DOE M 440.1-1A, DOE Explosives Safety Manual

MANUAL DOE M 440.1-1A Approved: 1-9-06 DOE EXPLOSIVES SAFETY MANUAL AVAILABLE ONLINE AT: INITIATED BY: www.directives.doe.gov Office of Environment, Safety and Health U.S. DEPARTMENT OF ENERGY Office of Environment, Safety and Health DOE M 440.1-1A i 1-9-06 DOE EXPLOSIVES SAFETY MANUAL 1. PURPOSE. Department of Energy (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 workplace for employees. DOE has also prescribed that a. All personnel shall be protected in any explosives operation undertaken. b. The level of safety provided shall be at least equivalent to that of the best industrial or government practice, but in no case shall the level of safety be less than that developed through a DOE practice. c. The risk of death or serious injury shall be limited to the lowest practicable minimum, and d. DOE and National Nuclear Security Administration (NNSA) and their contractors shall continually review their explosives operation with the aim of achieving further refinements and improvement in safety practices and protective features. e. This Manual describes the Department’s explosive 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. In addition, it is essential that applicable criteria and requirements for implementing this policy be 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. 2. CANCELLATION. DOE M 440.1-1, Explosives Safety Manual, dated 3-29-96. Cancellation of a directive does not modify or otherwise affect any contractual obligation to comply with the directive. Canceled directives incorporated by reference in a contract remain in effect until the contract is modified to delete the references to the requirements in the canceled directives. 3. APPLICABILITY. a. DOE Elements. (1) Except for the exclusions in paragraph 3c, this Manual applies to all DOE elements with responsibility for DOE-owned or -leased facilities. (See Attachment 1 for a complete list of DOE elements as of the date of this Manual. This Manual automatically applies to DOE elements created after that date.) Except for the exclusions in paragraph 3c, the requirements in this Manual apply to all DOE elements that engage in developing, manufacturing, handling, storing, transporting, processing, or testing explosives, pyrotechnics and propellants, or assemblies containing ii DOE M 440.1-1A 1-9-06 these materials. With the notable exception of onsite explosives storage and transportation, this description is not meant to include routine construction or routine tunnel blasting which are covered by OSHA safety requirements. (2) The NNSA Administrator will ensure that NNSA employees and contractors comply with their respective responsibilities under this Manual. b. DOE Contractors. (1) The CRD (Attachment 2) sets forth requirements that are to be applied to contractors involved with developing, manufacturing, handling, storing, transporting, processing, or testing explosives, pyrotechnics and propellants, or assemblies containing these materials.

(2) Once notified, the contracting officer is responsible for incorporating the applicable requirements of the CRD into the laws, regulations, and DOE directives clause of each contract of contractors that perform work at or for any DOE facility affected by the facility safety hazards described in and requirements established by this Manual. (3) Regardless of the performer of the work, the contractor is responsible for compliance with the requirements of the CRD that are incorporated in its contract. The prime contractor is responsible for flowing down the requirements of the CRD to subcontractors at any tier to the extent necessary to ensure the contractor’s compliance with the requirements and the safe performance of work. c. Exclusions. (1) With the notable exception of onsite explosives storage and transportation of explosives or explosive assemblies, this Manual is not meant to govern routine construction or routine tunnel blasting which are covered by OSHA safety requirements. (2) Pursuant to Executive Order (E.O.) 12344, Naval Nuclear Propulsion Program, the Director, Naval Nuclear Propulsion Program, will implement and oversee requirements of this Order for programs under the Director’s cognizance as set forth in the Defense Procurement Reform Act of 1984 (P.L. 98-525) and the Military Lands Withdrawal Act of 1999 (P.L. 106-65). (3) Requirements of this Manual do not apply to the Bonneville Power Administration. DOE M 440.1-1A iii (and iv) 1-9-06 4. CONTACT. Questions, comments, and suggestions concerning this Manual should be referred to the Office of Nuclear and Facility Safety Policy at 301-903-3190. BY ORDER OF THE SECRETARY OF ENERGY: CLAY SELL Deputy Secretary DOE M 440.1-1A v 1-9-06 TABLE OF CONTENTS List of Figures .............................................................................................................................. xiii List of Tables ............................................................................................................................... xiii Acronyms ......................................................................................................................................xv CHAPTER I—INTRODUCTION ...................................................................................................1 1.0 Scope, Purpose, and Justification.........................................................................................1 2.0 Applicability ........................................................................................................................3 3.0 Exemptions ..........................................................................................................................5 3.1 Each such request shall contain the following information:....................................5 3.2 Exemptions Achieving Equivalent Safety ...............................................................5 3.3 Exemptions Not Achieving Equivalent Safety ........................................................5 4.0 Waivers ................................................................................................................................7 4.1 Each waiver shall contain, as a minimum, the following information: ...................7 5.0 Manual Administration and Management ...........................................................................9 5.1 DOE Explosives Safety Committee Organization...................................................9 5.2 DOE Explosives Safety Committee Functions ......................................................10

6.0 Definitions..........................................................................................................................11 CHAPTER II—OPERATIONAL SAFETY..................................................................................25 1.0 General Operations Safety Guidelines...............................................................................25 1.1 Protection of Explosives ........................................................................................25 1.2 Equipment Checks .................................................................................................25 1.3 Inspection Frequency .............................................................................................26 1.4 Laboratory Operations ...........................................................................................26 1.5 Toxicity Hazards....................................................................................................26 1.6 Hazard Identification and Communication............................................................26 1.7 Process Hazard Analysis........................................................................................27 2.0 Work Environment.............................................................................................................29 2.1 General Requirements............................................................................................29 2.2 Emergency Exit Requirements for Explosives Operations....................................29 3.0 Building and Equipment Maintenance...............................................................................35 3.1 Cleaning .................................................................................................................35 3.2 Maintenance and Repair ........................................................................................35 3.3 Hot Work Permits ..................................................................................................36 4.0 Remote Operations.............................................................................................................39 4.1 Personnel Protection ..............................................................................................39 4.2 Access and Equipment Controls ............................................................................39 5.0 General Explosives Area Controls.....................................................................................41 5.1 Smoking, Matches, Lighters, Metal Articles .........................................................41 5.2 Cooking and Eating................................................................................................41 5.3 Access to Explosives Areas ...................................................................................41 vi DOE M 440.1-1A 1-9-06 CONTENTS (continued) 6.0 Protection of Electroexplosive Devices (EEDs) from Electromagnetic Radiation ...........43 7.1 General...................................................................................................................45 7.2 Bonding and Grounding of Equipment..................................................................45 7.3 Testing Bonded Equipment Grounds.....................................................................45 7.4 Conductive Floors, Shoes, Mats and Wristbands ..................................................46 7.5 Conductive Floor, Work Surface, and Wristband Specifications ..........................46 7.6 Conductive Floor Tests ..........................................................................................47 7.7 Humidification .......................................................................................................48 7.8 Ground Fault Circuit Interrupter............................................................................48

8.0 Electrical Equipment and Wiring.......................................................................................49 8.1 Location/Operation Electrical Hazard Classification ............................................49 8.2 Electrical Supply System .......................................................................................51 8.3 Building Electrical Service Entrance .....................................................................52 8.4 Permanent Wiring, Fixtures and Equipment..........................................................52 8.5 Flexible Cords/Wiring ...........................................................................................53 8.6 Electrical Equipment and Instrumentation.............................................................54 8.7 Electrical Requirements for Outdoor Test Areas...................................................55 8.8 Hand-held, Battery-Powered Lights and Instruments............................................55 8.9 Non-Rated Extension Lighting ..............................................................................56 8.10 Laboratories ...........................................................................................................56 8.11 Modifications .........................................................................................................57 9.0 Vacuum Equipment ...........................................................................................................59 9.1 General...................................................................................................................59 9.2 Labeling .................................................................................................................59 9.3 Disassembly ...........................................................................................................59 9.4 Traps or Filters.......................................................................................................59 10.0 Explosives Dust Exhaust Ventilation and Collection Systems..........................................61 10.1 General...................................................................................................................61 10.2 Exhaust Ventilation................................................................................................61 10.3 Dust Collection Systems ........................................................................................61 10.4 Dust Collection Location .......................................................................................62 11.0 Drains and Sumps ..............................................................................................................63 11.1 Collection...............................................................................................................63 11.2 Effluent ..................................................................................................................63

12.0 Processing ..........................................................................................................................65 12.1 Heating, Drying, and Thermal Conditioning .........................................................65 12.2 Pressing..................................................................................................................68 12.3 Extruding................................................................................................................70 12.4 Machining ..............................................................................................................71 12.5 Dry Screening ........................................................................................................76 12.6 Blending.................................................................................................................77 12.7 Melting...................................................................................................................77 12.8 Assembly and Disassembly ...................................................................................78 DOE M 440.1-1A vii 1-9-06 CONTENTS (continued) 12.9 Inspection...............................................................................................................79 12.10 Synthesis ................................................................................................................80 12.11 Formulation............................................................................................................82 12.12 Concurrent Contact Operations..............................................................................84 12.13 Contamination Prevention .....................................................................................84 12.14 Hand-Cutting and Finishing Operations ................................................................85 12.15 Use of Low-Pressure Fluids...................................................................................85 13.0 TESTING...........................................................................................................................87 13.1 General...................................................................................................................87 13.2 Test Planning .........................................................................................................87 13.3 Test Firing..............................................................................................................87 13.4 Test Firing in Tanks or Chambers .........................................................................95 13.5 Gun Firings ............................................................................................................96 13.6 Ballistic, Environmental, Physical Property and Sensitivity Testing ....................97 13.7 Test Failures and Misfires......................................................................................99 13.8 Electrical Instruments for Use with Explosives Systems ....................................100 14.0 MATERIALS HANDLING.............................................................................................103 14.1 General.................................................................................................................103 14.2 Manual Handling of Bare Consolidated Explosives............................................103 14.3 Carts or Hand Trucks ...........................................................................................104 14.4 Mechanical Handling Equipment ........................................................................104

15.0 MATERIALS RECEIPT .................................................................................................104 15.1 Motor Vehicles.....................................................................................................105 15.2 Railcars ................................................................................................................106 15.3 Damaged Shipments ............................................................................................106 16.0 TRANSPORTATION......................................................................................................107 16.1 Equipment and Operations...................................................................................107 16.2 General Operation Guidelines..............................................................................112 16.3 Emergency Conditions.........................................................................................113 17.0 EXPLOSIVES STORAGE ..............................................................................................115 17.1 Storage Magazine Facilities.................................................................................115 17.2 Storage Magazine Operations ..............................................................................116 17.3 Storage Review Program .....................................................................................118 17.4 Storage Compatibility ..........................................................................................119 17.5 Containers (Onsite) ..............................................................................................125 17.6 Storage in Buildings Other Than Storage Magazines..........................................126 18.0 DECONTAMINATION AND CLEANING ...................................................................129 18.1 General.................................................................................................................129 18.2 Cleaning Contaminated Equipment .....................................................................129 18.3 Cleaning Screw Threads ......................................................................................129 18.4 Final Decontamination and Disposal of Equipment ............................................130 18.5 Inspection.............................................................................................................130 18.6 Identification and Control of Decontaminated Items...........................................131 viii DOE M 440.1-1A 1-9-06 CONTENTS (continued) 18.7 Decontamination of Real Estate...........................................................................132 18.8 Decontamination and Cleaning References .........................................................132 19.0 WASTE COLLECTION..................................................................................................133 19.1 General.................................................................................................................133 19.2 Solid Wastes.........................................................................................................133 19.3 Vacuum Collection of Explosives Dusts .............................................................133 19.4 Explosives Slurries...............................................................................................135 19.5 Metal Scrap ..........................................................................................................135 19.6 Explosives Recovery and Reuse ..........................................................................135

20.0 WASTE DISPOSAL........................................................................................................137 20.1 Preparation for Open Burning..............................................................................137 20.2 Destruction by Burning or Flashing.....................................................................138 20.3 Ignition System Malfunctions..............................................................................138 20.4 Postburn Operations.............................................................................................139 20.5 Disposal Area.......................................................................................................139 20.6 Destruction by Detonation ...................................................................................141 20.7 Use of Solvents ....................................................................................................141 21.0 LABORATORY OPERATIONS ....................................................................................143 21.1 General.................................................................................................................143 21.2 Safety Shields.......................................................................................................143 21.3 Heating Operations ..............................................................................................145 21.4 Laboratory Setups ................................................................................................145 21.5 Low Concentration of Explosives in Solution.....................................................146 21.6 Explosives Sample Control..................................................................................146 22.0 EMERGENCY CONTROL.............................................................................................147 22.1 Placarding and Fire Symbols ...............................................................................147 22.2 Explosives Emergency Control Plans..................................................................147 CHAPTER III—EXPLOSIVES AND PERSONNEL LIMITS AND CONTROL.....................149 1.0 EXPLOSIVES LIMITS ...................................................................................................149 2.0 PERSONNEL LIMITS ....................................................................................................151 3.0 LIMIT CONTROL...........................................................................................................153 3.1 Posting and Recording .........................................................................................153 3.2 Limit Review and Approvals ...............................................................................153 3.3 Personnel Controls ...............................................................................................153 3.4 Explosives Control...............................................................................................153 4.0 INSENSITIVE HIGH EXPLOSIVE LIMITS.................................................................155 CHAPTER IV—PERSONAL PROTECTIVE CLOTHING AND EQUIPMENT .....................157 1.0 CLOTHING AND PERSONAL EQUIPMENT..............................................................157

