DOE M 440.1-1, DOE Explosives Safety Manual

iii Revision 8 DOE M 440.1-1 3-29-96 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 CANCELE D iv 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 CANCELE D v DOE M 440.1-1 Revision 8 3-29-96 This page intentionally left blank. CANCELE D vi Revision 8 DOE M 440.1-1 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 OperationsII-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 CANCELE D vii 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 CANCELE D viii DOE M 440.1-1 Revision 8 3-29-96 TABLE OF CONTENTS (Continued) 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

CANCELE D ix 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 CANCELE D x Revision 8 DOE M 440.1-1 3-29-96 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 CANCELE D xi 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 CANCELE D xii DOE M 440.1-1 Revision 8 3-29-96 TABLE OF CONTENTS (Continued) 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 SystemsII-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 CANCELE D xiii 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 CANCELE D xiv Revision 8 DOE M 440.1-1 3-29-96 TABLE OF CONTENTS (Continued) 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 MagazinesII-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 ItemsII-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 CANCELE D xv 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 CANCELE D xvi DOE M 440.1-1 Revision 8 3-29-96 TABLE OF CONTENTS (Continued) 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 CANCELE D xvii 2.0 SUPERVISORY RESPONSIBILITY . . . . . . . . . . . . . . . V-1 3.0 TRAINING AND QUALIFICATION PROGRAMS . . . . . . . . . . V-1 CANCELE D xviii 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 REFERENCESVI-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 CANCELE D xix 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 CANCELE D xx 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 DevelopmentVIII-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 CANCELE D xxi 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 CANCELE D xxii IX-5 IHE hazard classification . . . . . . . . . . . . . IX-5 CANCELE D xxiii DOE M 440.1-1 Revision 8 3-29-96 This page intentionally left blank. CANCELE D xxiv 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 CANCELE D xxv TNT trinitrotoluene UL Underwriters Laboratory UNO United Nations Organization CANCELE D Chapter I DOE M 440.1-1 Revision 8 3-29-96

I-1 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 CANCELE D DOE M 440.1-1 Chapter I 3-29-96 Revision 8 I-2 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. CANCELE D Chapter I DOE M 440.1-1 Revision 8 3-29-96 I-3 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: C description of the condition;| C safety requirement necessitating deviation;| C reason why compliance cannot be achieved; C steps taken to provide protection; C statement of whether equivalent safety is provided and, if not, assessment of the residual risk; C any proposed corrective action and schedule; and C duration of the exemption. The DOE Director, Office of Field Support (EH-53), shall be notified and sent copies of all exemptions granted. CANCELE D DOE M 440.1-1 Chapter I 3-29-96 Revision 8 I-4 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:

