Safety in Handling of High Energy Materials.

P C ROUTRAYOutstanding Scientist (Sc ‘H’)

&Associate Director, ITR,

DRDO, ChandipurRS/ITR(DRDO)/01

Brief Introduction about ITR.

STEC Guidelines on QD criteria.

Range Safety Scenario of ITR.

Aim.

Missions Undertaken.

Safety Organization Structure.

Integral Parts of Range Safety.

Ground Safety.

Flight Safety

On site Safety.

Supports for reinforcement of Safety measures during Launch

operations.

Conclusion.

OUTLINE OF PRESENTATION

&

RS/ITR(DRDO)/02

ITR, Chandipur is the premiere Test Range of DRDO and is the only

Test Range in the Country for testing & performance evaluation of

wide range of flight vehicles (Developmental / Users) including Air

borne weapon systems.

Operating since 1982 and presently it has evolved into a world class

test range.

An ISO 9001:2015 Certified estt. providing Test & Evaluation

services to Flight Vehicles and Airborne Weapon systems.

A workforce of about 475 employees with a little more than 100

Scientists.

Role of ITR is to provide safe and reliable launch facilities for testing

and performance evaluation of Rockets, Missiles & Airborne weapon

systems.

ABOUT ITR

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Historical Milestones of ITR1982 Founded under leadership of Dr. A P J Abdul Kalam as its 1st

Director.

1989 First Agni TD Launch.

1990 First Akash STA Launch.

1992 First Prithvi SSBM Launch.

1999 First Agni from launch from Launch Complex-IV.

2000 First DHANUSH Launch from the ship.

2001 Conducted the first Test Launch of BrahMos.

2003 First ASTRA Launch.

2005 First Underwater launch from a pontoon.

2012 First launch of Agni-5 ICBM (Non-Cannisterised).

2013 First Nirbhay Launch.

2015 First launch of Agni-5 ICBM (CANNISTERISED).

2019 First launch of A-SAT Missile.

2019 First HSTDV launch.

RS/ITR(DRDO)/04

OUR VISION & GOAL

To become a global benchmark in the field of Test and

Evaluation of Weapon systems through innovation andtechnical excellence.

GOAL:

To be a trusted Integrated Test facility, delivering reliable andquality services to all it’s valued customers.

VISION:

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Safety is everybody’s concern : Let us strengthen it.

MOTTO:

A huge test bed spreading over thousands of

kilometres.

Coexisting with economic activities.

Providing reliable data for entire flight duration

for a wide variety of flight vehicles. Multi launch,

low altitude & low observable flying objects.

Maintaining NIL accident record through

effective enforcement of appropriate Range

Safety Norms.

OPERATIONAL CHALLENGES

RS/ITR(DRDO)/06

Successful performance evaluation of flight vehicles for

more than 2000 launches

Established Range facilities at par with other Test Ranges

of the world

Proven capability to test different types of Airborne

Weapon Systems (Short Range to ICBM class), Air

Defence (Surface to Air, Air to Air and BMD), Under water

launches, Cruise Missiles (Subsonic & Supersonic),

UAVs etc.

Development of state of the art Range technologies

towards achieving self reliance.

ACHIEVEMENTS

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Launch Complex

Launch Complex

Launch Complex

Launch Complex

RadarTM & EOTS

Data Processing

Precise Timing Range Safety Power SystemsCommunication

Network

HOW DO WE DO IT

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RS/ITR(DRDO)/09

Explosives being energetic materials,

Present a potentially significant

hazard to the public and personnel.

if they are not handled

and transported safely.

EXPLOSIVES AND AMMUNITION

EXPLOSIVES

EXPLOSIVES ARE CHEMICAL SUBSTANCES OR COMBINATION OF

CHEMICAL SUBSTANCES WHICH BY NATURE ARE LIABLE TO BE

INITIATED BY SPARK, FRICTION AND PERCUSSION.

ONCE INVOLVED IN A FIRE, MAY LEAD TO MASS EXPLOSION / MASS

FIRE AND DISASTROUS CONSEQUENCES

CREATE SUDDEN AND INTENSE PRESSURE ON SURROUNDINGS.

EVOLUTION OF LARGE QUANTITY OF HEAT, SOUND AND FLASH.

