NSACRANEINST 8020.1E - Explosives Safety Program at NSA Crane.pdf

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NSACRANEINST 8020.1E

2 Jul 2019

NAVAL SUPPORT ACTIVITY CRANE

EXPLOSIVES SAFETY

MANAGEMENT PROGRAM

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UNITION

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TECHNOLOGY

NAVAL SUPPORT ACTIVITY

CRANE

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TABLE OF CONTENTS

Chapter 1 EXPLOSIVES SAFETY MANAGEMENT PROGRAM

1. References

2. Purpose

3. Scope and Applicability

4. Discussion

5. Definitions

6. Policy

7. Responsibilities

8. The Process for ESI Inspections of Crane

9. Crane’s CAP Process

10. The ESSA Process

11. ESSA Reports

12. ESSA Report Format

13. Corrective Action Plan (CAP)

14. ESSA Program Comments

Exhibit 1-1 Explosives Safety Management Program Responsibilities Organization

Chapter 2 SAFETY REQUIREMENTS IN EXPLOSIVES AREAS

1. References

2. Purpose

3. Scope and Applicability

4. Discussion

5. Smoking and Flame Producing Devices

6. Explosives and Personnel Limits

7. Safety Permits

8. Process Supervisors

9. Explosive Placard and Other Firefighting Symbols

10. Notification of After Hours Explosives Operations and Testing

11. Explosives Demonstrations

12. Red (BRAVO) Flag, Flashing Lights, Barricades, and Signage

13. Hazard Control Briefs for Visitors to Explosives Operating Buildings, Magazines, and Ranges

14. Housekeeping

15. Employees Working Alone

16. Transmitting Devices

17. Reporting Explosive Mishaps, Unsafe Conditions and Near Misses

18. Ordnance Handling Equipment

19. Clothing

20. Handling Operations involving Explosives/Energetic Materials

21. Tools

22. Inspections of Explosives Facilities

23. Clearing Barrels ii

24. Amnesty Program

25. Explosives Safety Deviations

26. Eating

27. Essential Personnel

28. Lean Processes for Navy Ordnance/Explosives Operations

Exhibit 2-1 Request for Authorized Smoking Area in Explosives Areas Exhibit 2-2 JQR Sample Format for Process Supervisors Exhibit 2-3 Sample Visitor Hazard Control Brief

Chapter 3 GROUNDING SYSTEM TEST PLAN

1. References

2. Purpose

3. Scope and Applicability

4. Policy

5. Action

Exhibit 3-1 Conductive Floor Test Procedure Exhibit 3-2 Earth Resistance Test Procedure Exhibit 3-3 Bonding Resistance Test Procedure Exhibit 3-4 Visual Inspection Procedure Exhibit 3-5 Magazine Test Procedure Exhibit 3-6 Building Visual Inspection Checklist Exhibit 3-7 Magazine Inspection Checklist Exhibit 3-8 Inspection/Test Requirement Standards Exhibit 3-9 Electrical Test Job Plans Exhibit 3-10 Grounding System Test Plan Descriptions

Chapter 4 PARKING OF PRIVATELY-OWNED VEHICLES IN EXPLOSIVES-

STORAGE MAGAZINE AREAS

1. References

2. Purpose

3. Scope and Applicability

4. Discussion

5. Policy

6. Action

Exhibit 4-1 Privately-Owned Vehicle Parking In Explosive Magazine Storage Areas

Chapter 5 WILDFIRE PREVENTION AND CONTROL

1. References

2. Purpose

3. Scope and Applicability

4. Background

5. Policy

6. Action iii

Exhibit 5-1 Wildfire Prevention and Control Plan Exhibit 5-2 Range Requirements

Chapter 6 OPERATIONS DURING ELECTRICAL STORMS

1. References

2. Purpose

3. Scope and Applicability

4. Background

5. Discussion

6. Definitions

7. Policy

8. Action

Exhibit 6-1 Requirements For Shut Down of Explosive Operations Exhibit 6-2 Operational Characteristics of Crane's Pre-Strike System

Chapter 7 MATERIAL POTENTIALLY PRESENTING AN EXPLOSIVES HAZARD

DECONTAMINATION, INSPECTION, CERTIFICATION, AND

VERIFICATION

1. References

2. Purpose

3. Scope and Applicability

4. Policy

5. Action

Exhibit 7-1 MPPEH Management Exhibit 7-2 Disposal Turn-In Document, DD Form 1348-1 (Example) Exhibit 7-3 Decontamination of Equipment and/or Facility Exhibit 7-4 Visual Inspections Exhibit 7-5 Controlled Document Links

Chapter 8 EXPLOSIVES SAFETY SITE PLANS

1. References

2. Purpose

3. Scope and Applicability

4. Discussion

5. Definitions

6. Policy

7. Action

Exhibit 8-1 Critical Parameters for Establishing and Maintaining a Facility License Exhibit 8-2 Explosives Safety Site Approval Request Determination Project Assessment Tool iv

Chapter 9 INERT ORDNANCE CERTIFICATION

2. Purpose

3. Scope and Applicability

4. Discussion

5. Policy

6. Action

Exhibit 9-1 Identification and Control of Inert Ordnance Exhibit 9-2 Sample Request for Inert Ordnance Certification

Exhibit 9-3 Nomination of Individual for Certifying Ordnance Inert Exhibit 9-4 Sample of Completed Inert Ordnance Inventory Memorandum Exhibit 9-5 Sample of Inert Ordnance Inventory Manager Appointment Letter

