This document is no longer a CPR. This document implements the requirements of Corporate procedure ESH100.2.EXP.1, Manage Explosives Safety.

IMPORTANT NOTICE: A printed copy of this document may not be the document currently in effect. The official version is the online version located on the Sandia Restricted Network (SRN).

Subject Matter Expert: Danton Humphries; CA Counterpart: Herman Armijo Contributors: Timothy Wallace and Ronald O’Hara
MN471011, Issue L
Revision Date: March 4, 2010; Replaces Document Dated: July 29, 2009
Review Date: July 17, 2006
Administrative Changes: April 9, 2010, and January 23, 2012

CHAPTER I - INTRODUCTION

• 1-1.0 Scope, Purpose, and Justification
• 1-1.0S Purpose
• 1-2.0 Applicability
• 1-2.0S Applicability
• 1-3.0 Exemptions
• 1-3.1 Each Such Requests Shall Contain the Following Information
• 1-3.2 Exemptions Achieving Equivalent Safety
• 1-3.3 Exemptions Not Achieving Equivalent Safety
• 1-4.0 Waivers
• 1-4.1 Each Waiver Whall Contain, As a Minimum the Following Information
• 1-5.0 and 1-5.OS Manual Administration and Management
• 1-5.1 DOE Explosives Safety Committee Organization
• 1-5.2 DOE Explosives Safety Committee Functions
• 1-6.0 and 1-6.0S Definitions
• 1-7.0 and 1-7.0S Acronyms
• 1-8.0 Measurement Abbreviations
• 1-9.0S Roles, Responsibilities, Authorities, and Interfaces
• 1-9.1S Organization Responsibilities
• 1-9.2S Personnel Responsibilities
• 1-9.3S Safety Engineering Responsibilities
• 1-9.4S Facilities Engineering Responsibilities
• 1-9.5S Site Responsibilities
• 1-9.6S Corporate Explosives Program Manager (CEPM)
• 1-9.7S Sandia Explosives Safety Committee (SESC)
• 1-9.8S Sandia Safety Explosives Subcommittees

CHAPTER II - OPERATIONAL SAFETY - CONTENTS

CHAPTER II - OPERATIONAL SAFETY - PART 1

• 2-1.0 General Operations Safety Guidelines
  • 2-1.1 Protection of Explosives
  • 2-1.1S General and Specific Requirements
  • 2-1.2 Equipment Checks
  • 2-1.3 Inspection Frequency
  • 2-1.4 Laboratory Operations
  • 2-1.5 Toxicity Hazards
  • 2-1.6 Hazard Identification and Communication
  • 2-1.7 Process Hazard Analysis
  • 2-1.7S Process Hazard Analysis
• 2-2.0 Work Environment
  • 2-2.1 General Requirements
  • 2-2.2 Emergency Exit Requirements for Explosives Operations
  • 2-2.2.1 Building or Structure Occupancy
  • 2-2.2.2 Hazards of Contents Classification
  • 2-2.2.3 Personnel Protective Restrictions and Requirements
  • 2-2.2.4 Requirements for Existing Facilities
  • 2-2.2.5 Requirements for New Facilities
  • 2-2.2.6 Single Exits
  • 2-2.2.7 Blast Resistant Doors
  • 2-2.2.8 Slide Escapes
• 2-3.0 Building and Equipment Maintenance
  • 2-3.1 Cleaning
  • 2-3.2 Maintenance and Repair
  • 2-3.2S Maintenance and Repair
  • 2-3.3 Hot Work Permits
  • 2-3.4S Explosive to Nonexplosive Building Notification
• 2-4.0 Remote Operations
  • 2-4.1 Personnel Protection
  • 2-4.2 Access and Equipment Controls
• 2-5.0 General Explosives Area Controls
  • 2-5.1 Smoking, Matches, Lighters, Metal Articles
  • 2-5.2 Cooking and Eating
  • 2-5.3 Access to Explosives Areas
• 2-6.0 Protection of Electroexplosive Devices (EED) from Electromagnetic Radiation
• 2-7.0 Static Electricity
  • 2-7.1 General
  • 2-7.1S General
  • 2-7.2 Bonding and Grounding of Equipment
  • 2-7.3 Testing Bonded Equipment Grounds
  • 2-7.4 Conductive Floors, Shoes, Mats, and Wristbands
  • 2-7.4S Conductive Floors, Shoes, Mats, and Wristbands
  • 2-7.5 Conductive Floor, Work Surface, and Wristband Specifications
  • 2-7.6 Conductive Floor Tests
  • 2-7.6S Conductive Ground-Plane Tests
  • 2-7.7 Humidification
  • 2-7.8 Ground Fault Circuit Interrupter
  • 2-7.8S Ground Fault Circuit Interrupter
• 2-8.0 Electrical Equipment and Wiring
  • 2-8.1 Location/Operation Electrical Hazard Classification
  • 2-8.2 Electrical Supply System
  • 2-8.3 Building Electrical Service Entrance
  • 2-8.4 Permanent Wiring, Fixtures, and Equipment
  • 2-8.5 Flexible Cords/Wiring
  • 2-8.6 Electrical Equipment and Instrumentation
  • 2-8.7 Electrical Requirements for Outdoor Test Areas
  • 2-8.8 Hand-held, Battery-Powered Lights and Instruments
  • 2-8.9 Non-Rated Extension Lighting
  • 2-8.10 Laboratories
  • 2-8.11 Modifications

