Contractor's_Operations_Manual_(10-06).pdf

NSACRANE COM 1C

DISTRIBUTION STATEMENT

Distribution is authorized to personnel who perform contracted work or who support such work as managers or through technical document development at the Crane site.

Published by NAVSUPPACT Crane

October 2006 i ii

TTAABBLLEE OOFF CCOONNTTEENNTTSS

TITLE PAGE

CHAPTER 1 – INTRODUCTION TO CONTRACTOR OPERATIONS

ON CRANE

POLICY

BACKGROUND

ORGANIZATION OF THE MANUAL

CHAPTER 2 – EXPLOSIVES SAFETY

EXPLOSIVE HAZARD SYMBOLS

SAFETY & BUILDING AVAILABILITY PERMIT

PARKING IN EXPLOSIVE MAGAZINE AREAS

RADIO TRANSMITTER USE ON CRANE

IMPORTANT RULES FOR SAFETY IN EXPLOSIVE AREAS

EXPLOSIVE TRANSPORTATION CONTRACTORS

CHAPTER 3 – OCCUPATIONAL SAFETY

SPECIAL NAVY REQUIREMENTS

Lifting Cranes & Weight Handling Equipment Operations Around and Involving the Railroad Excavations

OTHER OSH-TYPE INTERFACE PROGRAMS

Confined Space Entry Energy Lockout/Tagout Program Hazardous Materials Control

CHAPTER 4 – FIRE PREVENTION

SMOKING GUIDELINES

STORAGE AND HAULING OF GASOLINE OR OTHER FLAMMABLE

LIQUIDS

BASIC FLAME TOOL/HOT WORK PERMIT REQUIREMENTS

(EXPLOSIVES AREAS ONLY)

SPECIAL REQUIREMENTS FOR WORK IN EXPLOSIVE AREAS

TAR KETTLES

ADDITIONAL GENERAL REQUIREMENTS

iii

TITLE PAGE

OTHER FIRE SAFETY CONSIDERATIONS

CHAPTER 5 – SECURITY

CHAPTER 6 – ENVIRONMENTAL PROTECTION

CONSTRUCTION SITE CONSIDERATIONS

CONSIDERATIONS FOR ALL CONTRACTORS

SPILLS OF HAZARDOUS MATERIALS

CHAPTER 7 – EMERGENCY ACTIONS AND CONTACTS

EMPLOYEE INJURY

FIRE OR EXPLOSION

HAZARDOUS MATERIAL SPILL

NOTES PAGES

CRANE POINTS OF CONTACT.....................................................Back Cover

– CHAPTER 1 –

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NNAAVVAALL SSUUPPPPOORRTT AACCTTIIVVIITTYY CCRRAANNEE

POLICY. It is the policy of the Department of the Navy that all contractor activities conducted on Crane (including the Lake Glendora Test Facility) be in accordance with the applicable rules and regulations. In addition to rules imposed by agencies such as the Department of Labor (OSHA); there are those rules, considered local in nature, that are pertinent to the work conducted by all who come aboard. These rules are critical to maintaining safe and secure operations for both Government and contractor personnel. These rules are to be clearly understood and followed by all.

BACKGROUND. Through the years, the amount of work conducted by contract has been ever increasing. Work that was once limited to construction efforts now includes long-term service efforts and special projects where contractors interface on a day-to-day basis with Crane Government personnel. Contractors need access to a long list of important rules and regulations that have been in effect for a number of years. Compliance with these rules and regulations helps to maintain the safety and security of all personnel at Crane recognizing the unique hazards that may be encountered. These rules and local regulations pertain to the following general areas of consideration:

Explosives Safety - Addresses the Ordnance Industry functions of Crane

Occupational Safety - Addresses the OSH type of interface issues of Crane

Fire Prevention - Addresses the vigorous efforts to maintain Crane free from structure and land fires

Security - Addresses the security requirements of Crane pertinent to maintaining physical security of assets and information

Environmental Protection - Addresses precautions and actions pertinent to maintaining the land, water and air of Crane in compliance with State of Indiana and Federal EPA requirements

ORGANIZATION OF THE MANUAL. This manual is organized in chapters with each chapter dedicated to one of the five major areas of regulations outlined above. Where beneficial, points of contact by office and location are provided. If a form, such as a permit, is discussed, a copy of a typical form of that nature is presented.

– CHAPTER 2 –

EEXXPPLLOOSSIIVVEESS SSAAFFEETTYY

GENERAL. Crane was constructed as a Naval Ammunition Depot during World War II. Most of the land area is dedicated to supporting the ordnance functions now shared between the Navy and the Army. Except for an area south of Lake Greenwood, known as the Industrial Area, and an area around four major warehouses located on the northeast corner, the land surface is “encumbered” by explosives safety quantity distance arcs (ESQD) that must be observed by contractor employees. For the most part, if you have no contract related work in an area, stay clear of that area unless you must use a road for access to your assigned work location. Many of the explosives operating buildings are surrounded with a security fence. Do not enter the fenced area unless the contract work calls for such entry and your presence is expected. Even then, report to the building or area supervisor immediately. The following guidance is pertinent to the explosives safety rules and regulations that must be followed while working on Crane.

