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/ 2005
/ March
/ Tuesday, March 29, 2005
[Federal Register: March 29, 2005 (Volume 70, Number 59)]
[Proposed Rules]
[Page 16037-16077]
From the Federal Register Online via GPO Access [wais.access.gpo.gov]
[DOCID:fr29mr05-37]
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Part III
Department of Defense
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Office of the Secretary
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32 CFR Part 184
Contractors' Safety for Ammunition and Explosives; Proposed Rule
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DEPARTMENT OF DEFENSE
Office of the Secretary
32 CFR Part 184
RIN 0790-AH76
[DoD 4145.26-M]
Contractors' Safety for Ammunition and Explosives
AGENCY: Office of the Secretary of Defense.
ACTION: Proposed rule for comment.
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SUMMARY: The Department of Defense (DoD) is codifying its revised
explosives safety standards for ammunition and explosives (A&E) work
performed under DoD contracts. This proposed rule is necessary to
minimize the potential for mishaps that could interrupt DoD operations,
delay project completion dates, adversely impact DoD production base or
capability, damage or destroy DoD-owned material/equipment, cause
injury to DoD personnel, or endanger the general public. The benefits
of this proposed rule in terms of the protection of the public and
ensuring contract performance are expected to balance its potential
cost or administrative impacts. Only provisions related to conventional
AE operations have been included in this proposed rule. No attempt was
made to encompass general industrial safety, occupational health
concerns, chemical warfare agents, radiation, or over-the-road
transportation requirements, because these are either the
responsibility of other regulatory agencies (for example DOT, DOL/OSHA,
or NRC) or may be addressed elsewhere in the contract by the procuring
activity. Budgetary effects of this proposed rule are minimal since
existing DoD Federal Acquisition Regulation Supplement coverage already
requires compliance with safety requirements in AE solicitations and
contracts. Finally, because this proposed rule is needed to minimize
the potential for AE mishaps that could adversely impact DoD and the
public, timely publication in the Federal Register is important.
DATES: Comments are to be received not later than May 31, 2005.
FOR FURTHER INFORMATION CONTACT: Dr. Jerry M. Ward, Director, Engineer
Technical Programs Division, DDESB, telephone (703) 325-2525, fax:
(703) 325-6227; e-mail: Jerry.Ward@DDESB.OSD.mil.
SUPPLEMENTARY INFORMATION: Pursuant to the authority vested in the
Secretary of Defense in accordance with 10 U.S.C. 172, DoD Directive
6055.9 established the Department of Defense Explosives Safety Board as
a joint activity of the Department of Defense subject to the direction,
authority and control of the Secretary of Defense. The majority of the
standards impacting upon the public were adopted prior to the enactment
of the Administrative Procedure Act. This proposed rule is intended to
ensure public awareness of the extent of the explosives safety
standards as well as offer the public an opportunity to comment on the
standards. The information addresses the HCSDS sometimes furnished with
solicitations or contracts to provide an insight into potentially
hazardous characteristics of the materials involved in the production
of the item addressed in the solicitation. Contractors retain the
ultimate responsibility for assuring the safety of their personnel and
establishment. Information provided by the HCSDS is derived from other
sources. Verification of such data as shipping and storage hazard
division and storage compatibility group information must be done
through the DoD Joint Hazard Classification System (JHCS) or Title 49,
Code of Federal Regulations.
These classifications pertain to AE packaged for transportation or
storage. Such hazard classification information may not be valid when
applied to the hazards associated with manufacturing or loading
processes. For such processes, the materials and processes must be
analyzed on a case-by-case basis. Sources of information to support
this analysis are available from service research and development
organizations through contract channels and other sources.
Executive Order 12866
This proposed rule does not:
(1) Have an annual effect of the economy of $100 million or more or
adversely affect in a material way the economy, a sector of the
economy, productivity, competition, jobs, the environment, public
health or safety, or state, local, or tribal governments.
(2) Create a serious inconsistency or otherwise interfere with an
action taken or planned by another agency.
(3) Materially alter the budgetary impact of entitlement, grants,
user fees, or loan programs or the rights and obligations of recipients
thereof; or
(4) Raise novel legal or policy issues arising out of legal
mandates, the President's priorities, or the principles set forth in
this Executive Order.
Regulatory Flexibility Act of 1980 (5 U.S.C. 605(b))
Regulatory Flexibility Act. It has been certified that this
proposed rule, if promulgated, shall be exempt from the requirements
under 5 U.S.C. 601-612. This proposed rule does not have a significant
economic impact on small entities as defined in the Act.
Unfunded Mandates Act of 1995 (Sec. 202, Pub. L. 104-4)
This proposed regulatory action does not contain a Federal mandate
that will result in the expenditure by State, local, and tribal
governments, in aggregate, or by the private sector of $100 million or
more in any one year.
Paperwork Reduction Act of 1995 (44 U.S.C. Chapter 35)
Paperwork Reduction Act. The proposed rule imposes no obligatory
information requirements beyond internal Department of Defense needs.
Federalism (Executive Order 13132)
This proposed regulatory action does not have federalism
implications, as set forth in Executive Order 13132. It will not have
substantial direct effects on the States, on the relationship between
the national government and the States, or on the distribution of power
and responsibilities among the various levels of government.
Section 202, Public Law 104-4, ``Unfunded Mandates Reform Act''
It has been determined that this rule does not involve a Federal
mandate that may result in the expenditure by State, local and tribal
governments, in the aggregate, or by the private sector, of $100
million or more and that such rulemaking will not significantly or
uniquely affect small governments.
List of Subjects in 32 CFR Part 184
Ammunition and explosives, DoD contractors.
Accordingly, 32 CFR part 184 is proposed to be added to read as
follows:
PART 184--DOD CONTRACTORS' SAFETY MANUAL
Sec.
184.1 Introduction.
184.2 Mishap investigation and reporting.
184.3 General safety requirements.
184.4 Quantity-distance and siting.
184.5 Hazard classification, storage principles, and compatibility
groups.
184.6 Electrical safety requirements for AE facilities.
184.7 Manufacturing and processing propellants.
184.8 Safety requirements for manufacturing and processing
pyrotechnics.
184.9 Storage of ammunition and explosives.
184.10 Fire protection.
184.11 Risk identification and management.
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184.12 AE building design and layout.
184.13 Safety requirements for specific AE and AE operations.
184.14 Test and testing requirements.
184.15 Collection and destruction requirements for AE.
184.16 Construction and siting criteria.
Appendix A to 32 CFR Part 184--Glossary
Authority: 10 U.S.C. 172.
Sec. 184.1 Introduction.
(a) Purpose. This part provides safety requirements, guidance and
information to minimize potential mishaps which could interrupt
Department of Defense (DoD) operations, delay production, damage DoD
property, cause injury to DoD personnel, or endanger the public during
contract work or services involving ammunition and explosives (AE). The
part contains the minimum contractual safety requirements to support
the objectives of DoD. These requirements are not a complete safety
program and this part does not relieve a contractor from complying with
Federal, State and local laws and regulations.
(b) Applicability. These safety requirements apply to contractors
performing AE work or AE services on DoD contracts, subcontracts,
purchase orders, or other procurement methods. The requirements also
apply to non-DoD contractor operations to the extent necessary to
protect DoD work or services.
(c) Mandatory and advisory requirements. The part uses the term
``shall'', or an affirmative statement, to indicate mandatory
requirements. The terms ``should'' and ``may'' are advisory. When
advisory provisions are not met, adverse consequences might develop and
become proximate causes of AE mishaps.
(d) Compliance with mandatory requirements. (1) The Department of
Defense requires compliance with mandatory provisions of this part and
applicable portions of DoD 6055.9-STD.\1\ Siting criteria for AE are
provided in quantity distance (Q-D) standards contained in Chapter 9 of
DoD 6055.9-STD. In order to provide consistent and current information
to all DoD AE contractors, Q-D requirements of DoD 6055.9-STD are
incorporated by reference in paragraph C317.
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\1\ Copies may be obtained via Internet at http://www.dtic.mil/whs/directives
.
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(2) Waivers. Procuring contracting officers (PCO) may grant
contract-specific waivers to mandatory provisions of this part.
Rationale for waiver of DoD pre-award safety surveys must be documented
and provided to the cognizant ACO for transmittal to the cognizant DoD
Component explosives safety office for their records. Military or
commercial ammunition and explosives shall not be procured unless their
use is authorized by the cognizant DoD Component explosives safety
approval authority. Methods of addressing non-compliance with mandatory
requirements and requests for waivers are different during the pre- and
post-award phases of a contract.
(3) In the pre-award phase, the PCO will request a DoD pre-award
safety survey to help determine contractor capability. During pre-award
surveys, noncompliance with mandatory safety requirements normally
results in a recommendation of ``no award.'' Any noncompliance should
be resolved during the pre-award survey. Contractors may choose to
correct the deficiencies immediately, may offer a letter of intent to
correct the deficiencies (which will become binding upon award of
contract), or may request that the PCO accept specifically identified
existing conditions of facilities (contract-specific waiver).
(4) In the post-award phase, the contractor has 30 days from the
date of notification by the administrative contracting officer (ACO) to
correct the noncompliance and inform the ACO of the corrective actions
taken. The contracting officer may direct a different time period for
the correction of any noncompliance. If the contractor refuses or fails
to correct any noncompliance within the time period specified by the
ACO, the Government has the right to direct the contractor to cease
performance on all or part of affected contracts. When the contractor
cannot comply with the mandatory safety requirements of the contract,
the contractor will develop and submit a request for a waiver through
the ACO to the PCO for the final determination. The request will
contain complete information concerning the requirements violated,
actions planned to minimize the hazard, and a proposed date for
correction of the deficiency.
(e) Pre-award safety survey. DoD safety personnel conduct pre-award
surveys to evaluate each prospective contractor's ability to comply
with contract safety requirements. The pre-award safety survey is also
an opportunity for the contractor to request clarification of any
safety requirement or other AE issue that may affect the contractor's
ability to comply. During pre-award surveys, the contractor shall
provide the following:
(1) Site plans conforming to paragraphs (h)(5)(i) through
(h)(5)(iv) of this section for proposed facilities to be used in
contract performance.
(2) Evidence of implementation of a safety program containing at
least mandatory requirements described in Sec. 184.3.
(3) General description of proposed contract facilities, including
size, building layouts, construction details, and fire resistive
capabilities.
(4) Fire prevention program and available firefighting resources
including local agreements or other documentation demonstrating
coordination.
(5) Copies of required licenses and permits or demonstration of the
ability to obtain approvals necessary to support the proposed contract.
(6) A safety history including mishap experience, safety survey or
audit reports by insurance carriers or Federal, State, and local
authorities, and any variances, exemptions or waivers of safety or fire
protection requirements issued by Federal, state or local authorities.
(7) Details of proposed operations and equipment to include process
flow narrative/diagram, proposed facility or equipment changes, hazard
analysis, and proposed procedures for all phases of AE operations.
(8) Subcontractor information. (i) Identification of all
subcontractors proposed for the AE work.
(ii) Methods used to evaluate capability of subcontractor to comply
with the requirements of this part.
(iii) Methods used to manage subcontractor compliance.
(f) Preoperational safety survey. The DoD reserves the right to
conduct a preoperational survey after contract award of new items with
limited contractor experience, after major new construction or major
modifications, or after an AE mishap. When these situations occur, the
contractor shall notify the ACO, sufficiently in advance, to provide
the Department of Defense the opportunity to schedule and perform a
preoperational survey.
(g) Post-award contractor responsibilities. The contractor shall:
(1) Comply with the requirements of this part and any other safety
requirements contained within the contract.
(2) Develop and implement a demonstrable safety program, including
operational procedures, intended to prevent AE-related mishaps.
(3) Designate qualified individuals to administer and implement
this safety program.
(4) Prepare, and keep available for review, all hazard analyses
used to justify alternative methods of hazards control that differ from
those recommended in this part.
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(5) Provide access to facilities and safety program documentation
to Government safety representatives.
(6) Report and investigate AE mishaps in accordance with Sec.
184.2.
(7) Provide identification and location of subcontractors to the
ACO for notification or approval in accordance with terms of the
contract.
(8) Establish and implement management controls to ensure AE
subcontractors comply with paragraphs (g)(1) through (g)(7) of this
section.
(h) Site and construction plans. (1) Contractors must prepare site
and construction plans for support of the pre-award process, and for
any change in layout or construction potentially affecting Q-D incident
to the contract. Contractors shall also maintain a current site map
depicting Q-D relationships for all AE locations within the facilities.
