TOVEX SECTION

 Personal Protective Equipments:

 Gas respiratory mask (for MMA decanting)
 Acid protective suit (for dealing with acid)
 Rubber gloves
 Rubber shoes

 Monomethylamine (MMA) Hazards and Safety Considerations

 Anhydrous Monomethylamine physical properties and hazards data are as follows
 Boiling Point -6.3°C
 Freezing Point -93.5°C
 Autoignation temperature 430°C
 Vapour Pressure at 25°C = 50.7 psia
 Density Liquid at 25°C = 0.6562g/ml
 Flammable limit in air % by volume
Lower = 4.9% Upper = 20.7%
 Exposure Limits 10 ppm 12mg/mp3 for 8 hours
 Methylamines are highly alkaline materials. Both the anhydrous materials and the water
solution cause burns to eyes and skin.
 Avoid contact with MMA solution or vapours. Do not breath gases or vapours use self
contained breathing equipments or full face air line respirator. Wash thoroughly after
handling.
 All equipments containing MMA should be properly grounded.
 Air must be excluded from lines tanks and equipments used for storage and handling of
anhydrous MMA to avoid a fore or explosion hazard.
 Before initial service and after shutdown for inspection and maintenance the system must be
purged with Nitrogen before using Anhydrous MMA.
 Direct contact of MMA with mercury may produce an explosion reaction. Therefore use of
instruments containing mercury for measurements and tests on MMA is prohibited.
 MMA is corrosive to Aluminum Copper alloys galvanized metal Magnesium and Zinc alloys
and therefore use of these materials is prohibited.
 The potential for accidental leaks and spills must be reviewed by each site.
 The simplest and safest way to unload MMA is to create a pressure difference between the
delivery container and the storage tank.
 Corken compressor is the only type presently approved and used for degassing tank car or
container of Anhydrous MMA.
 Anhydrous MMA tanks are equipped with pressure relief valve set at 225 psig. However it is
recommended that the unloading pressure be kept below 60 psig.
 Truck drivers are not permitted to unload. Only qualified operators are permitted to unload
and operate truck valves.
 Non sparking tools must be used for connecting and disconnecting the unloading lines.
 Storage tanks must not be completely filled because of high coefficient of expansion of
MMA. Leaving at least 15% of the volume of tank as vapour space.
 A working pressure of 110 psig is suggested along with a design pressure of 150psig.
 Tanks must be hydrostatically tested at one times before being placed in service.
 Nitric Acid Hazards and Safety Consideration
 Nitric Acid is a clear colourless to light brown liquid with a characteristic acrid odor. It is
strong Acid with powerful oxidizing and Nitrating properties.
 It is capable of causing sever skin damage and eyes burns and its vapours especially the
oxides can cause lungs damage.
 Nitric Acid or its vapours are nonflammable.
 Strong Nitric Acid in contact with wood or organic material may cause fire.
 Nitric Acid reacts explosively with metallic powder Carbides Hydrogen Sulfides and
Turpentine.
 Nitric acid can react with variety of materials to generate gasses which if not properly
ventilated can cause eruption.
 Avoid accumulation of MMA NO NO2 vapour and air through ventilation or evacuation.
 The potentials for leaks and spills must be reviewed by each side.
 Use of liquid filled gauges in Nitric acid is prohibited due to the possibility of Nitration.

 MMAN Hazards and Safety Consideration

 MMAN is cape sensitive explosive and in water solution is a primer sensitive explosive.
MMAN sensitivity will increase with the addition of air bubbles.
 The condition which could lead to MMAN being subjected to either contamination high
temperature high impact energy or confinement must be prevented to avoid explosion hazard.
 MMAN under normal working condition does not present a serious health hazard. The hot
solution can cause thermal burns and contact must be avoided.
 If MMAN is spilled on skin or eye flush immediately with cold water.
 The potential leaks spills must be reviewed.
 All lubricants and gasketing materials must be tested for compatibility with MMA MMAN
and Nitric Acid before being authorized for use in MMAN service.
 The reaction of MMA and Nitric Acid out side the vessel must be avoided.
 Backflow of Nitric acid into MMA system especially the batch neutralized spurger is
prevented by shutoff valve.
 A water flush of spurger must be done after Nitric acid is in the neutralized just before amine
flow is started and whenever amine flow is stoles before resumed.

