DOE-STD-1212-2019, Explosives Safety

DOE TECHNICAL STANDARD EXPLOSIVES SAFETY DOE-STD-1212-2019 MEASUREMENT SENSITIVE U.S. Department of Energy AREA SAFT Washington, D.C.20585 DISTRIBUTION STATEMENT A. Approved for public release; distribution is unlimited. November 2019 (This page left intentionally blank.) DOE-STD-1212-2019 i FOREWORD 1. This Department of Energy (DOE) Standard has been approved to be used by DOE, including the National Nuclear Security Administration, and their contractors. 2. Comments (recommendations, additions, and deletions) and data, that may be of use in improving this document, should be e-mailed to thomas.garcia@nnsa.doe.gov or sent to: NA-513 U.S. Department of Energy National Nuclear Security Administration P.O. Box 5400 Albuquerque, NM 87185-5400 3. This Standard is the successor to DOE-STD-1212-2012. It provides requirements for an Explosives Safety Program. 4. This official version of the Standard may be found online at: https://www.standards.doe.gov/standards-browse DOE-STD-1212-2019 ii (This page left intentionally blank.) DOE-STD-1212-2019 iii Table of Contents 1. Scope/Purpose……………………………………………………….………….. 1 2. Applicability …..……………………………………………………..…………… 1 3. Administration and Management …..…………………………………............ 1 3.1. Office of Primary Interest Designation …...…………………………………… 1 3.2. Exemption ………………………………………………..………….…………... 2 3.3. Equivalency ………………………………………..……………….…………… 3 3.4. Waiver ….….….……………………………………………………….…………. 3 4. Explosives Safety Program Requirements ……………………..................... 4 4.1. ESP Content ……………………………………………….……………………. 4 5. Roles and Responsibilities …..…………………………………….………...... 5 5.1. NNSA Associate Administrator for Safety, Infrastructure, and Operations . 5 5.2. Central Technical Authority ………………………………………................... 5 5.3. Explosives Approval Authority ………………………………………………… 5 5.4. Head of DOE Field Element ……………………………………….................. 5 5.5. Explosives Safety Subject Matter Expert (DOE/NNSA Sites) ……………… 6 5.6. DOE/NNSA Explosives Safety Committee Chair ...………………………….. 6 5.7. Contractor Facility Manager ………………………………………………….... 6 5.8. Contractor Facility Management ………………………………………………. 6 5.9. Contractor Explosives Safety Program Manager ……………………………. 7 5.10. Contractor Explosives Safety Authority Having Jurisdiction ……………….. 7 6. General Operational Safety ………………………….………………………… 8 6.1. Cardinal Principle …………………………………………………………......... 8 6.2. Protection of Explosives …………………………………………………..…… 8 6.3. Equipment Checks ……………………………………………………………… 8 6.4. Inspection Frequency …………………………………………………………... 9 6.5. Hazard Identification and Communication …………………………………… 9 6.6. Work Environment ……………………………………………………………… 9 6.7. General Explosives Area Controls ……………………………………………. 10 6.8. Concurrent Contact Operations …………………………………………......... 10 6.9. Contamination Prevention ……………………………………….…………..… 11 7. Explosives Facility Design/Site Criteria ………………………….……........... 12 7.1. Explosives Facilities ………………………………………………………......... 12 7.2. Blast Resistant Design ………………………………………………………..... 12 7.3. Criteria for Lightning Protection Systems ………………………………......... 12 7.4. Unproven Facility Design ……………………………………………..……….. 13 7.5. Design of New Facilities ……………………………………………………..… 13 7.6. Site and General Construction Plans …………………………………..…….. 14 8. Hazard Analysis ………………………………..………………………..……… 15 8.1. Hazard Analysis ……………………………………………………………….... 15 8.2. Similar Processes ………………………………………………………………. 16 8.3. High Risk ………………………………………………………………………… 16 8.4. Electrical Hazard Classification Analysis …………………………………….. 17 9. Operating Procedures ………………………………………………………...... 17 9.1. Procedures ………………………………………………………………………. 17

DOE-STD-1212-2019 iv 9.2. Approval …….……………………………………………………………………. 18 9.3. Operating Procedures Content ………………..………………………………. 18 9.4. Special or Experimental Procedures ………………………………………….. 19 10. Training …………………………………………………………………………… 19 10.1. Explosives Safety Training ……………………………………………………... 19 10.2. Training and Qualification Programs ………………………………………….. 20 10.3. Unexploded Ordnance Qualification …………………………………………... 20 11. Quantity-Distance ……………………………………………………….….….... 21 11.1. Explosives Safety Site Plan Submission and Approval …………………..…. 21 11.2. Quantity-Distance Criteria …………………………………..………………….. 22 12. Level-of-Protection Criteria ……………………………………..……………… 25 12.1. Required Level-of-Protection ………………………………………..…………. 25 12.2. Hazard Class 0 ………………………………………………………………….. 25 12.3. Hazard Class I …………………………………………………………………... 26 12.4. Hazard Class II ……………………………………..…………………………… 27 12.5. Hazard Class III …………………………………….………………………….... 28 12.6. Hazard Class IV ………………………………………..………………………... 28 13. Remote Operations ……………………………………..………………………. 29 13.1. Personnel Protection ……………………………………..……………............. 29 13.2. Access and Equipment Controls ………………………………………............ 29 14. Limits and Control ………………………………………………..……………... 30 14.1. Explosives Limits …………………………………………….………………….. 30 14.2. Personnel Limits ………………………………………..………………............. 30 14.3. Limit Control ………………………………………….………………………….. 31 15. Personal Protective Equipment ………………………………..….…………... 32 15.1. Clothing …………………………………………………………….…………….. 32 15.2. Footwear …………………………………………………………………………. 32 15.3. Wristbands ………………………………………………………….……………. 32 16. Insensitive High Explosives Qualification ………………………………......... 33 16.1. Revisions to Insensitive High Explosives Test Description and Criteria …... 33 16.2. Insensitive High Explosive Materials ………………………………………….. 33 16.3. IHE Qualification Testing ……………………………………………………….. 33 16.4. IHE Qualification Process ………………………………………………........... 35 16.5. IHE Subassemblies Testing ……………………………………………............ 36 16.6. IHE Subassembly Qualification Process ……………………………………... 38 16.7. IHE Weapons ……………………………………………………………………. 39 17. Laboratory Operations ………………………………………………………….. 42 17.1. Operational Requirements ……………………………………………………... 42 17.2. Blast Shields ……………………………………………………………………... 42 17.3. Heating Operations ……………………………………………………………... 44 17.4. Laboratory Setups ………………………………………………………………. 45 17.5. Low Concentration of Explosives in Solution ………………………………… 45 17.6. Explosives Sample Control …………………………………………………….. 46 17.7. De minimis or Residual Quantities …………………………………………….. 46 17.8. Laboratory Wiring and Equipment …………………………………………….. 46 18. Inspection ………………………………………………………………………... 47 DOE-STD-1212-2019 v

18.1. Inspections ……………………………………………………………………….. 47 18.2. Inspection Methods ……………………………………………………………... 47 18.3. Equipment Inspection Design and Operation ………………………………... 47 19. Explosives Development and Formulation Scaleup …………………………. 48 19.1. Contractor Explosives Development Committee …………………………….. 48 19.2. Development Process …………………………………………………………... 48 19.3. Sensitivity Testing ……………………………………………………………….. 50 19.4. Compatibility Testing ……………………………………………………............ 51 19.5. Phase I-Preliminary Development …………………………………………….. 51 19.6. Phase II-Experimental Characterization and Development ……………….... 52 19.7. Phase III-Full-Scale Testing and Production Development ………………… 53 20. Synthesis and Formulation …………………………………………………….. 53 20.1. Synthesis …………………………………………………………………........... 53 20.2. Formulation ………………………………………………………………............ 55 21. Heating, Drying, and Thermal Conditioning ………………………………….. 57 21.1. Hazards of Heating Explosives ………………………………………………... 57 21.2. Critical Temperature and Thermal Analysis Methodology ………………….. 58 21.3. Heating and Drying Equipment ………………………………………………... 59 21.4. Heating and Drying Operations ………………………………………………... 60 22. Dry Screening, Blending, and Melting ……………………………………….... 62 22.1. Dry Screening ……………………………………………………………........... 62 22.2. Blending ………………………………………………………………………….. 62 22.3. Melting ……………………………………………………………………………. 63 23. Pressing and Extruding …………………………………………………………. 64 23.1. Pressing ………………………………………………………………………….. 64 23.2. Extruding …………………………………………………………………………. 66 24. Machining ………………………………………………………………………... 67 24.1. Equipment Requirements ………………………………………………............ 67 24.2. Contact or Remote Operations ………………………………………………... 68 24.3. Setup and Preparation Prior to Machining ……………………………........... 70 24.4. Operations Requirements ………………………………………………........... 70 24.5. Drilling …………………………………………………………………………….. 72 24.6. Coring …………………………………………………………………………….. 72 24.7. Sawing ……………………………………………………………………............ 73 25. Low Pressure Fluids …………………………………………………………….. 73 25.1. Use of Low Pressure Fluids ……………………………………………………. 73 26. Laser Ablation …………………………………………………………………… 74 26.1. Laser Ablation Operations …….……………………………………………….. 74 27. Hand Cutting and Finishing …………………………………………………….. 74 27.1. Hand-Cutting and Finishing Operations ………………………………............ 74 28. Assembly and Disassembly ……………………………………………............ 75 28.1. Tools ……………………………………………………………………………… 75 28.2. Assembly Operations ………………………………………………………….... 75 28.3. Loading Assemblies with Plastic or Extrudable Explosives ……………….... 75 28.4. Disassembly Operations ……………………………………………………….. 75 28.5. Personnel Protection for Disassembly Operations ………………………….. 76 DOE-STD-1212-2019 vi

29. Testing ………………………………………………………………………….... 76 29.1. Test Planning ……………………………………………………………………. 76 29.2. Firing Areas ………………………………………………………………........... 77 29.3. Checkout of Dynamic Engineering Test Equipment ………………………… 77 29.4. Testing of Explosives and Hazardous Radioactive Materials ………........... 78 29.5. Heating of Explosives Test Specimens ……………………………………….. 78 29.6. Instrumentation ………………………………………………………………….. 79 29.7. Explosives Accumulation Limits ……………………………………………….. 79 30. Test Firing ………………………………………………………………………... 79 30.1. General Range Standards ……………………………………………………... 79 30.2. Grass Fires ………………………………………………………………………. 81 30.3. Test Setup ……………………………………………………………………….. 81 30.4. Pin Switches and Other Non-initiating Circuits ………………………………. 82 30.5. Low-Energy Electro-explosive Devices ……………………………………….. 82 30.6. Explosives Storage in Firing Areas ……………………………………............ 83 30.7. Firing Leads …………………………………………………………………….... 83 30.8. Unattended Test Assemblies ………………………………………................. 83 30.9. Firing Control Circuit Criteria …………………………………………………... 83 30.10. Test Firing in Containment Apparatus ………………………………………... 85 30.11. Gun Firings ………………………………………………………………………. 86 30.12. Drop Testing …………………………………………………………….............. 87 30.13. Post-firing Controls …………………………………………………………….... 87 30.14. Contamination of Firing Areas …………………………………………………. 88 31. Test Failures and Misfires ……………………………………………………… 88 31.1. Explosives Misfire ……………………………………………………………….. 88 31.2. Misfire of a Remotely Fired Gun ………………………………………………. 89 32. Explosives Storage ……………………………………………………………... 90 32.1. Storage Magazine Facilities ……………………………………………............ 90 32.2. Storage Magazine Operations …………………………………………............ 91 32.3. Storage Review Program ………………………………………………………. 93 32.4. Storage Compatibility ………………………………………………………….... 93 32.5. Onsite Containers ……………………………………………………………….. 97 32.6. Storage in Buildings Other Than Storage Magazines ………………………. 98 33. Transportation …………………………………………………………………… 107 33.1. Explosives Transportation …………………………………………………….... 107 33.2. Onsite Shipments ……………………………………………………………….. 108 33.3. Materials Handling Equipment ………………………………………............... 109 33.4. General Operation Requirements ……………………………………………... 110 33.5. Hazardous Conditions …………………………………………………............. 110 34. Materials Receipt ………………………………………………………………... 111 34.1. Motor Vehicles …………………………………………………………………... 111 34.2. Damaged Shipments ……………………………………………………........... 113 35. Materials Handling ………………………………………………………………. 113 35.1. Material Handling ………………………………………………………………... 113 35.2. Manual Handling of Bare Consolidated Explosives …………………………. 114 35.3. Carts or Hand Trucks ………………………………………………………….... 114 DOE-STD-1212-2019 vii 35.4. Vacuum Handling ……………………………………………………………….. 115 36. Electrical ………………………………………………………………………….. 115 36.1. Electrical Equipment and Wiring ………………………………………………. 115 36.2. Electrical Hazard Classification for Explosives Operations or Activities …... 116 36.3. Electrical Supply System ……………………………………………………….. 117 36.4. Electrical Equipment and Instrumentation ……………………………………. 119 36.5. Hand-held, Battery-Powered Lights and Instruments ……………………….. 120 36.6. Non-Rated Extension Lighting …………………………………………............ 121 37. Electrical Test Instruments ……………………………………………………... 121 37.1. Terminology Specific to this Chapter ………………………………………….. 121 37.2. Classification …………………………………………………………………….. 122 37.3. Approval and Certification ……………………………………………………… 122 37.4. Electrical Instruments for Use with Initiating Electrical Circuits …………….. 123 37.5. Electrical Instruments for Use with Non-Initiating Electrical Circuits ………. 124 38. Electro-Explosive Devices ……………………………………………………... 124 38.1. Protection from Electromagnetic Radiation …………………………………... 124 39. Static Electricity ………………………………………………………………….. 126 39.1. Bonding and Grounding of Equipment ………………………………………... 126 39.2. Testing Bonded Equipment Grounds …………………………………………. 126 39.3. Conductive Floors, Shoes, Mats, and Wristbands …………………………... 127 39.4. Conductive Floor, Shoes, Work Surface, Wristband, and Rubber Hose

Specifications ……………………………………………………………............ 127 39.5. Conductive Floor, Shoes, Work Surface, and Wristband Tests ……............ 128 39.6. Humidification ……………………………………………………………............ 129 40. Fire Protection ………………………………………………………………….... 130 40.1. Vegetation Control ………………………………………………………............ 130 40.2. Fire Protection Criteria ………………………………………………………….. 130 41. Facility Egress ………………………………………………………………….... 131 41.1. Personnel Protective Restrictions and Requirements ………………………. 131 41.2. Requirements for Existing Facilities …………………………………………... 131 41.3. Requirements for New Facilities ………………………………………………. 132 41.4. Single Exits ………………………………………………………………………. 132 41.5. Blast Resistant Doors …………………………………………………………... 133 41.6. Slide Escapes ……………………………………………………………........... 134 42. Lightning Protection …………………………………………………………….. 135 42.1. Lightning Protection Systems ………………………………………………….. 135 42.2. Conditions Where Lightning Protection Is Not Required ……………............ 135 42.3. Lightning Warning and Protection Plan ……………………………………….. 136 42.4. Lightning Threat Actions ………………………………………………………... 136 42.5. Pause of Operations ……………………………………………………………. 138 43. Building and Equipment Maintenance ……………...……………………....... 139 43.1. Cleaning ………………………………………………………………………….. 139 43.2. Maintenance and Repair ……………………………………………………….. 140 43.3. Hot Work Permits ……………………………………………………………….. 141 44. Decontamination and Cleaning ………………………………………………... 141 44.1. Cleaning Operations ……………………………………………………………. 141 DOE-STD-1212-2019 viii 44.2. Cleaning Screw Threads ……………………………………………………….. 142 44.3. Final Decontamination and Disposal of Equipment …………………………. 142 44.4. Inspection ………………………………………………………………………... 143 44.5. Identification and Control of Decontaminated Items ………………………… 143 45. Collection Systems …………………………………………………………….... 144 45.1. Vacuum Equipment ……………………………………………………………... 144 45.2. Explosives Dust Exhaust Ventilation and Collection Systems ……………... 145 46. Drains and Sumps ……………………………………………….………........... 146 46.1. Collection …………………………………………………………………........... 146 46.2. Effluent ……………………………………………………………………........... 148 47. Waste Collection ……………………………………….………………………... 148 47.1. Removal of Explosives Waste …………………………………………………. 148 47.2. Solid Wastes …………………………………………………………………….. 148 47.3. Vacuum Collection of Explosives Dusts ………………………………........... 149 47.4. Explosives Slurries ……………………………………………………………… 151 47.5. Metal Scrap ………………………………………………………………………. 151 47.6. Salvaged Explosives ……………………………………………………………. 152 48. Waste Disposal ………………………………………..……………………….... 152 48.1. Preparation for Open Burning ………………………………………………….. 152 48.2. Destruction by Burning or Flashing ……………………………………........... 153 48.3. Ignition System Malfunctions …………………………………………………... 154 48.4. Post-burn Operations ………………………………………………………….... 154 48.5. Disposal Area ……………………………………………………………………. 155 48.6. Destruction by Detonation …………………………………………………….... 156 48.7. Use of Solvents ………………………………………………………………….. 156 49. Emergency Control ………………………………………..……………………. 157 49.1. Placards and Fire Symbols …………………………………………………….. 157 49.2. Emergency Plans ……………………………………………………………….. 157 50. Security Response Force Ammunition ………………………………............. 157 50.1. Security Vehicles and Personnel Carrying HD 1.1/1.2 Ammunition ……….. 157 50.2. Security Ammunition Surveillance …………………………………………….. 157 50.3. Pre-positioned Storage …………………………………………………………. 157 50.4. Security Working Dog Explosives Training Aids …………………………….. 158 Appendix A: Acronyms …………………………………………………………………… 160 Appendix B: Definitions……………………………………………………………………. 166 Appendix C: Measurement Abbreviations ………………………..…………………….. 174 Appendix D: References ………………………………………….………….................. 176

DOE-STD-1212-2019 ix (This page left intentionally blank.) DOE-STD-1212-2019 1 1. SCOPE/PURPOSE 1.1. This Technical Standard provides the basic technical requirements for an explosives safety program necessary to ensure safe operations involving explosives, explosives assemblies, pyrotechnics and propellants, and assemblies containing these materials. 1.2. This Technical Standard establishes safety controls and standards not addressed in other existing DOE or non-DOE regulations and is intended to close the safety gap created by DOE’s unique activities to govern the DOE explosives safety process and ensure explosives safety is commensurate with the risk. 1.3. This Technical Standard is based on the Cardinal Principle of Explosives Safety, which is to limit exposure to a minimum number of personnel, for a minimum amount of time, to a minimum amount of explosives, consistent with safe and efficient operations. 2. APPLICABILITY 2.1. This Technical Standard applies to all DOE sites engaged in any of the following activities involving explosives, pyrotechnics, or propellants as well as assemblies containing these materials:  Developing  Manufacturing  Handling  Storing  Transporting  Processing  Testing 2.2. Existing facilities that do not meet the requirements of this technical standard may continue to be used for the balance of their functional lives if the following two conditions are met and documented: 2.2.1. The current operation presents no significantly greater risk than that assumed when the facility was originally designed. 2.2.2. It can be demonstrated clearly that a modification to bring the facility into compliance is not feasible. 3. ADMINISTRATION AND MANAGEMENT 3.1. NA-513 Office of Worker Safety and Health Services is the National Nuclear Security Administration (NNSA) Office of Primary Interest (OPI) for this Technical Standard. NA-513 shall act as the Preparing Activity DOE-STD-1212-2019 2 for this Technical Standard. The DOE/NNSA Explosives Safety Committee (ESC) shall review, evaluate, and recommend proposed changes to this Technical Standard. The changes shall be consonant with state-of-the-art technical changes in the field and include lessons learned from DOE/NNSA, other Governmental, and Industry experience and mishaps. NA-513 shall evaluate proposed changes to this Technical Standard on an annual basis. The OPI may decide to submit a section into RevCom for review and approval. 3.1.1. The DOE/NNSA ESC shall evaluate proposed changes at the request of the OPI. 3.1.2. Throughout this Standard, requirements are denoted by the words “shall” and “should.” Note: The use of the word “may” with reference to application of a procedure or method denotes an acceptable means of performing the task. 3.1.2.1. “Shall” requirements are mandatory. Note 1: Relief from a "shall" requirement requires an exemption (see section 3.2 of this chapter). Note 2: A contractor may use an approved equivalency as an alternative approach to meet a "shall" requirement, (see section 3.3 of this chapter). 3.1.2.2. “Should” requirements are advisory. Note: Relief from a “should” requirement requires a waiver (see section 3.4 of this chapter). 3.2. Exemption 3.2.1. Exemptions are the release from requirements in this Standard. 3.2.2. Exemptions are approved by the Head of DOE Field Element (DOE/NNSA Field/Operations/ Production Office) or designee, and documented for the OPI in a memorandum.