(2) When the place of performance of the contract is at a DoD-owned
facility, site and construction plans shall be prepared and processed
(content and staffing) in accordance with the requirements of DoD
6055.9-STD, as well as, appropriate military service regulations
contained within the contract.
(3) For contractor-owned, contractor-operated (COCO) facilities,
the contractor shall submit, through the ACO to the PCO, site and
construction plans for all new construction or major modification of
facilities for AE activities and for the facilities that may be exposed
to AE hazards if improperly located. The contractor shall provide
sufficient copies for the review process. The contractor shall not
begin construction or modification of proposed facilities until
receiving site and construction plan approval from the PCO through the
ACO.
(4) Minor new construction, changes, and modifications of existing
AE facilities involving Hazard Class/Division (HC/D) additions and
deletions or that add or remove small portable operating buildings and
magazines may not require formal site plan submission. Minor applies to
all changes that involve only 1.4 HC/D materials. Minor also applies to
changes of other HC/D materials that do not increase the existing
maximum credible event (MCE) for an AE facility or do not extend any
quantity distance arcs beyond existing fragment, inhabited building,
and public traffic route distance arcs for other nearby potential
explosion sites (PES). When the contractor thinks a modification/change
is minor, he shall notify the ACO and request a determination. The ACO
shall make the final determination as to whether a formal site plan
submission is necessary.
(5) Site plans shall comply with the following:
(i) Plans shall include maps and drawings which are legible,
accurate, and of a scale which permits easy determination of essential
details. For general layout of buildings, this is normally a scale of 1
inch to 400 feet (or metric equivalent) or less. Site plans may require
other-scaled drawings, which provide details of construction, structure
relationships within the project area, barricades, or other unique
details. Plans may also include pictures to illustrate details and
videotapes of MCE testing data.
(ii) Maps and drawings shall identify distances between all PESs,
all exposed sites (ESs) within the facility, the facility boundary, any
additional property under contractor control, ESs on adjacent property
when applicable, public railways and highways, power transmission lines
and other utilities.
(iii) Plans shall identify and briefly describe all PESs and all
ESs within any applicable fragmentation distance and/or inhabitable
building distance of a PES. Site plans for major new construction or
modification shall also identify and briefly describe all PESs whose
inhabitable building distance are includes the proposed new or modified
site.
(iv) Plans shall include the maximum net explosive weight(s) (NEW)
and the HC/Ds of all PESs and, when applicable, shall include MCE
information and maximum NEW for each room or bay. Plans shall also
include engineering or test data when substituting construction or
shielding for distance to protect from fragmentation or overpressure.
(v) Plans shall include a topographical map in sufficient detail to
permit evaluation, when the contractor uses natural terrain for
barricading to reduce fragment distance.
(6) Construction plans for proposed facilities shall contain the
information required in paragraphs (h)(5)(i) through (h)(5)(v) of this
section and construction details of dividing walls, venting surfaces,
firewalls, roofs, operational shields, barricades, exits, ventilation
systems and equipment, AE waste disposal systems, lightning protection
systems, grounding systems, processing equipment auxiliary support
structures, and, general materials of construction, as applicable.
Sec. 184.2 Mishap investigation and reporting.
(a) General. This section contains requirements for investigating
and reporting mishaps involving AE.
(b) Reporting criteria. The contractor shall investigate and report
to the ACO and cognizant Defense Contract Management Agency (DCMA)
contract safety specialist all mishaps involving ammunition or
explosives that result in one or more of the following:
(1) One or more fatalities.
(2) One or more lost-work day cases with days away from work as
defined by 29 U.S.C. 651-678.
(3) Five or more non-fatal injuries (with or without lost
workdays).
(4) Damage to government property exceeding $20,000.
(5) Delay in delivery schedule exceeding 24 hours. (This
requirement does not constitute a waiver or amendment of any delivery
schedule required by the contract.).
(6) Contractually required notifications of mishaps other than in
paragraphs (b)(1) through (b)(5) of this section; or
(7) Any mishap that may degrade operational or production
capability, or is likely to arouse media interest.
(c) Mishap investigation requirements. Paragraph (e) of this
section contains the elements of information which a basic
investigation shall produce. Based upon the seriousness of the mishap
and impact on munitions or munitions systems involved, the ACO or PCO
may require an additional, more comprehensive investigation. The PCO
retains the right to participate in contractor investigations, or to
perform an independent DoD investigation. In the event the PCO directs
DoD participation, or an independent DoD investigation, the contractor
shall preserve the mishap scene, taking only those actions necessary to
protect life and health, preclude further damage, or prevent access by
unauthorized persons in order to preserve investigative evidence. The
contractor shall obtain the PCO's permission to disturb the evidence,
with the exception of paragraph (b)(2) of this section. Nothing in the
reporting requirements contained in this part relieve the contractor of
making other notifications required by Federal, State, or local
requirements.
(d) Telephone report. The contractor shall report any mishap
described in paragraph (b) of this section by telephone to the ACO and
cognizant DCMA contract safety specialist as soon as practicable, but
not later than three hours after the mishap.
(e) Written report. (1) The contractor shall submit a written
report to the ACO and cognizant DCMA contract safety specialist by the
end of the second business day after mishap occurrence.
(i) Contractor's name and location.
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(ii) Date, local time, and plant facility/location of the mishap.
(iii) Type of mishap (explosion, fire, loss, other).
(iv) Contract, subcontract, or purchase order.
(v) Item nomenclature, hazard classification, lot number.
(vi) Mishap narrative.
(vii) Number of injuries, fatalities, degree of injuries. (viii)
Description of property damage and cost.
(ix) Quantity of energetic material involved (pounds, units,
rounds).
(x) Probable cause(s).
(xi) Corrective action taken or planned.
(xii) Effect on production.
(xiii) Name, title or position, and phone number of person
submitting the report.
(xiv) Remarks.
(2) The contractor shall provide to the ACO supplemental
information to the initial report within 30 days of mishap occurrence.
(f) Special technical mishap investigations and reports. When
warranted by the circumstances of a mishap, the PCO may require a
special technical investigation conducted by DoD personnel. The PCO may
also direct the contractor to conduct a special technical
investigation. In either case, the investigation report shall provide
details such as fragmentation maps, photographs, more detailed
description of events of the mishap, effects on adjacent operations,
structural and equipment damage, Q-D drawings, detailed description of
occurrence and related events, findings and conclusions. If the
contractor performs the special technical mishap investigation, the
contractor shall forward the report through the ACO to the PCO within
60 days of the direction by the PCO to perform the investigation. Upon
determination by the PCO that a DoD investigation is required, the PCO
will immediately advise the contractor.
Sec. 184.3 General safety requirements.
(a) General. This section provides general safety requirements for
all AE operations addressed in this part. When these practices exceed
or differ from local or national codes or requirements, the more
restrictive shall apply.
(b) Personnel and material limits. (1) Control of all locations or
operations presenting real or potential hazards to personnel, property,
or the environment is essential for safety and efficiency. Control
measures include minimizing the number of personnel exposed, minimizing
the duration of the exposure, and minimizing the amount of hazardous
material consistent with safe and efficient operations.
(2) All buildings, cubicles, cells, rooms, and locations containing
AE shall have AE and personnel limits prominently posted. Include
supervisors, production workers, and transient personnel when
determining personnel limits. Posted personnel limits are not required
in storage magazines, magazine areas, or transfer points.
(3) All buildings, cubicles, cells, rooms or locations containing
AE shall have prominently posted limits for the quantities of AE
permitted. The posted limits shall not exceed the quantity stipulated
in the site plan, and shall accurately reflect current process
requirements. Post AE limits in storage magazines when the limit
differs from that for other magazines in the block, or when
circumstances prevent the limit from being readily apparent. It is not
required to express AE limits in units of weight or in the number of
items. Express limits in terms of trays, boxes, racks, or other units
more easily observed and controlled.
(c) Standard operating procedures (SOP). (1) Clearly written
procedures are essential to avoid operator errors and ensure process
control. Therefore, before commencing manufacturing operations
involving AE, qualified personnel shall develop, review, and approve
written procedures.
(2) Preparation. The contractor shall prepare and implement written
procedures which provide clear instructions for safely conducting AE
activities. The use of controlled tests is an acceptable method for
developing and validating SOPs. SOPs shall include the following:
(i) The specific hazards associated with the process.
(ii) Indicators for identifying abnormal process conditions.
(iii) Emergency procedures for abnormal process conditions or other
conditions which could affect the safety of the process.
(iv) Personal protective clothing and equipment required by process
personnel.
(v) Personnel and AE limits.
(vi) Specific tools permitted for use by the process operator.
(vii) The chronological sequence of job steps the operator is to
follow in performing the work.
(viii) Procedures for disposing of any scrap and waste AE.
(3) Dissemination. Personnel involved with AE processes, and
personnel who maintain AE equipment, shall have written operating
procedures readily accessible.
(4) Training. Personnel shall receive appropriate training before
performing work involving exposure to AE. The training shall include
emphasis on the specific safety and health hazards, emergency
operations including shutdown, and safe work practices applicable to
the employee's job tasks. The contractor shall ascertain that each
employee involved in an AE process has received and understood the
training. The contractor shall prepare a record that contains the
identity of the employee, the date of training, and the means used to
verify that the employee understood the training.
(5) Emergency procedures. The contractor shall instruct employees
on procedures to follow in the event of electrical storms, utility or
mechanical failures, equipment failures, process abnormalities, and
other emergencies occurring during the manufacturing, handling, or
processing of AE.
(6) Revalidation. Qualified personnel shall review SOPs on a
regular basis. The managing authority shall change and validate SOPs as
often as necessary to reflect improved methods, equipment
substitutions, facility modifications, or process revisions.
(d) Storage in operating buildings. (1) The contractor may store
limited quantities of hazardous materials, other than AE materials,
which are essential for current operations in an operating building.
(2) The contractor shall store AE materials that exceed minimum
quantity necessary for sustained operations in a service magazine
located no closer than the intraline distance (ILD) (based on the
quantity in the magazine) from the operating building or area. If ILD
distance is not available for a separate service magazine, the
contractor may designate storage locations within the operating
building. Designated storage locations shall preclude immediate
propagation from the operational location to the storage location. The
quantity of AE material in the internal storage location shall not
exceed that needed for one half of a work shift. The contractor should
consider personnel exposure, structural containment afforded, and the
venting ability of the proposed storage location when determining where
to locate a designated storage location. When storage containers
completely contain all fragments, debris, and overpressure, AE material
may be stored without regard to Q-D requirements.
(3) At the end of the workday, personnel should remove all AE
material from processing equipment and store it in an appropriate
magazine or designated storage location. If operationally required,
personnel may store in-process AE materials in the
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building during non-operating hours provided the physical
characteristics and stability of the AE materials are not degraded, and
the AE material would not compromise the safety of the process
equipment or personnel when the process is restarted.
(4) The contractor may use a separate enclosed room or bay in an
operating building specifically adapted for the interim storage of
production items awaiting the results of testing before final pack-out.
The room or bay must afford the equivalent of service magazine distance
protection to other parts of the building, and ILD to other buildings.
Such a room or bay is limited to its defined and designed function and
items, but is not subject to the four-hour supply limitation for the
building or the ultimate pack-out operation.
(e) Housekeeping in hazardous areas.
(1) The contractor shall keep structures containing AE clean and
orderly.
(2) Explosives and explosive dusts shall not accumulate on
structural members, radiators, heating coils, steam, gas, air or water
supply pipes, or electrical fixtures.
(3) Written procedures shall include instructions for the removal
of spilled material.
(4) Floor cleaning methods shall not create an ignition hazard or
alter the conductive ability of floors in AE areas, nor should they
result in an environmental contamination potential.
(5) Cleaning methods for AE processing equipment shall not result
in any foreign material or AE remaining in the equipment.
(f) Precautions for maintenance and repairs to equipment and
buildings. (1) The contractor shall examine and test all new or
repaired AE processing equipment prior to placing the equipment in
service in order to ensure that it is safe to operate.
(2) Before proceeding with maintenance or repairs to AE processing
equipment, contractor personnel shall decontaminate the equipment to
the degree necessary to perform the work safely. The contractor shall
protect maintenance personnel from the effects of a reaction resulting
from AE material in or on other parts of the equipment. Contractor
personnel shall tag AE processing equipment before proceeding with
repairs. The tag shall identify the decontaminated parts of the
equipment, and those parts that contain AE.