Chapter 10 EXPLOSIVES PERSONNEL QUALIFICATION AND CERTIFICATION

PROGRAM

1. References

2. Purpose

3. Scope and Applicability

4. Action

Chapter 11 HAZARDS OF ELECTROMAGNETIC RADIATION TO ORDNANCE

(HERO) PROGRAM

1. References

2. Purpose

3. Scope and Applicability

4. Discussion

5. Policy

6. Action

Exhibit 11-1 HERO Program Procedures Exhibit 11-2 HERO Warning Label Exhibit 11-3 Radio Frequency Hazard Signs Exhibit 11-4 Ordnance Operations General Hero Requirements

Chapter 12 RANGE SAFETY MANAGEMENT

1. References

2. Purpose

3. Scope and Applicability

4. Definitions

5. Discussion

6. Policy

7. Action

8. RSO and RCO Qualification Requirements

9. Reporting Requirements

10. Reports v

Exhibit 12-1 Sample Format - Range Safety Officer Designation for Testing Operations

Performed by Small Arms Weapons Systems Division Exhibit 12-2 Sample Format - Range Safety Officer Nomination Letter

Chapter 13 SHIELD CERTIFICATION

1. References

2. Purpose

3. Scope and Applicability

4. Policy

5. Action

Exhibit 13-1 Certification of Personnel Protective Shields

Chapter 14 MATERIALS, PROCESSES, EQUIPMENT, AND FACILITIES

1. References

2. Purpose

3. Scope and Applicability

4. Policy

5. Action

Exhibit 14-1 The MPERC Process Exhibit 14-2 Template for Peer Review Submissions for New Materials Exhibit 14-3 Format for Peer Review Submissions for Equipment, Processes, and Facilities Exhibit 14-4 Format for Peer Review Submissions for Equipment, Processes, and Facilities (MPERC not Required)

APPENDICES

A Acronyms

B Definitions

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CHAPTER 1

EXPLOSIVES SAFETY MANAGEMENT PROGRAM

1. References

a. DESR 6055.09 Edition 1 of 13 January 2019, DoD Ammunition and Explosives Safety Standards

b. DoD Instruction 4000.19 of 25 April 2013, Support Agreements

c. OPNAVINST 8020.14A, Department of the Navy Explosives Safety Management Policy Manual

d. NAVSEA OP 5, Volume 1, Seventh Revision, Ammunition and Explosives Safety Ashore

e. DA PAM 385-64 of 24 May 2011, Ammunition and Explosives Safety Standards

f. NOSSAINST 8020.14F, Navy Shore Station Explosives Safety Compliance Program

g. Memorandum of Understanding (CNRMA/NSWC Crane) of 13 October 2015, Joint Explosives Safety Management Onboard Naval Support Activity Crane

2. Purpose. To provide the host requirements for explosives safety per references (a) through (f). Reference (g) and Inter-Service Support Agreements (ISSAs) will identify explosives safety programs that are the responsibility of the host and tenants.

3. Scope and Applicability. This chapter applies to Naval Support Activity Crane (NSA Crane) and all tenants.

4. Discussion. This chapter identifies responsibilities and provides the process for establishing and maintaining host Explosives Safety Management Program (ESMP) as required by reference (a) and assessing compliance to the policy per references (c), (d), and (f). In addition, it identifies the Explosives Safety Self-Assessment (ESSA) Program.

5. Definitions

a. Explosives Safety Management. A cost effective risk management process, including policies, procedures, standards, engineering, and resources that addresses potential probabilities and consequences of mishaps involving Department of Defense (DoD) military munitions or other encumbering explosives or munitions, to sustain operational capabilities and readiness and to protect people, property, and the environment.

b. Explosives Safety Self-Assessment (ESSA). Formal plans that enable the activity to conduct continual periodic assessments of safety and compliance appraisals in support of the command’s explosives operations as well as the programs and processes that maintain a safe operational environment.

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c. Explosives Safety Steering Group (ESSG). The ESSG serves as the Technical Authority for administration and development of host ESMP policy in concert with DoD requirements and amplifying Department of the Navy (DON) and Department of the Army policy.

6. Policy

a. Explosives Safety Programs that are the responsibilities of the host and the tenants are delineated in reference (g). Host programs require either program administration or program oversight by NSA Crane. (Note: Host oversight is necessary when the actions of one organization can affect the operations and safety of another organization.)

b. Crane’s Joint ESMP identified by reference (g) is developed, implemented, managed, and assessed by the Explosives Safety Steering Group (ESSG). The ESSG ensures compliance with references (d), (e), and (f).

c. Host ESMP policy will be presented to applicable Crane organizations for review.

d. Reference (g) and Inter-service and ISSAs will reflect host ESMP policy. (Note: It is expected that policy and requirements will be effectively defined in reference (g), instructions, and ISSAs).

e. The ESSA program will emphasize the importance of maintaining a well-disciplined, proactive approach to explosives safety by applying the precepts of Operational Risk Management (ORM). Additionally, the ESSA program will promote the highest standards of Ammunition and Explosives (A&E) safety, integrity, and compliance and is a catalyst for creating and maintaining an operating environment that fosters concerted joint inter-service action in accomplishing safety-related goals at NSA Crane.

f. ESSAs will be conducted to evaluate the status of the 10 Explosives Safety Programs per reference (f). Crane Army Ammunition Activity (CAAA) will conduct assessments per Army policy and will participate in applicable host ESSA programs as appropriate.

g. Reference (f) requires the Explosives Safety Officer (ESO) to inform the Commanding Officer (CO) of the results of the annual ESSA associated findings and to keep the CO informed throughout the year on the progress made correcting the ESSA findings. A memorandum from the ESO documenting the meeting minutes from the quarterly ESSG meeting serves as the ESSA Program update to the CO. The update is provided to enhance the CO’s awareness of the health of the ESMP at NSA Crane.

h. The ESO of Naval Surface Warfare Center, Crane Division (NSWC Crane), will serve as the ESO for NSA Crane and other Navy tenant activities.

i. The CAAA Chief, Safety Office, will serve as the Explosives Safety Manager for CAAA.

