RZ_West_91-202.pdf

BY ORDER OF THE COMMANDER RZ-W OPERATING INSTRUCTION 91-202

AIR FORCE RESEARCH LABORATORY (AFRL)

24 June 2010

Safety

ENVIRONMENTAL SAFETY AND OCCUPATIONAL

HEALTH ESOH PROGRAMS

COMPLIANCE WITH THIS PUBLICATION IS MANDATORY

ACCESSIBILITY: Publications and forms are available at https://afrl.af.mil/RESOURCES/Library/afrl_all/pubs/default.asp

RELEASABILITY: There are no releasability restrictions on this publication.

OPR: AFRL DET 7/SE Certified by: AFRL DET 7/CC (Col Frederick Tanis)

Supersedes AFRL/PR OI 91-202, 20 Aug 2000 Pages: 111

This Operating Instruction (OI) establishes guidance and procedures for Environmental, Safety, and Occupational Health (ESOH) program requirements and responsibilities specific to Air Force Research Laboratory (AFRL)’s Propulsion Directorate (RZ-W) operations at Edwards AFB, CA. It supplements requirements of Air Force (AF), Air Force Materials Command (AFMC), and AFRL instructions and applies to all personnel working at AFRL/RZ West.

Contractors will comply with requirements identified in this OI. This instruction does not relieve contractors from compliance with federal, state, and local safety, health, and environmental regulations. Refer recommended changes and questions about this publication to the Office of Primary Responsibility (OPR) using the AF Form 847, Recommendation for Change of Publication; route AF Form 847s from the field through Major Command (MAJCOM) publications/forms managers. Ensure that all records created as a result of processes prescribed in this publication are maintained in accordance with Air Force Manual (AFMAN) 33-363, Management of Records, and disposed of in accordance with Air Force Records Information Management System (AFRIMS) Records Disposition Schedule (RDS) located at https://www.my.af.mil/gcss-af61a/afrims/afrims/. The use of the name or mark of any specific manufacturer, commercial product, commodity, or service in this publication does not imply endorsement by the Air Force.

SUMMARY OF CHANGES

This document is substantially revised and must be completely reviewed.