Depending on the work to be accomplished, more detailed rules and precautions will be issued either as a part of the contract language or at the time a pre-construction meeting is held.

APPLICABLE SOURCE DOCUMENTS

HIGHER LEVEL INSTRUCTIONS:

NAVSEA OP5, Volume 1, Explosives Safety Ashore, Safety Regulations for

Handling, Storing, Production, Renovation and Shipping

LOCAL INSTRUCTIONS:

8020.1 – Explosives Handling Certification Program

8020.4 – Parking of Privately-Owned Vehicles (POVs) in Explosive Storage

Magazine Areas

8020.11 – Hazards of Electromagnetic Radiation to Ordnance (HERO)

Program

Explosives Safety Orientation Handbook

EXPLOSIVE HAZARD SYMBOLS. All explosive areas, including buildings and magazines, that actually contain some amount of explosive materials are marked using unique symbols. The symbols have an orange background with black numerals. Those symbols are outlined in Figure 1.

3 4

FIGURE 1

Unless the contract documents specifically call for work inside of a building or area marked with at least one of the above signs, stay out of the building or area. If work is to be conducted inside of an area or building containing explosives, specific guidance will be provided during the pre-construction meetings or safety permit process as provided below.

SAFETY & BUILDING AVAILABILITY PERMIT. Before any work can be accomplished in an area or building either containing explosives (placarded with one of the above symbols) or has contained explosive materials, an inspection of the work area and any surrounding areas must be made by a representative of the Explosives Safety Office. For Army custody buildings this inspection duty has been delegated to the Army Safety Office. The inspection is for the protection of the contractor. Depending on the area where the work is to be accomplished, there is the possibility that explosive materials or residual from a process, can be hidden in areas where work needs to be done. Work involving welding, cutting, drilling and concrete removal is especially reviewed by the representative of the safety office. The permit, illustrated by Figure 2, is completed and issued to the contractor with very specific guidance as follows. Each permit is:

Issued for fixed amount of time depending on the type of work to be accomplished.

Issued addressing the work that is to be done based on what is stated at the inspection meeting in the building or at the area.

Issued for the specific area or building where the work is to be accomplished.

Contains general precautions that are valid for work in any area plus special guidance that addresses specific precautions and/or actions that must be taken by the contractor.

The permit is signed by a representative of the custodian of the area or building involved. This signature certifies that the work is needed and that the building or area is ready for turn-over to the contractor. The permit is also signed by the contractor performing the work. This signature indicates the contractor is aware of, and agrees with, the requirements. In addition, the permit is signed by the Safety Representative. The permit must be posted at the job site for the duration of the allowed work time.

PARKING IN EXPLOSIVE MAGAZINE AREAS. When work must be performed in areas where explosive storage magazines are located; there are specific regulations that must be followed for the temporary parking of motor vehicles. Work such as on roads, railroads, or power and communication lines requires efforts in magazine areas. The following requirements pertain to the temporary parking of motor vehicles.

Park your motor vehicle off to the side of a main roadway, allowing sufficient room on the roadway for emergency vehicles to pass. Do not park on any driveway leading to a magazine. Maintain a minimum of 250 feet separation between your parking location and any magazine door. If a motor vehicle is to be left overnight in a magazine area, you must notify the Security Department of the type of equipment and its location.

SAFETY & BUILDING AVAILABILITY PERMIT

(FOR NON-ROUTINE REPAIR OR MAINTENANCE IN OR NEAR EXPLOSIVES OPERATIONS)

ESO 8020/11 (Rev. Jan. 2002)

FROM AUTHORIZING CODE

ISSUED TO DATE

PERMIT TO PERFORM THE FOLLOWING WORK

DESCRIPTION OF WORK

LOCATION

DATES

APPLICABLE SAFETY PRECAUTIONS

General Safety Instructions (on the reverse side) deemed adequate.

In addition to the General Safety Instructions (on the reverse side), comply with the following:

BUILDING AVAILABLE AND WORK APPROVED

SIGNATURE (Supervisor)

SIGNATURE (Issuing Safety Specialist)

SIGNATURE (Person Performing Work)

DISTRIBUTION: ORIGINAL TO BUILDING SUPERVISOR, COPY TO EXPLOSIVES SAFETY OFFICE

FIGURE 2 (Front)

GENERAL SAFETY INSTRUCTIONS

1. Whenever, in the performance of duties a worker realizes that:

• the worker does not fully understand the work to be done,

• the work required will be greater than planned (as when routine work becomes non-routine), or

• the hazards of the job have changed to a different type or have materially increased;

the worker shall cease work and seek the advice of the worker’s supervisor.

2. Welding or other hot work is not permitted within 100 feet of a building, boxcar, or truck containing explosives or ammunition unless otherwise specified by the Explosives Safety Office and the Fire Department. A fire watch shall stand by within sight of, but not further than 20 feet from the work being performed and shall remain for 30 minutes after the operation is complete. Additionally, repairs requiring hot work will not be made to a magazine containing bulk explosives or bulk propellants prior to the removal of such materials from the magazine, followed by a thorough cleaning of the magazine that includes washing down the magazine interior with water.