1.1 Clothing................................................................................................................157 1.2 Footwear ..............................................................................................................157 1.3 Respirators ...........................................................................................................157 1.4 Eye Protection......................................................................................................157 DOE M 440.1-1A ix 1-9-06 CONTENTS (continued) 1.5 Gloves ..................................................................................................................157 2.0 MAINTENANCE AND TESTING.................................................................................159 2.1 Equipment Maintenance and Inspection..............................................................159 2.2 Conductivity Testing............................................................................................159 2.3 Cleaning and Disinfecting....................................................................................159 2.4 Contaminated Clothing ........................................................................................159 CHAPTER V—TRAINING ........................................................................................................161 1.0 GENERAL.......................................................................................................................161 2.0 SUPERVISORY RESPONSIBILITY .............................................................................161 3.0 TRAINING AND QUALIFICATION PROGRAMS .....................................................163 4.0 UNEXPLODED ORDNANCE (UXO) TRAINING.......................................................165 5.0 REFERENCES ................................................................................................................167 CHAPTER VI—QUANTITY-DISTANCE AND LEVEL-OF-PROTECTION CRITERIA FOR EXPLOSIVES ACTIVITIES ..........................................................................169 1.0 GENERAL.......................................................................................................................169 1.1 For New Explosives Facilities and Operations and Explosives Facilities Undergoing Major Modifications: .......................................................................169 1.2 For Existing Explosives Facilities and Operations: .............................................169 2.0 APPLICABILITY OF CRITERIA ..................................................................................171 2.1 Specific Applications ...........................................................................................171 2.2 Explosives Limits.................................................................................................171 2.3 Areas Where Criteria Are Not Applicable...........................................................171 3.0 QUANTITY-DISTANCE CRITERIA ............................................................................173 3.1 Hazard Classes and Class Division......................................................................173 3.2 Establishing Quantity of Explosives and Distances.............................................175

4.0 LEVEL-OF-PROTECTION CRITERIA.........................................................................179 4.1 Hazard Classes .....................................................................................................179 4.2 Required Level of Protection ...............................................................................180 5.0 FIRE PROTECTION.......................................................................................................183 5.1 Vegetation Control...............................................................................................183 5.2 Fire Protection Criteria ........................................................................................183 6.0 EXPLOSIVES FACILITY SITING AND DESIGN CRITERIA REFERENCES .........185 6.1 Site and General Construction Plans for Ammunition and Explosives Facilities ............................................................................................185 CHAPTER VII—OPERATING PROCEDURES .......................................................................191 1.0 GENERAL.......................................................................................................................191 1.1 Requirements .......................................................................................................191 1.2 Types of Procedures.............................................................................................191 2.0 GUIDELINES..................................................................................................................193 2.1 Before Operation..................................................................................................193 x DOE M 440.1-1A 1-9-06 CONTENTS (continued) 2.2 Supervisory Responsibility ..................................................................................193 2.3 Preparation ...........................................................................................................193 2.4 Approval ..............................................................................................................193 2.5 Control .................................................................................................................194 2.6 Audits...................................................................................................................194 2.7 Reviews................................................................................................................194 2.8 Content of Standard Operating Procedures..........................................................194 2.9 Content of Special or Experimental Procedures ..................................................196 3.0 REFERENCE DOCUMENTS.........................................................................................197 CHAPTER VIII—FORMULATION SCALEUP........................................................................199 1.0 EXPLOSIVES DEVELOPMENT PROGRAM ..............................................................199 1.1 Explosives Development Committee...................................................................199 1.2 Phase-by-Phase Approvals...................................................................................199 1.3 Modified Formulations ........................................................................................199 1.4 Sensitivity Data from Another Laboratory ..........................................................199

2.0 DEVELOPMENT PROCEDURES.................................................................................201 2.1 General.................................................................................................................201 2.2 Synthesis Phase....................................................................................................201 2.3 Compatibility Testing ..........................................................................................201 2.4 Phase I—Preliminary Explosives Testing ...........................................................203 2.5 Phase II—Experimental Characterization and Development ..............................203 2.6 Phase III – Full-Scale Testing and Production ....................................................204 CHAPTER IX—INSENSITIVE HIGH EXPLOSIVES QUALIFICATION..............................205 1.0 INSENSITIVE HIGH EXPLOSIVES (IHE)...................................................................205 2.0 IHE SUBASSEMBLIES..................................................................................................206 3.0 IHE WEAPONS...............................................................................................................211 4.0 REFERENCE DOCUMENTS.........................................................................................213 CHAPTER X—ELECTRICAL STORMS AND LIGHTING PROTECTION ..........................215 1.0 ELECTRICAL STORM HAZARDS ..............................................................................215 2.0 LIGHTNING PROTECTION SYSTEMS.......................................................................217 2.1 Lightning Protection System Basic Design .........................................................217 2.2 Lightning Protection Subsystems ........................................................................217 2.3 Approved Lightning Protection Systems .............................................................218 2.4 Lightning Protection Subsystem Criteria.............................................................223 3.0 INSPECTION AND TESTING OF LIGHTNING PROTECTION SYSTEMS.............231 3.1 Initial Installation or Approval.............................................................................231 3.2 Periodic Inspections and Testing .........................................................................231 3.3 Acceptable Electrical Test Measurements ...........................................................233 3.4 Procedures............................................................................................................234 3.5 Documentation and Trend Analysis.....................................................................234 3.6 Training................................................................................................................234 DOE M 440.1-1A xi (and xii) 1-9-06 CONTENTS (continued) 4.0 LIGHTNING PROTECTION EXCEPTIONS ................................................................235 5.0 LIGHTNING THREAT DETECTION ...........................................................................237 6.0 LIGHTNING THREAT ACTIONS ................................................................................239 7.0 SHUTDOWN OF OPERATIONS...................................................................................243 8.0 LIGHTNING WARNING AND PROTECTION PLAN ................................................245

8.1 Evaluation of Lightning Risk...............................................................................245 8.2 Lightning Protection System Installation.............................................................245 8.3 LPS Inspection and Maintenance.........................................................................245 8.4 Sideflash Separation (Standoff) Distances...........................................................246 8.5 Lightning Threat ..................................................................................................246 9.0 REFERENCE DOCUMENTS.........................................................................................247 APPENDIX A—REFERENCES.................................................................................................249 APPENDIX B—INDEX..............................................................................................................251 DOE M 440.1-1A xiii (and xiv) 1-9-06 LIST OF FIGURES Figure II-1. Testing Shoes on Wearer........................................................................................... 47 Figure VI-1. Application of Hazard Classification System......................................................... 174 Figure X-1. Single Mast Zone of Protection............................................................................... 219 Figure X-2. Example of Catenary System Zone of Protection ................................................... 220 Figure X-3. Integral system Zone of Protection ......................................................................... 220 LIST OF TABLES Table II-1. Minimum Safe Distances Between RF Transmitters and Electric Blasting Operations ........................................................................................... 91 Table II-2. Minimum Safe Distances Between TV and FM Broadcasting Transmitters and Electric Blasting Operations................................... 91 Table II-3. Minimum Safe Distances Between Mobile RF Transmitters and Electric Blasting Operations ........................................................................................... 92 Table II-4. Storage Compatibility Groups for Explosives and Explosive-Containing Devices............................................................................................. 123 Table II-5. Safety Shields for Explosive Laboratory Operations ............................................. 144 Table VI-1. Divisions of Class 1................................................................................................ 173 Table VI-2. Quantity-Distance Separation for Protection of Underground Service Installations .................................................................................. 176 Table VI-3. Explosives Facilities: Protective Design Requirements by Activity Type ........................................................................................... 189 Table VIII-1. Scaleup Procedure Guidelines for New Explosives and Formulations ...................................................................................... 201 Table IX-1. DOE IHE Qualification Tests. ............................................................................... 205 Table IX-2. Approved IHEs....................................................................................................... 206 Table IX-3. DOE Qualification Tests for IHE Subassemblies .................................................. 209 Table IX-4. Approved IHE Subassemblies................................................................................ 210 Table IX-5. IHE Hazard Classification...................................................................................... 210

DOE M 440.1-1A xv 1-9-06 ACRONYMS ACGIH American Conference of Government Industrial Hygienists AHJ Authority Having Jurisdiction ASTM American Society for Testing and Materials ASTI 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 Bridge Wire EDC Explosives Development Committee EED Electroexplosive Device EIDS Extremely Insensitive Detonating Substance EOD Explosive 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 LPS Lightning Protection System MCE Maximum Credible Event MSDS Material Safety Data Sheet NE Nuclear Explosive NEC National Electric Code NEO Nuclear Explosive Operation NEW Net Explosive Weight NEQ Net Explosive Quantity NFPA National Fire Protection Association NNSA National Nuclear Security Administration OSHA Occupational Safety and Health Administration PBX Plastic Bonded Explosive xvi DOE M 440.1-1A 1-9-06 PEL Permissible Explosive Limit PETN Pentaerythritol Tetranitrate RDX Cyclotrimethylene Trinitramine SOP Standard Operating Procedure SPMS Safety Performance Measurement System SSR Safe Secure Railcar SST Safe Secure Trailer TATB Triamino Trinitrobenzene TMAC Toxic Materials Advisory Committee TNT Trinitrotoluene UL Underwriters Laboratory UN United Nations UXO Unexploded Ordnance DOE M 440.1-1A 1 (and 2) 1-9-06 CHAPTER I—INTRODUCTION 1.0 SCOPE, PURPOSE, AND JUSTIFICATION a. This Manual prescribes the Department of Energy (DOE) safety standards and procedures used to implement the DOE safety policy contained in DOE O 440.1A, Worker Protection Management for DOE Federal and Contractor Employees (current version) for operations involving explosives, pyrotechnics, and propellants, or assemblies containing these materials. b. DOE explosives handling and processing operations 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 and National Nuclear Security Administration (NNSA) 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 is responsible for this task. c. 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 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 the risks.

d. This Manual establishes safety controls and standards not addressed in other existing DOE or non-DOE regulations to close the considerable safety gap created by DOE’s unique activities to govern the DOE explosives safety process and ensure that explosives safety is commensurate with the actual risk. However, the 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. Specific requirements from these documents are applicable and pertinent as determined by the “Authority Having Jurisdiction.” 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. DOE M 440.1-1A 3 (and 4) 1-9-06 2.0 APPLICABILITY a. 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 to the safe management of 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. b. The design of all new explosives facilities shall conform to the requirements established in this Manual and implemented in the current version of DOE O 420.1B, Facility Safety. 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 if the following two conditions are met: (1) The current operation presents no significantly greater risk than that assumed when the facility was originally designed. (2) It can be demonstrated clearly that a modification to bring the facility into compliance is not feasible. c. However, in the case of a major renovation, the facility must be brought into compliance with current standards. d. The requirements are presented as either mandatory or advisory. Mandatory requirements, denoted by the words “shall,” “must,” or “will,” must be followed unless the DOE Operations Officer or NNSA Site Manager grants an exemption. Advisory requirements denoted by “should” or “may,” may be deviated from with a written waiver granted by facility management. DOE M 440.1-1A 5 (and 6) 1-9-06 3.0 EXEMPTIONS a. An exemption is a written release from a mandatory safety requirement. Competent, knowledgeable, and experienced explosives safety engineers shall review all exemption requests. Approved exemption requests should feature methodologies to mitigate to the highest practical level the additional safety risks through additional engineering or administrative controls. 3.1 Each such request shall contain the following information: a. Description of the condition. b. Safety requirement necessitating deviation. c. Reason why compliance cannot be achieved. d. Steps taken to provide protection and to ameliorate the additional risk.

e. Statement of whether equivalent safety is provided and, if not, assessment of the residual risk. f. Any proposed corrective action and schedule. g. Duration of the exemption. 3.2 Exemptions Achieving Equivalent Safety a. The DOE Operations Officer or NNSA Site Manager is permitted to grant exemptions from the mandatory requirements of this Manual provided compliance is impracticable and the facility operator has demonstrated that the conditions, practices, means, methods, or processes to be used are equivalent. Requests for exemptions shall be submitted to the DOE Operations Officer or NNSA Site Manager for action. 3.3 Exemptions Not Achieving Equivalent Safety a. The DOE Operations Officer or NNSA Site Manager shall submit to the Program Secretarial Officer (PSO) all requests for exemptions from mandatory requirements for which equivalent protection of operating personnel, the public, and property cannot be achieved. The PSO, with the advice and recommendation from the Assistant Secretary for Environment, Safety and Health, shall make a final determination on the request for exemption. The DOE Operations Office or NNSA Site Manager may grant a temporary exemption while the PSO is processing an exemption request. The temporary exemption is limited to the shorter of 180 days from its granting or until the exemption is approved or denied. Exemptions will be reviewed for applicability and currency at intervals not to exceed 5 years. DOE M 440.1-1A 7 (and 8) 1-9-06 4.0 WAIVERS a. If an activity, operation, or process is determined to be out of compliance with the Manual’s advisory requirements, but the activity, operation, or process is determined to be safe and necessary, facility management may grant written approval in the form of a waiver for an alternate solution. Waivers will be granted for the minimum time necessary; ongoing waivers shall be updated every three years. Facility management shall maintain a central file of active waivers and provide a copy of each waiver to the local DOE contracting officer. 4.1 Each waiver shall contain, as a minimum, the following information: a. Description of the condition. b. Safety standard requiring alternate solution. c. Reason why compliance is not achieved. d. Steps taken to provide alternate protection. e. Any proposed corrective actions and schedule. f. Waiver duration or expiration date. DOE M 440.1-1A 9 1-9-06 5.0 MANUAL ADMINISTRATION AND MANAGEMENT a. This Manual shall be kept current. The Office of Facility Safety shall ensure that this Manual is kept up-to-date and that the DOE Directives System maintains a current version online at http://www.directives.doe.gov. b. The DOE Explosives Safety Committee, through the Office of Facility Safety, shall administer and manage this Manual. 5.1 DOE Explosives Safety Committee Organization a. The DOE Explosives Safety Committee is composed of a member from each of the following: [The membership listing has been updated by the Chairman of the DOE Explosives Safety Committee to reflect reorganizations in DOE/NNSA. Current membership is available upon request from the site representative to the Committee, or from the Committee Chairman]. (1) DOE Office of Facility Safety (2) NNSA Office of Military Application and Stockpile Support (3) NNSA Service Center, Albuquerque (4) NNSA Service Center (5) NNSA Livermore Site Office (6) NNSA Nevada Site Office (7) NNSA Sandia Site Office (8) NNSA Pantex Site Office