3.2.3. Central Technical Authority (CTA) or designee concurrence is required prior to the granting of exemptions for nuclear safety directives or successor documents identified in the current version of DOE O 410.1, Central Technical Authority Responsibilities Regarding Nuclear Safety DOE-STD-1212-2019 3 Requirements. CTA or designee concurrence is required for exemptions involving hazard category 1, 2, or 3 nuclear facilities. 3.2.4. Exemptions are processed by the Head of the DOE Field Element or designee. Follow DOE-O-251.1D Appendix E for the Exemption Process. 3.3. Equivalency 3.3.1. Equivalencies represent an alternative approach to meeting a “shall” requirement of the Standard intended to achieve an equivalent level of safety. 3.3.2. Required documentation for an equivalency:  Description of the condition.  Requirement(s) being affected.  Reason why requirement cannot be achieved.  Alternate approach.  Contractor Explosives Safety Authority Having Jurisdiction (AHJ) determination of equivalent safety.  Contractor Explosives Safety AHJ explanation of additional risk (if applicable). 3.3.3. The Contractor Explosives Safety AHJ shall evaluate, determine, and document that the proposed alternate approach complies with the intent of the provisions of this Standard. 3.3.4. The Contractor Explosives Safety AHJ shall provide a determination of equivalent safety. 3.3.4.1. If the equivalency introduces additional risk, the Contractor Explosives Safety AHJ shall include an explanation of the additional risk. 3.3.5. Equivalencies shall be coordinated with the Federal Explosives Safety Subject Matter Expert (SME) (DOE/NNSA Sites). 3.3.6. Equivalencies that do not introduce additional risk are approved by the Contractor Facility Manager. 3.3.6.1. Equivalencies that introduce additional risk are approved by the Head of DOE Field Element. 3.4. Waiver 3.4.1. A Waiver provides relief from a “should” requirement. DOE-STD-1212-2019 4 3.4.2. A Waiver is where the conditions, practices, means, methods, or processes to be used are determined to be safe and necessary. 3.4.3. The Contractor Explosives Safety AHJ shall evaluate, determine, and document that the proposed waiver complies with the intent of the provisions of this Standard. This documentation shall include a determination regarding the safety and necessity of the waiver. 3.4.4. Waivers are approved by Contractor Facility Management. 3.4.5. Required documentation for a waiver:  Description of the condition.  Requirement being affected.  Reason why compliance is not achieved.  Compensatory measures taken to provide protection.  Any proposed corrective actions and schedule.  Contractor Explosives Safety AHJ determination.  Duration of the waiver. 4. EXPLOSIVES SAFETY PROGRAM (ESP) REQUIREMENTS 4.1. All DOE sites within the scope of this Technical Standard shall establish and maintain a site-specific ESP based on the requirements in this Technical Standard and 10 CFR 851.24. ESPs shall address all applicable explosives operations and activities. The ESP shall include: 4.1.1. The organizational structure for site Explosives Safety operations and activities. Address the following committees as they apply: 4.1.1.1. A Contractor Explosives Development Committee to approve each phase of an explosives development program. 4.1.1.2. A Contractor Explosives Storage Review Committee to establish and approve storage review intervals for all bulk explosives stored at the facility.

4.1.2. The process to resolve technical conflicts between Explosives Safety requirements and other functional area technical requirements. 4.1.3. The process to apply specific Explosives Safety provisions to meet Level-of-Protection criteria. 4.1.4. The process to interact with other safety disciplines supporting explosives operations and activities performed at the site. DOE-STD-1212-2019 5 4.1.5. The hazard analysis process in support of explosives operations and activities, with a graded approach. 4.1.6. The training and qualification program to support explosives operations and activities. 5. ROLES AND RESPONSIBILITIES 5.1. NNSA Associate Administrator for Safety, Infrastructure, and Operations. 5.1.1. Designates Explosives Approval Authority (EAA) to approve qualification of Insensitive High Explosive (IHE) Material and/or Subassembly. 5.1.2. Exercises responsibilities delegated by the Administrator under this Standard. 5.2. Central Technical Authority (CTA) 5.2.1. Concurs with exemptions to this Technical Standard involving hazard category 1, 2, or 3 nuclear facilities. 5.3. Explosives Approval Authority (EAA) 5.3.1. Approves Qualification of Insensitive High Explosive Material and/or Subassembly. 5.4. Head of DOE Field Element (DOE/NNSA Field/Operations/Production Office). 5.4.1. Verifies that the facilities, activities, and programs under their purview operate in compliance with the requirements of this Technical Standard. 5.4.2. Approves exemptions to this Technical Standard. 5.4.2.1. Exemptions involving hazard category 1, 2, or 3 nuclear facilities require CTA concurrence. 5.4.3. Approves equivalencies to this Technical Standard that introduce additional risk. 5.4.4. Approves Explosives Safety Site Plans. 5.4.5. Approves site and general construction plans for explosives facilities. DOE-STD-1212-2019 6 5.4.6. Provides oversight of the Contractor ESP. 5.4.7. Appoints a primary and alternate field element representative to the DOE/NNSA Explosives Safety Committee (ESC). Ensures an appointed member attends each DOE/NNSA ESC Meeting. 5.5. Federal Explosives Safety Subject Matter Expert (SME) (DOE/NNSA Sites). 5.5.1. Reviews and recommends approval or disapproval to the Head of DOE Field Element or designee for: 5.5.1.1. Exemptions to this Technical Standard. 5.5.1.2. Equivalencies to this Technical Standard that introduce additional risk. 5.5.2. Reviews the Explosives Safety Site Plans (ESSP) and recommends approval or disapproval to the Head of DOE Field Element or designee. 5.5.3. Performs assessments of the Contractor ESP in accordance with DOE O 226.1, Implementation of Department of Energy Oversight Policy (current version). 5.5.4. Familiarizes themselves with the Contractor ESP and the explosives operations and activities under their contract. 5.6. DOE/NNSA ESC Chair. 5.6.1. Performs duties identified in this Technical Standard and the approved DOE/NNSA ESC Charter. 5.7. Contractor Facility Manager 5.7.1. Establishes and maintains a site-specific ESP. 5.7.2. Assigns a Contractor Explosives Safety Program Manager. 5.7.3. Appoints a primary and alternate Explosives Safety Subject-Matter- Expert as the Contractor Explosives Safety AHJ and Voting Member on the DOE/NNSA Explosives Safety Committee. Ensures an appointed member attends each DOE/NNSA ESC Meeting. 5.7.4. Approves equivalencies that provide equivalent safety. 5.8. Contractor Facility Management DOE-STD-1212-2019 7

5.8.1. Implements the Explosives Safety requirements of this Technical Standard into operations and activities involving explosives. 5.8.2. Verifies that the site training and qualification program addresses explosives workers. 5.8.3. Verifies that explosives-related activities performed on-site by entities other than DOE/NNSA contractors/subcontractors are coordinated through the Contractor Explosives Safety AHJ. 5.8.4. Transmits the ESSP to the Head of DOE Field Element or Designee for review and approval. 5.8.5. Selects hazard analysis methodology and addresses the results. 5.8.6. Approves explosives area electrical hazard classification analyses. 5.8.7. Establishes the levels of approval required for operating procedures, based on the operation’s inherent risk. 5.8.8. Establishes the frequency/interval of inspections, operational checks, storage review, and other items as identified in this Technical Standard. 5.8.9. Approves waivers. 5.9. Contractor Explosives Safety Program Manager 5.9.1. Assists Contractor Facility Management in implementing the requirements of this Technical Standard. 5.9.2. Performs site-specific explosives safety assessments to verify compliance with the requirements of this Technical Standard. 5.9.3. Recommends approval of the ESSP to Contractor Facility Management. 5.10. Contractor Explosives Safety Authority Having Jurisdiction (AHJ) 5.10.1. Assists Contractor Facility Management so that the level of explosives safety provided to site-specific explosives operations and activities is commensurate with the requirements of this Technical Standard. 5.10.2. Provides site-specific determinations, interpretations, and clarifications to the requirements of this Technical Standard. DOE-STD-1212-2019 8 5.10.3. Interfaces with other disciplines to resolve site-specific conflicts between national codes and standards and this Technical Standard. 5.10.4. Reviews and recommends approval of electrical hazard classification analyses. 5.10.5. Provides documented determinations and recommendations to Contractor Facility Management regarding proposed equivalencies and waivers to the requirements of this Technical Standard. 6. GENERAL OPERATIONAL SAFETY 6.1. Cardinal Principle 6.1.1. The Cardinal Principle of Explosives Safety is to limit exposure to a minimum number of personnel, for a minimum amount of time, to a minimum amount of explosives, consistent with safe and efficient operations. 6.1.2. The Cardinal Principle shall be observed at any location or in any operation involving explosives. 6.2. Protection of Explosives 6.2.1. Explosives are energetic materials that can react violently and 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. 6.3. Equipment Checks 6.3.1. Before being used in the explosives process, and at established intervals, processing and test equipment shall be checked for:  Proper design;  Proper function;  Specified clearances between parts in relative motion;  Abnormal metal to metal rubbing of moving parts potentially contacting explosive materials;  Cracks, voids, or screw threads where explosives may accumulate; and  Contamination that is incompatible with the process materials. DOE-STD-1212-2019 9

6.3.2. This checkout may require the use of mock explosives in process or test conditions. 6.3.3. Explosive materials shall 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. 6.4. Inspection Frequency 6.4.1. When this Technical Standard calls for an inspection, but the inspection interval is not specified, Contractor Facility Management shall establish the inspection interval. 6.4.2. Inspection intervals shall be modified when operational experience dictates a need. 6.5. Hazard Identification and Communication 6.5.1. Contractor Facility Management shall identify and maintain a current list of explosives and other hazardous materials used in conjunction with their operations. 6.5.2. Contractor Facility Management shall educate and train employees in the hazards and precautions required for handling explosives and materials used in conjunction with explosives. 6.6. Work Environment 6.6.1. Where solid bare explosive pieces are handled: 6.6.1.1. The floor should be resilient or covered with a resilient material. 6.6.1.2. All hard objects that explosives could strike in a handling incident should be covered with a resilient material where practical. Note: Physical safety systems demonstrated to preclude the explosives from being dropped or struck could meet these requirements. 6.6.2. A procedure should be established to account for hand tools that may be inadvertently dropped into an explosives processing operation, thus creating a hazard. 6.6.3. Personnel shall be assigned in such a manner that each worker’s presence is monitored frequently and assistance can be provided or aid summoned in the event of an emergency. DOE-STD-1212-2019 10 6.7. General Explosives Area Controls 6.7.1. Smoking, Matches, Lighters, Metal Articles 6.7.1.1. There shall be no smoking in explosives storage, processing, or test areas, except in designated locations. 6.7.1.2. No matches, lighters, or other fire, flame, or spark producing devices shall be taken into an explosives control area except with written authorization. If authorized to be carried, matches shall be contained in a metal carrying device too large to fit into pockets. “Strike anywhere” matches shall not be used. 6.7.1.3. Operating personnel should not carry metal articles (e.g., keys, jewelry, knives, coins) in explosives processing areas where such items could constitute a hazard if dropped into the process. 6.7.2. Cooking and Eating 6.7.2.1. Food or beverages shall not be consumed in explosives buildings, except in designated areas. 6.7.2.2. There shall be no personal dishes or utensils in an explosives building, except in designated eating areas. 6.7.2.3. Coffee pots, hot plates, ovens (including microwaves), and portable electric heaters shall not be permitted in rooms where:  Explosives may be present.  Combustible vapors or dust may be present.  Electrical classification of appliances is not compatible with the area. 6.7.3. Access to Explosives Areas 6.7.3.1. Access control procedures shall be established for entry to all explosives areas. 6.8. Concurrent Contact Operations 6.8.1. The preferred setup for explosives operations is to perform each operation in a separate location to preclude any adverse operation interaction. Because such an arrangement is frequently impractical, concurrent operations may be permitted if the following conditions exist:

DOE-STD-1212-2019 11 6.8.1.1. Potential equipment-operator interactions between the two operations have been analyzed and the risk is not appreciably greater than that for both operations considered separately. 6.8.1.2. Explosive materials in either operation are not exposed to stress conditions such as elevated temperature (melting or heat conditioning), elevated pressures (pressing or extruding), or deformation/shear (machining or cutting). 6.8.1.3. Mixing of materials in the concurrent operations does not create compatibility problems. 6.8.1.4. Each operator is aware at all times of concurrent operations in his or her area. 6.9. Contamination Prevention 6.9.1. Precautions shall be taken to avoid mutual contamination when two or more incompatible explosives or materials are handled on a single line or within one building or room. Note: This includes vacuum systems and explosives scrap collection. Note: Inadvertent mixing of incompatible explosives materials can be hazardous not only to manufacturing facilities and personnel but also to the user if such materials are loaded into explosives devices. 6.9.2. When two or more explosives are used in a line or within a building and mixing is not intended, the materials shall be segregated in separate locations. 6.9.2.1. Containers shall be clearly marked with the weight and contents identified. 6.9.2.2. Care shall be exercised to properly segregate material in service magazines and in operating buildings. 6.9.3. When a different explosive is to be used in process equipment, the equipment shall be thoroughly cleaned, and excess explosive from the previous job should be removed from the bay. Note: This eliminates the hazards caused by mixing materials. 6.9.4. In any explosives operation, permanent service lines shall be labeled as to their contents. DOE-STD-1212-2019 12 6.9.4.1. Valves and switches on service lines whose operation can result in a hazardous situation shall be labeled as to their function. 7. EXPLOSIVES FACILITY DESIGN/SITE CRITERIA 7.1. Explosive Facilities 7.1.1. Permanent explosives facilities shall comply with Unified Facilities Criteria (UFC) 3-340-02. 7.1.1.1. DOE/TIC-11268 may be used as a supplement as it often resolves some special DOE design considerations and may result in a more economical design. Note: As an example, it describes how to reduce blast overpressure from an explosion due to a high-altitude location. 7.1.2. Portable magazines should be ventilated and resistant to water, fire, and theft. 7.1.2.1. Portable magazines may be made of any material that meets these requirements. Note: Type 2 portable magazines that comply with 27 Code of Federal Regulations (CFR) Part 555.208 meet these criteria. 7.1.3. Portable magazines shall be sited per Department of Defense Explosives Safety Regulation (DESR) 6055.09 as aboveground magazines. 7.2. Blast Resistant Design 7.2.1. Blast-resistant design for personnel and facility protection shall be based on the TNT (Trinitrotoluene) equivalency of the maximum quantity of explosives and propellants. 7.2.2. TNT equivalency shall be increased by 20% for design purposes in accordance with UFC 3-340-02. 7.3. Criteria for Lightning Protection Systems 7.3.1. Lightning protection shall be designed in accordance with National Fire Protection Association (NFPA) 780, Standard for the Installation of Lightning Protection Systems, and Chapter 42 of this Technical Standard. DOE-STD-1212-2019 13

7.4. Unproven Facility Design 7.4.1. For an unproven facility design, either a validated model or full-scale test is required to validate structural adequacy unless a high degree of confidence can be provided by calculations or other technical bases. 7.4.1.1. Prior to full-scale testing, test plans shall be provided to the Head of DOE Field Element (DOE/NNSA Field/Operations/Production Office) for concurrence. 7.5. Design of New Facilities 7.5.1. The design of new explosives facilities and major modifications to existing explosives facilities shall conform to the following: 7.5.1.1. The requirements established in this Technical Standard. 7.5.1.2. The methods of analysis and design, as well as protective design features specified in UFC 3-340-02. Note: It is not intended that existing physical facilities be changed arbitrarily to comply with these provisions, except as required by law. 7.5.1.3. The following documents may be used to assist the design and analysis of blast-resistant design. The most current and updated version should be used.  DOE/TIC-11268  Department of Defense Explosives Safety Board (DDESB) TP-12  DDESB TP-13  DDESB TP-15  DDESB TP-16  DDESB TP-17 7.5.2. Studies necessary to provide the technical basis for location, engineering, design, and operation (under normal and potential design basis accident conditions) of buildings shall follow the stricter of this Technical Standard or DESR 6055.09 for establishing explosives quantity-distance (QD) separation. 7.5.3. To maintain maximum, long-term flexible use of facilities, Contractor Facility Management is encouraged to consider installing dual-rated (i.e., Class I, Division 1 and Class II, Division 1) permanent wiring and equipment in explosives operating rooms. As a minimum, installation should allow for easy conversion to dual-rated wiring and equipment. DOE-STD-1212-2019 14 7.6. Site and General Construction Plans 7.6.1. Site and general construction plans for explosives facilities, as well as plans for changes in utilization of facilities or mission changes that adversely affect the explosives QD requirements, shall be submitted to the Head of DOE Field Element (DOE/NNSA Field/Operations/Production Office) for review and approval. Plans shall be forwarded for: 7.6.1.1. New construction or major modifications of facilities for explosives activities. Note: When modifications or rehabilitation plans for existing facilities do not introduce additional hazards or do not increase the net explosives capacity or chemical agent hazard for which the facility was designed or sited, site and general construction plans are not required to be submitted to the Head of DOE Field Element (DOE/NNSA Field/Operations/Production Office) for review. 7.6.1.2. Facilities for activities not involving explosives that are in such proximity to explosives as to be exposed to hazards or for which a reasonable doubt may exist regarding possible exposure to hazards. 7.6.1.3. Facilities for activities not involving explosives that become exposed to blast, fire, or fragment hazards; or potential toxic chemical agent release due to change in facility mission or facilities usage. 7.6.2. When the review of site and general construction plans is required, Contractor Facility Management shall: 7.6.2.1. Indicate specifically in the letter of transmittal its approval of the proposal, along with changes, modifications, or specific precautionary measures considered necessary.

7.6.2.2. Comply with applicable requirements of DESR 6055.09 for site plan submission. 7.6.2.3. Retain a copy of the complete site plan and the final safety submission, together with DOE/NNSA Field/Operations/Production Office letter(s) of approval, as a permanent record at the facility/site of origin. 7.6.2.4. Keep facility maps current with the latest site plan approval and reconciled with the facility master planning document. 7.6.3. DESR 6055.09 identifies minimum distances for protection from fragment hazards and blast overpressure. DOE-STD-1212-2019 15 7.6.3.1. The methods of calculation presented in DDESB TP-13 may be used to establish a smaller fragment exclusion zone. Note: It is not intended that these minimum fragment distances be applied to operating facilities or dedicated support functions within an operating line. For these exposures, the DOE criteria presented in this Technical Standard for Class I, II, III, or IV Level-of-Protection activities with appropriate QD separations are the required protection levels. 7.6.4. In addition to this Technical Standard, the following are resource documents for the siting and design of explosives facilities:  DOE Order 420.1  DOE Order 430.1  10 CFR Part 830  UFC 3-340-02  DOE/TIC-11268  DESR 6055.09  DDESB TP-13  AMCR 385-100  TR-828  AD 411445  AFWL-TR-74-102  HNDM-1110-01-2 8. HAZARD ANALYSIS 8.1. Hazard Analysis 8.1.1. Before starting any operation involving explosives, a documented hazard analysis shall be performed per 10 CFR 851.21. 8.1.1.1. Hazard analyses shall be performed using a graded approach applicable to the specific explosives operation. 8.1.2. When an explosives operation changes, new hazards shall be addressed in a supporting hazard analysis which then becomes part of the original hazard analysis. 8.1.3. When modifying facility or process equipment, a documented analysis shall be performed to validate uniform standards are adhered to throughout the facility. 8.1.4. Contractor Facility Management shall address the results of a hazard analysis. Hazard prevention and abatement shall be conducted per 10 CFR 851.22. DOE-STD-1212-2019 16 8.2. Similar Processes 8.2.1. A single 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. 8.2.1.1. Selection criteria for the worst-case process are:  Sensitivity of materials;  Quantity of materials;  Number of personnel potentially affected; and  Impact on other operations and activities. 8.2.1.2. As a new process is considered for inclusion under an existing hazard analysis, each step of the new process shall be evaluated to determine if it is within the scope of the existing hazard analysis, and to identify any hazards not addressed in the existing hazard analysis. 8.3. High Risk 8.3.1. Hazard analysis supporting explosives synthesis, formulation, manufacturing, testing, or disposal operations shall be performed and revalidated as a team effort. The team shall consist of a minimum of three personnel, to include at least one technical member and one operator. The following makeup is recommended:  Team Leader, who is familiar with the analysis methodology used.  Technical Member(s), who is familiar with the process being analyzed.  Scribe, who writes notes of meetings and interviews and drafts reports.  Operator who actually performs the work being analyzed.  Explosives Safety Subject Matter Expert.