AMMUNITION

AN ENCLOSED EXPLOSIVE SUBSTANCE DESIGNED TO PRODUCE AN

EXPLOSIVE EFFECT

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Explosives

High Explosives Pyrotechnics

Secondary

explosivesFlashes

Flares

Fumes generator

Optical & acoustic signal

Fire works

Propellants

Gun propellants

Single base

Double base

Multiple based

propellant

Black powder

Flashes

Flares

Fumes generator

Optical & acoustic signal

Fire works

Single base

Double base

Multiple based

propellant

Black powder

Flashes

Flares

Fumes generator

Optical & acoustic signal

Fire works

Gun propellants

Single base

Double base

Multiple based

propellant

Black powder

Flashes

Flares

Fumes generator

Optical & acoustic signal

Fire works

Gun propellants

Single base

Double base

Multiple based

propellant

Black powder

Flashes

Flares

Fumes generator

Optical & acoustic signal

Fire works

Rocket

propellant

Gun propellants

Single base

Double base

Multiple based

propellant

Black powder

Flashes

Flares

Fumes generator

Optical & acoustic

signal

Fire worksGelatine

Powder

ANFO

slurries

TNT

RDX

PETN

HMX

TATB

FOX-7

CL-20

RDX

RS-RDX

NTO

Primary

(initiative explosives)

Lead azide

Lead styphnate

Mercury fulminate

Diazodinitro phenol

Tetrazene

Other mixtures

Explosives

High Explosives Pyrotechnics

Secondary

explosives

Flashes

Flares

Fumes generator

Optical & acoustic signal

Fire works

Gun propellants

Single base

Double base

Multiple based

propellant

Black powder

Double base

Composites

High Energy

Liquid

Flashes

Flares

Fumes generator

Optical & acoustic signal

Fire works

Single base

Double base

Multiple based

propellant

Black powder

Flashes

Flares

Fumes generator

Optical & acoustic signal

Fire works

Gun propellants

Single base

Double base

Multiple based

propellant

Black powder

Flashes

Flares

Fumes generator

Optical & acoustic signal

Fire works

Gun propellants

Single base

Double base

Multiple based

propellant

Black powder

Flashes

Flares

Fumes generator

Optical & acoustic signal

Fire works

Gun propellants

Single base

Double base

Triple base

High Energy

IR Flares

Illuminating Flares

Delays

Smoke

EEDs

Gelatine

Powder

ANFO

slurries

Industrial

explosives

Military

explosives

Primary

(initiative

explosives)

Lead azide

Lead styphnate

Mercury

fulminate

Diazodinitro

phenol

Tetrazene

Other mixtures

Family of Explosives

RS/ITR(DRDO)/11

EXPLOSIVE EFFECTIVENESS

FACTORS

1) Amount of Energy

Content.

2) Rate of Release of

energy.

3) Safe handling &

operational use.

PARAMETERS

Heat of explosion.

Temp. of explosion.

Pressure of explosion.

Explosive power (QV) &

Power Index (PI)

Rate of burning.

Detonation velocity.

Detonation pressure.

RS/ITR(DRDO)/12

RS/ITR(DRDO)/13

RS/ITR(DRDO)/14

RS/ITR(DRDO)/15

MoD Policy:

Potential explosion sites (PES) like buildings, stacks and vehicles in

which explosives are permitted, act as sources of potential risks to

the individuals and to property.

PES are located sufficiently clear of other buildings, stacks, road,

railways or places frequented by persons (both within and outside the

enclosed area) know as Exposed Sites (ES) so as to ensure the

minimum reasonably practicable risk to life and property in the event

of an explosion. This clearance or distance ‘D’ is called the

quantity Distance (Q-D).

It depends on the maximum net explosive quantity (NEQ) permitted at

the potential explosion site.

PRINCIPLES OF QUANTITY DISTANCES

PES ESD

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KINDS OF QUANTITY DISTANCES (QD)

Inside QD Outside QD

QD

SIQD PIQD IBD PTRD

PotentialExplosion

Site

ProcessBuilding

StorageBuilding

PIQD

SIQD

(Schematic representation of IQDs) (Schematic representation of OQDs)

PotentialExplosion

Site

P

U

B

L

I

C

R

O

A

D

IBD

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RANGE SAFETY

Aim of Range Safety is to ensures Safety of Life, Property

and Environment from any mal-functioning of weapon systems

under trial in a Range . A Flight Vehicle/ weapon system may

be considered as a failure, if it deviates from the desired

trajectory beyond a permissible limit.

This failure can be attributed to various reasons as follows:

• Misbehaviour of Propulsion System in Flight.

• Structural Failure in Flight

• Aerodynamics Parameters & Surface Failure

• Control & Guidance Failure in-flight

• Navigational System Failure

• OBC (On-board Computer) Failure

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Range Safety Activities

Study of the crucial flight vehicle details viz. propulsion, control and guidance, various limitations

Study of the vehicle dynamics and failure mode analysis – 6 degree of

freedom simulation.