(9) DOE Idaho Field Office (10) DOE Savannah River Office (11) Los Alamos National Laboratory (12) Lawrence Livermore National Laboratory (13) Pantex Plant (14) Kansas City Plant (15) Idaho National Engineering and Environmental Laboratory (16) Nevada Test Site 10 DOE M 440.1-1A 1-9-06 (17) Sandia National Laboratories (18) Wackenhut Services, Savannah River Site b. A representative of the DOE Office of Facility Safety shall chair the committee and will report directly to the DOE Director, Office of Facility Safety. 5.2 DOE Explosives Safety Committee Functions a. The DOE Explosives Safety Committee shall perform the following functions: (1) Review, evaluate, and act under authority delegated from the DOE Director, Office of Facility Safety, on proposed changes or revisions to this Manual. (2) Evaluate and respond to requests for interpretations of the Manual. (3) Meet periodically, as appropriate, to review and evaluate Manual adequacy and existing exemptions, and to initiate Manual changes as needed. b. The DOE Explosive Safety Committee (at the local level its individual voting members) is (are) the “Authority Having Jurisdiction” over DOE explosives safety matters. c. Changes to this Manual become effective once they have been approved by the DOE Explosives Safety Committee and the approval is published in the official minutes of committee meetings. DOE M 440.1-1A 11 1-9-06 6.0 DEFINITIONS For purposes of this Manual, the following terms are defined. AIR TERMINAL. (1) A component of a Lightning Protection System (LPS) designed to accept direct attachment of the lightning flash and transfer the current to the down conductor. (See STRIKE TERMINATION DEVICE). (2) A strike termination device that is a receptor for attachment of flashes to the LPS and is listed for the purpose. APPROVED. Complying with the provision(s) of this Manual and with instructions and details issued by the authority having jurisdiction or with those of other approving agencies specified herein. ARM. A general term that implies the energizing of electronic and electrical circuitry, which in turn controls power sources or other components used to initiate explosives. The arming operation completes all steps preparatory to electrical initiation of explosives except the actual fire signal. BARRICADE. An intervening approved barrier, natural or artificial, of such type, size, and construction as to limit in a prescribed manner the effect of an explosion on nearby buildings or personnel. BAY. A location (e.g., room, cubicle, cell, or 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. BOND. An interconnection of metal objects, generally to the LPS. (See BONDING). BONDED. The joining of metallic parts to form an electrically conductive path that will ensure electrical continuity and the capacity to conduct safely any current likely to be imposed. BONDING. (1) An electrical connection between a metal object and an LPS component. This produces electrical continuity between the LPS and the object and minimizes electro-magnetic potential differences. Bonding is done to prevent sideflash. (2) An electrical connection between an electrically conductive object and an LPS component that is intended to significantly reduce potential differences created by lightning currents.

BOOSTER. 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. Casuals do not perform hands-on work with explosives but are otherwise involved with the explosives operation being performed. 12 DOE M 440.1-1A 1-9-06 Casuals are accounted for in the established personnel limits for the area and are provided a level of protection consistent with the explosion hazard of operations in adjacent areas. CATENARY SYSTEM. An LPS consisting of overhead wire suspended from poles connected to a grounding system via down conductors. Its purpose is to intercept lightning flashes from the protected area. CLEAR ZONE. The required maximum quantity-distance for the protection of personnel and facilities from the Potential Explosion Site (PES). COMBUSTIBLE MATERIAL. Any material that, when ignited, will sustain burning. COMPATIBILITY. The chemical property of materials to coexist without adverse reaction for an acceptable period of time. Compatibility in storage exists when storing materials together does not increase the probability of an accident or, for a given quantity, the magnitude of the effects of such an accident. Storage compatibility groups are assigned to provide for segregated storage. CONCURRENT OPERATIONS. Operations performed simultaneously and in close enough proximity that an incident with one operation could adversely influence the other. CONDUCTOR. Usually a cable intended to be used to carry lightning currents between strike termination devices and ground terminals. The conductor also serves as a strike termination device for a catenary LPS. Conductors are usually heavy metallic cables but metallic building structural members, (e.g., steel I-beams) can also function as down conductors. 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. COUNTERPOISE. A type of an earth electrode system consisting of conductor cables buried around the structure to be protected. Generally, a counterpoise will have more surface area contacting the earth than ground rod systems. Commonly called a ground ring electrode. (See EARTH ELECTRODE SYSTEM). 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. DOE M 440.1-1A 13 1-9-06 Deflagration is a surface phenomenon with the reaction products flowing away from the unreacted material along the surface at subsonic velocity. The effect of a true deflagration under confinement is an explosion. Confinement of the reaction increases pressure, rate of reaction, and temperature and may cause transition into a detonation.

DETONATION. A violent chemical reaction within a chemical compound or mechanical mixture evolving 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 differential scanning calorimetry or DSC curve. The energy input is substituted for ΔT and is plotted in the same manner as a normal DTA curve. DIFFERENTIAL THERMAL ANALYSIS (DTA). A technique in which the temperature difference between 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 DTA curve. The energy input is substituted for ΔT and is plotted in the same manner as a normal differential thermal analysis (DTA) curve. DIRECT CONTACT WITH EXPLOSIVES. Physical contact between an electrical instrument or equipment to bare explosives, the metallic casing of an explosive, or the firing leads of an explosive device. DOWN CONDUCTOR. A form of a main conductor designed to conduct the current of a lightning flash vertically down to the earth electrode system. DRYING. The removal of volatiles from ingredients or mixtures. DSC. See DIFFERENTIAL SCANNING CALORIMETRY. DTA. See DIFFERENTIAL THERMAL ANALYSIS. EARTH ELECTRODE SYSTEM. Sometimes called a ground terminal. (1) A component of an LPS that transfers the current of a lightning flash to the earth. The earth electrode system is connected to the down conductor and is in direct contact with the earth. Examples of earth electrode systems include ground rods, a counterpoise, buried metal plates, Ufer grounds, or other similar devices. The matrix of a Faraday-like shield acts as the earth (ground) electrode for an LPS. (2) The portion of an LPS, such as a ground rod, ground plate, or ground conductor, that is installed to provide electrical contact with earth. EBW. See EXPLODING BRIDGEWIRE. 14 DOE M 440.1-1A 1-9-06 EED. See ELECTROEXPLOSIVE DEVICE. ELECTRICAL BONDING. Electrical connection between two conductive objects intended to prevent development of an electrical potential between them. ELECTROEXPLOSIVE DEVICE (EED). An EED is 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 which is designed to function as an explosive, or chemical compound which functions through self-reaction as an explosive, and which, 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 explosive. EXPLOSIVE DECONTAMINATION. The removal of hazardous explosive material. EXPLOSIVES FACILITY. A structure or defined area used for explosives storage or operations. Excluded are explosives presenting only localized, minimal hazards as determined by the Authority Having Jurisdiction. Examples of excluded items may include user quantities of small arms ammunition, commercial distress signals, or cartridges for cartridge actuated tools, etc. 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 having responsibility for conducting operations at a DOE facility. FARADAY CAGE or FARADAY-LIKE SHIELD. An LPS where the area to be protected is enclosed by a heavy metal screen (like a birdcage) or continuous metallic structure with no unbonded metallic penetrations. On such a system, the lightning current flows on the exterior of the structure, not through the interior. DOE M 440.1-1A 15 1-9-06 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 60°C and a vapor pressure not exceeding 280 kPa (41 psia) at 37.8°C. This is the definition as applied in this Manual; it includes some materials defined as combustible liquids by the Department of Transportation (DOT) and/or NFPA 70, Flammable and Combustible Liquids Code. FLASH. The total lightning event. A flash may involve several lightning strokes, generally using the same path through the air as the initial event. 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. (1) The operation of combining ingredients to produce a mixture of a final desired composition possessing specific physical and explosive properties. (2) An explosives composition. GROUND RESISTANCE. The value (in ohms) of the resistance between an earth electrode system and earth. GROUND RING ELECTRODE (GRE). An earth electrode system that encircles the structure, either on or buried in the earth. (See COUNTERPOISE and EARTH ELECTRODE SYSTEM). GROUND ROD. A component of one type of earth electrode system, generally a cylindrical device of approximately 3/4-in. diameter by approximately 10-ft long driven into the soil. The ground rod is attached to the down conductor and dissipates a lightning flash’s current into the earth.

GROUND TERMINAL. See EARTH ELECTRODE SYSTEM. GROUNDED. (1) Connected to earth or some conducting body that serves in place of the earth. (2) Connected to earth or some conducting body that is connected to earth. GROUNDING. Providing an electrical path to the earth, generally to the earth electrode system. 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. 16 DOE M 440.1-1A 1-9-06 HIGH PRESSURE. Gas pressure greater than 3,000 psig (21 MPa gauge); liquid pressure greater than 5,000 psig (35 MPa gauge). HOLE. (as applied to machine explosives). Any cavity that is more than one-half diameter deep, being cut by any tool with the direction of feed along the axis of rotation. HOT WORK (thermal). Any operation requiring the use of a flame-producing device, an electrically heated tool producing a temperature higher than 109°C, 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 or shipping containers or, if not in containers, by the spacing specified in TP 20-7. IMPEDANCE. The resistance and reactance to an electrical current. INDIRECT CONTACT WITH EXPLOSIVES. When bare explosives, the metallic casing of an explosive, or the firing leads of an explosive device make contact with electrical instrument or equipment through electrically conductive equipment or surfaces other than the equipment leads. INDUCTANCE. (1) The property of a conductor that makes it oppose any current change through it. (2) A process where an object having electrical or magnetic energy can produce similar properties in a nearby object without direct contact. INERT MATERIALS. Materials that show no exothermic decomposition when tested by DSC or DTA. Moreover, when tested by recognized compatibility tests, the inert material shall not show any incompatibility with energetic material with which it may be combined. Inert material shall neither alter the onset of exotherm of the DSC or DTA trace of the energetic material nor increase the rate of decomposition or gas evolution of the energetic material. IN-PROCESS STORAGE MAGAZINE (facility, vault, rest house, etc.). See SERVICE MAGAZINE. INHABITED BUILDING. A building or structure other than operating buildings, magazines, and auxiliary buildings occupied in whole or in part as a habitation for people or where people are accustomed to assemble, both within and outside DOE facilities. Land outside DOE facilities shall be considered as sites for inhabited buildings.

DOE M 440.1-1A 17 1-9-06 INHABITED BUILDING DISTANCE. The minimum distance permitted between explosives locations and inhabited buildings, administrative areas, site boundaries, main power stations, and other facilities of vital or strategic nature. INITIATION STIMULUS. Energy input to an explosive in a form potentially capable of initiating a rapid decomposition reaction. Typical initiation stimuli are heat, friction, impact, electrical discharge, and shock. INITIATION, WITH ITS OWN MEANS. Explosives or ammunition having their normal initiating device (e.g., detonators or 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 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. INSENSITIVE HIGH EXPLOSIVES (IHE). Explosive substances that, although mass detonating, are so insensitive that the probability of accidental initiation or transition from burning to detonation is negligible. The materials passing the DOE qualification tests in Table IX-1 are classified as IHE, and are listed in INTEGRAL SYSTEM. An LPS that has strike termination devices mounted on the structure to be protected. These strike termination devices are connected to the earth electrode system via down conductors. Metallic structure members can serve as parts of the LPS. 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 minimum distance permitted between any two operating buildings or sites within an operating line, at least one of which contains, or is designed to contain, explosives. INTRINSICALLY SAFE. An apparatus or system whose circuits are incapable of producing any spark or thermal effect capable of causing ignition of a mixture of flammable or combustible material under test conditions described in ANSI/UL 913. ISOSTATIC PRESSING. The operation of compacting a material in a sealed flexible container. The container is submerged in a pressure vessel, and the vessel is pressurized with liquid. LABORATORY OPERATIONS. Experimental study, testing, and analysis of small quantities of energetic materials. Manufacturing processes with small quantities of materials are not included. 18 DOE M 440.1-1A 1-9-06 LEL. See LOWER EXPLOSIVE LIMIT. LFL. See LOWER FLAMMABLE LIMIT. LIGHTNING DETECTION SYSTEM, (LDS). A device or system to detect the presence of lightning activity in the general area. LIGHTNING PROTECTION SYSTEM (LPS). A lightning protection system is a complete system of strike termination devices, conductors, ground terminals, interconnecting conductors, surge suppression devices, and other connectors or fittings required to complete the system.