Note: A technical member is an individual who has expertise in a particular technical discipline (e.g. engineering, chemistry, physics, and safety). 8.3.2. Contractor Facility Management shall select the analysis methodology used (e.g., What if Analysis, Fault Tree Analysis, Event Tree Analysis). 8.3.3. Employees and employee representatives shall be consulted on the hazard analysis. 8.3.4. The result of the hazard analysis shall be provided to employees involved in or affected by the operation. DOE-STD-1212-2019 17 8.3.5. The hazard analysis shall be updated and revalidated at least every five years. 8.4. Electrical Hazard Classification Analysis 8.4.1. If a documented analysis is used to determine the electrical hazard classification for areas where explosives operations or activities are conducted, the analysis shall be reviewed by the Contractor Explosives Safety AHJ and approved by Contractor Facility Management. 8.4.2. The scope of the analysis shall identify the specific location and specific explosives operation or activity. 8.4.3. The analysis should be limited to the following:  Enclosed areas, (e.g. rooms, bays, chambers).  Normal operating conditions. 8.4.4. The analysis should consider the following:  The physical configuration of the explosives, (encased, bare, consolidated, powder, packaged, unpackaged).  The explosives operation or activity being conducted.  Other activities or operations being conducted in the same area.  Migration of explosive or ignitable gases, vapors or dust mixtures to or from adjacent areas. Note: The analysis shall be updated and revalidated if any of these change. 9. OPERATING PROCEDURES 9.1. Procedures 9.1.1. Operating procedures shall be written and approved for each operation involving explosives. 9.1.2. Operating procedures shall implement all applicable controls derived from supporting hazard analysis prior to the procedure being approved for use. Note: Operating procedures that were not prepared using the current hazard analysis shall be evaluated to verify that all applicable controls (new or revised) derived from the current hazard analysis are implemented prior to the procedure being approved for use. DOE-STD-1212-2019 18 9.2. Approval 9.2.1. New or revised operating procedures shall be reviewed and approved prior to use. 9.2.2. Contractor Facility Management should establish levels of approval based on the operation’s inherent risk. 9.2.3. The review and approval process shall include line and safety organizations. 9.3. Operating Procedures Content 9.3.1. The introduction to the procedure should include the following: 9.3.1.1. A statement of the scope, nature of the operation and its objectives, and defining what facilities and equipment are covered. 9.3.1.2. The name of the department responsible for the operation and the procedure. 9.3.1.3. If the procedure serves as the basis for an exemption, equivalency, or waiver from the requirements of this Technical Standard, a statement to this effect and a specific reference shall be included. 9.3.2. The materials and equipment section should present the following information: 9.3.2.1. All significant tools, supplies, chemicals, and equipment necessary to perform the operation should be listed in the procedure or in a separate required document. 9.3.2.2. Specifications for approved chemicals, supplies, tooling, and equipment should be referenced where applicable.

9.3.2.3. An explanation of any specific hazard involved in the handling of chemicals or explosives, or a reference to a document that describes the hazards. 9.3.3. The safety section of the procedure should present the following information or reference a safety document that specifies the requirements: 9.3.3.1. General safety rules to be observed and techniques to be applied that verify safety of operations, prevent personnel injury or illness, and prevent equipment damage. DOE-STD-1212-2019 19 9.3.3.2. Additional or specific emergency controls not addressed by the facility emergency plan. 9.3.3.3. Protective equipment used during the operation. 9.3.3.4. The number of personnel (workers and casuals) and explosives weight limits associated with the operation being conducted. 9.3.4. The operations section should consist of sequential directions written or pictured in clear, concise steps that describe how to perform a particular operation: 9.3.4.1. General directions for operation of all major explosives handling equipment. 9.3.4.2. Particular emphasis should be placed on safety interlocks and controls, and their proper use. 9.3.4.3. If a particular operation requires that no other operation be performed concurrently in the same work area, this requirement shall be stated clearly in the procedure. 9.4. Special or Experimental Procedures 9.4.1. In addition to the applicable requirements listed for Operating Procedures, the following shall also be addressed: 9.4.1.1. Field operations (remote to normally occupied areas) shall include procedures to verify prompt response of both fire and emergency medical services. 9.4.1.2. Personnel involved with the operation shall be briefed or trained on any unique aspects of the operation and emergency procedures. 9.4.2. When a special or experimental operation shall be conducted a number of times, an Operating Procedure should be written and approved. 10. TRAINING 10.1. Explosives Safety Training 10.1.1. Personnel shall be properly trained before they are assigned to explosives operations or operate any explosives transport vehicle. DOE-STD-1212-2019 20 10.1.2. The training for explosives work serves to assist in conducting work safely and developing safety awareness and shall verify that personnel:  Develop and maintain a safe attitude towards work with explosives.  Define and understand the potential hazards involved.  Learn correct skills to perform tasks safely.  Are prepared for unexpected hazardous conditions.  Read and understand the appropriate operating procedures. 10.2. Training and Qualification Programs 10.2.1. Each Site's Training and Qualification Program shall address Explosives Safety training. 10.2.2. An employee shall not be permitted to continue working with explosives if the supervisor, with counsel from medical personnel, determines that he or she is unable to perform the task safely. Possible reasons include:  Physical injury or illness.  Disease.  Mental or emotional disturbances. 10.3. Unexploded Ordnance (UXO) Qualification 10.3.1. Personnel in charge of UXO removal/disposal should be US citizens and have successfully completed training at a US Military Explosives Ordnance Disposal (EOD) school. 10.3.1.1. Personnel shall provide documentation of completed training and have a minimum of 18 months operational EOD experience. 10.3.2. Personnel performing UXO removal or disposal shall have completed training at a US Military EOD school or have equivalent training or experience.

10.3.3. All other personnel engaged in UXO operations shall be trained thoroughly in applicable UXO recognition and Explosives Safety. 10.3.4. Personnel requiring access to areas known or suspected to contain UXOs shall be required to complete UXO awareness training and comply with any site-specific additional UXO area access requirements. 10.3.5. Sites containing UXOs shall establish site-specific UXO awareness training. DOE-STD-1212-2019 21 11. QUANTITY-DISTANCE 11.1. Explosives Safety Site Plan Submission and Approval 11.1.1. Contractor Facility Management shall verify that ESSPs are submitted to the Head of DOE Field Element (DOE/NNSA Field/Operations/Production Office) for review and approval. 11.1.2. Where there is an increase in risk, an ESSP shall be resubmitted and approved prior to start of operations for the following conditions:  There is an increase in explosive weight.  The facility undergoes a major modification.  The required Level-of-Protection changes. 11.1.3. Risk based explosives siting, as described in DDESB TP-14 is another tool to address explosives QD determinations of equivalency of safety. 11.1.4. The site plan package shall contain the following: 11.1.4.1. A QD Chart containing the following:  Each sited facility potential explosion site (PES) listing maximum net explosives weight (NEW) for each applicable Hazard Division (HD).  Actual and required distance to exposed sites (ES).  QD criteria used for siting each PES - ES relationship. 11.1.4.2. Map(s) showing each PES, its clear zone, and all ESs within the clear zone. 11.1.4.3. Personnel limits for the explosives facility. 11.1.4.4. Description(s) of explosives and non-explosives operations within the clear zone. 11.1.4.5. Justification(s) for facilities not meeting current criteria for the operation that address:  Bringing the facility up to current standards is not feasible, and  Operations present no significantly greater risk than that assumed when the facility was originally constructed. 11.1.5. If the siting has any unique characteristics, explain what they are and what criteria is being applied. Note: If a facility is built to control blast effects and fragments, QD to other facilities do not apply. DOE-STD-1212-2019 22 11.1.6. A letter of transmittal shall accompany each site plan or group of site plans. The letter shall contain the following: 11.1.6.1. Reason for submittal (preliminary or final siting of new facility, site plan/plans for grandfathered facility/facilities, change in operation with increased or decreased QD requirement). 11.1.6.2. Request for site plan approval. 11.1.6.3. For a grandfathered facility, note whether the facility meets current criteria for the operation being conducted. 11.2. Quantity-Distance Criteria 11.2.1. QD criteria shall account for the types and severity of hazards each explosive material presents, the construction and orientation of facilities to which the criteria are applied, and the degree of protection desired for personnel and facilities adjacent to the explosives operations. Note: The United Nations (UN) hazard classification system defines the types and severities of explosives hazards. 11.2.2. Hazard Divisions 11.2.2.1. Explosives shall be classified based on their reactions to specific initiating influences. 11.2.2.2. Personnel shall use the UN hazard classification system for DOE explosives classification, Table 11.1 lists the hazard divisions of Class 1.

Table 11.1 Division of Class 1 HD Designators Hazards 1.1 Mass detonating 1.2.1 Non-mass explosion, fragment producing with NEW for QD > 1.6 lbs 1.2.2 Non-mass explosion, fragment producing with NEW for QD ≤ 1.6 lbs 1.2.3 Non-mass explosion, fragment producing based on single package test only No reaction greater than burning from the external fire test, bullet impact test or slow cook-off test 1.3 Mass fire, minor blast or fragment 1.4 Moderate fire, no significant blast or fragment 1.5 Explosive substance, very insensitive (with a mass explosion hazard) 1.6 Explosive article, extremely insensitive DOE-STD-1212-2019 23 11.2.2.3. Classification tests (described by TB 700-2) and additional tests (as desired), including UN ST/SG/AC/10/1 and UN ST/SG/AC/10/11, shall be used to assign energetic materials to the appropriate HD SCG (Storage Compatibility Group). Supplemental tests may be used for additional characterization when material properties or anticipated material environments are expected to significantly influence the explosives classification. 11.2.2.4. Although Department of Transportation (DOT) hazard classifications require the use of the Bureau of Explosives' (BOE) Impact Apparatus to determine impact sensitivity, other impact apparatus may be used, providing:  Test results for at least two reference explosives are compared to results for the reference explosives on the BOE Impact Apparatus; and  A minimum of 10 trials each is run for the reference explosives and the explosives being classified. 11.2.3. The principles and tables presented in DESR 6055.09 shall be used to determine the total quantities of explosives in adjacent magazines, operating buildings, or other explosive facilities that shall be applied to QD tables, and inert storage locations. Note 1: When the levels of protection required by this Technical Standard differ from the requirements of DESR 6055.09, this Technical Standard shall take precedence. Note 2: The minimum separation distances required for the facilities are based on the desired Level-of-Protection and total quantities of explosives. Note 3: The total quantity of explosives is determined by defining and examining the maximum credible event (MCE). If an explosives event occurs, the MCE is the largest credible amount of explosives that could be involved (not necessarily the total quantity of explosives present). Note 4: Requirements for onsite de minimis or residual quantities of explosives can be found in Section 17.7. 11.2.4. Transport Vehicles 11.2.4.1. Explosives loaded vehicles in holding yards are considered aboveground magazines for QD purposes. They shall be kept in groups, and each group shall be limited to a maximum of 250,000 lbs (113,398 kg) of high explosives (HE). DOE-STD-1212-2019 24 11.2.4.2. When a classification yard, interchange yard, inspection station or specified location is the site where explosives are interchanged between the common carrier and facility transportation, QD provisions do not apply provided that vehicles are moved expeditiously to a suitable location. 11.2.5. Utilities Installations 11.2.5.1. Permanent DOE controlled underground utilities installations (excluding building service lines) should be separated from explosives locations containing HD 1.1 materials (see Table 11.2). Table 11.2 QD Separation for Protection of Underground Service Installations Quantity of explosives (Maximum) Distance Lbs. (kg) Feet (Meters) ≤ 10,000 (4,535.9) 80 (26)

20,000 (9,071.8) 85 (28) 50,000 (22,679.6) 110 (36) 100,000 (45,359.2) 140 (46) 250,000 (113,398.1) 190 (62) Note: If the potential donor building is designed to contain the effects of an explosion, the formula: D=3.0 W1/3 can be used to determine separation distances for less than 20,000 lbs (9,071.8 kg). 11.2.5.2 Privately owned or operated utilities installations (aboveground and underground) shall be separated from explosives locations by at least public traffic route distances. Installations that include structures should be separated from explosives facilities by inhabited building distance. 11.2.5.3. Certain auxiliary power facilities, transformer stations, etc., present fire hazards to explosives facilities. Transformers and associated electrical switching apparatus serving one explosives facility or complex that do not present a fire hazard to the facility (i.e., dry type, "less flammable" oil insulated) shall be located as specified in NFPA 70 and FMDS 5- 4/14-18. 11.2.5.4. Normal oil insulated transformers shall be located at least 50 ft from an explosives facility or as specified in DESR 6055.09. Note: See Section 36.3 for additional electrical supply system requirements. 11.2.6. Storage Tanks for Petroleum and Hazardous Materials DOE-STD-1212-2019 25 11.2.6.1. Storage tanks for petroleum and hazardous materials shall be sited using Storage Tanks for Hazardous Materials criteria as specified in DESR 6055.09. 11.2.7. Small Quantities of HD 1.1 Explosive Substances 11.2.7.1. Use Table 11.3 to determine distances for small quantities of explosive substances. Note: For many situations, it can be demonstrated that adequate personnel protection is provided at distances considerably less than those distances identified in DESR 6055.09. Table 11.3 Minimum QD Requirements for Small Amounts of Explosive Substances Having HD 1.1 Classification NEW Inhabited Building Distance Public Traffic Route Distance Intraline Distance Less than 0.0066 lb 0 ft 0 ft 0 ft (0.003 kg) (0 m) (0 m) (0 m) 0.0066 lb – 0.022 lb 16.40 ft 9.84 ft 6.56 ft (0.003 kg – 0.01 kg) (5 m) (3 m) (2 m) 0.022 lb – 0.55 lb 49.21 ft 29.52 ft 16.40 ft (0.01 kg – 0.25 kg) (15 m) (9 m) (5 m) 12. LEVEL-OF-PROTECTION CRITERIA 12.1. Required Level-of-Protection 12.1.1. The Level-of-Protection required for an explosives activity is based on the hazard class (accident potential) of the explosives activity involved. 12.1.2. Each bay (i.e., storage, handling, or processing building) that houses an explosives activity shall have a Level-of-Protection based on the hazard class determined for the activity. 12.1.3. Level-of-Protection may be provided by equipment design, structural design, operation separation, or provision of operational shields. 12.2. Hazard Class 0 12.2.1. Explosives operations involve the intentional initiation of explosives materials or articles. Note: Examples are explosives testing, firing activities associated with training, and destruction of explosives by detonation. DOE-STD-1212-2019 26 12.2.2. Areas used to conduct Class 0 activities shall protect all personnel from injury due to blast, fragments, and structural collapse of buildings. This protection may be achieved by measures (or combination of measures) to include control of fragments and overpressure by suppression, containment, or distance (location) as follows: 12.2.2.1. No structural damage to any facility due to overpressure, fragments, or debris.

12.2.2.2. No fragment or debris impact to operators. 12.2.2.3. Operator protection from any injurious thermal flux. 12.2.2.4. Overpressure, fragment, and debris impact to surrounding areas limited to approved site plans and DESR 6055.09 for intentional detonation of explosives criteria. 12.3. Hazard Class I 12.3.1. Explosives operations involve activities with a high accident potential where: (1) energies approach the upper safety limits, (2) loss of control of interfacing energy is likely to exceed safety limits, and (3) research and development where safety implications have not been fully characterized. Note: Examples are screening, blending, pressing, extrusion, drilling of holes, dry machining, machining explosives and metal in combination, some environmental testing, new explosives development and processes, explosives disposal by burning and some destructive testing. 12.3.2. Operations shall be conducted remotely because any personnel exposure is unacceptable. 12.3.3. Bays for Class I activities shall comply with the requirements for Class II bays, and, in addition, provide protection to prevent serious personal injuries to personnel performing the activity and personnel in other occupied areas. This protection can be achieved by controlling blast and debris through suppression, containment, or establishing an exclusion area with positive access control. Serious injury prevention is satisfied when personnel are not exposed to: 12.3.3.1. Overpressures greater than 5 psi maximal effective pressure, which should not exceed 2.3 psi peak positive incident pressure (2.3 psi is DOE-STD-1212-2019 27 specified in the DESR 6055.09 as required protection for all personnel exposed to remote operations). 12.3.3.2. Structural collapse of a facility or building from overpressure or debris impact. Structural collapse is a structural component’s failure as a direct result of loss of structural integrity. This collapse does not result in explosion propagation, fatalities, or severe personal injuries. 12.3.3.3. Hazardous fragment or debris having an impact energy greater than 11 ft lbs. 12.3.3.4. Thermal fluxes are limited to prevent the onset of second-degree burns. This value is specified in DESR 6055.09, as required protection for all personnel assigned to perform remote operations. 12.3.3.5. Transients shall be protected as specified in DESR 6055.09 using “Accidental Ignition or Initiation of Explosives” criteria. 12.4. Hazard Class II 12.4.1. Explosives operations involve activities with moderate accident potential due to the explosives type, condition of the explosives, or nature of the operations. These activities involve energies that do or may interface with the explosives are normally well within the safety boundaries for the explosives involved, but where the loss of control of these energies could approach the safety limits. Note: Examples are weighing, some wet machining, assembly and disassembly, some environmental testing, and some packaging operations. 12.4.2. Class II activities have an accident potential greater than Class III activities, but personnel exposure in contact operations is acceptable. 12.4.3. For Class II operations, access ramps and site roads are not considered occupied areas. 12.4.4. Bays for Class II activities shall comply with the requirements for Class III bays, and, in addition, provide protection to prevent fatalities and severe personnel injuries in all occupied areas other than the bay of occurrence. Prevention of fatalities and severe injuries is satisfied when personnel in occupied areas other than the bay of occurrence are not exposed to the following:

12.4.4.1. Overpressures greater than 15 psi maximal effective pressure. The threshold pressure for eardrum rupture is 5 psi; one-half of the DOE-STD-1212-2019 28 threshold pressure for lung damage is 15 psi (see chapter I-11.1 of UFC 3-340-02). 12.4.4.2. Structural collapse resulting from overpressure or debris impact. Structural collapse is a structural component’s failure as a direct result of a facility losing structural integrity. This collapse does not result in explosives propagation, fatalities, or severe personnel injuries. 12.4.4.3. Hazardous fragments or debris generated in acceptor-occupied areas having an impact energy of 58 ft-lbs or greater, (see chapter I-11.3 of UFC 3-340-02). 12.5 Hazard Class III 12.5.1. Explosives operations involve activities with low accident potential. Note: Examples are activities during storage and operations incidental to storage or removal from storage. 12.5.2. Bays for Class III activities shall provide protection from explosion propagation from bay to bay within buildings and between buildings that are located at intraline or intermagazine distance. 12.5.3. If intermediate storage of explosives is within an operating building containing Class II or Class I operations, the intermediate storage or staging bay shall require Class II Level-of-Protection. 12.5.4. Minimum separation distances may be reduced when explosives bays are designed to adequately contain the effects of an accident (blast pressures and missiles). 12.6. Hazard Class IV 12.6.1. Explosives operations involve activities with IHE or IHE subassemblies where the probability of accidental initiation or transition from burning to detonation is negligible. Note: Examples are processing and storage activities with IHE and IHE subassemblies. 12.6.2. The following explosives activities with IHE and IHE subassemblies shall remain Class I:  Pressing.  Some machining (see Paragraph 24.2.4).  Dry blending.  Dry milling. DOE-STD-1212-2019 29  Dry screening. 12.6.3. Bays for Class IV activities shall provide protection from fire hazards effects. 12.6.3.1. This protection may be achieved by HD 1.3 aboveground magazine distance separation or by a design that contains the effects of an accident. 12.6.3.2. Because accidental detonation is not considered credible, Class IV bays shall be sited and designed as acceptors rather than donors for the effects of blast overpressure, structural collapse, and missiles (hazardous fragments). 13. REMOTE OPERATIONS 13.1. Personnel Protection 13.1.1. Explosives operations that present a high accident potential as defined in Paragraph 12.3.1 shall be performed remotely. 13.1.2. Personnel involved in remote operations shall be provided the required Level-of-Protection for the hazard class of the operation. 13.1.3. Transient personnel shall be provided protection in accordance with the requirements in DESR 6055.09. 13.2. Access and Equipment Controls 13.2.1. Administrative and/or engineered controls shall be used to prevent entry into a hazardous location in which a remote operation is occurring or to prevent the operation from proceeding when personnel enter. 13.2.1.1. Roads shall be blocked at a minimum public traffic route distance (K24) or hazardous fragment distance from buildings where hazardous (remote) operations are being performed, whichever is greater. Note: Hazardous fragment distance may be satisfied by providing equivalent protection.