(3) The contractor shall have SOPs for maintenance personnel
performing work on AE equipment or performing building maintenance,
repair, or modification activities in AE areas. The SOPs shall include
a provision for inspecting equipment after maintenance work to ensure
no tools or foreign materials remain in AE equipment. The SOPs shall
identify the specific tools required to perform work on equipment which
may contain explosive residues or areas which could have an explosive
atmosphere.
(4) Before performing any building repair, modification or
maintenance activity, the contractor shall ensure the removal of all AE
materials from areas that may pose a hazard. The contractor shall also
ensure the decontamination of all places where AE material could
accumulate, such as, equipment, crevices, vents, ducts, wall cavities,
pipes and fittings.
(g) Operational shields. (1) The purpose of operational shields is
to prevent propagation of AE material from one AE operation or location
to another, protect facilities and equipment, and provide personnel
protection. Shields used for these purposes require an evaluation to
determine their suitability for their intended purpose. All AE
operations and processes require a hazard assessment prior to work
performance to determine the type of hazard involved, the level of risk
associated with the AE material or item, and the corresponding level of
protection required.
(2) The primary hazards that accompany explosions and deflagrations
are blast overpressure, fragmentation (primary and secondary) and
thermal effects. The hazard assessment shall consider these hazards and
the quantity of AE materials, initiation sensitivity, heat output, rate
of burning, potential ignition and initiation sources, protection
capabilities of shields, various types of protective clothing, fire
protection systems, and the acute and chronic health hazards of vapors
and combustion products on exposed personnel.
(3) When the hazard assessment indicates an unacceptable
probability of explosion or deflagration, conduct operations or
processes remotely. When an analysis of the hazard assessment indicates
the hazards associated with an explosion or deflagration are
controllable by using operational shields, the contractor shall design,
install, and use shields which effectively protect personnel from the
hazards. Shields complying with MIL-STD-398 are acceptable protection.
(4) The contractor shall test operational shields under conditions
that simulate the operational environment. AE materials or items used
in the test shall correspond to those that may be involved in a maximum
credible event (MCE), plus 25 percent. The contractor shall maintain
records of the test that demonstrate the shields will function as
planned. Analysis rather than testing of shields may be acceptable on a
case-by-case basis.
(5) When the doors of AE processing equipment function as
operational shields, interlocking devices are required to prevent the
operator from opening the door while the equipment is in operation.
(h) Protective clothing. (1) All AE operations require a hazard
assessment to determine the need for protective clothing and personal
protective equipment. The assessment shall include an evaluation of all
hazards and factors contained in paragraph (g)(2) of this section.
(2) The contractor shall provide a changing area for employees who
must remove their street clothes to wear protective clothing, such as
explosive plant clothing, anti-contamination clothing, impervious
clothing, and so forth. To avoid exposing personnel not involved in AE
operations to unnecessary risks, employees shall not wear or remove
protective clothing from the premises. Employees shall not wear any
static producing clothing in areas where static electricity is a
hazard.
(3) Explosives plant clothing, generally referred to as powder
uniforms, shall have nonmetallic fasteners and be easily removable.
(4) When sending explosives-contaminated clothing to an off-plant
laundry facility, the contractor is responsible for informing the
laundry of the hazards associated with the contaminants and any special
laundering or disposal requirements.
(i) Material handling equipment. (1) The contractor shall not
refuel gasoline, diesel or liquefied petroleum gas (LPG) powered
equipment inside buildings containing AE. Refueling shall take place at
least 100 feet from structures or sites containing AE. Doors and
windows through which vapors may enter the building shall not be open
during refueling. Position refueling vehicles at least 100 feet from
structures or sites containing AE during refueling.
(2) Gasoline-, diesel- or LPG-powered equipment shall not be stored
in buildings, loading docks, or piers containing AE. The contractor
shall store gasoline-, diesel-, and LPG-powered equipment at the
appropriate fire protection distance from buildings containing AE.
(3) Gasoline, diesel, and LPG powered equipment shall have spark
arrestors. The contractor shall perform and document inspections of the
exhaust and electrical systems of the equipment
[[Page 16043]]
as necessary to ensure that the systems are functioning within the
manufacture's specifications. The contractor shall maintain
documentation of the inspections for a period of one year.
(j) Parking of privately owned vehicles. (1) Control of parking of
privately owned vehicles within an AE establishment minimizes fire and
explosion hazards and prevents congestion in an emergency.
(2) Parking lots serving multiple PESs shall not be closer than the
ILD from each PES. Parking lots serving a single PES shall not be
closer than 100 feet to the associated facility to protect it from
vehicle fires, and shall be at least public traffic route distance from
unassociated PESs. Parking lots for administration areas shall be
located at public traffic route distance from all PESs.
(3) Vehicles shall not obstruct access to buildings by emergency
equipment or personnel.
(k) Ignition sources in hazardous areas. The contractor shall not
permit any nonessential ignition sources in operating buildings.
(l) Operational explosives containers. (1) Containers shall be
compatible with the material they contain.
(2) Containers used for intraplant transportation or storage of
process explosives and energetic materials shall not leak. Because of
their fragility and potential for fragmentation, glass containers are
not acceptable.
(m) Intraplant rail transportation. (1) The contractor shall
develop written procedures to ensure safe and efficient rail movement
of AE. The SOPs shall include information covering the inspection of
the engine, car mover, and cars, normal and emergency operating
procedures for the engine and car mover, AE loading and unloading
procedures, and emergency procedures including fire fighting.
(2) Railcars positioned for loading shall have their brakes engaged
to prevent movement. Contractor personnel shall inspect each railcar
before loading to ensure it is suitable to carry the specific AE cargo.
Contractor personnel shall check the cargo to ensure it is stable and
secure, and close the railcar doors before car movement. If using an
engine to move railcars, the contractor shall ensure that personnel
have connected the air brakes of the railcars in sequence to the
engine. If moving a railcar with a car mover the contractor shall
station an individual at the hand brake of the railcar.
(3) A single parked railcar shall have the hand brakes set and the
wheels chocked. When more than one railcar is parked, personnel shall
set hand brakes on enough railcars to ensure the cars will not move.
Personnel shall set hand brakes on the downgrade end of a group of
parked railcars. Do not rely on the automatic air brakes to hold parked
railcars.
(4) Contractor personnel shall avoid rough handling of railcars.
Personnel shall not disconnect railcars containing AE from each other
or a locomotive while in motion. Personnel shall couple railcars gently
in order to avoid damaging the AE cargo or shipping containers.
Disconnected railcars shall not strike railcars containing AE.
(5) The contractor shall maintain all rolling stock used for
intraplant transportation of AE in a safe and good working condition.
(6) Portable transmitters and railroad locomotives equipped with
two-way radios shall not transmit when passing AE operating buildings
where electro-explosive devices are in use. The contractor shall
determine minimum safe distances based on radio frequency and power
output of the transmitter.
(n) Intraplant motor vehicle transportation of AE. (1) The
contractor shall develop written procedures for the safe transportation
of AE in motor vehicles. The SOP shall include procedures for vehicle
inspection, vehicle operation, loading and unloading AE materials, and
emergency procedures, including fire fighting.
(2) The operator responsible for transporting AE material shall
perform a daily inspection of the vehicle before transporting
materials. The operator shall verify that the fire extinguisher is
charged and in working order, there are no fuels or other fluid leaks,
and that brakes, tires, steering, and other equipment are in good
operating condition. Before transporting AE, the operator shall inspect
the cargo compartment to ensure it does not contain any residual AE
material or any object which could present a hazard to the cargo.
(3) When loading or unloading AE, the operator shall shutoff the
vehicle's engine, unless the engine is required to provide power to
equipment for loading or unloading. The operator shall engage the
emergency brake and use wheel chocks when the vehicle could move during
loading or unloading. The operator shall stabilize and ensure the load
is secure to prevent damage to containers or their contents. The
operator shall not transport AE material in the passenger compartment
of the vehicle.
(4) The vehicle operator shall understand and follow established
procedures involving a vehicle fire, breakdown, accident, damaged or
leaking containers, and spilled material.
(5) Transportation containers shall not allow the contents to leak
or spill in transit.
(6) Non-sparking material shall cover the cargo compartment when
transporting AE in containers capable of exposing their contents if
damaged.
(7) Motor vehicles transporting AE within the establishment
boundaries but outside the AE area shall bear at least two placards.
Placards based on the fire division symbols discussed in Sec. 184.10,
``Fire Protection,'' are acceptable. Motor vehicles or equipment with
internal combustion engines, used near explosives scrap, waste, or
items contaminated with explosives shall have exhaust system spark
arresters and carburetor flame arresters (authorized air cleaners).
(8) The contractor shall maintain vehicles and material handling
equipment used to load and transport AE in a safe operating condition.
(9) Batteries and wiring shall be located to prevent contact with
containers of AE material.
(o) Inspection of AE mixing equipment. (1) The contractor shall
establish a preventative maintenance program which includes the
inspection of all AE mixing equipment on a periodic basis. The SOP for
the inspection shall include criteria for inspecting the blades to bowl
clearances, alignment of the blades and bowl, and detection of any
distortion of the blades or bowl. The inspection procedures shall also
include instructions for checking critical drive system components for
wear, damage or misalignment. The procedures shall include criteria for
determining that associated equipment used to control the mixer is
functioning as designed. The contractor shall maintain a record of all
inspections. After performing maintenance of the equipment, the
contractor shall run the equipment under load to ensure it is safe to
operate.
(2) The SOPs for operating mixing equipment shall include
instructions for inspecting specific equipment components before each
use.
(p) Facility requirements. (1) Buildings. The design, construction
techniques, process layout, and siting of AE buildings are important
considerations in explosives safety and directly influence quantity
distance (Q-D) requirements and the degree of exposure to personnel,
equipment, and facilities. Construction features which limit the amount
of explosives involved, attenuate the resulting blast overpressure or
thermal radiation, and reduce the quantity and range of
[[Page 16044]]
hazardous fragments and debris will help to minimize the effects of an
explosion. Incorporating Q-D criteria, when locating an exposed site
(ES) in relation to a potential explosive site (PES), will reduce the
amount of damage and injuries in the event of an incident.
(2) Building exteriors. The contractor should design and erect AE
buildings with the ability to allow for the venting of an internal
explosion without collapsing. The use of lightweight materials in
exterior wall and roof sections designed to vent the effects of an
explosion will help reduce the number of large fragments. Exceptions
from using lightweight materials include earth-covered magazines,
containment type structures, firewalls, substantial dividing walls,
special roof loadings, and walls and roofs used for external
overpressure protection. Non-combustible exterior wall and roof
coverings of operating buildings help prevent the spread of fire from
one area of a building to another and from building to building.
(3) Interior walls, roofs, and ceilings. (i) Non-combustible
material is preferred for the interior surfaces of buildings. The
contractor should treat or cover exposed combustion supporting building
materials with fire retardant material.
(ii) Where hazardous locations exist, interior surfaces shall be
smooth, free from cracks, crevices and openings which may create a
hazardous condition. This is important to prevent the accumulation or
migration of explosive dust and vapors which could result in an
incident. The National Fire Protection Association (NFPA), Standard 70
\2\ provides criteria for determining if a location is hazardous.
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\2\ Obtain NFPA publications from the National Fire Protection
Association at http://www.nfpa.org/catalog/home/index.asp.
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(iii) The contractor should use hard gloss, easily cleanable, paint
on painted surfaces.
(iv) Periodically clean any surface where explosive dust could
accumulate. Establish cleaning schedules on information obtained from
the job hazard analysis.
(v) Do not use suspended ceilings in hazardous locations.
(4) Floors and work surfaces. (i) Locations where exposed
explosives or hazardous concentrations of flammable vapor or gas are
present require non-sparking floors and work surfaces.
(ii) Sec. 184.12 provides requirements for conductive non-sparking
floors and work surfaces.
(iii) Floors and work surfaces require periodic cleaning to prevent
the accumulation of energetic materials. In addition, all conductive
and non-sparking floors and work surfaces require preventative
maintenance to ensure their functional integrity.
(5) Substantial dividing walls. The contractor shall design and
construct substantial dividing walls to prevent simultaneous detonation
of explosives on opposite sides of the wall. The design and
construction shall meet the criteria contained in Army TM 5-1300, Navy
NAVFAC P-397, or Air Force AFR 88-22 (different designations for the
same publication).
(6) Exits and doors. (i) All AE buildings require adequate exits
and doors. NFPA Standard No. 101, ``Life Safety Code,'' provides
information concerning exits and doors.
