DOE-STD-1212_June2012.pdf

DISTRIBUTION STATEMENT A. Approved for public release; distribution is unlimited.

DOE-STD-1212-2012

June 2012

DOE STANDARD

EXPLOSIVES SAFETY

U.S. Department of Energy AREA SAFT Washington, DC 20585

MEASUREMENT

SENSITIVE

i

TABLE OF CONTENTS

CHAPTER I. PURPOSE, SCOPE and APPLICABILITY, EXEMPTIONS, WAIVERS, ABBREVIATIONS, ACRONYMS, AND DEFINITIONS

1.0. PURPOSE

1.1. Scope and Applicability

2.0. STANDARD ADMINISTRATION AND MANAGEMENT

3.0. EXEMPTIONS

3.1. Exemption Requests

3.2. Exemptions Achieving Equivalent Safety

3.3. Exemptions Not Achieving Equivalent Safety

4.0. WAIVERS

4.1. Documentation of a Waiver

5.0. AUTHORITY HAVING JURISDICTION

6.0. LIST OF MEASUREMENT ABBREVIATIONS

7.0. ACRONYMS

8.0. DEFINITIONS

CHAPTER II. OPERATIONAL SAFETY

1.0. GENERAL OPERATIONS SAFETY GUIDELINES

1.1. Protection of Explosives

1.2. Equipment Checks

1.3. Inspection Frequency

1.4. Laboratory Operations

1.5. Toxicity Hazards

1.6. Hazard Identification and Communication

1.7. Process Hazard Analysis

2.0. WORK ENVIRONMENT

2.1. General Requirements

2.2. Emergency Exit Requirements for Explosives Operations

3.0. BUILDING AND EQUIPMENT MAINTENANCE

3.1. Cleaning

3.2. Maintenance and Repair

3.3. Hot Work Permits

4.0. REMOTE OPERATIONS

4.1. Personnel Protection

4.2. Access and Equipment Controls

5.0. GENERAL EXPLOSIVES AREA CONTROLS

5.1. Smoking, Matches, Lighters, Metal Articles

5.2. Cooking and Eating

5.3. Access to Explosives Areas

6.0. PROTECTION OF ELECTROEXPLOSIVE DEVICES (EED) FROM

ELECTROMAGNETIC RADIATION (EMR)

7.0. STATIC ELECTRICITY

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7.1. General

7.2. Bonding and Grounding of Equipment

7.3. Testing Bonded Equipment Grounds

7.4. Conductive Floors, Shoes, Mats and Wristbands

7.5. Conductive Floor, Work Surface, and Wristband Specifications

7.6. Conductive Floor Tests

7.7. Humidification

7.8. Ground Fault Circuit Interrupter

8.0. ELECTRICAL EQUIPMENT AND WIRING

8.1. Location/Operation Electrical Hazard Classification

8.2. Electrical Supply System

8.3. Building Electrical Service Entrance

8.4. Permanent Wiring, Fixtures and Equipment

8.5. Flexible Cords/Wiring

8.6. Electrical Equipment and Instrumentation

8.7. Electrical Requirements for Outdoor Test Areas

8.8. Hand-held, Battery-Powered Lights and Instruments

8.9. Non-Rated Extension Lighting

8.10. Laboratories

8.11. Modifications

9.0. VACUUM EQUIPMENT

9.1. General

9.2. Labeling

9.3. Disassembly

9.4. Traps or Filters

10.0. EXPLOSIVES DUST EXHAUST VENTILATION AND COLLECTION

SYSTEMS

10.1. General

10.2. Exhaust Ventilation

10.3. Dust Collection Systems

10.4. Dust Collection Location

11.0. DRAINS AND SUMPS

11.1. Collection

11.2. Effluent

12.0. PROCESSING

12.1. Heating, Drying, and Thermal Conditioning

12.2. Pressing

12.3. Extruding

12.4. Machining

12.5. Dry Screening

12.6. Blending

12.7. Melting

12.8. Assembly and Disassembly

12.9. Inspection

12.10. Synthesis

12.11. Formulation

12.12. Concurrent Contact Operations

12.13. Contamination Prevention

12.14. Hand-Cutting and Finishing Operations

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12.15. Use of Low-Pressure Fluids