13.2.1.2. Corridors leading to bays in which hazardous (remote) operations are being performed shall be marked to warn of the danger with established barriers. 13.2.1.3. When practical, visual methods should be used to monitor remote operations to enable viewing of the operating area conditions before DOE-STD-1212-2019 30 entering. Audio monitoring and video recording should also be considered. 13.2.1.4. Remote operating equipment should be interlocked to access doors for each remote operation. 13.2.1.5. Lights or similar warning devices shall conspicuously identify locations where remote operations are performed to indicate when remote operations are under way. 14. LIMITS AND CONTROL 14.1 Explosives Limits 14.1.1. The quantity of explosives at an operating location shall be the minimum necessary to carry out the operation safely and efficiently. 14.1.1.1. When practical, this quantity shall be subdivided and separated to prevent propagation of detonation. 14.1.1.2. Supplies exceeding this minimum quantity shall be removed from the operating area. 14.1.2. In no case shall the quantity of explosives permitted in an operating building exceed the maximum permitted by QD criteria. 14.1.3. QD criteria and requirements for application of these criteria are presented in Chapter 11. 14.1.4. IHE limits for pressing, dry blending, dry milling, dry screening, and certain machining operations (see Paragraph 24.2.4) should be the same as those established for HE operations. 14.2. Personnel Limits 14.2.1. The number of personnel at an operating location shall be the minimum consistent with safe and efficient operation. 14.2.2. Only jobs necessary to the performance of a hazardous explosives operation should be performed in the same location as the hazardous operation. 14.2.3. Only personnel needed for hazardous operations shall be allowed in hazardous locations. 14.2.4. Personnel limits shall allow for necessary casuals. DOE-STD-1212-2019 31 14.2.5. Sufficient personnel shall be available to perform a hazardous operation safely and to obtain help and aid the injured if an accident occurs. 14.2.6. Contractor Facility Management shall specify explosives activities that may be performed alone. 14.2.6.1. No person shall perform explosives work with a high risk of serious injury alone. 14.2.6.2. Prompt and easy communications with other employees shall be provided. 14.3. Limit Control 14.3.1. Posting and Recording 14.3.1.1. All rooms, bays, and buildings containing explosives shall have, posted in a conspicuous place, a standardized posting stating the maximum amount of explosives and the maximum number of workers and casuals permitted in the controlled area at any one time. 14.3.1.2. Maximum explosives and personnel limits for all buildings and bays for each explosives area shall be documented and maintained on file. 14.3.2. Limit Review and Approvals 14.3.2.1. Contractor Facility Management personnel with authority and jurisdiction over an operating bay or building shall review explosives and personnel limits for each location periodically and recommend changes as required. 14.3.2.2. When the use of a location changes, personnel and explosives limits shall be reviewed and limits reestablished as required. 14.3.2.3. Changes in explosives and personnel limits shall be reviewed and approved in the same manner as operating procedures (see Chapter 9). 14.3.2.4. A procedure shall be established for the approval of temporary changes in explosives and personnel limits for an operating location.

14.3.3. Personnel Controls 14.3.3.1. A system shall be established to control the presence of personnel within explosives operating areas. DOE-STD-1212-2019 32 14.3.3.2. The movement of transients in the vicinity of an explosives operating area should be controlled when their presence creates a congestion problem or other safety concern. 14.3.4. Explosives Controls 14.3.4.1. A verifiable system shall be established to control the amount of explosives present in an explosives facility. 15. PERSONAL PROTECTIVE EQUIPMENT 15.1. Clothing 15.1.1. Flame-retardant clothing may be desired for explosives operations with the potential for flash fire. 15.1.1.1. The clothing shall not have cuffs. 15.1.1.2. The clothing should not have metallic fasteners. 15.1.2. Operating procedures shall include protective clothing requirements. 15.1.3. Cotton or other antistatic outer and undergarments, including socks, should be worn where generation of static electricity would create a hazard. 15.2. Footwear 15.2.1. Personnel working in areas where electrostatic sensitive explosive powders or materials are handled shall wear conductive, non-sparking footwear. Note: Exception: Personnel working on electrical or electronic equipment shall not wear conductive footwear unless protected by insulated mats, ground fault circuit interrupters (GFCI), etc. 15.2.2. When conductive footwear is worn, the conductivity shall be tested immediately prior to each use. 15.2.3. Personnel working in areas where explosives contamination may be present shall wear non sparking footwear or bootie shoe coverings. 15.3. Wristbands 15.3.1. When conductive wristbands are worn, the conductivity shall be tested immediately prior to each use. DOE-STD-1212-2019 33 16. INSENSITIVE HIGH EXPLOSIVES QUALIFICATION 16.1. Revisions to Insensitive High Explosives (IHE) Test Description and Criteria 16.1.1. Revisions to LLNL-TR-679331/LA-UR-15-29238, “IHE Material and IHE Subassembly Qualification Test Description and Criteria” shall be approved by the proponent organizations (Lawrence Livermore National Laboratory, Los Alamos National Laboratory, and Pantex) and shall be reviewed for concurrence by the DOE/NNSA Explosives Safety Committee. Once concurrence is obtained, the Chair shall issue a letter of concurrence to the submitting organization. 16.2. Insensitive High Explosive (IHE) Materials 16.2.1. In scales that are conservative to the relevant nuclear weapon application, IHEs shall meet the following requirements: Note: For more information refer to Attachment A of this chapter - IHE QUALIFICATION BACKGROUND 16.2.1.1. Does not transition from deflagration to detonation (DDT). 16.2.1.2. Does not transition from shock to detonation (SDT).  Under 3.5 GPa, 3 µs 1-dimensional shock insult at 25°C.  Under 5.3 GPa, 0.5 µs 1-dimensional shock insult at 25°C.  Under 1.5 GPa, 3 µs 1-dimensional shock insult when heated to 10°C below the cook-off temperature of the explosive. 16.2.1.3. Passes IHE criteria outlined in LLNL-TR-679331/LA-UR-15-29238, "IHE Material and IHE Subassembly Qualification Test Description and Criteria."  Skid test  Bullet test 16.2.2. The qualification and approval process described herein is limited to DOE and nuclear weapons applications. 16.3. IHE Qualification Testing 16.3.1. Any explosive that is a candidate for classification as an IHE shall be subjected to the DOE qualification tests listed in Table 16.1.

Note: This includes three tiers of tests. Test procedures are contained in LLNL-TR-679331/LA-UR-15-29238. DOE-STD-1212-2019 34 Table 16.1 Required Testing to Qualify IHE Materials Tier 1: Prerequisites Tier 2: IHE Material Qualification Tier 3: Demonstration Tests1 Interim Hazard Classification DDT Test and SDT Test Skid Test and Bullet Test 1 Minimum of 20 drops per test series 16.3.2. Some or all of the test requirements of this section may be met by analogy as indicated below: 16.3.2.1. The DOE/NNSA Explosives Safety Committee determines the acceptability of analogy in lieu of test data. 16.3.2.2. Analogy submitted in lieu of test data shall include rationale. 16.3.2.3. Approved IHEs (listed in Table 16.2) with complete test data shall be used for baseline comparison purposes. 16.3.3. The DOE/NNSA Explosives Safety Committee may request additional information depending on circumstances surrounding the analogous information submitted. 16.3.4. A candidate IHE can be placed in one of the following analogy categories to define required tests depending on the type and extent of change in the candidate IHE relative to the baseline IHE and the potential effects of these changes on specific initiation mechanisms (shock, thermal, mechanical, impact): 16.3.4.1. If the analogy can be fully credited, no testing is required. Note: For example; the candidate IHE involves the same energetic and inert components as the approved baseline IHE, the only change being a volume-percent decrease in the energetic component content. 16.3.4.2. If the analogy can be partially credited, partial testing is required. Sufficient testing is required to verify that no chemical or physical incompatibilities have been introduced that would de-stabilize the base IHE. Note 1: For example; the candidate IHE formulation modifies an inert component of the approved baseline IHE. Note 2: In this case, test data normally generated by the requesting facility during their explosive development scale-up phasing process may be submitted in lieu of the qualification tests of Table 16.1. DOE-STD-1212-2019 35 Note 3: During the development phase, the Contractor Explosives Development Committee (EDC), or equivalent, may dictate restrictions consistent with an IHE that are internal to their facility only. 16.3.4.3. If the analogy cannot be credited, full testing is required. Note: For example; the candidate IHE involves the addition of an untested (IHE tests) energetic component to the approved baseline IHE. 16.4. IHE Qualification Process 16.4.1. IHE Materials qualified by previous methods shall remain qualified and are listed in Table 16.2 Table 16.2 Approved IHEs TATB TATB/KEL-F (or equivalent) Formulations 16.4.2. The organization with the need for IHE determination ( hereafter shall be referred to as the Requestor) shall perform or have performed the appropriate tests in accordance with the requirements of LLNL-TR- 679331/LA-UR-15-29238, after coordinating need for material qualification with the appropriate Headquarters (HQs) Program Office (e.g., NA-11, NA-12, or NA-19). 16.4.3. The Requestor submits the test data, for the candidate explosive, to the DOE/NNSA ESC Chair. 16.4.4. The DOE/NNSA ESC Chair assigns a Task Group for review and recommendation of approval/disapproval of the candidate explosives material. 16.4.5. If the request is not recommended for approval, the Task Group documents the rationale and requirements that were not met and provides this information to the DOE/NNSA ESC Chair who then communicates with the Requester through the DOE/NNSA ESC Chair.

16.4.6. If the request is recommended for approval, the Task Group assembles the test data and provides this information to the DOE/NNSA ESC Chair with a recommendation to approve the candidate explosive. 16.4.7. The DOE/NNSA ESC Chair prepares a written recommendation on the approval of the candidate explosive, and submits it along with the supporting explosives package to the NNSA/NA-50 Associate DOE-STD-1212-2019 36 Administrator for Safety, Infrastructure, and Operations; the Explosives Approval Authority (EAA) or designee. 16.4.8. The NNSA/NA-50 EAA approves or denies the candidate explosive for qualification as an IHE, and provides written documentation of their decision to the DOE/NNSA ESC Chair. 16.4.9. The DOE/NNSA ESC Chair provides documentation of the EAA's decision to requestor, and if approved, the IHE is added to Table 16.2. 16.5. IHE Subassemblies Testing 16.5.1. IHE Subassemblies are composed of IHE hemispheres or spheres with booster charges, with or without detonators that, as an assembly are so insensitive that the probability of accidental initiation or transition from burning to detonation is negligible, and therefore meet IHE criteria at a system-relevant scale. 16.5.2. Main charge materials that do not qualify as IHE materials in Section 16.3 may be used as main charges in an IHE Subassembly, provided they meet IHE criteria at a smaller, system-relevant scale. 16.5.3. Any explosive Subassembly that is a candidate for classification as an IHE Subassembly shall be subjected to DOE qualification tests as listed in Table 16.3. These tests shall be planned with consideration of worst- case scenarios. Testing approaches and methods are contained in LLNL-TR- 679331 / LA-UR-15-29238. The qualification approach evaluates each material in the assembly as follows: 16.5.4. Verify main charge is incapable of DDT and therefore meets IHE criteria for a material 16.5.4.1. Verify main charge meets IHE material criteria for SDT, as shown in Table 16.1, Tier 2 and defined in LLNL-TR-679331/LA-UR-15-29238. 16.5.4.2. Verify detonator material is incapable of DDT in a scale conservative to its relevant application. Note: Electrical threat to detonator is not part of this qualification. 16.5.4.3. Verify booster is incapable of DDT in a scale conservative to its relevant application DOE-STD-1212-2019 37 Table 16.3 DOE Qualification Tests for IHE Subassemblies* Test Results DDT No DDT in main charge, booster, and detonator materials tested at scales relevant to application, plus margin for conservatism. SDT No SDT in main charge material per tests in Table 12.1 for both ambient and heated materials. Multiple Bullet Impact No detonation or violent reaction of main charge with a 3-round bullet impact burst in worst-case configuration. Skid Test No burning or violent reaction of main charge (as evidenced by visible fireball) up to a specified height and test angle using Subassembly configuration modified for impact in worst-case geometry. * Tests are not required for subassemblies when main charge and booster charge explosives have been qualified as IHE by tests in Table 16.1. Note: The test plan shall specify applicable testing for cased and/or uncased configurations with or without detonators. 16.5.5. Some or all of these test requirements may be met by analogy as indicated below: 16.5.5.1. The DOE/NNSA Explosives Safety Committee determines the acceptability of analogy in lieu of test data.

16.5.5.2. Analogy submitted in lieu of test data shall include rationale. 16.5.5.3. Approved IHE Subassemblies with complete test data shall be used for baseline comparison purposes. 16.5.6. The DOE/NNSA Explosives Safety Committee may request additional information depending on circumstances surrounding the analogous information submitted. 16.5.7. A candidate IHE Subassembly can be placed in one of the following analogy categories to define required tests depending on the type and extent of change in the candidate IHE Subassembly relative to the baseline IHE Subassembly and the potential effects of these changes on specific initiation mechanisms (shock, thermal, mechanical, impact): 16.5.7.1. If the analogy can be fully credited, no testing is required. Note: For example; materials and scales remain the same and only minor changes that do not affect explosive characteristics. 16.5.7.2. If the analogy can be partially credited, partial testing is required. DOE-STD-1212-2019 38 Note: For example; minor changes to explosive materials or components. 16.5.7.3. If the analogy cannot be credited, full testing is required. Note: For example; a significant change to materials or configurations. 16.6. IHE Subassembly Qualification Process 16.6.1. IHE Subassemblies qualified by previous methods shall remain qualified and are listed in Table 16.4. 16.6.2. The Requestor submits a test plan to the DOE/NNSA ESC Chair and the test plan shall be coordinated with the appropriate DOE/NNSA site, after coordinating need for subassembly qualification with the appropriate HQs Program Office (e.g., NA-11, NA-12, or NA-19). 16.6.3. The DOE/NNSA ESC Chair assigns a Task Group for review and approval/disapproval of the test plan. 16.6.4. The ESC Task Group reviews the test plan for compliance with the IHE subassembly requirements and provides input (if necessary), and approves/denies the test plan. They then communicate their decision to the DOE/NNSA ESC Chair. 16.6.5. The DOE/NNSA ESC Chair communicates the approval/disapproval to the Requestor. 16.6.6. If the test plan is approved, the Requestor submits the test data, for the candidate subassembly, to the DOE/NNSA ESC Chair. 16.6.7. The DOE/NNSA ESC Chair submits the test data to the Task Group for review and recommendation of approval/disapproval of the candidate subassembly. 16.6.8. If the request is not recommended for approval, the Task Group documents the rationale and requirements that were not met and provides to the Requestor through the DOE/NNSA ESC Chair. 16.6.9. If the request is recommended for approval, the Task Group provides the DOE/NNSA ESC Chair with recommendation to approve the candidate subassembly. 16.6.10. The DOE/NNSA ESC Chair prepares a written recommendation on the approval of the candidate subassembly, and submits it along with the supporting subassembly package to the NNSA/NA-50 EAA. DOE-STD-1212-2019 39 16.6.11. The NNSA/NA-50 EAA approves or denies the candidate subassembly for qualification as an IHE subassembly. 16.6.12. The EAA provides written documentation of their decision to the DOE/NNSA ESC Chair. 16.6.13. If approved, the DOE/NNSA ESC Chair provides documentation of the EAA's decision to requestor. If approved, the IHE Subassembly is added to Table 16.4. Table 16.4 Approved IHE Subassemblies B61*3/4/6/7/8/10/11/12 W80* W81* B83* W84 W87 W89 * Approval limited to boosters of the size tested or smaller.

Note: Any redesign that dimensionally increases the booster size requires resubmission of an experimental plan and additional testing as another IHE Subassembly. 16.7. IHE Weapons 16.7.1. IHE weapons are those weapons listed in JNWPS TP-20-7, and are exempt from storage and transportation limits when stored or transported alone or in combination with each other. Note: This classification is valid only if storage containers provide adequate spacing between individual units. JNWPS TP-20-7 specifies the spacing requirements for materials stored or transported out of containers. DOE-STD-1212-2019 40 Attachment A – IHE QUALIFICATION BACKGROUND BACKGROUND The DOE IHE definition differs from that of Department of Defense (DoD)/UN Extremely Insensitive Substance (EIS) due to different risks and consequences associated with nuclear weapons application. The critical difference in risk is the possibility of special nuclear material (SNM) dispersal. Detonation is the response that impacts nuclear safety. Inadvertent nuclear yield should not be possible in modern weapons, so SNM dispersal is the critical nuclear safety improvement that IHE enables. SNM dispersal requires shock from explosive in direct contact, according to DOE-HDBK-3010-94 and NUREG/CR-6410. Absence of a detonation greatly reduces the likelihood of dispersal. A shock from any High Explosive violent reaction (HEVR) scenario, such as a violent deflagration, would be weak. Prompt Shock-to-Detonation Transition (SDT) cannot be excluded under all conditions because an IHE shall detonate to function as designed. The threshold should be clearly defined because nuclear safety requires that we know the SDT characteristics of an explosive. It is also important to confirm that the SDT characteristics are reasonably consistent across the lifecycle temperature range. SDT insults are generated with a gas gun which develops a sustained, 1D, shock pulse. These 1D shock pulses do not have a system-relevant scale, so all IHE materials and subassemblies undergo the same test. Deflagration-to-Detonation Transition (DDT) is the build-up of a burning reaction to a detonation. Ignition is a complex phenomenon governed by many competing processes. We assume ignition of a burning reaction in qualification testing since we cannot guarantee that ignition shall never occur in the various relevant hazard scenarios. Whether the ignited materials transition to a detonation is equally complex but is controlled by a few key variables, including the strength of confinement, charge size, and the state of the explosive. The DDT test is a large test with high confinement, and large margin. Deliberate ignition verifies DDT is not possible in the material in any scale relevant to a nuclear weapon. The inclusion of DDT testing eliminates the need for many standard ignition and reaction violence tests like ODTX, Susan, Spigot, Friction, Bonfire, and Slow Cookoff. Unknown to Detonation Transition (XDT). In some hazard scenarios with detonable solid rocket motors, initiation has been observed under conditions that are insufficient to develop either an SDT or DDT initiation. This response mode is termed XDT, where “X” stands for the unknown transition to detonation. It is believed that the XDT mechanism is the result of a process that includes severe damage and break-up of a bare energetic material in an unconfined space, expansion of this damaged material, and subsequent re- compaction of damaged material to develop ignition or initiation. The process is known to be highly complex and geometry dependent. There are no credible threats to nuclear weapons that include a geometry that allows this process to progress. Also, the final stage of both DDT and XDT is facilitated by the same underlying mechanism, shock initiation of damaged explosives. If an HE passes a conservatively-designed DDT test, then we can be

DOE-STD-1212-2019 41 confident that XDT is not a possibility under similar stimulus and geometry. Therefore, a test for XDT does not need to be included as a qualification test. High explosive violent reaction (HEVR) is a commonly used term to describe an unacceptable level of reaction. There is, however, no clear definition, either theoretically or empirically, of HEVR. DOE Order 452.1E and the D&P Manual both refer to HEVR as “ranging from a fast deflagration of the high explosive up to and including a detonation of the high explosive”. There is no threshold for what might constitute a fast deflagration. In other cases, including dispersal of material outside a facility perimeter, HEVR is essentially being defined in terms of causing a secondary effect rather than in terms of the phenomenon itself. Without a clear or consistent definition, it is impossible to define one or more tests with meaningful criteria to evaluate the candidate explosive for its propensity to undergo HEVR. Hence the absence of that specific term in the definition of IHE. Historical IHE test definitions similarly did not exclude the possibility of HEVR in an IHE. We can make some observations on the implications of the new definition to the potential for HEVR: the material properties that underlie DDT behavior also underlie HEVR responses, including the propensity for thermal ignition, deflagration rate, and shock sensitivity. Therefore, an explosive that meets the DDT criteria in the new definition is likely to be relatively benign in any HEVR. DEFINITIONS Scales conservative to a relevant nuclear weapon application: The scale of a given experiment is related to HE configuration in US nuclear weapons. This is related to the main charge with a margin of conservatism. The scale is not the same as classified scaled weapons experiments. Scales conservative to its relevant application: The scale of a given experiment is related to the HE configuration and confinement of the given application. For example, a booster application has a shorter run length and lower confinement relative to a main charge. REFERENCE DOCUMENTS The following documents set forth some of the procedures to be referenced when planning the IHE and IHE subassembly testing required by Table 16.1 and Table 16.3:  TB 700-2  MHSMP-84-22 Rev.1  UN ST/SG/AC.10/11/Rev.1  LLNL-TR-679331, LA-UR-15-29238, 2015  DOE HDBK-3010  NUREG-1320  JNWPS TP-20-7 DOE-STD-1212-2019 42 17. LABORATORY OPERATIONS 17.1. Operational Requirements 17.1.1. Laboratory personnel shall conduct work involving explosives materials in accordance with approved operating procedures supported by documented hazard analysis. 17.1.2. The quantity of explosives present in a laboratory shall be the minimum required for the operations and should be at or below assigned limits. 17.1.3. Storage of explosives not in process is allowed provided the explosives are secured when the laboratory is unoccupied. 17.1.4. Explosives shall be configured to preclude exceeding the maximum credible event (MCE). 17.1.5. Open flames shall be prohibited in laboratories where explosives or flammable solvent vapors are or may be present unless allowed by an approved hazard analysis or procedure. 17.1.6. Disposal of explosives through laboratory drains shall be forbidden unless the drain plumbing has no traps and is designed to handle explosives (i.e., is provided with a sump or other device for the collection of solids).