(ii) NFPA Standard No. 80, ``Standard for Fire Doors, Fire
Windows,'' provides information on the selection and installation of
fire doors and windows.
(iii) No AE hazards shall occupy space between an operator and an
exit.
(7) Safety chutes. Multi-storied locations where rapid egress is
vital and not otherwise possible require safety chutes.
(8) Passageways. (i) Weather-protected passageways and ramps for
travel between buildings or magazines should include features to help
prevent fire from spreading from one building to another. Fireproof
construction materials, fire stops, fire doors, and fire suppression
systems aid in preventing the spread of fire.
(ii) The incorporation of weak sections, openings, or abrupt change
in direction of passageways will aid in the prevention of funneling the
explosion forces from one building to another.
(9) Roads and walkways. (i) Only roads servicing a single magazine
or AE processing building, including its service facilities, may dead
end at the magazine or building.
(ii) Hard surfaced roads and walkways at the entrances to or
between adjacent operating buildings containing AE will help reduce the
amount of foreign material tracked into the building by personnel.
(iii) Avoid a road system which requires personnel to pass through
an AE area when traveling from one area to another.
(10) Windows and skylights. (i) Inhabited building distances do not
protect against glass breakage and the hazards of flying glass.
Buildings separated by inhabited building distance should not have
windows or other glass surfaces exposed to PESs.
(ii) Minimize personnel hazards from glass breakage by means such
as building orientation and/or keeping the number of exposed glass
panels and panel size to a minimum. When window panels are necessary
and risk assessment determines a glass hazard will be present, blast
resistant windows must be used. The framing and/or sash of such panels
must be of sufficient strength to retain the panel in the structure.
(11) Hardware. (i) AE operations and hazardous locations require an
evaluation to determine the safest type of hardware and fasteners to
use in order to reduce the risk of an accidental ignition. Consider
using non-sparking hardware and fasteners if they will meet the design
parameters of the intended application. Depending on the potential
hazard, a locking device or some other installation technique shall
retain the hardware and fasteners securely in place. This will prevent
the hardware and fasteners from becoming loose, entering process
equipment and creating a spark or pinch point.
(ii) The contractor should avoid installing hardware, pipes, ducts,
and other items on blowout panels in order to prevent the materials
from becoming secondary fragments. If it is necessary to install items
on blowout panels, select items made of materials which will not yield
heavy fragments in an explosion.
(12) Ventilation systems. (i) Well-designed ventilation systems
reduce personnel exposures to airborne contaminants and prevent the
accumulation of flammable or explosive concentrations of gases, vapors
or dusts. A local ventilation system, which removes the gases, vapors,
or dusts at the source, is more effective than a general ventilation
system.
(ii) A ventilation system is required in areas of buildings
generating potentially explosive dusts, gases or vapors. Testing,
inspection, and maintenance of ventilation systems used for contaminant
control require documentation.
(iii) Exhaust fans through which combustible dust or flammable
vapor pass shall have nonferrous blades or a casing lined with
nonferrous material. The electrical wiring and equipment of the system
should comply with provisions of NFPA Standard No. 70, ``National
Electrical Code''. Bonding and grounding of the entire system is
required.
(iv) A slight negative pressure is required in rooms where AE
operations generate explosive dust.
(v) NFPA Standard No. 91, ``Standard for Exhaust Systems for Air
Conveying of Vapors, Gases, Mists, and Noncombustible Particulate
Solids,'' provides standards for exhaust systems.
[[Page 16045]]
(13) Steam for processing and heating. (i) Steam used to heat
buildings containing explosives shall not exceed 228 [deg]F (108.9
[deg]C) or have a pressure greater than 5 psi (34.48 kPa).
(ii) Process steam shall not exceed 249.5 [deg]F (120.8 [deg]C), or
exceed 15 psi (103.43 kPa). Steam pressure greater than 15 psi (103.43
kPa) requires procuring contracting officer (PCO) approval.
(iii) The surface temperature of steam and hot water pipes in
contact with combustible materials shall not exceed 160 [deg]F (71
[deg]C). Pipes with an ambient temperature greater than 160 [deg]F (71
[deg]C) shall not contact combustible materials. An insulating pipe
covering capable of reducing the surface temperature of the covering to
160 [deg]F (71 [deg]C) or less is acceptable.
(iv) In AE handling or storage locations where resistance to ground
is high, ground steam and hot water lines where they enter the
building.
(v) When using a reducing valve, consider installing a relief valve
on the low-pressure piping. The throttling action of reducing valves
requires a positive means to prevent the production of superheated
steam.
(14) Tunnels. Tunnels between buildings that contain AE shall
incorporate features that resist the shock wave of an explosion. This
is important in order to minimize the possibility of an explosion in
one building from affecting the operations in the other building. For
further information on tunnels go to DoD 6055.9-STD.\3\
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\3\ See footnote 1 to Sec. 184.1(d)(1).
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(q) Quantity-distance (Q-D) requirements. (1) Minimum Q-D
requirements are contained in DoD 6055.9-STD, DoD Ammunition and
Explosives Safety Standards.
(2) For AE work involving an MCE of 0.25 kg (0.55 lbs) or less of
HD 1.1 materials, the use of the separation distances listed in Table 1
to Sec. 184.3 are acceptable for meeting minimum Q-D requirements.
Table 1 to Sec. 184.3.--Minimum Q-D Requirements for Small Quantities of Hazard Division 1.1 Material
----------------------------------------------------------------------------------------------------------------
Inhabited building and Public traffic route Intraline and fragment
Net explosive weight fragment distance and fragment distance distance
----------------------------------------------------------------------------------------------------------------
Less than 0.003 kg (0.0066 lb)....... 0...................... 0...................... 0.
0.003 kg-0.01 kg (0.0066 lb-0.022 lb) 5 m (16.5 ft).......... 3 m (9.9 ft)........... 2 m (6.6 ft).
0.01 kg-0.25 kg (0.022 lb-0.55 lb)... 15 m (49.5 ft)......... 9 m (29.7 ft).......... 5 m (16.5 ft).
----------------------------------------------------------------------------------------------------------------
Sec. 184.4 Quantity-distance and siting.
Refer to DoD 6055.9, Chapter 9 for guidance.
Sec. 184.5 Hazard classification, storage principles, and
compatibility groups.
Please refer to DoD 6055.9, Chapter 3 for guidance.
Sec. 184.6. Electrical safety requirements for AE facilities.
(a) General. Initiation systems often use the controlled input of
electrical energy to initiate explosive mixtures and compounds, which
start an explosive train. The uncontrolled release of electrical energy
in explosive atmospheres or near explosives and explosive-loaded
articles can result in unintended initiation and serious mishaps.
Electrical energy manifests itself in many forms (e.g., standard
electrical installations, lightning, electrostatic discharge,
electrical testing) and with various intensities which require special
precautions. This chapter contains minimum electrical safety
requirements for existing, new, or modified explosives facilities and
equipment.
(b) Electrical installations. (1) National Fire Protection
Association (NFPA) Standard No. 70 and this section are minimum
requirements for areas containing explosives. NFPA Standard No. 70 does
not specifically address explosives, but it does establish standards
for the design and installation of electrical equipment and wiring in
atmospheres containing combustible dusts and flammable vapors and
gasses which, in general, are comparably hazardous. NFPA Standard No.
70 (Article 500) defines ``hazardous locations'' according to the
hazard presented by electrical equipment installed in environments
where flammable gases or vapors, combustible dusts or flyings may
exist. The presence of AE may or may not result in rating a particular
location as a ``hazardous location.'' The following exceptions shall be
used by DoD contractors when applying the NFPA Standard No. 70
definitions of Class I, Division 1, and Class II, Division 1 hazardous
locations:
(i) Classify areas containing explosive dusts or explosive
substances which may produce dust capable of suspension in the
atmosphere as Class II, Division 1 hazardous locations.
(ii) Classify areas where explosive sublimation or condensation may
occur as both Class I Division 1 and Class II Division 1 hazardous
locations.
(iii) Exceptions are extraordinarily hazardous explosive
substances, such as nitroglycerin (NG), which require special
consideration, including physical isolation from electric motors,
devices, lighting fixtures and the like.
(2) Multiple classifications. In some potential explosion sites
(PES) (e.g., powder blending with solvents), hazards resulting from
both dusts and flammable vapors may exist. In these cases, it is
necessary for that area to have a dual, or multiple, classification.
Use only electrical equipment listed by Underwriters Laboratories (UL)
or other recognized testing laboratory as suitable for use in all
classes of hazardous locations.
(3) Change of classification. The specific processes performed in
operating buildings and magazines dictate the requirements for
electrical equipment installation. If functions performed in the
facility change, responsible personnel shall inspect, approve, or
reclassify the hazardous locations.
(4) Alternate power source. Facilities shall have an alternate
power source for special processes and operations requiring a
continuous supply of power, whenever the loss of power will result in a
more hazardous condition.
(5) Portable engine-driven generators. The exposed, non-current-
carrying, metallic frame and parts shall be electrically grounded. In
addition, observe the following requirements when supplying power to
magazines or explosives operating facilities.
(i) Place generating units at least 50 ft (15.2 m) from magazines
or hazardous (classified) locations.
(ii) Keep the ground area between and around the generator and the
NFPA Standard No. 70 hazardous (classified) location clear of debris
and other combustible materials.
(iii) The exhaust from the generator shall not impinge on grass or
any other combustible material.
(iv) Position the power cord connecting the generator to the load
to
[[Page 16046]]
prevent trucks or personnel from running over or otherwise damaging the
cord.
(v) Do not use cable-to-cable splices within a magazine, explosive
operating facility, or other NFPA Standard No. 70 hazardous
(classified) location. Use only three-wire, three-prong, approved
service type plugs and connectors.
(vi) Refer to Sec. 184.3(i)(1) for refueling procedures.
(6) Electric supply systems. Electrical and explosives hazards may
mutually exist when PES are in close proximity to electric supply
lines. To protect these hazards from each other, the following
separation requirements shall apply:
(i) Separate overhead service lines from a PES of combustible
construction or a PES in the open by the distance between the poles or
towers supporting the lines, unless an effective means is provided to
ensure that energized lines cannot contact the facility or its
appurtenances if they are severed. Four acceptable alternatives are
cable trays and messenger lines, a ground-fault circuit-interrupter
which causes a disconnecting means to open all ungrounded conductors of
the faulted circuit, weighted triangle line separators or similar
weights which ensure broken lines fall straight down away from PES, and
constructed physical barriers.
(ii) Separate electric distribution lines carrying less than 69 kV,
the tower or poles supporting those lines, and unmanned electrical
substations from PES by public traffic route distance (PTRD).
(iii) Separate electric transmission lines carrying 69 kV or more
and the tower or poles supporting them from PES by:
(A) Inhabited building distance (IBD) if the line in question is
part of a grid system serving a large area off the establishment.
(B) PTRD if loss of the line does not create serious social or
economic hardships. (Note: Base PTRD and IBD on airblast overpressure
only. Fragment distances shall not apply.)
(C) Distances in accordance with paragraph (b)(6)(1) of this
section when the line(s) in question can be interrupted without loss of
power (i.e., other lines or networks exist for rerouting power).
(iv) Avoid locating permanent electric installations in NFPA
Standard No. 70 Class I or Class II hazardous locations. When practical
operating reasons prevent locating permanent electrical installations
outside of hazardous locations, or require the use of portable
electrical equipment (e.g., lighting equipment) in hazardous locations,
contractors shall only install or use electrical equipment approved for
the National Electric Code (NEC) defined ``hazardous location'' and
listed by Underwriters Laboratories (UL) or other nationally recognized
testing agencies.
(c) Primary electric supply. The primary electric supply to an
entire explosives area should be arranged to allow cutting off the
supply by remote switches located at one or more central points away
from the area.
(d) Ventilation. Equip exhaust fans, through which combustible dust
or flammable vapor pass, with nonferrous blades, or line the casing
with nonferrous material. Motors shall meet the proper NEC class for
the hazard (NFPA Standard No. 70). Clean and service exhaust systems on
a regular schedule. Bond and ground the entire system.
(e) Lightning protection. When lightning protection systems are
installed, the installation, inspection, and maintenance shall comply
with the NFPA Standard No. 780, at a minimum. Typically, six month
visual tests and 24-month electrical tests of installed systems are
acceptable.
