This comprehensive manuscript applies to all DOE facilities engaged in developing, manufacturing, handling, storing, transporting, processing, or testing explosives, pyrotechnics and propellants, or assemblies containing these materials, and to the safe management of such operations.

Explosives handling and processing operations by the DOE are an integral part of DOE weapons and weapons related development, manufacturing, and dismantlement activities. Safety in all operations associated with weapons development is an ongoing, prime concern and must continually be given high priority in all program direction and management.

Explosives are energetic materials that can react violently. Explosives should be protected from abnormal stimuli or environments including Friction forces, excessive pressures and temperatures, Impact, shock, and pinching, deformation, electrical sparks, abrasive or welding sparks and open flame, contamination; and contact with incompatible materials.

Before being used in the explosives process, and at established intervals, processing and test equipment shall be checked. This checkout may require the use of mock explosives in process or test conditions. Explosive materials must not be pinched or confined between equipment lids or covers and their mating surfaces. These surfaces shall be cleaned before cover placement. This includes pressing operations.

Before beginning any explosives synthesis, formulation, manufacturing, testing, or disposal operation, a process hazard analysis shall be performed. A single process hazard analysis may be performed for similar processes performed in a single facility, provided that the “worst-case” process is the basis for the hazard analysis.

DOE occupancies containing high explosives dictate personnel protection from blast overpressures and fragments (and spread of plutonium in some occupancies) from an accidental detonation.

Slide escapes should be provided for elevated explosives operating locations from which rapid exit may be vital and cannot be obtained by other means. Slide escapes should be located on opposite sides of the explosives operation to reduce the likelihood of personnel being trapped by fire between them and a single slide

Structures containing explosives shall be kept clean and orderly. To maintain safe conditions, there shall be a regular cleaning program for building interiors to prevent explosives dust and waste accumulation. This program should not be conducted in any bay where a hazardous operation is being conducted.

Records shall be maintained for inspection, repair, and servicing of process and handling equipment and fire protection systems. There shall be no smoking in explosives storage, processing, or test areas, except in designated locations.

Whenever an electrical storm approaches, personnel shall exit any location wherein a hazard exists due to explosives being initiated by lightning. Evacuated personnel shall proceed to a suitable protective shelter. A suitable protective shelter is one that will protect personnel from overpressures greater than 16 kPa (2.3 si), structural collapse, and missiles in the event of explosion of any adjacent facility containing explosives.

Topics are covered in following order in this manuscript:

• PREFACE
• FOREWORD
• LIST OF TABLES
• LIST OF FIGURES
• ACRONYMS
• CHAPTER I—INTRODUCTION
  • Scope, Purpose, And Justification
  • Applicability
  • Exemptions
  • Waivers
  • Manual Administration And Management
  • Definitions
• CHAPTER II—OPERATIONAL SAFETY
  • Work Environment
  • General Operations Safety Guidelines
  • Work Environment
  • Building And Equipment Maintenance
  • Remote Operations
  • General Explosives Area Controls
  • Electrical Storms And Lightning Protection
  • Static Electricity
  • Electrical Equipment And Wiring
  • Vacuum Equipment
  • Explosives Dust Exhaust Ventilation And Collection Systems
  • Drains And Sumps
  • Processing
  • Testing
  • Materials Handling
  • Materials Receipt
  • Transportation
  • Explosives Storage
  • Decontamination And Cleaning
  • Waste Collection
  • Waste Disposal
  • Laboratory Operations
  • Emergency Control
• CHAPTER III—EXPLOSIVES AND PERSONNEL LIMITS AND CONTROL
  • Explosives Limits
  • Personnel Limits
  • Limit Control
  • IHE Limits
• CHAPTER IV—PERSONAL PROTECTIVE CLOTHING AND EQUIPMENT
  • Clothing And Personal Equipment
  • Maintenance And Testing
• CHAPTER V—TRAINING
  • General
  • Supervisory Responsibility
  • Training And Qualification Programs
  • UXO Training
  • References
• CHAPTER VI—QUANTITY-DISTANCE AND LEVEL-OF-PROTECTION CRITERIA FOR EXPLOSIVES ACTIVITIES
  • General
  • Applicability Of Criteria
  • Quantity-Distance Criteria
  • Level-Of-Protection Criteria
  • Fire Protection
  • Explosives Facility Siting And Design Criteria References
• CHAPTER VII—OPERATING PROCEDURES
  • General
  • Guidelines
  • Reference Documents
• CHAPTER VIII—FORMULATION SCALEUP
  • Explosives Development Program
  • Development Procedures
• CHAPTER IX—INSENSITIVE HIGH EXPLOSIVES QUALIFICATION
  • Insensitive High Explosives (IHE)
  • IHE Subassemblies
  • The Weapons
  • Reference Documents
• APPENDIX A—REFERENCES
• APPENDIX B—INDEX
• APPENDIX C—APPROVED CHANGES

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