Amendment 0002 - Appendix E Brass Deforming Operations_v2 (printed).pdf

Sheaffer, William J Mr CIV USA USARPAC

United States Army

7/1/2019

WC1JT3 BRASS DEFORMING OPERATIONS

SUPERVISOR’S STATEMENT

SOP NO.:___ WC1JT3-0000-M-006_______REV NO.:_______CHANGE NO.:___________DATE:1 JULY 2019____

1. THE SUPEVISOR WILL SIGN THIS STATEMENT:

A. WHEN FIRST ASSIGNED AS SUPERVISOR OF THE OPERATION.

B. WHEN AN APPROVED CHANGE IS MADE TO THE SOP.

C. AT LEAST ONCE PER QUARTER DURING CONTINUING OPERATIONS.

D. AFTER ABSENCE FROM THE JOB IN EXCESS OF 15 CONSECUTIVE WORKDAYS.

2. I HAVE PERSONNALLY REVIEWED EACH OF THE OPERATIONAL STEPS OF THE SOP AND HAVE

DETERMINED THAT THE OPERATION CAN BE PERFORMED SAFELY, EFFICIENTLY AND IN

COMPLIANCE WITH REGULATIONS AND RESTRICTIONS NOTED IN THE SOP. I HAVE VERIFIED TO

MY SATISFACTION THAT OPERATORS HAVE BEEN TRAINED AND ARE CAPABLE OF PERFORMING

THEIR PART OF THE OPERATION IN A SAFE AND EFFICIENT MANNER AND HAVE INSTRUCTED

THEM TO FOLLOW THE SOP WITHOUT DEVIATION.

SUPERVISOR’S PRINTED NAME: ____________________________________________________________

SUPERVISOR SIGNATURE DATE

OPERATOR’S STATEMENT

SOP NO.:WC1JT3-0000-M-006 REV NO.: 1 CHANGE NO.:_______________DATE:___01 JULY 2019____

1. THE OPERATOR WILL SIGN THIS STATEMENT:

A. WHEN FIRST ASSIGNED AS SUPERVISOR OF THE OPERATION.

B. WHEN AN APPROVED CHANGE IS MADE TO THE SOP.

C. AT LEAST ONCE PER QUARTER DURING CONTINUING OPERATIONS.

D. AFTER ABSENCE FROM THE JOB IN EXCESS OF 15 CONSECUTIVE WORKDAYS.

2. I HAVE PERSONNALLY REVIEWED EACH OF THE OPERATIONAL STEPS OF THE SOP AND HAVE

DETERMINED THAT THE OPERATION CAN BE PERFORMED SAFELY, EFFICIENTLY AND IN

COMPLIANCE WITH REGULATIONS AND RESTRICTIONS NOTED IN THE SOP. I CONFIRM THAT I

HAVE BEEN TRAINED AND AM CAPABLE OF PERFORMING MY PART OF THE OPERATION IN A

SAFE AND EFFICIENT MANNER AND WILL FOLLOW THE SOP WITHOUT DEVIATION.

NAME/SIGNATURE DATE OPERATION NUMBER

PART II

CHAPTER 15

BRASS DEFORMING OPERATIONS

1) PURPOSE:

This SOP is intended for use by individuals conducting expended brass deforming operations, and assigned the responsibilities for the preparation, operation, and maintenance of the SAFETY CERTIFICATION UNIT (SCU) for SMALL ARMS BRASS APE 1408M1 and BRASS DEFORMER APE 1410. It provides an overview of the brass handling process as well as technical information for inspection, safe operation, troubleshooting and preventive maintenance of the equipment.

2) REFERENCES.

a) AR 700-20, Ammunition Peculiar Equipment (APE)

b) AR 385-10, The Army Safety Program

c) DA PAM 385-64, Ammunition and Explosives Safety Standards

d) AMC-R 385-100, Safety Manual

e) SAFETY CERTIFICATION UNIT for SMALL ARMS BRASS APE 1408M1 and

BRASS DEFORMER APE 1410

f) Other references: DOD4140.62, DOD4145.26-M, DODM 4160.28-M-V3, DOD 6055.09

3) SCOPE:

This SOP applies to all assigned personnel and contractor personnel operating in the deformer yard or around the area where the SCU and Deformer is in operation.

4) POLICY:

a) There will be no attempt made to operate and/or conduct on this equipment until the person performing the task is fully trained by Ammo Supply Point (asp) personnel and becomes familiar with all publications pertaining to the equipment. In the event the machine becomes damaged or stops working, deforming operations will immediately cease. Qualified personnel are authorized to perform only procedures specified in the Operational Manual when attempting repair. If the problem cannot be resolved deforming operations will be suspended until qualified personnel are able to repair it.

b) During the calendar year (commencing on January 1), the amount of material that is recycled, or transferred to a different site for recycling, equals at least 75% by weight or volume of the amount of material accumulated at the beginning of the period to ensure compliance with 40 CFR 261.1(c)(8).

c) This SOP and a copy of the Operational Manual will be kept in the residue yard and at the ASP Administrative Building.

5) PROCEDURES:

a) Operations covered by this SOP include the receipt, storage, and deforming of expended brass .50 caliber in size or smaller. This includes the segregating, screening, inspecting and storing of deformed brass. This also includes the operation of Material Handling Equipment (MHE) and APE equipment, equipment PMCS, and specific guidelines on the use of personal safety equipment.

b) This SOP in conjunction with the APE owners’ manual provides clear concise guidance for operating equipment and implementing the conclusions of locally performed hazard analysis

c) Equipment malfunctions or breakdowns will be reported to the QRP-Manager or the

Ammunition Supply Point Manager.