Note 1: Even if a drain is designed to handle explosives, deliberate disposal of explosives in these drains should be avoided. These drains should be used only to clean up explosives spills. Note 2: Special care should be exercised to prevent entrance of compounds into drains that may react with iron or rust to form sensitive salts (e.g., picrates and picric acid). 17.1.7. Suitable guards shall be provided for all glass or fragile equipment that shall withstand reduced or elevated pressure. 17.2. Blast Shields 17.2.1. If determined through a documented hazard analysis that a laboratory operation presents a credible risk of explosives initiation, controls shall be incorporated, such as the use of blast shields or performing the operation remotely. Table 17.1 lists shields that have been tested and found acceptable for the indicated quantities of explosive. DOE-STD-1212-2019 43 17.2.2. If an experiment poses a metal-fragment hazard (as opposed to a glass-fragment hazard) and the experiment cannot be conducted remotely, the proposed shield should be tested and approved under conditions simulating an explosion in the experimental setup but with at least 125% of the anticipated explosive content. 17.2.3. The shield shall be anchored to the hood frame or bench top when it is being used for protection against more than 0.16 oz (5 grams) of TNT equivalent. Note: Shields listed in Table 17.1 were not tested for metal-fragment penetration (unless specifically indicated) and thus may not offer effective protection when the explosive is closely confined in a heavy-walled metal container (“heavy-walled” is defined here as wall thickness to diameter ratio greater than 0.01). 17.2.4. Other blast shields may be approved for use after successfully passing a test of 125% of the rated explosive charge. 17.2.5. For confined areas, a blast vent having less strength than the shield should be provided. 17.2.6. When explosives operations require personnel to reach around a shield to manipulate equipment, exposure shall be minimized. DOE-STD-1212-2019 44 Table 17.1 Blast Shields for Laboratory Operations Shield Minimum distance from explosive Explosives limit Leather gloves, jackets, or coats, and plastic face shields ---- 50 mg 3 mm tempered glass 8 cm 50 mg 7 mm Lucite/equivalent material 15 cm 2.5 g 20 mmLucite/equivalent material 15 cm 10 g 15 mm laminated resistant glass 20 cm 20 g 25.4 mm Lexan/Lexguard 30 cm 50 g 2 units each of 25.4 mm plate glass laminated with 12.4 mm polycarbonate with a 9.5 mm air gap between units (glass sides facing the explosive) 30 cm 50 g (steel confined) Note 1: Blast testing has shown that laminated tempered glass is superior to monolithic tempered glass, and polycarbonate is superior to acrylic plastics, such as Lucite. Laminated tempered glass is recommended instead of monolithic tempered glass and polycarbonate is recommended in lieu of acrylic. Note 2: The shields are recommended to be of equal or greater thickness than those listed in the table. Note 3: Proof testing is highly recommended. Note 4: When designing and/or replacing a blast shield with a polycarbonate, it should be UV stabilized, treated for abrasion resistance, and have met Mil Spec P-46144C. Note 5: When designing or replacing a blast shield with laminated glass, it should be coated with a 0.1 mm fragment-resistant film on the viewer’s side to minimize spalling. Note 6: The shield, shield frame, and anchoring system shall be designed to resist maximum credible overpressure and fragments.

17.3. Heating Operations 17.3.1. During synthesis, formulation, or experimental work, heat may be applied to initiate or maintain reaction, to increase solubility, etc. 17.3.2. Heat shall be applied indirectly using steam, a water bath, oil bath, or an approved laboratory electrical heating device such as a mantle. 17.3.3. Caution shall be exercised to verify that reactive material does not come in direct contact with the heating elements. 17.3.4. If an experiment requires a blast shield, any heating device shall be mounted so that temperature can be controlled from the operator side of the shield. 17.3.5. If an experiment requires a blast shield, any heating device should be mounted so it can be separated quickly from the reaction vessel without operator exposure. Note: During design of the experiment, consideration should be given to providing emergency cooling for the reaction vessel or its contents. DOE-STD-1212-2019 45 17.3.6. Heating systems that are operated unattended shall have dual controls, an override shutoff, or some other protection against failure of the primary heating control. 17.3.6.1. Heating of explosives with devices without these controls shall be monitored at all times Note: If the operator leaves for any reason, the heating device should be turned off. 17.3.7. Requirements in paragraph 17.3.6. may not apply to systems capable of totally containing the effects of an explosion. 17.3.8. Periodic checks should be made to verify that an experiment is proceeding satisfactorily and that the apparatus is not boiling dry, malfunctioning, etc. 17.3.9. In the case of remotely controlled operations, provisions shall be made for observation using mirrors, television monitors, etc. 17.4. Laboratory Setups 17.4.1. Equipment and apparatus shall be clean, in good condition, and in good working order. 17.4.2. All glassware and apparatus shall be inspected for cracks, defects, etc., before use. 17.4.3. Defective or damaged equipment shall be removed from service. 17.4.4. Setups shall be geometrically and structurally stable. 17.4.5. Work areas should be neat and uncluttered. 17.5. Low Concentration of Explosives in Solution 17.5.1. After explosives are in dilute solution (less than 25% explosives by weight), the primary hazard shall be considered as that associated with the solvent and not the explosive. Note: Where supported by technical data and approved by the EDC, a solvent/ explosives solution greater than 25% may also be similarly classified. 17.5.2. If the explosive recrystallizes or precipitates out of solution, safety requirements for explosives shall apply. DOE-STD-1212-2019 46 17.6. Explosives Sample Control 17.6.1. Samples shall be delivered to a laboratory only at specific designated locations. 17.6.2. Each sample shall be properly identified and labeled. 17.6.3. Upon completion of required tests or analyses, the sample should be removed from the laboratory. 17.6.4. A safety information sheet should accompany all samples of new experimental explosive material submitted to a laboratory for analysis. 17.7. De minimis or Residual Quantities 17.7.1. Based on a total mass size less than the critical diameter, primary explosives 1 mg or less and secondary explosives 10 mg or less are considered non-detonable by abnormal stimuli or environment (see Paragraph 6.2.1). Locations with explosives in these quantities are therefore exempt from the following requirements.  Electrical equipment requirements.  Posting of fire symbol signs and placards.  Quantity/distance requirements.  Posting of explosives limits.  Personnel Limits.

17.8. Laboratory Wiring and Equipment 17.8.1. Permanent wiring and equipment for existing laboratory areas are not required to meet the requirements of Chapter 36. 17.8.2. Process equipment used for synthesis, heating, drying, mechanical mixing, and blending shall be dual-rated (Class I, Division 1 and Class II, Division 1). 17.8.3. Weighing equipment shall be Class II, Division 1 or mechanical. 17.8.4. Synthesis, heating, drying, mechanical mixing, blending, and weighing operations shall be isolated from non-rated wiring, electrical equipment, and instrumentation in a manner that prevents dust or vapors reaching an ignition source. 17.8.5. When laboratory equipment cannot meet the requirements of Paragraphs 17.8.2, 17.8.3, and 17.8.4, apply Paragraphs 36.4.3 and 36.4.4. DOE-STD-1212-2019 47 18. INSPECTION 18.1. Inspections 18.1.1. Explosives shall be inspected to verify proper identification. 18.1.2. Incoming explosives raw materials shall be inspected for foreign bodies that could cause operating or safety problems in processing operations. 18.1.3. Pressed explosive billets shall be inspected for foreign bodies, voids, or cracks that could cause operating or safety problems in processing operations. 18.1.4. Explosives pieces and assemblies shall have their physical parameters measured where improper dimensions could cause safety problems in processing operations. 18.2. Inspection Methods 18.2.1. The following are examples of acceptable inspection methods:  Screening  Visual inspection  Magnetic separation  Radiography  Chemical analysis  Physical dimension 18.3. Equipment Inspection Design and Operation 18.3.1. Pinch points shall be eliminated or steps taken to preclude explosives contamination of pinch points. 18.3.2. Threaded fasteners or threads of measuring equipment shall be protected from explosives contamination. 18.3.3. Care shall be taken to prevent parts of the measuring or handling equipment from becoming loose and getting into the explosives. 18.3.4. Inspection fixtures shall be designed to secure the explosives piece or assembly effectively to prevent toppling, rolling, or dropping during measurement operations. Note: This is especially critical if the explosives assembly is in motion (e.g., spinning, vibrating) during measurement. DOE-STD-1212-2019 48 19. EXPLOSIVES DEVELOPMENT AND FORMULATION SCALEUP 19.1. Contractor Explosives Development Committee (EDC) 19.1.1. A committee shall be established at each DOE/NNSA facility engaged in explosives development to be the approving authority for each phase of an explosives development program. 19.1.2. This committee is referred to in this Technical Standard as the EDC, but it may have a different name at each DOE/NNSA facility. 19.1.3. Individuals selected to serve on the EDC should have considerable experience in explosives handling, processing, chemistry, sensitivity and safety. 19.1.4. The EDC shall approve phase-by-phase, modified formulations and sensitivity data as follows: 19.1.4.1. Shall review and approve data generated in each phase of a development project that involves a new explosive or new explosive formulation before the next phase begins. 19.1.4.2. Shall review and approve compositional modifications to previously evaluated explosive formulations and may approve minor modifications to the explosives formulation for a given phase of development without requiring all of the developmental steps and tests.

19.1.4.3. May waive some developmental phase tests if comparable sensitivity data for the subject material are available from another source. 19.2. Development Process 19.2.1. All DOE/NNSA explosives handling facilities shall establish an administrative process that defines the basic steps for developing and evaluating new explosives and explosive formulations. 19.2.2. The process shall require that each development effort proceed in phases from small to large quantities. The quantities of materials that may be handled in each phase shall be limited as specified below in Table 19.1. 19.2.3. The EDC shall be responsible for establishing criteria for acceptable explosive behavior in each test of each phase of the explosives development process. DOE-STD-1212-2019 49 19.2.4. The development process should consist of three phases plus sensitivity and compatibility testing, when required. DOE-STD-1212-2019 50 Table 19.1 Scaleup Process Guidelines for New Explosives and Formulations Quantity of New Materiala Recommended Dataa Data Desired Additional Recommendations Synthesis Specified by the lab performing the synthesis Impact, friction, spark, thermal stability Before using the new ingredient in a formulation ---- Formulation Compatibility Testing: 2 g Thermal compatibility of new ingredient with other ingredients of formulation Before proceeding to Phase I Materials should be processed remotely Phase I 10 g Impact, friction, thermal stability Before non-remote processing and handling in Phase I or scaleup to Phase II Materials should be processed remotely before passing sensitivity and stability tests Phase II 500 gb Compatibility c, impact, friction, spark, thermal stability, thermal characterization before elevated temperature pressing d, e f Phase III Specified by EDC Compatibility, high-speed machining, drop, skid Before Phase III machining or handling of billets 7 kg or greater Composition of formulation shall be fixed a. Quantities and recommended data apply to both new formulations and explosive ingredients. b. The EDC may allow more than 500 g in Phase II where larger quantities are needed for some tests. c. Compatibility of explosives and formulations with materials contacting the explosives in test and production assemblies. d. Before proceeding to Phase II if the composition of a formulation is modified so that the composition is no longer within the limits specified by the EDC. e. Before proceeding to Phase III if: 1. The formulation to be scaled up to Phase III differs from that tested in Phase I, or 2. The explosive or formulation prepared for Phase II development is produced by techniques different from those used in Phase I. f. Materials investigated in this phase should be produced by techniques similar to those that shall be used to produce larger batches in a subsequent phase. 19.3. Sensitivity Testing 19.3.1. Before mixing a new explosive with other materials, the sensitivity and stability of the explosive should be determined and should comply with the criteria set by the EDC. Recommended tests include the following:  Drop-weight impact  Friction DOE-STD-1212-2019 51  Spark  Thermal stability Note: Thermal stability tests should include two or more of the following:  Differential thermal analysis or differential scanning calorimetry  Thermal gravimetric analysis  Gas evolution rate at elevated temperature (chemical reactivity test, vacuum stability)  Time-to-explosion analysis

19.4. Compatibility Testing 19.4.1. If a proposed formulation contains new ingredients (explosive or non- explosive), the new ingredients should be tested for compatibility with the other ingredients before preparing batches for Phase I testing. 19.4.2. Compatibility tests should include any of the stability tests listed under Paragraph 19.3.1. 19.4.3. No more than 2g of the new formulation should be prepared, handled, or stored before compatibility testing. 19.4.4. Formulations for compatibility testing should be processed remotely, whenever possible. 19.5. Phase I—Preliminary Development 19.5.1. Whenever possible, material should be processed remotely. 19.5.2. The total quantity of material that may be processed, handled, or stored at any one time in Phase I should not exceed 10g. 19.5.3. The new explosive or formulation should be subjected to sensitivity and stability tests. Note 1: As a minimum, drop-weight impact, friction, spark sensitivity, and thermal stability tests should be performed. Note 2: Thermal stability testing need not be performed here if one or more of the compatibility tests listed under Paragraph 19.3.1 have already been conducted on the new formulation. 19.5.4. If the new explosive or formulation has acceptable sensitivity and compatibility results, it may be scaled up to Phase II. DOE-STD-1212-2019 52 Note: The EDC may impose handling or processing restrictions or precautions on the material if its performance in any of the above tests is questionable. 19.5.5. After Phase I testing of a formulation is complete, the EDC shall define, on the basis of the test results, what variations in composition are permissible during Phase II development without retesting. 19.6. Phase II—Experimental Characterization and Development 19.6.1. The total quantity of materials processed or handled at any one time in Phase II should not exceed 500g. Note: No limit exists on the quantity that may be stored, other than the storage facility limits for Group L explosives. 19.6.2. Materials investigated in Phase II should be produced by techniques similar to those that shall be used to produce larger batches in a subsequent scaleup phase. 19.6.3. A thermal characterization test and evaluation should be run before pressing the new material at elevated temperature. 19.6.4. The Phase I sensitivity and stability tests should be rerun in Phase II if any of the following conditions apply: 19.6.4.1. The formulation to be scaled up to Phase III differs from that tested in Phase I. In this case, testing should be completed before Phase III scaleup. 19.6.4.2. The explosive or formulation prepared for Phase II development is produced by techniques different than those used in Phase I. Note: Testing should be completed before Phase III scaleup. 19.6.4.3. During Phase II, the composition of a formulation is modified to an extent that the composition is no longer within the limits specified by the EDC (see Paragraph 19.5.5). Testing should be completed before proceeding with Phase II. 19.6.4.4. The compatibility of explosives and formulations with materials contacting the explosives in test and production devices shall be evaluated before any such device is assembled. Note: If compatibility testing is required, one or more of the tests listed under Paragraph 19.3.1 should be recommended. DOE-STD-1212-2019 53 19.7. Phase III—Full-Scale Testing and Production Development

19.7.1. The maximum quantity of materials processed or handled in Phase III shall be defined in the EDC grant of authorization to proceed with Phase III. Note: No limit is imposed for storage facilities except the limits imposed by the QD tables. 19.7.2. All additional testing necessary to define storage compatibility grouping should be completed before committing bulk quantities of the material to storage (see Section 32.4). 19.7.3. During Phase III development, the composition of all formulations should be fixed. 19.7.4. Any new explosive material that is to be contact machined shall be subjected to a machining overtest. Note: Reaction threshold should be determined if possible. 19.7.5. If billets of 7kg or greater are to be produced in Phase III, skid testing should be performed and EDC criteria for this test should be met. 19.7.6. Paragraph 19.6.4 should also apply to Phase III development. 20. SYNTHESIS AND FORMULATION 20.1. Synthesis 20.1.1. Synthesis operations are conducted both on laboratory and pilot scales. The EDC shall approve new operations and materials. In the laboratory, the new material shall initially be prepared on a small scale and characterized as to sensitivity, physical, and explosive properties. Also, the laboratory shall develop processing techniques for the material. If laboratory studies determine that the explosive is of continuing interest, it may be advanced to the Pilot Plant where processing techniques shall be refined and scaled up. The Pilot Plant shall produce sufficient material for larger scale physical, explosive, and sensitivity characterizations. 20.1.2. Laboratory Scale Synthesis 20.1.2.1. Before initiation of work, the subject matter expert who is directing or conducting the synthesis shall analyze each explosives or potential explosives experiment for the type and magnitude of hazards. They DOE-STD-1212-2019 54 shall be responsible for planning the proper selection of conditions, quantity of explosives, and safety devices to be employed. 20.1.2.2. Experiments should be designed to minimize the amount of explosives involved and to use the mildest conditions that yields the desired information. 20.1.2.3. New explosives materials shall be afforded extra protection against impact, pinching, friction, pressure, sparks, contamination, and deterioration. Note: If it is necessary to subject explosives to any of these conditions, the operation shall be conducted remotely or adequate personnel shielding shall be provided. 20.1.3. Pilot or Processing Scale Synthesis 20.1.3.1. Alarms should be provided for coolant flow to the reactor, for reaction vessel agitation, and for reactor temperature. These alarms should be energized whenever coolant supply or agitation is critical to prevent a runaway reaction. 20.1.3.2. When agitation is critical, the reactor should be equipped with at least two sources of power to maintain agitation in the event of failure. For example, a reactor might employ an air or inert gas bubble tube as a backup for a mechanical agitator. 20.1.3.3. The reaction vessel should be equipped with an emergency system that automatically cools the vessel or opens or closes a vessel dump valve as required by the process. Note: Contact operations should be conducted with a means to activate the emergency system manually. 20.1.3.4. An alarm or monitor should be provided for the critical exhaust ventilation system to warn operating personnel if airflow rates drop below a predetermined level.

20.1.3.5. Emergency plans shall be established for the synthesis area, specifying action to be taken in the event an alarm sounds. 20.1.3.6. Before operations begin, all equipment shall be set up and checked for proper function. 20.1.3.7. Prior to use with any hazardous material, new or infrequently used equipment shall be tested in a “dry run.” DOE-STD-1212-2019 55 20.1.3.8. Before starting any process operation, the transfer lines to be used should be properly labeled and their function specified in the operating procedure. 20.1.3.9. All control valves shall be correctly identified according to function. 20.1.3.10. Safety equipment and clothing shall be worn as defined in operating procedures. 20.1.3.11. Explosives warning signs shall be conspicuously displayed on any processing vessel in which explosive materials are to be left overnight. 20.1.3.12. All explosives synthesis process equipment shall be maintained routinely. 20.1.3.13. Equipment with defects that could affect safe operations shall be tagged to prevent its use until repairs are completed. 20.1.3.14. Transfer hoses and portable equipment not involved in the process shall be removed from the work area and stored in their proper places. 20.1.3.15. Agitator blades on reactors and mixers shall be inspected regularly for proper clearance to verify that there is no pinch point or metal to metal contact. 20.1.3.16. Any vessel that can be sealed and that can operate above atmospheric pressure shall be equipped with overpressure protection. 20.1.3.17. All closed vessels should be purged with inert gas before flammable liquids are introduced. 20..1.3.18. Inert gas pressure should be used to transfer flammable liquids when gravity flow or pumping is not practical. 20.2. Formulation 20.2.1. Formulation operations considered in this section involve combining compounds or mixtures when one or more of the ingredients are explosive. 20.2.2. Explosives should be loaded into mixers, mills, and deaerators as an operator attended, contact operation. However, the starting, operating, and stopping of such equipment with explosives present shall be accomplished remotely. As an exception, mixing type operations involving a low-energy transfer may be allowed as a contact operation (e.g., slurry coating and melt agitation). DOE-STD-1212-2019 56 20.2.3. Equipment used for explosives formulation shall be checked for proper operation before adding explosives. 20.2.4. Equipment shall be examined for proper clearances and for metal-to- metal rubbing of moving parts with the potential to contact explosives. 20.2.5. Bearings should be sealed to preclude explosives contamination. 20.2.6. Fast action deluge systems shall be considered for equipment (e.g., mixers, mills, and deaerators) used for easily ignitable explosives formulations. 20.2.7. Hot water, cold water, or steam may be applied to mixers and mills. Heating fluid temperatures shall not exceed known safe operating temperatures for the explosives involved. When roll milling, allowance shall also be made for viscous shear heating of the explosives in process. Heated systems shall comply with the requirements of Paragraphs 21.3.1 and 21.3.4. 20.2.8. Mixing 20.2.8.1. Mixer seals and gaskets shall be checked on a regular schedule and cleaned or replaced as required. 20.2.8.2. Checks should be made to verify that maximum particle sizes of ingredients or hard agglomerates of proposed mixes are less than the blade to blade or blade to bowl clearances.

