any data over and above that required in Table IX-1 will be
considered by the DOE Explosives Safety Committee in its
deliberations of the approval request.
2.0 IHE SUBASSEMBLIES
IHE subassemblies are composed of IHE hemispheres or spheres with
booster charges, with or without detonators. Successful
completion of the applicable DOE qualification tests listed in
Table IX-3 is required for classification as an IHE subassembly.
A test plan (defining specific test procedures) for candidates
for this classification shall be submitted by the DOE contractor
through the appropriate Operations Office to the DOE Explosives
Safety Committee for review. On approval of the plan, tests
shall be run and the DOE Explosives Safety Committee shall
independently analyze the data and recommend approval or
disapproval. DOE Headquarters will then issue a memorandum to
appropriate Operations Offices and DOE Contractors classifying
those configurations meeting the required test criteria as IHE
subassemblies. Approved IHE subassemblies are listed in
Table IX-4. Subassemblies will not be classified as IHE
subassemblies by analogy until reviewed by the DOE Explosives
Safety Committee. When no other explosives are present in the
same location, these subassemblies are classified as Class 1.3
explosives (see Table IX-5) for storage, processing, and
transportation purposes.
3.0 IHE WEAPONS
IHE weapons are those weapons listed in DOE-DNA TP 20-7 that are
exempt from storage and transportation limits when stored or
transported alone or in combination with each other. This
classification is valid only if the spacing between individual
units is that provided by storage containers, or if out of
containers, by the spacing specified in TP 20-7. These weapons
are classified as Class 1.3 explosives for storage, processing,
and transportation purposes.
Table IX-1. DOE qualification tests for IHE.
1. Drop-weight impact testa
Comparable to or less sensitive than Explosive D
(ammonium picrate). Minimum of 20 drops per test
series.
2. Friction testb
No reaction on Pantex friction machine (10 trials).
3. Spark testa
No reaction at minimum of 0.25 joules (10 trials).
4. Ignition and unconfined burning test
(small-scale burn)
TB 700-2 test procedures, any shape, minimum
thermal path of 25 mm, no explosion.
5. Card gap testb
No reaction at Explosive D 50% gap thickness (or
less) using a Pantex modified NOL card gap test
(6 trials). The test diameter must be greater than
the unconfined failure (critical) diameter of the
candidate IHE.
6. Detonation (cap) test
TB 700-2 test procedures-no detonation (5 trials).
7. Cookoff
No reaction of more than a pressure release using
the large-scale ODTX test conducted such that a
reaction must occur in not less than 4 hours
(6 trials).
8. Spigot testb
No reaction for 120-ft drop in LANL test (3 trials).
9. Skid testb
No reaction up to 20-ft (or sample failure) drop at
14-15 degrees test angle using standard size billets
(3 trials at worst-case condition).
10. Susan test
Less than or equal to 10% TNT output at a
minimum of 333 m/sec (3 trials).
11. Bullet impact
No violent reaction with 5.56 mm and .50 cal.
projectile impact on material in schedule 40 steel
pipe with closures on each end (6 trials in axial
orientation).
a These tests are not applicable to compacted explosives.
b These tests are not applicable for explosives powders. Table IX-2. Approved IHEs.
TATB
TATB/Kel-F Formulations
Table IX-3. DOE qualification tests for IHE subassemblies.a
1. Spigot test
2. Bonfire
3. Slow cookoff
4. Multiple bullet
impact
5. Skid test
No burning or violent reaction of main
charge of 120-ft drop on booster in
LANL test (3 trials).
No detonation or violent reaction of
main charge when engulfed in a fire (3
trials).
No detonation or violent reaction of
main charge when slowly heated to a
reaction (3 trials).
No detonation or violent reaction of
main charge with a 3-round burst of
7.62 mm projectile impact on booster (3
trials).
No burning or violent reaction of main
charge up to a 20-ft (or sample
failure) drop at 14 to 15 degrees test
angle using subassembly configuration
modified for impact on the booster
(3 trials at worst-case condition).
a Tests are not required for subassemblies when main charge and booster charge explosives have been qualified as
IHE by tests in Table IX-1.
Note: The test plan shall specify applicable testing for cased and/or uncased configurations with or without
detonators.
Table IX-4. Approved IHE subassemblies.
B61a3/4/6/7/8
B83a
W80a
W84
W85a
W87
W89
a Approval limited to boosters of the size tested or smaller. Any redesign that dimensionally increase the booster size
requires resubmission of an experimental plan and additional testing as another IHE subassembly.
Table IX-5. IHE hazard classification.
IHE alone 1.3
IHE at magazine distance or greater from Class 1.1 1.3
IHE at magazine distance or greater from Class 1.2 1.3
IHE with 1.1 items 1.1
IHE with 1.2 items 1.1
IHE with other 1.3 items 1.3
IHE with 1.4 items 1.3
IHE at less than magazine distance from Class 1.1 1.1
IHE at less than magazine distance from Class 1.2 1.1
Note: IHE may be stored with mock high explosives without regard to the quantity of mock high explosives.