The CAAA Commander is responsible for explosives safety within CAAA operations.

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7. Responsibilities

a. Installation Commanding Officer (ICO). The ICO is ultimately responsbile for overall safety for the installation. ICO will:

(1) Appoint an ESO in writing, and if desired, an Assistant ESO (AESO) who will act as the ESO when the ESO is not present.

(2) Ensure that the Explosives Safety Program is effectivly implemented.

(3) Maintain a Memoradum of Understanding (MOU) that reflects the explosives safety roles and responbilities between the host and teanants that conduct explosive operations.

(4) Review results and risk assessments identified during the ESSA via quarterly ESSG meeting minutes provided by the ESO.

(5) Acknowledge concurrence of ESSA results and risk assessments by signing the CO Acknowledgement Block provided on the ESSG meeting minutes memorandum.

b. Heads of Tenant Activies will:

(1) Appoint an ESO in writing, and if desired, an Assistant ESO (AESO) who will act as the ESO when the ESO is not present.

(2) Ensure the requirements of this instruction and reference (d) are implemeneted, adhered to, and enforced within their respective orginizations.

(3) Promote hazard awareness and ORM of all processes involving A&E within their orginizations.

(4) Maintain a culture of Explosives Safety within their organization.

c. Host ESO. The host ESO is organizationally assigned to Naval Surface Warfare Center Crane Division, Infrastructure Division, Safety Branch. The ESO will manage the ESMP and provide reasoned and informed advice to the ICO regarding compliance with the exisiting Navy A&E safety standards and acceptable levels of risk with regard to explosive operations. The ESO is vested with the authority to act for the ICO in matters related to Explosives Safety and is to execute duties in accordnace with reference (d). Specific duties and responsbilities include but are not limited to, ESO will:

(1) Report to and have direct access to the ICO.

(2) Act as the ESO for all orginzations that are conducting A&E operations on NSA Crane, less CAAA.

(3) Conduct periodic safety inspections of A&E magazines, storage areas, operating buildings and ranges and provide reports to the ICO for his situational awareness and acknowledgement.

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(4) Coordinate the submission of installation Explosives Safety Deviations to the appropriate approval authorites and maintain a file of all approvals.

(5) Chair the ESSG, submit meeting minutes to the ICO as required for acknowledgement, and maintain a file of meeting minutes.

(6) Schedule and conduct ESSG meetings.

(7) Accomplish the following for Explosives Safety Inspections (ESI):

(a) Serve as the Crane point of contact (POC) for liaison with the ESI Team Leader.

(b) Prepare and provide the ESI Information Book to the ESI Team Leader per reference (f).

(c) Prepare and submit the ESI Corrective Action Plan (CAP) electronically via the NOSSA Explosives Safety Compliance System (ESCS) within 45 calendar days from the date of the signed final ESI report, and 90-day CAP updates per reference (f).

(8) Maintain the individual ESSA deficiency/improvement actions. ESSA deficiencies will be entered into and tracked in Enterprise Safety Applications Management System (ESAMS). The Explosives Safety Office will enter all ESSA deficiencies into ESAMS.

Systemic ESSA deficiencies will be tracked via the ESSG. Review Corrective Action Plans and Root Cause Analysis for findings identified during the ESSA.

(9) Provide ESSG meeting minutes via memorandum to the ICO. The minutes will identify current ESSA and ESI findings, their status, and action. The memorandum will include the ESAMS Deficiency Report for the current ESSA that identifies the Hazard, Severity, Probability, and Risk Acceptance Code (RAC) required by reference (f).

(10) Provide scheduling, execution plan, and team construct for the ESSA.

(11) Provide ESSG quarterly agenda and ESSA updates to the ICO and members of the ESSG prior to the quarterly meeting.

(12) Maintain ESSA Program checklists. ESSA Program Checklists will be the current Navy ESI Program Evaluation Guides from the Naval Ordnance Safety and Security Activity (NOSSA) website that has been customized by the Explosives Safety Office to include local instruction or directive specific questions.

(13) Maintain Regional Explosives Safety Review Board (RESRB) reports, ESI CAPs, and ESSA associated records for at least four years (two ESI cycles), per reference (f).

d. Supervisory Personnel. Supervisors at all levels must be thoroughly familiar with the provisions of this publication and applicable instructions. They must act positively to eliminate any potential accident-hazards that exist in operations under their jurisdiction. Supervisors have

1-5 no authority to waive or alter OPNAV/MCO, NAVSEASYSCOM, or station safety regulations, nor will they permit violation of these regulations by others. Each supervisor will:

(1) Ensure that all processes are conducted per a command-approved Standard Operating Procedure (SOP).

(2) Explain to all employees under their immediate supervision the standard safety regulations and precautions that they must follow and enforce. Explain the characteristics of the ammunition, explosives, or other hazardous materials involved as well as the selection, use, and care of the necessary tools, materials, protective equipment and handling equipment.

(3) Ensure that all employees are qualified and certified to perform the job assigned and that their certification is current. Report promptly to the immediate superior all employees who, in their opinion, are not qualified for their assigned work.

(4) Determine the specific hazards involved and assuring that the appropriate instruction and documents (explosives safety technical manuals, pamphlets, etc.) are available. Assure that the SOPs relate directly to the ordnance and to the proposed operations.

(5) Assist the command ESO in conducting investigations and preparing the reports of all accidents involving operations, equipment, or personnel under their supervision.

(6) Identify all persons who are entering or approaching the area in their charge and determining their authority to enter and remain in the area. Exercise the authority to evict any person whose presence or actions, in their opinion, are detrimental to safety.

(7) Enforce personnel and explosives limits for their facility. Cease operations if their limits are exceeded and take corrective action to rectify the situations.