20.2.8.3. Initial cleaning with solvents used for dissolving or suspending the explosives residues shall be done remotely (except for melt mix or slurry coating vessels). 20.2.8.4. Explosive powders and plastic bonded explosives formulations should be mixed wet in a contact operation. This can be accomplished if the wet mixture cannot be initiated with energy sources available, the viscosity is kept low, and the possibility of isolated portions of the mix becoming dry is precluded. 20.2.9. Ball or Jar Milling 20.2.9.1. Balls that are porous or contain cavities shall not be permitted in mills for grinding explosives. 20.2.9.2. Grinding media contaminated with explosives slurry shall be protected from excessive impact when emptying of the mill. DOE-STD-1212-2019 57 20.2.9.3. After grinding, a careful inspection shall be made to verify that the explosive is free of grinding media. Dispose of any explosives contaminated with broken media. 20.2.9.4. After separating the explosive, the grinding media shall be thoroughly cleaned and inspected before reuse or disposal. 20.2.10. Roll Milling 20.2.10.1. Positive stops should be installed on roll mills to prevent rolls from rubbing against each other. 20.2.10.2. Before starting a milling operation on a roll mill, the contact of the scraper blade with the roll should be adjusted to the minimum pressure necessary to perform the operation. 20.2.10.3. Roll gaps should be set as wide as possible while still allowing adequate working of the material. The minimum gap setting shall be 0.1 mm. 20.2.10.4. Roll rpm should be held at the minimum required to process the material adequately. 20.2.10.5. All roll mills that should be contact operated (e.g., with nonexplosive materials) shall be equipped with emergency stop devices (breaker bar or chain) within easy reach of the operator. 21. HEATING, DRYING, AND THERMAL CONDITIONING 21.1. Hazards of Heating Explosives 21.1.1. Elevated temperature may increase an explosive’s sensitivity to other stimuli such as impact, shock, friction and static electricity. Note: A runaway chemical reaction may occur at or above the explosive’s critical temperature that can produce an explosion or fire. 21.1.2. Elevated temperature of an explosive in a sealed container may cause gas generation and pressure rupture of the containment even at temperatures below the critical temperature. 21.1.3. Chemically incompatible or reactive materials, which may be present as accidental contaminants, as components of the formulation, or in external contact with the explosive, may intensify the preceding dangers or cause them to occur at lower temperatures. DOE-STD-1212-2019 58 21.1.4. Non-uniform heating can cause excessively hot regions in the explosives. Causes may include inadequate agitation of fluid explosives, non-uniform heaters, and non-uniform heat conduction. 21.2. Critical Temperature and Thermal Analysis Methodology 21.2.1. Critical temperature is a system property that depends on a combination of the explosive’s chemical decomposition reactions, its mass and shape, heat transfer and other thermal characteristics of the system, and the confinement or pressure of decomposition products, especially gases. Several different methods of thermal analysis may be used to determine or estimate the critical temperature. The process is typically quite complex because of the complexity of normally occurring chemical reactions.

21.2.2. For operational safety, a conservative estimate (i.e., lower limit) of the critical temperature for a heating operation shall be made (uncertainties of 18°F to 45°F (10°C to 25°C) being common). Note: Analogy of one explosive or system to another similar system with a reliable thermal analysis should be used to determine safe heating temperatures and heating times (heating limits). 21.2.3. The differential thermal analysis (DTA), differential scanning calorimetry (DSC), or other comparable techniques may be used to measure the temperature of the onset of an exothermic reaction in an explosive. The test results may be used to rank the thermal stability of explosives and as part of a thermal analysis. Because of the complexity of chemical decomposition, however, the DTA/DSC exotherm has no systematic relationship to the critical temperature and is unreliable for estimating safe heating limits. Exotherm temperature is always considerably above critical temperature and usually increases with the heating rate of the test. 21.2.3.1. Where the DTA/DSC exotherm is specified as a standard for temperature control, the test heating rate shall not exceed 18°F (10°C) per minute. 21.2.3.2. DTA/DSC shall not be used as a sole means for establishing heating limits. 21.2.4. Each facility shall conduct or obtain thermal analysis of any explosives system before the explosive is heated in a contact operation or in association with hazardous radioactive materials as described in Section 29.4. DOE-STD-1212-2019 59 21.2.5. From this analysis, a heating limit for the explosives system shall be established which the EDC shall approve. 21.2.5.1. All factors in Sections 21.1 and 21.2 shall be considered. 21.2.5.2. Any significant change in the geometry or an increase in mass should be considered a new explosives system. 21.2.5.3. For a contact operation, the maximum temperature should be set at least 18°F (10°C) below the critical temperature. 21.2.5.4. For heating explosives in association with hazardous radioactive materials, the maximum temperature should be set at least 36°F (20°C) below the critical temperature. 21.2.5.5. Contractor Facility Management should approve heating to a temperature greater than the above specifications if a documented analysis of the explosive’s thermal characteristics indicates that an acceptable time or temperature safety factor is still present for a specific operation. 21.2.5.6. These operations shall be conducted remotely. 21.2.6. Heating controls for each operation shall be established and specified in written operating procedures. 21.2.6.1. Specified conditions should be set at the lowest temperatures and heating times to do the job efficiently. Temperatures should not exceed the heating limit for the explosives system. 21.2.6.2. Factors to consider when establishing heating controls include:  The heating limit and accuracy of the estimated critical temperature.  Accuracy of the temperature control equipment. The likelihood of incompatible chemical contamination and other operational parameters. 21.3. Heating and Drying Equipment 21.3.1. Heat should be supplied by steam, hot water, friction air, electrically heated transfer fluid, or electrical resistance elements. 21.3.2. Redundant, automatic heat controls shall limit temperatures. 21.3.3. Explosives heated using electrical resistance elements shall be separated from electrical resistance elements to avoid any possible contact. DOE-STD-1212-2019

60 21.3.4. In systems heated by steam only, the requirements for redundant, automatic heat controls shall be satisfied if a pressure reducing valve, pressure relief valve, and thermostatic valve on the system control the steam pressure. 21.3.5. In electricity heated systems, a manual reset secondary over- temperature system consisting of a controller, failsafe sensor, and an interrupting device shall be provided to interrupt the heat supply source if the primary system fails. 21.3.5.1. The secondary interrupter shall be separate from the primary interrupter. 21.3.5.2. The upper limit of the primary controller is determined by the desired operating temperature limit. 21.3.5.3. The secondary (override) controller is set at a higher temperature but should not exceed the maximum temperature determined by the heating limit specified for the explosives system as determined in Paragraph 21.2.4. 21.3.6. Visual and/or audible alarms should be provided to alert operating personnel to abnormal temperature conditions. 21.3.6.1. The heating of explosives should be monitored at all times. 21.3.7. The air or gas used to condition exposed explosives shall not be recirculated if directly heated by electrical resistance elements. 21.3.8. Drying or heating ovens should be vented to a safe location outdoors. Water wash or filtration of the exhaust may be required. 21.3.8.1. If exhaust fans are used, they shall be interlocked with the heat source. 21.4. Heating and Drying Operations 21.4.1. Heating and drying shall be performed under the mildest set of conditions to accomplish the task safely and efficiently. 21.4.2. A thermal analysis shall be made and a written procedure prepared consistent with Section 21.2. 21.4.3. The operating procedure shall include controls on the mass and geometry (thickness of the layer) of the material that may be heated. DOE-STD-1212-2019 61 21.4.4. Except as described in Paragraph 21.4.5, drying shall be achieved by circulating a warm, dry gas—either air or inert—over or through the material. 21.4.5. Small samples may be dried by placement in desiccators or by subjecting them to vacuum. 21.4.5.1. Vacuum drying of larger items should be preceded by drying at atmospheric pressure to remove quantities of moisture or solvent before vacuum is applied to remove the final traces of moisture or solvent. 21.4.5.2. Explosives having a vapor pressure exceeding 0.013 Pa (1 x 104 mm Hg) at the drying temperature shall not be subjected to vacuum drying. 21.4.5.3. A cold trap shall be used for vacuum drying where the vapor pressure of the explosives is unknown. 21.4.6. A vapor air mixture within explosive concentration limits shall be avoided. 21.4.6.1. Such a vapor air mixture can be controlled by providing sufficient airflow to maintain a vapor concentration well below the lower flammability limit or by using an inert atmosphere. 21.4.6.2. For inert atmosphere, positive purge shall be used to preclude oxygen leakage into the unit. 21.4.6.3. If vapor concentrations approaching a flammable level are anticipated, they shall be monitored. 21.4.6.4. Airflow shall be controlled to prevent dusting. 21.4.7. When heating explosives whose vapor pressure may cause undesired condensation of explosives on equipment parts, heating shall be conducted in a manner to control condensation of the explosive material. 21.4.7.1. This control should be accomplished by heating the exhaust system or by circulating the air at a rate that shall keep the explosives concentration below the level at which condensation could occur.

21.4.8. The proper operation of heater controls shall be verified on a regular schedule established by Contractor Facility Management. DOE-STD-1212-2019 62 22. DRY SCREENING, BLENDING, AND MELTING 22.1. Dry Screening 22.1.1. Use of magnetic separators is often advisable to remove ferrous materials that may have passed through the screens. 22.1.2. Operations using mechanical screens shall be performed remotely. 22.1.3. Screening small samples may be performed as a contact operation in accordance with approved operating procedures. 22.1.4. Operating areas and equipment therein shall be cleaned frequently to avoid accumulation of explosives dust. 22.1.5. Operations and equipment shall be set up to minimize and control dust generation. 22.1.6. Equipment shall be designed and operations performed to avoid subjecting explosive materials to pinching, friction, or impact. 22.1.7. Precautions shall be taken to prevent metals from rubbing together when the screens vibrate. 22.1.8. Vibrating equipment shall be inspected frequently for developing cracks subject to contamination by explosives. 22.1.9. Equipment shall be electrically bonded and grounded. Resistance to ground shall be 10 ohms or less and shall be inspected as established by Contractor Facility Management. 22.1.10. Equipment used to transfer electrostatic sensitive explosives to or from screens shall be conductive and electrically bonded to the screen during transfer. 22.2. Blending 22.2.1. Dry blending of explosives shall be performed remotely. 22.2.2. Dry, hand blending of small samples may be performed as a contact operation in accordance with approved operating procedures. 22.2.3. Equipment should be designed and operations performed to minimize generation and dispersion of explosives dust. DOE-STD-1212-2019 63 22.2.4. Equipment shall be electrically bonded to provide a continuous path to ground. 22.2.4.1. Resistance to ground shall be 10 ohms or less and shall be inspected as established by Contractor Facility Management. 22.2.5. Equipment used to transfer electrostatic sensitive explosives to or from blenders shall be conductive and electrically bonded to the blender during transfer. 22.3. Melting 22.3.1. The heat for melting explosives shall be supplied by saturated steam, hot water, or another temperature controlled medium. The steam pressure shall be controlled in accordance with Paragraph 21.3.4. 22.3.2. Temperatures for contact melting of TNT based explosives (except those containing PETN (Pentaerythritol Tetranitrate), e.g., pentolite) and keeping them molten shall not exceed 249.8°F (121°C). 22.3.2.1. The temperature limit for TNT explosives containing PETN shall be 228.2°F (109°C). 22.3.3. Alarms shall be provided on the melt temperature and on melt kettle agitation when the operation shall be left unattended. 22.3.3.1. Alarms shall sound if the temperature exceeds the specifications of Paragraph 22.3.2 above, or if agitation ceases. 22.3.4. Provisions should be made for emergency emptying of melt kettles in the event of temperature control problems or power failures. 22.3.5. Feeding of the melt kettle and the melting operation shall be controlled or regulated to prevent the formation of large chunks of explosives. 22.3.6. Wherever possible, valves, piping, and threaded bolts and fasteners should be eliminated from melted explosives handling systems. 22.3.7. Melt kettles shall be constructed with corrosion resistant materials.

22.3.7.1. Construction shall not contain blind holes, threads, or cracks in areas exposed to melted explosives. 22.3.7.2. Welds shall be inspected and found free of cracks and porosity. DOE-STD-1212-2019 64 23. PRESSING AND EXTRUDING 23.1. Pressing Note: Explosives pressing operations subject explosives to high pressures to achieve a physical change. Pressing of explosives formulations is done routinely to consolidate explosive materials into configurations required for test assemblies or weapon systems. Two common types of pressing operations commonly performed are isostatic/hydrostatic and punch and die. The following requirements apply to these types of pressing operations. 23.1.1. Explosives pressing operations shall be conducted remotely. 23.1.2. The correct functioning of press interlock systems shall be verified at intervals established by Contractor Facility Management. 23.1.3. Pressing mandrels, punches, and dies used in explosives operations shall be examined regularly during periods of use for evidence of structural failure. 23.1.3.1. Suitable nondestructive test methods shall be used to perform the examination. 23.1.3.2. Contractor Facility Management shall establish intervals between inspections for each tooling design before committing the tooling to use. 23.1.3.3. The inspection interval and updating should be based on experience with similar tooling designs and configurations. 23.1.4. All new or modified mandrels, punches, and dies shall be inspected before their first use. 23.1.4.1. At least one pressing cycle shall be completed with mock explosives before proceeding to explosives. 23.1.5. Pressure controllers and indicators shall be calibrated periodically to verify accurate control and monitoring of pressing operations. 23.1.6. Press parts that contact explosive materials shall be cleaned thoroughly to remove residual explosives before use with a different explosive formulation. 23.1.7. Temperature control for heated presses and dies shall comply with the requirements of Paragraphs 21.3.1 and 21.3.4. DOE-STD-1212-2019 65 23.1.8. All pressing assemblies shall be designed or procedural controls established to minimize or eliminate the extrusion of explosives between two mating metal surfaces during the pressing operation. 23.1.9. Operations with explosive powders should be performed in a manner that reduces the release of explosives dust and thereby reduces operator exposure and general room contamination. 23.1.9.1. For operations involving large amounts of powders, local exhaust ventilation with a dust collection system should be provided. 23.1.9.2. Respiratory protection to prevent inhalation of explosives dust may be required when adequate ventilation is not available. 23.1.10. Isostatic/Hydrostatic Pressing 23.1.10.1. Before an elastomeric container or mandrel constructed of a new material is introduced into a pressing operation (where it shall contact explosives), the material shall be evaluated for compatibility with the explosives. 23.1.10.2. All pressing vessels shall be examined for evidence of cracking or other signs of incipient structural failure at regular use intervals by suitable nondestructive test methods. Contractor Facility Management shall establish examination intervals. 23.1.10.3. Before large scale pressings of new explosives or explosives formulations, the materials shall be evaluated for thermal stability (see scaleup procedures in Chapter 19).

Note 1: “New explosives or explosives formulations” refer to those that are “new” to large scale pressing. Note 2: Stability test results shall be used to assist in establishing safe pressing conditions for the specific pressing size. 23.1.10.4. For isostatic pressing, procedural controls shall be established to validate that:  An acceptable vacuum can be obtained on the mandrel assembly to prevent adiabatic heating during pressing; and  Air is bled out of the press before pressurization. 23.1.10.5. Consideration should be given to the use of fire resistant hydraulic fluids. DOE-STD-1212-2019 66 Note: New fluids shall be checked to verify compatibility with the explosives used. 23.1.11. Punch and Die Pressing 23.1.11.1. All pressing punches and dies shall be inspected visually for damage, deformation, and cleanliness before installation on a press. Note: Any questionable condition shall be resolved before the pressing proceeds to verify that the operation’s safety is not compromised. 23.1.11.2. All punches, dies, and press attachment fixtures shall be designed to minimize the possibility of the punch being misaligned with the die (resulting in gouging of a die surface during pressing). Note: Press setup procedures shall provide for operator verification of proper alignment before pressing. 23.1.11.3. The responsible user of a gauging section capable of performing the necessary measurements shall control punches and dies. Note: Punches and dies should be maintained in matched sets. 23.1.11.4. A group other than the user shall check critical punch and die dimensions before initial use and at suitable intervals thereafter. Note: Suitable check intervals for each punch and die design should be determined as in Paragraph 23.1.4. 23.2. Extruding 23.2.1. Extrusion operations shall be conducted remotely. 23.2.2. Contact extrusion should be performed only when extruding nonexplosive or mock materials or when hand extruding small quantities with no metal to metal contact. 23.2.3. Precautions shall be taken to prevent personnel from being injured by the rupture of pressurized equipment. 23.2.4. The explosive shall be protected against extrusion beyond the tooling cavity. 23.2.5. Precautions shall be taken to prevent foreign material from entering the explosives. DOE-STD-1212-2019 67 23.2.6. New designs and significant design changes in equipment, tooling or components shall be tested by mock explosives extrusion before actual explosives extrusion. 23.2.7. Pressure controllers and indicators shall be calibrated periodically to validate that proper sealing and extrusion pressures are maintained. 23.2.8. Extrusion press parts shall be cleaned thoroughly of residual explosives remaining from the previous operation before the press is loaded with a different explosive formulation. 23.2.9. Hand loading of extrudable explosives is covered in Section 28.3. 24. MACHINING 24.1. Equipment Requirements 24.1.1. Interlocks shall be provided for wet machining operations to verify coolant flow before machine operation. 24.1.1.1. The coolant flow shall be monitored and the equipment automatically and safely shut down if loss of coolant flow is detected. 24.1.1.2. The coolant interlocks shall be protected from tampering and unauthorized disabling by physical means, or supervisory control. 24.1.2. The vacuum on vacuum chuck holding fixtures shall be monitored and interlocked with the equipment for automatic shutdown of machining in the event of vacuum loss.

24.1.3. Tool path controls (stops, limits, design patterns) shall be provided to prevent the unplanned travel path of a tool or work piece. 24.1.4. Positive means or secondary verification shall control and limit equipment speed and feed rates. 24.1.5. Pressure-relief devices should be installed on pneumatically or hydraulically powered equipment to provide for safe operation. 24.1.6. Metal chip waste from machining operations should be kept separate from explosives waste. 24.1.6.1. When this is not possible, mixed explosives and metal waste should be completely segregated from unmixed waste and held for separate disposal. DOE-STD-1212-2019 68 24.1.7. A cutting tool inspection and control program shall be established for explosives machining operations. 24.1.8. Dull or damaged tools shall not be used. 24.1.9. Consideration shall be given to additional safety control devices (e.g., design patterns, safety templates, chip thickness sensors, tool pressure sensors), depending on the type of machining operations, size of explosives pieces, types of explosives, and other factors. 24.1.10. The “machining over-test” shall be considered a testing operation (see Paragraph 24.4.13) and is exempt from equipment requirements. 24.2. Contact or Remote Operations 24.2.1. The following explosives may be contact machined if a compatible, nontoxic, noncombustible coolant is used. Explosives not listed below shall be machined remotely.  Amatol  Baratol  Boracitol  Explosive D  Octol with no more than 75% HMX (Cyclotetramethylene Tetranitramine)  Pentolite with no more than 50% PETN  RDX/TNT compositions with no more than 75% RDX (Cyclotrimethylene Trinitramine). These compositions include Composition B, Composition B-3, and 75/25 Cyclotol  TATB (Triamino Trinitrobenzene) and TATB compositions with an inert plastic binder  TNT 24.2.2. Explosive assemblies composed of any combination of explosives listed in the Paragraph 24.2.1 and the following non-explosive materials may be contact machined if a compatible, nontoxic, noncombustible coolant is used.  Foamed plastics  Solid plastics  Adhesives  Amorphous graphite  Calcium sulfate casting powder  Explosives mockup 24.2.3. If an assembly contains an explosive not listed in Paragraph 24.2.1 or a nonexplosive material not listed in Paragraph 24.2.2, the assembly shall be machined remotely. DOE-STD-1212-2019 69 24.2.4. On any explosive, with certain exceptions for TATB and TATB/KEL-F (or equivalent) formulations and explosives machined by fluid jet (see Paragraph 24.2.6), the following operations shall be performed remotely:  Drilling of holes smaller than 5cm in diameter (except for TATB and TATB/KEL-F (or equivalent) formulations, where drilling of holes smaller than 5 mm).  Coring operations (except contact operations on those explosives listed in Paragraph 24.2.1, when the requirements of Section 24.6 are met and a coolant is used).  Machining of any metal/explosives interface.  Machining TATB and TATB/KEL-F (or equivalent) formulations subassemblies with HD 1.1 boosters installed.  Machining of explosives in Phase II or earlier stage of scaleup (see Chapter 19).  Dry machining Note: TATB and TATB/Kel-F (or equivalent) formulations booster pellets may be contact machined provided a dust collection system is used. 24.2.5. Machining of primary explosives shall be avoided. Consider other methods, such as forming or pressing to final dimensions, to achieve the desired shape.