4.0 REFERENCE DOCUMENTS
The following documents set forth some of the non-DOE procedures
to be used in the IHE and IHE subassembly testing required by
Tables IX-1 and IX-3:
TB 700-2, NAVSEA INST 8020.8A, TO 11A-1-47, DLAR 8220.1,
Department of Defense Ammunition and Explosives Hazard
Classification Procedures, Departments of the Army, the
Navy, the Air Force, and the Defense Logistics Agency,
Washington, D.C.
MHSMP-84-22, IHE Material Qualification Tests, Description
and Criteria (Rev. 1, July 1985), National Technical
Information Service, U.S. Department of Commerce, 5285 Port
Royal Road, Springfield, VA 22161.
INDEX
Acceptor(s), VI-8
Access control, II-15, VI-9
Access ramps, VI-8
Accident potential, VI-6-8
Accident, vehicle, II-88-89
Accidental releases, VI-9
Accounting procedure(s), II-5
Actuators, II-64, 75, 77, 95-96, 99,
114
Adiabatic heating, II-43
Administration areas, II-81, VI-5
Advisory requirements, I-2
Agitation, II-39, 51, 55-56
Aircraft, II-62
Airspace, II-62
Aisle(s), II-92
Alarm(s), II-6, 10, 28, 41, 51, 55;
VI-11
Ammunition, I-10, 13; II-18, 61, 66,
70,
82, 85-86, 95-100, 108; VI-1, 3, 11-
12
Analogy, II-40, 88; IX-1-2
Approval procedure, II-12
Approved IHE, IX-1-2, 4
Arm, I-5, 13; II-62, 69-71, 85, 97-98
Arrestor, II-28, 85, 87
Assembly, I-10; II-26-27, 34, 45, 47,
50, 53-55, 64-65, 68, 71-73, 77, 107;
VI-7
Audit(s), VII-3
Ball or jar milling, II-58
Bare explosive(s), II-6, 32, 50, 79
Barricade, I-5, 12; II-102
Battery-powered equipment, II-32, 87
Battery-powered lights, II-32
Bay of occurrence, VI-8
Bay, I-5, 13; II-8-9, 12, 14, 18, 37,
48, 60, 72, 88, 108, 111; III-1-2;
VI-7-10
Bearing(s), I-11; II-20, 57
Blast vent, II-121
Blast, I-13; II-7-10, 27, 54, 62-63,
116, 121;
VI-2, 8-9, 11-12
Blast-resistant door(s), II-9
Blending, I-5; II-26-27, 33, 52; VI-6-7
Blocking and bracing, II-83
Bonding, II-19-20
Booster, I-5, 9; II-48; IX-2, 4
Brush(es), II-106-107
Brushes or scraper(s), II-107
Burial, II-117-118
Burning area, II-114-115
Cart, II-79
Cased explosive(s), II-117; VI-10
Casual, I-5, III-1
Cell, I-5, II-8, 32, 73-74
Checklist, II-3, 81, 83
Chemical cleaning agent, II-106
Chemical processing, II-54
Chock block(s), II-84
Class 1.1 material(s), VI-5
Class 1, I-14; VI-2-3
Class I, II-25-26, 28-29, 31-32, 86;
VI-6-8, 11
Class II, II-25-26, 28-29, 31-32, 86;
VI-6-8, 10
Class III, VI-7-8, 11
Class IV, VI-7-10
Classification test(s), VI-3
Classified by analogy, IX-1
Cleaning, II-11, 37, 57, 105-106, 108,
110, 119;
IV-2
Cleanup procedure(s), II-20, 82
Closed circuit television, II-13
Clothing, II-2, 11, 56; IV-1-2
Cold trap, II-41
Combustible material(s), I-5, 10;
II-93, 97, 109,
116; VI-10
Commercial carrier, II-87
Common carrier(s), II-83; VI-5
Communication equipment, II-91
Compatibility testing, II-72, 99;
VIII-2-5
Compatibility, I-5, 9; II-43-44, 58,
72, 93,
95-99, 102, 110-111, 113; VI-3;
VII-3; VIII-5
Compliance with procedure(s), VII-2
Concurrent burning operation(s), II-114
Concurrent contact machining, II-47
Concurrent operation(s), I-6, II-58
Condensation, II-42
Conductive floor(s), II-19-20, 22
Conductive footwear, IV-1-2
Conductive shoes, II-20
Conductive wristband(s), II-20, 22
Conductivity, IV-2
Construction operation(s), II-11
Contact machining, II-47-49
Contact operation(s), I-6; II-40, 47,
50-51,
56-59, 64, 72; VI-7
Container(s), I-9-10; II-26, 39, 43,
58, 77-78,
82-85, 87, 92-94, 96, 98-102, 109,
113-114, 119-120; VI-7; IX-2
Contamination prevention, II-58
Contamination zone, II-68
Contamination, I-9; II-1, 20, 33, 35,
40, 51-53,
56, 58, 68, 93, 100, 105-107; IV-1-2;
VI-9
Control key, II-69