(8) Permit the use of only those tools and handling equipment that are authorized for the operations and used in the manner specified by SOPs or NAVSEA Technical Manuals.

(9) Maintain cleanliness of the operating or magazine area. Maintain all safeguards and preventing the blocking of safety exits, aisles, and accesses to firefighting equipment.

(10) Prior to securing operations for the day, ascertain that all conditions in the cognizant areas comply with orders relating to operations shutdown or completion. When the operation is not relieved by an incoming shift, making certain that windows and doors are closed and locked, that interior lights and processing equipment are turned off and that red flags have been removed or taken down at the end of the shift. When their operation is relieved by an incoming shift or for any other reason, report to the relief any situation that requires immediate attention or that should be kept under observation.

(11) Enforce compliance with safety regulations that concern personal protective clothing and equipment (PPE). Inspect and maintain, or replace if necessary, PPE required for the safe performance of the work for which the person is responsible.

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(12) Contact the Explosives Safety Office with any requests, suggestions, or comments they may have about safety standards.

(13) Alert their immediate supervisor of the need for Explosive Ordnance Disposal (EOD) personnel to remove defective or suspect ammunition from the work area.

e. Operating Personnel. It is recognized that operating personnel are the first lines of defense for identifying workplace safety hazards when involved in ammunition and explosive evolutions. Accordingly, operating personnel will:

(1) Only conduct operations that are covered by a command-approved SOP.

(2) Read, understand, and strictly observe all safety standards, requirements, and precautions applicable to their work or duty.

(3) Immediately report to their supervisor any of the following:

(a) An unsafe condition, employee action, or equipment or material that they consider unsafe.

(b) Any injury or evidence of impaired health, physical or mental, to themselves or other employees that could preclude them from performing their duties.

(c) The presence of unauthorized personnel in the area.

(4) Immediately warn other personnel when they are in danger by known hazards or by their failure to observe safety precautions.

(5) Wear or use approved PPE when it is required.

(6) Be prepared, in case of an unforeseen hazardous occurrence, to give an audible warning to the other employees and to exercise reasonable caution appropriate to the situation.

(7) Report any accident, incident, or near miss to their supervisor.

(8) Do not engage in horseplay or other unprofessional behavior while participating in explosives operations.

Note: If any person feels an unsafe condition exists, they must stop work until management reviews the task and determines that the risks are acceptable and it is a safe operation.

f. ESSG will:

(1) Consist of the following members:

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(a) NSA/NSWC Crane ESO (Chairperson);

(b) NSWC Crane Special Warfare and Expeditionary Systems Department Director or Deputy Director;

(c) NSWC Spectrum Warfare Systems Department Director or Deputy Director;

(d) Naval Facilities and Engineering Command Mid-Atlantic Public Works Department Crane (NAVFAC MidLant PWD) Public Works Officer (PWO) or Deputy PWO;

(e) CAAA representative;

(f) NSA Crane representative;

(g) Explosives Ordnance Disposal Mobile Unit TWO Detachment Crane Officer-in- Charge.

(h) NSWC Inventory Accuracy Officer

(i) NSWC AA&E Physical Security Officer

(j) NSWC Occupational Health & Safety representative

(k) NSA Emergency Management Officer

(l) NSA/NSWC Range Safety Manager

(m) NSA Fire & Emergency Services

(n) NSA Force Protection Department

(2) Determine when host policy is required and ensure appropriate organizational representation during policy development. Review reference (g) annually to evaluate its effectiveness and determine if any modifications are needed. Document completion of review in the ESSG meeting minutes.

(3) Hold quarterly meetings. Meeting minutes will be recorded by the Chairperson and provided to the CO for awareness, review, and acknowledgment.

(4) Use subject matter experts to assist in policy development.

(5) Oversee the biennial process for NOSSA ESIs of Crane per reference (f).

(6) Oversee the implementation of Crane’s ESI CAP process per reference (f).

(7) Oversee the ESSA process.

(8) Oversee the implementation of corrective actions with Command interest (e.g., issues resulting from accident investigations or external inspection findings).

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(9) Oversee site plans and stipulations/mitigations for site approvals.

(10) Schedule and ensure completion of the ESSA for all functional areas within the calendar year, and culturally stress that the ESSA is a continual self-assessment process, not an annual event.

g. ESSG members will appoint at least one alternate who will attend ESSG meetings in the ESSG member's absence, having full authority to act during ESSG meetings in the ESSG member's absence.

8. The Process for ESI Inspections of Crane

a. The ESSG is responsible for the oversight of the process for ESI inspections at Crane.

b. The ESSG will track through completion, all ESI findings using Crane’s CAP process.

9. Crane’s CAP Process

a. Each ESI finding of Crane will be addressed via ESCS which identifies the following:

(1) The finding itself

(2) Discussion

(3) Root Cause

(4) Root Cause Analysis of the finding

(5) Corrective Action

(6) Current Status

b. The ESSG will track through completion, all ESI findings and all root cause analyses by use of the ESCS CAP.

c. The CAP and 90-day CAP update will be submitted to NOSSA per reference (f).

10. The ESSA Process

a. Annual ESSA schedule will be coordinated by the ESO and briefed at the ESSG.

b. Individual teams will be coordinated by the ESSG to conduct ESSAs. All tenant commands that perform explosives operations are expected to provide ESSA team members.

c. The ESSG will track the progress of the quarterly ESSAs.

d. The ESSG will establish the tasks to be performed by ESSA teams.

e. The ESSG will conduct final report review for each individual ESSA.

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f. The ESSG will identify and track through completion via ESAMS, the individual deficiency and improvement actions for resolving explosives safety issues that were identified during the individual ESSAs as systemic, to include:

(1) Follow-Up;

(2) Root Cause Analysis (causative research);

(3) Trend Analysis as applicable.

g. Each ESSA Team Leader will:

(1) Perform the ESSA to identify process problems and to recommend solutions and process improvements associated with NSA Crane's ESMP.

