Explosives Safety
Initial Training
Course # 5.01
Rev. 08041-TO
Explosive Safety Initial
Course # 5.01 Rev. 08041- TO
Terminal Objective: Identify safe practices for work on or around explosives in
accordance with the DOE Explosives Safety Manual, DOE M
440.1-1A, (Pantex Manual 240176).
Enabling Objectives:
EO1: Describe basic explosives hazards.
EO2: Identify UN Hazard Class 1/Division Placards used at Pantex
EO3: Describe explosives labeling and marking used on containers at Pantex.
EO4: Identify explosive safety Engineering and Administrative controls in use at
Pantex.
EO5: Describe the symbols for fire divisions associated with the explosives hazard at
Pantex Plant.
EO6: Identify the difference between explosives areas and non-explosive areas at
Pantex.
EO7: Describe the purpose and identification of exclusion areas at Pantex.
EO8: Identify correct responses when encountering explosives moves.
Introduction
B&W Pantex performs a significant amount of work involving explosives. Explosives
are located in many areas at plant site. While you are physically at plant site, you may
either be indirectly or directly exposed to the hazard of explosives. In case of an
inadvertent explosion, the risk of being injured or becoming a fatality does exist for each
of us.
EO1: Describe basic explosives hazards.
There are two main hazards resulting from an explosion, heat and blast.
• Heat which is created by
the chemical reaction. Heat
precedes the blast effects.
Heat may produce thermal
burns.
• A rapid generation of high
pressures from the released
gas can create a shock wave
which is commonly called
blast.
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Explosive Safety Initial
Course # 5.01 Rev. 08041- TO
Blast is broken down into three effects.
1. Primary effect is overpressure. Overpressure can cause damage to the eardrums,
the sinuses, and the lungs.
2. Secondary effect is fragmentation. Fragments can cause “impact” damage or
penetrate the body.
3. Tertiary effect is a physical displacement of a person.
EO2: Identify UN Hazard Class 1/Division Placards used at Pantex
The United Nations (UN) established a system, based on actual tests, of identifying
hazardous materials or dangerous goods. The placard is a diamond shape with orange
background and black lettering and/or numbering. It uses a Class/Division designator
and is recognized Internationally. It is used by Department of Defense, Department of
Transportation, and Department of Energy.
Hazardous materials/dangerous goods are divided into classes on the basis of the specific
chemical characteristics producing the risk. The division is used as a descriptor of the
effect or results. Class 1 identifies the hazard as explosives. It is then sub-divided into 6
Divisions. Simply stated, the smaller the number, the more dangerous the explosive
hazard. (e.g. .1.6 used at Pantex, 1.5 is not used at Pantex) Also, a letter designator
identifies the compatibility group assigned to help segregate items during transport or
storage.
• Class 1/Division 1 (1.1) - mass explosion
hazard. (e.g. at Pantex: LX-04, PBX-9404, and
LX-10.)
• Class 1/Division 2 (1.2) - Non-mass explosion,
but are fragment producing. (e.g at Pantex:
Some Spin Rocket Motors, some Security
Response Force Munitions.)
• Class 1/Division 3 (1.3) - Mass Fire, and may produce minor blast or
fragments.(e.g. at Pantex: Gas generators and insensitive high
explosives(IHE) LX-17, PBX-9502.)
• Class 1/Division 4 (1.4) - Moderate fire, with no significant blast or fragment
hazard. (e.g. at Pantex: Squibs, Actuators, Valves, and some small
detonators.)
• Class 1/Division 6 (1.6) - Minor fire hazard, with an insignificant mass
explosion hazard. (e.g. at Pantex: IHE consolidated charges without boosters
or detonators, IHE nuclear explosive assemblies and subassemblies with
boosters, with or without detonators, and IHE articles with 1.4 items.)
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Course # 5.01 Rev. 08041- TO
EO3: Describe explosives labeling and marking used on containers at Pantex.
At Pantex, hundreds of containers, boxes, and shipping configurations are used. It is
important to correctly and easily identify the content and hazardous potential. Labels are
easily recognized and are a form of communication. (diamond shaped, orange
background, with the class/division number, and a symbol-may/may not be exhibited on
label. e.g. explosive.) Pantex is required to identify these using the UN Hazardous
Material Classification/Division labels or placards. This allows everyone at Pantex to
easily recognize the potential hazard the item poses.
