BY ORDER OF THE SECRETARY OF THE AIR FORCE AIR FORCE MANUAL 91-201 12 ...

485 Pages·2015·5.91 MB·English

BY ORDER OF THE AIR FORCE MANUAL 91-201
SECRETARY OF THE AIR FORCE
12 JANUARY 2011
Incorporating Change 1, 22 June 2012
MOODY AIR FORCE BASE
Supplement
8 JULY 2015

Safety
EXPLOSIVES SAFETY STANDARDS
COMPLIANCE WITH THIS PUBLICAITON IS MANDATORY
ACCESSIBILITY: This publication is available digitally on the e-Publishing website at
www.e-publishing.af.mil for downloading or ordering
RELEASABILITY: There are no releasability restrictions on this publication.
OPR: AFSC/SEW Certified by: AF/SED
(Mr. Roberto I. Guerrero)
Supersedes: AFMAN 91-201, 17 Pages: 485
November 2008
(MOODYAFB)
OPR: 23 WG/SE Certified by: 23 WG/CC
(Col Chad P. Franks)
Pages:16

This Manual implements Air Force Policy Directive (AFPD) 91-2, Safety Programs, and DoD
6055.09-M, Volumes 1–8, DoD Ammunition and Explosives Safety Standards. It establishes a
central source for explosive safety criteria. It identifies hazards and states safety precautions and
rules when working with explosives. It applies to everyone involved in explosives operations of
any kind at Air Force, Air National Guard and Air Force Reserve-owned or leased facilities and
to US-titled ammunition in contractor or host-nation facilities. Compliance is mandatory, but
only as minimum safety standards. The use of the name or mark of any specific manufacturer,
commercial product, commodity, or service in this publication does not imply endorsement by
the Air Force. Send major command (MAJCOM) supplements to AF/SE, 9700 Avenue G SE,
Kirtland AFB NM 87117-5671, for approval before publication. Send recommended changes on
AF Form 847, Recommendation for Change of Publication, any conflicts with other Air Force
directives as well as general correspondence about the content of this Manual through command
channels to AFSC/SEW, 9700 G Avenue SE, Kirtland AFB NM 87117-5670. Ensure that all
records created as a result of processes prescribed in this publication are maintained in
accordance with AFMAN 33-363, Management of Records, and disposed of in accordance with
2 AFMAN91-201_MOODYAFBSUP 8 JULY 2015
the Air Force Records Disposition Schedule (RDS) located at
https://www.my.af.mil/afrims/afrims/afrims/rims.cfm.
(MOODYAFB) This supplement applies to anyone involved with explosives operations on
Moody AFB and to contractor-owned explosives or ammunition being used on Moody AFB.
The term Moody AFB includes Detachment-1, 23d Fighter Group at Avon Park Air Force Range
(APAFR), Florida, unless specifically exempted.
(MOODYAFB) AFMAN 91-201, 12 January 2011 with Change 1, 22 June 2012, and HQ ACC
Supplement to AFMAN 91-201, 3 January 2013, are supplemented as follows: This supplement
implements Moody Air Force Base Supplement 1, Explosives Safety Standards. This supplement
is not intended as a standalone document, but is intended to be used in conjunction with AFMAN
91-201 and its ACC Supplement. This supplement establishes minimum standards for the
conduct of explosives operations on Moody AFB and aligns Moody AFB operations with the
higher headquarters manuals, establishing unique requirements at Moody AFB. Send comments
and suggested improvements on an AF Form 847, Recommendation for Change of Publication,
through channels to 23 WG/SEW. Ensure that all records created as a result of the processes
prescribed in the publication are maintained in accordance with Air Force Manual (AFMAN) 33-
363, Management of Records, and dispose of them IAW AF Records Information Management
System (AFRIMS) Records Disposition Schedule (RDS) located at
https://www.my.af.mil/afrims/afrims/afrims/rims.cfm.