C description of the condition; C safety guidance requiring alternate solution;| C reason why compliance is not achieved; C steps taken to provide alternate protection; C any proposed corrective actions and schedule; and C 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). CANCELE D Chapter I DOE M 440.1-1 Revision 8 3-29-96 I-5 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: C DOE Office of Field Support (EH-53); C DOE Office of Military Application and Stockpile Support; C DOE Operations Office, Albuquerque; C DOE Operations Office, Oakland; C DOE Operations Office, Nevada; C DOE Kirtland Area Office; C DOE Operations Office, Idaho; C Los Alamos National Laboratory; C Lawrence Livermore National Laboratory; C Pantex Plant, Mason & Hanger-Silas Mason Co., Inc.; C Mound, EG&G Applied Technologies, Inc.; C Kansas City Plant, Allied Signal, Inc.; C Idaho National Engineering Laboratory, LITCO; C DOE Operations Office, Nevada, Bechtel Nevada Corporation; and C 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. CANCELE D DOE M 440.1-1 Chapter I 3-29-96 Revision 8 I-6 5.2 DOE Explosives Safety Committee Functions The DOE Explosives Safety Committee shall perform the following| functions.| C Review, evaluate, and act under authority delegated from the DOE Director, Office of Field Support, on proposed changes or revisions to this Manual. C Evaluate and respond to requests for interpretations of the Manual. C 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. CANCELE D Chapter I DOE M 440.1-1 Revision 8 3-29-96 I-7 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. CANCELE D DOE M 440.1-1 Chapter I 3-29-96 Revision 8 I-8 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. CANCELE D Chapter I DOE M 440.1-1 Revision 8 3-29-96 I-9 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. CANCELE D DOE M 440.1-1 Chapter I 3-29-96 Revision 8 I-10 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. CANCELE D Chapter I DOE M 440.1-1 Revision 8 3-29-96 I-11 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 60EC and a vapor pressure not exceeding 280 kPa (41 psia) at 37.8EC. 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).| | CANCELE D DOE M 440.1-1 Chapter I 3-29-96 Revision 8 I-12 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 109EC, 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. CANCELE D Chapter I DOE M 440.1-1 Revision 8 3-29-96 I-13 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. CANCELE D DOE M 440.1-1 Chapter I 3-29-96 Revision 8 I-14 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. CANCELE D Chapter I DOE M 440.1-1 Revision 8 3-29-96 I-15 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. CANCELE D DOE M 440.1-1 Chapter I 3-29-96 Revision 8 I-16 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 CANCELE D Chapter I DOE M 440.1-1 Revision 8 3-29-96 I-17 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| CANCELE D DOE M 440.1-1 Chapter I 3-29-96 Revision 8 I-18 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. CANCELE D Chapter I DOE M 440.1-1 Revision 8 3-29-96 I-19

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. CANCELE D DOE M 440.1-1 Chapter I 3-29-96 Revision 8 I-20 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. CANCELE D Chapter II DOE M 440.1-1 Revision 8 3-29-96 II-1 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: C friction forces; C excessive pressures; C excessive temperatures; C impact, shock, pinching; C deformation; C electrical sparks, abrasive or welding sparks, open flame; C contamination; and C 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: C proper design; C proper function;

C specified clearances between parts in relative motion; C abnormal metal-to-metal rubbing of moving parts potentially contacting explosive materials; C cracks, voids, or screw threads where explosives may accumulate; and CANCELE D DOE M 440.1-1 Chapter II 3-29-96 Revision 8 II-2 C 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 CANCELE D Chapter II DOE M 440.1-1 Revision 8 3-29-96 II-3 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 CANCELE D DOE M 440.1-1 Chapter II 3-29-96 Revision 8 II-4 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: C sensitivity of materials; C quantity of materials; C number of personnel potentially affected; and C impact on other operations/activities. CANCELE D Chapter II DOE M 440.1-1 Revision 8 3-29-96 II-5 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. C Team Leader, who is familiar with the analysis methodology used; C Technical Member(s), who is/are familiar with the process being analyzed; and C 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: C Preliminary Hazard Analysis; C Checklist (usually for similar batch operations); C What-if Analysis; C Hazard and Operability Study (HAZOP); C Failure Modes, Effects, and Criticality Analysis (FMECA); C Fault Tree Analysis; and C 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 CANCELE D DOE M 440.1-1 Chapter II 3-29-96 Revision 8 II-6 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. CANCELE D Chapter II DOE M 440.1-1 Revision 8 3-29-96 II-7 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 CANCELE D DOE M 440.1-1 Chapter II 3-29-96 Revision 8 II-8 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. CANCELE D Chapter II DOE M 440.1-1 Revision 8 3-29-96 II-9 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. CANCELE D DOE M 440.1-1 Chapter II 3-29-96 Revision 8 II-10 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. CANCELE D Chapter II DOE M 440.1-1 Revision 8 3-29-96 II-11 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 ft , and the occupant load of the room shall2| be restricted to two operators and two transients. CANCELE D DOE M 440.1-1 Chapter II 3-29-96 Revision 8