2 RZ-W OI 91-202 24 June 2010

Chapter 1 – SAFETY PROGRAM

1.1. Mission First, Safety Always

1.2. Core Values

1.3. Risk Management

1.4. “VPP Awareness” Recognition

Chapter 2 – THE SAFETY ORGANIZATION

2.1. Safety Staff

2.2. Managing the Safety Program

2.3. Safety Office Equipment/Table of Allowance (TA)

2.4. Publications Library

Chapter 3 – SAFETY INSPECTIONS

3.1. Safety Inspections

3.2. RZ-West Safety Inspection Process

3.3. Branch Safety Inspection Process

Chapter 4 – NEAR MISS AND HAZARD REPORTING PROGRAM

4.1. Near-Miss Reporting

4.2. Hazard Reporting

Chapter 5 – MISHAP & TEST/OPERATIONAL/RESEARCH FAILURE/ANOMALY

REPORTING/INVESTIGATION

5.1. Mishap Definition:

5.2. Test/Operational/Research Failure/Anomaly Definition

5.3. Initial Documentation Requirements

5.4. Calling 911

5.5. Safety Mishap Investigations

5.6. Trend Analysis

Chapter 6 – SAFETY EDUCATION & TRAINING

6.1. Safety Training

6.2. Responsibilities

6.3. Contractors

6.4. RZ-West Core Training Requirements

6.5. Contractor/Visitor Safety Training

RZ-W OI 91-202 24 June 2010 3

6.6. Operational Risk Management (ORM)

6.7. USAF Military Specific Training

6.8. RZ-West Specific Training

6.9. Branch Trainers

6.10. Branch Environmental, Safety and Occ Health Monitor (ESOHM)

6.11. Functional Manager/Supervisor Training

6.12. Safety Review Board (SRB) Member Training

6.13. Test Operations Safety Training

Chapter 7 - BIOENVIRONMENTAL

7.1. General

7.2. Test and R&D Support

7.3. Routine Occupational Health Surveillance

7.4. HAZCOM/Chemical Hygiene Plan

7.5. Radiation

7.6. Drinking Water (DW)

Chapter 8 – GROUND SAFETY

8.1. Program Management

8.2. Safety Standards

8.3. Self-Inspections

8.4. Confined Spaces

8.5. Lock-Out/Tag-Out

8.6. Welding, Brazing, Hot Work

8.7. Fall Protection

8.8. Ladders

8.9. Personal Protective Equipment (PPE)

Chapter 9 – SYSTEM SAFETY

9.1. Principles

9.2. Applicability

9.3. Responsibilities

Chapter 10 – WEAPONS SAFETY

10.1. Weapons Safety Program

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10.2. Responsibilities

10.3. Radio Frequency (RF) Systems

10.4. Additional Duty Weapons Safety Manager (ADWSM)

10.5. General Interim Hazard Classification Guidance

10.6. Explosive Guidelines for New Propellant Formulation

Table 10-1. Scaleup Procedure Guidelines for New Propellants and Formulations

Chapter 11 - ENVIRONMENTAL

11.1. Environmental Protection

11.2. Environmental Guidance

11.3. Environmental Assessment

11.4. Water Quality

11.5. Hazardous Materials Management

11.6. Spill Response Plan

Chapter 12 – GENERAL SITE OPERATION GUIDANCE

12.1. Overview

12.2. Site Operations Control Center (SOCC)

12.3. Emergency Notifications

12.4. Personnel at RZ-West Event/Emergency Notification System (PRENS):

12.5. After Hours Operations and Work Restrictions

12.6. Test Operations

12.7. Confined Space

12.8. Fire and Chemical Hazard Symbol Change

12.9. Explosive Transports

12.10. Helicopter Landings

12.11. General Area Access Procedures

12.12. Area Warning Lights, Flags, and Signs

Figure 12.1 – Access Control Warning Lights and Action

12.13. Buddy System

12.14. Adverse Weather Advisories

12.15. High Wind Restrictions

12.16. Facility Use General Requirements

RZ-W OI 91-202 24 June 2010 5

12.17. Hazardous Facility Use General Requirements

12.18. Operations Safety, Facility and Area Inspections

12.19. Hazardous Ground Operations General Requirements

12.20. Access Control of Hazardous Operations

12.21. Personnel Restrictions for Hazardous Operations

12.22. Procedures/Technical Data

12.23. Contractors

Chapter 13 – TEST SAFETY REVIEW PROCESS

13.1. Policy

13.2. Responsibilities

13.3. Test Safety Review Process

13.4. AFRL Form 4, Initial Safety Assessment

Figure 13.1 Test Safety Review Process

13.5. Concept Briefing

13.6. Test Safety Planning

13.7. Technical Review Board

13.8. Safety Reviews

13.9. Safety Review Board (SRB)

13.10. Qualification Tests

13.11. Test Safety Coordination

13.12. Test Readiness Review (TRR)

13.13. Test Approval Authority (TAA)

13.14. Test Execution/Conduct

13.15. Special Test Safety Considerations

13.16. Test Safety Plan Revisions

Chapter 14 – BASIC RESEARCH SAFETY REVIEW PROCESS

14.1. Applicability

14.2. Policy

14.3. Responsibilities

14.4 Training……………………………………………………………………………...83

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14.5. Documentation

14.6. Basic Research Safety Review Process

14.7. Research Execution

14.8. Permit Renewals

14.9. Lessons Learned

14.10. Materials Removal/Disposal

14.11. Project Termination/Close-Out

Table 14.1 Management of Change

Figure 14.1 Basic Research Safety Review Process Flowchart

Chapter 15 - FORMS

15.1. Prescribed Forms

15.2. Adopted Forms

ATTACHMENT 1 – GLOSSARY OF REFERNCES AND SUPPORTING INFORMATION 88

ATTACHMENT 2 – RISK ASSESSMENT TABLES AND MATRIX FOR RZ-WEST

ACTIVITIES

ATTACHMENT 3 – DOCUMENT APPROVAL MATRIX

ATTACHMENT 4 – INSTRUCTIONS FOR COMPLETING AFRL/RZ-W FORM 27

ATTACHMENT 5 – INSTRUCTIONS FOR COMPLETING AFRL/RZ-W FORM 5

ATTACHMENT 6 – AFMC FORM 228, JOB SAFETY ANALYSIS

RZ-W OI 91-202 24 June 2010 7

Chapter 1

SAFETY PROGRAM

1.1. Mission First, Safety Always. Personnel working at RZ-West plan, implement, and integrate risk management into all Air Force operations and missions. This creates a “Mission First, Safety Always” culture, transforming a compliance-based AFOSH Program to a performance-based system recognized through the Occupational Safety and Health Administration’s (OSHA) Voluntary Protection Program (VPP).

1.1.1. All personnel, at all levels, will lead the transition from a system managed program led by ESOH professionals to a continuously improving, “best-in-class”, injury and illness prevention program as outlined in the Voluntary Protection Program (VPP).

All personnel will take charge of their own safety and occupational health issues and as importantly, they will assume ESOH responsibility for their wingman. Contractors will be held responsible for their safety and health program, but they will be required to strive towards providing their employees safety and health protection equal in quality to that provided AF employees. Compliance alone is not sufficient; VPP focuses on safety and health performance.

1.1.2. Scope of VPP in USAF. The Secretary of the Air Force (SECAF) directed implementation of VPP throughout the Air Force in March 2006. SECAF made it clear that the VPP would provide the focus to develop “best-in-class” ESOH programs. In executing the VPP, the AF will build on its AFOSH management system in creating collaborative partnerships among leadership, unions and employees, and Occupational Safety and Health Administration (OSHA). VPP is also the logical extension of the AF Wingman concept. As VPP principals and key concepts are taught across the AF and incorporated into our work processes they will be used with the AF Operational Risk Management (ORM) program so that every individual will have a fundamental safety situational awareness. Each individual has the inherent responsibility and accountability for recognizing and acting to correct unsafe and unhealthy conditions.

1.1.3. DET 7 CC Policy. The safety and well-being of RZ-West personnel and their families is my top priority. There is nothing that we do in the Propulsion Directorate that would warrant placing our people or resources at unnecessary risk. I expect leadership by example from every individual and the application of risk management to all tasks, from routine to complex, both on and off duty. Utilize Operational Risk Management (ORM) principles. No operation or activity may be undertaken without first assessing the risk to mission, personnel, facilities, and the environment or without approved procedures. My philosophy is achievable and simple. Provide a safe and healthy working environment to all personnel. Supervise, educate, reduce risk, seek out and eliminate conditions, practices, and habits that threaten the safety of our people. Under VPP, I will put measures in place which can facilitate and track an increase in hazard reporting and safety suggestions using tools accessible to everyone. Beginning CY 2010, I will ensure that we conduct trend analysis using our site’s injury rates which will include military, civilian and contractor data.

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1.2. Core Values. The following core values are essential in preventing mishaps:

1.2.1. Everyone will promote safety as a core value in everyday work as compared to a priority, contributing to the mishap prevention program. An effective program depends on individuals integrating mishap prevention at every functional level and being responsible for complying with applicable safety standards.

1.2.2. Leaders and managers will provide visible leadership by going above and beyond safety and health compliance. This is accomplished by establishing clear lines of communication of safety and health policies, creating an environment that allows employee access to top site management, setting the example for safe and healthful behavior, and promoting a “team atmosphere” to evaluate and mitigate risk.

