CUI
OSI ENGINEERING STANDARD
Title: General Design and Fabrication Practices, Process Equipment
11507
Handling Explosives
Current Approved Date: June 3rd 2021
PAGE 1 of 11
Revision: 2
11507
General Design and Fabrication Practices, Process Equipment
Handling Explosives
EXPORT CONTROLLED DATA. This document contains technical information whose export is governed by
the U.S. Export Administration Regulations (EAR). This information must not be transferred to a foreign
person/entity without proper authorization of the U.S. Government. Violations may result in administrative, civil
or criminal penalties.
TF Page G123 of G872
CUI
CUI
OSI ENGINEERING STANDARD
Title: General Design and Fabrication Practices, Process Equipment
11507
Handling Explosives
Current Approved Date: June 3rd 2021
PAGE 2 of 11
Revision: 2
Table of Contents
1.
Scope ............................................................................................................................................................. 3
1.1
Introduction ...................................................................................................................................... 3
1.2
Applicability ..................................................................................................................................... 4
2.
General Guidelines ...................................................................................................................................... 4
3.
Fastening and Joining ................................................................................................................................. 5
3.1
Welding ............................................................................................................................................ 5
3.2
THREADED FASTENERS ............................................................................................................. 8
3.3
OTHER JOINING DEVICES AND PROCESSES ......................................................................... 8
4.
SURFACE FINISHES ................................................................................................................................ 8
5.
ELECTRICAL COMPONENTS ............................................................................................................... 8
6.
ELECTRICAL GROUNDING AND BONDING..................................................................................... 8
7.
MATERIALS OF CONSTRUCTION ....................................................................................................... 8
8.
CASTINGS................................................................................................................................................... 9
9.
SPECIAL APPROVAL OR EXCEPTIONS............................................................................................. 9
10.
EQUIPMENT CONSTRUCTION AND FABRICATION INSPECTION ............................................ 9
11.
10.1
Photographs ...................................................................................................................................... 9
10.2
Pre-Contract Meeting and Job Discussion ....................................................................................... 9
10.3
Intermediate Inspections................................................................................................................. 10
10.4
Final Inspection .............................................................................................................................. 10
References .................................................................................................................................................. 10
11.1
BAE Standards ............................................................................................................................... 10
11.2
Other References ............................................................................................................................ 10
EXPORT CONTROLLED DATA. This document contains technical information whose export is governed by
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CUI
OSI ENGINEERING STANDARD
Title: General Design and Fabrication Practices, Process Equipment
11507
Handling Explosives
Current Approved Date: June 3rd 2021
PAGE 3 of 11
Revision: 2
Revision History
ECO
NUMBER
REVISION
NUMBER
1
ECO-001000
2
DATE
APPROVED
12-2009
6/3/2021
DESCRIPTION OF CHANGE
Updated to new format. Updated notes about PT, Weld map
example and additional weld X-rays when welds fail X-ray
inspection.
1. Scope
1.1
Introduction
1.1.1
The design and fabrication of process equipment for Holston Army Ammunition Plant
(HSAAP) to handle high-energy explosives requires the application of principles and
practices not normally found in the chemical processing industry.
1.1.2
For obvious reasons, emphasis is placed on designing equipment and processes to
maximize the safety of those that must operate and maintain them. Also of concern in
design is the prevention of lost production capability (that can result from explosions).
Normal concerns in design work (i.e. economy, efficiency, ease of fabrication, etc.) are
considered important, but are addressed only after the above requirements are satisfied.
1.1.3
Explosives manufactured and processed at HSAAP are usually in a particulate form.
Depending on the processing stage, explosive particles may be found in water slurry, acid
or solvent slurry or solution, or in some stage of drying (from moist cake to dry powder).
Also, TNT (in molten form) is processed. At various processing stages, explosives can
be found as coatings on the equipment, dry and hard-packed into pockets or crevices, and
(in some cases) having migrated into service lines connected to the equipment. The
variety of forms and behavioral characteristics of these explosives explains (to a degree)
the unusual design requirements contained in this standard.
1.1.4
Generally speaking, explosives are more sensitive to initiation as the liquid amount (water
or acid) involved decreases. Initiation sources commonly encountered in equipment
design are impact, friction, and electrostatic discharge. Thermal heating and impingement
are also possible initiation sources. Electrical arcing is also a possible initiation source.