Selection of launch azimuth, fixation of launch corridor and danger

zone, identification including notification to various authorities.

Evaluation of flight safety policies, flight termination criteria and

minimum instrument configuration.

Workout range safety background display chart and information for

real time display of flight trajectory and safety monitoring.

Safety monitoring of real time flight including termination if required.

Ensure readiness of launch complex facilities and life saving

equipments.

Ensure readiness of emergency support facilities.

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( ICBM / IRBM / MRBM )

LONG RANGE STRIKE

BEYOND ENEMY STRIKE CAPABILITY

TARGET STRATEGIC INSTALLATIONS

DISRUPT COMMUNICATION NETWORK

PSYCHOLOGICAL IMPACT

TOTAL DESTRUCTION THREAT

ROLE OF STRATEGIC MISSILES

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* SHORT RANGE BALLISTIC MISSILE (SRBM) : < 1000Km

(EXAMPLE PRITHIVI, AGNI-I, SCUD ETC)

* MEDIUM RANGE BALLISTIC MISSILE (MRBM) : 1000-3000 Km (EXAMPLE : AGNI-2)

* INTERMEDIATE RANGE BALLISTIC MISSILE (IRBM) : 3000-5500 Km (EXAMPLE: AGNI-3,AGNI-4)

* INTER CONTINENTAL BALLISTIC MISSILE (ICBM) : >5500 Km (EXAMPLE : AGNI-5, MINUTEMAN-III)

•PLATFORMS

LAND BASED : EARTH SURFACE.

SEA BASED : WATER SURFACE (SHIP BASED),

UNDER WATER BASES : SUBMARINES.

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MISSIONS UNDERTAKEN

SAFETY ORGANISATION STRUCTURE

RS/ITR(DRDO)/22

Range Safety

Ground SafetyFlight Safety

Functional

Classification

Range safety is an integral part of any test Range from Test Range performance point of view.

Fire Safety

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PART-I

To Provide safe and reliable launch facilities during testing & performance

evaluation of Rockets, Missiles & Airborne weapon systems right from receipt

of classified stores at the Range till their safe disposal at the end of launch

campaigns.

ROLE

GROUND SAFETY ASPECTS

GROUND SAFETY ASSIGNMENTS FROM RECEIPT TILL LIFT OFF.

ACCIDENTS & THEIR HAZARD LEVELS.

EXPLOSIVE SAFETY : CLASSFICATION, HAZARD DIVISIONS &

POTENTIAL INITIATING CONDITION.

STORAGE & TRANSPORT OF EXPLOSIVE COMMITTEE (STEC).

CRITERIA FOR SAFE STORAGE & PROCESSING OF EXPLOSIVES.

SAFETY INFRASTRUCTURE AT ITR.

SAFETY PRECAUTIONS TO BE UNDERTAKEN.

READINESS CHECKS.

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Mission Support Activities

Pre-mission Phase Mission Phase Post Mission Phase

Critical study of Flight Test Plan.

Readiness of Launch Complex facilities as per ISO Checklist.

Safety Checklist for hazardousoperations on Flight Vehicle.

Preparation of Range Safety related mission Documents.

Load testing of Materialhandling equipments.

Readiness checks for Firefighting systems and conductof mock fire drills.

Evolving effective strategy forEmergency Handling tomitigate any mission relatedcatastrophes.

Mitigation of emergencysituations, if required.

Recovery / demolition ofundetonated explosives /debris in the event of flightfailure.

Safe disposal/despatch ofhazardous stores toearmarked destinations.

Temporary storage andmaintenance of left-overhazardous stores.

Safe storage & handling ofexplosives as per STECguidelines.

Critical examination of Qualification test reports for propulsion & other explosive components.

Meticulous enforcement ofsafety measures.

Safety Management during critical Launch (count down) Phases.

Handling of emergencysituations during CountdownStage.

Evacuation of launch phaseDanger Zone.

Ground Safety Assignments pertaining to Mission Support

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CRITICAL HAZARDOUS ACTIVITIES

PERTAINING TO EXPLOSIVES.

STORAGE (TRANSIT AS WELL AS LONG TERM)

HANDLING (ASSY., INTEGRATION, PACKING, STACKING

ETC.)

TRANSPORTATION (ROAD, WATER & AIR)

DISPOSAL OF UNDETONATED EXPLOSIVES.

A) SAFE STORAGE C) SAFE DISPOSALB) SAFE HANDLING

&

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D) SAFE HANDLING

G) READY FOR ARTICULATION

F) SAFE TRANSPORTATION

H) HANDLING OF INTEGRATED ARTICLE.