II-12 c. The room containing an ordinary-hazard explosives occupancy shall not exceed 1,000 ft .2| 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. C Swinging doors may exceed 48 in. wide. C It is acceptable to omit the NFPA-required swinging| doors adjacent to a revolving blast door. CANCELE D Chapter II DOE M 440.1-1 Revision 8 3-29-96 II-13 C Revolving blast doors need to collapse into book-fold position. C Where fire-rated doors are required, blast doors are considered to have the required fire rating. C 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: CANCELE D DOE M 440.1-1 Chapter II 3-29-96 Revision 8 II-14 C angle, 40 to 50 degrees horizontal; C slide depth, 24 in.; C radius at bottom of slide, 12 in.; and C 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. CANCELE D Chapter II DOE M 440.1-1 Revision 8 3-29-96 II-15 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 110EC). 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 CANCELE D DOE M 440.1-1 Chapter II 3-29-96 Revision 8 II-16 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 109EC. Explosives decontamination of the immediately affected work areas and explosives removal shall be required before hot work operations. CANCELE D Chapter II DOE M 440.1-1 Revision 8 3-29-96 II-17 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. CANCELE D DOE M 440.1-1 Chapter II 3-29-96 Revision 8 II-18 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. CANCELE D Chapter II DOE M 440.1-1 Revision 8 3-29-96 II-19 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. CANCELE D DOE M 440.1-1 Chapter II 3-29-96 Revision 8