24.2.6. IHE, PBX 9404 (Plastic Bonded Explosive), and LX-10 may be contact machined by high-pressure fluid jet. 24.2.6.1. The fluid jet system pressure shall not exceed 20,000psig. 24.2.6.2. The velocity of the fluid jet shall not exceed 520m/sec (theoretical). 24.2.6.3. The jet nozzle orifice diameter shall not exceed 0.01in. 24.2.6.4. The system machining fluid shall be water and shall not contain any abrasives. Note: See Chapter 25 for use of low-pressure fluids. 24.2.7. Concurrent contact machining operations in the same bay should not be permitted. However, concurrent TATB and TATB/KEL-F (or equivalent) formulations contact machining is permitted when other explosives are not present. DOE-STD-1212-2019 70 24.2.8. Provisions shall be made to monitor remote machining operations visually. Consideration should be given to video recording and audio monitoring. 24.3. Setup and Preparation Prior to Machining 24.3.1. Before setting up the explosive work piece, the equipment shall be checked for proper function and the absence of interference between stationary and moving parts. 24.3.2. An inert shape (e.g., wax, Lexan (polycarbonate), or mock explosive) should be used to test the equipment function of any operation using new tooling or new part programs. 24.3.3. The explosive component to be machined shall be inspected by radiography or other suitable nondestructive test methods for cracks, voids, and high-density foreign objects. 24.3.4. The explosive component shall be checked for proper size. 24.3.5. Caution shall be exercised during setup and adjustment to avoid pinching, dropping, crushing, or otherwise applying abnormal forces to explosives present. 24.3.6. Special care shall be given to mounting and centering a part on a vacuum chuck. 24.3.7. Special attention shall be given to the proper functioning of the vacuum system and its surface holding area. 24.3.8. Limits on machine speed, depth of cut, and feed rate shall be set before the machine is activated. 24.3.9. Interlocks shall be functional before the machine is used to machine explosives. They should be tested once per shift. 24.4. Operations Requirements 24.4.1. The minimum tool speed necessary for safe and efficient operation should be maintained. The following maximums shall apply:  The relative velocity between the explosives surface and the cutting tool shall not exceed 65m/min;  Work pieces or cutting tools shall not be rotated at speeds exceeding 525rpm; and  The feed rate of the cutting tool or work piece shall not exceed 1mm per revolution. DOE-STD-1212-2019 71 24.4.2. The work piece, fixture, cutting tools, equipment, floor, troughs, drains, etc., should be cleaned frequently to prevent accumulation of explosive wastes. 24.4.3. Approved measures should be taken to prevent rust and minimize deterioration of precision surfaces. 24.4.4. All tools, equipment, fixtures, and parts should be cleaned before removal from the work area for storage. 24.4.5. Coolant shall be used to aid in removing heat and cutting waste for contact machining operations. 24.4.6. Coolant should be used for remote operations when practical. 24.4.7. Coolant should be used on explosives/inert assemblies. 24.4.8. When the explosives portion is included in the cut, coolant shall be used for contact machining. 24.4.9. Coolant is not required if the explosives portion of the assembly is contained (no bare explosives) and is not included in the cut, or the machining is conducted remotely.

24.4.10. Spray mist coolant may be used during machining of the explosive-containing assemblies if the explosives portion is not included in the cut. 24.4.11. All visible explosives shall be removed from the machine before maintenance or repairs. 24.4.12. No safeguards or interlocks shall be removed or made inoperative, except by authorized personnel. 24.4.13. Before submitting an explosive for contact machining approval, a machining over-test shall be conducted to identify the machinability and associated hazards. 24.4.13.1. Machining over-test should be performed in facilities set aside for this purpose. 24.4.13.2. Machining over-test shall be conducted remotely. 24.4.13.3. Operations performed during sample preparation may include gaging and assembly, but shall not include any contact cutting, scraping, or other material-removing operations on explosives specimens. DOE-STD-1212-2019 72 24.5. Drilling 24.5.1. Drilling operations should be set up to maximize the ease of achieving and maintaining proper alignment and to facilitate removal of explosives chips, fines, and powder. 24.5.2. The fluting length on the drill bit shall exceed the depth of the hole to be drilled by a minimum of 1.3cm or one-hole diameter, whichever is greater. 24.5.3. The depth of a hole shall not be extended more than 1.5 times the hole diameter (up to a maximum of 2cm) during a single insertion of the drill into the material. Note: After each insertion, it may be advisable to withdraw the drill completely and remove loose explosives from the cavity and drill bit before reinserting. 24.5.4. Coolant flow (when used) shall be directed to the explosives/cutting edge interface. 24.5.5. Drill bits larger than 0.25in (6mm) should have a coolant channel to the tip of the drill. Note: Bits 0.25in (6mm) or less in diameter do not need coolant channels, but should limit the depth of each pass to no more than ½ the diameter of the bit to verify that the coolant flow is capable of keeping the hole clean. 24.5.6. Pulsating pressure types of coolant supplies are recommended for drills of 0.25in (6 mm) diameter or less to remove drill fines. 24.6. Coring Note: A machining operation that removes material in the form of a cylinder by cutting at the circumference to create a hole or recover the material from the center of the cut. 24.6.1. Coolant flow (when used) shall be directed at the explosives/cutting edge interface. 24.6.2. If the hole is not positioned to provide continuous breakout, the coring shall be accomplished incrementally. 24.6.3. When done in increments, no more than 1.5 times the diameter of the hole shall be cored at one time. DOE-STD-1212-2019 73 24.6.3.1. Before the maximum distance has been cored, the tool shall be totally retracted from the hole and cleaned. 24.6.3.2. The hole shall be flushed with coolant. 24.7. Sawing 24.7.1. The feed rate of the saw blade or work piece shall not exceed 7.5cm/min. 24.7.2. For band saws, coolant flow should be directed onto the saw blade at the cutting interface, guide rollers, and the drive wheel/saw blade interface. 24.7.3. For circular saws, the coolant flow should be directed at the explosives/cutting edge interface. 25. LOW PRESSURE FLUIDS 25.1. Use of Low Pressure Fluids 25.1.1. Low pressure fluids may be handled in explosives contact operations to aid in the following:  Dissolution  Rinsing  Flushing, or  Similar operations

25.1.2. The fluid system shall have a pressure relief device installed to prevent system over pressurization. 25.1.3. Low pressure fluid operations may be used with those explosives whose impact sensitivity is less than PETN. Note: Such operations may be used on other explosives only after analyzing the energies involved. 25.1.4. Solvents shall be compatible with the explosive material. Note: Controls for their use shall be specified in operating procedures. DOE-STD-1212-2019 74 26. LASER ABLATION 26.1. Laser Ablation Operations 26.1.1. Laser ablation shall be conducted as a Hazard Class 1 Level-of- Protection Activity. 26.1.2. During set-up, when personnel are exposed to the explosives hazard, the ablation laser beam shall not be able to reach the explosives or assembly containing explosives. Note: Low-power alignment lasers may be used. 26.1.3. Before setting up the explosive work piece, the equipment shall be checked for proper function and the absence of interference between stationary and moving parts. 26.1.4. Caution shall be exercised during setup and adjustment to avoid pinching, dropping, crushing, or otherwise applying abnormal forces to explosives present. 26.1.5. Interlocks shall be functional before the laser is used to ablate explosives. 26.1.6. During laser ablation operations, the operator should be provided an immediate means to block the laser beam from reaching the explosives. 27. HAND CUTTING AND FINISHING 27.1. Hand-Cutting and Finishing Operations 27.1.1. Hand-cutting and finishing of explosive materials shall be performed using the mildest energy input that shall accomplish the task safely and efficiently. 27.1.2. These activities may include:  Cutting  Trimming  Coring  Lapping (surface polishing) 27.1.3. The Contractor EDC shall review and approve the safety of hand-cutting and finishing operations, which shall then be incorporated into an operating procedure before starting the operation. DOE-STD-1212-2019 75 28. ASSEMBLY AND DISASSEMBLY 28.1. Tools 28.1.1. Hand tools and electrical and pneumatic tools that may subject the explosives to abnormal frictional forces, pinching, or excessive pressure, or cause significant deformation, shall not be used during assembly or disassembly. Note: Tools may be used on nonexplosive components. 28.2. Assembly Operations 28.2.1. Operators need to be alert for mismated parts and misaligned components during assembly operations. 28.2.2. Hard surfaces that contact explosives shall be precisely machined to mate with the explosives, lined with cushioning material, or otherwise configured to keep sharp corners or projections from being forced into explosives. 28.3. Loading Assemblies with Plastic or Extrudable Explosives 28.3.1. Contamination of these explosives with abrasive or foreign substances shall be avoided. 28.3.2. The assembly shall be loaded with small increments of explosives and may be tamped with suitable nonmetallic tools to eliminate air voids. 28.3.3. Plastic explosive compositions C-3 and C-4 may be softened by warming to between 69.8°F (21°C) and 100.4°F (38°C) before working. 28.3.4. Extrudable explosives LX-13 and XTX should be kept as cool as practical to prevent premature curing. 28.4. Disassembly Operations 28.4.1. Before beginning disassembly, the device’s condition shall be assessed to determine if it can be safely handled. 28.4.2. Disassembly operations shall be planned before actual disassembly. Possible problem areas caused by method of construction or physical condition shall be considered.

28.4.3. Approved operating procedures shall be used for each unique disassembly. DOE-STD-1212-2019 76 28.4.4. If disassembly would normally cause release of pressure or if a credible hazard exists of pressure causing components to fly apart, before beginning disassembly, pressurized units shall be thoroughly depressurized. 28.4.5. If approved for use, compressed air shall be applied cautiously during disassembly to avoid causing device components to fly apart. 28.4.5.1. This may require remote operation. 28.4.5.2. Use hydraulic pressure if possible. 28.5. Personnel Protection for Disassembly Operations 28.5.1. Operators and all other personnel shall be provided complete protection from disassembly operations involving conditions known or expected to require the use of abnormal force. 28.5.1.1. Such operations require either remote operation or the use of an operational shield. 28.5.2. When required, shielding shall be designed to protect personnel at other operations or locations from blast and fragments arising from a possible explosion. 28.5.3. When disassembly requires that the operator be protected by an operational shield, disassembly shall be defined as complete separation (threads or other connections) of component parts. Note: For example, parts shall not be loosened or separated while the operator is unprotected. 29. TESTING 29.1. Test Planning 29.1.1. All explosives testing involving the intentional initiation of explosives materials or articles shall be considered Class 0 operations and shall comply with the requirements of Chapter 12 of this Technical Standard. 29.1.2. Proposed testing programs shall undergo a hazard analysis based upon the maximum credible event. 29.1.2.1. This shall be done with knowledge of the construction and operation of all standard and nonstandard equipment to be used, as well as the type of explosives involved. DOE-STD-1212-2019 77 29.1.3. Large-scale tests with the potential to propel fragments off DOE testing locations shall receive a formal risk analysis of the worst-case conditions for each test type. 29.1.3.1. Such analysis shall address the probability and potential severity of hazards with respect to injury and property damage. 29.2. Firing Areas 29.2.1. A secured firing area (danger zone) shall be established for each test to protect personnel from hazardous blast overpressure, firebrands (burning or hot fragment), fragments, or projectiles from an explosives shot or gun firing. 29.2.1.1. The danger zone shall be determined by the application of the principles outlined in DESR 6055.09. 29.2.2. Selected firing areas shall minimize the potential for secondary fires and adverse effects to the environment. 29.3. Checkout of Dynamic Engineering Test Equipment for Explosive Assemblies 29.3.1. To minimize the possibility of an incident during dynamic testing of explosive assemblies, load-bearing members of the test equipment or explosive assembly should be proof-tested and examined if: 29.3.1.1. The test equipment is new or has undergone a design modification; 29.3.1.2. Existing test equipment is to be used under unusually severe test conditions (i.e., conditions of velocity, vibration, pressure, load); or 29.3.1.3. A new or modified explosive assembly is to be tested that affects the loading characteristics of the equipment. 29.3.2. Proof-testing of the explosive assembly or test equipment should be conducted before running tests involving systems with explosives.

29.3.3. At a minimum, proof-testing should consist of the following sequence of checkouts: 29.3.3.1. Check out load-bearing members (lifting devices, hold-down mechanisms, fixtures, vehicle cases) to at least 125% of rated load using simulated loads. DOE-STD-1212-2019 78 29.3.3.2. “Dry run” tests of actual systems with mock materials in place of explosives and hazardous radioactive materials. 29.3.4. If a part failure occurs in either of the checkout tests in Paragraphs 29.3.3.1 or 29.3.3.2, tests involving explosives or radioactive material shall not be run until additional checkout tests have demonstrated that the cause of failure has been eliminated. 29.4. Testing of Explosives and Hazardous Radioactive Materials 29.4.1. Explosives and hazardous radioactive materials (e.g., plutonium, enriched uranium) shall not be included in the same test or operation if the test or operation is not contained and involves any of the following: Note 1: Depleted uranium and natural thorium are not considered hazardous radioactive materials for this purpose. Note 2: Nuclear Explosive Operations, covered by DOE Order 452.2 are exempted from this requirement. 29.4.1.1. Application of high-energy stimuli (e.g., high shock, impact, or friction levels) to the explosive. 29.4.1.2. Heating the explosive to within 18°F (10°C) of the heating limit determined for the explosive system without hazardous radioactive materials consistent with Paragraph 21.2.4. 29.4.1.3. Intimate contact of incompatible material with the explosive as determined by compatibility testing. 29.5. Heating of Explosives Test Specimens 29.5.1. Before heating an explosive, a thermal analysis shall be conducted and a written procedure prepared consistent with Section 21.1. 29.5.2. For requirements on heating equipment see Section 21.3. 29.5.3. Contact operations on explosives specimens undergoing thermal conditioning may be permitted if: 29.5.3.1. The specimen is not subjected to excessive friction, impact, or spark stimuli during normal operations or during a credible accident scenario. 29.5.3.2. The explosive involved has satisfied appropriate scale-up sensitivity and stability criteria (see Chapter 19) and has sufficient handling history to reveal any special characteristics affecting safe use. DOE-STD-1212-2019 79 29.5.4. If an explosives test specimen in a contact operation is discovered to have exceeded the established heating limit for the explosive system, the test shall be terminated and the specimen cooled to ambient temperature. Note: An operating procedure should be prepared and approved for the required corrective action (i.e., disassembly or disposal). 29.6. Instrumentation 29.6.1. Instrumentation directly applied to explosives in a test specimen shall be physically disconnected, isolated, or grounded before personnel may enter the test cell. 29.6.1.1. Only instrumentation channels that contain devices that limit the current below the level capable of initiating the explosive are exempt. 29.6.2. Environmental control transducer leads, not attached to the test specimen and permanently installed in an approved control system, do not need to be grounded or disconnected. 29.7. Explosives Accumulation Limits 29.7.1. Explosives specimens shall not be permitted to accumulate in a test cell beyond the quantity required to sustain the test. 29.7.1.1. For short-term testing (less than one day), specimens present shall not exceed a 4-hr supply. 30. TEST FIRING

30.1. General Range Standards 30.1.1. Each DOE explosives test site shall establish procedures to verify that personnel are not exposed to firebrands (burning or hot fragment), fragments, or excessive blast overpressure from a test shot. 30.1.2. During test operations, personnel access to each test site shall be controlled. 30.1.2.1. Unattended roadblocks, gates, or doors used to prevent personnel from entering the danger zone during a test should be interlocked or locked with specially controlled keys. Note: In locations where interlocks or locks are not practicable, appropriate barriers and signage may be applied. DOE-STD-1212-2019 80 30.1.3. Before test firing, all firing site personnel and visitors shall be accounted for and in a safe place. 30.1.4. A visual inspection of the danger zone shall be performed immediately before each test shot or series of shots as applicable, to verify that no transients are present. 30.1.5. The danger zone shall be free of service personnel (e.g., telephone repairmen, surveyors, road maintenance crews) during test operations. 30.1.6. The control point shall notify service personnel of the specific requirements under which they may safely work in the area when testing is not in progress. 30.1.7. The control point shall notify firing site personnel of the presence and location of service personnel in their areas. 30.1.8. Clearance for a test or test series shall be coordinated with all test sites and other areas that could be affected. 30.1.9. A warning shall be provided to every affected area to warn personnel of an impending test firing. Note 1: This warning shall include standard audible signals. Note 2: Detonation of very large explosive shots, numerous smaller shots, or gun firings could exceed the DOE allowable limits for impulse noise. 30.1.10. During test operations, all personnel assigned to the test area shall be continuously alert for movement of personnel, vehicles, and aircraft. 30.1.11. Test firings often create hazardous conditions for aircraft operating in the airspace near the danger zone. If this airspace is subject to air traffic, precautions shall be taken to verify that the airspace is clear of traffic at the time of firing. 30.1.12. Each firing site shall establish personnel limits based on the number of people actually needed to conduct an operation and the number of casuals that should be present. The responsible person at the firing site shall enforce these personnel limits. 30.1.13. Testing of explosives can result in personnel exposure to toxic decomposition products such as carbon monoxide, hydrogen chloride, hydrogen fluoride, hydrogen cyanide, and nitrogen oxides. DOE-STD-1212-2019 81 30.1.13.1. Allow the detonation cloud to disperse before leaving protective bunkers. Note: Fragment-danger-zone distances are normally adequate to allow cloud dispersal and protect outside personnel from excessive exposure. 30.1.14. For testing that can result in abnormally long hazardous conditions following the test, the procedure shall require a suitable waiting period before personnel leave their shelter or safe haven area. 30.2. Grass Fires 30.2.1. Before conducting a test shot at an outside firing pad, an evaluation shall be made to determine the need to control grass fires that the test may initiate. 30.3. Test Setup 30.3.1. Test setup work should be done before receipt of explosives. When possible the following activities should be performed:

30.3.1.1. Firing site safety devices (at both the bunker and remote from the firing bunker) shall be checked as established by Contractor Facility Management. Note: Safety devices include warning lights, door and gate firing circuit interlocks, emergency firing circuit cutoff switches, and grounding. 30.3.1.2. Firing pad and shot stand setup work that require power tools or other potential spark-producing devices should be completed. Note: Special precautions and procedures shall be developed and implemented if power tools or other spark producing devices are needed after explosives are delivered to the firing pad. 30.3.1.3. The firing pad shall be cleared of all unnecessary equipment. 30.3.1.4. When possible, all diagnostic equipment shall be set up, checked, and tested in a “dry run.” 30.3.1.5. If a special structure is required, as much work as possible should be accomplished on the structure, including assembly of all materials. DOE-STD-1212-2019 82 30.4. Pin Switches and Other Non-initiating Circuits 30.4.1. Whenever pin switches and other non-initiating circuits are checked (such as for charging current or leakage) and are in contact with or in close proximity to explosives, the check should be performed remotely. 30.4.2. Other non-initiating electrical circuits include strain gauges, pressure transducers, thermocouples, etc., that may be affixed to or close to the explosives within an assembly. 30.4.2.1. A continuity-only (resistance) check may be accomplished as a contact operation with an electrical instrument approved for use with the particular explosive device. 30.4.3. When low-firing-current actuators are involved, consider conducting these tests remotely (see Section 37.4). 30.5. Low-Energy Electro-explosive Devices 30.5.1. Procedures shall be established to verify that Radio Frequency (RF), Frequency Modulation (FM), and television transmitters with sufficient output energy to initiate an electro-explosive devices (EED) at the test site are either restricted to a safe distance from the site or not operated. 30.5.2. Appropriate separation distances from Electromagnetic Radiation (EMR) transmitters shall be determined per Paragraph 38.1.3. 30.5.3. Low-firing-current igniters or detonators shall be kept separate from explosives at all times, except during actual test charge assembly and setup. 30.5.4. At all times, wiring systems for the explosive charge and any low-firing-current initiators shall be kept insulated from all sources of extraneous current unless the weapon components have an exposed electrical ground by design. 30.5.5. Connections made using weapon wiring connectors or cables are acceptable without further modification. 30.5.6. Shunts shall be left on low-energy initiators or lead wires until connections are made. 30.5.7. Connections shall be taped or otherwise insulated. 30.5.8. Test units containing low-firing-current actuators or detonators shall be clearly marked. DOE-STD-1212-2019 83 30.5.8.1. No contact operations involving electrical testing shall be permitted on this type of unit unless an electrical meter for the specific application is used. 30.6. Explosives Storage in Firing Areas 30.6.1. Explosives or ammunition storage at a firing area shall be located such that ignition, explosion, or detonation is improbable if a fire, unplanned explosion, or detonation occurs in the area. 30.6.2. Tests that require storage of explosives or ammunition at the firing site beyond a day’s event shall conform to the requirements of Chapter 32.