Control point, I-6; II-62
Control procedure(s), II-13, 15
Cooking and eating, II-15
Cookoff, IX-3-4
Coolant, II-45-47, 49-51, 55
Coring, I-6, II-47, 50, 59
Coverall(s), IV-1-2
Crack(s), II-1, 21, 36, 49, 52-54, 107,
123
Crane(s), II-79, 93
Critical temperature, I-6, 8; II-40-41
Criticality, II-4; VI-9-10
Cubicle(s), I-5; ;II-37, 70, 100, 111;
VI-12
Curing, II-53
Current-limiting(ed), II-76-77
Cushioning material, II-53
Cutting or welding, II-13
Cutting tool(s), I-11; II-46, 49
Damaged container(s), II-101
Danger zone, I-6; II-62-63, 74, 116
Dangerous good(s), VI-2
Deaerator(s), II-57
Debris impact, VI-7
Decomposition, I-9; II-40-41, 64, 80,
95, 98, 107
Decontamination, I-7; II-12-13,
106-109, 112
Deflagration, I-6
Degraded explosive, II-95
Degree(s) of protection, VI-2
Deluge system(s), II-57
Desiccator(s), II-42
Design and siting, VI-1
Design criteria, II-8; VI-11-12
Detonation(s), I-5-6, 10, 13; II-7, 9,
63-64, 67,
69-70, 74, 102, 114-117; III-1; VI-6-
8, 10; IX-1, 3-4
Detonator cable(s), II-68
Detonator(s), I-8-11, 13; II-65, 68-69,
74, 78,
96, 98, 100, 100-101, 115, 117; IX-2,
4
Development procedures, VIII-1, 3
Deviations, NFPA 101, II-8
Diagnostic equipment, II-64
Die(s), I-12; II-43-44, 55
Differential thermal analysis(es), I-7;
II-31;
VIII-3
Disassembly, II-34, 53-54, 73, 107;
VI-7
Disposal area, II-116-117
Disposal, II-4, 36, 46, 58, 73, 78,
101, 106-107,
110, 112, 114, 116-117, 120; VI-6
DNA TP 20-7, VI-9-10; IX-2
Dock, II-82
Documentation, II-5-6, 70
DoD 6055.9-STD, II-19, 28, 62, 98, 109,
124;
VI-3, 5-7, 11-12
Donor(s), VI-8
Door(s), II-7, 9-10, 14, 18, 21, 31,
42, 63-64,
70, 82, 84-85, 92-93
DOT regulation(s), II-84, 86, 88
Drain(s), II-11, 38, 49, 106, 120
Drilling, II-48, 50, 88, 108; VI-6
Drop test, II-74
Drop-skid test, II-80; VIII-5
Dry blending, II-52; VI-7
Dry-type collector, II-36, 111
Dry dust collection, II-111
Dry machining, II-26, 48; VI-6
Dry run(s), I-11; II-43, 49, 57
Dry screening, II-50; VI-7
Drying, I-7; II-26, 32, 38-41
DTA, I-7, 9; II-30, 39-40
Dual control(s), II-121
Dual rated, II-32
Dunnage, II-92
Dust collection, II-20, 35-36, 43, 47,
110
Dust generation, II-51
Dust hazard, II-25
Dynamic testing, II-71
Eardrum rupture, VI-8
EBW, I-7, 10-11; II-95, 97, 116
EDC, II-54, 59; VIII-1-5; IX-1
EED(s), I-7, 8, 11, 13; II-17, 20, 64,
68-69,
75, 77
Egress, II-6, 8-9, 70
Eight-hour supply, III-2
Electric line(s), II-27
Electric transmission lines, II-26
Electrical bonding, I-7
Electrical circuits, II-63, 68, 75-76
Electrical equipment, II-23, 25, 28-
30, 32, 119
Electrical instrument(s), II-64, 69,
74-76
Electrical resistance, II-18-20, 41
Electrical service entrance, II-27
Electrical storm(s), II-17-18, 93
Electrical substation(s), II-27
Electrical supply system, II-26
Electrically bonded, II-50-51, 111
Electroexplosive device(s), I-7; II-17,
20, 64; IV-1
Electrostatic-sensitive, II-17, 50-51;
IV-1
Emergency condition(s), II-87
Emergency control, II-123; VII-4-5
Emergency cooling, II-121
Emergency emptying, II-52
Emergency exit(s), II-5
Emergency plan(s), II-55, 87, 123;
VII-4
Emergency power, II-17
Emergency procedure, II-74; VII-5
Emergency stop device(s), II-58
Emergency, II-5, 9, 17, 52, 55, 58, 63,
74, 83, 85-88, 91, 105, 116; V-1,
VII-4-5
Environmental regulation(s), II-117
Environmental testing, VI-7
Equipment design, VI-7
Equipment maintenance, II-11; IV-2
Equipment speed and feed rate(s), II-45
Evacuation, II-6, 17, 124
Excelsior, II-113
Exceptions, NFPA 101, II-9
Exemption(s), I-2-5, VII-3
Exhaust ventilation, II-2, 35, 43, 55,
105;
IV-1
Exit(s), II-5-10, 17, 92
Experimental characterization, VIII-4