LIGHTNING WARNING SYSTEM. A system that detects the presence and range of lightning activity and thereby issues an alert or warning advisory. LOW-ENERGY EED. All EEDs except 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. MAST SYSTEM. An LPS system that consists of one or more poles with a strike termination device connected to an earth electrode system by down conductors. In the case of a metallic pole, the pole could serve as the strike termination device and down conductor. Its purpose is to intercept lightning flashes from the protected area. 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 or 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. DOE M 440.1-1A 19 1-9-06 MELTING. Operations involving change in the physical state of explosives from solid to liquid. MILLING. (1) Operations that either reduce solid material particle size by attrition or apply high shear mixing to incorporate solid materials into plastic binders. (2) A surface machining operation performed on a mill. MIXING. A mechanical operation that combines dissimilar materials. MOCK EXPLOSIVE. Substances bearing similar physical properties (texture, density, cohesion, etc.) to an explosive material. They are non-detonable. However, some are exothermic materials that 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. NET EXPLOSIVE WEIGHT (NEW). Net explosive weight expressed in pounds. NEW (OR EXPERIMENTAL) EXPLOSIVES. Explosive, explosive mixture or explosive and binder mixture that the Explosives Development Committee (EDC) has not characterized. NON-FACILITY PERSONNEL. Construction or maintenance personnel who do not have a continuing contract with DOE or NNSA or their agents at the facility concerned. NON-OCCUPIED or UNOCCUPIED AREA. A location where occupancy is of a transitory nature such as building corridors, access ramps, and facility roads. Other examples are locations such as mechanical equipment rooms, equipment/parts staging/storage areas, decontamination areas and janitors closets, which typically have a low personnel density and an intermittent and relatively short-term duration of occupancy for assigned work but in which personnel are not normally permanently assigned.

NUCLEAR EXPLOSIVE (NE). An assembly containing fissionable and/or fusionable materials and main charge high-explosive parts or propellants capable of producing a nuclear detonation (e.g., a nuclear weapon or test device). NUCLEAR EXPLOSIVE OPERATION (NEO). Any activity involving a nuclear explosive, including activities in which main charge high-explosive parts and pit are collocated. OCCUPIED AREA. Any work area that can be reasonably considered integral to an explosives operating area to which personnel are assigned or in which work is performed, however intermittently. Examples of areas to be considered as occupied are assembly/disassembly cells or bays, explosives operating bays, radiography control and film processing rooms, offices, break areas and rest rooms. 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. PENETRATION. A conductive object that passes through the zone of protection or exterior surface of an LPS. 20 DOE M 440.1-1A 1-9-06 PERSONNEL BARRIER. A device designed to limit or prevent personnel access to a building or an area during hazardous operations. POTENTIAL EXPLOSION SITE (PES). The location of a quantity of ammunition and explosives that will create a blast, fragment, thermal, or debris hazard in the event of an accidental explosion of its contents. PRESSING. The operation of increasing the density of explosive material by applying pressure. PRIMARY EXPLOSIVE. A sensitive explosive which nearly always detonates by simple ignition from such means as a spark, flame, impact and other primary heat sources of appropriate magnitude. Examples are mercury fulminate, lead azide, and lead styphnate, and other materials of similar sensitivities. PROGRAM SECRETARIAL OFFICER. A senior program official, which includes the Assistant Secretaries or Office Directors at the Assistant Secretary level for DOE or the Deputy or Associate Administrators for NNSA. PROPELLANT. Explosive composition used to propel projectiles and rockets and to generate gases for powering auxiliary devices. PUBLIC TRAFFIC ROUTE DISTANCE. The minimum separation distance required between a potential explosion site and any public street, road, highway, passenger railroad, or navigable waterway (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 non- detonative, self-sustaining exothermic chemical reactions. RATED ELECTRICAL EQUIPMENT, FIXTURES, INSTRUMENTATION AND MATERIALS. As used in the DOE Explosives Safety Manual, “rated” refers to those items used in explosives locations that meet identified standards or have been tested and found suitable for use in Class I or Class II hazardous atmosphere. For an item to be considered “rated,” a nationally recognized testing laboratory shall have approved its use (for example, Factory Mutual) or listed it for use (for example, Underwriters Laboratory) in the appropriate Class I or Class II hazardous atmosphere. “Rated” items are used to provide protection in explosives locations where the National Electrical Code Article 500 does not normally apply.

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. DOE M 440.1-1A 21 1-9-06 RESISTANCE. The property of a conductor to oppose the flow of an electric current and change electric energy into heat. For lightning protection purposes low resistance values are desired. Resistance is measured in ohms. RETURN STROKE. That part of a lightning flash where high electric currents are developed as the negatively charged leader encounters the positively charged return stroke. The phase of lightning that produces electric current, heat, a light flash and thunder. RISK. A measure of the combination of the probability and consequences of the hazards of an operation, expressed in qualitative or quantitative terms. ROLLING SPHERE ZONE OF PROTECTION MODEL. A theoretical concept describing the area protected by an LPS where an imaginary sphere (100-ft radius for explosive facilities) approaches an LPS from all angles and directions. The protected area is the area of the curve between where the curve is tangent to the ground, and the curve touches the LPS. For example, with the rolling sphere method the area protected by a mast system looks like a teepee. 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. SECONDARY EXPLOSIVES. An explosive substance which is relatively insensitive (when compared to primary explosives), which is usually initiated by primary explosives with or without the aid of boosters or supplementary charges. Such explosives may react as a deflagrating or as a detonating explosive. Examples are TNT, plastic bonded formulations, and other materials of similar sensitivity. SERVICE MAGAZINE, REST HOUSE, ETC. An auxiliary building or suitable designated room (vault) used for the intermediate storage of explosives materials not exceeding the minimum amount necessary for safe and efficient operation. SHUNT. An electrical interconnection of various portions of EED circuitry to prevent the development of an electrical charge differential between the parts. SIDEFLASH. (1) The phenomena where lightning current will jump through a non-conductive medium to attach to improperly bonded metallic objects. (2) An electrical spark, caused by differences of potential, which occurs between conductive metal bodies or between conductive metal bodies and a component of an LPS or ground. SITE PLAN. A formal explosives facility and operations safety document to be prepared by Facility Management for DOE/NNSA approval of explosives facilities siting and operations before the operation starts. This document becomes the authorization basis for explosives facility operations. SITE PLANNING. The process of performing and documenting an analysis of planned and existing facilities and missions involving ammunition and explosives, or occurring within the 22 DOE M 440.1-1A 1-9-06

hazard zones created by explosives. It may include evaluations of blast hazards; fragment hazards; protective construction; grounding, bonding, and lightning protection systems; electrical installations; natural or man-made terrain features; or other mission or local requirements. Effective site planning relies heavily on explosives safety standards, but it also incorporates survivability and operational considerations, and economic, security, environmental, and legal criteria to meet the goals and needs of the DOE community. 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 caliber less than 20 mm 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 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 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. STRIKE TERMINATION DEVICE. (1) A component or feature of an LPS that is intended to accept the direct attachment of a lightning flash or strike. Strike termination devices include overhead wires or grids, air terminals, or a building’s (grounded) steel structural elements. (2) A component of an LPS that intercepts lightning flashes and connects them to a path to ground. Strike termination devices include air terminals, metal masts, permanent metal parts of structures, and overhead ground wires installed in catenary LPSs. STROKE. The high electric current phase of a lightning strike. The term is better defined as the return stroke. 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. SURGE SUPPRESSION DEVICE. Also called a surge protector. (1) A device used on power and communication lines to attenuate, suppress or divert lightning induced electrical energy to ground. (2) A protective device used to limiting surge voltages by discharging or bypassing surge current. It can also prevent continued flow of follow current while remaining capable of discharging or bypassing surge current. SYNTHESIS. The chemical operation or operations required to produce a desired chemical compound. DOE M 440.1-1A 23 (and 24) 1-9-06 TARGET. The area, structure, or material into which a projectile is fired. TNT EQUIVALENT. A measure of the blast effects from explosion of a given quantity of material expressed in terms of the weight of TNT that would produce the same blast effects when detonated. TRANSFER IMPEDANCE. (1) A transmittance expressed as the ratio of the voltage at a pair of terminals divided by the driving current, with all other terminals terminated in a specified way. (2) A transmittance expressed as the ratio of the electric field on the interior of a shielded enclosure divided by the current density on the exterior of the shield.

TRANSIENT. Any person within inhabited building distance but not inside an explosives bay or other occupied areas (offices, break areas, shops, etc.). A transient’s presence within IBD of an explosives operation is transitory in nature, or to complete a relatively short-term, nonexplosives related work assignment in an area in which personnel are not permanently assigned, such as a building corridor, access ramp, or roadway. Transients are not accounted for in established personnel limits for any explosives operating area and are afforded a level of protection only from Class I explosion hazard activities. UFER GROUND. An LPS ground produced by electrodes encased in concrete. This can be a coil of cable encased in concrete or even the reinforcing steel in the footers or floor of buildings. (See EARTH ELECTRODE SYSTEM). UNEXPLODED ORDNANCE (UXO). Explosive ordnance which has been primed, fuzed, armed, or otherwise prepared for action, and which has been fired, dropped, launched, projected, or placed in such a manner as to constitute a hazard to operations, installations, personnel, or material and remains unexploded either by malfunction, design, or for any other cause. UNITED NATIONS (UN) CLASS 1 EXPLOSIVES. (1) 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; (2) 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 (3) Substances and articles not mentioned under (1) and (2) that are manufactured with a view of producing a practical, explosive or pyrotechnic effect. ZONE OF PROTECTION. (1) The area considered statistically safe from the direct attachment of a lightning strike as defined by the rolling sphere zone of protection model. (2) The space adjacent to an LPS that is substantially immune to direct lightning flashes. DOE M 440.1-1A 25 1-9-06 CHAPTER II—OPERATIONAL SAFETY 1.0 GENERAL OPERATIONS SAFETY GUIDELINES 1.1 Protection of Explosives a. Explosives are energetic materials that can react violently and should be protected from abnormal stimuli or environments, including: (1) Friction forces. (2) Excessive pressures and temperatures. (3) Impact, shock, and pinching. (4) Deformation. (5) Electrical sparks, abrasive or welding sparks, and open flame. (6) Contamination. (7) Contact with incompatible materials. 1.2 Equipment Checks a. Before being used in the explosives process, and at established intervals, processing and test equipment shall be checked for (1) Proper design. (2) Proper function. (3) Specified clearances between parts in relative motion. (4) Abnormal metal-to-metal rubbing of moving parts potentially contacting explosive materials. (5) Cracks, voids, or screw threads where explosives may accumulate. (6) Contamination that is incompatible with the materials to be introduced. b. This checkout may require the use of mock explosives in process or test conditions. c. 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.

26 DOE M 440.1-1A 1-9-06 1.3 Inspection Frequency a. When this Manual calls for an inspection, but the inspection interval is not specified, local facility management shall establish the inspection interval. Inspection intervals shall be modified when experience dictates a need. 1.4 Laboratory Operations a. The special safety guidelines applicable to general laboratory operations involving explosive materials are contained in section 21.0 of this chapter. 1.5 Toxicity Hazards a. 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. The most frequently reported effect from working with explosives is a skin rash resulting from skin contact with explosives materials, or with solvents and adhesives used with explosives operations. 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: (1) Know the health hazard and controls before beginning operations. (2) Evaluate the operation during startup to assure that occupational exposure limits are not exceeded; routine operations should be monitored periodically. (3) Handle materials in a well ventilated area; local exhaust ventilation is preferred. (4) Avoid skin contact; use appropriate protective clothing. (5) 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 a. Before beginning explosives operations, managers shall ensure the following: (1) Identify and maintain a current list of explosives and other hazardous materials used in conjunction with their operations. (2) 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 DOE M 440.1-1A 27 1-9-06 Advisory Committee (TMAC). Health hazard information must be available and communicated to employees who work with or generate hazardous materials. (3) Educate and train employees in the hazards and precautions required for handling explosives and materials used in conjunction with explosives operation. This training should be a 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. 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. If required, a shield or other protective measure shall be employed. Selection criteria for the worst-case process are: (1) Sensitivity of materials. (2) Quantity of materials. (3) Number of personnel potentially affected. (4) Impact on other operations/activities. b. The process hazard analysis shall be performed as a team effort. The team shall consist of a minimum of three personnel, and preferably no more than seven personnel. The team shall include at least one engineer and one operator, and should have the following makeup:

(1) Team Leader, who is familiar with the analysis methodology used. (2) Technical Member(s), who is familiar with the process being analyzed. (3) Scribe, who writes notes of meetings and interviews and drafts reports. c. The facility manager or team leader may select the analysis methodology used, which should be one of the following: (1) Preliminary Hazard Analysis. (2) Checklist (usually for similar batch operations). (3) What-if Analysis. (4) Hazard and Operability Study (HAZOP). 28 DOE M 440.1-1A 1-9-06 (5) Failure Modes, Effects, and Criticality Analysis (FMECA). (6) Fault Tree Analysis. (7) Event Tree Analysis. d. The process hazard analysis shall be formally documented. e. Employees and employee representatives shall be consulted on the process hazard analysis. The result of the process hazard analysis shall be provided to employees involved in or affected by the operation. f. The process hazard analysis shall be updated and revalidated at least every five years by a team meeting the criteria in section 1.7b. g. The facility manager shall be responsible for establishing a system to address the team’s findings and recommendations promptly. Corrective actions, schedules for corrective actions, and completion of corrective actions shall be formally documented. Such documentation shall be filed with the process hazard analysis. h. Files containing process hazard analyses, updates, and corrective actions status shall be maintained for the life of the process. DOE M 440.1-1A 29 1-9-06 2.0 WORK ENVIRONMENT 2.1 General Requirements a. Workspace shall be adequate 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 explosives could strike in a handling incident should be cushioned where practical. Physical safety systems demonstrated to preclude the explosives from being dropped or struck could meet these requirements. e. A procedure should be established to account 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 monitored frequently and assistance can be provided or aid summoned in the event of an emergency. g. Safety analyses of explosives facilities and operations 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 prepare and obtain DOE/NNSA approval of the Site Plan. The Site Plan shall include the result of this analysis. 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 a. Exit requirements for any building or structure containing explosives shall comply with the intent of the Life Safety Code, NFPA 101, except as otherwise permitted in this section. 2.2.1 Building or Structure Occupancy a. In determining occupancies: 30 DOE M 440.1-1A 1-9-06