CHAPTER II, OPERATIONAL SAFETY - PART 2

• 2-9.0 Vacuum Equipment
  • 2-9.1 General
  • 2-9.2 Labeling
  • 2-9.3 Disassembly
  • 2-9.4 Traps or Filters
• 2-10.0 Explosives Dust Exhaust Ventilation and Collection Systems
  • 2-10.1 General
  • 2-10.2 Exhaust Ventilation
  • 2-10.3 Dust Collection Systems
  • 2-10.4 Dust Collection Location
• 2-11.0 Drains and Sumps
  • 2-11.1 Collection
  • 2-11.2 Effluent
• 2-12.0 Processing
  • 2-12.1 Heating, Drying, and Thermal Conditioning
    • 2-12.1.1 General
    • 2-12.1.2 Heating and Drying Equipment
    • 2-12.1.3 Heating and Drying Operations
  • 2-12.2 Pressing
    • 2-12.2.1 General
    • 2-12.2.2 Isostatic/Hydrostatic Pressing
    • 2-12.2.3 Punch and Die Pressing
  • 2-12.3 Extruding
  • 2-12.4 Machining
    • 2-12.4.1 Equipment Requirements
    • 2-12.4.2 Contact or Remote Operations
    • 2-12.4.3 Setup and Preparation
    • 2-12.4.4 Operations Guidelines
    • 2-12.4.5 Specific Machining Operations
  • 2-12.5 Dry Screening
  • 2-12.6 Blending
  • 2-12.7 Melting
  • 2-12.8 Assembly and Disassembly
    • 2-12.8.1 Assembly Operations
    • 2-12.8.2 Loading Assemblies with Plastic or Extrudable Explosives
    • 2-12.8.3 Disassembly Operations
    • 2-12.8.4 Personnel Protection for Disassembly Operations
  • 2-12.9 Inspection
  • 2-12.10 Synthesis
    • 2-12.10.1 Laboratory-Scale Synthesis
    • 2-12.10.2 Pilot- or Processing-Scale Synthesis
  • 2-12.11 Formulation
    • 2-12.11.1 General
    • 2-12.11.2 Mixing
    • 2-12.11.3 Ball or Jar Milling
    • 2-12.11.4 Roll Milling
  • 2-12.12 Concurrent Contact Operations
  • 2-12.13 Contamination Prevention
  • 2-12.14 Hand-Cutting and Finishing Operations
  • 2-12.15 Use of Low-Pressure Fluids
• 2-13.0 Testing
  • 2-13.1 General
  • 2-13.2 Test Planning
    • 2-13.2.1 Hazards Analysis
    • 2-13.2.2 Firing Areas
    • 2-13.2.2S Firing Areas
    • 2-13.2.3S Hazards
    • 2-13.2.4S Other Considerations and Actions
  • 2-13.3 Test Firing
    • 2-13.3.1 General Range Standards
    • 2-13.3.2 Test Setup
    • 2-13.3.3 Pin Switches and Other Noninitiating Circuits
    • 2-13.3.4 Lightning Storms
    • 2-13.3.5 Low-Energy Electroexplosive Devices
    • 2-13.3.6 Explosives Storage in Firing Areas
    • 2-13.3.7 Warning Signals
    • 2-13.3.8 Grass Fires
    • 2-13.3.9 Firing Leads
    • 2-13.3.10 Unattended Test Assemblies
    • 2-13.3.11 Post-Firing Controls
    • 2-13.3.12 Contamination of Firing Areas
    • 2-13.3.13 Test Range Firing Circuit Criteria
  • 2-13.4 Test Firing in Tanks or Chambers
  • 2-13.5 Gun Firings
  • 2-13.6 Ballistic, Environmental, Physical Property, and Sensitivity Testing
    • 2-13.6.1 Checkout of Dynamic Engineering Test Equipment for Explosive Assemblies
    • 2-13.6.2 Testing of Explosives and Hazardous Radioactive Materials
    • 2-13.6.3 Heating of Explosives Test Specimens
    • 2-13.6.4 Instrumentation
    • 2-13.6.5 Explosives Limits
    • 2-13.6.6 Drop Testing
  • 2-13.7 Test Failures and Misfires
    • 2-13.7.1 Explosives Misfire
    • 2-13.7.2 Misfire of a Remotely Fired Gun
  • 2-13.8 Electrical Instruments for Use with Explosives Systems
    • 2-13.8.1 Classification
    • 2-13.8.2 Certification
    • 2-13.8.2S Certification
    • 2-13.8.3 electrical Instruments for Use with Initiating Electrical Circuits
    • 2-13.8.4 Electrical Instruments for Use with Noninitiating Electrical Circuits
    • 2-13.8.5S SNL Certified Instruments