WARNING: Adhere to all safety precautions and warnings provided in the owner’s manual and attached to the machine.

6) GENERAL SAFETY INFORMATION:

a) Employees will report any injury, accident or other emergency to Supervision (ASP and QRP). Injury that is a threat to life, limb or eyesight initiates an immediate call to 9-1-1.

In the event of a fire that cannot immediately be contained, call 9-1-1.

b) Access to the Residue yard is locked and shall be restricted to personnel directly engaged in deforming operations, but may include authorized observers by the discretion of supervision. This may include certified ammunition handlers, occupational health personnel, or commanders as appropriate. Personnel will not approach the APE or its controls during operation unless directly engaged in loading brass or unloading deformed brass.

c) All personnel directly involved with material handling and/or brass deforming will wear required Personal Protective Equipment to include ANSI Z87.1 eye protection, hearing protection, steel-toed boots and gloves.

d) Maintenance, preventative or otherwise, will only performed when the 1408 & 1410 are not operating and are at full stop. The application of grease or other lubricants will be accomplished when the units are cool and prior to startup. Excess grease and lubricant will be whipped off prior to equipment start up.

e) All personnel around the area where the SCU and Deformer are operating must wear hearing protection and leather gloves..

7) RECEIPT:

a) JBER ASP SOP# WC1JT3-0000-B-01, Explosive Operator Issue/Turn-In procedures and JBER ASP SOP# WC1JT3-0000-B-02 Residue Yard describe actions relating to processing brass. SOPs will be available to the 1408M1 & 1410 operators prior to operations start up.

b) Spent Ammunition Brass will be segregated and stacked by type after the ammunition turn in process and visual inspection for live ammunition. Spent brass will be funneled into wooden wire-bound boxes, limiting the weight to approx. 50 lbs.

8) STORAGE:

a) Brass that has been visually inspected IAW SOP WC1JT3-0000-B-02 will be stored by type of brass on wooden pallets.

b) Brass must be placed in a storage unit with a label indicating the first date that the material began to be accumulated and weight. If placing a label on the storage unit is not practicable, the accumulation period must be documented through an inventory log.

c) Care will be taken not to create choke points, block equipment (i.e. fire extinguishers) or facility utilities (i.e. fuse panels) or emergency exits while storing sorted brass.

9) SCU OPERATIONS:

a) Refer to the owner’s manuals for step-by-step procedures for start- up and shut down procedures. Owner’s manual will be located at the operating site along with this SOP.

NOTE: 9mm brass by itself is too dense to be ran through the certification unit and will cause mechanical failures.

b) The SCU/Deformer is located at the residue yard under a cover facility. This unit is stationary because of being hooked to natural gas line.

c) 9mm ammunition brass will not be processed by itself, 9mm brass will be scooped into the hopper when processing 7.62mm or 5.56mm. Additionally, 9mm Brass will not be processed with 50cal. Brass.

d) The 1408&1410, Material Handling Equipment and any other lifting devices will be inspected and serviceable prior to operations.

e) Verify there are no obstructions that may cause malfunctions during operations (i.e.

Remove debris, run power cords, stage material and equipment).

f) Ensure all safety guards, access hatches, adjustment covers are properly installed IAW the owner’s manual.

g) Inspect the barrel tipping device for damage and operation.

h) 1408M1 SCU feeds the Deformer via conveyor belt. As the deformed brass exits the 1410 DEFORMER, an Inclined Outfeed Conveyor carries them to the waiting container.

i) When the containers catching the deformed brass is 85-90% full, stop the deformer immediately, and wait until the brass deformer comes to a full stop.

j) Remove the container from the deformer catch area and replace with an empty container prior to restarting operations.

k) Place a lid on containers with processed brass and weigh the container using the pallet scale. Security seal will be installed to alert personnel to any tampering to processed brass.

l) MATERIAL DOCUMENTED AS SAFE (MDAS) CERTIFICATION FORM (Appendix

A) will be filled and seal numbers documented on the MDAS by the contractor.

m) DD Form 1348 will be filled out and quantity will be documented by weight minus the Tare weight of the containers (approx. 770lbs). Security Seal numbers will be placed on the DD Form 1348.

10) EMERGENCY ACTIONS:

a) In the event of an obstruction, stop the machine by pressing any of the “RED” Stop buttons on the machine or power box. Do not proceed until the machine is completely stopped.

b) If there is a mechanical obstruction DO NOT reach into any working areas of the machine with your hand or arm to remove the obstruction. Power down the equipment at the breaker before using a tool to dislodge the obstruction.

c) After the obstruction is removed, inspect the machine to make sure the obstruction and its removal has not damaged the machine. Replace all GUARDS AND SHUT ALL DOORS

PRIOR TO UNLOCKING THE “RED” STOP AND RESUMING OPERATION.

d) The 1408M1 is designed and tested to safely contain detonations up to and including .50 caliber ammunition, however these detonations and other debris can greatly shorten the service life of the machine and its components. Care must be taken to ensure no live ammunition or debris intentionally enters the 1408M1 or 1410 Deformer.

11) RECEIPT AND STORAGE OF MATERIAL DOCUMENTED AS SAFE (MDAS):

a) All deformed brass casings must be sealed, secure container (tipping bin or standard 55 gal steel drum), and each container will be accompanied by a completed MDAS certificate (see Appendix A). The MDAS certificate will bear the number of the seal used to secure the container after inspection.

b) Containers of brass will be allowed to cool enough to touch prior to transport to a recycler.

Appendix A. MDAS Certificate

MATERIAL DOCUMENTED AS SAFE (MDAS) CERTIFICATION FORM