3. Drilling incidental with maintenance work is not permitted in a room containing explosives or ammunition unless otherwise specified by the Explosives Safety Office or the Fire Department.

4. Steel tools shall be used as little as possible in rooms of buildings containing explosives or ammunition, and then only with the approval of the Explosives Safety Office.

5. Before any work is performed on electrically powered equipment, the main power switch shall be locked out and tagged. The switch shall be unlocked only by the person who locked it and only after making certain that nothing is in the way of the machine. Similar precautions, as appropriate, shall be observed when working on equipment powered by other means.

6. On completion of work, all areas shall be cleaned and left in as good a condition as when the work began.

7. An explosive operator shall carefully clean equipment that may have been contaminated with explosives.

8. If at any time during the progress of work explosive contamination is discovered, work shall be stopped until qualified personnel remove the contamination.

ESO 8020/11 (Back)

FIGURE 2 (Back)

During periods of high fire danger (as stipulated by the Fire Danger Board at the

Gates), park only on graveled areas or areas where vegetation has been controlled by mowing to less than 6 inches. This is to prevent fires ignited by catalytic converters.

RADIO TRANSMITTER USE ON CRANE. The use of portable or fixed transmitters, including radios and cell phones, while on Crane is not permitted unless specific approval is granted in advance by the Explosives Safety Office.

Transmitters emit electromagnetic energy which, if not controlled, can initiate some explosive devices. The higher the output of the transmitter the more likely this emission can adversely affect ordnance. If radio usage is required (land telephone lines not available or usable), approval can be granted on a case-by-case basis from the Explosives Safety Office. Contact your Government contract representative to get the approval process started. The following information is necessary for approval:

Work to be performed and areas where it will be accomplished that will need the use of radio transmitters on Crane.

Power output of the transmitter(s).

Frequency/Frequencies

Antenna Gain

The Explosives Safety Office will perform an assessment of the transmitter and where it is proposed to be used. If there are no major hazards posed by the transmitter to ordnance stored, transported, or processed at Crane; permission for use will be issued. There may be restrictions placed on their use as stated by the approval document.

Certain areas of Crane are posted “NO TRANSMITTING”. Inside of these areas, no radios are to be used at any time. The permission for use document mentioned above is not valid for these areas. For these areas, a sign (see Figure 3) is posted on the roadway. (NOTE: Private cell phones are authorized for use outside of Ordnance (no Transmitting ) Areas. )

RED YELLOW

FIGURE 3

IMPORTANT RULES FOR SAFETY IN EXPLOSIVE AREAS. The following are considered the most important rules to be followed by all when working in and around explosives.

Smoking is very restricted in explosive areas. No matches and lighters are allowed to be carried on the person or in vehicles. See the smoking rules in Chapter 4 for specific information.

Do not proceed with any work until the proper permits have been secured.

Perform only the work specifically called for in advance on drawings, specifications or other official documents.

Perform the work only as described to the Safety Representative at the time a permit is issued.

If conditions change from those present at the time safety permits were issued, stop, notify the contract representative who will in turn notify the Explosives Safety Office (or Army Safety Office where applicable) to review the work area again.

Never use flame producing equipment without first getting a flame tool permit issued by the Fire Department as described in Chapter 4.

If at anytime during the work, what is thought to be explosive contamination is found (when in doubt have it checked out), stop the work and notify the building or area representative immediately. If not possible, call either the Explosives Safety Office or the Army Safety Office (Office numbers are on the back of this pamphlet). As a final resort, when no contact can be made, telephone 1333 and describe the situation to the emergency operator.

There are many different test ranges on Crane. Do not enter an area posted as a test range, or demolition range, or ammunition burning ground. These postings are present along roads and in fire breaks outside of the active range areas.

Do not enter an area marked with a revolving red beacon. These beacons are used to indicate that specifically hazardous work is on-going in a building located beyond the beacon. Some areas are cordoned off using road gates. The same rule applies. DO NOT ENTER!

Equipment refueling can only be accomplished if at a minimum of 100 feet from a placarded building, magazine, railcar, or motor vehicle.

EXPLOSIVE TRANSPORTATION CONTRACTORS. For those contractors required to transport explosives on Crane, the following pertains:

All drivers hauling explosives onto Crane must stop at the Crane Gate for required check-in. Security will direct to an unloading point. Material or load inspection will be deferred to an inspector located at the unloading point.

Placarded vehicles must stop at all railroad crossings unless the crossing is specifically posted as “EXEMPT”.

In case of threatening weather (dangerous lightning), follow the directions of the crew leader at the unloading point.

Certain areas of Crane are posted “NO ORDNANCE PERMITTED”

(see Figure 4). Be aware that this sign is very similar to the “NO TRANSMITTING” sign. When transporting explosives, be sure that you do not enter an area that is posted “NO ORDNANCE PERMITTED”.

RED YELLOW

FIGURE 4

– CHAPTER 3 –

OOCCCCUUPPAATTIIOONNAALL SSAAFFEETTYY

GENERAL. This chapter is primarily associated with “construction type” contracts. Other contract requirements are found in specific contract language.