(1) Explosives operating buildings shall be classified as industrial occupancies (NFPA 101, Chapter 40). (2) Explosives storage or staging buildings or structures shall be classified as storage occupancies (NFPA 101, Chapter 42). 2.2.2 Hazard of Contents Classification a. The hazard of contents classification of any explosives occupancy shall be determined using the guidelines given in NFPA 101 and the following requirements: (1) High-hazard explosives contents are those which, because of form, character, or volume, are likely to burn with extreme rapidity can release poisonous fumes or explosions in a fire. The expectation of poisonous fumes or explosions is 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. (2) Reduced-hazard explosives contents are those that burn with rapidity that is moderate or less and will not produce poisonous vapors. This criterion shall be documented by a hazard analysis. 2.2.3 Personnel Protective Restrictions and Requirements a. DOE occupancies containing high explosives dictate that personnel be protected from blast overpressures and fragments (and spread of plutonium in some occupancies) from an accidental detonation. Accidental detonation of explosives is usually the result of stimuli other than a fire. b. Non-compliance 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: (1) 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. DOE M 440.1-1A 31 1-9-06 (2) 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. (3) 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 section 2.2.5 of this chapter. 2.2.4 Requirements for Existing Facilities a. Existing facilities may deviate from current NFPA 101 requirements in the following situations: (1) Current code requirements were not in effect when the building was constructed. The building, however, is still required to meet the code of record. (2) Deviations were made to meet the level-of-protection and design criteria in Chapter VI, section 6, of this Manual. (3) 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 risk.

(4) The risk from deviation has been analyzed and accepted by current hazards analysis. NOTE: 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 section 2.2.5 of this chapter. 2.2.5 Requirements for New Facilities a. 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. 32 DOE M 440.1-1A 1-9-06 a. Clear pathways to exit in explosives bay or workroom. b. Potential for sustained fire from the presence of combustible and flammable materials and the presence of ignition sources in work environments. 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 section 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 six people to exit the workroom or bay, including the opening of doors where necessary, is 30 seconds or less. The total time for twenty 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 a. Where NFPA 101 requires at least two exits, but 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 sections 2.2.3 and 2.2.4 of this chapter and the following are met: (1) The path of exit travel shall be arranged so it is not through or toward a hazardous operation. (2) A room containing a high-hazard explosive occupancy shall not exceed 500 ft2, and the occupant load of the room shall be restricted to two operators and two transients. (3) A room containing a reduced-hazard explosive occupancy shall not exceed 1,000 ft2. b. 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. DOE M 440.1-1A 33 1-9-06 2.2.7 Blast-Resistant Doors a. Blast-resistant doors required to protect personnel from the effects of an accidental detonation may be located in the means of egress, provided the requirements of sections 2.2.3 through 2.2.5 of this chapter and the following are met: (1) Where power-operated doors are required to accomplish unlatching and opening, they shall have redundant features or be capable of being opened manually (to permit exit travel) or closed where necessary to safeguard exits. (2) The time required to fully open or close a door shall be as short as reasonably possible. (3) 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.

(4) The following exceptions to NFPA 101 may be allowed when justified and documented. (a) Swinging doors may exceed 48 in. wide. (b) The NFPA-required swinging doors adjacent to a revolving blast door can be omitted. (c) Revolving blast doors need to be designed to collapse into book-fold position. (d) Where fire-rated doors are required, blast doors are considered to have the required fire rating. (e) An airlock with two or more doors that is intended during routine operations to prevent continuous and unobstructed passage by allowing the release of only one door at a time shall be permitted in a means of egress. In such cases, there shall be provisions to allow for continuous and unobstructed travel during an emergency egress condition. (f) Panic hardware is not required on blast doors. 2.2.8 Slide Escapes a. Slide escapes should be provided for elevated explosives operating locations from which rapid exit may be vital and cannot be obtained by 34 DOE M 440.1-1A 1-9-06 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. b. Exits to slide escapes must open onto platforms that are not less than 3 ft2, 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: (1) Angle, 40 to 50 degrees horizontal. (2) Slide depth, 24 in. (3) Radius at bottom of slide, 12 in. (4) Height at lower end of slide, not over 24 in. above the landing. c. If necessary, the end of the slide shall have a horizontal run sufficient to prevent employee injury from 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. Metal sheets constructing the slide must overlap in the direction of travel. DOE M 440.1-1A 35 1-9-06 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 the accumulation of explosives dust and waste. This program should not be conducted in any bay where a hazardous operation is being conducted. d. In buildings containing explosives, floors should be cleaned with hot water or a water-steam mix wherever practical. Non-abrasive sweeping compounds that are compatible with the explosives involved may be used when a water-steam mix or hot water is not practical. Such sweeping compounds may be combustible but must not be volatile (closed-cup flash point must not be lower than 110°C). Sweeping compounds containing wax shall not be used on conductive flooring. Where nitrated organic explosives (which may form sensitive explosive compounds with some alkalis) are involved, the use of cleaning agents containing those alkalis is prohibited.

e. Before beginning explosives decontamination activities involving large amounts of organic solvents (generally over 1L), provisions must be made for adequate ventilation or respiratory protection, fire protection, and adequate protective clothing. 3.2 Maintenance and Repair a. Records shall be maintained for inspection, repair, and servicing of process and handling equipment and fire protection systems. b. Maintenance operations involving major repairs, changes, or the use of hazardous equipment should not be performed within bays (rooms) while explosives are present. Before beginning such maintenance, 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. Non-facility personnel performing maintenance or construction operations shall be at least intraline distance from any explosives operation and should be at least intraline distance from any building containing explosives. This requirement does not apply to personnel making job site inspections or equipment repairs requiring less than eight hours (e.g., technical 36 DOE M 440.1-1A 1-9-06 representatives, architect-engineering surveyors, etc.). Providing equivalent protection may satisfy the intraline distance separation requirement. Transportation of explosives is permitted on roadways at less than intraline distance. d. Facility management shall determine the minimum practical distance by which non-facility personnel (e.g., technical representatives, service representatives, architect-engineering surveyors, etc.) shall be separated from explosives operations while making job site inspections or equipment repairs requiring less than eight hours. Facility management shall control explosives operations so that the chance of an explosion shall be kept to a minimum. The rationale for establishing the minimum practicable distance and additional control measures taken shall be documented and maintained until operations have been completed and personnel have permanently vacated the work site. All such personnel shall be informed of the risk of working at less than intraline distance and shall agree to accept such risk. e. 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 Standard (DOE-STD-1090-current version) may be used as a guide. f. Only authorized personnel shall perform maintenance work. g. Before resuming operations following maintenance, the area shall be cleaned and approved by the operations supervisor. 3.3 Hot Work Permits a. Where explosives are involved, a written permit shall be required for the temporary use of portable, heat-producing equipment that generates temperatures higher than 228°F (109°C). Explosives decontamination of the immediately affected work areas and explosives removal shall be required before beginning hot work operations. The permit should state the location, time, duration, purpose of use, details of safety, and fire-fighting equipment required. The permit shall be available at the named location for checkout by supervisory personnel. (1) Permits shall be authorized by signature of personnel designated by local facility management. Designated personnel should be qualified by experience in explosives work, fire prevention, and general safety precautions, in particular, the purging of equipment, presence of flammable mixtures, and the avoidance of electrical and mechanical hazards that could be incident to repair work.

(2) Personnel designated to sign the hot work permit should represent supervision of the work location, supervision of personnel performing DOE M 440.1-1A 37 (and 38) 1-9-06 the hot work, and a third group independent of the first two (usually the safety and fire protection group). (3) An individual 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 supervision should inspect the job site before, during, and after completion of the job. DOE M 440.1-1A 39 (and 40) 1-9-06 4.0 REMOTE OPERATIONS 4.1 Personnel Protection a. Explosives operations judged to present a significant level of risk to be performed remotely shall be conducted in facilities where the construction of the operating bay or the control room affords sufficient protection to personnel to prevent serious injuries. Chapter VI, section 4.2.1d specifies criteria for the prevention of serious injuries. b. Prevention of serious injury from a remote operation applies to both transient personnel and personnel involved in the operations. 4.2 Access and Equipment Controls a. Procedures and equipment shall be used to prevent entry into a hazardous bay or area in which a remote operation is occurring or to prevent the operation from proceeding when personnel enter, as follows: (1) 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. (2) Corridors leading to bays in which hazardous (remote) operations are being performed shall be marked to warn of the danger. Barriers shall also be set up. (3) Visual methods such as closed circuit television should be used to monitor remote operations and to enable viewing of the operating area conditions before entering. Remote audio monitoring and video recording should also be considered. (4) Interlocking of remote operating equipment to access doors should be required for each remote operation. (5) Lights or similar warning devices shall conspicuously identify buildings or bays in which remote operations are performed to indicate when remote operations are under way. DOE M 440.1-1A 41 (and 42) 1-9-06 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, or 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 into pockets. Kitchen “strike anywhere” matches shall not be used. c. Operating personnel should not carry metal articles (e.g., keys, jewelry, knives, coins, etc.) in explosives processing areas where such items could constitute a hazard if dropped into the process operation. 5.2 Cooking and Eating a. Food or beverages shall not be consumed in explosives buildings, 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 microwaves), and portable electric heaters shall not be permitted in rooms where: (1) Explosives may be present. (2) Combustible vapors or dust may be present.

(3) Smoking or drinking is prohibited because toxic materials are present. (4) Electrical classification of appliances is not compatible with the area. 5.3 Access to Explosives Areas a. Access control procedures shall be established for entry to all explosives areas. DOE M 440.1-1A 43 (and 44) 1-9-06 6.0 PROTECTION OF ELECTROEXPLOSIVE DEVICES (EED) FROM ELECTROMAGNETIC RADIATION a. EEDs are vulnerable to initiation from a variety of sources. One potential hazard associated with EEDs is the accidental initiation by stray electromagnetic energy. This hazard exists when an electromagnetic field of sufficient intensity is generated to induce or otherwise couple currents and/or voltages of magnitudes large enough to initiate electroexplosive devices or other sensitive explosive components of weapon systems, or other explosive devices. This unintended actuation could have safety (premature firing) or reliability (duding) consequences. b. A large number of these devices are initiated by low levels of electrical energy and are susceptible to unintentional initiation by many forms of direct or induced stray electrical energy, such as from lightning discharges, static electricity, or tribo-electric (friction generated) effects, and radio frequency (RF) energy. Hazards from lightning discharges are covered in Chapter X. Lightning protection systems and requirements normally preclude the inadvertent initiation of EEDs by direct lightning strikes. Precautions for static electricity discharges are addressed in section 7 of this chapter. Stray energy, such as transients and other forms of induced energy, can be imposed on circuits affecting EEDs from other subsystems by various methods. Examples are inductive or capacitive coupling; sneak ground circuits; defective components or wiring; errors in design, modification, or maintenance. c. The degree to which EEDs are susceptible to unintentional initiation by exposure to the radiated fields of RF emitters depends on many variables. These variables include the ability of the leads, circuit, or installation to capture RF energy; the type and characteristics of RF energy; and methods of coupling which can introduce this energy into the EED. d. Emitter operating frequencies, power levels, modulation, and illumination angles are some of the factors that affect the vulnerability of EEDs to RF energy. e. As a precautionary measure, EEDs should normally be left inside their containers until ready for use. Shorting clips or other safety devices should not be removed until the EED is actually ready for use. f. For precautionary separation distances, see Chapter II, section 13, Tables II-1, II-2, and II-3. DOE M 440.1-1A 45 1-9-06 7.0 STATIC ELECTRICITY 7.1 General a. 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 a. Bonding straps can 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. Pressure contact alone is not adequate grounding for permanent equipment in contact with conductive floors or tabletops. 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, or driven ground rods of lightning protection systems. If a structure is equipped with a lightning protection system, all grounds shall be interconnected. Wires used as static ground conductors should be at least No. 10 AWG or equivalent.