1.2.3. Everyone must set the example and be a Wingman to foster safety as a core value. This is accomplished by participating in teams, groups, committees, audits, investigations; receiving feedback from suggestions and hazard reports;

identify/report/correct hazards and understanding basic elements of VPP.

1.2.4. The end goal of having safety as a core value, setting the example for safe and healthful behavior, creating a supportive atmosphere and going above and beyond safety and health compliance will produce, maintain and sustain a world-class safety and health program.

1.3. Risk Management:

1.3.1. Everyone should work as a team (Wingman) to keep each other safe and abate/mitigate hazards/conditions until corrected. The proper way to eliminate a particular hazard or condition is often difficult to determine. After considering all factors, choose the alternative (mitigation) that contributes the most to safe activities and overall mission accomplishment.

1.3.2. The risk management process is used to mitigate hazards and unsafe work conditions. Risk evaluation exists on three levels (on/off duty):

1.3.2.1. Time-Critical: Time-critical risk management is an “on the run” mental or verbal review of the situation using the basic risk management process without necessarily recording the information (i.e. looking for snakes, using appropriate length ladders, backing vehicles)

1.3.2.2. Deliberate: Deliberate risk management is the application of a complete process. (JSA, SPA, six-step ORM, etc))

RZ-W OI 91-202 24 June 2010 9

1.3.2.3. Strategic: This is the deliberate process with more thorough hazard identification and risk assessment involving research of available data, use of diagram and analysis tools, etc. (THA, fish-bone, FMECA, etc)

1.3.3. An effective risk management program is the primary key for conducting safe activities and mitigating/abating hazards at RZ-West.

1.4. “VPP Awareness” Recognition

1.4.1. The “VPP Awareness” recognition is reserved for individuals who go above-and-beyond their normal day-to-day activities and “think outside the box” making an activity or process safer by being better defined, more streamlined or by identifying a safer approach to complete the task.

1.4.2. Criteria for monthly award.

1.4.2.1. Anyone may nominate self or an individual for this recognition by preparing a short 3-4 sentence paragraph detailing the achievement and submitting the nomination to the AFRL Det 7 VPP CoP. Alternatively, these nominations can also be made via emails or other alternative media, which will get documented on the VPP CoP. The address for CoP nomination is:

https://afkm.wpafb.af.mil/Questionnaire/DisplayQuestionnaire.aspx?Filter=OO-

SE-MC-55&QID=8152

1.4.2.2. The award winners will be selected by the Det 7 Commander with the help of voting by site employees. Up to two award winners may be selected and these individuals will be recognized publically during Commander/Directors/Site Calls.

1.4.3. Criteria for the yearly (FY) “VPP Awareness – MVP (Meaningful Voluntary

Participant)” award.

1.4.3.1. The Det 7/CC evaluates the twelve monthly award winner’s submissions and the site employees get to vote for the best and most meaningful safety contribution for the year. The winner is awarded “VPP Awareness – MVP (Meaningful Voluntary Participant)” award.

1.4.3.2. Branches winning the most VPP Awareness Awards though out a CY will be awarded the Commander’s Annual VPP Challenge Trophy.

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Chapter 2

THE SAFETY ORGANIZATION

2.1. Safety Staff AFRL DET 7/SE is led by a Chief of Safety reporting directly to the Detachment Commander. The AFRL/SE office has authorizations to cover the chief of safety, ground, weapons, system safety, bio-environmental and environmental functional areas. AFRL DET 7/SE will be the single interface to host-base safety. AFRL DET 7/SE staff is tailored to meet the DET 7’s mission and operating environments IAW 91-series AFI’s and associated AFMC and AFRL supplements.

2.2. Managing the Safety Program. DET 7 Commander will establish and execute a management strategy that:

2.2.1. Ensures that functional managers and supervisors (rather than the safety staff) commit funds and take corrective action for deficiencies.

2.2.2. Involves the safety staff in appropriate meetings, conferences, and councils.

2.2.3. Integrates safety into all operations and missions.

2.2.4. Seek VPP Star Status, by producing and sustaining a world-class safety and health program.

2.2.5. Emphasizes risk management and accountability.

2.2.6. Convening Authority: The detachment commander is the convening authority for Ground Class C and D ground mishaps, and Class E events unless assumed by a higher level of command.

2.3. Safety Office Equipment/Table of Allowance (TA). AFRL DET 7 /SE are authorized the following allocation of resources:

2.3.1. Three 4X4 vehicles (four passenger) capable of off-road travel for emergency response, test preparation, inspection for explosive easement, safety/environmental inspections, bio-environmental test support and operational/buildup/test inspections.

2.3.2. Three mishap investigation kits.

2.3.3. Land Mobile Radios and cellular phones.

2.4. Publications Library. AFRL Det 7/SE is authorized the following publications in its library:

RZ-W OI 91-202 24 June 2010 11

2.4.1. National Fire Protection Codes.

2.4.2. OSHA 29 Federal Code Regulations (CFR).

2.4.3. CFR 49, Transportation of Hazardous Materials

2.4.4. State of California Occupational Safety and Health Titles.

2.4.5. ASTM, ANSI Standards.

2.4.6. Special computer software tools for analyzing toxic corridors, explosive zones, etc.

2.4.7. Software for safety meeting’s/compliance.

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Chapter 3

SAFETY INSPECTIONS

3.1. Safety Inspections.

3.1.1. Safety Inspection checklists are tailored to the RZ West mission/operating environment, encompassing applicable items in current HQ AFMC/IG and HQ AFMC/SE checklists.