Crane has a great deal of general industry type of work that follows Occupational Safety and Health Agency (OSHA) requirements and regulations. This chapter provides some particular requirements of the Navy which are in addition to OSHA regulations, and addresses contractor to Government interface situations that are called out in OSHA regulations. The following guidance is pertinent to the general safety rules and regulations that must be followed while working on Crane.

APPLICABLE SOURCE DOCUMENTS

HIGHER LEVEL INSTRUCTIONS:

Code of Federal Regulations, Title 29 CFR Part 1910, Safety Regulations for

General Industry

Code of Federal Regulations, Title 29 CFR Part 1926, Safety and Health

Regulations for Construction

U. S. Army Corps of Engineers, EM 385-1-1, Safety and Health Requirements

Manual

NAVFAC Guide Specification, UFGS-J-01525

NAVFAC P307, Management of Weight Handling Equipment

LOCAL INSTRUCTIONS:

NSWCCRANEINST 5090.6, Hazardous Materials Control and Management

Program

OPNAVINST 5100.23, Occupational Safety And Health Program Manual

NSWCCRANEINST 5100.5A-9, Construction Safety and Health Program

NSWCCRANEINST 5100.5A-11, Lockout/Tagout

NSWCCRANEINST 5100.5A-20, Traffic Safety

NSWCCRANEINST 5100.5A-22, Weight Handling Safety Program

NSWCCRANEINST 5100.5A-25, Confined Space Entry Program

OICC Crane Policy #00-03; Contractor Crane Oversight Plan

SPECIAL NAVY REQUIREMENTS. All contractors shall submit an Accident Prevention Plan (APP) and Activity Hazards Analysis (AHA) for each definable feature of work in accordance with EM 385-1-1. The contractor shall ensure all environmental, safety and health issues have been addressed prior to job start. The following are those requirements that are special in nature in that each is in addition to standard practices in General Industry settings.

1. LIFTING CRANES (Category I and IV) and Weight Handling Equipment - The Navy executes a very rigorous program for the control of hazards associated with lifting cranes. These cranes can be from a variety of sources and are generally incidental to construction contracts, demolition contracts, maintenance and other service contracts, and deliveries of supplies and equipment. Cranes include mobile units both truck mounted and crawler mounted with or without articulating booms.

Because of problems encountered with cranes brought onto Navy property by contractors, additional controls are being applied. This section discusses those additional controls.

a. Regulatory Compliance - The contractor is required to comply with specific activity regulations pertaining to crane safety and operation, and to notify the contracting officer 15 days in advance, of any cranes entering the activity. The contractor is required to comply with ASME B30.5 for mobile cranes, and ASME B30.22 for articulating boom cranes.

b. Certificate of Compliance - The contractor is required to provide the representative of the contracting officer a certificate of compliance that the crane and rigging gear meet applicable OSHA regulations (29 CFR 1926). The contractor shall also certify that all of the crane operators working on Crane have been trained not to bypass safety devices (e.g., anti-two block devices) during lifting operations.

In addition, the contractor must certify that crane operators are qualified and trained for the operation for which the crane is to be used. Figure 5 illustrates the certificate that must be posted on the crane/weight handling equipment while on Crane.

c. Crane Operator’s Daily Checklist – The contractor shall complete a daily checklist (see Figure 6).

d. Critical Lift Plan - A critical lift plan is required for each of the following lifts: lifts over 80 percent of the capacity of the crane or hoist (at radius of lift); lifts involving more than one crane or hoist; lifts of personnel; and lifts involving non-routine rigging or operation, sensitive equipment, or unusual safety risks. The plan shall include the following as applicable:

(1) The size and weight of the load to be lifted, including crane and rigging components that add to the weight. The OEM’s maximum load capacities for the entire range of the lift shall also be provided.

(2) The lift geometry, including the crane position, boom length and angle, height of lift, and radius for the entire range of the lift. This applies to both single and tandem crane lifts.

(3) A rigging plan, showing the lift points, rigging gear, and rigging procedures.

(4) The environmental conditions under which lift operations are to be stopped.

(5) For lifts of personnel, the plan shall demonstrate compliance with the requirements of 29 CFR 1926.550(g).

d. Weight Handling Equipment Accident Report. The contractor is required to notify the contracting officer as soon as practical, but not later than four hours, after an accident involving a fatality, in-patient hospitalization, overturned crane, collapsed boom, or any other major damage to the crane or adjacent property. The contractor is required to provide to the contracting officer within 30 days of any accident (defined by the contracting officer’s representative) a Weight Handling Equipment Accident Report using a Navy supplied form. It shall consist of a summary of circumstances, an explanation of cause(s), photographs, and corrective actions taken. The contractor must secure the accident site and protect evidence until released by the contracting officer. The contractor is required to conduct an accident investigation to establish the root cause(s) of the accident. Crane operations shall not proceed until cause is determined and corrective actions have been implemented to the satisfaction of the contracting officer.