II-20 This page intentionally left blank. CANCELE D Chapter II DOE M 440.1-1 Revision 8 3-29-96 II-21 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: C explosives may be present; C combustible vapors or dust may be present; C smoking or drinking is prohibited because there are toxic materials present; and CANCELE D DOE M 440.1-1 Chapter II 3-29-96 Revision 8 II-22 C 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. CANCELE D Chapter II DOE M 440.1-1 Revision 8 3-29-96 II-23 This page intentionally left blank. CANCELE D DOE M 440.1-1 Chapter II 3-29-96 Revision 8 II-24 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. C 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.) C Explosives-carrying vehicles and railroad cars and locations within magazine distance of the hazard. C 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. CANCELE D Chapter II DOE M 440.1-1 Revision 8 3-29-96 II-25 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 CANCELE D DOE M 440.1-1 Chapter II 3-29-96 Revision 8 II-26 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. CANCELE D Chapter II DOE M 440.1-1 Revision 8 3-29-96 II-27 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: CANCELE D DOE M 440.1-1 Chapter II 3-29-96 Revision 8 II-28 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. CANCELE D Chapter II DOE M 440.1-1 Revision 8 3-29-96 II-29 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.CANCELE D DOE M 440.1-1 Chapter II 3-29-96 Revision 8 II-30 Figure II-1. Testing shoes on wearer. CANCELE D Chapter II DOE M 440.1-1 Revision 8 3-29-96 II-31 d. Conductive floors must be compatible with the explosive materials to be processed. CANCELE D DOE M 440.1-1 Chapter II 3-29-96 Revision 8 II-32 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). CANCELE D Chapter II DOE M 440.1-1 Revision 8 3-29-96 II-33 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. CANCELE D DOE M 440.1-1 Chapter II 3-29-96 Revision 8 II-34 This page intentionally left blank. CANCELE D Chapter II DOE M 440.1-1 Revision 8 3-29-96 II-35 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 CANCELE D DOE M 440.1-1 Chapter II 3-29-96 Revision 8 II-36 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: CANCELE D Chapter II DOE M 440.1-1 Revision 8 3-29-96 II-37 C Migration of explosives into the General Purpose Area from the classified area will not occur under normal operating conditions; C 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: C inhabited-building distance if the line in question is part of a grid/system serving a large, off-site area; C 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| CANCELE D DOE M 440.1-1 Chapter II 3-29-96 Revision 8 II-38 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 C 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. CANCELE D Chapter II DOE M 440.1-1 Revision 8 3-29-96 II-39 C 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. CANCELE D DOE M 440.1-1 Chapter II 3-29-96 Revision 8 II-40 (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 CANCELE D Chapter II DOE M 440.1-1 Revision 8 3-29-96 II-41 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 120EC. (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. CANCELE D DOE M 440.1-1 Chapter II 3-29-96 Revision 8 II-42 C Malfunction of electrical equipment or process instrumentation. C Breach of containment resulting in exposed explosives or spillage of explosives. C Ignition sources arising from physical damage to the wiring method used (e.g., crushing by forklift or other material handling equipment, frayed cords, etc.). C Exposed electrical conductors or connectors that could make contact with leg wires or cables of explosive devices during routine handling. C Exposed electrical conductors or connectors on which explosives dust or vapors could collect. C Collection of explosives dust on or in the equipment. C 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 CANCELE D Chapter II DOE M 440.1-1 Revision 8 3-29-96 II-43 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 CANCELE D DOE M 440.1-1 Chapter II 3-29-96 Revision 8 II-44 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. C Lights shall be mounted on heavy tripod stands. C The lights shall be fitted with exterior globes to prevent the falling of hot sparks or particles that might ignite the explosives. C The lights shall be fitted with adequate guards to protect the globes from physical damage. C The wire providing power to the lights shall be positioned so as to prevent vehicles and personnel damaging the cord. C The flexible cord shall comply with paragraph 8.5 of this chapter. C The light stand shall be secured to prevent tipping. C Neither the light nor the power cord shall be allowed to come in direct or indirect contact with the explosives. C 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). CANCELE D Chapter II DOE M 440.1-1 Revision 8 3-29-96 II-45 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. CANCELE D DOE M 440.1-1 Chapter II 3-29-96 Revision 8 II-46 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.CANCELE D Chapter II DOE M 440.1-1 Revision 8 3-29-96 II-47 This page intentionally left blank. CANCELE D DOE M 440.1-1 Chapter II 3-29-96 Revision 8 II-48 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. CANCELE D Chapter II DOE M 440.1-1 Revision 8 3-29-96 II-49 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. CANCELE D DOE M 440.1-1 Chapter II 3-29-96 Revision 8 II-50 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 CANCELE D Chapter II DOE M 440.1-1 Revision 8 3-29-96 II-51 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. CANCELE D DOE M 440.1-1 Chapter II 3-29-96 Revision 8 II-52 12.0 PROCESSING 12.1 Heating, Drying, and Thermal Conditioning 12.1.1 General a. Heating explosives is potentially dangerous for several reasons. C Elevated temperature can increase the sensitivity of an explosive to other stimuli such as impact, shock, friction, and static electricity. C 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. C 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. C 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. C 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, CANCELE D Chapter II DOE M 440.1-1 Revision 8 3-29-96 II-53 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 25EC 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 10EC 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 10EC below the critical temperature. For heating CANCELE D DOE M 440.1-1 Chapter II 3-29-96 Revision 8 II-54 explosives in association with hazardous radioactive materials, the maximum temperature should be set at least 20EC 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 CANCELE D Chapter II DOE M 440.1-1 Revision 8 3-29-96 II-55 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| CANCELE D DOE M 440.1-1 Chapter II 3-29-96 Revision 8 II-56 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. CANCELE D Chapter II DOE M 440.1-1 Revision 8 3-29-96 II-57 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. CANCELE D DOE M 440.1-1 Chapter II 3-29-96 Revision 8 II-58 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: C an acceptable vacuum on the mandrel assembly can be obtained to prevent adiabatic heating during pressing; and C air is bled out of the press before pressurization. CANCELE D Chapter II DOE M 440.1-1 Revision 8 3-29-96 II-59 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 CANCELE D DOE M 440.1-1 Chapter II 3-29-96 Revision 8 II-60 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| CANCELE D Chapter II DOE M 440.1-1 Revision 8 3-29-96 II-61 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 CANCELE D DOE M 440.1-1 Chapter II 3-29-96 Revision 8 II-62 a. The following explosives may be contact machined if a compatible, nontoxic, noncombustible coolant is used. Explosives not listed below shall be machined remotely. C Amatol C Baratol C Boracitol C Explosive D C Octol with no more than 75% HMX C Pentolite (no more than 50% PETN) C RDX/TNT compositions with no more than 75% RDX. These compositions include: Composition B, Composition B-3, 75/25 cyclotol. C TATB and TATB compositions with an inert plastic binder C 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: C foamed plastics, C solid plastics, C adhesives, C amorphous graphite, C calcium sulphate casting powder, or C explosives mockup. CANCELE D Chapter II DOE M 440.1-1 Revision 8 3-29-96 II-63 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: C drilling of holes smaller than 5 cm in diameter, except for IHE, where drilling of holes smaller than 5 mm shall be done remotely; C 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); C machining of any metal/explosives interface; C machining IHE subassemblies with Hazard Class/Division 1.1 boosters installed; C 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 C 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.| CANCELE D DOE M 440.1-1 Chapter II 3-29-96 Revision 8 II-64 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. CANCELE D Chapter II DOE M 440.1-1 Revision 8 3-29-96 II-65 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. CANCELE D DOE M 440.1-1 Chapter II 3-29-96 Revision 8 II-66 (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 CANCELE D Chapter II DOE M 440.1-1 Revision 8 3-29-96 II-67 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 CANCELE D DOE M 440.1-1 Chapter II 3-29-96 Revision 8 II-68 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.