13.0. TESTING

13.1. General

13.2. Test Planning

13.3. Test Firing

13.4. Test Firing in Tanks or Chambers

13.5. Gun Firings

13.6. Ballistic, Environmental, Physical Property, and Sensitivity Testing

13.7. Test Failures and Misfires

13.8. Electrical Instruments for Use with Explosives Systems

14.0. MATERIALS HANDLING

14.1. General

14.2. Manual Handling of Bare Consolidated Explosives

14.3. Carts or Hand Trucks

14.4. Mechanical Handling Equipment

15.0. MATERIALS RECEIPT

15.1. Motor Vehicles

15.2. Railcars

15.3. Damaged Shipments

16.0. TRANSPORTATION

16.1. Equipment and Operations

16.2. General Operation Guidelines

16.3. Emergency Conditions

17.0. EXPLOSIVES STORAGE

17.1. Storage Magazine Facilities

17.2. Storage Magazine Operations

17.3. Storage Review Program

17.4. Storage Compatibility

17.5. Containers (Onsite)

17.6. Storage in Buildings Other Than Storage Magazines

18.0. DECONTAMINATION AND CLEANING

18.1. General

18.2. Cleaning Contaminated Equipment

18.3. Cleaning Screw Threads

18.4. Final Decontamination and Disposal of Equipment

18.5. Inspection

18.6. Identification and Control of Decontaminated Items

18.7. Decontamination of Real Estate

18.8. Decontamination and Cleaning References

19.0. WASTE COLLECTION

19.1. General

19.2. Solid Wastes

19.3. Vacuum Collection of Explosives Dusts

19.4. Explosives Slurries

19.5. Metal Scrap

20.0. WASTE DISPOSAL

20.1. Preparation for Open Burning

20.2. Destruction by Burning or Flashing

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20.3. Ignition System Malfunctions