Therefore, electrical equipment of the proper hazardous area classification must be used.
The design and fabrication guidelines presented in this standard are directed at prevention
of these initiation sources.
1.1.5
NOTES:
1.1.5.1 Please read this OSI Engineering Standard carefully
1.1.5.2 All requirements in this OSI Engineering Standard apply to the item(s) being
fabricated, constructed or supplied for the specific purchase stated.
1.1.5.3 Prior fabrication or construction requirements performed on previous purchases
do not apply if there is a contradiction to this OSI Engineering Standard.
EXPORT CONTROLLED DATA. This document contains technical information whose export is governed by
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TF Page G125 of G872
CUI
CUI
OSI ENGINEERING STANDARD
Title: General Design and Fabrication Practices, Process Equipment
11507
Handling Explosives
Current Approved Date: June 3rd 2021
PAGE 4 of 11
Revision: 2
1.1.5.4 All exceptions to all OSI Engineering Standards must be in writing and included
in the Purchase Agreement.
1.1.5.5 Equipment construction and fabrication inspections, including x-ray options are
required unless otherwise stated in writing in the Purchase Agreement.
1.1.6
1.2
DG-0035 was created and to be used in conjunction with 11507 to help provide clarity
around the intent of 11507
Applicability
1.2.1
This standard is to be used for the design and fabrication of all process equipment handling
explosive material within the Holston and Radford Army Ammunition Plant.
2. General Guidelines
2.1.1
OSI is contractually obligated to incorporate the requirements of Army Safety Manual
AMC-R 385-100 and Federal Occupational Safety and Health Act (OSHA) into its
designs and installations.
2.1.2
Surfaces exposed directly to the explosives shall be smooth and free of discontinuities.
Surface finishes shall be as stated in the specifications or on the drawings. There shall be
no cracks, crevices, or protrusions that could promote growth of explosives crystals. (See
Paragraph 3.1. for welds and Paragraph 8.0. for castings)
2.1.3
Process-wetted surfaces shall have no points where explosives particles can be exposed
to the action of two metal parts moving relative to one another (either in impact or sliding
motion). This includes cracks in metal parts that can produce relative movement of sides
during thermal expansion and contraction. The use of threaded fasteners in following
locations must be avoided:
2.1.3.1 Where exposed directly to the process
2.1.3.2 In a position to fall (or end up) in the process
2.1.3.3 Where the process may splash (or be dropped) onto them
2.1.4
The elimination of threaded fasteners may require extensive design (or redesign) of
existing equipment to meet this requirement. Dead-ended bolts and cap screws are not
permitted, except where authorized by OSI. All threaded fasteners that absolutely cannot
be eliminated must be approved (in writing) by OSI before fabrication begins.
2.1.5
Process equipment shall be designed to permit easy visual inspection and clean up of all
parts exposed to explosives. The use of hollow shafts (or support members) is to be
avoided. Solid shafts are required, as are solid types of structural shapes for supports.
Hollow members (even when the ends have been welded shut) have been found to contain
enough explosives to be classified as serious safety hazards, especially when welding
repairs are performed.
2.1.6
Larger, more complicated pieces of process equipment shall be designed so there are no
areas that could trap personnel in the event of an emergency.
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CUI
OSI ENGINEERING STANDARD
Title: General Design and Fabrication Practices, Process Equipment
11507
Handling Explosives
Current Approved Date: June 3rd 2021
PAGE 5 of 11
Revision: 2
2.1.7
In general, the factors of safety, service factors, and specifications (used in process
equipment design) should exceed industry practice for similar equipment. Explosives
processing equipment must be as safe and reliable as practicable.
2.1.8
The use of thermal insulation on explosives processing equipment is not permitted without
OSI written approval.
2.1.9
Electrical components used on explosives processing equipment must meet NEC
requirements. (See Paragraphs 5. and 6.)
2.1.10 When designing process equipment, the occurrence of parts rotating relative to one
another is unavoidable. In such cases, the design strategy that must be followed is to
minimize the hazard potential. To accomplish this, the designer may either:
2.1.10.1
Reduce the probability for contact between rotating and stationary part by
designing in adequate clearances
2.1.10.2
Reduce the probability of explosives entering the "hazard zone" between
the rotating and the stationary part (by flushing, shielding or positioning).
