DEPARTMENT OF THE AIR FORCE HEADQUARTERS UNITED STATES AIR ...

DEPARTMENT OF THE AIR FORCE HEADQUARTERS UNITED STATES AIR FORCE

WASHINGTON, DC

AFMAN91-201_AFGM2016-01

9 March 2016

MEMORANDUM FOR DISTRIBUTION MAJCOMs/FOAs/DRUs

FROM: HQ USAF/SE 1400 Air Force Pentagon Washington DC 20330-1400

SUBJECT: Air Force Guidance Memorandum to AFMAN 91-201, Explosives Safety Standards

By Order of the Secretary of the Air Force, this is an AF Guidance Memorandum (AFGM) immediately implementing changes to AFMAN 91-201. This AFGM updates local lightning warning system information in the event of an electrical storm as it pertains to nuclear and conventional weapons operations. To the extent its directions are inconsistent with other Air Force publications; the information herein prevails, in accordance with AFI 33-360, Publications and Forms Management.

In advance of a rewrite of AFMAN 91-201, the Attachment to this Memorandum is updated to provide guidance changes that are effective immediately. An asterisk (*) indicates newly revised material.

The Memorandum becomes void after one-year has elapsed from the date of this Memorandum, or upon incorporation of an Interim Change or rewrite of AFMAN 91-201, whichever is earlier.

Attachment: Guidance Change

ANDREW M. MUELLER, Maj Gen, USAF Chief of Safety

Attachment

Guidance Change

The change below to AFMAN 91-201, dated 12 January 2011, is effective immediately.

*5.22. Facilities Requiring Lightning Protection Systems. Properly maintained lightning protection systems (LPS) are required for all explosives facilities (to include open locations), except as noted in paragraph 5.25. The DoD has selected the LPS criteria of NFPA 780, Standard for the Installation of Lightning Protection Systems, for ammunition and explosives (AE) facilities. If LPS test methods or designs are used, other than prescribed in this section, they must offer equivalent protection to those prescribed in this section and be approved via the explosives site plan. DoD 3150.02, DoD Nuclear Weapon System Safety Program Manual, and AFI 91-100 series Weapons System Safety Rules provide LPS program guidance for nuclear weapons facilities and operations.

*7.33. Local Lightning Watch, Warning and Advisory Support. The servicing AF weather unit will provide lightning watch, warning, and advisory support to installations allowing units time to take precautionary measures (see AFVA 15-137, Operational Weather Squadron Areas of Responsibility, to assist in contacting your servicing weather unit). Supervisory personnel will consult with the supporting weather unit and/or review the local weather support plan to ensure advisories, watches and warnings provide coverage for their working areas and become familiar with the base notification process. In addition weather personnel will coordinate with all installation organizations to ensure weather requirements are being met, in accordance with AFMAN 15-129, Volume 2, Air and Space Weather Operations - Exploitation.

*7.34. Procedures in the Event of Lightning for Conventional AE.

*7.34.3. Locations with nuclear weapons will request notification of lightning within 10 miles of their location according to DoDM 3150.02, from their servicing weather unit. Local procedures for these advisories are documented in AFMAN 91-201, Explosive Safety Standards, Section 7H-- Procedures in the Event of Electrical Storms. DoDM 3150.02 prescribes response actions for nuclear weapons operations when 10 mile lightning advisories are issued.

*(added) 7.34.4. See section 5H for additional LPS information.

*Attachment 1

*(added) DoDM 3150.02, DoD Nuclear Weapon System Safety Program Manual, 31 January 2014, Incorporating Change 1, 15 January 2015

*(added) AFMAN 15-129, Volume 2, Air and Space Weather Operations - Exploitation, 7 December 2011

*(added) AFVA 15-137, Operational Weather Squadron Areas of Responsibility, 27 Oct 2015

BY ORDER OF THE SECRETARY OF THE AIR FORCE

AIR FORCE MANUAL 91-201 12 JANUARY 2011

Incorporating Change 1, 22 June 2012 Safety

EXPLOSIVES SAFETY STANDARDS

COMPLIANCE WITH THIS PUBLICAITON IS MANDATORY

ACCESSIBILITY: This publication is available digitally on the e-Publishing website at e-publishing.af.mil for downloading or ordering

RELEASABILITY: There are no releasability restrictions on this publication.