7.3 Testing Bonded Equipment Grounds a. Grounding systems shall be tested for electrical resistance and continuity after installation has been completed and, in the case of active equipment, at intervals to be locally determined. If the equipment has been inactive for more than one month, the ground system shall be visually inspected for continuity before reactivation of the system. 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 an electrically isolated device or a belt-driven machine. In measuring the total resistance-to-ground for belt-driven machinery (to assure compliance with the section below), resistance of the belting is to be excluded. The maximum resistance-to-ground permitted for different types of equipment is as follows in section 7.3b. b. Hazardous locations (operations where a static spark discharge may be dangerous). All conductive parts of equipment shall be bonded; in the case of grounded equipment, bonding shall be such that resistance to ground does not exceed 25 ohms, unless resistance is not to exceed 10 ohms because of a lightning protection installation. For existing equipment, the rate of static generation should be considered before making changes in grounding systems. The resistance of conductive rubber hose should not exceed 250,000 ohms. 46 DOE M 440.1-1A 1-9-06 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, lead azide, lead styphnate, mercury fulminate, CP, etc.) that are sensitive to initiation by the electrostatic spark discharge from a person. Static discharge from a person may ignite many flammable liquids and air mixtures. In areas where personnel come into the proximity of (i.e., possible contact with) static-sensitive explosives or vapors, conductive floors shall be installed except where adequate housekeeping, dust collection, ventilation, or solvent recovery methods eliminate the hazards of dust-air or flammable vapor-air mixtures. Conductive floors may also be required in areas where operations involve 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 shall meet all specifications and test requirements that apply to conductive floors. Conductive wristbands may be substituted for conductive mats and footwear at fixed, grounded or bonded workstations or outdoor locations. 7.5 Conductive Floor, Work Surface, and Wristband Specifications a. Conductive floors must be made of non-sparking material such as conductive rubber or conductive flooring composition and shall meet the following requirements: (1) The flooring and its grounding system must provide for electrical resistance not to exceed 1,000,000 ohms (measured as specified in section 7.6 of this chapter). (2) 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 explosives dust can cause contamination. The large number of joints and the tendency of tiles to loosen provide areas in which explosive dust can become lodged, making normal cleanup procedures difficult.

(3) 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, tabletops on which exposed explosives or dusts are encountered should be covered with a properly grounded or bonded conductive material that meets the same requirements as those for flooring. DOE M 440.1-1A 47 1-9-06 (4) Conductive floors must be compatible with the explosive materials to be processed. (5) Conductive wristbands shall not exceed a resistance between the wearer and ground or bonding point 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. (6) Table-top work surface mats that are not part of a total conductive system (section 7.5a(3) shall have a resistance not to exceed 1,200,000 ohms. This resistance shall be measured by a method similar to that outlined in section 7.6 and records shall be maintained. Figure II-1. Testing Shoes on Wearer 7.6 Conductive Floor Tests a. Initial tests shall be made of all conductive floors, and subsequent tests shall be made at least semi-annually. 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. 48 DOE M 440.1-1A 1-9-06 b. Maximum floor resistance shall be measured with a suitably calibrated ohmmeter that operates on a normal open circuit output voltage of 500 volts DC and a short circuit current of 2.5 milliamperes with an effective internal resistance of approximately 200,000 ohms. Minimum floor resistance will be measured with an ohmmeter suitably calibrated for the task. c. Each electrode shall weigh 2.3 kg and shall have a dry, flat, circular contact area 6.5 cm in diameter, which shall comprise a surface of aluminum or tinfoil 1.3- to 2.5-mm thick, backed by a layer of rubber 0.6- to 0.65-cm thick and measuring between 40 and 60 durometer hardness as determined with a Shore Type A durometer (ASTM D-2240-68). d. The floor shall be clean and dry. “Electrode jelly” such as brushless shaving soap or saline solution shall not be used. e. The resistance of the floor shall be more than 5,000 ohms in areas with 110 volt service and 10,000 ohms in areas with 220 volt service, and less than 1,000,000 ohms in all areas, as measured between a permanent ground connection and an electrode placed at any point on the floor and also as measured between two electrodes placed 3 ft apart at any points on the floor. Measurements shall be made at five or more locations in each room. If the resistance changes appreciably with time during a measurement, the value observed after the voltage has been applied for about five seconds shall be considered as the measured value. 7.7 Humidification a. Humidification to prevent static electricity accumulations and subsequent discharges is usually effective if the relative humidity is above 60 percent. However, due to the possibility of spontaneous ignition, certain materials such as metallic powders and some pyrotechnic mixtures cannot be exposed to air with 60 percent relative humidity. 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 a. Ground fault circuit interrupter protection shall be provided in static grounded areas where personnel may come in contact with AC-powered electrical equipment. DOE M 440.1-1A 49 1-9-06 8.0 ELECTRICAL EQUIPMENT AND WIRING 8.1 Location/Operation Electrical Hazard Classification a. The National Electrical Code (NEC) shall be followed in all situations where the code normally applies. Although the NEC does not specifically address explosives, Article 500, Hazardous (Classified) Locations, requirements for the design and installation of electrical equipment and wiring in “classified” locations shall be used as guidance for the installation of rated equipment and fixtures where required by this section. The use of rated wiring, fixtures, equipment, and instrumentation where the code normally does not apply, provides additional safety for work with explosives materials by (1) restricting electrical ignition sources, such as sparks, electrical faults (shorts, power surges, etc.), (2) controlling surface temperatures of electrical items, and (3) reducing the potential for electrically initiated fires. Rated wiring, fixtures, equipment, and instrumentation shall be used for the operations specified below unless demonstrated unnecessary through analysis for a specific operation and location. The analysis shall be performed and documented per sections 8.4 and 8.6 of this chapter. b. Explosives do not normally fit the NEC definitions for groupings, classes, divisions, and area classifications. In order to apply Article 500 as a guide, vapors containing explosives shall be treated as Group D (unless NEC requires a higher classification because of other components of the vapor) and dusts of explosives or solid explosives shall be treated as Group G. Class, division, and area classification determinations shall be based on the explosives operation being performed, as specified below, and not on the location or surrounding atmosphere, nor its potential for producing an ignitable or explosive mixture. Maximum temperature limits shall be based on the thermal analysis of the explosives used in the operation. Division 1 items can be substituted for Division 2 items, but never Division 2 for Division 1 items. Where there is a conflict between the requirements of the code and requirements of this Manual, the more stringent of the two applies. c. Rated wiring, equipment and instruments shall be approved for use by a nationally recognized testing laboratory. Rated items shall have labels and/or clearly identifiable markings to show Class, Division, Group, and Temperature Range for which they are approved. Equipment approved for one Hazard Class is not interchangeable with another Hazard Class. d. The operations discussed below shall comply with the recommended class/division unless it is determined unnecessary through documented analysis for a specific operation and location. (1) Class I, Division 1 wiring, fixtures, process equipment, and instrumentation are recommended for operations involving flammable 50 DOE M 440.1-1A 1-9-06 gases or chemicals/materials expected to produce flammable vapors with explosives present. (2) Class I, Division 1 and Class II, Division 1 (dual rated) wiring, fixtures, process equipment, and instrumentation are recommended for synthesis, formulation, mixing, wet blending, and casting explosives, heating/drying of uncased explosives, plus any explosives processing that is expected to produce sublimation.

(3) Class II, Division 1 wiring, fixtures, process equipment, and instrumentation are recommended for screening, grinding, blending, pressing, dry machining explosives, and weighing of explosives powders, the use of explosive or ignitable dust mixtures with explosives present, plus any explosives process that is expected to produce dust from explosives that is suspended in the air. (4) Class II, Division 2 wiring, fixtures, process equipment, and instrumentation are recommended for storage, inspection, assembly, and wet machining of explosives, heating of fully encased explosives, plus, any explosives operation capable of producing dust of explosives that can accumulate on electrical equipment or apparatus. Class II, Division 1 or dual-rated equipment and wiring can be substituted. (5) General Purpose wiring, fixtures, process equipment, and instrumentation are allowed for shipping and receiving operations with fully encased explosives or explosives packaged in DOT/DoD approved shipping containers and areas in explosives facilities where no explosives are present. Examples are offices, control rooms, halls, rest rooms, and mechanical equipment rooms. General Purpose Areas may be established in explosives locations if facility management can determine, based on documented analysis of the processes involved and the separation between explosives operations requiring Class I or Class II rated electrical wiring, fixtures, process equipment, and instrumentation and the General Purpose Area is established and maintained such that: (a) Migration of explosive or ignitable gases, vapors or dust mixtures into the General Purpose Area from the rated area (not to be confused with the NEC Classified locations) will not occur under normal operating conditions. (b) Ignition energy that may be developed in the General Purpose Area will not be transferred to the rated area (not to be confused with the NEC Classified locations), even under electrical fault conditions. DOE M 440.1-1A 51 1-9-06 (6) Due to the potential for unacceptable consequences concerning operations with nuclear explosives, subassemblies, or components, they shall be evaluated in accordance with section 8.0 of this chapter to determine the appropriate electrical hazard classification. (7) Facility management shall evaluate, by using the principles given above, all explosives operations not specified elsewhere in this section to determine the appropriate electrical classification. The analysis shall be documented. 8.2 Electrical Supply System a. 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. Electric supply lines that can be interrupted without loss of power, i.e., power is rerouted through existing lines and/or networks, can be separated from explosives sites in accordance with section 8.2a(1)(c) below. (1) 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: (a) Inhabited-building distance if the line in question is part of a grid/system serving a large, offsite area.

(b) Public traffic route distance if loss of the line will not create serious social or economic hardships to offsite areas. (c) 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. (3) Aboveground, DOE-controlled electric service lines required to be in close proximity to a combustible constructed or uncovered explosives facility shall be no closer to that facility than the length of the lines between the poles or towers supporting the lines, unless an effective means is provided to ensure that broken, energized lines cannot come into contact with the facility or its appurtenances. Acceptable controls include, but are not limited to, geographic terrain features, instantaneous circuit interrupters, cable trays, and linking lines together. Equivalent underground service lines shall be located as specified in Chapter VI, section 3.2.4 and Table VI-2. 52 DOE M 440.1-1A 1-9-06 (4) Electric lines serving explosives facilities shall be installed underground from a point not less than 50 ft away from such facilities. (5) 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. (6) 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. (7) Uninterrupted Power Supply (UPS) should be provided if electrical power is critical to an explosives operation during a power shut down or interruption. 8.3 Building Electrical Service Entrance a. Each electrical service entrance for explosives facilities should be provided with the following protection. (1) Arrestors (a) Lightning arrestors shall be the appropriate size and class for the application and system voltages and shall be provided on the primary side of the transformer located in, on, or near the facility. See Chapter X for additional lightning protection guidance. (b) Surge arrestors and surge capacitors shall be provided on the supply side of the main service disconnect. (2) Grounding b. 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, Fixtures and Equipment 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 permanent wiring. Permanent equipment also DOE M 440.1-1A 53 1-9-06 includes equipment such as HVAC, hoods, vacuum pumps, hydraulic pumps, etc. b. New Facilities and Renovations (1) All permanent equipment and wiring of a room shall conform to section 8.1 of this chapter 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 should allow for easy conversion to dual-rated wiring and equipment. (3) Rated electrical fixtures shall not be painted. (4) Where equipment cannot meet the above requirements, the equipment should be located outside the hazardous environment. Otherwise, the equipment shall be analyzed and controlled as specified for electrical equipment and instrumentation in section 8.6 of this chapter. 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 section 8.4b of this chapter If remodeling or renovation would affect the wiring or equipment. (2) As a minimum, the permanent wiring and equipment shall meet the requirements of section 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 analyzed and controlled as specified for electrical equipment and instrumentation in section 8.6 of this chapter. 8.5 Flexible Cords/Wiring a. Wiring from the permanent premises wiring to process equipment or process instrumentation should be rated for actual explosives operation being performed, per section 8.1 of this chapter. As a minimum, flexible cords shall be hard usage service cord. 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 Hazard Class I or Class II, Division I or 54 DOE M 440.1-1A 1-9-06 dual-rated operations, the cord shall also be equipped with explosion-proof attachment plugs. Flexible cords shall not be used where fixed installed electrical wiring is required by equipment design. 8.6 Electrical Equipment and Instrumentation a. Non-permanent electrical equipment and instrumentation shall comply with the following: (1) Process instrumentation and process equipment should be rated for the actual environment based on the explosives operation being performed as defined in section 8.1 of this chapter. (2) If the thermal properties of an explosive are such that Group G or Group D equipment provides inadequate surface temperature limits, special protection shall be provided, or the equipment shall be excluded from the hazardous location. 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 section 12.1.1c of this chapter and Chapter VIII, section 2.2d. Approved instrumentation and equipment shall be administratively controlled and marked accordingly.

