REVISED DOE M 440.1-1, EXPLOSIVES SAFETY MANUAL

0,52

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285

stron

3583

ID

U.S. Department of Energy

1996

rok

TABLE OF CONTENTS

FOREWORD iii

FIGURES xiii

TABLES xiii

ACRONYMS xv

CHAPTER I—INTRODUCTION

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

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

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 ClassificationII-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

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

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