Plant 44 Audit Reports - Wright-Patterson Air Force Base

•FOR OFFICIAL USE ONLYDistribution authorized to DoD components and their contractors only; administrative/operational use; August]9,2005. Other requests for this document shall be referred to the Chief, Acquisition Environmental Safety &Health Division, Engineering Directorate, ASC/ENV, Wright Patterson Air Force Base, OH 45433Air Force Plant 44 Facilities ReviewRaytheon Missile Systems Company4 - 8 April 2005Explosive Safety Evaluation1.0 OVERVIEW: The annual ASC/ENV Explosive Safety Review of the RaytheonMissile Systems Company (RMSC), Air Force Plant 44, Tucson, Arizona, was conducted4-8 April 2005. Maj. Robert Schmedake, ASC/GRS on behalf of ASC/ENV, performedthe Explosive Safety evaluation. Mr. Ron Orr and Mr. Doug Long RMSC Safety,accompanied Maj. Schmedake. The purpose of the review was to conduct an examinationof the RMSC responsible facilities/workplaces and evaluate the Explosive SafetyProgram administration and its effectiveness. Due to the time constraints, it was notintended to perform a thorough examination of the facilities visited; therefore, all hazardsand/or deficiencies that may exist within the work place may not be identified.2.0 PREVIOUS OBSERVATIONS: After visual inspection from the 2004 a repeatfinding is related to the lightning protection system air tenninals, down conductors. Thediscrepancy is cited relates to AFI32-1065, which is applied to Raytheon through 0004145.26M, paragraph CI.6 that directs the contractor to 000 6055.9 and the applicableservice regulation. In this case, construction of Lightning Protection Systems on AirForce property is in accordance with AFI 32-1065. 0004145.26M also directs thecontractor to applicable NFPA standards for lightning protection systems. Thesestandards are consistent with each other.05-01 Repeat Finding - Lightning Protection System Deficiencies:Many down conductors and connections for conductors are painted on a number offacilities, including BIds 864, 865, 811, and 812. I expect that most of the facilities havethis issue. Raytheon does perform the periodic visual inspections (6months) andresistance tests (2 years) and does maintain record for these inspections. According to thestandard AFI 32-1065:A4.1.9. Do not paint down conductor connectors unless they are the highcompressionor exothermic (or welded) type. Conductors on roofs must be bare.000 4145.26M refers the contractor to NFPA 780-14, which states:K.5.3 Painting. Bonding connectiom and conductor splices should not be painted.Paint on lightning protection conductors should not exceed a level at which theconductor's physical continuity can be confirmed.Recommend all conductors be cleaned to the point that continuity may be confinned. Allconnections that are painted need to be replaced and bonding connections need to be re­accomplished without any paint present at the connection.Other Findings05-02 BId 864 Test Cell (North) a piece of test equipment had frayed wiring on thepower cord. The outside insulation was stripped.Attachment 3