2.1.11 The designer may also select a combination of the two basic approaches. If the
"clearance" technique is chosen, the designer must size the various components so that
the specified clearance is positively maintained (under all possible operating conditions).
When specifying a flushing liquid, the fluid used must be compatible with the process and
there must be safeguards to insure the flush is maintained.
2.1.12 A gasket should be placed between all non-moving touching parts where explosives could
be expected to accumulate. This can be inside a machine (or vessel) or outside (where
explosives could be spilled or washed into joint).
3. Fastening and Joining
3.1
Welding
3.1.1
EXPLOSIVE WELD REQUIREMENTS
3.1.1.1 All welds on process equipment that are directly exposed to (or wetted by) the
process, in a position where the process may splash (or drop) on weld seam, or
indicated on the drawings or in the specifications, shall be of a quality to meet
explosive weld standards, as described below.
3.1.1.2 The purpose of this procedure is to produce parts free of any internal enclosed
pockets (or voids) within the weld, between parent metals, or between weld beads
(where explosives may collect). This is accomplished through high quality,
continuous, full-penetration welds. The welds are to be applied on both sides,
where possible.
3.1.1.3 The mating edges of metals to be welded shall be beveled and an adequate rootgap provided (to allow for full-penetration welding).
EXPORT CONTROLLED DATA. This document contains technical information whose export is governed by
the U.S. Export Administration Regulations (EAR). This information must not be transferred to a foreign
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CUI
OSI ENGINEERING STANDARD
Title: General Design and Fabrication Practices, Process Equipment
11507
Handling Explosives
Current Approved Date: June 3rd 2021
PAGE 6 of 11
Revision: 2
3.1.1.4 The welds shall be continuous, with full-joint penetration (i.e. the molten metal
of the weld bead on one joint side must be fully contacted by the weld on other
joint side), leaving no voids, pits, cracks or crevices in connection).
3.1.1.5 Welding rings, lapped joints, or "seal" welded joints are unacceptable. (See Page
6 for examples of acceptable and unacceptable weld joints)
3.1.2
WELD SURFACE
3.1.2.1 All weld surfaces, both sides of all welds (where accessible) must be 100% dye
penetrant tested (PT) and documented in accordance with ASME Code, Section
VIII, Division 1. It is important that the dye penetrant examination and repairs are
completed on a particular weld before radiograph examination is done on the same
weld.
3.1.2.2 Weld surfaces shall be free of cracks, pits, crevices, pinholes, weld spatter,
impurities, etc. Any imperfection shall be repaired by grinding out the
imperfection and refilling the weld. All surface imperfections shall be reexamined after repair.
3.1.2.3 The final surface finish (of a weld exposed to the explosives process) shall match
the finish requirements of the metal surfaces that the weld joined. Undercutting
or grinding flush of the parent metal and weld is not permitted.
3.1.2.4 All weld discoloration shall be removed.
3.1.3
RADIOGRAPHY (X-RAY) REQUIREMENTS
3.1.3.1 A specified percentage of all explosive weld joints (based on the total length) shall
be randomly radiograph-examined. All welds includes (but is not limited to)
nozzle connections to vessels, nozzle pipe welds, seam welds, baffles, gussets, or
any other welded joints.
3.1.3.2 Any ASME Code x-ray requirement shall be in addition to the explosive x-ray
requirements and will not count toward the total percentage of x-rays required.
3.1.3.3 An OSI Engineering Inspection Representative will determine which weld joints
are to be x-rayed after welding is complete. The welds selected to be x-rayed are
to be identify on approval drawings and labeled to create a weld map. Below is
an example of a weld map labeling.
EXPORT CONTROLLED DATA. This document contains technical information whose export is governed by
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CUI
CUI
OSI ENGINEERING STANDARD
Title: General Design and Fabrication Practices, Process Equipment
11507
Handling Explosives
Current Approved Date: June 3rd 2021
PAGE 7 of 11
Revision: 2
3.1.3.4 Welds must be x-rayed prior to assembly or further fabrication, if it is not possible
to x-ray later. Intermediate inspections for the OSI Engineering Inspection
Representative shall be planned to observe fit-up and to select x-ray points of
completed welds.
3.1.3.5 Radiograph examination shall be accomplished successfully before the pressure
test (if applicable).