 Interlocks for Acid Feed

 Acid feed without water flush ( Should not Start)
 Acid feed with dump valve opened ( Should not Start)
 Acid feed with low eductor pressure ( Should not Start)

 Interlocks for MMA feed

 MMA Feed without Acid level ( Should not Start)
 MMA Feed without water flush ( Should not Start)
 MMA Feed without cooling water ( Should not Start)
 MMA Feed without eductor pressure ( Should not Start)
 MMA Feed without agitator running ( Should not Start)
Concentrated Nitric Acid Shop:
 Personal Protective Equipment
 Acid Proof Suit
 Rubber Shoes
 Rubber Gloves
 Fumes Mask

 Safety Measures:
 Put on safety equipments.
 Never ever use shortcuts.
 Don't ignore abnormal sound.
 Avoid contact with acid fumes.
 Make sure the availability of water near handling of acid
 Don't unnecessary play with acid or acid containing vessel.
 Detailed Safety measures for Nitric Acid are as discussed in Tovex section.

PETN Shop:
 Personal Protective Equipments
 Acid Proof Suit
 Rubber Shoes
 Rubber Gloves
 Fumes Mask

 Safety Measures:
 Detailed Safety measures for Nitric Acid are as discussed in Tovex section
 Put on Safety Equipments while handling 99% Nitric Acid.
 Check for leakage of brine circulation coil in Nitration Tank before starting new batch.
 Check the operation of three way valve.
 Lubricate dump valve (ball valve) and 3way valve time to time for easy operation.
 Check and ensure the supply of brine through out the nitration of PE.
 Before start the feed keep the temperature of Nitric Acid bellow 10C.
 Add PE in small intervals in continual manner so that the temperature does not exceed 15C.
 If the temperature exceeds 15C stop the and cool the tank through brine.
 If PE feed is stoles and cooling is in process even then temperature rises above than 25C
operate the 3 way valve and dumped the batch into water hose and escape from that place.
 Neutralize the acid traces in PETN crystals through washing it with washing soda.
 Take care of fire against Acetone as it is highly inflammable
 If Acetone comes in contact with skin immediately wash with water.
 Do not store Acetone and explosive together.
 Air should be properly ventilated where Acetone is stored.
 Do not bring fire or spark near Acetone.
 Safety Improvements in PETN Shop
 3 way valve of Nitration Tank is situated in the lower section and in case of emergency it
does not have a quick and easy access save running towards it or calling for some other
person where as actually emergency doesn’t give enough time for these actions there must be
automatic control dump valve whose control lies near the operator so that in case of any
emergency he will be able to dump the batch in safety water hose.
 The operator at the Nitration section has to run dozen of steps to reach ground floor. In case
of any emergency he must be given an exit rout (like slide or lift) so that he could easily
escape and save his life.
 The ball valve under the Nitration tank is 2-3 inch below the tank bottom. The PETN
synthesized in the Nitration tank accumulates in this area which chokes the valve some times
and liable to explode. The valve must be replaced by Gate valve to stop this accumulation
and risk.

Detonating Cord Manufacturing:

 Personal Protective Equipments:
 Ear Plug
 Dust Mask
 Gloves
 Goggles

 Safety Measures:
 Put on safety equipments.
 Keep inflammable material away from PETN.
 Do not put on gloves when changing yarn bobbin.
 Be careful of friction impact while treating PETN.
 Clean scattered PETN powder on the machine when charging PETN.
 Before starting coating check the operation of safety cutter.
 Tape at the end of D.C (while spooling) to stop the PETN to flow.

Lead Azide Lead Styphenate Shop:

 Personal Protective Equipment
 Acid Proof Suit
 Rubber Shoes
 Rubber Gloves
 Fumes Mask
 Safety Measures:
 Put on safety equipments.
 When measuring large quantities repeat it measuring smaller quantities several times.
 Make a rule not to measure more than one kind of material a day. And under no circumstance
Pb(NO3)2 and NaN3 to be measure the same day.
 Before each measurement check the inside of measuring room to make sure that material dust
has not been accumulated and that things are going in good order.
 Prevent the scattering of material powder. After measurement of material wipe off the dust
been scattered.
 Wet sister for Lead Nitrate and Sodium Azide should be placed separately.
 Before starting a new batch check the working condition of motor up down and hydraulic lift.
 Detailed Safety measures for Nitric Acid are as discussed in Tovex section

Metal Shop:
 Personal Protective Equipments:
 Ear Plug / Muff ( for all stations)
 Safety Goggles
 Gloves

 Safety Measures:
 Do not remove or modify safety devices.
 When installing the Al strip do it together with other peoples.
 No other man is allowed to operate machine expect operator.
 Do not kept unnecessary metals mold or tools on the surface plate while repairing.
 When operating machine put on gloves.
 When leaving machine turn off switch.
 Before operating check whether safety devices work well.
 Ultrasonic cleaning and drawing.
 Put on the safety equipment (rubber gloves anti gas mask).
 Check oil and machine condition before working.