Experimental explosive(s), II-96, 99,
122
Experimental operating procedure, I-7
Exploding bridgewire (EBW), I-7, 8, 11;
II-75, 95,
97, 116
Explosion propagation, VI-8-9
Explosive assembly(ies), I-1; II-68,
72, 78
Explosive device(s), II-31, 65, 99, 100
Explosive powder(s), II-7, 44, 58; IV-1
Explosive projectile, II-75
Explosive(s), I-1, 2, 4-5, 7-14; II-1-
3, 5-9,
11-13, 15, 17-20, 22, 25-33, 36-64,
66-79,
81-89, 91-103, 105-111, 113-117, 119-
123; III-1-2; IV-1-2; V-1-3; VI-1-12;
VII-1, 4-5;
VIII-1-5; IX-1-5
Explosives activity(ies), I-5; III-1;
VI-1, 6-7, 9
Explosives billet(s), II-53
Explosives classification, VI-2-3
Explosives development, I-12; VI-6;
VIII-1
Explosives Development Committee,
II-41, 55, 100
Explosives dust(s), II-11, 25, 30, 35-
36, 43, 51,
109-110
Explosives formulation(s), II-42-43,
56-57;
VIII-1; IX-1
Explosives in solution, II-82, 122
Explosives inspection, II-53
Explosives limit(s), II-73, 101, 110;
III-1; VI-1
Explosives occupancy, II-7, 9
Explosives recovery, II-111
Explosives Safety Committee, I-1, 4-5
Explosives shot, II-61
Explosives slurry(ies), II-57, 111
Explosives target(s), II-70
Explosives waste container(s), II-113
Explosives waste, II-37, 45, 109, 111,
113-116
Explosives-carrying vehicle(s), II-17,
84, 87-88; V-1
Exposed explosive(s), II-19-20, 22, 25,
30-31,
41, 84
Extru(ding) (sion), I-7; II-43-45, 58;
VI-6
Extrudable explosive(s), II-45, 52
Eye protection, IV-1
Facilities, I-1-2, 9; II-2, 5, 7, 13,
18, 25-28, 37, 49, 54, 56, 58, 68,
75, 81, 83-85, 87, 91, 97,
99, 105-108, 115; VI-2, 3-
4, 6-7, 10-12; VII-3;
VIII-1, 5
Facility boundary(ies), II-81; VI-5, 11
Facility management, I-2-3, 8; II-5,
12, 26, 28, 29-31, 40, 50-51, 56, 67,
86, 94; III-1; VI-10
Facility operator, I-2, 8
Facility siting and design, VI-11
Facility, I-2-3, 7-9, 12-13; II-2-5,
11-12, 17,
26-32, 40, 50-51, 56, 67-68, 75, 81-
82, 86-87, 93-94, 117, 119, 123;
III-2; VI-5-6, 8-12; VII-4; VIII-1,
4; IX-1-2
Fault tree analysis, II-3
File(s), I-3; II-4, 18, 22, 85; III-2;
VII-2-3
Final decontamination(s), II-106-111
Fire alarm(s), VI-11
Fire control circuit, II-68
Fire extinguisher(s), II-84, 88, 91
Fire fighting, II-116
Fire protection, II-8, 11-12, 28, 119;
VI-9-10
Fire symbol(s), II-123
Firebrand(s), I-6, 8; II-61-62, 115
Firing area(s), II-61, 64, 66, 68
Firing circuit(s), II-63, 68-69, 73,
113-114
Firing in Tank(s), II-69
Firing key, II-113
Firing lead(s), II-67
Firing mechanism, II-70, 74
Firing pad, I-8; II-63, 67
Firing site, I-8; II-62-63, 66, 69
Firing unit capacitor, II-67
Firing vessel, II-69
Flame-retardant coverall(s), IV-1
Flammable gas(s), II-19, 22, 25-26
Flammable liquid(s), I-8; II-20, 25,
55-56, 93
Flammable vapor, II-20
Flanged connector(s), II-35
Flash point, I-8, II-11
Flashing, II-114-115
Flexible cords/wiring, II-29
Floor cushioned, II-5
Floor resistance, II-22
Footwear, II-20; IV-1-2
Foreign material, II-44, 53
Foreign object(s), II-48
Forklift(s), II-30, 85
Formulation(s), I-1, 8; II-3, 39,
42-43, 45,
56-57, 96, 120; VIII-1-5; IX-1, 4
Four-hour supply, II-73
Fragment(s), I-6, 8; II-6-7, 28, 61-63,
103,
115-16, 120; VI-2, 8, 9, 11-12
Friction air, II-40
Fueling, II-87
Full-scale testing, VIII-5
Furnace, II-114
Gauging, II-44, 49
Gas gun, II-70
Gasoline-powered, II-85-86
Gate(s), II-62-63
General operating procedure(s),
VII-2-3, 5
Glass container(s), II-100
Glassware, II-122
Glove(s), IV-2
Grass Fire(s), II-67
Grinding, II-25, 57
Ground fault circuit interrupter,
II-23; IV-1
Grounding, II-19-20, 27, 63, 68
Guard(s), II-31, 102, 119
Gun firing(s), II-61-62, 70
Gun(s), II-61-62, 70-71, 74