OPR: AFSC/SEW

Supersedes: AFMAN 91-201, 17 November 2008

Certified by: AF/SED (Mr. Roberto I. Guerrero)

Pages: 473

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 the Air Force Records Disposition Schedule (RDS) located at .

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

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AFMAN91-201 12 JANUARY 2011

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.

Chapter 1--INTRODUCTION AND EXCEPTION PROGRAM

28

Section 1A--Explosives Safety General Instructions

28

1.1. Purpose. .................................................................................................................. 28

1.2. Scope. ..................................................................................................................... 28

Section 1B--Exception Program

30

1.3. General. .................................................................................................................. 30

1.4. Deviations. ............................................................................................................. 31

1.5. Operational Waivers. ............................................................................................. 33

1.6. Waivers. ................................................................................................................. 34

1.7. Exemptions. ........................................................................................................... 34

1.8. SECAF Waivers and Exemptions for New Construction. ..................................... 35

1.9. Exceptions for Non-DoD Explosives Activities on Air Force Installations. ......... 35

1.10. Waiver and Exemption Information Requirements. .............................................. 35

1.11. HAF-Level Waiver and Exemption Information Requirements. ........................... 36

1.12. Waiver or Exemption Decision Nomograph. ......................................................... 37

1.13. Periodic Reviews for Exceptions. .......................................................................... 38

1.14. Cancellation of Waivers and Exemptions. ............................................................. 39

Table 1.1. Likelihood of a Mishap. ......................................................................................... 40

Table 1.2. Exposure. ............................................................................................................... 40

Table 1.3. Possible Consequences of a Mishap. ..................................................................... 41

Table 1.4. Periodic Review Levels for HAF-Level Waivers and Exemptions. ...................... 42

Figure 1.1. Exception Decision Nomograph?Day-to-Day Operations. .................................... 43

Figure 1.2. Exception Decision Nomograph?Contingency and War Plans. ............................ 44

Figure 1.3. Nomograph Plotting Example. ............................................................................... 45

Chapter 2--REACTION EFFECTS

46

Section 2A--Principal Effects of High Density (HD) 1.1 Events

46

2.1. Blast. ...................................................................................................................... 46

2.2. Fragments. .............................................................................................................. 48

2.3. Thermal Hazards. ................................................................................................... 48

AFMAN91-201 12 JANUARY 2011

3

2.4. Groundshock and Cratering. .................................................................................. 48 2.5. Expected Consequences. ........................................................................................ 49

Section 2B--Principal Effects of HD 1.2 Events.

51

2.6. Blast. ...................................................................................................................... 51

2.7. Fragments. .............................................................................................................. 52

2.8. Thermal Hazards. ................................................................................................... 52

2.9. Ejected Items. ......................................................................................................... 52

2.10. Propelled Items. ..................................................................................................... 52

2.11. Firebrands. ............................................................................................................. 52

2.12. Expected Consequences. ........................................................................................ 52

Section 2C--Principal Effects of HD 1.3 Events

53

2.13. Gas Pressures. ........................................................................................................ 53

2.14. Fragments. .............................................................................................................. 53

2.15. Thermal Hazards. ................................................................................................... 53

2.16. Propelled Items. ..................................................................................................... 53

2.17. Firebrands. ............................................................................................................. 53

2.18. Expected Consequences. ........................................................................................ 54

Section 2D--Principal Effects of HD 1.4 Events

54

2.19. Blast. ...................................................................................................................... 54