CHAPTER II, OPERATIONAL SAFETY - PART 3

• 2-14.0 Materials Handling
• 2-14.1 General
• 2-14.1S General
• 2-14.2 Manual Handling of Bare Consolidated Explosives
• 2-14.3 Carts or Hand Trucks
• 2-14.4 Mechanical Handling Equipment
• 2-14.4S SNL Mechanical Handling Equipment
• 2-15.0 Materials Receipt
• 2-15.1 Motor Vehicles
• 2-15.2 Railcars
• 2-15.3 Damaged Shipments
• 2-15.3S Damaged Shipments
• 2-16.0 Transportation
• 2-16.1 Equipment and Operations
• 2-16.1.1 General
• 2-16.1.2 Motor Vehicles
• 2-16.1.3 Railcars
• 2-16.1.4 Materials Handling Equipment
• 2-16.2 General Operation Guidelines
• 2-16.2S General Operation Guidelines
• 2-16.2.1S Explosives Transportation Containers
• 2-16.2.2S Packaging Guidelines
• 2-16.3 Emergency Conditions
• 2-17.0 Explosives Storage
• 2-17.0S SNL Storage Requirements
• 2-17.1 Storage Magazine Facilities
• 2-17.1S Storage Magazine Facilities
• 2-17.2 Storage Magazine Operations
• 2-17.3 Storage Review Program
• 2-17.3S Storage Review Program
  • 2-17.3.1 Common Requirements
  • 2-17.3.2 Storage Review by Analogy
• 2-17.4 Storage Compatibility
• 2-17.5 Containers (Onsite)
• 2-17.5S Containers (Onsite)
• 2-17.6 Storage in Buildings Other Than Storage Magazines
• 2-17.6.1 Packing and Shipping Buildings
• 2-17.6.2 Service Magazines
• 2-17.6.2S Service Magazines
• 2-17.6.3 Warehouses
• 2-17.6.4 Prepositioned Storage of Security Response Munitions
• 2-18.0 Decontamination and Cleaning
• 2-18.2 Cleaning Contaminated Equipment
• 2-18.3 Cleaning Screw Threads
• 2-18.4 Final Decontamination and Disposal of Equipment
• 2-18.5 Inspection
• 2-18.6 Identification and Control of Decontaminated Items
• 2-18.7 Decontamination of Real Estate
• 2-18.8 Decontamination and Cleaning References
• 2-19.0 Waste Collection
• 2-19.1 General
• 2-19.1S General
• 2-19.2 Solid Wastes
• 2-19.3 Vacuum Collection of Explosives Dusts
• 2-19.4 Explosives Slurries
• 2-19.5 Metal Scrap
• 2-19.6 Explosives Recovery and Reuse
• 2-20.0 Waste Disposal
• 2-20.0S General Requirements
• 2-20.1 Preparation for Open Burning
• 2-20.2 Destruction by Burning or Flashing
• 2-20.2S Destruction by Burning or Flashing
• 2-20.3 Ignition System Malfunctions
• 2-20.4 Postburn Operations
• 2-20.5 Disposal Area
• 2-20.6 Destruction by Detonation
• 2-20.7 Use of Solvents
• 2-21.0 Laboratory Operations
• 2-21.1 General
• 2-21.2 Safety Shields
• 2-21.2S Safety Shields
• 2-21.3 Heating Operations
• 2-21.4 Laboratory Setups
• 2-21.5 Low Concentration of Explosives in Solution
• 2-21.6 Explosives Sample Control
• 2-21.7 De Minimis or Residual Quantitie
• 2-22.0 Emergency Control
• 2-22.1 Placarding and Fire Symbols
• 2-22.1S Placarding and Fire Symbols
• 2-22.2 Explosives Emergency Control Plans
• Attachments
• 2-1 – Gunpowder, Bulk Propellant, and Ammunition
• 2-2 – Rocket Motors and Missile Systems
• 2-3 – Bulk Materials, Powders, Pellets, Bulk Moldables, Shaped Charges, Linear Materials, and Thermites
• 2-4 – Articles, Subassemblies, and Assemblies
• 2-5 – Hazard Mitigation Techniques