20.4. Post-burn Operations

20.5. Disposal Area

20.6. Destruction by Detonation

20.7. Use of Solvents

21.0. LABORATORY OPERATIONS

21.1. General

21.2. Safety Shields

21.3. Heating Operations

21.4. Laboratory Setups

21.5. Low Concentration of Explosives in Solution

21.6. Explosives Sample Control

21.7. De minimis or Residual Quantities

22.0. EMERGENCY CONTROL

22.1. Placarding and Fire Symbols

22.2. Explosives Emergency Control Plans

CHAPTER III. EXPLOSIVES AND PERSONNEL LIMITS AND CONTROL

1.0. EXPLOSIVES LIMITS

2.0. PERSONNEL LIMITS

3.0. LIMIT CONTROL

3.1. Posting and Recording

3.2. Limit Review and Approvals

3.3. Personnel Controls

3.4. Explosives Control

4.0. INSENSITIVE HIGH EXPLOSIVE LIMITS

CHAPTER IV. PERSONAL PROTECTIVE CLOTHING AND EQUIPMENT

1.0. CLOTHING AND PERSONAL EQUIPMENT

1.1. Clothing

1.2. Footwear

1.3. Respirators

1.4. Eye Protection

1.5. Gloves

2.0. MAINTENANCE AND TESTING

2.1. Equipment Maintenance and Inspection

2.2. Conductivity Testing

2.3. Cleaning and Disinfecting

2.4. Contaminated Clothing

CHAPTER V. TRAINING

1.0. GENERAL

2.0. SUPERVISORY RESPONSIBILITY

3.0. TRAINING AND QUALIFICATION PROGRAMS

4.0. UNEXPLODED ORDNANCE (UXO) TRAINING

5.0. REFERENCES

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CHAPTER VI. QUANTITY-DISTANCE AND LEVEL-OF-PROTECTION

CRITERIA FOR EXPLOSIVES ACTIVITIES

1.0. GENERAL

1.1. Explosives Safety Site Plan Submission and Approval

1.2. Explosives Safety Site Plan Development

2.0. APPLICABILITY OF CRITERIA

2.1. Specific Applications

2.2. Explosives Limits

2.3. Areas Where Criteria Are Not Applicable

3.0. QUANTITY-DISTANCE CRITERIA

3.1. Hazard Divisions

3.2. Establishing Quantity of Explosives and Distances

4.0. LEVEL-OF-PROTECTION CRITERIA

4.1. Hazard Classes

4.2. Required Level of Protection

5.0. FIRE PROTECTION

5.1. Vegetation Control

5.2. Fire Protection Criteria

6.0. EXPLOSIVES FACILITY SITING AND DESIGN CRITERIA REFERENCES .. 164

6.1. Site and General Construction Plans for Ammunition and Explosives

Facilities

CHAPTER VII. OPERATING PROCEDURES

1.0. GENERAL

1.1. Requirements

1.2. Types of Procedures

2.0. GUIDELINES

2.1. Before Operation

2.2. Supervisory Responsibility

2.3. Preparation

2.4. Approval

2.5. Control

2.6. Audits

2.7. Reviews

2.8. Content of Standard Operating Procedures

2.9. Content of Special or Experimental Procedures

3.0. REFERENCE DOCUMENTS

CHAPTER VIII. FORMULATION SCALEUP

1.0. EXPLOSIVES DEVELOPMENT PROGRAM

1.1. Explosives Development Committee

1.2. Phase-by-Phase Approvals

1.3. Modified Formulations

1.4. Sensitivity Data from another Laboratory

2.0. DEVELOPMENT PROCEDURES

2.1. General

2.2. Synthesis Phase

2.3. Compatibility Testing

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2.4. Phase I—Preliminary Explosives Testing

2.5. Phase II—Experimental Characterization and Development

2.6. Phase III—Full-Scale Testing and Production

CHAPTER IX. INSENSITIVE HIGH EXPLOSIVES QUALIFICATION

1.0. INSENSITIVE HIGH EXPLOSIVES (IHE)

2.0. IHE SUBASSEMBLIES

3.0. IHE WEAPONS

4.0. REFERENCE DOCUMENTS

CHAPTER X. ELECTRICAL STORMS AND LIGHTNING PROTECTION

1.0. ELECTRICAL STORM HAZARDS

2.0. LIGHTNING PROTECTION SYSTEMS

2.1. Lightning Protection System Basic Design

2.2. Lightning Protection Subsystems

2.3. Approved Lightning Protection Systems

2.4. Lightning Protection Subsystem Criteria

3.0. INSPECTION AND TESTING OF LIGHTNING PROTECTION SYSTEMS

3.1. Initial Installation or Approval

3.2. Periodic Inspections and Testing

3.3. Acceptable Electrical Test Measurements

3.4. Procedures

3.5. Documentation and Trend Analysis

3.6. Training

4.0. LIGHTNING PROTECTION EXCEPTIONS

5.0. LIGHTNING THREAT DETECTION

6.0. LIGHTNING THREAT ACTIONS

7.0. SHUTDOWN OF OPERATIONS

8.0. LIGHTNING WARNING AND PROTECTION PLAN

8.1. Evaluation of Lightning Risk

8.2. Lightning Protection System Installation

8.3. LPS Inspection and Maintenance

8.4. Sideflash Separation Distances

8.5. Lightning Threat

9.0. REFERENCE DOCUMENTS

APPENDIX A. REFERENCES .................................................................................... A-1

APPENDIX B. EXPLOSIVES SAFETY COMMITTEE ORGANIZATIONS AND

FUNCTIONS .......................................................................................... B-1

APPENDIX C. INDEX ................................................................................................. C-1 vii