(3) When Hazard Class I or II, as applicable, equipment or instrumentation is required but 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 Hazard Class II locations, sealed to prevent explosives contamination. When the equipment is purged or sealed, the surface temperature shall not exceed 120°C for normal operations, or 165°C for overload conditions. (4) All electrical equipment or instrumentation in hazardous locations that do not meet the requirements of section 8.6a(3) above shall be evaluated and documented as to their suitability for use in the specific area and operation. The following are suggested areas for evaluation: (a) Malfunction of electrical equipment or process instrumentation. 1 Consequences of electrical initiated fire. 2 Initiation of explosives by electrical current. (b) Initiation of explosives by electrical fault. (c) Breach of containment resulting in exposed explosives or spillage of explosives. DOE M 440.1-1A 55 1-9-06 (d) Ignition sources arising from physical damage to the wiring method used (e.g., crushing by forklift or other material handling equipment, frayed cords, etc.). (e) Exposed electrical conductors or connectors that could make contact with leg wires or cables of explosive devices during routine handling. (f) Exposed electrical conductors or connectors on which explosives dust or vapors could collect. (g) Collection of explosives dust on or in the equipment. (h) Sensitivity to heat and spark, and thermal stability of explosives involved. (5) If the equipment is purged, the airflow shall be monitored per NFPA 496 and interlocked to the equipment, or alarmed, if operator shutdown of the machine can be reliably performed immediately upon receipt of that alarm. (6) A waiver is not required when the wiring, equipment or instrumentation meets the requirements of either section 8.6a(3) or 8.6a(4) of this chapter. If the wiring, 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 a. 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 Hazard Class II, 56 DOE M 440.1-1A 1-9-06 Division 2 rated hazardous operations and during setup of Hazard 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 Hazard Class I or Class II, Division 1 hazardous operations.

c. Hand-held, battery-operated equipment shall not come in direct or indirect contact with bare explosives. Batteries shall not be removed or replaced in hazard rated areas (section 8.1 of this chapter). 8.9 Non-Rated Extension Lighting a. When it is necessary to use extension lights within 10 ft of exposed explosives, where no airborne dust exists, the following requirements shall apply: (1) Lights shall be mounted on heavy tripod stands. (2) The lights shall be fitted with exterior globes to prevent the falling of hot sparks or particles that might ignite the explosives. (3) The lights shall be fitted with adequate guards to protect the globes from physical damage. (4) The wire providing power to the lights shall be positioned so as to prevent vehicles and personnel damaging the cord. (5) The flexible cord shall comply with section 8.5 of this chapter. (6) The light stand shall be secured to prevent tipping. (7) Neither the light nor the power cord shall be allowed to come in direct or indirect contact with the explosives. (8) 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 section 8.4 of this chapter, except as noted in section 8.4c(1). b. Process equipment used for synthesis, heating, drying, mechanical mixing, and blending shall be dual-rated. Weighing equipment shall be Class II, Division 1 or mechanical. These operations shall be isolated from non-rated DOE M 440.1-1A 57 (and 58) 1-9-06 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 section 8.10b of this chapter, apply section 8.6a(3) or 8.6a(4) of this chapter. 8.11 Modifications a. 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. DOE M 440.1-1A 59 (and 60) 1-9-06 9.0 VACUUM EQUIPMENT 9.1 General a. Precautions shall be taken to prevent explosives from entering any vacuum system not specifically designed to collect explosives. 9.2 Labeling a. All vacuum lines used for explosives operations should be labeled to warn maintenance personnel that explosive residue may be present in these lines. One suggested label is: DANGER, MAY CONTAIN EXPLOSIVES 9.3 Disassembly a. All vacuum lines that are potentially contaminated with explosives shall be disassembled according to approved operating procedures. Disassembly should be accomplished at flanged connections or elastomeric tubing whenever practical. No attempt should be made to disassemble a vacuum line at a threaded connection. The design or installation of any new vacuum lines shall not employ demountable, internal screwed, or threaded fittings or connections unless welded or fixed permanently in place. 9.4 Traps or Filters a. Vacuum pumps used to evacuate processes for explosives operations shall be equipped with primary and secondary intake line traps or filters to prevent explosives from contaminating the pump. DOE M 440.1-1A 61 1-9-06 10.0 EXPLOSIVES DUST EXHAUST VENTILATION AND COLLECTION SYSTEMS 10.1 General

a. Exhaust ventilation should be used to control explosives dust (or other hazardous materials used in or resulting from explosives operations) that could be hazardous to operating personnel or contaminate the operating area. Exhaust ventilation used to remove explosives dust requires an approved dust collection system to prevent the release of the dust outside the building. 10.2 Exhaust Ventilation a. Exhaust ventilation and collection systems that control 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 a Standard Operating Procedure (SOP). b. Dust collectors shall be designed to prevent explosives dust from reaching any mechanical power source of the collection system. c. All conductive portions of the collection system shall be grounded and bonded. d. A dust collection system shall not have screw threads, recesses, or cracks that may be exposed to explosives contamination. 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 the ducts or pipes. 62 DOE M 440.1-1A 1-9-06 g. Dust collectors shall be emptied and cleaned on a regular basis as system use warrants 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. DOE M 440.1-1A 63 1-9-06 11.0 DRAINS AND SUMPS 11.1 Collection a. All drain lines handling explosive wastes shall be provided with sumps, clarifiers, weirs or basins of adequate design and capacity for 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, clarifier, weir or other 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 assure removal of all hazardous material from drain gutters. c. Sumps must be designed to prevent suspended and settleable solid explosive material from being 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. Sumps 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). When using settling basins 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 to lift 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 explosive and the sump shall be troughs with rounded bottoms and removable ventilated covers to facilitate inspection for accumulation of explosives. This requirement applies to all new construction and major modifications and should be considered for existing facilities. Short sections of closed pipe or trough are permitted if they can be visually inspected for blockage or explosives buildup. Explosives or explosives-contaminated waste liquids shall not be released into closed drains and sewers. f. Drains shall be inspected periodically and necessary steps taken to prevent the buildup of explosive deposits. 11.2 Effluent a. Drains containing explosive 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. 64 DOE M 440.1-1A 1-9-06 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 handling explosives that are appreciably soluble in water, sweeping and other dry collecting measures shall be used to keep such out of the drainage system. c. The combination of sumps, settling ponds, and other systems must remove explosives so that outflows meet environmental standards. DOE M 440.1-1A 65 1-9-06 12.0 PROCESSING 12.1 Heating, Drying, and Thermal Conditioning 12.1.1 General a. Heating explosives is potentially dangerous for several reasons: (1) Elevated temperature can increase an explosive’s sensitivity to other stimuli such as impact, shock, friction and static electricity. (2) At or above the explosive’s critical temperature (see definition in Chapter I, section 6.0) a runaway chemical reaction may occur that can produce an explosion or fire. (3) Elevated temperature of an explosive in a sealed container can cause gas generation and pressure rupture of the containment even at temperatures below the critical temperature. (4) 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. (5) 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. Critical temperature is a system property that depends on a combination of the explosive’s chemical decomposition reactions, its mass and shape, heat transfer and other thermal characteristics of the system, and the confinement or pressure of decomposition products, especially gases. Several different methods of thermal analysis can be used to determine or estimate the critical temperature. The process is typically quite complex because of the complexity of normally occurring chemical reactions. 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 25°C being 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 (differential scanning calorimetry), or other comparable techniques can be used to measure the temperature of the onset of an exothermic reaction in an explosive. The test results can be used to rank 66 DOE M 440.1-1A 1-9-06 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. Exotherm temperature is always considerably above critical temperature and usually increases with the heating rate of the test. Where the DTA/DSC exotherm is specified as a standard for temperature control, the test heating rate shall not exceed 10°C per minute. DTA/DSC shall not be used as a sole means for establishing heating limits (except as specified in section 8.6a(4) of this chapter). d. Each facility shall conduct or obtain 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 section 13.6.2 of this chapter. From this analysis, a heating limit for the explosives system shall be established which the EDC shall approve. All factors in sections 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 10°C below the critical temperature. For heating explosives in association with hazardous radioactive materials, the maximum temperature should be set at least 20°C below the critical temperature. Facility management may approve heating to a temperature greater than the above specifications 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. Specified conditions 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. Factors to consider when establishing heating controls include the heating limit and accuracy of the estimated critical temperature, accuracy of the temperature control equipment, and the likelihood of incompatible chemical contamination and other operational parameters. 12.1.2 Heating and Drying Equipment a. Heat should be done by steam, hot water, friction air, or electrically heated transfer fluid. Redundant, automatic heat controls shall limit temperatures. b. In systems heated by steam only, the requirements for redundant, automatic heat controls shall be satisfied if a pressure-reducing valve, pressure relief valve, and thermostatic valve on the system control the steam pressure. DOE M 440.1-1A 67 1-9-06 c. In electricity heated systems, a manual reset secondary overtemperature system consisting of a controller, failsafe sensor, and an interrupting device shall be provided to interrupt the heat supply source if the primary system fails. The secondary interrupter shall be separate from the primary interrupter. The upper limit of the primary controller is determined by the desired operating temperature limit. The secondary (override) controller is set at a higher temperature but should not exceed the maximum temperature determined by the heating limit specified for the explosives system as determined in section 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 section 12.1.1. 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 section 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 placement 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 x 10-4 mm Hg at the drying temperature shall not be subjected to vacuum drying. A cold trap shall be used for vacuum drying where the vapor pressure of the explosives is unknown. d. A vapor-air mixture within explosive concentration limits shall be avoided. Such a vapor-air mixture can be controlled by providing sufficient airflow to maintain a vapor concentration well below the 68 DOE M 440.1-1A 1-9-06 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 equipment parts, heating shall be conducted in a manner to control condensation of the explosive material. 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 a. Explosives pressing operations subject explosives 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 common types of pressing operations commonly performed are isostatic/hydrostatic and punch and die. The following safety guidelines apply to these types of pressing operations. 12.2.1 General a. Explosives pressing operations shall be conducted as remote operations. b. The correct functioning of press interlock systems shall be verified at regular intervals.

c. Pressing mandrels, punches and dies used in explosives operations shall be examined regularly during periods of use for evidence of structural failure. Suitable nondestructive test methods shall be used to perform the examination. Site management shall establish intervals between inspections for each tooling design before committing the tooling to use. The inspection interval and updating should be based on 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. DOE M 440.1-1A 69 1-9-06 e. Press parts that contact explosive materials shall be cleaned thoroughly to remove residual explosives before use with a different explosive formulation. f. Temperature control for heated presses and dies shall comply with the requirements of sections 12.1.2a and 12.1.2b of this chapter. g. All pressing assemblies shall be designed or procedural controls established to minimize or eliminate the extrusion of explosives between two mating metal surfaces during the pressing operation. h. Operations with explosive powders should be performed in a manner that reduces the release of explosives dust and thereby reduces 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. Local management shall establish examination intervals. c. Before large-scale pressings of new explosives or explosives formulations, the 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: (1) An acceptable vacuum can be obtained on the mandrel assembly to prevent adiabatic heating during pressing; and (2) Air is bled out of the press before pressurization. 70 DOE M 440.1-1A 1-9-06 e. Consideration should be given to the use of fire-resistant hydraulic fluids. New fluids must be checked to ensure compatibility with the explosives used. 12.2.3 Punch and Die Pressing a. All pressing punches and dies shall be inspected visually for damage, deformation, and cleanliness before installation on a press. Any questionable condition 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. The responsible user of a gauging section capable of performing the necessary measurements shall control punches and dies, which should be maintained in matched sets. 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 section 12.2.1c of this chapter. 12.3 Extruding a. 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 apply to this type of extrusion operation. (1) Extrusion operations shall be conducted remotely. Contact extrusion may be performed only when extruding nonexplosive or mock materials or when hand-extruding small quantities with no metal-to-metal contact. Precautions shall be taken to prevent personnel from being injured by the rupture of pressurized equipment. (2) The explosive shall be protected against extrusion beyond the tooling cavity. Precautions shall be taken to prevent foreign material from entering the explosives. (3) New designs and significant design changes in equipment, tooling or components shall be tested by mock explosives extrusion before actual explosives extrusion. (4) Pressure controllers and indicators shall be calibrated periodically to ensure that proper sealing and extrusion pressures are maintained. DOE M 440.1-1A 71 1-9-06 (5) Extrusion press parts shall be cleaned thoroughly of residual explosives remaining from the previous operation before the press is loaded with a different explosive formulation. (6) Hand-loading of extrudable explosives is covered in section 12.8.2 of this section. 12.4 Machining a. Explosives machining is a class of operation that involves cutting of the explosive material, often in conjunction with harder inert materials. Heat buildup from friction at the cutting surface can result in thermal initiation of the explosive substance. Precautions must be taken to limit this buildup and to facilitate the dissipation of thermal energy. 12.4.1 Equipment Requirements a. Interlocks shall be provided for wet machining operations to ensure coolant flow before machine operation. The coolant flow shall be monitored and the equipment automatically and safely shut down if loss-of-coolant flow is detected. The interlocks shall be protected from tampering and unauthorized disabling by physical means, or supervisory control. b. The vacuum on vacuum chuck holding fixtures shall be monitored and interlocked with the equipment for automatic shutdown of machining in the event of vacuum loss. c. Tool path controls (stops, limits, design patterns, etc.) shall be provided to prevent the unplanned travel path of a tool or work piece. Positive means or secondary verification shall control and limit equipment speed and feed rates. d. Pressure-relief devices should be installed on pneumatically or hydraulically powered equipment 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 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, and other factors. 72 DOE M 440.1-1A 1-9-06 h. The “machining overtest” shall be considered a testing operation (see section 12.4.4e of this section) and shall be exempt from equipment requirements. 12.4.2 Contact or Remote Operations a. The following explosives may be contact machined if a compatible, nontoxic, noncombustible coolant is used. Explosives not listed below shall be machined remotely. (1) Amatol (2) Baratol (3) Boracitol (4) Explosive D (5) Octol with no more than 75 percent HMX (6) Pentolite with no more than 50 percent PETN (7) RDX/TNT compositions with no more than 75 percent RDX. These compositions include Composition B, Composition B-3, and 75/25 Cyclotol. (8) TATB and TATB compositions with an inert plastic binder (9) TNT b. Explosive assemblies composed of any combination of explosives listed in the above section 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 section or a nonexplosive material not listed below, the assembly shall be machined remotely: (1) Foamed plastics. (2) Solid plastics. (3) Adhesives. (4) Amorphous graphite. (5) Calcium sulfate casting powder. (6) Explosives mockup. DOE M 440.1-1A 73 1-9-06 c. On any explosive, with certain exceptions for IHE and explosives machined by fluid jet (see section 12.4.2e of this section), the following operations shall be performed remotely: (1) Drilling of holes smaller than 5 cm in diameter, except for IHE, where drilling of holes smaller than 5 mm shall be done remotely. (2) Coring operations (except contact operations on those explosives listed in section 12.4.2a of this chapter, when the requirements of section 12.4.5b of this chapter are met and a coolant is used). (3) Machining of any metal/explosives interface. (4) Machining IHE subassemblies with Hazard Class/Division 1.1 boosters installed. (5) Dry machining, except that IHE booster pellets may be contact machined provided a dust collection system (see section 10.0 of this chapter) is used. (6) 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. IHE, PBX 9404, and LX-10 may be contact-machined 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 m 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 section 12.15 of this section for use of low-pressure fluids. f. Concurrent contact machining operations in the same bay should not be permitted. However, concurrent IHE contact machining is permitted when other explosives are not present. g. Provisions shall be made to monitor remote machining operations visually. Consideration should be given to video recording and audio monitoring.