(f) Static electricity and grounding. (1) Two unlike materials (at
least one of which is non-conductive) produce static electricity due to
contact and separation. Contact creates a redistribution of charge
across the area of contact and establishes an attractive force.
Separation of the materials overcomes these attractive forces and sets
up an electrostatic field between the two surfaces. If no conducting
path is available to allow the charges to equalize on the surfaces, the
voltage difference between the surfaces can easily reach several
thousand volts as they separate.
(2) The potential hazard of static electricity arises when an
accumulated electrical charge subsequently discharges as a spark in the
presence of hazardous atmospheres, flammable vapors, dusts, exposed
sensitive explosives, or electro-explosive device (EED). Electrostatic
discharge (ESD) does not present a substantial hazard during the
handling of most bulk explosive substances if the explosives are in
approved containers. It also does not present a hazard near explosives
totally contained and unexposed within loaded articles. It is not
possible to prevent the generation of static electricity entirely.
Elimination of potential ESD hazards requires proper grounding to
dissipate static charges before they accumulate to dangerous levels.
The NFPA, UL and the U.S. Department of Commerce publish detailed
discussions of the hazards of static electricity and ways of reducing
it. Where static spark discharge may be hazardous, NFPA Standard No.
77, shall apply, except as otherwise specified.
(3) Static ground system. A static ground system consists of one or
more electrodes in contact with the earth and a conductor (i.e., metal
wire) bonded to the electrode and routed throughout the protected
facility. The static ground system may use building structural steel
(unless structural steel is used as lightning protection down
conductor), metallic water pipes, ground cones, buried copper plates,
and rods driven into the earth as electrodes. The ground system shall
not use gas, steam, or air lines, dry pipe sprinkler systems, or air
terminals and down conductors of lightning protection systems as earth
electrodes. A static ground system provides a conductive path to earth
from conductive floors, conductive work surfaces, and AE equipment and
allows any generated static charges to dissipate.
(4) Testing equipment grounds. Trained personnel shall test ground
systems after installation, after repairs, and at locally determined
intervals and shall keep all records. Remove all exposed explosive or
hazardous materials from the room or area before testing. The
resistance of the electrode to earth shall not exceed 25 ohms. The
electrical resistance from any point on the conductor to the electrode
shall not exceed 1 ohm. The ground system design shall provide for
interconnecting all ground electrodes of structures equipped with a
lightning protection system.
(5) Grounding of equipment. Contractor maintenance personnel shall
bond all AE equipment (e.g., mixers, grinding mills, screening and
sifting devices, assembly and disassembly machines, conveyors,
elevators, steel work tables, presses, hoppers) to the ground system
wherever ESD presents an ignition hazard. The resistance of the AE
equipment to the grounding system shall not exceed 1 ohm. Trained
personnel shall test this resistance initially at installation and at
least semiannually thereafter, and shall keep all records. Exclude the
resistance of conductive belting when testing for resistance of belt-
driven machinery to the ground system. Bonding straps shall bridge
contact points where oil, paint, or rust could disrupt electrical
continuity. Permanent equipment in contact with conductive floors or
tabletops does not meet the bonding requirement to the ground system.
Maintain compatibility of metallic bonding and grounding cables,
straps, or clamps with the explosives involved in the process.
[[Page 16047]]
(6) Belts. Use conductive belting wherever ESD is an ignition
hazard. The resistance of conductive conveyor belts shall not exceed
one million ohms as measured between two electrodes placed on the belt
and as measured between an electrode placed on the conductive conveyor
belt and an electrode attached to the ground system. Do not use static
combs to drain off static charges generated from belts or pulleys used
in hazardous locations.
(g) Conductive floors, tabletops, and footwear. Contractors shall
use conductive tabletops and, shall use conductive floors and
conductive shoes for grounding personnel at operations involving
exposed explosives with electrostatic sensitivity of 0.1 J or less
(e.g., primer, initiator, detonator, igniter, tracer, and incendiary
mixtures). Bonding wires or straps shall connect the tabletops and
floors to the static ground system. Materials sensitive to initiation
by ESD sparks include lead styphnate, lead azide, mercury fulminate,
tetrazene, diazodinitrophenol, potassium chlorate-lead styphanate
mixtures, igniter compositions, grade B magnesium powder, and exposed
layers of black powder dust. Dust from solid propellants can be ignited
from spark energy, making conductive floors and shoes necessary where
such dust is present. Air and dust mixtures of ammonium picrate,
tetryl, tetrytol, and solid propellants are also sensitive to
initiation by ESD. Testing indicates mixtures of air with vapors from
many flammable liquids (e.g., ethyl ether, ethyl alcohol, ethyl
acetate, acetone, and gasoline) may ignite by ESD from the human body.
Therefore, contractors shall equip areas where personnel might contact
these kinds of explosives or with conductive floors and tabletops,
except when hazard analysis indicates adequate housekeeping, dust
collection, ventilation, or solvent recovery methods eliminate the
ignition hazard.
(1) Unless hazard analyses indicate otherwise, conductive
tabletops, floors, and shoes shall also protect operations involving
the following:
(i) Unpackaged detonators and primers and electro-explosive
devices.
(ii) Electrically initiated items, such as rockets, with exposed
circuit and
(iii) Hazardous materials capable of initiation by ESD from the
human body.
(2) When a hazard remains localized, the contractor may use
conductive mats or runners instead of conductive floors throughout an
entire building or room. These mats and runners shall meet all the
specifications and test requirements that apply to conductive floors.
When justified by hazard analysis, contractors may use conductive wrist
straps in place of conductive floors and shoes for grounding personnel
at small scale and isolated operations. When using wrist straps,
operators shall test wrist straps before each use (whenever removed and
re-worn) and record test results. The resistance of the wrist strap
while the operator is wearing the strap shall fall within a range of
25,000 ohms (minimum) and 1,200,000 ohms (maximum) when measured from
opposite hand to ground. Use test equipment capable of testing
1,200,000 ohms + 10%. (Note: Operators with dry skin may use special
contact creams to decrease the resistance to the required value.)
(3) Conductive floor and tabletop specifications. Conductive floors
and tabletops, made of, or covered with non-sparking materials such as
lead, conductive rubber, or conductive compositions, shall meet the
following requirements:
(i) Provide a continuous electrical path to the static ground
system and the electrical resistance shall not to exceed the limits
specified in paragraph (g)(5)(i) of this section.
(ii) Provide a reasonably smooth surface which is free from cracks.
and
(iii) Maintain compatibility of conductive floor and tabletop
materials with the energetic materials present.
(4) Conductive footwear. Operators shall wear conductive shoes in
areas requiring conductive mats, floors, or runners. Personnel visiting
such areas shall wear conductive shoes, ankle straps, or similar
devices, one on each leg. Prominent markings should identify conductive
shoes to help supervisors ensure personnel compliance. Personnel
required to work on electrical equipment in areas where conductive
floors are installed shall not wear conductive shoes and shall not
begin work until operators remove all AE.
(5) Testing conductive footwear, floors, and tabletops. (i) Test
criteria. The maximum resistance of a body, plus the resistance of the
conductive shoes, plus the resistance of the floor to the ground system
shall not exceed 1 million ohms total. That is, if 500,000 ohms is the
maximum resistance allowed from the floor to the ground system, then
500,000 ohms is the maximum combined resistance allowed for the
person's body plus the resistance of the conductive shoes (i.e.,
500,000 + 500,000 does not exceed 1 million). The contractor can set
the maximum resistance limits for the floor to the ground system and
for the combined resistance of a person's body plus the shoes, as long
as the total resistance does not exceed 1 million ohms.
(ii) To protect against electrocution, the minimum resistance of
the floor to the ground system and the minimum resistance of the
tabletop to the ground system shall exceed 11,000 ohms in areas with
110 volts service and 22,000 ohms in areas with 220 volts service. A
ground fault interrupt (GFI) circuit also meets this requirement.
(iii) Tabletop test criteria. The maximum resistance of conductive
tabletops to the ground system shall not exceed 1 million ohms.
(iv) Conductive footwear. All personnel shall test conductive
footwear daily before use to ensure that the combined resistance of the
person's body and the conductive shoes do not exceed the limit
specified in paragraph (g)(5)(i) of this section. Supervisors shall
keep documentation of all test results, including calibration of test
equipment. The test voltage of the shoe tester shall not exceed 500
volts. The short circuit current across the shoe tester electrodes
(plates) should be limited between 0.5 ma and 2.0 ma. The design of the
test instrument shall include built-in safeguards to prevent the test
subject from experiencing electric shock. Personnel shall not test
shoes in rooms or areas with exposed explosives or flammable gas
mixtures. Personnel shall not wear static generating stockings such as
silk, wool, and synthetics; and shall not use foot powders, which have
a drying action which can increase resistance. Dirt and grit increase
resistance of conductive shoes. Personnel should avoid wearing
conductive shoes outdoors and shall keep shoes clean.
(v) Trained personnel shall test conductive floors and tabletops
upon installation and at least annually thereafter using test equipment
specifically designed for this purpose and shall keep records of all
test results for at least five years. Testing shall proceed only when
the room or area is free from exposed explosives and flammable gas
mixtures. The test procedure shall measure the resistance of the floor
between an electrode attached to the ground system and an electrode
placed at any point on the floor or tabletop and also as measured
between two electrodes placed 3 ft (1 m) apart at any points on the
floor or tabletop. Each electrode shall weigh 5 lb (2.3 kg) and shall
have a dry, flat, circular contact area diameter of 2.5 in (64 mm). The
contact area shall have a surface of aluminum or tin foil which is
0.0005 in to 0.001 in (0.013 mm to 0.025 mm) thick and is backed by a
layer of rubber 0.25 in (6.4 mm) thick. The surface hardness shall
measure between 40 and 60 Shore A when measured by
[[Page 16048]]
a Shore Type A Durometer (see American Society for Testing and
Materials (ASTM) D-2240-68, Institute of Electrical and Electronics
Engineers (IEEE) Standard 14 and NFPA Standard No. 99. Make both
electrode-to-electrode and electrode-to-ground system measurements at
five or more locations in each room with at least two of the points in
heavily trafficked areas. If the resistance measurement changes
appreciably with time, record the resistance at the 5-second interval.
To prevent biased measurements, locate the electrodes for both the
electrode-to-electrode and electrode-to-ground measurements a minimum
of 3 ft (1 m) away from an earth ground or other grounded items such as
a door frame, ordnance handling equipment, or any grounded item resting
on a conductive floor. (Note: The size of the floor or tabletop may
make it impractical to conduct five surface resistance (electrode-to-
electrode) or resistance-to-ground measurements and still remain 3 ft
(1 m) away from all grounded items. In such cases, take enough
measurements to ensure adequate testing of all parts of the conductive
surface and document the justification for a reduced number of
electrode-to-electrode or electrode-to-ground measurements in the
grounding system test plan.) Only trained personnel shall operate and
maintain test instruments.
(h) Handling low-energy initiators. Supplement typical precautions,
such as shielding and safety glasses, with the following measures, as
appropriate, when manufacturing, processing, using, or testing low-
energy initiators initiated by 0.1 J of energy or less.
(1) Electrically bond and ground all metal parts of equipment.
(2) Ensure personnel wear clothing which prevents generation of
static electricity. Test conductive shoes with a resistance meter
before entering an area where low-energy initiators are being
processed.
(3) When low-energy initiators are being handled, ground personnel
directly by wrist straps. The acceptable resistance reading, taken once
daily when the operator is wearing the strap, shall be between 250,000
and one million ohms when measured from opposite hand to ground.
Special contact creams may be used to decrease the resistance to the
required value.
(4) Periodically coat glass, acrylic, or polycarbonate materials
required for transparent shielding with an anti-static material to
prevent buildup of static electricity, when static sensitivity is
indicated to be a hazard.
(5) The sounding of a static electricity alarm, installed with the
setting best able to provide ample warning, signals a work stoppage
until the problem has been located and corrective action taken.
(6) Check relative humidity and temperature before starting
operations and throughout the workday where such conditions are used to
mitigate or prevent safety problems (i.e., hydroscopicity or static
control).
(7) Do not paint metal surfaces subjected to rubbing or friction.
If a lubricant is necessary, use a composition which allows the metal's
surface resistance to remain at or below 25 ohms.
(8) Work on or with low-energy initiators only in areas equipped
with conductive floors and table tops. Exceptions may be made when the
initiators are in their original packaging, or are part of a finished
metallic end item affording them complete protection from
electromagnetic or electrostatic energy.