3.1.2. DET 7/SE staff will conduct an annual safety inspection (ASI) of all explosive/industrial facilities to include safety programmatics. Administrative facilities will be inspected every two years. DET 7/SE staff will provide the branch a formal report within thirty days of the inspection. The branch will submit corrective actions with an estimated correction date (ECD) for each discrepancy that could not be closed. All findings will be tracked in the local ESOH Directory by the branch until closed, once closed DET 7/SE will validate closure.

3.1.3. DET 7 staff will conduct no-notice safety spot inspections on facilities, administrative, industrial, explosive, and test operations. DET 7/SE staff will inspect areas through spot inspections/evaluations.

3.1.4. Branches use tailored checklists to effectively evaluate the safety and health program, processes, equipment and facilities to validate safe working conditions for all personnel.

3.2. RZ-West Safety Inspection Process.

3.2.1. Annual Safety Inspections.

3.2.1.1. DET 7/SE will publish an annual safety inspection schedules by the end of December.

3.2.1.2. DET 7/SE will contact the branch chief and ESOHM or ADWSM thirty days prior to their scheduled safety inspections to confirm availability of branch representation for the scheduled date.

3.2.1.3. DET 7/SE will in-brief the branch chief/rep of current open findings and scope of the inspections (explosives, ground, environmental, etc).

3.2.1.4. DET 7/SE out-briefs the branch chief/rep of their preliminary inspection findings.

RZ-W OI 91-202 24 June 2010 13

3.2.2. Spot inspections (Observations/Findings).

3.2.2.1. All spots will be recorded in the ESOH Directory.

3.2.2.2. Observations (System Safety, Environmental, etc) coded “action required” requires branch responses.

3.2.2.3. Spot findings that have RAC’s assigned require action from the appropriate branch chief/rep within thirty days of notification.

3.2.2.4. High interest spot inspections are “no notice” inspections.

3.2.2.5. High interest spot inspections are conducted for active operations and tests.

3.2.2.6. Observations/findings from high interest inspections are documented and tracked the same as spot inspections.

3.3. Branch Safety Inspection Process.

3.3.1. Each branch will profile applicable work areas by answering the questions in the Safety Checklist Questionnaire at the beginning of each inspection cycle (ESOH Directory). The completed questionnaire will produce the required local safety and health checklists. The completed safety profile and checklists must be kept in the ESOH Monitors Safety Book for one inspection cycle. ADWSM’s must keep the completed weapons checklists in the ADWSM handbook.

3.3.2. Tailored checklists are used for monthly and quarterly self-inspections. All completed checklists are kept in the ESOHM Safety Book for one ASI inspection cycle.

3.3.3. The local safety checklists are also a good tool for initial assessment of facility buildup/tests and or operations.

3.3.4. Status all open findings/observations until closed in the AFMC 315 section of the ESOH Directory.

3.3.5. RAC 1-3 open status will be updated quarterly in the AFMC 315 section of the local ESOH Directory until closed.

3.3.6. RAC 4-5 open status will be updated during budget development for either test or annual FY cycles and prior to the annual safety inspection.

3.3.7. The branch is required to maintain hard copies of AFMC 315’s for one inspection cycle from their last ASI (twelve months for industrial and four for administrative areas).

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3.3.8. AFMC 315’s findings/observations are located and can be printed from the ESOH Directory.

3.3.9. All findings closed by the branch chief/rep are required to be validated closed by DET 7/SEG/SEW. The branch chief/representative or safety monitor is required to contact DET 7/SEG/SEW to validate the closure.

3.3.10. Inspection findings/status will be briefed at SRR/FRR and TRR’s.

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Chapter 4

NEAR-MISS AND HAZARD REPORTING PROGRAM

4.1. Near-Miss Reporting. A near miss is an unplanned event that did not result in injury/illness or damage greater than $2,000, but had the potential to be more serious. Only a fortunate break in the chain of events prevented an injury, fatality or damage.

4.1.1. Although human error is commonly an initiating event, a faulty process or system invariably permits or compounds the harm, and should be the focus of improvement.

4.1.2. Other familiar terms for these events is a "close call", or in the case of moving objects, "near collision". The often misunderstood phrase is so-called to stress that not only had things gone remotely off course towards danger, but they had actually only "barely missed" catastrophe. For instance, commercial airliners are considered dangerously close if they are one mile apart. If they pass at a quarter mile apart or less, this is a "near miss" because they were extraordinarily near each other when they missed collision.

4.1.3. Near Misses are reported to the supervisor and documented in the near-miss reporting tool located on the VPP COP or in ESOH Directory.

4.2. Hazard Reporting. It is everyone’s responsibility to identify, report, and correct hazards. Hazards left unreported increases the probability of injuries, mishaps, equipment damage, test or operational delays, etc. Anyone may report a hazard. Submit a hazard report or observation on any event or condition that affects test, research, ground, weapons safety or occupational exposures and environmental impacts. Examples of reportable hazards are unsafe conditions, inadequate training, unsafe procedures, poor work practices, and unsafe facilities/equipment or damaged/improperly maintained motor vehicles.

4.2.1. Reporting Process.

4.2.1.1. Observations/Hazards may be reported in numerous ways.

4.2.1.1.1. Verbally report observations/hazards to the leader (work-lead, group-lead, red crew leader, facility manager, safety and health monitor, supervisor, program manager, etc.), and correct if possible.

4.2.1.1.2. Document observations/hazards in the ESOH Directory:

click the EOSH icon on your desktop, click the Safety /Findings/Observation Tab, click the Observation tab, and enter the hazard. Once this is accomplished notify your leader.

4.2.1.1.3. Drop observations in the Safety Observation Suggestions (SOS) drop boxes (reports can be submitted anonymously.)