(2) Use the Explosives Safety Office provided checklist. The checklist will be a customized version of the current NOSSA Navy Shore Station Explosives Safety Inspection Program Evaluation Guides that includes local instruction/directive specific questions. Team Leaders may request specific questions be added to the checklist if there are areas where they feel the checklist is not comprehensive enough to fully evaluate the program or program element.

(3) Ensure their Team, as required, obtains all instructions, documents, SOPs, Supplemental Documents (SDs), and records relevant to each program under assessment.

(4) Perform an initial desktop assessment of whether an effective process is in place via instructions, documents, SOPs, and SDs. Determine whether these documents provide adequate authority and direction to meet the requirements of each program and that an adequate ORM assessment/hazard analysis has been performed, as appropriate.

(5) Prepare and submit a draft report to the Explosives Safety Office.

(6) Present the final report to the ESSG.

h. ESSA Team Members will:

(1) Participate fully with the conduct of the ESSA.

(2) Provide assistance as required to aid in the implementation of internal controls and monitor processes to preclude recurrences of deficiencies.

(3) Monitor progress of enhancements identified during the ESSA process and ensure that corrective actions are adequate and accomplished expeditiously.

(4) Utilize appropriate sections of the Explosives Safety Office provided Navy ESI Program Evaluation Guide as the tool in performing the assessment.

(5) Evaluate the effectiveness of the assigned program document findings and provide comments and feedback for improvement as required.

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(6) Perform the specific tasks assigned by the ESSG and Team Leader.

11. ESSA Reports: ESSA reports are a valuable tool in keeping leadership onboard the installation informed of the overall health of the ESMP. They will be published by the Explosives Safety Office before and in preparation for the quarterly ESSG meeting. Report formats for each year will be determined by the ESSG and completed by the ESSA Team Leader in conjunction with the Explosives Safety Office. Reports may be generated in the two formats below:

a. Organization Report: This type of report will be used when multiple programs are inspected within an organization, code or section.

b. Program Report: This type of report will be used when one program is inspected throughout an organization, across multiple groups or the entire installation.

12. ESSA Report Format. ESSA Reports will include the information below. Templates and example reports may be obtained from the Explosives Safety Office.

a. Draft ESO Memo that indicates the scope of the inspection (organization, program, functional area, etc.) and the methodology of how it was conducted. The first paragraph of the memo should include a summary that describes the overall explosives safety posture of the organization and program. Other required information is below and should be considered the minimum requirement for all reports.

(1) Dates the ESSA was conducted.

(2) Organization(s)/program(s) inspected.

(3) Names of the Team Leader and Team Members as required (including Codes).

(4) Two enclosures; current year findings and all open findings from previous ESIs/ESSAs.

(5) Full descriptions and references for the findings in the enclosures.

(6) If any ESI findings listed are still active, for each one provide:

(a) The ESI Finding number

(b) The ESI description of the finding

(c) The current status of the finding

ESSA Findings – State the number of individual findings identified during the ESSA, their status (open/closed) and that a full description of the ESSA Findings is provided in enclosure (1).

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13. Corrective Action Plan (CAP). ESSA Reports will be sent to the responsible code or Division upon being signed by the ESO. CAPs will then be completed by the responsible code or division and returned to the Explosives Safety Office within 30 days. ESSA reports and CAPs are essential to and used during the quarterly ESSG meetings. If adjudication is required for any findings, it will be completed within the 30 days provided. Example formats of CAPs can be obtained from the Explosives Safety Office and the minimum requirements for them are below:

a. Finding – Identify the finding, finding number and current status for each.

b. Discussion – Finding explanation. Explain the “who”, “what”, “when”, “where”, “why”, and “how” the finding came to exists.

c. Root Cause – Policy (federal, DoD, DON, or local; Resources (lack of funding, insufficient human resources, etc.); Training (lack of training, training was inadequate);

Compliance (failed to comply, human error, does not fall into other categories).

d. Root Cause Analysis – Provide and explanation of the determination of the reason(s) why the finding exists.

e. Corrective Action(s) – Describe the actions that have been/will be taken to correct the deficiency.

14. ESSA Program Comments. Program comments are areas of concern noted by the inspection team that potentially could become a finding during and ESI or ESSA. Program comments can also be associated with an “unsafe” condition or act witnessed by the team during the assessment. They are provided for the leaderships information and situational awareness.

Program comments do not require a CAP unless it is specifically requested in the ESO’s memo or during the ESSG.

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EXHIBIT 1-1

EXPLOSIVES SAFETY MANAGEMENT PROGRAM

RESPONSIBILITIES ORGANIZATION

EXPLOSIVE SAFETY PROGRAMS NSA NSWC CAAA NAVFAC EOD

Program 1 - Explosives Safety Administration/Management

1.1 - Explosive Safety Management X

1.2 - Mishap/Accident Reporting X X X X X

1.3 - Emergency Management/Fire Plans/Maps X

1.4 - Inert Ordnance Management X X X X

1.5 - Safety Equipment/Fire Protection X

1.6 - Explosives Safety Self-Assessment X X X X X Program 2 - Facility Certification/Master Planning (Pillar Program)

2.1 - Site Management X X

2.2 - Site Compliance X X

2.3 - New Construction/Modification to Site Planning X X

2.4 - Deviations X X Program 3 - A&E Qual Cert and Training (Pillar Program)

3.1 - Implementation X X X* X X

3.2 - Training X X X* X X

3.3 - Qualification X X X* X X

3.4 - Certification X X X* X X

3.5 - Qual/Cert Records X X X* X X Program 4 - A&E Standard Operating Procedures

4.1 - Development X X X* X X

4.2 - SOP Content Requirements X X X* X X

4.3 - Review Process X X X* X X

4.4 - Implementation X X X* X X

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Program 5 - A&E Facilities/Operations