SUMMARY OF CHANGES
This interim change implements guidance for handling Joint Test Assemblies, eliminates
MAJCOM interim ESP approval, modifies (Event) Operational Waiver process, clarifies
placarding of multicubes, maintenance of land in and around storage locations, requirements for
risk assessments, and Airfield deviations, Lightning Protection System design and operational
requirements, and updates Intentional Detonation Site requirements . A margin bar (|) indicates
newly revised material.
(MOODYAFB) This publication is new and must be reviewed completely. NOTE: The
numbering in this supplement directly correlates with the specific numbering sequence in
AFMAN 91-201 and its ACC Supplement. Additionally, AFMAN 91-201 and its ACC
Supplement use different terms for the unit weapons safety personnel. Use of the following
terms is interchangeable: Weapons Unit Safety Representative (USR), Weapons Safety USR
(WS USR), Additional Duty Weapons Safety Manager (ADWSM), Additional Duty Weapons
Safety Representative (ADWSR).

Chapter 1—INTRODUCTION AND EXCEPTION PROGRAM 29
Section 1A—Explosives Safety General Instructions 29
1.1. Purpose. .................................................................................................................. 29
1.2. Scope. ..................................................................................................................... 29
Section 1B—Exception Program 32
AFMAN91-201_MOODYAFBSUP 8 JULY 2015 3
1.3. General. .................................................................................................................. 32
1.4. Deviations. ............................................................................................................. 33
1.5. Operational Waivers. ............................................................................................. 34
1.6. Waivers. ................................................................................................................. 35
1.7. Exemptions. ........................................................................................................... 35
1.8. SECAF Waivers and Exemptions for New Construction. ..................................... 36
1.9. Exceptions for Non-DoD Explosives Activities on Air Force Installations. ......... 36
1.10. Waiver and Exemption Information Requirements. .............................................. 37
1.11. HAF-Level Waiver and Exemption Information Requirements. ........................... 37
1.12. Waiver or Exemption Decision Nomograph. ......................................................... 39
1.13. Periodic Reviews for Exceptions. .......................................................................... 40
1.14. Cancellation of Waivers and Exemptions. ............................................................. 41
Table 1.1. Likelihood of a Mishap. ......................................................................................... 41
Table 1.2. Exposure. ............................................................................................................... 42
Table 1.3. Possible Consequences of a Mishap. ..................................................................... 42
Table 1.4. Periodic Review Levels for HAF-Level Waivers and Exemptions. ...................... 43
Figure 1.1. Exception Decision Nomograph–Day-to-Day Operations. .................................... 44
Figure 1.2. Exception Decision Nomograph–Contingency and War Plans. ............................ 45
Figure 1.3. Nomograph Plotting Example. ............................................................................... 46
Chapter 2—REACTION EFFECTS 47
Section 2A—Principal Effects of High Density (HD) 1.1 Events 47
2.1. Blast. ...................................................................................................................... 47
2.2. Fragments. .............................................................................................................. 49
2.3. Thermal Hazards. ................................................................................................... 49
2.4. Groundshock and Cratering. .................................................................................. 49
2.5. Expected Consequences. ........................................................................................ 50
Section 2B—Principal Effects of HD 1.2 Events. 52
2.6. Blast. ...................................................................................................................... 52
2.7. Fragments. .............................................................................................................. 53
2.8. Thermal Hazards. ................................................................................................... 53