E) SAFE HANDLING

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READINESS CHECKS FOR LC BLDGS

AND INFRASTRUCTURE

Earthing checks

LPS checks

Power point checks

Leakage checks

Load testing and Certification of EOT Cranes.

Checks for antistatic / conductive flooring.

(A) ELECTRICAL CHECKS

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Static charge elimination system

Availability of appropriate PPEs

Toxic Gas Monitoring system

Availability of Safety appliances for integration

Availability of dedicated CCTV views of launcher

Availability of Effective Communication Systems at the Safety consoles.

(C) MISCELLANEOUS CHECKS :

Load testing and certification of HOT cranes and Material Handling equipments.

Compressed for Breathing System (CABS)

Readiness of fire fighting systems.

(B) MECHANICAL CHECKS :

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PART-II

TRAJECTORY & FAILURE MODE DATA ANALYSIS.

APPLICATION FOR ISSUE OF AIR-NAVAREA CLEARANCE.

FINALISATION OF RANGE SAFETY DISPLAY CONFIGURATION.

SIMULATION CHECK & DISPLAY VALIDATION.

REAL TIME HEALTH MONITORING.

AIR TRAFFIC MONITORING.

FLIGHT TERMINATION IN THE EVENT OF ERRANT BEHAVIOR OF FV.

ROLE

FLIGHT SAFETY ASPECTS

Aims at ensuring Safety of FV and Range (Personnel & Props) from the Post lift offoccurrence till touch down.

MAJOR ACTIVITIES

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STAGE

IMPACT POINTS

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FLIGHT TERMINATION SYSTEM

Command Encoder

Transmitter

Antenna

GROUND STATION ONBOARD SYSTEM

Command Receiver

Decoder

Safety Actuation Logic

Pyro chain

FLSC Cord

Power Supply with two

independent chains.

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DESTRUCT MECHANISM:(Schematic)

RSO

Co

nso

le

Digital Command Encoder

FM Modulator

Digital Command Encoder

FM Modulator

Switch

Matrix

RF Power Amplifier

RF Power Amplifier

Directional Antenna Omni

Antenna

Dummy Load-1

Dummy Load-2

AUTO-CHANGE OVER UNIT

SP

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ON SITE SAFETY MANAGEMENT

Notification of Danger Zone.

Evacuation of Civil population

Imposition of manlimit

Safety checklist

Schematic action plan for mitigation of Mission

catastrophes.

Deployment of Mission Support facilities.

PART-III

MAJOR ASSIGNMENTS.

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CRITICAL LP OPERATIONS:

Pyro-arming.

Mechanical barrier removal.

Articulation of FV.

Pre-launch checks.

Launch phase.

ASSOCIATED SAFETY

MEASURES :

Earthing of FV.

Lightning Protection.

Imposition of RF silence.

Availability of MET Data.

CCTV recording.

FF & Ambulance support.

Readiness of Fire Hydrants &

Waterjet monitors.

Readiness of CDS.

Readiness of EHT.

Evacuation from Launch

Phase Danger zone.

Final Clearance through

audible siren & imposition of

road block.

Road block

point 2

Launch Pad

Block

House

Evacuation

camp - 1

Emergency

Handling Site

Launch

Complex

Evacuation

camp - 2

Road blockpoint 3

Road Block point 1

Launch Phase

Danger Zone

VO Site-2

S

E

A

VO Site-1

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SUPPORT FACILITIES FOR SMOOTH

LAUNCH OPERATIONS

Security Coverage

Fire Fighting Services

Medical Coverage

Close Circuit Television Network

Meteorology Support Services

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(A) HANG FIRE SITUATION.

EFFECTIVE MITIGATION OF MISSION RELATED CATASTROPHES.

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(B) TOPPLING OF FV ON LAUNCH PAD.RS/ITR(DRDO)/38

(C) HANG FIRE SITUATION.RS/ITR(DRDO)/39

(D) FAILURE AFTER LIFT-OFF COMMANDRS/ITR(DRDO)/40

(E)BLASTING OFF OF ROCKET MOTOR IN AIR AFTER LIFT-OFF.RS/ITR(DRDO)/41

CONCLUSION

Range Safety is of paramount importance for a Test

Range like ITR where tonnes of propellants /

Energetic materials are handled.

If you respect explosives, they will respect you. If you

make a mistake with explosives, probably it will be

your last mistake.

It is better to be careful a hundred times than to be

killed once.

When Seconds count……..

You don’t have Second Chance….!!

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