Hand blending, II-51
Hand tool(s), II-5, 52
Hand truck(s), II-78
Handling equipment, II-5, 11-12, 30,
54, 78, 85; VII-4
Handling, I-1, 3; II-2-3, 5, 11-12, 18,
25-26, 30, 37, 51, 54, 56, 72, 77,
78, 85-87, 92-94, 100;
VI-7; VII-4-5; VIII-1-2, 4
Hard surface(s), II-52, 77
Hazard and Operability Study (HAZOP),
II-3
Hazard class (activities), VI-6-7, 13
Hazard class (explosives), II-77 83-85,
96,
102-03; III-2, VI-6, 11
Hazard classification system, VI-2
Hazard classification, explosives, II-6
Hazard(s), I-5, 12, 14; II-2-9, 12, 15,
17, 19-20,
25-28, 30-31, 35, 49, 53-55, 59, 61,
68, 70, 77, 85, 91, 94, 96, 99, 100,
108, 120, 122-123; IV-1-2; VI-1-3,
6-7; VII-1, 5
Hazard(s) analysis, II-3-4, 6-7, 61
Hazardous condition(s), II-62-63, 87;
V-1; VI-5
Hazardous fragment(s), VI-8-9, 11
Hazardous locations (NEC), II-86
Hazardous radioactive materials, II-40,
71-72
Hearing protection, II-62
Heat-producing equipment, II-12
Heater control(s), II-42
Heating coil(s), II-11, 91
Heating control(s), II-40, 121
Heating equipment, II-72
Heating fluid, II-57
Heating limits, I-8; II-39-40, 72
Heating, I-6, 8; II-11, 25-26, 32, 39,
40, 42-43, 57-58, 72, 91, 106, 113,
120-121
High accident potential, VI-6, 8
High-energy initiator(s), II-75
High explosive(s), I-9-10; II-6, 95,
97, 99; VI-5, 10; IX-1, 5
High-hazard explosives, II-6, 8
Hoist(s), II-78, 92
Hoisting and rigging, II-12, 78
Holding fixture(s), II-45
Holding yard(s), II-81; VI-5
Hole(s), I-6, 8-9; II-47, 49, 50, 52;
VI-6
Hot work permit(s), II-12
Hot work, I-8; II-12
Hot-wire initiator(s), II-75
Hydraulic fluid(s), II-44
Hydraulic pressure, II-53
Hydraulically powered
equipment, II-45
Hydrostatic pressing, I-9; II-43
Ignition train, II-113-114
IHE subassembly(ies), I-9; II-47; VI-7,
9-10;
IX-1-2, 5
IHE weapon(s), I-9; VI-9-10
IHE, I-9-10; II-47; III-2; VI-7, 9-10;
IX-1-5
In-process storage magazine, I-9
Inactive procedure(s), VII-2-3
Incinerator(s), II-114
Incompatible explosive(s), II-58, 109,
113
Industrial hygiene, II-2
Industrial occupancy(ies), II-5
Industrial truck(s), II-86-87
Inert mockup, II-48
Inhabited-building distance, I-9, 13;
II-17, 26,
81, 103; VI-5-6
Initiating explosive(s), II-95, 97, 113
Initiating systems, II-75-76
Initiation circuit(s), II-75
Initiation stimulus(i), I-7-9; II-109
Initiation, I-5, 7-11, 14; II-18-19,
29, 45,
54, 75, 79, 95, 97-98, 109; VI-3, 7;
IX-1
Insensitive High Explosive(s), I-9-10;
IX-1
Inspection equipment, II-53
Inspection frequency, II-1
Inspection station, II-81
Inspection, I-5; II-1-2, 11, 18, 25,
35, 37, 42,
45, 51, 53-54, 56-57, 62, 68-69, 75,
78, 81-82, 87, 92-93, 107; IV-2; VI-5
Instrumentation, II-28-30, 32, 72, 107
Instruments, II-18, 22, 31, 69, 74-76
Interchange yard, II-81
Interlock(s), II-30, 41-42, 45, 48-49,
62-63, 68;
VII-4
Interlocked, II-30, 41, 45, 62, 69
Interlocking, II-13
Intraline distance, I-10; II-11-12,
110, 116
Intraplant shipping, II-83
Inventory, II-92, 94, 102
Isostatic pressing, I-10; II-43
Labeling, II-33; V-3
Laboratory coat(s), IV-1
Laboratory operation(s), I-10; II-2,
119-120
Large-scale test(s), II-61; IX-3
Laundering, IV-2
LEL, I-10-11
LFL, I-10-11
Life Safety Code, II-5, 7
Lifting device(s), II-71
Lighter(s), II-15, 87
Lightning arrestor, II-27
Lightning protection, II-17-19, 27
Lightning storm(s), II-64
Liquid addition, II-93
Loss criteria, VI-10
Low-energy EED, I-7, 11
Low-energy initiator(s), II-64, 75
Low-firing-current initiator(s), II-64,
68
Lower explosive limit, I-10-11
Lower flammable limit, I-10-11
Lung damage, VI-8
Machine speed, II-48
Machining overtest, I-11; II-46, 49;
VIII-5
Machining, I-6, 11; II-25, 45-49, 58,
