Mechanical Integrity Program for Liquid Explosive Process
Identified covered equipment; developed written mechanical integrity program manual including administrative procedures, inspection and testing plan, inspection and testing procedures, inspection and testing forms, and an equipment deficiency report.

PHA for Automobile Air Bag Propellant Manufacturing Process
FMEA, logic diagrams, risk assessment, design criteria, sensitivity and hazards testing.

Quantity/Distance Siting Evaluation for New Automobile Air Bag Propellant Manufacturing Facility
Using the results from TNT equivalency tests, evaluated design, explosive quantities, siting orientation and locations to minimize the anticipated exposure of personnel and facilities to hazardous conditions; evaluation also used to inform local government and regulatory authorities.

Safety Standards for Treating Explosives for Automobile Air Bag Manufacturing Process
Created formal safety standards for plant operations with explosives; assisted client in developing corporate safety charter and organizing top-level safety board; trained plant personnel to apply these standards in operating areas.

PHA for Nitroglycerin Manufacturing in a Commercial Smokeless Powder Plant
Hazards analysis of nitroglycerin manufacturing: acid handling, Nitrator, spent acid handling, nitroglycerin education.

PHA for Solventless Propellant Extrusion Process
Hazards analysis: ingredient feeding, twin-screw extruder, propellant handling; explosion vent sizing.

PHA for Shotgun, Rifle, and Pistol Ammunition Manufacturing Process
Hazards analysis: primer insertion, powder handling, loading, blending, mixing, drying, and pressing, assembly, ammunition packing, and handling.

PSM Documentation System for Ammunition Manufacturer
Implemented a software-based PSM documentation system.

PSM Compliance Manual
Prepared a PSM manual which included programs, references, and documents to comply with the 14 required elements of OSHA 29 CFR 1910.119.

PSM Compliance Audit for Army Ammunition Plant
Conducted PSM compliance audit of several processes including continuous nitroglycerin nitration process (BIAZZI) for evaluation of the 14 required elements of OSHA 29 CFR 1910.119.

Process Hazards Analysis Training for Manufacturer of Solid Propellant Rocket Motors
Conducted a training course at the customer's site to provide a PSM overview and to train personnel in PHA methodologies to enable conformance to OSHA and state regulations.

Sensitivity Testing - Nitroglycerin/Propellant Manufacturing Materials
Testing to characterize the sensitivity and explosive properties of materials associated with nitroglycerin and propellant manufacturing.

PSM Development/Implementation for State-of-the-Art Demilitarization Processes
Developed and implemented complete PSM programs for two state-of-the-art demilitarization processes for the removal of propellants: (1) ammonia washout including dissolution and recrystallization of raw propellant ingredients; (2) liquid nitrogen washout including propellant recycling.

PHA for Demilitarization Processes
Hazards analysis of reverse assembly demilitarization process which included review and design recommendations for propellant grinder, cutters, deactivation/ neutralization reactors, supercritical water oxidation system, and gas phase chemical reduction system.

PHA for Munitions Cryofracture Demilitarization Facility
Hazards analysis of robot handling system and munition cryofracture equipment, including presses, transport conveyors, cutters, cryofracture baths, etc.

Accident Investigation for HMX Dryer Building Explosion
Participated on the investigating team and provided testing support, hazards analysis support, and failure scenario probability data.