2.9. Ejected Items. ......................................................................................................... 53
2.10. Propelled Items. ..................................................................................................... 53
4 AFMAN91-201_MOODYAFBSUP 8 JULY 2015
2.11. Firebrands. ............................................................................................................. 53
2.12. Expected Consequences. ........................................................................................ 53
Section 2C—Principal Effects of HD 1.3 Events 54
2.13. Gas Pressures. ........................................................................................................ 54
2.14. Fragments. .............................................................................................................. 54
2.15. Thermal Hazards. ................................................................................................... 54
2.16. Propelled Items. ..................................................................................................... 54
2.17. Firebrands. ............................................................................................................. 54
2.18. Expected Consequences. ........................................................................................ 55
Section 2D—Principal Effects of HD 1.4 Events 55
2.19. Blast. ...................................................................................................................... 55
2.20. Fragments. .............................................................................................................. 55
2.21. Thermal Hazards. ................................................................................................... 55
2.22. Firebrands. ............................................................................................................. 55
2.23. Compatibility Group (CG) S Items. ....................................................................... 55
2.24. Expected Consequences. ........................................................................................ 55
Section 2E—Principal Effects of HD 1.5 and HD 1.6 Events 55
2.25. HD 1.5 Effects. ...................................................................................................... 55
2.26. HD 1.6 Effects. ...................................................................................................... 55
Table 2.1. Expected Peak Incident Pressures From HD 1.1 Events. ...................................... 55
Table 2.2. Probability Of Window Breakage From Incident Pressure. .................................. 56
Table 2.3. General Blast Effects On Personnel–Eardrum Rupture. ........................................ 57
Table 2.4. General Blast Effects On Personnel–Lung Damage. ............................................. 58
Table 2.5. General Blast Effects On Personnel – Lethality Due To Lung Rupture. ............... 58
Chapter 3—HAZARD CLASSIFICATION 59
Section 3A—DoD Hazard Classification System 59
3.1. Purpose of Hazard Classification. .......................................................................... 59
3.2. Responsibility for Hazard Classification. .............................................................. 59
3.3. Hazard Classification Authorities. ......................................................................... 59
3.4. Standards for Determining DoD Hazard Classification. ........................................ 59
3.5. Description of DoD Hazard Classification System. ............................................... 59
3.6. Net Explosive Weight and Net Explosive Weight for Quantity-Distance. ............ 60
AFMAN91-201_MOODYAFBSUP 8 JULY 2015 5
3.7. Requirement for DoD Hazard Classification. ........................................................ 61
Section 3B—Storage and Transportation Without DoD Hazard Classification 61
3.8. Storage and Transportation Without DoD Hazard Classification. ......................... 61
3.9. Explosives With DOE Hazard Classifications. ...................................................... 61
3.10. DoD-Owned Non-Stock-Listed Commercial Explosives. ..................................... 62
3.11. Manufacturing, Research and Development Items. ............................................... 63
3.12. Foreign Explosives. ............................................................................................... 63
3.13. Non-DoD-Owned Explosives. ............................................................................... 64
Section 3C—HAZARD CLASSIFICATION Error! Bookmark not defined.
3.14. Hazard Classification of Unpackaged Items. ......................................................... 66
3.14. (MOODYAFB) Hazard Classification of Unpackaged Items. .............................. 67