30.7. Firing Leads 30.7.1. All detonator lead wires shall be electrically insulated. 30.7.2. During setup on the firing point, firing leads or cables of low-energy detonators for explosive assemblies shall be kept shorted. 30.8. Unattended Test Assemblies (during off-shift hours, when necessary) 30.8.1. If explosives are present, appropriate safety warning signs shall be displayed at all entrances to the firing pad. 30.8.2. Protective services and fire department personnel shall be notified of the explosives location. 30.8.3. This location shall be in a controlled-access or secured area. 30.8.4. If low-energy detonators are present on the assembly, their leads or cables shall be shorted. 30.9. Firing Control Circuit Criteria 30.9.1. The criteria in this section apply to electrical circuits used to initiate EEDs used for test firing. Note 1: These criteria apply regardless of whether the circuit is energized using an internal or external power source. Note 2: A Firing Circuit shall be treated as capable of firing without warning as soon as it is coupled to an EED. DOE-STD-1212-2019 84 Note 3: A Firing Circuit that is connected to explosives shall not be armed during contact operations. 30.9.2. Firing Control Circuits shall be documented, reviewed, and approved for safety and operational control purposes. 30.9.2.1. Documentation shall include complete wiring diagrams, electrical schematics, and cable function lists. 30.9.3. All Firing Control Circuits, including changes and modifications, shall be reviewed for safety and compliance with Section 30.9, and approved by Contractor Facility Management prior to use with explosives. 30.9.4. Firing Control Circuits not meeting the safety criteria of Section 30.9 may be used with explosives only if equivalent safety is provided as determined by a documented analysis reviewed by the Contractor Explosives Safety AHJ, and approved by Contractor Facility Management. 30.9.5. Firing Control Circuits shall include both an arm and a fire control. 30.9.5.1. For low-energy EEDs, the safe mode of the arming circuit shall interrupt the firing circuit, short-circuit the EED terminals, and should ground the EED terminals. Note: Manual shorting and grounding is permitted. 30.9.6. Each Firing Control Circuit shall include an interlock device which prevents unauthorized or inadvertent energization of a firing circuit. 30.9.6.1. The interlock device shall be unique for its application. 30.9.6.2. If key-operated controls are used, they shall be designed to lock in the safe (Off) position when the control key is removed. 30.9.6.3. Duplicate keys, safety plugs, or other interlock devices shall not be permitted in any single test area. 30.9.6.4. During shot preparation, the key, safety plug, or other interlock device, whichever is used, shall be in the control of the lead operator at all times. 30.9.7. Each Firing Control Circuit shall be isolated from all other circuits so as to prevent inadvertent energization by other circuits. DOE-STD-1212-2019 85 30.9.8. Firing Control Circuits shall be failsafe. Failure of any single component shall not result in inadvertent initiation of the EED prior to arming. 30.9.9. Firing Control Circuits shall be marked clearly or otherwise distinctively identified. 30.9.10. Developmental and/or Self-Contained Firing Circuits designed to initiate EEDs shall meet the requirements of Section 30.9 before being used with explosives.

30.10 Test Firing in Containment Apparatus (Tanks, Chambers, or Vessels) 30.10.1. Explosives may be detonated in containment apparatus. 30.10.2. All containment components shall be capable of withstanding and confining the effects of the explosion. 30.10.3. When new firing containment apparatus are designed and put into service, a safety factor to their operational explosives weight limit shall be included during certification testing. 30.10.3.1. This over-test load should be based on a percentage of the operational explosives weight limit. Note: For example, a certification test should be performed with an appropriate explosive material weighing at least 125% TNT equivalency of the intended operating limit. 30.10.4. The firing circuit should be interlocked with the containment apparatus access door latch so that the door shall be closed and latched before the explosive can be fired. 30.10.5. Qualified engineering personnel shall periodically inspect the containment apparatus to verify that its structural integrity is maintained after repeated detonations. 30.10.6. Test firing is often conducted inside large containment apparatus that allow personnel entry but provide a confined working space and limited egress. 30.10.6.1. The operating procedure shall include requirements for ventilating and evaluating the containment apparatus’ atmosphere before personnel entry. DOE-STD-1212-2019 86 30.11. Gun Firings 30.11.1. The gun shall be rigidly mounted so that the impact area is defined and controlled. 30.11.2. The target shall have an adequate backstop. 30.11.3. Provision should be made to remotely move the gun, remotely remove the propellant charge, or remove the explosives from the line of fire if the gun misfires, unless the hazardous effects of an accidental detonation of the explosive target is contained or effectively shielded from personnel. 30.11.4. Provisions shall be made to collect and remove undetonated explosives from the chamber or area. 30.11.5. Work, adjustment, or observation shall not be permitted on a gun while a live round is in the firing chamber. The only exception is to check azimuth and elevation. 30.11.6. Precautions shall be taken to protect personnel or equipment against hazards resulting from errors in assembly or preparation of equipment and ammunition. In particular, the following areas shall be checked:  Fluid level of hydraulic recoil mechanisms.  Function of the firing mechanisms.  Absence of obstructions in the bore. 30.11.7. Firing mechanisms, particularly electric firing mechanisms, shall be tested before use to verify that merely inserting a round or closing of the breech does not result in firing. 30.11.8. Test weapons other than manually-fired small arms should be equipped for remote control of the safety and for remote cocking. Note: The safety shall not be advanced to the fire position and the weapon shall not be cocked until all personnel are in a safe location. 30.11.9. When using hydrogen gas to fire a light gas gun, the operation shall be remote while hydrogen is present in the gun pressure tanks or in the gun barrel and catch tank after firing. 30.11.9.1. The hydrogen shall be purged from the entire system with inert gas and the atmosphere checked before personnel are allowed to reenter the gun bay. DOE-STD-1212-2019 87 30.12. Drop Testing 30.12.1. After an explosives drop test, personnel shall wait a minimum of 5 minutes before leaving the control bunker to inspect the test pad.

30.12.1.1. If smoke or flame is observed at the drop test area, entry shall not be permitted until at least 30 minutes after all visual signs have disappeared. 30.13. Post-firing Controls 30.13.1. If the firing appears to be normal, test personnel shall remain in the protective shelter for a suitable waiting period. 30.13.1.1. The test procedure shall specify the waiting period, which shall be sufficient to verify adequate dissipation of smoke and dust. Note: In some cases, developing and analyzing the diagnostic film for misfires may be helpful. 30.13.2. During the waiting period, all power to the firing units shall be turned off or disconnected. 30.13.2.1. Whenever possible, detonator cables should be disconnected from the firing units and shunted and grounded, and the firing unit capacitor grounded. 30.13.3. After the waiting period, one qualified person (or more, when required by a documented hazard analysis) shall physically inspect the firing pad to determine the results of the shot before other personnel leave the shelter. 30.13.3.1. When a partial detonation or a test misfire occurs or is suspected, the firing area shall be inspected for unreacted explosives (see Chapter 31). 30.13.3.2. If the inspection confirms that safe conditions exist, the lead person shall signal “all clear.” 30.13.4. Recovered explosives from a destructive test shall be placed in an explosives storage magazine as Storage Compatibility Group L unless a documented analysis determines that the explosives do not present a special risk. DOE-STD-1212-2019 88 30.14. Contamination of Firing Areas 30.14.1. A contamination zone for each firing area shall be established and permanently documented. 30.14.2. Personnel access to explosives-contaminated areas shall be controlled. Note: Unless determined unnecessary, through documented analysis reviewed by the Contractor Explosives Safety AHJ and approved by Contractor Facility Management. 30.14.3. Service personnel shall not work in the area without the permission of testing-area management and only when supervised by a management-approved person. Note: Unless determined unnecessary, through documented analysis reviewed by the Contractor Explosives Safety AHJ and approved by Contractor Facility Management. 31. TEST FAILURES AND MISFIRES 31.1. Explosives Misfire 31.1.1. If no audible detonation is heard after once pulsing the firing circuit, the firing circuitry and detonators may be checked for continuity. These checks shall be accomplished from within the control bunker or from a protected location. If the firing circuits and detonators appear operative, additional attempts to fire may be made. 31.1.2. If the shot still does not fire, the following precautions shall be taken: 31.1.2.1. Disconnect and de-energize all electrical power sources connected to the shot. 31.1.2.2. Verify that all personnel in the danger zone are aware of the misfire and that they shall remain under cover until released. 31.1.2.3. Before personnel are permitted to leave the cover of the bunker, a pre- established waiting period shall be observed. Note: A minimum 30 minute waiting period is advised. 31.1.2.4. A carefully prepared review of the situation should be initiated in consultation with another knowledgeable person. DOE-STD-1212-2019 89 31.1.2.5. After an agreement has been reached and before other personnel are permitted to leave the cover of the bunker, one qualified person should carefully approach and examine the setup to verify that it is safe.

31.2. Misfire of a Remotely Fired Gun 31.2.1. When a misfire occurs, several more attempts to fire the gun may be made. If subsequent attempts are also unsuccessful, the following precautions should be taken: 31.2.1.1. Disconnect all electrical circuitry to the gun so the firing system cannot be energized. 31.2.1.2. Before approaching a light-gas-driven gun, verify that it is in a safe condition by venting all pressure in the gun breech. 31.2.1.3. To reduce the risk of a gas explosion if the driving gas is flammable, the gun breech shall be purged with inert gas after venting. 31.2.1.4. A minimum waiting period of 10 minutes shall be observed before permitting personnel to approach to the gun. 31.2.1.5. When approaching the gun, if there is any indication that powder is burning, personnel shall return to a safe area and observe an additional waiting period of at least 20 minutes. 31.2.1.6. The gun shall not be approached within the known recoil distance behind the breech or from the front. Approach to and work on the gun shall be from the sides. 31.2.1.7. For separate loading guns (i.e., propellant charge is loaded separate from projectiles), the propellant igniter shall be disconnected from the firing mechanism and removed from the gun before any other gun operations. 31.2.1.8. If possible, the powder chamber of the gun shall be checked for the presence of pressure and vented to the atmosphere before opening the chamber. 31.2.2. If an unforeseen failure situation arises (e.g., the explosive projectile is stuck in the bore), an emergency procedure shall be prepared and followed to resolve the situation. DOE-STD-1212-2019 90 32. EXPLOSIVES STORAGE 32.1. Storage Magazine Facilities 32.1.1. Permanent Facilities and Portable Magazines 32.1.1.1. New permanent explosives facilities shall comply with UFC 3-340-02, Unified Facilities Criteria. Note: DOE/TIC-11268 may be used as supplemental guidance. 32.1.1.2. Legacy facilities with an approved QD site plan may continue to be used as explosives facilities (see Chapter 11). 32.1.1.3. Portable magazines should be ventilated and resistant to water, fire and theft. They may be made of any material that meets these requirements. Note: Portable facilities that comply with 27 CFR Part 555.203, 27 CFR Part 555.207, 27 CFR Part 555.208, 27 CFR Part 555.209, 27 CFR Part 555.210, or 27 CFR Part 555.211 meet these requirements. 32.1.1.4. Portable magazines shall be sited per DESR 6055.09 as above ground magazines. 32.1.2. Placards shall be posted on or near each magazine door, specifying explosive and personnel limits and general safety precautions that should be observed during work in the magazine. 32.1.3. Vegetation around storage magazines should be controlled to minimize potential damage to the magazine (Section 40.1). 32.1.4. At least two fire extinguishers, minimum rating 2A-10BC should be provided for immediate use by personnel working around a magazine. 32.1.5. Rated telephone or other emergency communication equipment should be provided in magazine storage areas. 32.1.6. All communication equipment located outdoors should be protected from the weather. 32.1.7. Temperature control. 32.1.7.1. In general, storage magazines should not be heated unless heating is necessary to prevent damage caused by sudden temperature changes or when dimensional changes of components are undesirable. DOE-STD-1212-2019 91 32.1.7.2. Magazines requiring heat should be heated with steam, hot water, or electrically heated hot water.

32.1.7.3. Magazines with temperature control requirements, may require both heating and air conditioning. 32.1.7.4. Electrical systems with forced air through ducts may be allowed if the systems are located exterior to any explosive hazard. 32.1.7.5. Heating coils shall be arranged so that explosives material cannot come into contact with the coils. They shall be equipped with covers designed to prevent storage of materials on top of the coils. 32.1.7.6. Maximum and minimum temperature monitors should be provided in all heated magazines. 32.2. Storage Magazine Operations 32.2.1. Explosives items shall be properly packaged and stored in either DOT-approved manufacturers’ containers/packages or in approved onsite containers (see Section 32.5). 32.2.2. Explosives may be stored on magazine shelves. 32.2.2.1. The bottom of the container should not be more than 2m off the floor, except as permitted by Section 32.2.3. 32.2.3. Explosives and explosives containers in storage shall be positioned safely and securely. If explosives containers are stacked, they shall be placed in stable arrays. 32.2.4. Load limits shall be established for shelving in magazines. 32.2.4.1. If overloading is possible, the loading conditions shall be posted. 32.2.5. Materials shall not be left suspended by booms, cranes, or hoists in any explosives storage facility. 32.2.6. Stacks of explosives should be arranged so that air freely circulates to all parts of the stack. 32.2.6.1. To prevent moisture accumulation, pallets or appropriate dunnage should be used so containers are not stacked directly on the magazine floor. DOE-STD-1212-2019 92 32.2.7. Aisles shall be wide enough to accommodate inspection, inventory, sampling, and materials handling operations of the stored explosives containers. 32.2.8. Crews shall not be permitted to work in a position that requires passing the work aisle or the position of a second crew to reach the exit. 32.2.9. Each crew working in a magazine shall have their own exit route that does not interfere with exit routes for other crews (see Chapter 41). 32.2.10. Magazines shall be locked at all times except when permissible operations are in progress or when opened for ventilation. 32.2.11. Personnel shall be present while the magazine is open for ventilation. 32.2.12. All exit doors shall be unlocked and open when personnel are working in the magazine. 32.2.13. Each magazine shall be inventoried at least annually to determine the total weight of explosives present. Note: For the purpose of inventories, “annually” refers to the one-year anniversary of the last inventory or inspection plus or minus 30 days. 32.2.13.1. Materials that are not properly identified or labeled shall be dispositioned. 32.2.14. The liquid level in storage containers for wetted explosives shall be checked and replenished as necessary at least once a year. 32.2.14.1. A log of the checks shall be maintained. 32.2.15. Empty containers, tools, conveyors, lift trucks, skids, etc., should not be stored in a magazine containing explosives. 32.2.16. Combustible materials such as excess dunnage, packing material, and boxes shall not be stored in a magazine containing explosives. 32.2.17. Flammable liquids shall not be stored or used in explosives magazines unless the liquid is an explosive, is needed as an explosives-wetting agent, or is an integral part of an explosives device.

32.2.18. Explosives-handling operations shall not be performed when magazine entranceways are icy or do not provide adequate footing for any other reason. DOE-STD-1212-2019 93 32.2.19. Operations involving hazardous materials shall not be permitted in any magazine with the following exceptions: 32.2.19.1. Those operations incident to storage or removal from storage. 32.2.19.2. Inspection and surveillance sampling of compatibility Group D materials, and Group C materials consisting of bulk propellants and IHE, provided that each storage container sampled is in good condition (i.e., the container is not leaking, no evidence exists of explosives contamination at the closure or of seal failure, and the closure is mechanically sound and free of excessive corrosion). 32.2.19.3. Only one container of explosives shall be opened at one time in a magazine. 32.2.19.4. Adding liquid to adjust the liquid composition level in which a Group D explosive is stored (water and alcohol mixtures may be used). If only water is added to the explosive, the water should be distilled or de- ionized (bacteria present in untreated water may produce gas during storage). 32.3. Storage Review Program 32.3.1. Contractor Facility Management shall establish a program to review stored explosive materials. Explosives may degrade during prolonged storage, increasing the hazards of handling or use. Note: An example storage review program is provided in Attachment A of this chapter. 32.4. Storage Compatibility 32.4.1. Explosives shall not be stored with materials or items that increase the risk of initiation or decomposition. Note: Examples are mixed storage of explosives with flammable or combustible materials, acids, or corrosives. 32.4.2. Different types of explosives may be stored in the same magazine if they are compatible. 32.4.2.1. Explosives shall be assigned to a storage compatibility group (SCG) when they can be stored together without significantly increasing either the probability of an accident or, for a given quantity of explosive, the magnitude of such an accident. DOE-STD-1212-2019 94 32.4.3. Each type of explosive shall be assigned to an appropriate SCG (A through G, L, and S) for the purpose of storage at DOE facilities. The groups are defined in the following sections. Note 1: These definitions and Table 32.1 are in accordance with the principles and tables in DESR 6055.09. Note 2: Table 32.1 presents some examples of commonly used materials that are assigned to each storage compatibility group. This list does not enumerate all materials that may be included in each group. 32.4.3.1. Group A: Initiating explosives. Bulk initiating explosives that have the necessary sensitivity to friction, heat, or shock to make them suitable for use as initiating elements in an explosives train. Note: Examples are lead azide, lead styphnate, mercury fulminate, and tetracene. 32.4.3.2. Group B: Detonators and similar initiating devices not containing two or more independent safety features. Items containing initiating explosives that are designed to initiate or continue the functioning of an explosives train. Note: Examples are detonators (all types, excluding Exploding Bridge Wires (EBW) and slappers), blasting caps, small arms primers, and fuses. 32.4.3.3. Group C: Bulk propellants, propellant charges, and devices containing propellant with or without their own means of initiation. Items that shall deflagrate, explode, or detonate upon initiation.

Note: Examples are single-, double-, triple-base, and composite propellants, rocket motors (solid propellant), and ammunition with inert projectiles. 32.4.3.4. Group D: High explosives (HE) and devices containing explosives without their own means of initiation and without a propelling charge, or articles containing a primary explosives substance and containing two or more effective protective features. Note: Example includes explosives and ammunition that can be expected to explode or detonate when any given item or component thereof is initiated. DOE-STD-1212-2019 95 32.4.3.5. Group E: Explosives devices without their own means of initiation and with propelling charge (other than one containing a flammable or hypergolic liquid). Note: Examples are artillery ammunition and rockets. 32.4.3.6. Group F: Explosives devices with their own means of initiation and with or without propelling charge. Note: Examples are offensive and fragmentation grenades. 32.4.3.7. Group G: Pyrotechnic materials and devices containing pyrotechnic materials. Note: Examples are devices that, when functioning, result in an incendiary, illumination, lachrymatory, smoke, or sound effect. 32.4.3.8. Group H: Ammunition containing both explosives and White Phosphorus or other pyrophoric material. Ammunition in this group contains fillers, which are spontaneously flammable when exposed to the atmosphere. Note: Examples are White Phosphorus, Plasticized White Phosphorus (PWP), or other ammunition containing pyrophoric material. 32.4.3.9. Group J: Ammunition containing both explosives and flammable liquids or gels. Ammunition in this group contains flammable liquids or gels other than those that are spontaneously flammable when exposed to water or the atmosphere. Note: Examples are liquid or gel filled incendiary ammunition, fuel-air explosive (FAE) devices, flammable liquid fueled missiles, and torpedoes. 32.4.3.10. Group K: Ammunition containing both explosives and toxic chemical agents. Ammunition in this group contains chemicals specifically designed for incapacitating effects more severe than lachrymation. Note: Examples are artillery or mortar ammunition (fuzed or unfuzed), grenades, and rockets or bombs filled with a lethal or incapacitating chemical agent. 32.4.3.11. Group L: Explosives or ammunition not included in other compatibility groups that present a special risk, requiring isolation of each type. This group shall include explosives or ammunition having characteristics that do not permit storage with other similar or dissimilar materials. DOE-STD-1212-2019 96 Note 1: Examples are damaged explosives; suspect explosives; and explosives, explosive devices, or containers that have undergone severe testing unless documented determination is made that these items do not present a special risk; fuel/air explosive devices, and water-activated devices. Note 2: Also included are experimental explosives, explosives of temporary interest, newly synthesized compounds, new mixtures, and salvaged explosives until they have been established to be compatible with the original materials. Types presenting similar hazards may be stored together. 32.4.3.12. Group N: HD 1.6 ammunition containing