CANCELE D Chapter II DOE M 440.1-1 Revision 8 3-29-96 II-69 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 121EC. The temperature limit for TNT explosives containing PETN shall be 109EC. 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. CANCELE D DOE M 440.1-1 Chapter II 3-29-96 Revision 8 II-70 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 21EC and 38EC 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. CANCELE D Chapter II DOE M 440.1-1 Revision 8 3-29-96 II-71 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 CANCELE D DOE M 440.1-1 Chapter II 3-29-96 Revision 8 II-72 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: C screening, C visual inspection, C magnetic separation, C radiographic inspection, and C 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 CANCELE D Chapter II DOE M 440.1-1 Revision 8 3-29-96 II-73 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 CANCELE D DOE M 440.1-1 Chapter II 3-29-96 Revision 8 II-74 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. CANCELE D Chapter II DOE M 440.1-1 Revision 8 3-29-96 II-75

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. CANCELE D DOE M 440.1-1 Chapter II 3-29-96 Revision 8 II-76 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 CANCELE D Chapter II DOE M 440.1-1 Revision 8 3-29-96 II-77 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. CANCELE D DOE M 440.1-1 Chapter II 3-29-96 Revision 8 II-78 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. CANCELE D Chapter II DOE M 440.1-1 Revision 8 3-29-96 II-79 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 CANCELE D DOE M 440.1-1 Chapter II 3-29-96 Revision 8 II-80 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. CANCELE D Chapter II DOE M 440.1-1 Revision 8 3-29-96 II-81 This page intentionally left blank. CANCELE D DOE M 440.1-1 Chapter II 3-29-96 Revision 8 II-82 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. CANCELE D Chapter II DOE M 440.1-1 Revision 8 3-29-96 II-83 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. CANCELE D DOE M 440.1-1 Chapter II 3-29-96 Revision 8 II-84 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 CANCELE D Chapter II DOE M 440.1-1 Revision 8 3-29-96 II-85 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. CANCELE D DOE M 440.1-1 Chapter II 3-29-96 Revision 8 II-86 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 CANCELE D Chapter II DOE M 440.1-1 Revision 8 3-29-96 II-87 Table II-1. Minimum safe distances between RF transmitters and electric blasting operations. Minimum safe distances (feet) Transmitter power (watts) Commercial AM broadcast transmitters HF transmitters other than AM broadcast 100 500 1,000 4,000 5,000 10,000 25,000 50,000 a 100,000 500,000 b 750 750 750 750 850 1,300 2,000 2,800 3,900 8,800 750 1,700 2,400 4,800 5,500 7,600 12,000 17,000 24,000 55,000 Present maximum power of U.S. broadcast transmitters in commercial AMa Broadcast Frequency Range (0.535 to 1.605 MHz). Present maximum for International Broadcast.b