107, 114;
VI-6-7; VIII-2, 5
Magazine distance, I-11; II-17; VI-8;
IX-5
Magazine(s), I-9, 11-13; II-6, 8, 17,
32, 59,
84-85, 91-93, 97, 100-102, 115, 119
Magnetic separation, II-53
Maintenance, I-2, 6; II-11-12, 25, 33,
49, 62, 75, 78, 85, 87, 105, 107;
IV-2; V-1; VI-10, 12
Mandatory standard(s), I-3
Mandrel(s), II-42-43
Manual administration, I-3
Manual handling, II-77
Mass detonating, I-10; VI-7; IX-1
Match(es), II-15, 87
Material(s) handling, II-30, 77, 85, 92
Maximal effective pressure, VI-8-9
Maximum Credible Event, I-11; VI-4
Maximum explosives limit(s), VI-1
Mechanical handling equipment,
II-78, 100
Melt agitation, II-56
Melting, I-11; II-51, 58
Metal article(s), II-15
Metal chip waste, II-45
Metal container(s), II-100, 120
Metal scrap, II-111
Metal-to-metal, II-1, 44, 51, 56
Metal/explosive(s), II-47
Metric system, VI-5
Milling, I-11; II-57-58; VI-7
Mirror(s), II-84, 122
Misfire(s), II-67-68, 70, 73-74
Missile(s), II-17, 53, 61; VI-8-9
Mixed storage, II-97
Mixer(s), II-56-57
Mixing, I-5, 11; II-26, 32, 56-59, 97,
99, 109; VIII-3
Mock, I-7, 11; II-1, 42, 46, 48, 71
Motor vehicle(s), II-81, 83-84; VI-5
MSDS, II-2
National Electrical Code (NEC), II-25-
26, 28-29,
31, 86
New equipment, II-12, 55
New explosive(s), I-1-2; II-5, 40, 43,
54, 94;
VI-1, 6; VIII-1-5
New explosives facility(ies), I-2; II-5
No-fire rating, II-69, 76
Noise, I-14); II-5, 62
Non-DOE facility personnel, I-12; II-11
Noninitiating circuits, II-63
Nonpropagating array(s), II-80
Nonsparking footwear, IV-1
Nuclear test shot location(s), VI-2
Occupancies, II-5-7
Occupied area(s), I-13; VI-8
On-the-job training, V-1
Open burning, II-113, 115
Open container(s), II-101
Open flame(s), II-1, 107, 119
Operating contractor, VII-2-3
Operating procedure(s), I-7, 13; II-40,
55-56, 59,
105, 119; III-2; V-1; VII-1-5
Operating temperature limit, II-41
Operation(s), I-1, 3-6, 8-13; II-1-5,
7-9, 11-13,
15, 17-20, 25-26, 28-29, 31-33, 35,
39-59, 61-64, 69-72, 74-78, 83, 85-
87, 92-93, 101-102, 106-108, 110-111,
113-116, 119-120, 122; III-1-2; IV-1-
2; V-1, 3; VI-1-2, 6-7, 8, 11-12;
VII-1-2, 4-5; IX-1
Operational shield(s), I-6, 12; II-53,
110; VI-7
Outdoor operation(s), II-17
Oven(s), II-15, 41
Overpressure(s), I-6; II-6-7, 17, 26,
56, 61-62,
115; VI-8-9
Own means of initiation, II-95, 97-98
Packing and shipping building(s),
II-101
Packing material, II-93
Partially burned explosive(s), II-115
Pellet(s), I-13; II-47, 100
Permanent wiring, II-28, 32
Personnel access, II-62, 68
Personnel barrier, I-12
Personnel casualty(ies), VI-2
Personnel limit(s), II-7, 63, 91;
III-1-2
Personnel protection, II-6-8, 13, 53
Pilot plant, II-54
Pin switch(es), II-63, 76
Pinch point(s), II-53, 56
Pit(s), II-113-115
Placarding, II-123
Plastic bonded explosive(s), II-95
Plastic explosive(s), II-44, 52
Plutonium, II-6, 71; VI-9-10
Pneumatic tool(s), II-52
Portable building(s), VI-2
Powdered metal(s), II-111
Power tool(s), II-63
Power-operated door(s), II-9
Press setup procedures, II-44
Pressed explosive(s), II-53, 100
Pressing, I-9-10, 12; II-1, 25, 42-44,
47, 58;
III-2; VI-6-7; VIII-2, 4
Pressure controller(s), II-42, 44
Pressure transducer(s), II-63, 76
Pressure vessel(s), I-10; II-69
Pressurized unit(s), II-53
Primary explosive(s), I-7, 10; II-47,
95, 97, 116
Process equipment, II-17, 29, 32, 55,
59
Process hazard analysis, II-3
Process operation(s), II-15, 53, 55
Projectile(s), I-12-13; II-61, 70, 74,
97, 115;
IX-3-4
Proof-tested(ing), II-71, 78
Propagation, I-11, 13; II-99; III-1;
VI-8-9
Propellant(s), I-1-2, 12; II-6, 19-20,
74, 93-99;
VI-11
Property damage, VI-2