Section 3D—Class 1 Divisions and Subdivisions 68
3.15. HD 1.1 – Mass-explosion. ..................................................................................... 68
3.16. HD 1.2 – Non-mass Explosion, Fragment Producing. ........................................... 68
3.17. HD 1.3 – Mass Fire, Minor Blast or Fragment. ..................................................... 69
3.18. HD 1.4 – Moderate Fire, No Significant Blast or Fragment. ................................. 69
3.19. HD 1.5 – Explosive Substance, Very Insensitive (With Mass Explosion Hazard).
................................................................................................................................. 69
3.20. HD 1.6 – Explosive Article, Extremely Insensitive. .............................................. 69
Section 3E—Compatibility Groups and Sensitivity Groups 69
3.21. Storage and Transportation Compatibility Groups. ............................................... 69
3.22. Sensitivity Groups. ................................................................................................. 70
Chapter 4—RISK ASSESSMENTS AND PROTECTION PRINCIPLES 72
Section 4A—Risk Assessments 72
4.1. Requirements for Risk Assessments. ..................................................................... 72
4.1. (MOODYAFB) Requirements for Risk Assessments. .......................................... 72
4.2. Risk Assessments. .................................................................................................. 72
4.3. Risk Management (RM). ....................................................................................... 73
4.4. System Safety. ....................................................................................................... 73
4.5. Professional Assistance for Risk Assessments and System Safety Analyses. ....... 73
Section 4B—Munitions Systems and Equipment 73
4.6. Safety Certification of Munitions Systems. ........................................................... 73
6 AFMAN91-201_MOODYAFBSUP 8 JULY 2015
4.7. Risk Assessments for Explosives Equipment. ....................................................... 73
4.7. (MOODYAFB) Risk Assessments for Explosives Equipment. ............................. 73
Section 4C—Explosives Operations and Facilities 73
4.8. Risk Assessment for Explosives Operations. ......................................................... 74
4.8. (MOODYAFB) Risk Assessment for Explosives Operations. .............................. 74
4.9. Risk Assessments for Explosives Facilities. .......................................................... 74
4.9. (MOODYAFB) Risk Assessments for Explosives Facilities. ............................... 74
Section 4D—Glass Breakage Risk Assessments 74
4.10. Purpose of Glass Breakage Risk Assessments. ...................................................... 74
4.11. Requirements for Performance of Glass Breakage Risk Assessments. ................. 75
4.11. (MOODYAFB) Requirements for Performance of Glass Breakage Risk
Assessments. .......................................................................................................... 75
4.12. Software Tools for Glass Breakage Risk Assessments. ......................................... 75
4.13. Methodology for Glass Breakage Risk Assessments. ............................................ 76
4.14. Engineering Mitigation Actions for Reducing or Eliminating Glass Breakage
Hazards to Personnel. ............................................................................................ 77
Section 4E—Health Hazard and Environmental Assessments 77
4.15. Health Hazard Assessments. .................................................................................. 77
4.15. (MOODYAFB) Health Hazard Assessments. ....................................................... 77
4.16. Environmental Assessments. ................................................................................. 77
Section 4F—Protection Principles 77
4.17. Protective Shielding and Remotely Controlled Operations. .................................. 77
4.18. Intentional Ignition or Initiation of AE. ................................................................. 78
4.19. Protective Measures. .............................................................................................. 79
4.20. Emergency Operations. .......................................................................................... 79
4.20. (MOODYAFB) Emergency Operations. ............................................................... 80
Figure 4.1. Five Step Process for Risk Management ............................................................... 80
Chapter 5—GENERAL EXPLOSIVES FACILITY DESIGN, CONSTRUCTION AND
MAINTENANCE, AND EQUIPMENT DESIGN, MAINTENANCE AND
INSPECTION 82
Section 5A—Introduction 82
5.1. Applicability. ......................................................................................................... 82
Section 5B—Glass Panels 82
AFMAN91-201_MOODYAFBSUP 8 JULY 2015 7
5.2. Glass Panels in Facilities Exposed to Explosives Hazards. ................................... 82
Section 5C—Hazardous Locations 83
5.3. Hazardous Locations. ............................................................................................. 83
5.4. Electrical Equipment in Hazardous Locations. ...................................................... 83
5.5. Interior Surfaces in Class II Hazardous Locations. ................................................ 84
5.6. Hardware in Hazardous Locations. ........................................................................ 84
5.7. Static Electricity in Hazardous Locations. ............................................................. 84
5.8. Ventilation in Hazardous Locations. ...................................................................... 84
Section 5D—Electric Supply Systems 85
5.9. Electric Supply Systems. ....................................................................................... 85
5.10. Backup Power. ....................................................................................................... 85