3.1.3.6 The radiograph film shall be U.S. manufactured, Class I type.
3.1.3.7 Radiograph interpretation shall be performed by a Level III x-ray technician
certified by ANST or equivalent, unless noted otherwise.
3.1.3.8 Interpretation Sheets and radiograph film shall be submitted to the Buyer for
review.
3.1.4
WELD ACCEPTANCE CRITERIA
3.1.4.1 Weld Surface: See Paragraph 3.1.2.
3.1.4.2 Weld Interior: All requirements (as stated above) shall be met. Furthermore, the
acceptance criteria for indications seen only by x-ray are: Any one indication shall
not exceed 0.030” in size, and no more than five indications (0.030" or less) are
allowed in an inch of weld. When evaluating indication size, the tail shall be
included. Indications may be from imperfections due to porosity, slag, or tungsten.
3.1.4.3 Other interior weld acceptance criteria shall meet the requirements of ASME
Boiler and Pressure Vessel Code, Section VIII, Paragraph UW-51.
3.1.4.4 Unacceptable welds must be repaired and re-examined.
3.1.4.5 For each unacceptable weld, two additional welds (of same size) must selected be
x-rayed and tracked per the weld map labeling (3.1.3.3)
EXPORT CONTROLLED DATA. This document contains technical information whose export is governed by
the U.S. Export Administration Regulations (EAR). This information must not be transferred to a foreign
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CUI
OSI ENGINEERING STANDARD
Title: General Design and Fabrication Practices, Process Equipment
11507
Handling Explosives
Current Approved Date: June 3rd 2021
PAGE 8 of 11
Revision: 2
3.2
3.3
THREADED FASTENERS
3.2.1
The use of metallic and non-metallic threaded fasteners in and around explosives
processing equipment is to be avoided. There are basically two concerns with the use of
threaded fasteners. One is the initiation source produced by turning fasteners with
explosives contaminated threads. The other is the possibility of a fastener loosening
during operation and falling into the explosives product. The elimination of threaded
fasteners may require extensive design (or redesign) of existing equipment to meet this
requirement. All threaded fasteners that absolutely cannot be eliminated must be
approved (in writing) by OSI before fabrication can begin.
3.2.2
The prevention of threaded fasteners loosening during equipment operation is addressed
in OSI Engineering Standard 05051.
OTHER JOINING DEVICES AND PROCESSES
3.3.1
Other joining devices and processes may be used with special approval by OSI (in writing)
on a case-by-case basis.
4. SURFACE FINISHES
4.1.1
The surface finish for explosives process equipment shall be specified by OSI in the
specification or on drawings and shall be consistent with ANSI B.46.1.
5. ELECTRICAL COMPONENTS
5.1.1
All electrical components used in explosives processing equipment must meet same
requirements as the other mechanical components where exposed directly to explosives.
5.1.2
In addition, every electrical component used on explosives processing equipment must be
approved by a certified testing agency (i.e. UL or FM) for use in the appropriate electrical
hazardous area classification.
6. ELECTRICAL GROUNDING AND BONDING
6.1.1
Electrostatic bonding shall be provided at each point on a piece of explosives processing
equipment where a relatively non-conductive element (i.e. a gasket) is placed between
two conductive metal parts. The resistance to ground from any point on a piece of
equipment shall not exceed 10 ohms.
6.1.2
Conductive belts and hoses used on explosives processing equipment shall have a
resistance to ground not exceeding 1,000,000 and 250,000 ohms respectively.
6.1.3
When necessary, rotating metal parts in a piece of explosives processing equipment may
be grounded using loose, sliding metallic rings. These rings should be positioned as far
from exposure to the explosives as possible and kept wet.
7. MATERIALS OF CONSTRUCTION
7.1.1
The factors considered in selecting materials for use in fabricating explosives processing
equipment are: compatibility with the explosives product, strength, resistance to
corrosion, cleanliness and cleanability, ease of fabrication, availability and cost.
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CUI
CUI
OSI ENGINEERING STANDARD
Title: General Design and Fabrication Practices, Process Equipment
11507
Handling Explosives
Current Approved Date: June 3rd 2021
PAGE 9 of 11
Revision: 2
7.1.2
Examples of materials that should not be selected are: asbestos, fiberglass, glass, materials
containing fiberglass or glass fibers, ceramics, and materials that are classed as static
generators.