FIGURE 5

FIGURE 6

e. Oversight Actions - The Navy at Crane is required to provide oversight of contractor crane operations. Figure 7 is a checklist that will be in use during oversight efforts. The amount of oversight will be based on an assessment of risk conducted of the crane operations.

FIGURE 7

2. OPERATIONS AROUND AND INVOLVING THE RAILROAD. Crane currently has 147 miles of active track. This fact about Crane must be taken into account in many areas. Specific guidance will be provided for contractors involved with railroad upkeep but in general the following is pertinent:

a. Passing of explosive trucks while they are stopped at rail crossings is prohibited.

b. Materials and vehicles are to be kept at least 6.5 feet from the edge of the railroad tracks to allow for adequate train clearance.

c. If work is required where encroachment of the track is necessary, any approach to the area by rail must be flagged.

d. Work at a railroad crossing, where the lights are either constantly in operation or the lights have been disabled, requires the crossing to be flagged. The contractor’s flag person must be equipped with an orange vest or red flag.

e. If work is being conducted on or around railroad tracks, the railroad dispatcher must be contacted at 854-1613.

3. EXCAVATIONS. Much like a city, Crane has numerous buried utility cables, pipes and conduits the exact locations of which need to be known in advance of any excavations. A digging permit is required prior to beginning any excavations.

Using maps and special locators, Crane personnel will, when notified, mark on the surface, the locations of utilities. The contracting officer’s representative will inform the contractor of the procedure for requesting a digging permit at the time the project is initiated. Contractors are to complete Digging Permit request forms at Building 56. Figure 8 shows a Digging Permit.

OTHER OSH-TYPE INTERFACE PROGRAMS. The following are the other Crane OSH programs that potentially interface with contractor operations.

1. CONFINED SPACE ENTRY. There are a number of spaces at Crane that meet the OSHA definition as Confined Spaces. Many spaces, such as manholes, crawl spaces and utility tunnels, have been marked in advance. However, not all have been located and new ones are constantly being discovered. The contractor is

FIGURE 8

cautioned not to go by what is posted as the only means of determining a confined space. The OSH guidelines for General Industry must be followed for the protection of contractor personnel. All gas free checks and assessments of confined spaces prior to contractor personnel entry must be conducted by the contractor. The Navy cannot provide such services for contractors. Information on the confined space entry permit may be obtained by calling the project manager. An example permit is shown in Figure 9.

2. ENERGY LOCKOUT/TAGOUT PROGRAM. Depending on the building involved and the nature of the contracted work, the contracting officer’s representative will provide additional details at the time the project is initiated.

EM 385-1-1 shall be followed.

3. HAZARDOUS MATERIALS CONTROL. Besides the contractor having to train contract employees regarding the safe use, handling, storage, and disposal of hazardous materials brought aboard Crane for contracted efforts, there is a responsibility to ensure proper interfaces are established and maintained between contractor personnel and Government personnel. The following pertains:

a. Contractors, who plan to bring hazardous materials onto Crane to use, must submit material safety data sheets (MSDSs) for the materials to the affected facility coordinator/project manager (identified at the pre-construction conference) at least 5 days prior to performance of the contract field efforts.

b. MSDSs are to be current and complete. The hazardous materials which are brought on Crane property are to be labeled, which includes at a minimum:

manufacturer information, the hazardous chemical components and the appropriate hazard warnings.

c. Upon arrival for a contract performance at the worksite, the contractor is to brief the facility coordinator/project manager, of the intent to use hazardous materials in the area designated for contractor work. The contractor is to ensure that MSDSs are provided and any precautionary measures needed coordinated for normal operating schedules and especially for emergency situations.

FIGURE 9 (PAGE 1)

FIGURE 9 (PAGE 2)

d. The contractor should expect to be informed by Government (or other contractor) personnel, occupying the area near the worksite, of any hazardous materials the contractor’s personnel may be exposed to while at the contracted worksite. Those hazardous material MSDSs must be made available and any precautionary measures applicable for either routine or emergency situations. Both parties are to be aware of the hazardous materials labeling system(s) being used.

e. The contractor is to notify the facility coordinator/project manager of that area about any intent to store hazardous materials on the job site until the job is completed. Approval for the storage location must be obtained from the facility coordinator for the duration of the contract. MSDSs for the hazardous materials stored must be located near the storage point for quick reference.

f. All hazardous material must be stored in approved storage lockers. Unless stored properly, this material must be removed from Crane at the end of each shift by the contractor.

– CHAPTER 4 –

FFIIRREE PPRREEVVEENNTTIIOONN

GENERAL. Contractor operations are not exempt from complying with rules and regulations with regard to preventing fires. All extinguishers mentioned in this chapter are 10 lb. ABC type with a minimum rating of 2A 60 BC, and are to be contractor supplied. The following guidance is pertinent to the fire prevention rules and regulations that must be complied with while working on Crane.

APPLICABLE SOURCE DOCUMENTS

HIGHER LEVEL INSTRUCTIONS:

NFPA, National Fire Protection Association

OPNAVINST 11320.23F, Shore Activities Fire Protection and Emergency Services Program

NAVSEA OP 5, Volume 1, Ammunition and Explosives Safety Ashore

LOCAL INSTRUCTION:

NSACRANEINST 11320.2 CH 1, Fire Protection Manual

SMOKING GUIDELINES. Due in part to the explosives stored and processed at Crane, the following restrictions must be strictly observed:

Smoking in vehicles at any time or location is strictly prohibited.