LIST OF FIGURES

Figure II-1. Testing Shoes on Wearer

Figure VI-1. Application of Hazard Classification System

Figure X-1. Single Mast Zone of Protection

Figure X-2. Example of Catenary System Zone of Protection

Figure X-3. Integral System Zone of Protection

LIST OF TABLES

Table II-1. Reserved for Future Use

Table II-2. Reserved for Future Use

Table II-3. Reserved for Future Use

Table II-4. Storage Compatibility Groups for Explosives and Explosive- Containing Devices

Table II-5. Storage Compatibility Mixing Chart

Table II-6. Safety Shields for Explosive Laboratory Operations*

Table VI-1. Divisions of Class 1

Table VI-2. Quantity-Distance Separation for Protection of Underground Service Installations

Table VI-3. Guidelines for Minimum QD Requirements for Small Amounts of Explosive Substances Having Hazard Division 1.1 Classification

Table VIII-1. Scaleup Procedure Guidelines for New Explosives and Formulations

Table IX-1. DOE IHE Qualification Tests

Table IX-2. Approved IHEs

Table IX-3. DOE Qualification Tests for IHE Subassemblies*

Table IX-4. Approved IHE Subassemblies

Table IX-5. IHE Hazard Classification viii

INTENTIONALLY BLANK

CHAPTER I. PURPOSE, SCOPE AND APPLICABILITY, EXEMPTIONS,

WAIVERS, ABBREVIATIONS, ACRONYMS, AND DEFINITIONS

1.0. PURPOSE

This Technical Standard contains the safety requirements that were contained in the Department of Energy (DOE) Manual (M) 440.1-1A, DOE Explosives Safety Manual (2006). It provides the basic technical requirements for an explosives safety program necessary for operations involving explosives, explosives assemblies, pyrotechnics and propellants, and assemblies containing these materials. Technical changes in this Standard may differ from the former DOE Explosives Safety Manual or site-issued versions of the Manual. However, all of the changes have been proposed, reviewed, deliberated, and recommended by the DOE Explosives Safety Committee and are approved in accordance with DOE’s Technical Standard Program requirements. This Technical Standard will serve as the successor document for the DOE Explosives Safety Manual and may be used in accordance with requirements of 10 CFR 851 Appendix A 3.(b).

1.1. Scope and Applicability

a. This Technical Standard 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 Technical Standard does not apply to commercial activities such as routine construction or routine tunnel blasting.

b. This Technical Standard establishes safety controls and standards not addressed in other existing DOE or non-DOE regulations to close the safety gap created by DOE's unique activities to govern the DOE explosives safety process and ensure that explosives safety is commensurate with the 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.

c. The design of all new explosives facilities shall conform to the requirements established in this Standard. 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.

d. However, in the case of a major modification, the facility must be brought into compliance with current standards.

Major Modification is a planned project that significantly extends the building’s useful life through alterations including deferred maintenance that total more than 30 percent of the replacement value of the building. In addition a major modification results when there is a change in the building’s function resulting in a significant increase in hazard or risk, or significant increase in occupancy or planned life of the building.

e. 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 Head of Field Element or National Nuclear Security Administration (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.

2.0. STANDARD ADMINISTRATION AND MANAGEMENT

a. This Technical Standard will be kept current to ensure life and facility safety. The standard will be maintained i.e., reviewed, approved, and issued In accordance with DOE Order 252.1A, Technical Standards Program. Upon approval of a revised standard it will be considered the official document that shall be incorporated into contracts, as appropriate. This official version of the standard may be found online at:

http://www.hss.doe.gov/nuclearsafety/ns/techstds/standard/standard.html.

b. The DOE Explosives Safety Committee (ESC) promotes DOE policy that requires all DOE explosives activities to be conducted in a manner that protects the safety of the public and provides a safe and healthful workplace for employees, will act as the Preparing Activity for this standard in support of the DOE Office of Primary Interest (OPI). The Committee will review, evaluate, and recommend proposed changes to the Standard. The changes will be consonant with state-of-the-art technical changes in the field and include lessons learned from DOE, other Governmental, and Industry experience and mishaps.