12.4.3 Setup and Preparation a. The following precautions are provided for preparation and setup before beginning the machining operation. 74 DOE M 440.1-1A 1-9-06 (1) 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. (2) A mock explosive should be used to test the equipment function of any operation using new tooling or new part programs. (3) The explosive component to be machined shall be inspected by radiography or other suitable nondestructive test methods for cracks, voids, and high-density foreign objects. The component shall also be checked for proper size. (4) 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. (5) Limits on machine speed, depth of cut, and feed rate shall be set before the machine is activated. (6) Interlocks shall be functional before the machine is used to machine explosives. They should be tested once per shift. 12.4.4 Operations Guidelines a. The minimum tool speed necessary for safe and efficient operation should be maintained. The following maximums shall apply: (1) The relative velocity between the explosives surface and the cutting tool shall not exceed 65 m per minute; (2) Work pieces or cutting tools shall not be rotated at speeds exceeding 525 rpm; and (3) The feed rate of the cutting tool or work piece shall not exceed 1 mm per revolution. b. The work piece, fixture, cutting tools, equipment, floor, troughs, drains, etc., should be cleaned frequently to prevent accumulation of explosive wastes. (1) Approved measures should be taken to prevent rust and minimize deterioration of precision surfaces. (2) All tools, equipment, fixtures, and parts should be cleaned before removal from the work area for storage. DOE M 440.1-1A 75 1-9-06 c. For contact machining operations, coolant shall be used to aid in removing heat and cutting waste. Coolant should be used for remote operations when practical. (1) Coolant should be used on explosives/inert assemblies. When the explosives portion is included in the cut, coolant shall be used for contact machining. Coolant is not required if the explosives portion of the assembly is contained (no bare explosives) and is not included in the cut, or the machining is conducted remotely. (2) Spray mist coolant may be used during machining of the explosive-containing assemblies if the explosives portion is not included in the cut. d. All visible explosives shall be removed from the machine before maintenance or repairs. No safeguards or interlocks shall be removed or made inoperative, 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 overtest shall be conducted remotely. (2) Operations performed during sample preparation may include gaging and assembly, but shall not include any contact cutting, scraping, or other material-removing operations on 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) The fluting length on the drill bit shall exceed the depth of the hole to be drilled by a minimum of 1.3 cm or one hole diameter, whichever is greater. (3) The depth of a hole shall not be extended more than 1.5 times the hole diameter (up to a maximum of 2 cm) during a single insertion of the drill into the material. After each insertion, it may be advisable to withdraw the drill completely and remove loose explosives from the cavity and drill bit before reinserting. 76 DOE M 440.1-1A 1-9-06 (4) Coolant flow (when used) shall be directed to the explosives/cutting edge interface. Drill bits with coolant channels to the tip of the drill should be used. Pulsating pressure types of coolant supplies are recommended for drills of 6-mm diameter or less to remove drill fines. b. Coring (1) Coolant flow (when used) shall be directed at the explosives/cutting edge interface. (2) If the hole is not positioned to provide continuous breakout, the coring shall be accomplished incrementally. 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 a. Dry explosives often require screening for size classification or to remove extraneous objects. Magnetic separators are often advisable to remove ferrous materials that may have passed through the screens. The following guidelines shall be observed for screening operations and equipment: (1) Operations using mechanical screens shall be performed remotely. Equipment shall be designed and operations performed to avoid subjecting explosive materials to pinching, friction, or impact. (2) Screening small samples may be performed as a contact operation if approved by written procedures. (3) 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. DOE M 440.1-1A 77 1-9-06 (4) Operations and equipment shall be set up to minimize and control dust generation. (5) Operating areas and equipment therein shall be cleaned frequently to avoid accumulation of explosives dust. (6) Precautions shall be taken to prevent metals from rubbing together when the screens vibrate. Vibrating equipment shall be inspected frequently for developing cracks subject to contamination by explosives. 12.6 Blending a. Dry blending of explosives shall be performed remotely. However, dry, hand blending of small samples may be performed as a contact operation when approved by facility management. b. Equipment should be designed and operations performed to minimize generation and dispersion of explosives dust.

c. Equipment shall be electrically bonded to provide a continuous path-to-ground. Resistance-to-ground shall be 10 ohms or less and shall be inspected regularly. 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 another temperature-controlled medium. The steam pressure shall be controlled in accordance with section 12.1.2b of this section. b. Temperatures for contact melting of TNT-based explosives (except those containing PETN, e.g., pentolite) and keeping them molten shall not exceed 121°C. The temperature limit for TNT explosives containing PETN shall be 109°C. 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 section 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. 78 DOE M 440.1-1A 1-9-06 f. Provisions should be made for emergency emptying of melt kettles in the event of temperature control problems or power failures. g. Melt kettles shall be constructed with corrosion-resistant materials. 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 a. 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 during assembly or disassembly. However, they may be used on nonexplosive components. 12.8.1 Assembly Operations a. During assembly operations, the operator should be alert for mismated parts and misaligned components. Hard surfaces that will contact explosives shall be precisely machined to mate with the explosives, lined with cushioning material, or otherwise configured 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 increased temperature. Plastic explosive Compositions C-3 and C-4 may be softened by warming to between 21°C and 38°C before working. Extrudable explosives LX-13 and extex should be kept as cool as practical to prevent premature curing. b. Contamination of these explosives with abrasive or foreign substances shall be avoided. c. The assembly shall be loaded with small increments of explosives and may be tamped with suitable nonmetallic tools to eliminate air voids. 12.8.3 Disassembly Operations a. Before beginning disassembly, the device’s condition shall be assessed to determine if it can be safely handled. b. Disassembly operations shall be planned before actual disassembly. Possible problem areas caused by method of construction or physical condition shall be considered. A safety procedure for each unique disassembly shall be written and reviewed. c. If disassembly would normally cause release of the pressure or if there is a credible hazard of the pressure causing components to fly apart,

DOE M 440.1-1A 79 1-9-06 before beginning disassembly, pressurized units shall be thoroughly depressurized. d. If approved for use, compressed air shall be applied cautiously during disassembly to avoid causing to fly apart. This may require remote operation. Use hydraulic pressure if possible. 12.8.4 Personnel Protection for Disassembly Operations a. Operators and all other personnel shall be provided complete protection from disassembly operations involving conditions known or expected to require the use of abnormal force. Such operations require either remote operation or the use of an operational shield. The shielding shall be designed to protect personnel at other operations or locations from blast and missiles arising from a possible explosion. b. When disassembly requires that the operator be protected by an operational shield, disassembly shall be defined as complete separation (threads or other connections) of component parts. For example, parts shall not be loosened while the operator is properly protected and then separated without the same protection. 12.9 Inspection a. This section deals with the following types of explosives inspection operations: (1) Inspecting incoming explosives raw materials and pressed explosive billets for foreign bodies or cracks that could cause operating or safety problems in processing operations; and (2) Measuring physical parameters of explosive pieces and assemblies. b. To enhance the safety of process operations, positive steps shall be taken to assure the proper identification of explosives used and to prevent foreign material from entering the operation via the explosives raw materials or via materials in process (i.e., pressed explosive billets). Some of the means by which this can be accomplished include: (1) Screening. (2) Visual inspection. (3) Magnetic separation. (4) Radiographic inspection. (5) Chemical analysis. 80 DOE M 440.1-1A 1-9-06 c. The following principles shall be followed in the design and operation of explosives inspection equipment. (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 parts of the measuring or handling equipment from becoming loose and getting into the explosives. (3) Inspection fixtures shall be designed to secure the explosives piece or assembly securely to prevent toppling, rolling, or dropping during measurement operations. This is especially critical if the explosives assembly is in motion (i.e., spinning, vibrating, etc.) during measurement. 12.10 Synthesis a. 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. The Explosives Development Committee (EDC, Chapter VIII) will approve new operations and materials. 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 laboratory studies determine that the explosive is of continuing interest, 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 shall analyze each explosives or potential explosives experiment for the 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 amount 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 DOE M 440.1-1A 81 1-9-06 conditions, the operation shall be conducted remotely or adequate personnel shielding shall be provided. 12.10.2 Pilot- or Processing-Scale Synthesis a. When operations are conducted using flammable or toxic liquids or gases, local ventilation shall be provided to prevent hazardous vapor concentrations from forming 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. When 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, the emergency system will automatically cool the vessel or will open or close a vessel dump valve as required by the process. Contact operations should be conducted with a means to activate the emergency system manually. 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 airflow 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 operations begin, all equipment shall be set up and checked for proper function. Now or infrequently used equipment shall be tested in a “dry run” before being used with any hazardous material. h. All explosives synthesis process equipment shall be maintained routinely. Equipment with defects that could affect safe operations shall be tagged to prevent its use until repairs are completed. i. Before starting any process operation, the transfer lines to be used should be properly labeled and their function specified in the operating procedure. 82 DOE M 440.1-1A 1-9-06 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 operating procedures. m. Agitator blades on reactors and mixers shall be inspected regularly for proper clearance to ensure that there is no pinch point or metal-to-metal contact. Local facility management shall set up and approve the inspection schedule.

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 flammable liquids are introduced. q. Inert gas pressure should be used to transfer flammable liquids when gravity flow or pumping is not practical. 12.11 Formulation a. Formulation operations considered in this section involve combining compounds or mixtures when one or more of the ingredients are explosive. Combining ingredients is commonly accomplished at DOE explosives handling facilities to obtain some desired physical property, combination of properties, or reaction parameters. 12.11.1 General a. Explosives may be loaded into mixers, mills, and deaerators as an operator-attended, contact operation. However, the starting, operating, and stopping of such equipment with explosives present shall be accomplished remotely. As an exception, mixing-type operations involving a low energy transfer may be allowed as a contact operation (e.g., slurry coating and melt agitation). b. Equipment used for explosives formulation shall be checked for proper operation before adding explosives. Equipment shall be examined for proper clearances and for metal-to-metal rubbing of moving parts with DOE M 440.1-1A 83 1-9-06 the potential to contact explosives. Bearings should be sealed to preclude explosives contamination. c. Fast-action deluge systems shall be considered for equipment (e.g., mixers, mills, and deaerators) used for easily ignitable explosives formulations. d. Hot water, cold water, or steam, can be applied to mixers and mills. Heating fluid temperatures shall not exceed known safe operating temperatures for the explosives involved. When roll milling, allowance shall also be made for viscous shear heating of the explosives in process. Heated systems shall comply with the requirements of sections 12.1.2a and 12.1.2b of this section. 12.11.2 Mixing a. Mixer seals and gaskets shall be checked on a regular schedule and cleaned or replaced as required. b. Checks should be made to ensure that maximum particle sizes of ingredients or hard agglomerates of proposed mixes are less than the blade-to-blade or blade-to-bowl clearances. c. Initial cleaning with solvents used for dissolving or suspending the explosives residues shall be done remotely (except for 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 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 when 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 separating the explosive, the grinding media shall be thoroughly cleaned and inspected before reuse or disposal. 84 DOE M 440.1-1A 1-9-06 12.11.4 Roll Milling

a. Positive stops should be installed on roll mills to prevent rolls from rubbing against each other. b. Before starting a milling operation 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. The 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, or chain) within easy reach of the operator. 12.12 Concurrent Contact Operations a. The preferred setup for explosives operations is to perform each operation in a separate location to preclude any adverse operation interaction. Because such an arrangement is frequently impractical, concurrent operations may be permitted if the following conditions exist: (1) 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. (2) 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). (3) Mixing of materials in the concurrent operations will not create compatibility problems. (4) Each operator is aware at all times of concurrent operations in his or her area. 12.13 Contamination Prevention a. Precautions shall be taken to avoid mutual contamination when two or more incompatible explosives or materials are handled on a single line or within one building or room. This includes vacuum systems and explosives scrap collection. Inadvertent mixing of incompatible explosives materials can be DOE M 440.1-1A 85 (and 86) 1-9-06 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. Containers shall be clearly marked with the weight and contents identified. Care shall be exercised to properly segregate material in service magazines and 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, permanent service lines shall be labeled as to their contents. Valves and switches on service lines whose operation can result in a hazardous situation shall be labeled as to their function. 12.14 Hand-Cutting and Finishing Operations a. Hand-cutting finishing, which may include cutting, trimming, coring, and lapping (surface polishing) explosive materials shall be performed using the mildest energy input that will accomplish the task safely and efficiently. The facility EDC shall review and approve the safety of hand-cutting and finishing operations, which shall then be incorporated into an operating procedure before starting the operation. 12.15 Use of Low-Pressure Fluids a. Low-pressure fluids (liquid pressure less than 1,500 psig) may be handled as in contact operations to aid explosives dissolution, rinsing, system flushing and similar operations under the following conditions: (1) The fluid system shall have a pressure relief device installed to prevent system overpressurization. (2) Low-pressure fluid operations may be used with those explosives whose impact sensitivity is less than PETN. Such operations may be used on other explosives only after analyzing the energies involved. (3) Solvents shall be compatible with the explosive material. Controls for their use sh