(9) Do not work in the vicinity of actual or potential
electromagnetic or electrostatic fields (e.g., radio transmission,
electrical storms, transformer stations, high voltage transmission
lines, improperly grounded electric circuitry, rotating equipment,
belts, etc.). Establish adequate lightning protection and grounding and
adequate resistances for fixed sources of energy for locations with
low-energy initiator operations. Shield these areas to afford
protection against local mobile radio transmission.
(10) Locate electrical equipment out of the range of an operator
working with a low-energy initiator. With soldering irons, it may be
advisable to ground and limit energy to levels below initiating
thresholds.
(11) When not part of an end item or end item subassembly,
transport initiators only when packed according to the latest packing
specifications for low-energy initiators.
(i) Electrical test equipment. Use the lowest possible power source
for all electrical and electronics test equipment. When possible, use
batteries in lieu of 110 Vac power sources. During testing, do not use
power sources capable of initiating the AE. When test specifications
require using electrical energy at or above the initiating threshold
level of explosive devices, use test chambers or provide shielding
capable of containing all hazards and apply energy remotely. Provide
safeguards against the possibility of human error.
(j) Humidification and ionization. (1) Humidification which
maintains relative humidity above 60 percent effectively prevents
static electricity accumulations and subsequent discharges. This
technique involves pre-operational checks and regular monitoring of the
humidity levels throughout the day. Do not use humidification with
metallic powders unless hazard analysis indicates the powders are not
susceptible to spontaneous ignition in air with 60 percent relative
humidity.
(2) Ionization is electrical neutralization and serves as an
effective method of removing static charges from certain processes and
operations. Methods of application can be found in NFPA Standard 77.
(3) Contractors may use ionization or humidification to augment
their ESD control program but, may not use them in lieu of conductive
floors and footwear (where required).
Sec. 184.7 Manufacturing and processing propellants.
(a) General. (1) These requirements apply to propellant
manufacturing and augment other requirements contained in this part.
(2) The safety precautions for fabrication of propellants,
propellant loaded items, gun ammunition, and rocket motors follow the
generally accepted principles used for many types of explosives and
energetic materials. Solid propellants can be divided into general
categories such as single, double, and triple base, castable composite,
and modified double base composite. (e.g., castable composite
propellant modified with explosive plasticizer such as nitroglycerin).
Liquid propellants include a wide range of liquid fuels, liquid
oxidizers and fuel-oxidizer monopropellants.
(3) Although processing safety considerations for finished
propellant AE and loaded rocket motors are similar, each propellant
type has its own characteristics for processing of raw materials,
intermediate compositions, and final processing. Hazards data for
intermediate and finished propellant can help to define the
requirements that ensure safety in processing. Hazards data includes
initiation thresholds to such stimuli as impact, friction, heat, and
electrostatic discharge for specific processes and handling situations.
In evaluating and properly applying the guidelines of this chapter,
consider the response of the materials in terms of energy input
sensitivity and magnitude of energy release. Follow the general
requirements for manufacturing and processing of pyrotechnics given in
Chapter 8 for safety precautions for ignition system fabrication.
(Note: An exception to this requirement is processing of a
[[Page 16049]]
propellant grain igniter the same as motor propellant until the grain
is mated with the initiator assembly.)
(4) In addition to generally accepted safety precautions for
handling of explosives and other energetic materials, the following
paragraphs provide general guidance pertinent to the manufacturing of
propellants, propellant loaded items, gun ammunition and rocket motors.
(b) Properties of propellants. Knowledge of the properties and
types of propellants is critical to the establishment of proper hazard
controls. Propellants present a wide range of hazard characteristics
even within the various types due to variations in grain size of
ingredients and energy content of additives, both solid and liquid. As
described below, test data is essential for determining the chemical,
physical, physiological and explosive properties and hazards of raw
materials, intermediate compositions, processing aids, and liquid or
solid propellant, both uncured and cured.
(1) Single base propellants. Single base propellants have the
principal explosive ingredient of nitrocellulose. Remaining ingredients
include stabilizers as well as other additives. The mixture is shaped
into tubes, perforated tubes, flakes, etc. by extrusion and cutting.
(2) Double base propellants. Double base propellants contain
nitrocellulose and nitroglycerine (or other liquid nitrate ester) as
the two main ingredients. Remaining ingredients include stabilizers as
well as other additives. This propellant can be extruded/cut or cast
into its final shape.
(3) Triple base propellants. Triple base propellants contain three
main components: nitrocellulose, nitroglycerine (or other liquid nitric
acid ester), and nitroguanidine. This propellant can be extruded, cut
or cast into its final shape.
(4) Composite propellants. Composite propellants consist of finely
divided oxidizers dispersed in fuel matrix with the binder normally
being made of plastic material. Nitrates and perchlorates are commonly
used as oxidizers. Common binders include: hydroxyl terminated
polybutadiene, carboxyl terminated polybutadiene, polybutadiene-
acrylonitrile, polyurethane, polybutadieneacrylic acid, and
polysulfides. This propellant is typically cast into its final shape.
(5) Composite modified double base propellants. Composite modified
double base propellants contain a dispersed phase of finely ground
oxidizer and usually powdered fuel additive. This propellant is
typically cast into its final shape.
(6) Liquid propellants. Liquid propellants include a wide range of
liquid fuels, liquid oxidizers and fuel-oxidizer monopropellants.
(Note: Refer to the DOD 6055.9-STD, 9.6 for more information and
requirements associated with specific liquid propellants.
(c) In-process hazards. (1) During scale up from research and
development of new propellants to an existing manufacturing process,
determine the chemical, physical, physiological, explosive properties,
and hazards of raw materials, intermediate compositions, processing
aids, and liquid or solid propellant, both uncured and cured.
(2) Unless available from other sources, conduct testing to
determine thermal stability, chemical compatibility of ingredients,
exothermic reactions, and sensitivity to ignition or detonation from
friction, impact, and electrostatic discharge. Additionally,
deflagration-to-detonation and card gap test data can be valuable.
Applicable tests are described in TB 700-2, Explosives Hazard
Classification Procedures.
(3) Minimum testing may satisfy the classification requirements for
several in-process operations. For example:
(i) If reliable data exist that indicate that the propellant mixing
operations are H/D 1.1, no testing would be needed to adopt this
classification.
(ii) If testing shows that uncured propellant will detonate, the
casting and curing operations are HD 1.1 hazards.
(iii) If detonation tests show that the cured propellant will
detonate, all operations with cured or curing propellant are HD 1.1
hazards.
(4) Make safety information for all materials used in the
formulation available as required. Train personnel on the hazards
involved in propellant process situations.
(d) Q-D requirements. Operate new manufacturing and support
facilities for processing of propellants and propellant loaded items to
conform to the latest QD requirements for the HD of the propellant in
its in-process condition.
(e) Separation of operations and buildings. (1) Perform propellant
and rocket motor manufacturing and processing in special areas (i.e.,
operating lines) whose boundaries are separated from all other areas
outside the line in accordance with applicable QD criteria. Table 1 to
Sec. 184.7 provides remote control and personnel protection
requirements for certain propellant processing operations.
(2) Generally treat sequential operations on rocket motors as one
process operation in one building.
(3) When the hazard classification of a propellant has not been
established, classify the propellant during site and construction
planning as the most hazardous class/division that might possibly apply
during manufacturing and processing.
(4) Locate safety shelters, lunchrooms, convenience buildings, and
private vehicle parking for personnel working in an operating building
in accordance with applicable QD criteria.
Table 1 to Sec. 184.7.--Control and Personnel Protection Requirements
for Certain Propellant Processing Operations
------------------------------------------------------------------------
Personnel
Operation Remote control protected \1\
------------------------------------------------------------------------
Blending and screening of Mandatory......... Mandatory.
ammonium perchlorate.
Blending, screening of nitramines Mandatory \2\..... Mandatory.\2\
and Mandatory perchlorates other
than ammonium.
Grinding, and mechanized drying Mandatory......... Mandatory.
of perchlorates and nitramines.
Grinding, blending, screening, Advisory.......... Advisory.
and mechanized drying of
ammonium nitrates.
Rotating blade propellant mixing. Mandatory......... Mandatory.\4\
Power-driven cutting, machining, Mandatory \3\..... Mandatory.\3\
sawing, planing, drilling, or
other unconfined operations in
which rocket motors or
propellant of Hazard Division
1.1 and 1.3 are involved.\2\
Mandrel break away removal from Mandatory \3\..... Mandatory.\3\
cured propellant.
Pressing, extruding, pelletizing Mandatory......... Mandatory.
or blending.
Casting Propellants.............. Mandatory \3\..... Mandatory.\3\
------------------------------------------------------------------------
\1\ Operating personnel shall be at K24 or in a control room that will
limit overpressure to less than 2.3 psi.
[[Page 16050]]
\2\ Attended screening of wet material may take place if shown
acceptable by hazard analysis.
\3\ Attended operation permitted if shown to be acceptable by hazard
analysis.
\4\ The attended operation may take place when a hazard analysis shows
the MCE to only be fire hazard.
(f) Equipment and facilities. (1) Except as provided for in other
applicable documentation, follow the mandatory requirements of this
part for the design, layout, and operation of facilities and equipment
for propellant operations. Where there is no guidance, govern
operations by the results of hazard tests and analyses (see Sec.
184.12) performed and documented to address specific operations. As
some propellants can be sensitive to initiation by static electricity,
consider bonding and grounding of equipment, tooling, and rocket motor
conductive components along with other means of static elimination and
control. Use conductive work surfaces and floors or floor mats for
assembly of igniters and igniter subassemblies.
(2) Use non-sparking and non-rusting materials, which are
chemically compatible with the propellant material, for equipment,
tooling, and machinery that will come in contact with propellant or
propellant ingredients.
(3) Certain propellant operations involve significant energy input
that enhances the possibility of ignition. Examples are rolling mills,
machining and drilling operations. In these situations, conduct
complete hazard analysis and evaluation prior to starting the
operation.
(4) Special requirements of this part apply to heat-conditioning
equipment.
(5) Exposed radiant surfaces in the form of S-shaped smooth pipe or
fin-type radiators are easy to clean. Other types of radiators are
acceptable, but are less desirable because of cleaning difficulties.
(6) When mechanical ventilating equipment is used in operations
involving potential concentrations of solvent vapors, dusts, and
nitroester vapors, do not locate the electric motor and motor controls
directly in the potentially contaminated air stream. Provide the
ventilation system with a suitable means of collecting condensate.
(7) Design air conditioning and cure oven air-circulating equipment
of the closed system type to prevent contaminated air from contacting
the air motor and controls. Monitor recirculated air to ensure
concentration of vapors and dusts do not reach flammable (or
explosive), or personnel threshold limits. Use dustproof and vaporproof
electric motors and controls. Preferably use air mover blades that are
nonmetallic.
(8) Rigidly fix and stabilize the equipment during mixing to
preclude contact between fixed and movable parts. Design mix bowl lift
mechanisms (i.e., elevators) to assure adequate blade-to-blade and
blade-to-bowl clearances during the complete operation cycle.
(9) Provide positive controls to physically block or stop bowl or
mixer head movement in case of drive mechanism malfunction. Assure
maintenance of blade-to-blade and blade-to-bowl clearance at all times.
(10) Use rigid and strong mix blades and shaft to ensure minimum
flex from viscosity of the mix and speed of the shaft.
(11) Use electrical components of all mixers that meet the
appropriate electrical classification or remotely locate them or shroud
and purge them with inert gas. Design purged systems to provide
automatic warning upon loss of gas pressure.
(12) Equip mixer blade shafts with seals or packing glands that
prevent migration of liquids or solvent vapors into bearings. Avoid
submerged bearings and packing glands. However, if used periodically
test them for contamination and clean them.
(13) Establish a program to detect significant changes in blade/
shaft position relative to mixer head. Check clearances between mix
blades and mixer bowls at regular intervals based on operating time and
experience to make sure the clearance is adequate. Maintain a record of
such checks, mixer blade adjustments, and any damage to the mixer
blades and bowls.
(14) Electrically bond and ground mix bowl, blades, and drive unit.
(15) Inspect blades and other moving parts of new mixers and
replacement parts for old mixers. Inspect (i.e., magnaflux or X-ray)
for cracks, crevices, and other flaws.
(16) Interlock electric service to propellant mixers with fire
protection system controls so that the mixer cannot start when the fire
protection system is inoperative.
(17) Regularly check and maintain all process equipment that
applies energy to in-process propellant for wear and misalignment. Keep
a record of these checks and any maintenance performed for the process
equipment.