2.20. Fragments. .............................................................................................................. 54

2.21. Thermal Hazards. ................................................................................................... 54

2.22. Firebrands. ............................................................................................................. 54

2.23. Compatibility Group (CG) S Items. ....................................................................... 54

2.24. Expected Consequences. ........................................................................................ 54

Section 2E--Principal Effects of HD 1.5 and HD 1.6 Events

54

2.25. HD 1.5 Effects. ...................................................................................................... 54

2.26. HD 1.6 Effects. ...................................................................................................... 54

Table 2.1. Expected Peak Incident Pressures From HD 1.1 Events. ...................................... 54

Table 2.2. Probability Of Window Breakage From Incident Pressure. .................................. 55

Table 2.3. General Blast Effects On Personnel?Eardrum Rupture. ........................................ 56

Table 2.4. General Blast Effects On Personnel?Lung Damage. ............................................. 57

Table 2.5. General Blast Effects On Personnel ? Lethality Due To Lung Rupture. ............... 57

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AFMAN91-201 12 JANUARY 2011

Chapter 3--HAZARD CLASSIFICATION

58

Section 3A--DoD Hazard Classification System

58

3.1. Purpose of Hazard Classification. .......................................................................... 58

3.2. Responsibility for Hazard Classification. .............................................................. 58

3.3. Hazard Classification Authorities. ......................................................................... 58

3.4. Standards for Determining DoD Hazard Classification. ........................................ 58

3.5. Description of DoD Hazard Classification System. ............................................... 58

3.6. Net Explosive Weight and Net Explosive Weight for Quantity-Distance. ............ 59

3.7. Requirement for DoD Hazard Classification. ........................................................ 59

Section 3B--Storage and Transportation Without DoD Hazard Classification

60

3.8. Storage and Transportation Without DoD Hazard Classification. ......................... 60

3.9. Explosives With DOE Hazard Classifications. ...................................................... 60

3.10. DoD-Owned Non-Stock-Listed Commercial Explosives. ..................................... 61

3.11. Manufacturing, Research and Development Items. ............................................... 62

3.12. Foreign Explosives. ............................................................................................... 62

3.13. Non-DoD-Owned Explosives. ............................................................................... 63

Section 3C--Hazard Classification of Unpackaged Items

65

3.14. Hazard Classification of Unpackaged Items. ......................................................... 65

Section 3D--Class 1 Divisions and Subdivisions

66

3.15. HD 1.1 ? Mass-explosion. ..................................................................................... 66

3.16. HD 1.2 ? Non-mass Explosion, Fragment Producing. ........................................... 66

3.17. HD 1.3 ? Mass Fire, Minor Blast or Fragment. ..................................................... 67

3.18. HD 1.4 ? Moderate Fire, No Significant Blast or Fragment. ................................. 67

3.19. HD 1.5 ? Explosive Substance, Very Insensitive (With Mass Explosion Hazard). ................................................................................................................................. 67

3.20. HD 1.6 ? Explosive Article, Extremely Insensitive. .............................................. 67

Section 3E--Compatibility Groups and Sensitivity Groups

67

3.21. Storage and Transportation Compatibility Groups. ............................................... 67

3.22. Sensitivity Groups. ................................................................................................. 69

Chapter 4--RISK ASSESSMENTS AND PROTECTION PRINCIPLES

70

Section 4A--Risk Assessments

70

4.1. Requirements for Risk Assessments. ..................................................................... 70

AFMAN91-201 12 JANUARY 2011

5

4.2. Risk Assessments. .................................................................................................. 70 4.3. Risk Management (RM). ....................................................................................... 70 4.4. System Safety. ....................................................................................................... 71 4.5. Professional Assistance for Risk Assessments and System Safety Analyses. ....... 71

