INTERNAL LETTERNORTH ANNUCAN A7 IAS OW, INC.

368-64-3DATE 27 October 1964

TO Those Concerned FROM J. mpmADDRESS ADDRESS D/991-368, Z-l1

5176

SUBJECT Safety and Operating Pr cedure for Propellant Mt dng andCasting in Bldg, 372 at the Iiapw Palley Facility

Building 372 at the Happy Palley Facility idll henceforthbe used for three operations, Quicto 4 , Reinforced GrainWinding and pellant preparation . An interim prooedwes~enalosure l prepared by J. D. Cordill covers propellantpreparation in support of G.Oe SW* The fines . versionfor the Research Procedures Manual of this procedure andothers covering Qvickmix and Reinforced Grain Winding inbuiiding 372 are in preparation .

J. cilyemnPrind pal ScientistHigh Bnergy ApplicationsResearch Department

Group ScientistPropellant & lcploatve ApplicationsResearch Department

Approved: G. D. Art,

JG:nf

Picas (1) See attached

II I II III I II III V I I I I IBNA07274558

HDMSe00423728

Enclosure 1

Safety and Operating Procedure for Propellant Mixing and Casting in Call 6,9Bldg, 372 at the Happy Valley Facility

Prepared Byt J. D. Cordill

Scope

This bulletin describes the procedure to be followed in mixing and castingof propellant in Building 372 at the Happy Valley Facility .

II General Operating Procedures

1, Operating Criteria

a) Propellant batch mixing and casting operations shall be confinedto can 6 In building 372,

b) Mixing or casting in cell 6 can be conducted simultaneously withreinforced grain operations being conducted in cells 2 and 3 0

c) then these operations are being conducted no other "test" opera-tions shall be permitted in building 372,

d) Conversely , when the Quick=ix pilot plant in building 372 is inoperation , no other operations will be permitted.

e) Operations are to be conducted in accordance with the currentstandard operating procedures unless instructed otherwise bythe Engineer-in-charge (BIC). Standard operating proceduresfor the Happy Valley Facility are described in the ResearchProcedures Mannal (RPM) section III, procedure 300 .

f) Procedures outlined in this RPM apply only to Military Class 2ICC Class B propellants which do not coast-in toxic ingredients .Propellants which are Military Class 9s ICC Class As, nncharao-terized, or toxic will Zj be processed by this procedure ,

g) The engineer in charge of the propellant processing operationwill insure that the leadman has read and understands thisprocedure and that all other persons working an the programare equally informed.

20 Responsibilitie s

a) The overall responsibility for the Happy Valley area andoperations conducted therein is designated to 0. D . Artso

b) The responsibility of Bldg . 372, Hap Valley and operationsconducted therein is assigned to J . o

c) The responsibility for propellant processise operations cos-dusted in Bay 6, Bldg. 372, Happy Valley shall be assigned toa designated EIC . The EIC is responsible for insuring compli-ance with this procedure through the supervisor efforts of theleadman.

II I II III I II III V I I I I IBNA07274559

HDMSe00423729

d) Ar4r conflicts o supporting operations or conflicts of facilityusage '4 1 be scheduled by W . L. Kennedy.

3. Personnel Area Controls

a. t'orldng personnel and visitors are not to exceed the establishedlimits provided for the processing faeilitV,

b. Propellant quantities are not to exceed the established limitsprovided for the processing facility.

Go A minimum of two men will be required for all propellant processoperations to function as safety back-up or "buddy system" .

d. A roadblock will be established by lowering Gate 6 (Figure 1)during the mixing and casting of propellant . Vehicles andpedestrians must obtain permission from the EIC in charge ofthe propellant preparation before passing the roadblock orentering the area .

e. A red flag will be hoisted in full view over the mix bayduring propellant preparation operations o

f. Access to each side of the east bays in Bldg . 372 will beblocked with a barricade and a sign denoting processing opera-tions in progress., when propellant is being prepared *

g. Personnel not engaged in propellant processing may remain inBldg. 372, but must notify the EIC of their location. Personnelnot engaged in propellant processing 11 not pass the barricadeson each side of the mix bay and will wt enter the storage areaeast of the mix bay during propellant mixing and casting opera-tions unless the EIC authorizes sam e

4. Personnel Safety &tuitament

a, :137, personnel engaged in propellant processing are required towear protective coveralls or coats .* conductive safety shoes orgrounding straps, safety glasses and hard hats .

b. Gloves ., 'white cloth., will be worn when handling the propellant .

50

Go A fire extinguisher will be available for use in the area of themix bay.

Ewrmnc7 Can, itions

a. An emergency will be declared in the event of a fire and/orexplosion i volving the propellant .

b. The Happy Valley alarm systama iiill be actuated and all personnelin the valley must proceed to the nearest safe area . Safe areasare the control center and inside roams of Bldg. 372 with allexternal doors closed,

I I I IIBNA07274560

HDMSe00423730

c, After personnel are in the safe areas' procedures for emergencyoperations will be instituted,

d, Call 1-5333 ; report the emergency In a slow, clear `mice andsupply the fb1loidng information :

1. Location, Happy Valley .

2. Inaq, ambulance required or not?

3, Fire , lasge or sms11 , control3e d or uncontrolled.

4. Fire Department support. Is Fire Department supportrequired to fight fare, or as standby ?

5. The operator will notify the necessary personnel. Stay onthe line and give him your name and atgr other informationwhich is requested *

e. Notify Tunnel area personnel of to situation and institute aroad block at this point to keep out all vehicular and pedestriantraffic with the exception of the authorized emergency vehicles .

f. Notify responsible supervision.