5.1 - A&E Storage and Compatibility X X X* X 5-2 - Storage Procedure and Safety X X X* X

5.3 - PES Inspections X X X* X

5.4 - Operating Buildings X X X*

5.5 - Explosive Hazardous Waste & Waste Military Munitions Management X X X X

5.6 - Facilities Maintenance (Mag/Bldgs) X X X* X Program 6 - Lightning Protection/Grounding/EMCON

6.1 - EMCON/HERO X

6.2 - Lightning Protection/Grounding X

6.3 - LP/G Equipment/Maintenance X Program 7 - MPPEH/Ranges

7.1 - Training Ranges X

7.2 - Test/Treatment Ranges X X X

7.3 - MPPEH Management X X X X

7.4 - Small Arms/Skeet Ranges X X Program 8 - AA&E Transportation & Equipment

8.1 Motor Vehicles X X X X X

8.2 - Ordnance/Material/Weight Handling Equipment X

8.3 - Equipment Safety Maintenance & Testing X

8.4 - Railroad Transportation X* Program 9 - AA&E Physical Security

9.1 - General Polices, Waivers, Exceptions & Surveys X X X* X

9.2 - Intrusion Detection System, Lighting, Construction, Storage X X X* X

9.3 - Security Force/Checks X X X* X

9.4 - Ready For Issue/Accountability X

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9.5 - Locks and Key Management X X X* X Program 10 - A&E Inventory Management (Pillar Program)

10.1 - Administrative Asset Management X X X* X

10.2 - NAR Management X X X* X

10.3 - Program Management X X X* X

10.4 - Inventory Accuracy X X X* X

*Annotates programs CAAA manages per Army regulations.

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CHAPTER 2

SAFETY REQUIREMENTS IN EXPLOSIVES AREAS

a. NAVSEA OP 5, Volume 1, Seventh Revision, Ammunition and Explosives Safety Ashore

b. NSACRANEINST 5100.13A, NSA Crane Smoking and Tobacco Use Policy

c. NSWCCRANEINST 5100.1A, Occupational Safety and Health Program

d. OPNAVINST 5102.1D, Navy and Marine Corps Mishap and Safety Investigation, Reporting, and Record Keeping Manual

e. NAVSEA OP 3565 Vol 2 Electromagnetic Radiation Hazards (Hazards to Ordnance)

f. OPNAVINST F3100.6J, Special Incident Reporting (OPREP-3 PINNACLE, OPREP-3 NAVY BLUE, and OPREP-3 NAVY UNIT SITREP) Procedures

2. Purpose. To provide general safety requirements not included in specific program areas that apply to explosive operations conducted onboard Naval Support Activity (NSA) Crane.

3. Scope and Applicability. This chapter applies to NSA Crane, all tenants, contractors, and visitors.

4. Discussion. This chapter provides some of the general safety requirements that apply to the explosives operations conducted on NSA Crane. Reference (a) provides detailed information relative to ordnance operations and safety. Safety of operations must be the prime concern of all personnel during work involving explosive materials. Every effort will be made to eliminate unsafe practices and minimize risks. Improper handling of ammunition, ammunition components, and/or explosive materials may result not only in component malfunction, but also in catastrophic accidents, which may cause considerable damage and result in injury to personnel and/or loss of life.

5. Smoking and Flame Producing Devices. Smoking is not allowed at any time in any vehicle onboard NSA Crane, whether it be a Privately Owned Vehicle (POV) or Government Owned Vehicle (GOV). Smoking is permitted only in designated areas and is strictly prohibited within any areas where explosives and ammunition are present. The carrying of matches, lighters, or other spark/flame-producing devices is prohibited in any explosives area unless it is required for an operation such as hot work, welding, etc. Smoking areas must be authorized as required by references (a) and (b). The approval of designated smoking areas is delegated to the Explosives Safety Office. A smoking area authorization will be requested by the first line manager through the format provided by Exhibit 2-1. The smoking area should be located outside the fenced boundary of restricted areas and as far as possible from an explosives site. Smoking areas will meet the requirements of reference (a) including:

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a. Posted with a "Designated Smoking Area" sign.

b. A posted copy of the approved Exhibit 2-1.

c. Installed electric, if electrical power is present or handheld flameless lighters of a type that can be lit only by a positive action. (Note: No flame producing devices are allowed in explosives containing facilities).

d. A 2½-gallon stored pressure water extinguisher or equivalent.

e. A metal receptacle for cigarette butts, preferably containing water or sand. Receptacles will be emptied at least weekly, or preferably at the end of the workday.

f. Personnel wearing clothing contaminated with metal powder, explosives, or dust that is explosive or highly flammable, are prohibited from entering a smoking area until contaminated clothing has been removed.

6. Explosives and Personnel Limits. Placard stating the maximum number of personnel (Operators/Transients) allowed in a building, cell, room or other similar space that contains ammunition, explosives, or other hazardous materials, will be conspicuously posted. Personnel limits do not need to be posted in magazines or magazine areas. Explosives and personnel limits should never be exceeded for any reason.

7. Safety Permits

a. For maintenance, repair, and construction work in and around explosives areas that involves hot work (e.g., work requiring soldering, melting of asphalt, welding, use of blow torches or other heat or spark-producing devices in and around explosives areas), a Safety Permit from the Explosives Safety Office is required prior to the commencement of work. The permit will be signed by the Building Supervisor, the person performing the work, and an Explosives Safety representative. The approved permit must be available at the work site.