NOTE: To assist in the transition of DOE Manual 440.1-1A, DOE Explosives Manual into a Technical Standard, the Manual’s content describing the Explosives Safety Committee organizations and functions has been included in Appendix B of this document.

3.0. EXEMPTIONS

a. Mandatory requirements, denoted by the words “shall,” “must,” or “will,” must be followed unless the DOE Head of Field Element or NNSA Site Manager grants an exemption. Advisory requirements denoted by “should” or “may” can be granted a written waiver by facility management.

b. An exemption is a written release from a mandatory safety requirement.

Competent, knowledgeable, and experienced explosives safety subject matter experts 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. Exemption Requests

Requests for an exemption shall contain the following information:

a. Description of the condition.

b. Safety requirement necessitating deviation.

c. Reason why requirement 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 Field/Operations Manger or NNSA Site Manager is permitted to grant exemptions from the mandatory requirements of this Technical Standard provided compliance is impracticable and the facility operator has demonstrated that the conditions, practices, means, methods, or processes to be used result in equivalent safety. Requests for exemptions shall be submitted to the DOE Field/Operations Manger or NNSA Site Manager for documented review and approval.

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 concurrence from HS-1, the Chief Health, Safety and Security Officer, 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 five years.

4.0. WAIVERS

a. If an activity, operation, or process is determined to be out of compliance with the Technical Standard’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. Documentation of a Waiver

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. Any proposed corrective actions and schedule.

e. Waiver duration or expiration date.

5.0. AUTHORITY HAVING JURISDICTION

The NNSA Site Office Manager or DOE Field/Operations Manager has the ultimate responsibility to resolve all safety matters. The title Authority Having Jurisdiction (AHJ) as used in this Technical Standard, refers to specific persons assigned functional responsibilities to assist their management in assuring that the level of explosives safety provided to site-specific explosives operations and activities is commensurate with the requirements of this Technical Standard.

Each site that works with explosives usually has two local AHJs, whose areas of responsibility are as follows:

a. A federal AHJ is the NNSA Site Office Manager or DOE Field/Operations Manager, or his/her designee. He/she performs all inherently governmental AHJ functions as determined by the NNSA Site Manager or DOE Field/Operations Manager. He/she is a voting member on the DOE Explosives Safety Committee.

b. A contractor AHJ is a Subject Matter Expert who is appointed by the M&O Contractor to provide day-to-day support to ongoing and planned explosives operations and activities. He/she is a voting member on the DOE Explosives Safety Committee.

6.0. LIST OF MEASUREMENT ABBREVIATIONS

The following list expresses measurement abbreviations as used in this Technical Standard:

oC degrees Celsius cm centimeters oF degrees Fahrenheit ft feet ft2 square feet g grams gal gallons gr grains in inches kg kilograms kPa kilopascals

L liters lbs pounds m meters m2 square meters mg milligrams min minute mm millimeters mm Hg millimeters of mercury oz ounces

Pa pascals psi pounds per square inch psig pounds per square inch, gauge pressure pt pints rpm revolutions per minute sec seconds

NOTE: Some conversions from standard to metric and from metric to standard have been rounded up or down to the nearest practical figure (no more than four significant figures) with a margin of error less than 0.1%. When a conversion has occurred, the original figure is in bold while conversion is not.

Examples:

standard (metric): This indicates that the standard figure is the original figure while the metric figure is a conversion.

standard (metric): This indicates that the metric figure is the original figure while the standard figure is a conversion.

standard (metric): This indicates that both the standard figure and the metric figure are original figures that have not been converted.