Propellant Preparation

1. General

a, The 5 gal., Baker-Parkins mixer is to be used primarily for mixingpropellant batches larger than 1 gallon and equal to or less than5 gallons .

b. Specific operations include mixer equipment set up , propellantingredient weighing , propellant mixing, propellant casting, andpropellant curing.

c, Only trained and authorized personnel may prepare propellant,

2, Prose Ine Mdient ' sipb

a. All oxidizer components of the propellant will be stored andweighed at NM. Oxidizer requiring a dry environment will bekept in the oven in gild g. 362 prior to use. The oxidizer willbe transferred to the Happy Valley mix bar Just prior to mid; g.All trays of oxidizer will be placed in the mix-bay and addedto the mixer as required ,

b. All fuel components of the propellant will be stored and weighedat either N.1KA or a selected bay in Bldg, 372 at Happy apppy adde

dThe fuel components will be placed in the mix to themixer as required.

a. Scales for all weighing will be in calibrati on and weights of theingredients will be recorded on a propellant batch sheet.

II I II III I II III I II I I II I IBNAO727456 1

HDMSe00423731

iIL~' id Tj~OBAtt S~~iL1U

a. The miAng equipment and peripheral systems, (i.e., hot watervaonu, etc.) will be operated prior to adding propellant in-gredients to mixer to insure proper functioning of the equipeent .I snwe that no foreign material is present in the equipent .

b. t'ritten Instructions on the propellant mixing procedure will befurnished by the EIC . The EIC will insure that all personnelengaged in the mixing understand the mixing procedure .

co The mix pot will be heated to the required temperature prior toadding ingredients.

d. The propellant ingredients will be added to the mixer in thesequence required In the propellant mixing procedure and mixedfor the requested time. Can will be taken in adding the propellantingredients to the mixer . A plastic or none-sparking spatula willbe used fbr all ingredients and propellant handling,

e. During propellant mitng the bay will be evacuated of personnel,and barricades placed on access walkways to each side of the eastbays as shown in Figure 1.

f. No Personnel will pass barricades during mixing operations and a&

per will be allowed In the storage area east of the mix baVduring nixing . The mixer will be completely stopped prior topersonnel entry into bay for stepwise propellant ingredient addi-tiono

g. After the mixing is complete , the miner will be stopped andpersonnel will remove the mix pot from the mixer.

h. After the propellant is removed, the mixer v rill be cleaned perstandard procedures.

4. Pronet C astir

a. The casting ecuipmennt and peripheral systems (i.e., vanvibration, etc.) will be operated prior to adding propellantingredients to assure proper functioning of the equipment .

b. r'ritten instructions on the propellant casting procedure willbe furnished by the EIC . The SIC will insure that all personnelengaged in the casting understand the casting Procedure*

c . The casting pot wil l be heated to the required temperature priorto adding propellant .

d. The propellant trill be transferred in a container from the mixpot to the cast pot . A plastic or non-sparking spatula will beused for scraping down propellant in the mixer, transfer container,and casting pot. The propellant will be transferred without delayto prevent heat lose.

I I I IBNA07274562

HDMSe00423732

ea The casting operations will be conducted by personnel located inthe bay with the casting equiatent . Only those persons engagedin casting will be permitted in the bay and this number may notexceed the personnel nwnber limits . Barricades will be placedon the access walkways to each side of the East bays as shor tin Figure 1.

f, No unauthorized person„ el wil l pass the barricades during theIn operations. No unauthorized personnel will be allowediii the storage area east of the mix bay unless the EIC givespermission to enter the area e

go After the grain is cast the casting pot will be removed andcleaned per standard procedures,

5. Propellant Curl

a. The uncured propellant grain will be cured in ar of several ovensavailable for conventional propellants. The EJC will insure thatpropellant grain weight meets oven propellant weight limits,

b. Written instructions on the propellant curing 4U be furnishedby the EIC . The EIC will insure that all personnel concernedunderstand the cure schedule .

fco The uncured propellant grain will be transported from the casting

bay to the oven in a safe manner (i.e.s explosives cart , explosivestrack).

do 11 red flag or red warning light will be used to indicate that livepropellants are in the oven .

IV Propellant Processing

1o Gsnerral

as Specific operations for propellant processing include grain removalfrom the casting equipments grain machining, grain inhibiting., andpropellant storage ,

b. Only trained and authorized per.,, nnel may process propellant .

2 1 Removal of Grain from Casti =n nt

a, After the propellant cure cycl es is canpleteds the propellant grainwill be removed from the propellant casting equipment o

b. Written instructions on the grain removal technique will be fbr-nished by the EIC0 The EM will insure that all personnel concernedunderstand the grain removal technique .

co The cured propellant grain will be transported from the curing ovento the casting equipment removal area in a safe manners (foesexplosives carts explosives truck) .

d. If it is necessary to use a press for casting equipment removal,the operation will be conducted remotely. If remote operationis not possible ., permission for manual grain removal idth thepress must be obtained from responsible supervision,

II I II II I 0 I II I II I I I II II I IBNA07274563

HDMSe00423733

3. P 11ant Machining

a. 'Tritten instructions will be furnished by the EM on aqy propellantmachining operations. The ESC will inn we that all pommel con-cerned widerstami the machining operation .

b. RPM, Section V, Procedure 572 will be followed for all propellantmachining operations .

4. Inhibiting or Restricting P ellSI

as Written instructions will be furni shed by the EIC on propellantinhibiting requirements, The E will insure that all pe rea mel.understand the grain inhibiting rsquirements o

50 Provellant Storage

a; The propellant grain will be stored in aaW of several magazinesavailable for conventional propellant , The EIC will, ineure thatpropellant grain weight meets magazine propellant watght limits ,

II I II III I II III1 ~~ II II I IBNA07274564

HDMSe00423734

X7'"'1 K .v 1 c - :.

j