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4.2.1.1.4. Submit hazard reports using the AFRL Det 7/SE Safety Main Community of Practice (COP) Website:

https://wwwd.my.af.mil/afknprod/ASPs/CoP/ClosedCoP.asp?Filter=O

O-SE-MC-49

4.2.1.1.5. Submit hazard reports using the AFRL RZ-West VPP COP Website:

https://afkm.wpafb.af.mil/ASPs/CoP/OpenCoP.asp?Filter=OO-SE-

MC-55

4.2.1.1.6. Submit an AF Form 457, USAF Hazard Report (HR), by telephone or in person to DET 7/SE (reports can be submitted anonymously).

4.2.1.2. The leader ensures the hazard is documented in the AFMC 315 of the ESOH Directory.

4.2.1.3. If the hazard presents imminent danger, take immediate action to correct the situation or apply interim control measures and notify your branch chief and DET 7/SE.

4.2.1.4. The safety staff investigates all hazards and assists the leader to determine the best interim control and corrective action and updates the ESOH Directory.

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Chapter 5

MISHAP & TEST/OPERATIONAL/RESEARCH FAILURE/ANOMALY

REPORTING/INVESTIGATION

5.1. Mishap Definition:

5.1.1. A mishap is an unplanned occurrence, or series of occurrences, that results in damage or injury as described in paragraph 5.1.1.1. and meets Class A, B, C, or D mishap reporting criteria with potential damage greater than $20,000 and an injury or illness.

Refer to AFI 91-204 for specific mishap reporting criteria.

5.1.1.1. Damage or injury includes: damage to DoD property; occupational illness to DoD military or civilian personnel; injury to on- or off-duty DoD military personnel; injury to on-duty DoD civilian personnel; damage to public or private property, or injury or illness to non-DoD personnel caused by Air Force operations.

5.1.1.2. Although motor vehicle mishaps often result from some form of misconduct (e.g., speeding, driving while intoxicated, and reckless driving) they will be reported in accordance with AFI 91-204.

5.1.2. An event is an unplanned occurrence, or series of occurrences, that does not meet mishap reporting criteria as defined in paragraph 5.1.1. with potential damage between $2,000-$20,000 and no injuries or illnesses as defined in AFI 91-204. Class E events may require a safety investigation and report, but will be documented and researched for trending purposes and mishap prevention.

5.2. Test/Operational/Research Failure/Anomaly Definition:

5.2.1. Test/Operational/Research failures or anomalies are unplanned occurrences or results of test/research activities. The reporting criteria is defined in the AFMC supplement to AFI 91-204.

5.3. Initial Documentation Requirements:

5.3.1. Ground Mishaps are reported using AFFTC Form 5844, Ground Mishap Form.

5.3.1.1. Initial verbal notification of the mishap will occur as soon as reasonably possible to the supervisor and safety.

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5.3.1.2. All personnel (civilian/contractor on-duty; military both off- and on-duty) who are involved in mishaps must complete an AFFTC Form 5844 and submit to DET 7/SE. Contractors must submit a copy of their completed mishap form to DET 7/SE for the purpose of prevention/trending. All reports must be completed and turned in NLT 48hrs or the first following duty day (whichever is earlier).

5.3.2. Operational, test or research failures/anomalies are reported using the AFRL Form 29, AFRL Test Safety Mishap Worksheet.

5.3.2.1. Initial verbal notification to SOCC will be initiated immediately after the test/research anomaly event is secured.

5.3.2.2. The written Report will be will submitted as soon as reasonably possible of the event.

5.4. Calling 911.

5.4.1. Injured or ill personnel should call 911 and have a wingman follow-up with a call to Site Operations control Center (SOCC) 661-275-5632. Emergency medical/fire response is activated through use of the 911 system.

5.4.2. If the call is made to 911 from a government facility/landline, it will be routed directly to the AFFTC Emergency Control Center (ECC). Answer all questions, to the 911 operator, to the best of your knowledge, and do exactly what is asked of you. The ECC will dispatch emergency support services to your location which may consist of Fire, Medical and Security.

5.4.3. When calling 911 from a cellular phone, the call will go to an off-base emergency center, so, the caller must notify the operator the 911 event is on EAFB. The call will be rerouted or information passed on to the AFFTC/ECC. Due to this transfer, there will be a time delay dispatching emergency services. The AFFTC ECC commercial emergency number for cellular phones on Edwards AFB and AFRL RZ West is 661-277-4540. It is recommended that this number be added to each cellular (private and government) and listed as “Edwards AFB 911”.

5.4.4. When using Land Mobile Radios (LMR) (Command and Control), call SOCC directly on the LMR, inform the operator it is a “911” emergency and provide the requested information.

5.4.5. Under a test / hazardous operation, follow emergency steps from the emergency section of the procedure.

RZ-W OI 91-202 24 June 2010 19

5.4.6. All areas and facilities have written emergency guidelines to follow for emergencies. The basic guidelines are in the areas/facilities emergency section of area’s standard operating instruction (SOI). All personnel should read this section and be briefed within 30 days of assignment to the area/facility; and every year, each individual is required to review and sign the SOI or when the SOI is updated.

5.4.7. The nearest hospital is located approximately fifty miles from AFRL RZ-West.

Travel time by ambulance is 50 minutes and 60 minutes by privately owned vehicles.

There is one emergency medical technician and one paramedic on duty at RZ-West during normal working hours and during hazardous operations.

5.5. Safety Mishap Investigations.

5.5.1. Safety investigations are conducted to prevent reoccurrence of mishaps; they cannot be used for punitive action. Safety investigations take priority over any corresponding legal investigations, accident investigations, Commander Directive Investigation, etc.

5.5.2. DET 7/SE ensures all mishaps are investigated properly and reported according to

AFI 91-204.

5.5.3. When a mishap occurs, the mishap scene needs to stay intact, vehicles not moved, switches not altered with (if safe to do so), and records not altered. The lead person at the scene must impound the area surrounding the scene and notify DET 7/SE immediately.