7.0. ACRONYMS

ACGIH American Conference of Government Industrial Hygienists

AHJ Authority Having Jurisdiction

ANSI American National Standards Institute

ASTM American Society for Testing and Materials

BEC Blast Effects Computer

BOE Bureau of Explosives

CFR Code of Federal Regulations

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

ECM Earth-covered Magazine

EDC Explosives Development Committee

EED Electroexplosive Device

EIDS Extremely Insensitive Detonating Substance

EMR Electromagnetic Radiation

EOD Explosive Ordnance Disposal

ES Exposed site

ESC Explosives Safety Committee

FMECA Failure Modes, Effects, and Criticality Analysis

GFCI Ground Fault Circuit Interrupters

GRE Ground Ring Electrode

HAZOP Hazard and Operability Study

HE High Explosive

HMX Cyclotetramethylene Tetranitramine

HSS Office of Health, Safety and Security

IHE Insensitive High Explosive

LDS Lightning Detection System

LEL Lower Explosive Limit

LFL Lower Flammable Limit

LPS Lightning Protection System

LTA Lightning Threat Alert

LTDS Lightning threat detection system

LTW Lightning Threat Warning

LWP Lightning Warning Plan

LWPP Lightning Warning and Protection Plan

LWS Lightning Warning System

MCE Maximum Credible Event

MSDS Material Safety Data Sheet

MSHA Mine Safety and Health Administration

NE Nuclear Explosive

NEC National Electric Code

NEO Nuclear Explosive Operation

NEQ Net Explosive Quantity

NEW Net Explosive Weight

NFPA National Fire Protection Association

NLDN National Lightning Detection Network

NNSA National Nuclear Security Administration

OPI Office of Primary Interest

OSHA Occupational Safety and Health Administration

PBX Plastic Bonded Explosive

PEL Permissible Explosive Limit

PES Potential Explosion Site

PETN Pentaerythritol Tetranitrate

PSO Program Secretarial Officer

Q-D Quantity-Distance

RDX Cyclotrimethylene Trinitramine

RF Radiofrequency

SA Safety Assessment

SAR Safety Analysis Report

SOP Standard (Standing) Operating Procedure

SPD Surge Protection Device

SPL Sound Pressure Level

SPMS Safety Performance Measurement System

SSR Safe Secure Railcar

SST Safe Secure Trailer

TATB Triamino Trinitrobenzene

TMAC Toxic Materials Advisory Committee

TNT Trinitrotoluene

UFC Unified Facilities Criteria

UL Underwriters Laboratory

UN United Nations

UPS Uninterrupted Power Supply

UXO Unexploded Ordnance

8.0. DEFINITIONS

For purposes of this Technical Standard, 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 Technical Standard 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.

AUTHORITY HAVING JURISDICTION (AHJ). The National Nuclear Security Administration (NNSA) Site Office Manager or DOE Field/Operations Manager has the ultimate responsibility to resolve all safety matters. The title Authority Having Jurisdiction (AHJ) as used in the Technical Standard, refers to specific persons assigned functional responsibilities to assist their management in assuring that the level of explosives safety provided to site-specific explosives operations and activities is consistent with the requirements of this Technical Standard.

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) 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.

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.

CONTRACTOR - AHJ. A contractor AHJ is a Subject Matter Expert who is appointed by the M&O Contractor to provide day-to-day support to ongoing and planned explosives operations and activities.

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.

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.

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 the earth.

ELECTRICAL BONDING. Electrical connection between two conductive objects intended to prevent development of an electrical potential between them.

ELECTRICAL DISTRIBUTION LINES. These are normally electrical lines solely supplying multiple facility locations.

ELECTRICAL SERVICE LINES. Those electrical lines supplying individual facility locations.

ELECTRICAL SUPPLY LINES. Electrical lines classified by purpose as transmission, distribution, or service.

ELECTRICAL TRANSMISSION LINES. Those electrical lines supplying locations outside the facility uniquely, or in common with the facility. Any line carrying 69kv or more shall be classified as a transmission line for Q-D purposes.