CHAPTER III - EXPLOSIVES AND PERSONNEL LIMITS AND CONTROL

• 3-1.0 Explosives Limits
• 3-2.0 Personnel Limits
• 3-2.0S Personnel Limits
• 3-3.0 Limit Control
  • 3-3.1 Posting and Recording
  • 3-3.1S Posting and Recording
  • 3-3.2 Limit Review and Approvals
  • 3-3.3 Personnel Controls
  • 3-3.4 Explosives Control
  • 3-3.4S Explosives Control
• 3-4.0 IHE Limits

CHAPTER IV - PERSONAL PROTECTIVE CLOTHING AND EQUIPMENT

• 4-1.0 Clothing and Personal Equipment
• 4-1.1 Clothing
• 4-1.1S Clothing
• 4-1.2 Footwear
• 4-1.3 Respirators
• 4-1.4 Eye Protection
• 4-1.5 Gloves
• 4-2.0 Maintenance and Testing
• 4-2.1 Equipment Maintenance and Inspection
• 4-2.2 Conductivity Testing
• 4-2.3 Cleaning and Disinfecting
• 4-2.4 Contaminated Clothing

CHAPTER V - TRAINING

• 5-1.0 General
• 5-2.0 Supervisory Responsibility
• 5-2.0S Supervisory Responsibility
• 5-3.0 Training and Qualification Programs
• 5-3.0S Training and Qualification Programs
• 5-4.0 Unexploded Ordnance (UXO)Training
• 5-5.0 References
• Attachments
• 5-1 – Training Requirements
• 5-2 – Qualification Card
• 5-3 – Job Certification Record

CHAPTER VI - QUANTITY-DISTANCE AND LEVEL-OF-PROTECTION CRITERIA FOR EXPLOSIVES ACTIVITIES

• 6-1.0 General
• 6-1.0S General
• 6-1.1 For New Explosives Facilities and Operations and Explosives Facilities Undergoing Major Modifications
• 6-1.2 For Existing Explosives Facilities and Operations
• 6-2.0 Applicability of Criteria
• 6-2.1 Specific Applications
• 6-2.2 Explosives Limits
• 6-2.3 Areas Where Criteria Are Not Applicable
• 6-3.0 Quantity-Distance Criteria
• 6-3.1 Hazard Classes and Class Division
• 6-3.2 Establishing Quantity of Explosives and Distances
• 6-3.2.1 General
• 6-3.2.1S General
• 6-3.2.2 Use of Metric System
• 6-3.2.3 Railcars and Transport Vehicles
• 6-3.2.4 Utilities Installations
• 6-3.2.5 Petroleum Storage Tanks
• 6-3.2.6 Minimum Quantity-Distance Requirements for Small Amounts of Energetic Material Having 1.1 Hazard Classification
• 6-4.0 Level-of-Protection Criteria
• 6-4.1 Hazard Classes
• 6-4.2 Required Level of Protection
• 6-4.2.1 Explosives Bay
• 6-4.2.2 Bays for Joint Explosives-Plutonium Activities
• 6-5.0 Fire Protection
• 6-5.1 Vegetation Control
• v5.2 Fire Protection Criteria
• 6-6.0 Explosives Facility Siting and Design Criteria References
  • 6-6.1 Site and General Construction Plans for Ammunition and Explosives Facilities

CHAPTER VII - OPERATING PROCEDURES

• 7-1.0 General
• 7-1.1 Requirements
• 7-1.2 Types of Procedures
• 7-2.0 Guidelines
• 7-2.1 Before Operation
• 7-2.2 Supervisory Responsibility
• 7-2.3 Preparation
• 7-2.4 Approval
• 7-2.5 Control
• 7-2.6 Audits
• 7-2.7 Reviews
• 7-2.7S Reviews
• 7-2.8 Content of Standard Operating Procedures
  • 7-2.8.1 General Operating Procedures
  • 7-2.8.2 Unit Operating Procedures
  • 7-2.8.2S Unit Operating Procedures
• 7-2.9 Content of Special or Experimental Procedures
• 7-3.0 Reference Documents