5.5.4. Personnel involved with the mishap and witnesses should not leave the area (excluding injured or exposed personnel), until cleared by the safety investigator.

5.5.5. The mishap scene will stay impounded until cleared by the assigned safety investigator.

5.5.6. The division chief or branch chief will provide all resources necessary to the safety investigator upon request.

5.5.7. If the division or branch chief conducts a separate investigation, they must notify the Commander and the safety investigator. The Commander and safety investigator will determine when their investigation can start and will notify the division or branch chief when they are cleared to begin.

5.5.8. Applicable results from mishap investigations will be documented in the lessons learned tool.

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5.6. Trend Analysis. Trending is a method of examining findings identified from reports on injury and illness, employee report of hazards, first aid, accidents, hazards identified during inspections and near misses.

5.6.1. Trends are reviewed quarterly.

5.6.2. Plans of action are continuously monitored for effectiveness.

5.6.3. Results are shared with division management, branch chiefs and ESOH monitors to actively engage employees for suggestions and corrections to continuously improve the working environment and be documented in the Lessons Learned Tool.

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Chapter 6

SAFETY EDUCATION AND TRAINING

6.1. Safety Training. Safety training and education is the fundamental building block in arming personnel with the right knowledge to maintain a safe and healthful work/home environment. Continual education/evaluation/mitigation prevents unsafe acts in day-to-day activities, assures a “mission first” priority and establishes a “safety always” culture.

6.2. Responsibilities. A fundamental premise of the safety and health guidelines is that all employees must understand their safety and health responsibilities and the hazards to which they may be exposed, and how to prevent harm to themselves and others from such exposures.

Without such an understanding, managers, supervisors, and other employees will not perform their responsibilities for safety and health effectively. For this to happen, the training/mentoring must ensure the following:

6.2.1. Managers, supervisors and leaders understand their safety and health responsibilities and are able to carry them out effectively. These responsibilities may include analyzing the work under their supervision to identify unrecognized potential hazards, maintaining physical safeguards in their work areas, and reinforcing employee training on the nature of potential hazards in their work and on needed protective measures, through continual performance feedback and, if necessary, through enforcement of safe work practices.

6.2.2. All employees are mentored/trained on hazards and are taught how to recognize hazardous conditions and the signs and symptoms of work-related illnesses. All employees are also provided with information and training in the safety and health program and the provision of applicable standards.

6.2.3. All employees are mentored and learn the safe work procedures to follow in order to protect themselves from hazards. This includes what is being done to control these hazards and the protective measures the employee must follow to prevent or minimize exposure to these hazards.

6.2.4. All employees and visitors on site understand what to do in emergency situations.

6.2.5. Where personal protective equipment is required, employees understand that it is required, why it is required, its limitations, how to use it, and how to maintain it, and use it properly.

6.3. Contractors. Contractors who work on AFRL will be trained in accordance with the State of California Safety and Health requirements.

22 RZ-W OI 91-202 24 June 2010

6.3.1. Contractors are responsible to conduct their core safety and health training.

Taking part in monthly and quarterly USAF safety meetings, conferences and or briefings does not relieve the contractor from the state of California requirements.

6.3.2. Contractors are held responsible by their contract with the USAF and must ensure that they are current in OSHA training and RZ-West core/specific training requirements.

6.4. RZ-West Core Training Requirements. All personnel working at RZ-West will complete the following classes:

6.4.1. RZ-West Newcomers Awareness Briefing. All personnel at RZ-West will attend the RZ-West newcomers briefing. This training is conducted by RZ-West support branches. Training covered includes: Base and RZ-West roadway hazards, RZ-West Area Warning Systems, explosive awareness, Desert Tortoise briefing, Fire Extinguisher, Disaster Preparedness, Intro to ORM/PSM, USAF 457 Hazard reporting, 911 Emergency, initial HAZCOM and VPP 101. Other required AFRL non-safety training is also covered.

6.4.2. Safety Training Profile. All personnel will have safety profiles conducted within 30 days of initial or new assignment to RZ-West by the supervisor. The training requirements are profiled using the Profile area in the Training section of the ESOH Directory. Profiles are required to be accomplished initially during in-processing and anytime work assignments change. The supervisor shall train or provide the training to each employee and qualify the individual prior to job assignment.

6.4.3. Computer Based Training(CBT) (must achieve 80% on written exam) is used in conjunction with area specific training that is conducted when reviewing the Safety Operating Instructions (SOI) located at each of the areas/labs. The training is documented in the Training section of the ESOH Directory. The CBT’s include:

Emergency Preparedness, Bloodborne Pathogens, Fire Extinguisher Training and Use, Eye Protection, Hearing Conservation, How to Prevent Slips and Falls, Back Injury Protection, Electrical Safety, Personal Protective Equipment, Office Safety Orientation, ORM Fundamentals (Level 3) and ORM Essential for Leader (Level 2).

6.4.4. Job Safety Training (JST) is conducted by the supervisor with each employee and documented in the Training section of the ESOH Directory. JST Outline’s encompasses all areas listed on the AF Form 55, Safety and Health Training Record. JST outline templates for admin are available through DET 7/SE. SOI’s may be used as the JSTO for test/lab areas. The SOI template for test/lab areas are available through DET 7/SE. All personnel requiring unescorted access to a specific test area, signs the SOI documentation in the respective areas.

6.4.5. Contractors attend RZ-West Newcomers Awareness briefing. Contractors show equivalent training for CalOSHA/OSHA requirements. All personnel requiring unescorted access to a specific test area, signs the SOI documentation in the respective areas.

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6.4.6. Training Documentation. Training is documented in the training section of the ESOH Directory. Contact DET 7/SE for training to access the ESOH Directory.