Note: The Crane Army Ammunition Activity (CAAA) Safety Office provides the permits within CAAA operations. Joint Safety permits issued by CAAA and Navy Explosives Safety may be required on a case-by-case basis.

b. For maintenance, repair, and construction work in and around explosives areas that does not involve hot work (e.g., work requiring soldering, melting of asphalt, welding, use of blow torches or other heat or spark-producing devices in and around explosives areas), a written Safety Permit is not required. The Building Supervisor’s approval is required prior to the commencement of work. Additionally, the Building Supervisor will contact the Explosives Safety Office for concurrence prior to approving the initiation of work.

Note: The Crane Army Ammunition Activity (CAAA) Safety Office provides work permits within CAAA operations.) Joint Safety permits issued by CAAA and Navy

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c. For maintenance, repair, and construction work in and around explosives areas, a Safety Permit from the Explosives Safety Office is required prior to the commencement of work. The permit will be signed by the facility custodian, the person performing the work, and an Explosives Safety representative. The approved permit must be available at the work site.

Note: The Crane Army Ammunition Activity (CAAA) Safety Office provides the permits within CAAA operations.) Joint Safety permits issued by CAAA and Navy

8. Process Supervisors. Process Supervisors of Navy Research, Development, Test, and Evaluation (RDT&E) operations conducted in explosives operating buildings will be appointed in writing by the Division Manager. The designation letter will assign clear authority and responsibility. The Process Supervisor is responsible for ensuring explosives operations are conducted per reference (a), Standard Operating Procedures (SOP), and other applicable directives. The designated Process Supervisor will assign another Process Supervisors upon leaving the building to ensure clear delegation of authority is transferred. If no Process Supervisor is available, all explosives operations will cease until a designated Process Supervisor is available. A Process Supervisor must hold a Team Leader (TL) explosives certification level in all Work Task Codes (WTC) and Ordnance Family Groups for explosive operations that are ongoing within their designated areas of responsibility. Process Supervisors must complete an approved Job Qualification Requirement (JQR) for Process Supervisor. An example of the JQR is located in Exhibit 2-2. Process Supervisors appointed in writing prior to issuance of revision “D” of this instruction are not required to complete the JQR.

9. Explosive Placard and Other Firefighting Symbols

a. Vehicle Placards. All government vehicles transporting Hazard Class 1 (explosives) material on NSA Crane will placard their vehicle. This includes placarding vehicles transporting all quantities of Hazard Class 1, Division 4 material. These placards will be displayed on the front, rear, and both sides of the vehicle. Specification for and the placement of these placards must be per reference (a).

Exception: Security vehicles and Security personnel transporting small arms ammunition for security purposes are not required to placard their vehicles.

b. Fire Symbols for Magazines and Explosive Operating Buildings. Appropriate fire symbols will be used to indicate the presence of ammunition or explosives material in any magazine or operating building. Additional placards may be required to indicate special firefighting techniques (no water symbols, respirators required, etc.) Reference (a) provides information related to symbols and posting requirements.

c. EMPTY or INERT signs will be posted outside magazines and operating buildings which do not contain explosives or energetic materials. EMPTY/INERT placards will not be the same shape as the designated fire symbols identified in reference (a).

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10. Notification of After Hours Explosives Operations and Testing. When explosives operations or functional testing is planned outside of normal working hours, whether on a weekday or weekend, notify Explosive Ordnance Disposal (EOD), Explosives Safety Office, NSA Crane Force Protection Department, and NSA Crane Fire Department. The following information will be provided:

a. Building number or Range

b. Specific hours the operation will be underway

c. Type of explosive operation

d. Total number of personnel onsite

e. POC (Process Supervisor or Range Safety Officer) with contact phone number

11. Explosives Demonstrations. Demonstrations conducted on ranges, including the use of pyrotechnics, small arms live fire, etc., must be conducted per reference (a).

a. Demonstrations will be requested by the Division Manager or equivalent and approved by the Explosives Safety Office. If the requested range is external to the requesting management chain, the owning range organizational head will also be an approver.

b. Only personnel who are essential to the operation may be within the Explosives Safety Quantity Distance (ESQD) arc of the ordnance. Approval of personnel as essential to the operation will be determined by either:

(1) Department Director or equivalent

(2) Technical Director

(3) Commanding Officer

c. All approval requests will state the names of the individuals participating in the demonstration and a brief description of the need or value added to Crane.

d. Approval requests will reference the SOP that addresses the demonstration including the latest revision number and date. The SOP will address all aspects of the event and the protection of essential and nonessential personnel.

e. All personnel will be thoroughly briefed on the hazards of the ordnance demonstration.

f. Visitors will be under the constant supervision of the Range Safety Officer (RSO) and will be provided with protection necessary to meet the requirements of reference (a).

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12. Red (BRAVO) Flag, Flashing Lights, Barricades, and Signage

a. A red flag must be displayed prominently near the entrance of any explosive operating building, magazine and or magazine area whenever work connected with explosives or ammunition is in progress. The red flag is to indicate from a distance that personnel and explosives are in the building or magazine. Flags are to be removed when operations are completed for the day and all personnel have vacated the building or magazine.

b. A red flag will be displayed prominently near the entrance of any range or flown at the entry point of the range to indicate that the range area is “hot” (e.g., explosives testing is in progress or detonations are planned to occur). When operations cease, the flag will be hauled down or removed.

c. Red flashing lights that are visible from all normal approaches in addition to the red flags, warn personnel of the presence of a significant hazard such as a remotely controlled operation or a test firing/detonation in progress.

d. Barricades and gates are frequently used to secure a road or area during testing, burning, or demolition operations. These barricades or gates will not be passed in any fashion without specific clearance from the Range Control Officer (RCO) or RSO conducting the operation.