Section 5E—Static Grounding and Bonding 85
5.11. Areas Requiring Static Grounding and Bonding Systems. .................................... 85
5.12. Static Grounding and Bonding Requirements. ...................................................... 85
5.13. Permanent Static Grounding Systems. ................................................................... 86
5.14. Temporary Static Grounding or Bonding Cables. ................................................. 87
5.15. Static Grounding or Bonding Reels. ...................................................................... 87
5.16. Belting. ................................................................................................................... 88
Section 5F—Conductive Floors 88
5.17. Areas Requiring Conductive Floors. ...................................................................... 88
5.18. Requirements for Conductive Floors. .................................................................... 88
5.19. Testing and Maintenance of Conductive Floors. ................................................... 88
5.20. Testing and Maintenance of Conductive Footwear. .............................................. 89
Section 5G—Installed Systems and Equipment Grounds 89
5.21. Installed Systems and Equipment Grounds. .......................................................... 89
Section 5H—Lightning Protection Systems 89
5.22. Facilities Requiring Lightning Protection Systems. .............................................. 89
5.23. Lightning Protection System Design. .................................................................... 89
5.24. Lightning Protection System Inspection, Maintenance, Testing, and Training. .... 93
5.25. Lightning Protection System Exceptions. .............................................................. 93
Section 5I—General Design Considerations for Explosives Facilities 95
5.26. Blowout-type Construction. ................................................................................... 95
8 AFMAN91-201_MOODYAFBSUP 8 JULY 2015
5.27. Non-combustible Construction. ............................................................................. 95
5.28. Underground Explosives Storage Facilities. .......................................................... 96
5.29. Outdoor Explosives Storage Sites. ......................................................................... 96
5.30. Stairways. ............................................................................................................... 96
5.31. Fixed Ladders. ....................................................................................................... 96
5.32. Platforms, Runways, and Railings. ........................................................................ 96
5.33. Passageways. .......................................................................................................... 96
5.34. Walkways. .............................................................................................................. 97
5.35. Roads. .................................................................................................................... 97
5.36. Gates. ..................................................................................................................... 97
5.37. Drainage. ................................................................................................................ 97
5.38. Drains and Sumps. ................................................................................................. 97
5.39. Tunnels. .................................................................................................................. 98
5.40. Laundries. .............................................................................................................. 98
5.41. Steam for Explosives Processing or Facility Heating. ........................................... 98
5.42. Magazine Ventilation and Vermin-Resistance. ..................................................... 99
Section 5J—Emergency Exits for Explosives Buildings 99
5.43. General. .................................................................................................................. 99
5.44. Building Exits. ....................................................................................................... 100
5.45. Exit Doors. ............................................................................................................. 100
5.46. Safety Chutes. ........................................................................................................ 100
Section 5K—Explosive Dust Collection Systems 101
5.47. Vacuum Collection. ............................................................................................... 101
5.48. Location of Dry-Type Collection Chambers. ........................................................ 101
5.49. Location of Wet-Type Collection Chambers. ........................................................ 102
5.50. Design and Operation of Collection Systems. ....................................................... 102
Section 5L—Water Supply and Fire Suppression Systems for Explosives Facilities 103
5.51. Water Supply for Explosives Manufacturing Areas and Loading Plants. ............. 103
5.52. Automatic Sprinkler Systems. ............................................................................... 103
5.53. Deluge Systems. ..................................................................................................... 103
Section 5M—Monitoring of Design and Construction of Explosives Facilities 104
5.54. Monitoring of Design of Explosives Facilities. ..................................................... 104
AFMAN91-201_MOODYAFBSUP 8 JULY 2015 9
5.55. Monitoring of Construction of Explosives Facilities. ............................................ 104
Section 5N—Maintenance and Repair of Explosives Facilities and Equipment 104
5.56. Removal of Explosives. ......................................................................................... 104