Plain Detonator Shop:

 Personal Protective Equipments
In this shop following are the PPE which the workers are required to wear.
 Safety Goggles (for PETN loading)
 Bullet Proof Jacket (for all stations)
 Ear Plug / Muff ( for all stations)
 Conductive Shoes (for all stations)
 Earthing Strip (for packing)
 Safety Measures
 Put on safety equipments
 Completely remove scattered explosive with wet cloth.
 Sprinkle some water on the floor of room to keep it wet while Aspiration is in process.
 Keep the humidity at over 70%. Handle the trays containing explosive with both hands.
 Spread L.A/L.S compo on trays with conductive rubber scoop.
 Do not go into Sieving while dumping and sieving operation is carried out.
 Clean dumping and sieving device every time changing container.
 Avoid impact, friction, fire or falling in drying room.
 Dry the explosive only in drying room.
 Do not move more than 1 kg explosive at a time.
 Limit quantity of drying room is 15 kg.
 Do not use deformed tubes and tubes with impurities
 Keep the limited quantity of PETN less than3 kg.
 Check the operating condition of press before PETN pressing (working of metal sensor,
alignment of punches).
 After pressing 20 trays clean off the dust on the punches with cloth rolled bamboo stick.
 Observe the pressing through reflecting mirror behind the press.
 Keep thee limited quantity of tube trays that is 4 tube trays
 The operator is required to stand behind the protective wall and observe AS compo loading
through reflecting mirror.
 Keep the limited quantity of trays (4trays)
 Test operate the inner capsule inserting machine
 Take out the crushed inner capsule with stuffed muzzles.
 Inspection and packing should be done behind safety guard.
 Wear Earthing strip while packing and inspection is done.

 Safety Improvements:
 Bullet proof jackets present in the shop are not according to the standard of work. Kindly
purchase and provide good quality Bullet proof jackets.
 To wear conductive shoes is the requirement of the shop but practically not a single worker is
given conductive shoes. Kindly act in this accordance.
 Earthing strips present in the packing section are out of order. Kindly bring some new
Earthing strips for packing section.

 Safety Violations:
 The explosive limit of PETN loading station is just 3 kg but actually more than this limited
quantity is found in this section.
 Only 4 trays are acceptable to place in PETN pressing station where as in practice more than
this limited quantity of trays is found in PETN pressing station.
 Final packing section is in between PETN pressing and inner capsule insertion and pressing
where as it should be away from these stations.
Electric /Seismic Detonators Shop
 Personal Protective Equipments
 Ear Plug / Muff ( for all stations)
 Conductive Shoes (for all stations)
 Earthing Strip (for crimping & packing)

 Safety Measures
 Wipe off the explosive dust all around during weighting, sieving and explosive grinding.
 Turn on the ventilator during grinding operation
 Keep the explosive wet with Acetone during all operations.
 The operator should be out of room when grinding operation is performed.
 Store the ignition mix in desiccators.
 Explosive limit of ignition mix is 300gram.
 If Acetone is touched with skin wash with soap.
 During shrinking of sleeves keep the head of air gun at some distance to avoid the bead to
initiate.
 Spot welding should be done behind safety guard to avoid the flame if bead ignites.
 During crimping operation human arm should be grounded.
 Working table should be grounded.
 Crimping operation should be done behind the safety guard.
 Shunting of wire should be done during crimping.
 Only single operator should be present in each station.
 Only single detonator should be taken from detonator box.
 Detonator box should be placed away from crimper.

Delay Detonators Shop

 Personal Protective Equipments
 Face Shield (for Explosive loading)
 Ear Plug / Muff ( for all stations)
 Conductive Shoes (for all stations)
 Gloves (for all stations)
 Earthing Strip (for pressing & packing)
 Safety Measures
 Put on safety equipments.
 Wipe off explosive dust during batch manufacturing and Lead tubes loading.
 Be care full while loading explosive into the tubes. Never use metallic rod while pressing
explosive into the tubes.
 Never touch Lead with bare hand always use gloves to handle with Lead (tube/raw)
 Be care full of spark while passing explosive filled Lead Tubes through rollers.
 Take care of friction while cutting explosive filled tubes in cutter.
 Loading and pressing of Delay Material into detonators should be done before safety guard.
 Keep the limited quantity of Detonators at loading and pressing station.