6.4.6.1. AF Form 55 requirements. The AF Form 55, Employee Safety and Health Record, is used to document safety, fire protection and health training. All DoD personnel will have safety training documented on the AF Form 55.

6.4.6.1.1. Per AFI 91-301 and the associated AFMC supplement, AFRL RZ-W has been approved to utilize the electronic version of this form along with computer signature verification.

6.4.6.1.1.1. Use the AFRL Training portion of the

ESOH Directory to prepare and maintain the AF Form 55.

All personnel must have access to view their AF Form 55.

6.4.6.1.1.2. Entry into the ESOH Directory must be

accomplished NLT 30 days from the first day of assignment.

6.4.6.1.1.3. Utilize the remarks section of the AF Form

55 to annotate the date that electronic signature verification began.

6.4.6.1.1.4. Electronic AF Form 55’s do not need to

printed. Place a memo in the 971 folder (civilian) or 623 package (enlisted) that the AF Form 55 is being kept electronically in the ESOH Directory.

6.4.6.1.1.5. If computer access is unavailable to the

worker, the primary method is to maintain a hard copy with the required signatures within the 971 folder (civilians) or 623 package (enlisted). If the AF Form 55’s are not maintained in the above mentioned locations, place a memo in the 971 file or 623 package where the AF Form 55 is being maintained.

6.4.6.1.1.6. Personnel should notify their

supervisor/training coordinator as soon as practical when a training event is completed.

6.4.6.1.1.7. All training is actively recorded on the AF

Form 55 within the ESOH Directory. Supervisors must review the workers electronic AF Form 55 at regular intervals to ensure digital signatures are entered within 30 days of a training event.

24 RZ-W OI 91-202 24 June 2010

6.5. Contractor/Visitor Safety Training. This training/briefing is given to contractors/visitors who are not residents of AFRL. The training is a shortened version of the AFRL Newcomers Briefing and encompasses explosives awareness, emergency actions, site entry, and accountability procedures. For short duration visits (1-2 days), this training may be provided by the area using the SOI.

6.6. Operational Risk Management (ORM). All personnel at RZ-West will receive appropriate ORM training. There are four (4) levels of ORM training:

6.6.1. Level 1 - ORM Applications Course for Instructors/Advisors/Facilitators is the highest level of training. Anyone who completes this level qualifies as an advisor/facilitator/instructor on ORM processes.

6.6.2. Level 2 – ORM Essentials for Leaders - This level training applies for supervisors, managers, leaders (such as red crew leaders, work leaders, group leaders, engineers, program managers, and branch chiefs) who prepare and implement ORM processes to their operations.

6.6.3. Level 3 – Fundamentals Course – This level provides basic ORM training for all personnel. This level is designed to provide personnel a working knowledge of ORM processes.

6.6.4. Level 4 – ORM Executive Leaders – This level training is designed for senior executives such as commanders, deputies, division chief and deputy, directorate level and commanders as an aid to understand the ORM process and apply the risk management process within the organization.

6.7. USAF Military Specific Training.

6.7.1. The commander, executive officer, or first sergeant will ensure all newly assigned active duty military personnel under the age of 26 receive a job specific newcomer's safety briefing within 30 days of arrival. Document the briefing on AF Form 55. Maintain the completed form in individual’s personal information file (PIF) until he or she departs permanent change of station (PCS) or permanent change of assignment (PCA), retires, etc.

6.7.2. Ensure military personnel under the age of 26 receive a pre-departure safety briefing before they depart on leave, TDY, or PCS.

6.7.2.1. The unit commander, first sergeant or immediate supervisor will conduct the briefing and document pre-departure safety briefings and maintain the completed documentation until individual completes PCS.

6.7.3. Personal Risk Management Assessment. Supervisors will conduct a PRM assessment with personnel who are participating in “High Risk” off-duty activities.

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6.8. RZ-West Specific Training. RZ-West specific training is geared and required for all individuals performing related duties at RZ-West. The training includes specific requirements for notification, documentation and conducting related tasks.

6.8.1. Explosive (Energetic Materials) Safety Training. Energetic materials training is required for individuals who work with, operate, handle, transport, maintain, load, or dispose of explosives/energetic materials; solids/powders, or gases/liquids. This training is conducted annually by DET 7/SE or by ADWSM’s, and provides basic weapons safety requirements, and guidance of standards. ADWSM’s will conduct area specific training utilizing approved lesson plans or approved procedures/instructions. (Refer to Chapter 10)

6.8.2. Explosive Laden Training. Explosive Laden vehicle training is required for those personnel who transport energetic materials by vehicles, forklifts, cranes, etc.

6.8.2.1. Explosive Laden vehicle training is valid for one year; the restrictions are the same as the energetic materials training when lapsed.

6.8.2.2. Prerequisite of explosive laden vehicle training. The person must have a valid state license, have 20/20 or corrected vision to 20/20, not be color blind, and be able to read, communicate and be current in energetic materials training and possess a Government driver’s license.

6.8.2.3. The Explosive Laden training is only valid for RZ-West use only. If the worker is to transport on a public highway they must meet the California Highway hazardous materials driver requirements.

6.8.3. Confined Space Training. All personnel who enter into confined spaces will be trained in accordance with the RZ-West Confined Space Plan.

6.8.4. Lock-out/Tag-out (LOTO) Training. Personnel performing LOTO will be qualified to perform LOTO. Personnel must complete a LOTO CBT/training and site specific LOTO training.

6.8.5. Fall protection. Personnel who work at four feet and at elevated levels, outside of OSHA approved hand rails, will be trained and qualified in fall protection. Personnel who use fall protection equipment must complete a fall protection CBT/training and site specific fall protection training. Site specific training is required yearly.

6.8.6. Ladder Safety Training. All personnel who use ladders daily and who work at elevated levels above four feet will complete a ladder safety CBT/training and site specific ladder safety training. Site specific training is required yearly.