Section 4B--Munitions Systems and Equipment

71

4.6. Safety Certification of Munitions Systems. ........................................................... 71

4.7. Risk Assessments for Explosives Equipment. ....................................................... 71

Section 4C--Explosives Operations and Facilities

71

4.8. Risk Assessment for Explosives Operations. ......................................................... 71

4.9. Risk Assessments for Explosives Facilities. .......................................................... 72

Section 4D--Glass Breakage Risk Assessments

72

4.10. Purpose of Glass Breakage Risk Assessments. ...................................................... 72

4.11. Requirements for Performance of Glass Breakage Risk Assessments. ................. 72

4.12. Software Tools for Glass Breakage Risk Assessments. ......................................... 73

4.13. Methodology for Glass Breakage Risk Assessments. ............................................ 74

4.14. Engineering Mitigation Actions for Reducing or Eliminating Glass Breakage Hazards to Personnel. ............................................................................................ 74

Section 4E--Health Hazard and Environmental Assessments

75

4.15. Health Hazard Assessments. .................................................................................. 75

4.16. Environmental Assessments. ................................................................................. 75

Section 4F--Protection Principles

75

4.17. Protective Shielding and Remotely Controlled Operations. .................................. 75

4.18. Intentional Ignition or Initiation of AE. ................................................................. 76

4.19. Protective Measures. .............................................................................................. 76

4.20. Emergency Operations. .......................................................................................... 77

Figure 4.1. Five Step Process for Risk Management ............................................................... 78

Chapter 5--GENERAL EXPLOSIVES FACILITY DESIGN, CONSTRUCTION AND

MAINTENANCE, AND EQUIPMENT DESIGN, MAINTENANCE AND

INSPECTION

79

Section 5A--Introduction

79

5.1. Applicability. ......................................................................................................... 79

Section 5B--Glass Panels

79

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AFMAN91-201 12 JANUARY 2011

5.2. Glass Panels in Facilities Exposed to Explosives Hazards. ................................... 79

Section 5C--Hazardous Locations

80

5.3. Hazardous Locations. ............................................................................................. 80

5.4. Electrical Equipment in Hazardous Locations. ...................................................... 80

5.5. Interior Surfaces in Class II Hazardous Locations. ................................................ 81

5.6. Hardware in Hazardous Locations. ........................................................................ 81

5.7. Static Electricity in Hazardous Locations. ............................................................. 81

5.8. Ventilation in Hazardous Locations. ...................................................................... 81

Section 5D--Electric Supply Systems

82

5.9. Electric Supply Systems. ....................................................................................... 82

5.10. Backup Power. ....................................................................................................... 82

Section 5E--Static Grounding and Bonding

82

5.11. Areas Requiring Static Grounding and Bonding Systems. .................................... 82

5.12. Static Grounding and Bonding Requirements. ...................................................... 82

5.13. Permanent Static Grounding Systems. ................................................................... 83

5.14. Temporary Static Grounding or Bonding Cables. ................................................. 84

5.15. Static Grounding or Bonding Reels. ...................................................................... 84

5.16. Belting. ................................................................................................................... 85

Section 5F--Conductive Floors

85

5.17. Areas Requiring Conductive Floors. ...................................................................... 85

5.18. Requirements for Conductive Floors. .................................................................... 85

5.19. Testing and Maintenance of Conductive Floors. ................................................... 85

5.20. Testing and Maintenance of Conductive Footwear. .............................................. 85

Section 5G--Installed Systems and Equipment Grounds

86

5.21. Installed Systems and Equipment Grounds. .......................................................... 86

Section 5H--Lightning Protection Systems

86

5.22. Facilities Requiring Lightning Protection Systems. .............................................. 86

5.23. Lightning Protection System Design. .................................................................... 86

5.24. Lightning Protection System Inspection, Maintenance, Testing, and Training. .... 90

5.25. Lightning Protection System Exceptions. .............................................................. 90

Section 5I--General Design Considerations for Explosives Facilities

92

5.26. Blowout-type Construction. ................................................................................... 92

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