8. CASTINGS
8.1.1
Due to the nature of the casting process, minor pitting might be difficult to avoid. Where
possible, the quality required in Paragraph 2.3. should be maintained. OSI realizes that
minute voids could be present. In these cases, the following exceptions will be granted:
One pit, (maximum of 0.004" diameter and 0.004" deep) will be allowed for every 4
square inches of surface area (average). The minimum distance between pits to be 1".
Cracks are not allowed.
9. SPECIAL APPROVAL OR EXCEPTIONS
9.1.1
Any deviation taken to the requirements and specifications requires OSI approval (in
writing).
10. EQUIPMENT CONSTRUCTION AND FABRICATION INSPECTION
10.1
Photographs
10.1.1 Starting with receipt of materials until final inspection a minimum of four (4) weekly
digital photographs are required.
10.1.2 Submittal of weekly photographs is not dependent upon progress. Photographs must be
sent regardless of progress.
10.1.3 Photographs shall be e-mailed to the OSI Engineering Inspection Representative in an
acceptable format.
10.1.4 The photographs shall include but not limited to materials inventory, metal cut, metal
formed, welding fit-up, tack welding, welding, machining, grinding, polishing, dye
penetrant testing, x-ray, hydrostatic testing, shipping fixtures and/or crates, loading for
shipment, etc.
10.1.5 Failure to provide photographs will delay milestone payments if applicable.
10.2
Pre-Contract Meeting and Job Discussion
10.2.1 This meeting is intended for new Contractors that are not familiar with OSI construction
and fabrication requirements, and it is optional for OSI to request this meeting. However,
a Pre-contract meeting and job discussion may be requested by the Contractor before any
job start.
10.2.2 At the pre-contract meeting and job discussion it is expected that the Contractor have his
representatives present for every facet of the job including management, sales
representatives, engineers, quality control personnel, shop personnel, and all proposed
subcontractors.
10.2.3 There will be a thorough discussion of all specifications, drawings, OSI Standards and
inspections.
EXPORT CONTROLLED DATA. This document contains technical information whose export is governed by
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CUI
CUI
OSI ENGINEERING STANDARD
Title: General Design and Fabrication Practices, Process Equipment
11507
Handling Explosives
Current Approved Date: June 3rd 2021
PAGE 10 of 11 Revision: 2
10.3
Intermediate Inspections
10.3.1 Intermediate inspections will be scheduled for strategic “hold points”; such as, milestone
payments, specific points of construction and fabrication, specific points of testing, etc.
10.3.2 OSI will determine the intermediate inspection “hold points.”
10.3.3 It will be the Contractor’s responsibility to notify OSI fourteen (14) days ahead of time
for an intermediate inspection so that travel arrangements can be made.
10.4
Final Inspection
10.4.1 Final Inspection will include a detailed review of all construction and fabrication.
10.4.2 It will be the Contractor’s responsibility to furnish the necessary labor, tools and
machinery for the OSI Engineering Inspection Representative to accomplish a thorough
inspection.
10.4.2.1
The first step of final inspection will be a general visual inspection to
verify construction and fabrication completeness, for example, nozzles, manways,
supports, lugs, agitators, motors, fasteners, gaskets, etc.
10.4.2.2
Next will be a detailed dimensional check, level, plum, straight, visual
welding inspection, finish, paint, etc.
10.4.2.3
Review dye penetrant test results, x-ray test results, hydrostatic test
reports and/or witness, review mil spec reports.
10.4.2.4
Either prepare a repair plan of action or approve for final shipment.
11. References
11.1
BAE Standards
11.1.1 16450-8 – Electrostatic Bonding for Process Piping
11.1.2 05051 – Securing Fasteners in the Explosives Plant
11.2
Other References
11.2.1 Army Safety Manual AMC-R 385-100
11.2.2 Federal Occupational Safety and Health Act (OSHA)
11.2.3 National Electrical Code (NEC)
11.2.4 ASME Boiler and Pressure Vessel Code, Section VIII, Paragraph UW-51 "Radiographic
Examination of Welded Joints
11.2.5 ANSI B.46.1
11.2.6 DG-0035 Explosive Service Equipment Design Guide
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OSI ENGINEERING STANDARD
Title: General Design and Fabrication Practices, Process Equipment
11507
Handling Explosives
Current Approved Date: June 3rd 2021
PAGE 11 of 11 Revision: 2
UNACCEPTABLE
ACCEPTABLE
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