6.8.7. Welding/burning/hot work. Personnel, who conduct hot work, and their fire watches, must be current in fire extinguisher training.

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6.8.8. Heavy/light equipment (motorized/non-motorized), forklift, cranes (fixed/portable), munitions trailers, hoists, etc. Personnel operating light/heavy equipment will be trained, certified or qualified per the manufacturer’s requirements and per the AFSOH standard for specific equipment.

6.8.9. Laser Safety Officers (LSO). A unit LSO must be assigned for each functional area using readily accessible ANSI Class 3b or 4 lasers. Unit LSOs must receive initial and annual laser safety training from Det 7 SEB (Site LSO). Unit LSOs, in-turn, train laser users within their functional areas.

6.8.10. Laser Users. Initial and annual general laser safety training is required for all users of readily accessible ANSI Class 3b or 4 lasers (IAW AFOSH 48-139). Consult with Det 7 SEB for additional guidance.

6.9. Branch Trainers. Each branch chief will assign trainers to train personnel on safety and health standards, procedures, and requirements of the job tasks and document the training.

6.9.1. Trainers must have attended and graduated from an OSHA train the trainer course or attend the AFFTC Train-the-Trainer course.

6.9.2. Trainers will be designated in writing by the branch chief.

6.9.3. Safety and health training will have an approved safety lesson plan to follow with an identification of criteria elements to be signed off prior to being qualified/certified by the certifier.

6.9.3.1. Safety lesson plans will be coordinated with DET 7/SE and reviewed annually.

6.9.3.2. Safety Lesson Plans cannot cover multi-equipment, such a 60 ton bridge crane and a 60 ton hydraulic (tire) pick and reach crane, etc.

Manufacturer’s manuals should be used for conducting training, including approved procedures.

6.9.4. Additional Duty Weapons Safety Manager (ADWSM). The ADSWM is appointed by the Branch Chief and is the focal point for the branch weapon (energetic) safety program. They must have a thorough understanding of the unit’s mission and activities. The ADWSM will be the point of contact for the AFRL Weapons Safety office for external weapons safety inspections/audits during mishap investigations, spot visits and annual evaluations. The ADWSM is trained by AFRL Det 7 Weapon Safety within 30 days of assignment. (See Chapter 10)

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6.9.4.1. Energetic Materials training is valid for one year. Extensions beyond 12 months must be approved by the AFRL Det 7 WSM. Extensions will not be granted beyond the 15 month time period. Personnel must be removed from energetic materials hazardous operations until retrained.

6.10. Branch Environmental, Safety and Occ Health Monitor (ESOHM). Individuals assigned collateral duty safety responsibilities at the unit level receive training from DET 7/SE every two years. Each branch chief is responsible for maintaining training records. ESOHM’s and their alternates will begin training within 30 days after appointment.

6.11. Functional Manager/Supervisor Training. All functional managers, supervisors, group leads, program managers, and lead engineers are required to attend Functional Manager/Supervisor Training specific to RZ-West. This training will be documented in the ESOH Directory.

6.12. Safety Review Board (SRB) Member Training. All appointed SRB members will receive the Safety Review Board training at the initial meeting. The training will include as a minimum: purpose/objective, goals, review documents, members responsibility, conflict/resolution, voting system, action items, risk management, etc. All SRB members will have completed Energetic Materials (solids and liquids), eye protection, hearing conservation, emergency preparedness, fall protection, electrical safety, personal protective equipment, hazard communications, lock out/tag out, and confined space training, as applicable to the project. In addition, prior to the first meeting, the SRB members will complete the following:

6.12.1. All members are required to complete ORM Level 2 training.

6.13. Test Operations Safety Training. Branch chiefs, deputy branch chiefs, project managers, engineers, scientists, test crews and in-house support contractors responsible for managing programs at RZ-West will complete initial project environmental, safety, and health requirements training before approving any safety risk management assessments.

6.13.1. The responsible test organization with concurrence from the Chief of Safety will designate in writing the test director and test conductor for each project test activity; and associated safety training for the test activity will be completed prior to assumption of duties.

6.13.2. Test directors and test conductors will receive an annual evaluation by their Branch Chiefs that will include as the minimum:

6.13.2.1 Familiarity with applicable test policies, laws and instructions, test discipline, and overall test requirements.

6.13.2.2. Understanding of hazards, failure modes of test system, and action required to control the situation.

6.13.2.3. Capable of making safety, security and technical decisions.

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Chapter 7

BIOENVIRONMENTAL

7.1. General. Bioenvironmental engineering (BE) conducts health risk assessments for routine, test and R&D related occupational health (OH) hazards for DoD employees at RZ-West.

Worker health is protected by eliminating hazards, controlling hazards or protecting the worker from the hazards. Hazards include but are not limited to: toxic industrial chemicals, high pressure, hazardous noise, confined spaces, ergonomic stress, thermal stress, radiation and lasers.

7.2. Test and R&D Support.

7.2.1. Test/R&D Activities. The RZ-West Form 5 and Form 27 document hazards for test and R&D activities. Det 7 BE reviews these forms and conducts a health risk assessment of the hazards. These are non-routine occupational health evaluations provided specifically by the DET 7 BE to ensure worker health is protected above and beyond what annual or biennial routine workplace occupational health assessments can provide.

7.2.2. Safety Review Board (SRB). The DET 7 BE is a SRB member and attends as needed to evaluate test/research processes and procedures to ensure hazards are mitigated and the workers are adequately protected.

7.2.3. Toxic Corridor Evaluation and Dispersion Modeling. DET 7 BE provides a dispersion model for all tests involving toxic chemicals and effluent products. The dispersion model includes at a minimum the IDLH distance, clear zone distance and the appropriate wind corridor required to conduct the test.