(18) Control equipment performing sequential operations on
propellants (e.g., extrusion and cutting) to prevent interference.
(g) In-process quantities and storage. (1) Allow only the quantity
of propellant and loaded subassemblies needed to ensure a safe and
efficient workflow, when conducting operations in an operating
building. Short-term storage of larger quantities in an operating
building is permissible when it is not in use for other operations.
(2) Completed assemblies with or without installed ignition system
may be stored in operating buildings provided there are no other
operations in progress and quantity/distance complies with
requirements.
(3) Production igniters may be stored in designated areas within an
assembly or disassembly facility.
(4) Indoor storage is preferable for all types of explosives and is
mandatory for bulk HE, solid propellants, and pyrotechnics. Give
priority of existing indoor storage to AE requiring the most protection
from the weather (based on the method of packing). Protect propellant
and propellant materials from overheating by exposure to direct
sunlight when in transit or on temporary hold.
(5) Consider the propulsive characteristics and the ignition
probability of AE (e.g., propellant loaded devices, rocket motors,
assist take-off units and missiles) during all logistical phases in
order to obtain as much safety as possible under the circumstances.
Because of the great number of types and sizes of propellant loaded
devices and conditions of assembly encountered, only general safety
guidance is provided in this part. Thus, the contractor should make
every effort to prevent ignition of any units being manufactured,
assembled, disassembled, handled, stored, transported or deployed. Use
approved flight restraining devices (tie-downs) to the maximum extent
possible. When doubt exists as to whether a given AE or configuration
(state of assembly) is propulsive or nonpropulsive, treat the AE as
propulsive until pertinent technical information can be obtained.
(h) Ingredients processing. (1) Weighing, measuring, and handling
raw materials. (i) Electrically ground scales for weighing raw
materials, where needed, to properly protect the operation. This
grounding is especially important where flammable or combustible
materials are involved.
(ii) Provide separate weight or measurement rooms, cubicles, or
areas (dependent upon the quantity and sensitivity of the materials
handled) provided. Separate oxidizer and metallic powder weighing from
each
[[Page 16051]]
other and from other materials by physical barriers rather than
distance.
(iii) It is important that containers, equipment, hand tools, scale
pans, etc., used for weighing processes do not mix with those weighing
or measuring oxidizers and fuels, particularly where distance rather
than physical barriers separates these areas. Use positive measures to
ensure the complete separation of such equipment and tools.
(iv) Do not change the designated use of space and equipment
without a thorough cleaning and inspection to make sure that all traces
of the previous material have been removed, if any possibility exists
that materials are incompatible.
(2) Oxidizer Processing. Solid propellant oxidizing agents are
perchlorates, nitrates, nitroesters, and nitramines used in solid
rocket motor propellants.
(i) Avoid contaminating an oxidizer agent with any metal or
chemical (fuel) which may result in a more sensitive composition.
(ii) Use closed systems as much as possible for dust, humidity, and
tramp material control.
(iii) Use fire-retardant materials to make flexible connections
(socks) in pipes or duct systems that convey oxidizer materials and
dust socks in collectors or hoppers. Only use connection materials that
are chemically compatible with the oxidizers.
(iv) Make the pipes and duct systems electrically continuous. Avoid
threaded joints and fittings in contact with oxidizer. Preferably use
quick clamp neuter end pipe joints.
(v) Use static electricity control measures to dissipate static
charges to an acceptable level if transporting oxidizer by
fluidization.
(3) Oxidizer drying. (i) Establish the safe temperature for drying
each material and do not exceed that temperature at any point in the
drying apparatus or drying room.
(ii) Use thermostatic controls to prevent exceeding the maximum
safe temperature in the drying process. Install and use redundant
temperature controls.
(iii) Do not use electrical heating elements that may contact the
oxidizer or oxidizer dust.
(iv) Hold dust to a minimum in the drying process. Use a dust
collection system if dusting can create a potential hazard.
(v) Exercise care to prevent drying of incompatible materials
simultaneously in the same drying process. Do not dry oxidizers in an
oven, drying room, etc., used for processing flammable or other
incompatible materials until after cleaning and inspection shows it is
free of any residual contamination.
(4) Screening oxidizers. (i) Construct screening equipment so it
cannot subject oxidizer material to pinching, friction, or impact as a
result of metal-to-metal contact. Keep rooms in which screening units
are operated thoroughly clean to eliminate hazardous accumulations of
dust.
(ii) Electrically ground oxidizer screens and bond them to the
receiving vessel.
(5) Blending oxidizers. (i) If blending of oxidizers generates
gases, design and install a suitable means of gas pressure relief into
the blender.
(ii) Electrically bond the blender throughout.
(iii) Construct blending equipment so it cannot subject oxidizer
material to pinching, friction, or impact between metal-to-metal
surfaces.
(iv) When blending ammonium perchlorate using powered mechanical
equipment, protect operating personnel. Use remote controls for
mechanical blending.
(v) When using powered mechanical methods for blending HD 1.1
substances (such as RDX or HMX), use remote controls and personnel
protection (See Note 1 to Table 1 to Sec. 184.7).
(6) Grinding oxidizers. (i) When using impact type mills, provide
sufficient clearance between stationary and moving parts to prevent
metal-to-metal contact. Check clearances as often as needed to ensure
they are adequate. Air purge mill bearings to prevent contamination. Do
not use impact type grinders for HD 1.1 substances.
(ii) Pass oxidizer feed materials through a screen mesh with
openings no greater than the clearance between hammer and plate. Use
the smallest screen mesh size for ammonium nitrate that allows free
flow of the prills. Use magnetic separators if screening is not
possible.
(iii) Use only compatible lubricants in grinding equipment.
(iv) Install and use heat sensing devices for the bearing housing
of grinding and conditioning equipment.
(v) Determine the optimum cleaning cycle and method for grinding
equipment and include them in SOP.
(vi) Provide grinding operations with wet dust collection systems,
where appropriate.
(vii) Thoroughly ground and bond pneumatic grinding operations to
provide for electrostatic charge dissipation.
(7) Preparation of fuel compositions. (i) Determine the sensitivity
characteristics of fuel compositions prior to production mixing
operations.
(ii) Establish compatibility of materials. Develop procedures that
preclude the formation of highly sensitive compositions or hazardous
conditions during processing, such as, dry AP and powdered metal
mixtures.
(iii) Preferably bond equipment, piping, and vessels used in fuel
preparation to form a continuous electrical path with each other and to
building ground. When pouring metallic powder or flammable liquids from
one container to another, bond the containers together prior to the
transfer.
(iv) Minimize the formation and accumulation of dust in all
preparation operations.
(v) Use fume hoods, dust socks, closed systems, and dust/fume
vacuum exhaust hoses, as appropriate, to prevent vapors and dust
getting into the operating areas.
(8) Transfer operations. (i) Transfer finely divided powdered
ingredients by methods that control flow rate and minimize
electrostatic charge generation.
(ii) Before transferring flammable solvents, electrically bond the
transfer and receiving vessels to eliminate electrostatic potential
differences.
(i) Mixing. (1) Secure hardware and associated equipment to prevent
loose items falling into mixers.
(2) Pass liquids and powders to be added to the mix vessels through
a screen or orifice with an opening(s) less than the smallest clearance
in the mixer. You may directly add smaller amounts of material,
provided a positive means exists to ensure the material does not
contain any foreign material.
(3) Use other means such as x-rays to examine materials that you
cannot screen or that are opaque or not easily inspected.
(4) When consistent with the process system and requirements, cover
the mixer bowl after completing charging or mixing to prevent the
accidental introduction of foreign objects into the mixer and to
prevent sunlight impinging directly on the materials in the bowl.
(5) Use only non-sparking devices for hand scrapping the sides and
blades of mixers. Set up controls to prevent accidental introduction of
these and other devices into the mixer.
(6) Account for all loose tools and equipment before starting or
continuing mixing operations.
(7) Do not allow loose objects such as jewelry, pens and coins in
the mixer operating area where accidental introduction into the mixers
might occur. Pocketless coveralls should be used.
[[Page 16052]]
(8) Provide direct and unobstructed routes for personnel egress
from mixer buildings or bays.
(9) Do not attempt to fight propellant fires.
(10) Preferably equip propellant mixers, inside and outside of the
mixing vessel, with a high-speed deluge system.
(j) Casting and curing. (1) Personnel may attend cast operations if
you first conduct a thorough safety review of the operation is
conducted.
(2) Multiple or single production line type casting is permitted.
However, when the survivability of the production facility is critical
or the risk to the program is significant, the PCO may require the
contractor to provide protection that prevents propagation of an
incident from the casting operation to adjacent bells or pits.
(3) Use only smooth cast piping surfaces in contact with
propellant. Use tooling free of cracks, pits crevices, and weld slag
for propellant casting and curing operations. Avoid threaded joints as
much as possible, especially at unions requiring disassembly for
process operation or cleaning.
(4) Do not design or use cast tooling and mandrels that permit
metal-to-metal friction or impact sites.
(5) Design and use propellant flow valves that prevent propellant
pinching or compression between two metal surfaces.
(6) Design and use pressurized casting vessels capable of
withstanding at least twice the maximum allowable working pressure.
(7) Secure lids to pressurized casting vessels so that they will
withstand the rated pressures of the vessels.
(8) Do not exceed the working line pressure of casting vessels.
Install a relief valve downstream of the regulator on pressure lines.
(9) Equip each vessel with a blowout disk (burst diaphragm)
designed to blow out at less than 120% of the vessel's maximum
allowable working pressure. Allow for the release of the potential
rapid rise of pressure in the vessel should the propellant ignite.
(10) When curing or casting propellant under pressure, provide
emergency pressure relief.
(11) Pressurize and depressurize propellant cure operations
remotely.
(12) Physically and electrically disconnect casting vessels from
lifting devices during cast operations.
(k) Extrusion processes. (1) Design solventless extrusion presses
and compression molding equipment to remove air from the propellant
before compaction and extrusion begin. Assure that procedures provide
for checking operation of the vacuum system and for cleaning it of
propellant residue and condensed vapors such as those generated from
nitroglycerin volatilization.
(2) Check ramheads for alignment with the press bore to preclude
metal-to-metal contact. Include flashing removal in the process
procedures.
(3) Provide interlocks to preclude press operation during loading
or other attended operations.
(l) Propellant loaded AE. (1) When performing operations on cured
propellant contained in pressure vessels or rocket motor cases and
there may be a risk of ignition due to energy inputs (e.g., electrical
check of pyrotechnic devices). In such cases, secure the unit in a
fixture capable of withstanding 2.5 times the rated thrust of the
assembly.
(2) Use remote control to apply mechanical force to ``breakaway''
the mandrel or other tooling embedded in propellant. However, see Table
1 to Sec. 184.7 for exceptions.
(3) Avoid moving loaded rocket motors with cores in place. If
loaded motors containing cores must be moved, however, support the core
and motor case by or suspended from a common source or in some manner
locked or tied together to prevent independent movement of either.
(4) When determining the safest method to use, evaluate and
consider the hazard characteristics of individual propellants you will
cut, machine, or contour.
(5) Design propellant machining equipment:
(i) To prevent contact of cutting tools or blades with motor cases
and other metal objects.
(ii) To minimize generation of heat.
(iii) To facilitate removal of dust and chips, and to afford
personnel protection. If there is a possibility that a metal or other
foreign object may be in the propellant, x-ray the motor or grain prior
to machining.
(6) Frequently remove propellant dust, chips and shavings from the
work area during machining and contouring.
(7) Preferably position rocket motors in final assembly process to
permit ready access to all sides of the motor. Keep aisles and exit
doors clear and unobstructed. Install quick release hardware on all
exit doors.
(8) Keep the number of items in the final assembly building at the
minimum consistent with a safe and efficient operation.
(9) Grounding of propellant loaded assemblies in storage is
optional, based on a case-by-case review.
(10) If the process requires removing an igniter-shorting clip,
keep the igniter shorted until immediately before insertion. Minimize
the time that the igniter remains unshorted.
(11) Provide means for controlled dissipation of static electrical
charges during igniter insertion.
(12) Conduct operations that involve electrical continuity
checking/testing of ignition systems installed in rocket motors
according to thoroughly reviewed and approved procedures. Conduct these
checks by remote control with the motor mounted in a test stand
designed to withstand 2.5 times the thrust of the motor.
(m) Disassembly. (1) As much as possible, avoid metal-to-metal
movement and trapping of explosive substance in process equipment or
tooling that require disassembly in a process operation.