CHAPTER VIII - FORMULATION SCALEUP

• 8-1.0 Explosives Development Program
  • 8-1.1 Explosives Development Committee
  • 8-1.1S Explosives Development Committee
  • 8-1.2 Phase-by-Phase Approvals
  • 8-1.3 Modified Formulations
  • 8-1.4 Sensitivity Data from Another Laboratory
• 8-2.0 Development Procedures
  • 8-2.1 General
  • 8-2.2 Synthesis Phase
  • 8-2.3 Compatibility Testing
  • 8-2.4 Phase I-Preliminary Explosives Testing
  • 8-2.5 Phase II-Experimental Characterization and Development
  • 8-2.6 Phase III-Full-Scale Testing and Production

CHAPTER IX - INSENSITIVE HIGH EXPLOSIVES QUALIFICATION

• 9-1.0 Insensitive High Explosives (IHE)
• 9-2.0 IHE Subassemblies
• 9-3.0 IHE Weapons
• 9-4.0 Reference Documents

CHAPTER X – ELECTRICAL STORMS AND LIGHTNING PROTECTION

• 10-1.0 Electrical Storm Hazards
• 10-2.0 Lightning Protection Systems
• 10-2.1 Lightning Protection System Basic Design
• 10-2.2 Lightning Protection Subsystems
• 10-2.3 Approved Lightning Protection Systems
• 10-2.3.1 Mast System
• 10-2.3.2 Catenary System
• 10-2.3.3 Integral Air Terminal System
• 10-2.3.4 Faraday-Cage and Faraday-like System
• 10-2.4 Lightning Protection Subsystem Criteria
• 10-2.4.1 Components of Strike Termination System
• 10-2.4.2 Grounding
• 10-2.4.3 Bonding
• 10-2.4.4 Surge Suppression for Incoming Conductors
• 10-2.4.5 Sideflash (Arcing) Protection
• 10-3.0 Inspection and Testing of Lightning Protection Systems
• 10-3.1 Initial Installation or Approval
• 10-3.1.1 Structures with Catenary, Integral, or Mast Lightning Protection Systems
• 10-3.1.2 Structures with Faraday-like Shield Lightning Protection System
• 10-3.2 Periodic Inspections and Testing
• 10-3.2.1 Structures with Catenary, Integral, or Mast Lightning Protection Systems
• 10-3.2.2 Structures with Faraday-Cage and Faraday-like Shield Lightning Protection Systems
• 10-3.2S Lightning Protection Periodic Inspections and Testing
• 10-3.3 Acceptable Electrical Test Measurements
• 10-3.3.1 Structures with Catenary, Integral, or NFPA 780 Lightning Protection Systems
• 10-3.3.2 Structures with Faraday Cage/Faraday-like Shield Lightning Protection Systems
• 10-3.3.3 Test Instruments
• 10-3.3.4 Alternative Testing
• 10-3.4 Procedures
• 10-3.5 Documentation and Trend Analysis
• 10-3.6 Training
• 10-4.0 Lightning Protection Exceptions
• 10-5.0 Lightning Threat Detection
• 10-6.0 Lightning Threat Actions
• 10-7.0 Shutdown of Operations
• 10-8.0 Lightning Warning and Protection Plan
• 10-8.1 Evaluation of Lightning Risk
• 10-8.2 Lightning Protection System Installation
• 10-8.3 LPS Inspection and Maintenance
• 10-8.4 Sideflash Separation (Standoff) Distances
• 10-8.5 Lightning Threat
• 10-9.0 Reference Documents

CHAPTER XI – EXPLOSIVES INVENTORY SYSTEM (EIS)

• 11-1.0 General
• 11-2.0 Roles and Responsibilities
• 11-2.1 Organization/EIS Manager
• 11-2.2 EIS TU Owners
• 11-2.3 EIS TU Owner Groups
• 11-2.4 Location TU Owner
• 11-3.0 Acquisition
• 11-3.1 Acquisition System
• 11-3.2 Submit an Acquisition
• 11-3.3 Receiving
• 11-4.0 Inventories
• 11-4.1 Inventory Procedures
• 11-4.2 Annual Inventories
• 11-4.3 Transfer of TU Owner's Inventory
• 11-4.4 Explosives Stock Level Management
• 11-5.0 Expenditures
• 11-6.0 Resource Recovery and Disposition Account (RRDA)

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