Smoking is NOT ALLOWED in explosives areas without approval. Contact the Safety Office.

Contractor supervisors or crew leaders are responsible for enforcing and observing all safe smoking procedures.

STORAGE AND HAULING OF GASOLINE OR OTHER FLAMMABLE

LIQUIDS. Storage of bulk amounts of fuel or oil is permitted on Crane, but only if properly located and contained in approved diked areas or on holding pallets specially designed to contain spills. Double wall tanks, if approved by Fire Prevention and the Safety Office, may be used. The following requirements pertain to the outside storage of flammable liquids:

“NO SMOKING WITHIN 50 FEET” signs are to be posted in fueling areas.

All containers are to be marked as to their contents and ownership.

One 10 lb. ABC extinguisher is to be located within a 50 ft. travel distance of each storage site.

Equipment/vehicles are not to be fueled with engines running. In addition, vehicle lights and radios are to be shut off during refueling.

As a reminder from Explosives Safety, Chapter 2, no fueling is to be conducted within 100 feet of a placarded building or vehicle(s).

Only approved, spring loaded/self closing, metal, safety gasoline containers, bearing the UL or FM label, are to be used for the transporting or handling of flammable or combustible liquids.

BASIC FLAME TOOL/HOT WORK PERMIT REQUIREMENTS

(EXPLOSIVE AREAS ONLY).

Before any operation utilizing open flame, arc welders, grinders, or other heat or spark-producing equipment is allowed in or around an explosive/pyro area(s), a Flame Tool/Hot Work Permit, illustrated in Figure 10, must be requested by calling the Fire Department at (812) 854-1235. This call should be made on the day the permit is required.

The dispatched Fire Prevention Inspector will visit each explosive/pyro worksite and, if the area meets minimum requirements, the permit will be issued.

Each permit will list specific requirements/restrictions that must be met prior to the hot work being performed.

Basic flame tool requirements include, but are not limited to, the following:

Keep combustible materials a minimum of 35 feet from the hot work area.

Keep flammable liquids a minimum of 50 feet from the hot work area.

Keep open explosive materials a minimum of 100 feet from the hot work area, unless the area in question is a magazine, in which case a different distance requirement will be determined and directed by the on scene inspector (see “Special Requirements…” below).

Authorized flame retardant type material (e.g. Refrasil-type cloth), when required, must be used to cover and protect exposures (including those items listed above) that cannot be removed from the hot work area.

All work involving open flame or spark-producing equipment must be done under the added protection of a designated Fire Watch/Standby.

This individual (must be someone other than the permit holder) must have no other duties and be trained in the use of portable fire extinguishers. An approved 10 lb. ABC type extinguisher is the minimum required extinguisher that must be provided by the contractor.

The Fire Watch’s signature is also required on the Hot Flame Permit.

Fire Watch/Standby(s), with the approved extinguisher, must be present in the immediate hot work area during and at least 30 minutes after the work is complete. The Fire Watch/Standby must have read and fully understand the instructions and requirements on the permit (see Figure 10).

Permit will normally be issued for only the amount of time required to perform the work, not to exceed two (2) weeks. Additional time may be requested by contacting the Fire Department and requesting that the existing permit be renewed.

The person who signs as the “Permit Holder” must be the person performing the hot work within the explosive/pyro area. This person must be present in order to date and sign the permit. The permit holder must read and understand all instructions and requirements listed on the front and reverse side of the permit before signing.

Prior to hot work beginning each day, the Permit Holder is responsible for ensuring the area is fire-safe and that the guidelines of the Hot Flame Permit are still in place. If not, contact Fire Prevention and/or the area supervisor.

All permits for explosive/pyro production building(s), magazine(s) or other explosive/pyro holding areas require the building/area supervisor or a designated building/area representative to be present and after reviewing the permit, sign the permit, as well. Army and/or Navy Safety must be contacted to determine if permits are required, in addition to the Hot Flame Permit.

SPECIAL REQUIREMENTS FOR WORK IN EXPLOSIVE AREAS. When work is to be done in areas where there is a good possibility that open explosive/ pyro type materials may have been present, the following pertains:

Prior to a hot flame permit being issued for work pertaining to an explosive/pyro building or magazine, a review of the proposed work project must be performed by the Fire Prevention Branch. This is partially accomplished during the review of drawings, spec review, pre-con meetings, etc.

During any work involving flame or spark producing work in explosive/pyro production buildings, storage magazines, or other explosive/pyro storage sites where there is a possibility of open explosive or explosive residue, the on scene inspector will require the contractor to provide a vehicle* equipped with the following:

A water tank (minimum of 100 gallons capacity)

A hose reel (at least 20 feet of 3/4 inch high pressure hose)

A fog/straight stream nozzle

A water pump powered by at least a 3 H.P. engine and capable of spraying a water stream to a distance of 20 to 30 feet (be prepared to demonstrate/ operate, upon request).