5.57. Requirements for Maintenance and Repair With Explosives Present. .................. 105
5.58. Maintenance of Explosives Facilities. ................................................................... 105
5.59. Maintenance and Repair in Hazardous Locations. ................................................. 106
5.60. Maintenance and Repair of Hazardous Location Equipment and Electrical
Installations. ........................................................................................................... 106
5.61. Maintenance and Repair of Electrical Equipment. ................................................ 106
5.62. Post-Maintenance and Repair of Explosives Facilities and Equipment. ................ 106
Table 5.1. Lightning Sideflash Policy for Nuclear Weapon Configurations .......................... 107
Chapter 6—PROTECTIVE CONSTRUCTION AND SPECIFIC EXPLOSIVES
FACILITY DESIGNS 108
Section 6A—Introduction 108
6.1. General. .................................................................................................................. 108
6.2. Above Ground Magazines. .................................................................................... 108
6.3. Special Structures. ................................................................................................. 108
6.4. High Performance Magazines and Underground Explosives Facilities. ................ 108
Section 6B—Protective Construction 108
6.5. Purpose of Protective Construction. ...................................................................... 108
6.6. Requirements for Use of Protective Construction. ................................................ 108
Section 6C—Earth-Covered Magazines 110
6.7. Earth-Covered Magazines. ..................................................................................... 110
6.8. Earth-Covered Magazine NEWQD Limits. ........................................................... 110
6.9. Earth-Covered Magazine Design Load Criteria. .................................................... 111
6.10. Earth-Covered Magazine Earth Cover Criteria. ..................................................... 111
6.11. Earth-Covered Magazine Drawings. ...................................................................... 111
Section 6D—Barricaded Open Storage Modules 112
6.12. Barricaded Open Storage Modules. ....................................................................... 112
6.13. Barricaded Open Storage Modules NEWQD and AE Type Limits. ...................... 112
6.14. Barricaded Open Storage Module Design Criteria. ............................................... 113
Section 6E—Barricades 114
10 AFMAN91-201_MOODYAFBSUP 8 JULY 2015
6.15. Barricades. ............................................................................................................. 114
6.16. Barricade Size and Orientation to Prevent Prompt Propagation Due to High-
Velocity, Low-Angle Fragments. .......................................................................... 114
6.17. Barricade Size and Orientation for Barricaded ILD Protection. ............................ 115
6.18. Barricade Size and Orientation for Protection Against Overpressure. .................. 116
6.19. Barricade Construction Materials. ......................................................................... 116
6.20. Barricade Designs. ................................................................................................. 116
6.21. Natural Barricades. ................................................................................................ 116
6.22. Inspection of Barricades. ....................................................................................... 116
Section 6F—Earth-Filled, Steel Bin-Type Barricades for Outside Storage 117
6.23. Earth-Filled, Steel Bin-Type Barricades for Outside Storage. ............................... 117
6.24. ARMCO, Inc. Revetment HD Limits. ................................................................... 117
6.25. Types of ARMCO, Inc. Revetments. ..................................................................... 117
6.26. Requirements for ARMCO, Inc. Revetments. ....................................................... 117
6.27. ARMCO, Inc. Revetment Designs. ........................................................................ 118
Section 6G—Substantial Dividing Walls and Blast Doors 118
6.28. Substantial Dividing Walls. ................................................................................... 118
6.28. (MOODYAFB) Substantial Dividing Walls. ......................................................... 118
6.29. Blast Doors. ........................................................................................................... 121
Section 6H—Multicube or Segregated Magazines 121
6.30. Multicube or Segregated Magazines. ..................................................................... 121
Figure 6.1. Typical Eight-Cell Barricaded Open Storage Module. .......................................... 122
Figure 6.2. Determination of Barricade Length and Height to Prevent Prompt Propagation
Due to High-Velocity, Low-Angle Fragments. ..................................................... 123
Figure 6.3. Determination of Barricade Length and Height for Barricaded ILD Protection. ... 124
Table 6.1. HD 1. ...................................................................................................................... 124
Chapter 7—EXPLOSIVES OPERATIONS AND STORAGE 126
Section 7A—Introduction 126
7.1. Introduction. ........................................................................................................... 126
Section 7B—Locally Written Instructions 126
7.2. Locally Written Instructions. ................................................................................. 126
7.2. (MOODYAFB) Locally Written Instructions. ....................................................... 126
7.3. Contents of Locally Written Instructions. .............................................................. 127