Pantex marks containers with other specific information using a label identified as
“PX-form” (e.g. PX-1234.) This PX-form will contain information which clearly
identifies the contents of the package/container with information important to Pantex.
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Explosive Safety Initial
Course # 5.01 Rev. 08041- TO
EO4: Identify explosive safety Engineering and Administrative controls in use at
Pantex.
Hazardous events associated with operational activities involving nuclear material and
explosives are evaluated to determine consequences according to the type of material,
source of insult, and effect to workers at Pantex, the public, and environment. Controls
are selected and used to help protect the employee, the item or weapon system. Controls
may be either engineering or administrative.
Engineering controls. There are two kinds of engineering controls. There are design
features and limiting conditions of operation (LCO).
• A design feature is a structure, system
or component (SSC) where the
properties of the material provide the
safety function. It only relies on its
material. (e.g. Reinforced concrete
construction; interlocking gates, doors,
and electrical circuits in remote
operations; design of special tooling and
equipment; fire suppression system.)
• LCOs describe the lowest functional capability or performance level of
Critical Safety structures, systems, component and their support systems
required for normal safe operation of the facility. (e.g. High Pressure Fire
Loop, Lightning Protection System)
Administrative controls are the provision relating to organization and management,
procedures, record keeping, reviews, and audits necessary to ensure safe operation of
the facility and maintain the underlying assumptions in the Technical Safety Bases. The
requirements of these programs are identified as either Administrative Control
Programmatic Requirements or Administrative Control Specific Requirements. It
requires action by an individual. Administrative controls must be followed for
Engineering controls to be effective. (e.g. Approved operational procedures, training,
posted Limit Placards)
• Approved operational procedures – According to the Level of Use, the
procedures direct operations.
• Training – designed to provide employees the knowledge, skills, and attitudes
necessary to perform job functions.
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• Nuclear Material and Explosive
Inventory Program - Posted Limit
Placards (PX-100-35) – designates the
maximum amount or quantity of
radioactive material, explosives, and
personnel allowed in each work location or
storage facility.
EO5: Describe the symbols for fire divisions associated with the explosives hazard
at Pantex Plant.
All buildings or storage sites containing explosive materials, flammable or combustible
liquids, or gases are marked with a symbol to identify the most severe hazard associated
with the materials in a building or storage site. (e.g. Octagon, cross, inverted triangle,
diamond, or circle) The numerical designator is assigned according to the UN Hazard
Class/Division (e.g. UN Hazard 1.4, the fire symbol will have a “4” as the designator.)
These symbols alert emergency responders of the expected hazard. These are easily
visible to approaching fire fighting forces from the maximum practical distances on the
exterior of the facility. For building of long dimensions or where access to the building is
from several directions, more than one symbol may be necessary. All explosive fire
symbols are orange background with black numbers/symbol and the shape
determines the potential result of the hazard involved.
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Explosive Safety Initial
Course # 5.01 Rev. 08041- TO
EO6: Identify the difference between explosives areas and non-explosive areas at
Pantex.
As you have learned, we perform a great deal of explosives work at Pantex. We perform
work with explosives in many different areas at plant site. While these explosives
activities impact every location at Pantex, there are some areas that are more hazardous
than others.
The more hazardous areas are called explosives areas. Personnel physically present in
explosives areas are exposed to a greater risk factor. Explosives areas must offer
personnel a greater protective factor because of the inherent risk. Characteristics of
explosive areas and facilities:
• Constructed with reinforced
concrete or steel armor plate.
• Identified with a Fire Symbol
(Orange) on exterior
• Reinforced concrete structures
with Steel Barriers or earthen
shielding.
• Warning signs, lights, and audible
horns.
• Warning barriers or gates to
prohibit entry during operations.
The less hazardous areas are called non-explosives areas. These areas are intermixed
and border each other all over plant site. Characteristics of non-explosive areas and
facilities:
• Buildings built without concrete
reinforcement.
• Buildings constructed with metal
siding and roofs. (e.g. Morgan™
buildings)
• Buildings with windows.