Protective clothing, II-2, 11; IV-1
Protective equipment, II-5, 105; IV-2;
V-3; VII-5
Protective shelter, II-17, 67
Public highway(s), II-83
Public traffic route(s), I-12; II-13,
115; VI-3, 5
Punch and die pressing, I-12; II-44
Purging, II-12
Pyrotechnic(s), I-1, 2, 7, 12, 14;
II-6, 19-20,
23, 95, 98, 101
Qualification program, II-3; V-1
Qualification tests for IHE, IX-1-5
Quantity-distance, II-26, 81, 84-85,
93, 101-102,
110; III-1; VI-1-3, 5, 11; VIII-5
Quick-disconnect switch, II-84
Radio transmitter(s), II-113
Radioactive material(s), II-40, 71-72
Radiographic inspection, II-53
Radiography, II-48
Railcar(s), II-82-83, 85; VI-5
Railroad car(s), II-17
Railroad crossing(s), II-87
Range standard(s), II-62
Raw material(s), II-53
Reaction vessel(s), II-55, 120-121
Receipt, II-63-64, 81, 101
Record(s), I-7; II-11, 18, 22, 75, 94,
111, 117;
V-2
Reduced hazard classification, II-6
Reduced-hazard explosives, II-6
Refresher training, V-2
Relative humidity, II-23
Remote control, II-70, 120
Remote operation(s), I-12; II-13, 42,
46, 49-50,
53, 75; VI-6, 11
Remotely fired gun, II-74
Repair(s), II-11-12, 18, 25, 49, 55,
62, 75, 85,
87-88, 100, 107
Resistance check(s), II-69
Resistance-to-ground, II-19, 50-51
Respirator(s), IV-1
Review, I-3-5, 7; II-73, 93-94, 96;
III-2; V-2,
VI-11; VII-1-3; VIII-1; IX-1-2
Revolving door(s), II-9
RF transmitter(s), II-64
Risk analysis, II-61; VII-1
Road(s), I-12; II-13, 62, 87-88; VI-8
Roadblock(s), II-62
Rocket(s), I-12; II-95, 97-98
Roll milling, II-57
Rubbish, II-109, 116
Safe attitude, V-1
Safe distance(s), II-64, 88
Safe Secure Railcar (SSR), II-83
Safe Secure Trailer (SST), II-83
Safety analysis, I-12; II-5; VI-9;
VII-1
Safety equipment, II-56
Safety plug, II-68
Safety procedure(s), II-52
Safety shield(s), II-120
Salvaged explosive(s), II-96, 99, 111
Sawing, II-50
Scaleup, II-43, 47, 72, 94; VIII-2, 4;
IX-1
Scrap collection, II-58
Scraping, II-49
Screening, I-12; II-25, 50, 53, 87;
VI-6-7
Screw thread(s), II-1, 35, 105
Security response munitions, II-102
Sensitive salt(s), II-119
Sensitivity data, VIII-1-4
Sensitivity testing, II-61, 71
Serious injury(ies), II-13; III-1;
VI-8-9
Service line(s), II-27, 59; VI-5
Service magazine(s), I-9, 11, 13;
II-59, 101-102,
119
Service personnel, II-62, 68
Settling basin(s), II-37, 111
Severe injury(ies), VI-8
Shelf life, II-96
Shield(s), I-6, 12; II-53, 69, 85, 110;
VI-7, 14
Shipment(s), II-82-85, 87, 96, 101
Shipping and receiving, II-26, 101
Shoe covering(s), IV-2
Shot stand, II-63
Shunt(s), I-13; II-64, 114
Shutdown of Operations, II-17
Single Exit, II-8
Siting, VI-1, 11-12
Slapper detonator(s), I-8, 10-11, 13;
II-95
Slide escape(s), II-9-10
Sling(s), II-78
Slurry coating, II-56
Small arm(s), I-13; II-61, 70, 96-97
Smoking, II-2, 15, 85, 87, 119
Solvent(s), II-2, 11, 19-20, 25, 41,
57, 59, 96,
105-106, 109, 116, 119, 122
Solvent-explosives mixture, II-116
SOP(s), I-13; II-35, 70, 108; VII-1, 3-
5
Spark arrestor, II-84
Spark-producing device(s), II-15, 63,
87
Special operating procedure, I-13
Spray mist coolant, II-49
Squib(s), I-10; II-68, 75, 95, 114
Stability test(ing), II-43, 94;
VIII-2-4
Stacks of explosive(s), II-92
Stair(s), II-78
Standard operating procedure(s), VII-1
Static electricity, II-19, 23, 39; IV-1
Static ground(s), II-19
Static spark, II-19
Steam, II-19, 40, 51, 57, 91, 105-106,
120
Storage compatibility, I-6; II-95, 97,
99, 102,
110-111, 113; VI-2; VIII-5
Storage container(s), II-93, 119; IX-2
Storage in building(s), II-101
Storage magazine(s), I-9, 11; II-6, 8,
91-92,
100-102; VI-10
Storage review, II-93-94, 96
Storage, I-1-2, 6, 9-11, 13; II-2, 6,
15, 18, 25,