Table II-2. Minimum safe distances between TV and FM broadcasting transmitters and electric blasting operations. Minimum safe distances (feet) Effective radiative power (watts) Channels 2-6 & FM Channels 7-13 UHF Table II-3. Minimum safe distances between mobile RF transmitters and electric blasting operations. Minimum safe distances (feet) Transmitter power (watts) MFa HFa VHF(1)a VHF(2)a UHFa 5 b 10 50 100 180 c 250 500 d 600 e 1,000 f 10,000 g --- 40 90 125 --- 200 --- 300 400 1,200 --- 100 220 310 --- 490 --- 760 980 --- --- 40 90 130 --- 205 209 315 410 1,300 --- 15 35 50 65 75 --- 115 150 --- --- 10 20 30 40 45 --- 70 90 --- MF 1.6 to 3.4 MHz Industriala HF 28 to 29.7 MHz Amateur VHF(1) 35 to 44 MHz Public use 50 to 54 MHz Amateur VHF(2 144 to 148 MHz Amateur 150.8 to 161.6 MHz Public use UHF 450 to 460 MHz Public use Citizens band radio (walkie-talkie), 26.96 to 27.23 MHz and cellular telephones, 3 watts power, 825 tob 845 MHz; minimum safe distance; 5 ft. Maximum power for 2-way mobile units in VHF, 150.8- to 161.6-MHz range, and for 2-way mobile andc fixed-station units in UHF, 450- to 460-MHz range. Maximum power for major VHF 2-way mobile and fixed-station units in 35- to 44-MHz range.d Maximum power for 2-way fixed-station units in VHF, 150.8- to 161.6-MHz range.e Maximum power for amateur radio mobile units.f Maximum power for some base stations in 42- to 44-MHz band and 1.6- to 1.8-MHz band.g levels. CANCELE D DOE M 440.1-1 Chapter II 3-29-96 Revision 8 II-88 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. CANCELE D Chapter II DOE M 440.1-1 Revision 8 3-29-96 II-89 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 CANCELE D DOE M 440.1-1 Chapter II 3-29-96 Revision 8 II-90 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." CANCELE D Chapter II DOE M 440.1-1 Revision 8 3-29-96 II-91 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. CANCELE D DOE M 440.1-1 Chapter II 3-29-96 Revision 8 II-92

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. CANCELE D Chapter II DOE M 440.1-1 Revision 8 3-29-96 II-93 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 CANCELE D DOE M 440.1-1 Chapter II 3-29-96 Revision 8 II-94 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.

C Adequate filling of hydraulic recoil mechanisms. C 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.) C 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. CANCELE D Chapter II DOE M 440.1-1 Revision 8 3-29-96 II-95 (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. CANCELE D DOE M 440.1-1 Chapter II 3-29-96 Revision 8 II-96 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 10EC 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. CANCELE D Chapter II DOE M 440.1-1 Revision 8 3-29-96 II-97 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. CANCELE D DOE M 440.1-1 Chapter II 3-29-96 Revision 8 II-98 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. CANCELE D Chapter II DOE M 440.1-1 Revision 8 3-29-96 II-99 (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. CANCELE D DOE M 440.1-1 Chapter II 3-29-96 Revision 8 II-100 (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. CANCELE D Chapter II DOE M 440.1-1 Revision 8 3-29-96 II-101 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 CANCELE D DOE M 440.1-1 Chapter II 3-29-96 Revision 8 II-102 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 CANCELE D Chapter II DOE M 440.1-1 Revision 8 3-29-96 II-103 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 1