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Explosive Safety Initial
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EO7: Describe the purpose and identification of exclusion areas at Pantex.
Exclusion Areas are specific physical locations where the required protection from
explosives blast and debris is not provided through suppression or containment for
personnel, the public, and environment.
Exclusion areas are only active during explosive operations. Personnel are not allowed
in Exclusion Areas during Explosives Operations. If in the exclusion area when the
visual/audible warnings begin, personnel have 4 minutes to make their way into a safe
area outside the exclusion area. DO NOT ENTER active Exclusion Areas and DO NOT
ALLOW others to enter active exclusion areas. Should you observe someone in an active
Exclusion Area, advise them to leave the Exclusion Area immediately and immediately
notify the Operations Center at ext.5000.
Identified by a combination of physical barriers and visual/audible warnings.
• Physical barriers
o Gates
o Chained corridors, ramps, or hallways
o Roadblock – Railroad type barrier
• Visual/audible warnings
o Flashing/blinking lights
o Audible – warnings sounding like horns/sirens
o Posted “Danger/Warning” signs
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Course # 5.01 Rev. 08041- TO
EO8: Identify correct responses when encountering explosives moves.
While you are going about your business on the Plant, you may encounter Explosives
Moves either on roadways or inside the ramps, corridors, hallways or loading/unloading
docks of Pantex Plant. It is important to the safety of both the transport material and
personnel encountering the move to know how to react and respond.
Recognition of Transportation Explosive Truck on Pantex roadways: Several types of
vehicles are used.
• Amber flashing lights on vehicle, or the vehicles hazard lights flashing.
• Orange Placarded for explosives.
Vehicle traffic on site roadways approaching an Explosive Move: (from front, rear, or
either side). AMBER Flashing
• Pull to side of roadway
• Stop
• Allow the Explosive Move to proceed past or move away from you.
• Ensure the Explosive Move is approximately 300 feet away before
continuing vehicle movement to destination.
PLACARD
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Recognition of Nuclear Explosive (NE), Nuclear Material (NM) or Nuclear Explosive
Like Assembly (NELA) transport on Pantex roadways(Pantex Dr., S. 13th St., Lafayette
Dr., to Z12 MAA):
• Convoy Escorts: 2 vehicles with flashing AMBER lights.
Approximately 300 feet to the front and rear of NE transport vehicle.
• NE/NM transport vehicle - Tractor with trailer (no placards)
• Convoys travel only on approved routes (Zone 4 Material Access
Area(MAA) to Zone 12 MAA, Protected and Limited Area, or vice-versa.)
• Traveling speed – 20 mph.
CAUTION
SPEED LIMIT FOR ALL VEHICLES ON CONVOY ROUTE is posted at
20 MPH AT ALL TIMES.
Exception: Emergency Response & Security personnel who are responding to alarms,
security incidents, or emergency incidents
Vehicle traffic on site roadways approaching a NE, NM, or NELA Move: (from front,
rear, or either side.) Exception: Emergency Response & Security personnel who are
responding to alarms, security incidents, or emergency incidents.
• Do not approach, stay approx. 300 feet from transport.
• Pull to side of roadway
• Stop
• Remain stopped until the Convoy has passed and a separation
distance of approx. 300 feet has been accomplished.
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Explosive Safety Initial
Course # 5.01 Rev. 08041- TO
NOTE:
Walker/spotter requirements for Hazard Class 1.1 or 1.2 explosives or IHE with
detonators apply only to the Zone 12 MAA.
CAUTION
Vehicles must never come from behind and pass material in transit unless given
direction by the walker/spotter.
Vehicular, bicycle and/or pedicycle, or pedestrian traffic in Zone 12 MAA approaching
an Explosive Move escorted by walker/spotter who is wearing a red/orange fluorescent
vest. (from front, rear, or either side):
• Separation distance of 25 feet from all
forklifts regardless of load.
• Follow directions of walker/spotter.
• Pull to side of ramp, corridor, or hallway.
• Stop and allow transport items to pass. (25
ft. separation distance.)
If transport item is stopped:
• Follow directions of walker/spotter.
• Stop
• Await permission to pass.
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