28, 48, 66, 68, 77, 82, 91-102, 110-
111, 113, 119; VI-3, 5, 8; VIII-4-5;
IX-2
Strain gauge(s), II-63, 76
Structural collapse, II-17; VI-8-9
Sublimation, II-26, 87
Substantial dividing wall, I-13
Sump(s), II-37-38, 119
Surge arrestor(s), II-27
Surge capacitor(s), II-27
Surveillance sampling, II-93
Suspect car, II-82; VI-5
Sweeping compound(s), II-11
Synthesis, I-1, 13; II-3, 26, 32,
54-55, 120;
VIII-2-3
Target(s), I-13; II-70
TB 700-2, VI-3; IX-3, 5
Team, II-3-4, 11
Telephone, II-62, 91
Temperature control, II-40, 43, 52, 91
Temporary storage, II-101
Test firing, I-8; II-62, 64, 68-70
Test instrument(s), II-74-76
Test planning, II-61
Test procedure(s), II-30; IX-1-3
Test shot(s), II-61-62, 67-68; VI-2
Test site(s), I-4, 6; II-62, 64, 68
The National Electrical Code (NEC), II-
25-26,
28-29, 31, 86
Thermal analysis, I-7; II-30, 39-41,
72; VIII-3
Thermal conditioning, II-39, 72
Thermal flux(es), VI-9
Thermal stability, II-30, 39, 43;
VIII-2-4
Thermocouple(s), II-63, 76
Threaded fastener(s), II-54, 105
Threaded fitting(s), II-33
Tiedown, II-78, 84
TNT equivalent, I-13; II-120
Tool path control(s), II-45
Tool speed, II-48
Tooling, II-42, 44, 77; VII-5
Toxicity, II-2, 35; VII-3
Traffic rule(s), II-87
Training, II-3, 83, 87; IV-1; V-1-3;
VII-1
Transfer line(s), II-55
Transient(s), I-13; II-8, 13, 62-63;
VI-9
Transmitters, II-64, 113
Transportation, I-1-2, 8-9; II-12, 77,
83-84, 87,
91, 100-102; IX-2
Transportation vehicle(s), II-87, 91,
101
Trap(s), II-33, 41, 119
Trough(s), II-37, 48
Unattended test assembly(ies), II-67
Unit operating procedure(s), VII-4
Unloading, II-81-82, 84
UNO, I-13; VI-2-3
Utilities installation(s), VI-5
Vacuum chuck, II-45, 48
Vacuum collection, II-109-110
Vacuum drying, II-41
Vacuum equipment, II-33
Vacuum lifting, II-78
Valve(s), II-10, 27, 40, 51, 55, 59,
86, 96
Vapor concentration(s), II-41-42, 55
Vault, I-9, 13
Vegetation control, II-91
Vehicle(s), II-17, 31, 62, 71, 81, 83-
85, 87-88,
91, 101, 113; V-1; VI-5
Vented, II-41, 74, 86; VI-12
Ventilation, II-2, 11, 20, 35, 43, 55,
92, 105;
VI-9
Viscous shear heating, II-57
Visual inspection, II-18, 53, 62, 107
Visual monitoring, II-47
Waiting period, II-63, 67-68, 73-74
Waiver(s), I-2-3; II-30; VII-3-4
Walkway(s), II-5, 77
Warehouse(s), II-102
Warning light(s), II-63
Warning sign(s), II-56, 67
Warning signal(s), II-67
Wastewater, II-111
Waste disposal, II-105, 113, 116
Water-explosives mixture(s), II-30
Watertight equipment, II-30
Weapons courier(s), II-83, 87
Wet box(es), II-111
Wet collector, II-35
Wet or dry vacuum system, II-109
Wet machining, II-25, 45; VI-7
Wheels chocked, II-81
Wiring, II-25-32, 64, 69, 75-76, 119
Work alone, III-1
Work environment(s), II-5, 7
Wristband(s), II-19-20, 22
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American National Standards Institute (ANSI), National Electrical
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United States Government Department of Energy
Oak Ridge Operations Office
memorandum
DATE: April 10, 1996
REPLY TO
ATTN OF: AD-440:Edwards
SUBJECT: REVISED DOE M 440.1-1, EXPLOSIVES SAFETY MANUAL
TO: Gerald Meyers, Office of Field Support, EH-53, 5th Floor, 19901 Germantown Road,
Germantown, MD 20874
We have completed an editorial review of the subject Manual. Attached are a copy of the
edited version (attachment 1) and diskettes of the edited version and the redline/strikeout
version, which shows where changes from the original draft were made.
Karen Edwards, Leader
Directives Management Group
cc:w/attachment:
J. Whitman, HR-62
Attachment 1
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