Contact the appropriate RCO/RSO prior to entering and leaving these areas. Witnessing others pass through a barricade does not constitute permission to follow. They may be part of the team conducting the operation and have permission to re-enter the area. Certain areas may be closed for extended periods, including weekends and nights. Some test operations may be conducted continually.

e. Signage is posted on the installation to warn installation personnel and visitors of specific hazardous areas and areas requiring restricted access. Examples are:

(1) Ordnance Ranges have perimeter and entry point signage posted to warn personnel they are entering into a danger area and to check in with the RCO/RSO. Signage states, “Warning Explosives Test Area Do Not Enter.”

(2) Entrance into the ordnance area is posted on roadways encumbered by explosives quantity distance arcs. Signage states “Warning Explosives Area Authorized Personnel Only”. A portion of Highway 101 between highways 5 and 45 is only authorized for Ordnance Workers and it is posted as “Warning Explosives Area Explosive Related Worker Only.”

(3) Hazard of Electromagnetic Radiation to Ordnance (HERO) signs are posted at any location where radar equipment or other possible sources of electromagnetic radiation (EMR) might create the potential for premature initiation of ordnance due to HERO. This symbol is placed along ordnance transportation routes at NSA Crane gates and at entrances to ordnance operations areas to alert operators of mobile and portable emitter systems such as radios and cellular telephones to a potential hazard when using radios and cellular telephones past this point. The sign specifies turning off any unauthorized transmitters.

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(4) No Ordnance Transportation area signs are posted at the entrance to areas that have transmitters (radar or other source of EMR). This sign is used to alert ordnance truck drivers to the potential hazard of transporting ordnance in an area that might create the potential for premature detonation of the ordnance being transported.

13. Hazard Control Briefs for Visitors to Explosives Operating Buildings, Magazines, and Ranges. Visitors to explosives operating buildings, magazines, ranges or any other facility that has explosives present, must receive a Hazard Control Briefing (HCB) relevant for that facility.

a. Visitors are required to sign the HCB to acknowledge they are aware of the hazards present.

(1) Authorized Visitor – Personnel conducting project or mission related functions that require them to be present in the explosives area for a limited time. Examples are NAVFAC or contractor personnel performing maintenance or repairs and official tours by sponsors or other installation-related personnel.

(2) General Public – Persons not associated with a DoD installation’s mission or operation such as visitors, to include guests of personnel assigned to the installation, or persons not employed by the DoD or contracted by the installation.

b. The visitor HCB should be given monthly for returning visitors; however, the frequency is dependent on the changing status of the building, area, or facility.

c. Process Supervisors will provide the HCB to visitors if explosives operations are ongoing in the facility. If no explosives operations are ongoing, any Team Leader permanently assigned to the facility may provide the visitor the HCB. The brief should include at a minimum: (see Exhibit 2-3 as an example of a visitor HCB):

(1) General awareness information pertaining to the area, building, or facility.

(2) Smoking policy for the area and that no flame or spark producing devices such as lighters and matches are allowed in the area.

(3) Cell phone, blackberry, and transmitter policy.

(4) Evacuation/emergency action plan and rally points in case of fire or other emergency.

(5) Personnel protective equipment (PPE) requirements.

(6) Location of explosives and if testing is ongoing or not.

d. Visiting personnel that are participating in hands-on work with explosives must receive and sign the HCB for the specific SOP being used for the operation they are participating in, and are not required to have the visitor HCB.

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14. Housekeeping

a. All magazines and explosives operating buildings will be kept clean. Any combustible materials such as paper, oily rags, cotton waste, paints, wood, etc., needed to complete operations conducted within the area will be removed daily. All work areas will be cleaned and tools properly stowed prior to the end of each workday. Scrap materials (banding material scrap, pallets, etc.) will not be permitted to accumulate in or near magazines or explosive operating buildings.

b. During operating hours, doors will be fastened only with anti-panic latches or approved quick-acting devices. They will be kept in good working order.

c. Access to safety equipment such as fire alarms, fire hydrants, fire extinguishers, safety showers, eye wash stations, first aid kits, emergency stops, electrical panels and fire bills will not be blocked. The location of safety equipment will be appropriately and conspicuously marked to indicate the equipment’s accessibility.

15. Employees Working Alone. During any operation involving explosives or energetic material, no employee will be permitted to work alone in a location where assistance from another cannot be given immediately in the event of an accident. Reference (a) allows for a Safe Person Plan for RDT&E explosives/energetic processes for situations that may warrant it. The plan must be documented in the applicable SOP per reference (c), Chapter 4.

16. Transmitting Devices. Transmitters operating in an explosives area must have HERO approval. Additional information on the HERO program and requirements are in Chapter 11.

17. Reporting Explosive Mishaps, Unsafe Conditions, and Near Misses

a. All employees are responsible for reporting any accident, unsafe conditions or unsafe acts observed to their supervisor and the Explosives Safety Office. When an unsafe condition exists, operations affected by the unsafe condition will cease until the condition can be corrected. Any person can request a delay or cessation of an explosive operation if they feel it is unsafe. Once reported, the supervisor or Explosives Safety will conduct a safety review prior to the resumption of operations. Employees can request a safety review without fear of reprisal. All Near Misses must be reported to the appropriate Safety Office.

b. All commands must report explosives mishaps and near misses to the Host Explosives Safety Office. The Explosives Safety Office will investigate, report, and maintain records of all mishaps and near misses per reference (d). CAAA will follow Army Regulations. Navy commands Near Misses will be reported using ESAMS by the appropriate supervisor of the explosives operation once investigated by Explosives Safety.

c. Explosive Mishap. Includes all of the occurrences, near-occurrences, or circumstances listed below.

(1) Dangerous Defect. A defect, found upon visual examination or local test, in an explosive material or system that is capable of resulting in an explosive mishap (e.g., ruptures of

2-8 explosive containers exposing filler, protruding…