Hot work being performed in front of, or on explosive storage magazine doors will require the contractor to cover the entranceway with a sufficient amount of Refrasil-type cloth. This covering will be placed - top to bottom, and from side to side (overlapping) - so sparks and slag are prevented from entering the magazine.

During work on or near a magazine door, if the inspector deems it safe enough, a 15 foot radius (from inside of door) must be established and maintained free of explosive/combustible material. Black powder magazines and bulk powder magazines require special attention, and in most cases, will require that the magazine be down loaded prior to work being allowed.

TAR KETTLES. Installation and use of a tar kettle will be in accordance with NFPA Code 241. Each kettle shall be positioned within a controlled/safe area outside of the building(s), and away from all combustible material. At no time will the kettle be located on the roof. The tar kettle must be positioned a minimum of 15 feet from any structure and a minimum of 10 feet from any means of egress. An operator must be present at all times. A minimum of two (2) approved 10 lb.

extinguishers shall be present. One will be located no less than five (5) nor more than 25 feet from the kettle. The second extinguisher is required on the roof with the roofing crew. A third extinguisher will be required if torch-applied equipment is used.

ADDITIONAL GENERAL REQUIREMENTS. The following pertains to any construction project(s) or area(s) occupied by a contractor on a long term basis:

For large construction equipment, such as earthmovers, bulldozers, etc., one dry chemical fire extinguisher is to be mounted to each piece of equipment.

All on-site compressed gas cylinders are to be secured in an upright position (exception - those cylinders expressly designed to be used or stored in the horizontal position).

The construction site should be laid out in such a manner so as to allow access to most areas by fire vehicles and other emergency response vehicles.

Good housekeeping practices must be established and maintained at all times.

OTHER FIRE SAFETY CONSIDERATIONS. The following pertains:

If there is a natural gas leak or a gas line ruptures, evacuate the construction site and move upwind of the rupture and contact the Fire Department.

Stay away from downed power lines.

Always be aware of weather and vegetation conditions. Extreme weather or dry vegetation conditions will determine if a hot permit will be issued. Also, if conditions worsen after the permit is issued, a cessation of hot work activity could be required.

All fires, regardless of size, are to be immediately reported to the Crane Activity Fire Department by dialing 911 (land-line) or (812) 854-1333/1100 (cell phone).

If possible, the Fire Watch/Standby is expected to attempt to extinguish all fires during their beginning stage.

When reporting emergencies, give as much detail as possible to the emergency operator.

FIGURE 10 (Front)

FIGURE 10 (Back)

– CHAPTER 5 –

SSEECCUURRIITTYY

RREESSEERRVVEEDD

UUnnddeerr RReevviissiioonn

– CHAPTER 6 –

EENNVVIIRROONNMMEENNTTAALL PPRROOTTEECCTTIIOONN

GENERAL. Crane must adhere to both State of Indiana and Federal environmental laws and regulations. All operations must be examined and approved in accordance with various permits currently on file. Contractor operations can pose a significant threat to the environment thus are of special interest to Crane management. It is true that progress has a price. However, that price must be affordable when it comes to protecting the environment. For the most part, construction efforts are supported by quality designs and design considerations that take into account the potential impact of the effort to the environment. This chapter pertains to concerns that exist even when good solid planning has been applied to a project.

APPLICABLE SOURCE DOCUMENTS

HIGHER LEVEL INSTRUCTIONS:

OPNAVINST 5090.1B, Environmental and Natural Resources Program

Manual

LOCAL INSTRUCTIONS:

NAVSURFWARCENDIVCRANEINST 5090.2, Hazardous Waste

Management Plan

NAVSURFWARCENDIVCRANEINST 5090.5, Oil and Hazardous

Substances Spill Contingency Plan

CONSTRUCTION SITE CONSIDERATIONS. Assuming that a construction contract is involved along with a specific site, the following pertains:

If any ordnance item or historical artifact is found during site work or construction, stop operations and report the situation immediately to the Resident Officer in Charge of Construction (ROICC) Office. If ordnance related, there are safety as well as environmental issues to be addressed. So do not move it! The

Explosive Ordnance Disposal (EOD) Team may be required to either render the item safe or as a minimum determine if the item is “live”. Aside from safety issues, these items may be considered hazardous waste and will need to be assessed and handled accordingly.

Work within the Ammunition Burning Grounds (ABG), Old Rifle Range, or

Demolition Range requires an environmental briefing prior to start of the work.

Depending on the work to be done, the briefng may be conducted by the Range Safety Officer, the Range Control Officer, or by a representative of the Environmental Protection Department. These areas are classified as Hazardous Waste Treatment Facilities to which specific training requirements apply.

Ensure that the ROICC has determined whether or not the project location is within the boundaries of a Solid Waste Management Unit (SWMU). Special requirements may apply if a project is within an SWMU.

Asbestos requirements:

Demolition and/or Renovation: Comply with Crane Title V Air Quality

Operating Permit and 326 IAC 14-10-3(1).

Construction: A statement from the contractor is required, stating that the materials used for construction are Asbestos Free.