(2) Use clean, external clamp fittings on pipe assemblies for
propellant transfer.
(3) Before starting non-routine disassembly of equipment or tooling
(such as that necessary for equipment repair or for securing the
process), evaluate potential hazards of trapped material or process
residuals.
Table 1-1 to Sec. 184.7.--Control and Personnel Protection
Requirements for Certain Propellant Processing Operations
------------------------------------------------------------------------
Personnel
Operation Remote controls protected \1\
------------------------------------------------------------------------
Blending and screening of Mandatory......... Mandatory.
ammonium perchlorate.
Blending, screening of nitramines Mandatory \2\..... Mandatory.\2\
and perchlorates other than
ammonium.
Grinding, and mechanized drying Mandatory......... Mandatory.
of perchlorates and nitramines.
Grinding, blending, screening, Advisory.......... Advisory.
and mechanized drying of
ammonium nitrates.
Rotating blade propellant mixing. Mandatory......... Mandatory.\4\
[[Page 16053]]
Power-driven cutting, machining, Mandatory \3\..... Mandatory.\3\
sawing, planing, drilling, or
other unconfined operations in
which rocket motors or
propellant of Hazard Division
1.1 and 1.3 are involved \2\.
Mandrel break away removal from Mandatory \3\..... Mandatory.\3\
cured propellant.
Pressing, extruding, pelletizing Mandatory......... Mandatory.
or blending.
Casting propellants.............. Mandatory \3\..... Mandatory.\3\
------------------------------------------------------------------------
\1\ Operating personnel shall be at K24 or in a control room that will
limit overpressure to less than 2.3 psi.
\2\ Attended screening of wet material may take place if shown
acceptable by hazard analysis.
\3\ Attended operation permitted if shown to be acceptable by hazard
analysis.
\4\ The attended operation may take place when a hazard analysis shows
the maximum credible event (MCE) to only be fire hazard. For guidance
on ENERGETIC (PROPELLANT) LIQUIDS, please refer to DoD 6055.9, Section
9.5.
Sec. 184.8 Safety requirements for manufacturing and processing
pyrotechnics.
(a) General. (1) Pyrotechnics, as well as propellants and
explosives, are chemical mixtures which release large amounts of
energy. The amount of energy released, the speed of reaction, and the
form of the output energy are the characteristics that distinguish
between pyrotechnics and other forms of high-energy (HE) mixtures, and
between types of pyrotechnics. The safety precautions for manufacturing
and processing pyrotechnics parallel those of many types of explosives
and propellants. However, incident mitigation techniques must recognize
the unique characteristics of the particular mixtures, and not rely on
techniques appropriate to other types of explosive substances (e.g.,
HE). Rates of reaction of pyrotechnic mixtures vary greatly, from
mixtures with very low rates of reaction to rates equivalent to high
explosives. Energy output also varies from very low to very great.
Process variables, such as ingredient particle size, can affect
reaction rate and output to the extent that a change in process
variables can negate protective measures. Complicating safety in
pyrotechnics operations is the variety of highly flammable solvents
often used as processing aides.
(2) Pyrotechnics are mixtures of fuels and oxidizers, typically
held together by binders. Pyrotechnics display many different
characteristics, because they are formulated for different purposes.
General categories of pyrotechnics are: initiators (igniters);
illuminants; smokes. gas generators; sound generators; heat producers;
and timing compositions. Each has its own characteristics and attendant
processing requirements.
(b) Properties of pyrotechnic materials and mixtures. Knowledge of
the various pyrotechnic properties is critical to the establishment of
proper hazard controls.
(1) Oxidizers. Oxidizers are oxygen rich substances which decompose
to liberate oxygen gas, or substances which act as oxidizers with
active metal fuels. Typical inorganic oxidizers are nitrates,
chlorates, perchlorates, oxides, chromates, and dichromates. Fluorine
and chlorine, as in hexachloroethane and Teflon (brand of fluorine
containing compound) are examples of organic compounds used as
oxidizers. All oxidizers, if not well controlled, tend to increase the
risk of undesired reactions, particularly in the presence of organic
materials (including wood). Potassium chlorate compositions are
particularly susceptible to accidental ignition. Impurities in process
materials, or introduced by poor process control (e.g., oils,
lubricants) can readily increase the sensitivity of mixtures or result
in ignition. Some oxidizers with trace impurities, or by themselves
(i.e., ammonium perchlorate (AP)), can detonate when subjected to
severe stimuli such as an adjacent explosion or thermal energy. Safety
requires absolute control of oxidizers to prevent contamination,
uncontrolled moisture absorption (many are hydroscopic), fires or
explosions from accidental mixing with fuels.
(2) Fuels. Fuels react with the oxidizers to produce heat and an
oxidized product. It is the proper pairing of the fuel with an
appropriate oxidizer that determines the reaction characteristics, and
the use for the mixtures. Metals, such as magnesium or aluminum, create
high heat or light output. Fuels include an almost unlimited variety of
organic (sugars and red gum) and a more limited variety of inorganic
materials (e.g., sulfur boron, phosphorus, and sulfides). Although
generally more stable than oxidizers, fuels also have unique
characteristics that contribute to risk. These include the liberation
of hydrogen from magnesium and aluminum powders which become wetted.
Again, storage and handling of fuels requires tight process controls
which respect the characteristics of the specific materials and prevent
contamination which may result in a reaction.
(3) Binders. Homogeneity of the mixtures governs the effectiveness
of pyrotechnic compositions. Some pyrotechnics (e.g., black powder) are
self-bound by the manufacturing process to maintain the charcoal,
sulfur, and potassium nitrate in the correct, proportionate, intimate
mixture needed. Other mixtures, because of differences in particle size
or weight of ingredients, require the use of a binder to retain the
homogeneous blend. Other binders include lacquers, epoxies, and a
variety of polymers activated by heat or solvents. Some solvents are
similar in composition to fuels, and the binder may also be a fuel or
burn rate modifier. Some binders are flammable, others require the use
of a highly flammable solvent, and thus the ignition characteristics of
these materials are important risk factors.
(4) Types of pyrotechnic compositions. Pyrotechnic compositions are
usually grouped by the function of the end item. There is no universal
single grouping, but typical major groupings are: heat and delay
compositions (e.g., ignition, delay, heat, and propellant), color and
light compositions, smoke (e.g., obscuring and signal smokes, noise).
The range of sensitivity to initiation and the rate/amount of output
energy varies greatly both within and between groups.
(i) Heat and delay compositions. Pyrotechnic fuzes, electric
matches, first fires, primers, igniters, delay compositions are all
members of this group. The end products must function with very little
stimulus, and thus the mixtures, as well as individual ingredients, are
sensitive to initiation. First fire, igniter and primer mixtures are
generally the most sensitive to initiation stimuli (i.e., heat,
friction, impact, static electricity). (Note: Primer mixes containing
initiating explosives such as lead azide or lead styphnate are properly
classed as explosives.) These
[[Page 16054]]
mixtures often use black powder or potassium chlorate/metal
combinations or potassium chlorate/phosphorous mixtures. This group
also contains mixtures with high heat outputs for such purposes as
document destroyers and welding. These high heat producers are
generally metallic fuels and metallic oxidizers, as in the iron oxide/
aluminum powder formulations for Thermite. Black powder, when used to
launch or expel items is a propellant and is included in this group.
(ii) Color or light producing compositions. There are a wide
variety of mixes and compositions which produce light, color, or both.
Illuminant candles, photoflash, decoy flares all are part of this very
broad category. Many of the compositions, notably the photoflash and
decoy flare compositions, are characterized by very rapid reactions,
and extreme temperature outputs. Both have resulted in fatal accidents.
Metallic fuels are characteristic of the high light (visible, IR)
output mixtures. Output temperatures exceeding 2000 [deg]F (1093
[deg]C) characterize many of the items in this category. Accidental
initiation of large mix batches of some compositions may have a
significant pressurization effect in addition to the heat, with
resultant structural damage.
(iii) Smoke and noise producing compositions. Obscurants, colored
markers, weapons simulators and weapons effects simulators comprise
this category. Smoke compositions are characteristically slow burning
in finished form, but must burn at a temperature high enough to
vaporize the dye compound (usually organic). Chlorates are often the
oxidizer in colored smoke mixes. ``Flash-bang compositions'' used in
weapons simulators and weapons effects simulators are actually
explosives in most instances, and will detonate with adequate stimulus
in unconfined bulk form. ``Flash-bang'' compositions, particularly in
display or commercial fireworks, but also in military items, were the
cause of many injury-producing accidents. Similarly, ``whistle''
compositions are very sensitive to ignition and can detonate.
(c) Process requirements. Pyrotechnic operations, because of the
sensitive nature of the ingredients and compositions, the dangerous
effects of contamination, including cross contamination of oxidizers
and fuels, and the amount of open or exposed ingredients and mixtures,
require stringent housekeeping and cleanliness. Materials control and
cleanliness are mandatory not only to reduce the likelihood of
accidental initiations, but also to minimize the effects of a mishap.
(1) Do not allow ingredient or composition dusts to accumulate,
whether on the exterior work surfaces or the interior of process
equipment and ventilation systems. (Note: Accident investigations
frequently identify dust buildups as the source of initiation when
items are dropped on, or scraped across them.) Dust accumulations also
provide a propagation path, which can follow from initiation to a
significant source of material, causing an accident.
(2) Similarly, where flammable solvents are part of the process,
positive vapor control is mandatory to prevent initiation of a solvent
vapor cloud, which may be injurious in itself, or may be the
propagation path which ignites a mixture. Just as dusts in ventilation
systems may provide a propagation path for an event, solvent vapors in
ventilation systems, hallways, conduits, or pipes may also provide a
propagation path.
(3) As many pyrotechnic ingredients, mixtures or the solvents used
in their production are highly susceptible to initiation by static
electricity, static control systems (i.e., conductive floors/mats,
shoes, wrist straps, grounding of equipment, etc.) are mandatory where
hazard analysis indicates a need for static control.
(4) For all pyrotechnic operations, a documented hazard analysis
and risk assessment is mandatory to validate the layout of operations,
selection of materials and equipment, and process control parameters.
See Sec. 184.11.
(5) Weighing raw materials. Positive means of separation of fuels
and oxidizers is mandatory. The scale of the operation will dictate
whether separate rooms, cubicles, areas, or other means for separation
are required. It is important that equipment (e.g., containers, hand
tools, scale pans, etc.) used for weighing fuels or oxidizers are not
interchanged or shared among incompatible operations, unless thoroughly
cleaned between fuel and oxidizer use, particularly where distance
rather than physical barriers separates these areas. A hazard analysis
shall determine appropriate personnel protective equipment for
personnel weighing or handling exposed oxidizers or fuels.
(6) Drying materials. Drying materials may result in the generation
of flammable vapors or dust which have the potential to create an
explosive atmosphere. The dust settling out of the atmosphere may
increase in sensitivity. Operational hazard analysis must address these
possibilities and the possibility of initiation by over-temperature or
extended heating. Use the minimum temperature necessary for drying
component and pyrotechnic materials. Dust and residue control is very
important in drying operations, as elevated temperatures frequently
results in increased sensitivity of materials. The requirements for
drying apparatus are described in Sec. 184.8.
(7) Mixing and blending. Mixing, blending, and cleanup of
pyrotechnic compositions from equipment apparatus require attention
because of the high potential for mishaps during these operations. As
compositions vary, no single type of mixer or blender can be the
exclusively approved equipment for pyrotechnic mixing and blending
operations.
(i) Select the mixing equipment and methods appropriate for each
composition. Hazard analysis or test shall determine the type of mixer
or blender and batch size. Devices using a tumbling action eliminate
many of the problems associated with rotating blade mixers, plows and
scrapers. Rotating blade type mixers create points where frictional
heat may develop or where accidentally introduced foreign material can
create hot spots through friction or crushing of the composition. Equip
enclosed mixers and blenders with pressure relief, to preclude a
transition from burning to detonation. Minimize personnel exposure when
charging and emptying mixers and blenders. Unless hazard analysis
indicates otherwise, charge, operate and empty mixers and blenders
remotely. Use appropriate interlocks, clutch brakes, and similar
devices to preclude personnel exposure during mixer or blender
operation, and to preclude the movement of mixer or blender parts
during periods when operators are present.
(ii) Mixing and blending operations often present a high risk of
explosion. Facility construction and procedural controls, guided by
hazard analysis or test, must reflect this risk. Prevention of
propagation, protection of production capabili |