ELECTROEXPLOSIVE DEVICE (EED). A device containing some reaction mixture (explosive or pyrotechnic) that is electrically initiated. The output of the initiation is heat, shock, or mechanical action. See also LOW-ENERGY EED.

EXPERIMENTAL OPERATING PROCEDURE. A procedure prepared for conducting a specific experiment a limited number of times under close technical supervision.

EXPLODING BRIDGEWIRE (EBW). An EED that is initiated by the discharge of a high current through the device bridgewire, causing the wire to explode and produce a shockwave. An EBW as defined herein is a device containing no primary explosive.

EXPLOSIVE. Any chemical compound or mechanical mixture that is designed to function as an explosive, or chemical compound that functions through self-reaction as an explosive, and that, when subjected to heat, impact, friction, shock, or other suitable initiation stimulus, undergoes a very rapid chemical change with the evolution of large volumes of highly heated gases that exert pressures in the surrounding medium. The term applies to materials that either detonate or deflagrate. DOE explosives may be dyed various colors except pink, which is reserved for mock 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.

FEDERAL AHJ. A federal AHJ is the NNSA Site Manager or DOE Field/Operations Manager, or his/her designee. He/she performs all inherently governmental AHJ functions as determined by the NNSA Site Manager or DOE Field/Operations Manager.

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 Technical Standard; 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 the earth or some conducting body that serves in place of the earth. (2) Connected to the earth or some conducting body that is connected to earth.

GROUNDING. Providing an electrical path to the earth, generally to the earth electrode system.

HAZARD ANALYSIS: The identification of risks associated with the tasks being performed. It focuses on the relationship between the worker, the task, the tools, and the work environment.

HAZARDOUS FRAGMENT OR DEBRIS HAVING AN IMPACT ENERGY GREATER THAN 11

FT-LBS (15J) AND LESS THAN 58 FOOT POUNDS (79J). Fragments or debris that can cause serious injury.

HAZARDOUS FRAGMENT OR DEBRIS HAVING AN IMPACT ENERGY OF 58 FT-LBS (79J)

OR GREATER. Fragments or debris that can cause death or severe injury.

HEATING LIMITS. The conditions established for safely heating an explosive system (maximum temperature, heating time, heating rate, etc.). These limits are based on the estimated critical temperature of the explosive system with a suitable margin of safety.

HIGH-ENERGY INITIATOR. Exploding bridgewire systems, slapper detonators, and EEDs with similar energy requirements for initiation.

HIGH PRESSURE. Gas pressure greater than 3,000 psig (21 MPa gauge); liquid pressure greater than 5,000 psig (35 MPa gauge).

HOLE (as applied to machine explosives). Any cavity that is more than one-half diameter deep, being cut by any tool with the direction of feed along the axis of rotation.

HOT WORK (thermal). Any operation requiring the use of a flame-producing device, an electrically heated tool producing a temperature higher than 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 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 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 DOE-DNA TP 20-7.

IMPEDANCE. The resistance and reactance to an electrical current.

INDIRECT CONTACT WITH EXPLOSIVES. Contact between bare explosives, the metallic casing of an explosive, or the firing leads of an explosive device and electrical instruments 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 by which 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.

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 Table IX-2.

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.

INTENTIONAL FIRING. This operation involves intentionally initiating explosives materials or articles for the purpose of testing, training, demonstration, or destruction.

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.

LIGHTNING DETECTION SYSTEM (LDS). A device or system to detect the presence of lightning activity in the general area.

LIGHTNING PROTECTION SYSTEM (LPS). 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.

MAJOR MODIFICATION. A planned project that significantly extends the building’s useful life through alterations including deferred maintenance that total more than 30 percent of the replacement value of the building. In addition a major modification results when there is a change in the building’s function resulting in a significant increase in hazard or risk, or significant increase in occupancy or planned life of the building.

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.

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/ site concerned where construction or maintenance activities occur.

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 janitor’s 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.

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 that 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, 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…