For construction sites of more than one (1) acre in size, soil erosion control practices must be applied in accordance with the soil erosion control plan developed for the project and 327 IAC 15-5 “Rule 5”.

Inert fill materials such as excess soil, concrete, paving, masonry, and similar materials are not to be placed in ditches, streams, ponds, or lakes unless specifically approved by the Environmental Protection Department.

As with hazardous material considerations for safety, there are environmental considerations when hazardous materials are to be used on Crane. Actions to be taken in case of emergencies or acts of God need to be determined in advance of using hazardous materials.

The minimum of hazardous material needed for the project is to be considered for use at Crane. Over stocking of hazardous materials unnecessarily increases the risk of spills and exposures.

CONSIDERATIONS FOR ALL CONTRACTORS. All contractors and contract employees are to be aware that wastewater or waste chemicals are not to be poured onto the land or into any body of water. Wastewater may be discharged to the Crane sanitary sewer system as approved in advance by the Environmental Protection Department. Excess chemicals utilized by the contractor, during the project, must be removed from Crane property unless other storage/disposal arrangements have been approved by the ROICC Office and by the Environmental Protection Department.

SPILLS OF HAZARDOUS MATERIALS. Contractors who use hazardous materials in performance of their work must take precautions necessary to ensure they are stored, used and managed properly. This includes but is not limited to petroleum products such as lubricants, hydraulic fluids, gasoline and diesel fuel.

Contractors must have on site a Material Safety Data Sheet (MSDS) that represents the products being used. Any spills of hazardous materials must be reported and cleaned up. To that end the following pertains:

Report spills that pose immediate danger to life, health, property or if fire threatens or starts by immediately activating the nearest fire alarm. The alarm location is monitored by emergency responders. Personnel shall evacuate upwind/upgrade to a safe location and reentry to building/site will not be permitted until cleared by emergency personnel. Ensure that personnel in adjacent areas are notified. Meet the emergency response personnel with the information called for below.

If the building is not alarmed or there is no building nearby, telephone notification is required by the emergency number 854-1333. When placing the call, be prepared to provide as much of the following information as possible.

Name and phone number of person placing the call.

Location of incident.

Type of incident. (fire-related, explosion, or just a spill)

Any injuries or state no injuries.

Type and amount of material involved.

If the spill is small and does not pose the threat outlined above, reporting is still required. Notify the Environmental Protection Department, (812) 854-3114.

When safe to do so, efforts should be made to stop the source of the leak or minimize the spread of contaminants.

If materials being used have the potential to cause significant problems if spilled, an evacuation and notification plan should be developed before the materials are brought on Crane and used. Assistance in planning and preparedness can be obtained by contacting the Environmental Protection Department,

(812) 854-3114.

– CHAPTER 7 –

EEMMEERRGGEENNCCYY AACCTTIIOONNSS AANNDD CCOONNTTAACCTTSS

GENERAL. No matter the amount of prior planning that has gone before, prompt and correct action in the case of emergencies is needed to minimize the consequences. This chapter provides the minimum action required of a contractor’s personnel should an emergency occur at Crane. The chapter is laid out based on common types of emergencies that have occurred in the past.

EMPLOYEE INJURYEMPLOYEE INJURY

TELEPHONE 854-1333

TELL NATURE OF INCIDENT,

LOCATION OF WORK SITE,

AND NUMBER OF INJURED

– OR –

PULL NEAREST FIRE ALARM

GO OUTSIDE BUILDING AND

DIRECT RESPONDERS TO THE INJURED

FIRE OR EXPLOSIONFIRE OR EXPLOSION

TELL LOCATION OF WORK SITE

NATURE OF INCIDENT,

AND NUMBER INJURED (IF ANY)

GO OUTSIDE BUILDING

AND DIRECT RESPONDERS

ACCORDING TO THE SITUATION

HAZARDOUS MATERIAL SPILLHAZARDOUS MATERIAL SPILL

TELL LOCATION OF WORK SITE,

NATURE OF SPILL

(APPROXIMATE RATE OR AMOUNT),

TYPE OF HAZARDOUS MATERIAL,

AND NUMBER INJURED (if any)

GO OUTSIDE AND DIRECT RESPONDERS

ACCORDING TO THE NATURE OF THE SPILL

The most important issue is dealing with the problem at the site as quickly as possible utilizing the incident resources at Crane. Reporting the situation to the ROICC Office is to be accomplished as soon as possible after the incident responders have been summoned.

NOTES

BUSINESS LOCATIONS AND TELEPHONE NUMBERS

FUNCTION TELEPHONE

ENVIRONMENTAL PROTECTION OFFICE 812-854-3233

EXPLOSIVES SAFETY OFFICE (NAVY) 812-854-6569/7233

FIRE DEPARTMENT (FIRE PREVENTION) OFFICE 812-854-1235

OCCUPATIONAL SAFETY & HEALTH OFFICE (NAVY) 812-854-1625/7233

OFFICER IN CHARGE OF CONSTRUCTION OFFICE 812-854-3278

SAFETY OFFICE (ARMY) 812-854-3404

SECURITY OFFICE 812-854-3300

NSACRANE COM 1C